Chapter-9 Technical specification

Combined Scope of Work

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 Chapter-9 Technical specification

CONTENT

S.No. DESCRIPTION PAGE NO.

1 Brief plant description CS-3

2 Scope of Work CS-3

2a General CS-4

2b Process CS-5

2c Mechanical CS-6

2d Electrical CS-7

2e Instrumentation & control CS-8

3 Process – Schedule of quantities CS-10

4 Mechanical – Schedule of quantities CS-11

5 Electrical – Schedule of quantities CS-16

6 Inst. & Control – Schedule of quantities CS-19 to 22

7 List of long delivery items CS 23

8 Annexure-1: HWB/SPP(T)/CIVIL/0001A CS 24

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 Chapter-9 Technical specification

COMBINED SCOPE OF EPC WORK

1) BRIEF PLANT DESCRIPTION

SPP facility is a chemical process plant. The process involves various organic chemical
reactions in the Glass lined and Nickel lined reactors provided with agitators. The capacity of
the reactor varies from 2 KL to 5 KL. The solvent production process involves a single step or
multiple step reaction to achieve the crude product. The crude products are purified by washing
and distillation in the reactors to get the final product.
Various raw materials in the form of liquid are kept in Bulk storage tanks, day tanks,
drums etc., whereas the solid raw materials are kept in bags or suitable drums. Hazardous
materials handling system & area are provided with fire protection & fire fighting
system/ventilation system. The gases leaving from the reactors during the reaction are scrubbed
in vent scrubber system for removal of hazardous gases before discharging to the atmosphere.
The liquid effluents are collected and sent to ETP for treatment and disposal.
The utilities system like Vacuum system, Electrode boiler system for steam production,
Cooling water system, Vapour compression refrigeration system to produce chilled water are to
be provided to maintain the operating parameters like pressure and temperature at the desired
level. Operating pressure varies from 0.1 Torr to 10 kg/cm2. Operating temperature varies from
170 °C to -10 °C. Transportation of process fluid from one vessel to the other is carried out by
pressure transfer or pumps. Centrifugal & diaphragm pumps are to be used for pumping as per
the requirement.
Some of the raw materials like Butanol are used as excess reactant during the solvent
production reaction. The same is to be recovered and recycled back to the system by
employing distillation in a Butanol recovery system.
Plant equipment are to be erected in a Main building & Utility building (closed RCC
structure cladded with cement sheets), open outdoor structure for Butanol recovery unit and
dyked area for Bulk storages of flammable chemicals. There is a separate civil tender for
carrying out major civil works for the above.
As the plant handles corrosive chemicals like POCl3 & PCl3 and flammable chemicals
like Butanol, Iso amyl alcohol etc., the MOC and Electrical & Instrumentation equipment &
fittings are to be selected accordingly.
2) SCOPE OF WORK:

The Scope of Work of the EPC contractor is given below. It is broadly indicated in
Dwg. No HWB/SPP(T)/CIVIL/0001A , REV.00. All equipment, machinery, piping, electrical,
instrumentation and control come under the scope of the EPC contractor. Detailed scope of
work is given in the tender document under Technical Specification for Process, Mechanical,
Instrumentation and Electrical disciplines.

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 Chapter-9 Technical specification

2a) GENERAL:
1. Residual design & engineering :
i) Review and development of final P&I diagrams, conducting a HAZOP study
and development of equipment layouts.
ii) Preparation of technical specification for procurements of listed items.
iii) Design & development of fabrication drawing of equipment and piping
including piping isometrics.
iv) Design & development of control logic, DCS and field instrumentation.
v) Design & development of electrical power distribution systems.

2. Procurement & Material Handling:

i) Procurement, supply, fabrication & manufacturing of all listed items covered
in this tender as per the approved Technical Specifications/Data Sheets
including structural steel.
ii) Recommended vendor list for the procurement of respective items and
systems, is given in the tender document. It is suggested that the EPC
contractor adhere to this list. However, for including any other vendor in the
recommended list, approval of HWB is required.
iii) Safe loading, transportation, unloading, safe handling and storage at SPP site.
iv) EPC contractor shall follow a material accounting system for all the supplied
items. The surplus materials shall be taken out of the SPP facility by the
contractor with the approval of HWB.
v) The EPC contractor shall procure spares as listed in the tender.

3. Documentation &Project execution:

i) Preparation and supply of all operating and maintenance manuals, test
certificates and as built drawings (4 copies). Imparting training to HWB
personnel.
ii) Monitoring of the project activities and preparation of schedule required
therein. (PRIMAVERA or equivalent tools shall be employed).
iii) Complete supervision and coordination of the project by deploying of
manpower i.e. qualified resident engineers at site, supervisors, skilled and
unskilled workmen with requisite tools, tackles, consumables during
construction, pre-commissioning and commissioning of the equipment,
machineries and systems.

4. Construction:
i) Erection and installation of all equipment, machinery, instruments & control
systems, electrical systems as specified in the tender.
ii) Fabrication, welding and erection of interconnection piping work including
hooking up with the respective equipment & machineries as per approved
isometric drawings.

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 Chapter-9 Technical specification

iii) Supply & Erection of all support structures & access to equipment for safe
operation and maintenance
iv) Preparation of schedule for the construction and erection, field co-ordination,
field engineering, construction and installation supervision, field inspection
and verification, review of change notices and quantity certification.
v) Final hook up of the piping at the battery limits of various headers or any
other equipment wherever applicable.
vi) Assistance for Statutory Clearances by providing necessary documents.

5. Quality assurance:

i) Preparation of detailed Quality Assurance Plan for all items and activities and
submit the same to HWB for approval.
ii) Stage and final inspection and testing at manufacturer’s work and at site as per
approved QAP to ensure quality assurance of supply items as well as site
fabrication, erection, assembly work.
iii) Carrying out all NDTs as per approved QAP. Providing inspection tools as
recommended in equipment manufacturer manual, scaffoldings and temporary
lighting etc., for carrying out inspection. Calibration of all test instruments at
site.
iv) Maintain records of all the works and inspection reports.

6. Pre Commissioning and Commissioning:

Pre commissioning, commissioning and testing of equipment
systems/packages as defined in Part-II Volume-2.

2b) PROCESS
1. For detailed scope of work, Process Technical specification of this document shall
be referred.
2. Review of adequacy of design/ basic engineering.
3. Preparation of final Piping & Instrumentation diagrams.
4. Design, engineering, supply, erection of Auxiliary & Package utility systems.
5. Design basis report.
6. HAZOP study for process operation.
7. Cause and Effect diagram.
8. Preparation of line lists, valve list, equipment, machinery list etc.
9. Technical Specification & Process Data Sheets.
10. Preparation of Equipment layout.
11. Documentation for conducting commissioning, performance testing, schedule of
testing, operational procedures.
12. Deliverable as per the list indicated in process technical specification.
13. Preparation of operation & maintenance manual(s).

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2c) MECHANICAL
1. For detailed scope of work, Mechanical Technical specification of this document
shall be referred.
2. Equipment & machineries: Design and development of fabrication drawing,
engineering, procurement & supply of items including spare parts, testing,
inspection, safe delivery to HWB’s site, storage, erection at HWB’s premises, piping
hooking up and commissioning of the machineries.
3. Piping: Design and engineering, supply & erection of pipes, fittings, flanges, valves
as per approved isometric drawings and P&ID.
4. Structural Steel: Supply of all the structural steel required during erection of (i)
Equipment, (ii) Rotating / Reciprocating machineries, (iii) Package / Utility Systems
(iv) Piping including supports (v) platforms, walkways/stairs including supply of
consumables.
5. EOT Crane:Supply, erection and commissioning of EOT Crane as per the technical
specifications given in the tender.
6. Spares: Supply of all spares required for commissioning and maintenance of
equipment & machineries as listed in Tender document.
7. Project Management: Activity scheduling, work progress monitoring, variance
reports, milestones status, constraints, rescheduling of activities, catch-up plan,
implication of rescheduling on expenditure pattern, final project completion reports,
cost statements etc. PRIMAVERA or equivalent tool may be employed
8. Site Execution: Selection of work method, schedule for the construction and
erection, field co-ordination, field engineering, construction and installation
supervision, field inspection and verification, review of change notices, quantity
certification etc. Deployment of manpower. Preparation of Material Accounting
Statement & return of left over materials to stores with proper return vouchers.
9. Quality Assurance Plan: Preparation of detailed QAPs for fabrication of equipment,
piping and bought out items based on the tentative QAPs included in the tender. All
testing procedures shall be prepared and submitted for HWB’s approval.
10. Preparation of Equipment & Piping Layout: Preparation of Equipment & Piping
Layout Drawings, piping design and codal analysis, Isometric Drawings with full
details indicating Supports, final "AS BUILT" drawings, Bill of Material and Weld
Joint etc.
11. Ducting: Design & Supply of entire material, fabrication & erection for non metallic
hoods & ducting, supports required to complete the job, if any.
12. Machineries, Tools & Tackles for Erection: Arrangement of required machinery
like master level, torque wrench, electric welding sets and diesel generator welding
sets, diesel and electrically operated dewatering pumps, Hydro-testing pumps, air
compressors, winches, wooden sleepers, derricks, crane and other lifting tackles,
tractors and trailers, etc. as required for erection.
13. Testing and Inspection: Stage and final inspection and testing at manufacturer’s
works and at site ensuring quality assurance of supply items as well as site
fabrication, erection, and assembly work.
14. Passivation & Cleaning: All SS lines shall be properly cleaned and passivated,
where ever required, Acid cleaning for process piping and all equipment before

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erection, detergent cleaning for utility piping and local passivation, Cleaning of the
piping after assembly by air.
15. Pre-commissioning, Commissioning and Testing: All equipment/ systems/
packages & interfaces. Purging of equipment / machinery by nitrogen gas.
Preservation after erection, as per directions of owner/ equipment manufacturer.
16. Insulation (Cold and Hot as required) and Painting.

2d) ELECTRICAL
1. For detailed scope of work, Electrical Technical specification of this document shall be
referred.
2. Design and Detailed Engineering: The EPC contractor has to carry out design and
detailed engineering for all the electrical equipments listed under the scope of supply.
Preparation and submission of detailed Technical specification, data sheets, QAP,
detailed drawings etc.

3. Selection of equipments: Selection of electrical equipments shall be done by EPC

contractor to satisfy the specified service requirements, suitable for the environmental
conditions prevailing at site as mentioned elsewhere and corrosive/hazardous
atmosphere in the plant.

4. Factory Acceptance Test (FAT): EPC contractor shall carry out Factory Acceptance
Test i.e. Inspection and Testing at supplier’s works for all the equipment as per approved
QAP in presence of HWB or third party inspector (TPI) appointed by HWB.

5. Supply &Storage at Site: EPC contractor has to supply all the items to SPP site in a
safe manner without any damage. Items shall be packed with suitable materials to
prevent damage in the transit. EPC contractor has to ensure safe transportation to SPP
site and storage of all the equipments at SPP site.

6. Erection: EPC contractor has to carry out erection of all the equipments under the
scope of supply including cable laying & termination, mounting of push button etc.

7. Site Acceptance Test: The EPC contractor has carry out pre-commissioning test,
commissioning test at site as per approved QAP for each equipment.

8. Clearance from Regulatory Authorities: EPC contractor has to obtain clearance from
regulatory authorities like State / Central Electricity Authority etc. as applicable before
taking the electrical system into service.

9. Commissioning: After safe erection of the equipments, EPC contractor shall carry out
pre-commissioning and commissioning test as applicable as per the approved check
list/procedure.

10. Charging and handing over: The EPC contractor has to hand over the equipments to
HWB after successful completion of commissioning and performance tests acceptable

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to the HWB. The EPC contractor has to ensure that all the equipments can be taken into
service.

11. Retrofitting of 3.3KV feeders: Electrical power for SPP plant is to be tapped from two
dummy panels available in the existing 3.3KV switchgear at HWP site. 2nos of 3.3KV
VCB of 630A rating are to be supplied by the EPC contractor as per the technical
specification and to be retrofitted in the existing dummy panel of 3.3KV feeder along
with measuring and protective CT and necessary wiring shall be done. Detailed
Technical specification for 3.3 KV Breaker is given in Annexure – IV of Electrical
technical specification.

12. Cabling: Supply, laying & termination of all cables, cable trays, support structures,
under ground trenches shall be carried out by EPC contractor.

13. Associated Minor Civil Works: All the equipments shall be erected in the existing
RCC room in the SPP main plant building by the EPC contractor. Associated minor
civil works like chipping, grouting, providing oil soak pits, transformer rails etc.

14. Additional requirements: The EPC contractor has to supply the structural steel for
providing support for installation of electrical equipments, cable trays etc. wherever
required.

15. Drawings: After design and detailed engineering, the data sheets &drawings have to be
duly approved by the HWB and all the work should be executed as per the approved
Data Sheet and drawings.

16. Spare parts: Spare parts shall be supplied as per the list enclosed with the tender.
Maintenance tools for the above shall also be included in the scope of supply.

17. Tools & tackles: All tools & tackles shall be arranged by EPC contractor for erection
& commissioning.

2e) INSTRUMENTATION

1. For detailed scope of work, Instrumentation & control Technical specification of

this document shall be referred.
2. Detailed Engineering: EPC contractor shall carryout the design, detailed
engineering, preparation of data sheets & schematics of the instrumentation
systems, Emergency field Panel and associated auxiliary systems, required to
complete entire instrumentation and automation system for the plant.
3. Supply & Installation of DCS system and all associated panels: supply and
installation of DCS system, associated panels in control room and hookup with field
instrumentation, Calibration, Testing, total system integration and documentation etc.
4. Supply &Installation of complete field instrumentation and all associated
Components:
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Supply, Installation, cabling and hookup with pipes / vessels/ pumps and all other
equipment. The instrument shall be mounted with suitable isolation valves, drain
valves, bleeders and manifolds after first root valves.
5. Submission & approval of Documents:EPC contractor has to submit detailed
specification of all instruments & accessories, Layout Drawings, installation drawing,
wiring diagram, loop schematics, QAP & other required documents mentioned in
tender
6. QAP: Preparation of QAP and submission for approval by HWB. QAP includes
Factory Acceptance Test (FAT), Site Acceptance Test (SAT), Functional testing
7. Safe transportation to SPP site and Storage: EPC contractor has to supply all the
items to SPP site in a safe manner without any damage. Items shall be packed with
suitable materials to prevent damage in the transit and also ensure safe transportation
and storage of all the equipments at the SPP site.

8. Site Execution: Execution of instrumentation work at site shall be as per the

drawings and documents prepared by the bidder & approved by the HWB. Scope of
site execution work is given in the Technical specification of Instrumentation &
control.

9. Commissioning: The EPC contractor has to prepare and submit check list/procedure
for pre-commissioning test, commissioning test and charging the equipment or taking
it into service. EPC contractor shall carry out pre-commissioning and commissioning
test as applicable as per the approved check list/procedure. Calibration before and
after installation, Commissioning, loop checking of Instruments which include
sensors/final control elements of package plants also.

10. System handing over after commissioning: The EPC contractor has to hand over
the Instrumentation system after successful completion of commissioning and
performance tests acceptable to the purchaser or as per approved commissioning
procedure/manufacturer guidelines. The EPC contractor has to ensure that all the
Instruments can be taken into service.
11. Associated Minor Civil Works: All the instruments, cables, cable trays and DCS
system shall be erected in the existing RCC room by the EPC contractor. Associated
minor civil works are to be carried out by the EPC contractor like chipping, grouting
etc.
12. As Built Drawings: Preparation of “As Built” drgs. for Installation drawings, Cable
schedule drawing, Air supply network drawings, Isometric showing mainly the
installation of instruments, Loop drawings, Earthing network, GA drawing for Panels
etc.
13. Training: The EPC contractor shall arrange for in-depth training on operation and
maintenance/trouble shooting/ calibration of all types of instruments by experts from
respective instrument manufacturer.
14. Supply of Spares: EPC contractor shall supply the list of spares mentioned in the
Tender.
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3. PROCESS- SCHEDULE OF QUANTITES

S. No DESCRIPTION OF PACKAGE/AUXILIARY CAPACITY QTY. **

SYSTEM
1. Alkali Dissolution System 2 KL 1
2. Vent Scrubber System 100 kg/hr of 1
HCl
3. Vacuum System 6500 m3/hr at 2
0.1 Torr
4. Electrode Boiler System 400 kg/hr 2
5. Chilled Water System 60 TR 2
6. Cooling Water System 100 m3/hr 2
** Refer detailed Schedule of quantity in Process technical specification

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4.MECHANICAL- SCHEDULE OF QUANTITES

TAG
S.No DESCRIPTION QTY CAPACITY MOC REMARKS
NO.
(i) Process Vessels
1 Day Tank 43V01 1 2 SS 304L
2 Feed Tank 43V02 1 0.5 MSGL
3 Feed Tank 43V03 1 1.0 MSGL
4 Feed Tank 43V04 1 0.5 MSGL
5 Day Tank 43V05 1 1 MSGL
6 Day Tank 43V06 1 1 MSGL
7 Charging Vessel 43V07 1 1 SS 304L
8 Charging Vessel 43V08 1 1 SS 304 L
9 Day Tank 43V09 1 1 PPFRVE
10 Day Tank 43V10 1 1 SS 304L
11 Product Tank 43V11 1 1 MSGL
12 Receiver 43V12 1 1 MSGL
13 Receiver 43V13 1 1 MSGL
14 Receiver 43V14 1 1 MSGL
15 Receiver 43V15 1 1 MSGL
16 Excess Receiver 43V16 1 1 SS 304L
17 Dump Tank 43 V 17 1 2 MSGL
18 Drain Tank 43 V 18 1 1 PPFRVE
19 Drain Tank 43 V 19 1 0.5 PPFRVE
20 Day Tank 44V01 1 5 SS 304L
21 Charging Vessel 44V02 1 1 MSGL
22 Charging Vessel 44V03 1 1 MSGL
23 Feed Tank 44V04 1 2 SS 304L
24 Feed Tank 44V05 1 2 SS 304L
25 Dump Tank 44V06 1 4 MSGL
26 Feed Tank 44V07 1 2 SS 304L
27 Storage Tank 44V08 1 3 SS 304L
28 Product Tank 44V09 1 2 SS 304L
29 Drain Tank 44V10 1 2 PPFRVE
30 Drain Tank 44V11 1 2 PPFRVE
31 Feed Tank 45 V01 1 5 SS 304 L
32 Product Tank 45 V02 1 5 SS 304 L
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33 Decanter 45 D01 1 5 SS 304 L

S.No DESCRIPTION TAG QTY CAPACITY MOC REMARKS
NO.
34 Organic Column 45 C1 1 - SS 304 L
SA 516 gr
35 Aqueous Column 45 C2 1 - 70+1mm PTFE
lining
36 Storage Tank 49 V01 1 20 A 516 Gr 70
37 Storage Tank 49 V02 1 20 A 516 Gr 70
38 Dump Tank 49V03 1 30 A 516 Gr 70
39 Storage Tank 49V04 1 30 A 516 Gr 70
40 Storage Tank 49V05 1 30 A 516 Gr 70
(ii) Heat Exchangers
Cooling Water
41 43R01 1 Graphite
Condenser
Chilled Water
42 43R02 1 Graphite
Condenser
Cooling Water
44 43R03 1 Graphite
Condenser
Chilled Water
45 43R04 1 Graphite
Condenser
Cooling Water
46 43R05 1 SS 316L
Condenser
Chilled Water
47 43R06 1 SS 316L
Condenser
48 Condenser, S&T 44 E 1-A 1 SS 316l
49 Condenser, S&T 44 E 1-B 1 SS 316l
Cold Trap, Double
50 44 E3 1 SS 316l
Pipe Type
Cold Trap, Double
51 44 E4 1 SS 316l
Pipe Type
Organic column
52 45 R 1 1 SS316l
reboiler
Aqueous column
53 45 R 2 1 Graphite
reboiler
54 Head Condenser 45 E 1 1 SS316l
55 Cooler 45 E2 1 SS316l
56 Cooler 45 E3 1 Graphite
57 Condenser 45 E4 1 Graphite
(iv) Reactors
58 Jacketed Reactors with 43RV01 1 2 MSGL
Agitator & Motor and
59 Flush Bottom valves 43RV02 1 2 MSGL

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Jacketed Reactor
60 43RV03 1 2 CS-Ni
with Agitator & Motor
S.No DESCRIPTION TAG QTY CAPACITY MOC REMARKS
NO.
61 Reactor 44 RV01 1 5 MSGL
62 Reactor 44 RV02 1 5 MSGL
63 Reactor 44 RV03 1 5 MSGL
(v) Rotating Machinery
64 2EHA Pump 43 P01 A/B 2 5 SS 316 L
43 P05
65 2 1.5
HEXANE Pump A/B PP
43 P06
66 2 0.5
RCL Feed Pump A/B PP
ALKALI Charging 43 P07
67 2 0.8 SS 316 L
Pump A/B
ALKALI Charging
68 1 0.8 SS 316 L
Pump 43 P08 A
43 P09
69 2 0.5 PP
HCL Charging Pump A/B
DM WATER Feed 43 P10
70 2 2 SS 316 L
Pump A/B
Dump Tank 43 P17
71 2 6 pp
Recirculation A/B
43
72 1 --- Glass Lined
Agitator of RV01 ARV01
43
73 1 --- Glass Lined
Agitator of RV02 ARV02
43 Ni clad carbon
74 1 ---
Agitator of RV03 ARV03 steel
Na2CO3(aq) Dosing 44 P04
75 2 0.6 SS304l
Pump A/B
Na2CO3(aq) Dosing
76 1 0.6 SS304l
Pump 44 P05
Dump Tank 44 P06
77 2 6 pp
Recirculation A/B
Na2CO3(aq) Dosing 44 P07
78 2 3 SS304l
Pump A/B
44 P08
79 2 5 SS 316
I-Butanol Feed Pump A/B
44
80 1 --- Glass Lined
Agitator of RV01 ARV01
44
81 1 --- Glass Lined
Agitator of RV02 ARV02
44
82 1 --- Glass Lined
Agitator of RV03 ARV03
Organic Column Feed 45 P01
83 2 0.7 SS 304L
Pump A/B
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Purified Butanol
84 1 0.7 SS 304L
Transfer Pump 45 P02
45 P03
85 2 0.7 SS 304L
Purified Butanol Pump A/B
Aqueous Phase 45
86 2 0.1 SS 304L
Transfer Pump P04A/B
OrganicPhase Transfer 45 P05
87 2 0.7 SS 304L
Pump A/B
S.No DESCRIPTION TAG QTY CAPACITY MOC REMARKS
NO.
49 P01
88 EHA Feed Pump 2 5 SS 316
A/B
49 P02
89 IAA Feed Pump 2 5 SS 316
A/B
Dumped Liquid
90 49 P03 1 5 SS 316
Transfer Pump
49 P04
91 N-Butanol Feed Pump 2 5 SS 316
A/B
(vi) Piping & fittings
MSGL
4.0-
As per Piping SS 304 L
92. Pipes 0.5”-10” 4.5km
Specifications A 106 Gr B
(Approx.)
HDPE
Pipe Fittings (Elbows, MSGL
2500
Tees, Flanges, SS 304 L
93. 0.5”-10” Nos. As per Piping
Reducers & other A 106 Gr B
(Approx.) Specifications
miscellaneous fittings) HDPE
94. Diaphragm Valves As per As per As per Piping MSGL
P&ID P&ID Specifications
PP
As per
95. Ball Valves SS
P&ID
CS
As per PP
96. NRV P&ID SS
CS
As per SS
97. Gate Valve P&ID CS
As per As per Piping
98. Globe Valve As per P&ID Specifications SS
P&ID CS
(vii) EOT Crane
As per
As per Tender
99. EOT Crane Tech 1 10 Tons
Specifications
Specs
(viii) Miscellaneous
100. Spares As per LOT As per Specifications
Tech
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Specs

101. Hot & Cold Insulation As per LOT As per Specifications

Tech
Specs
102. Structural Steel To be 15 Tons As per detailed Engineering
decided
during
detailed
engg.

(Refer Process technical specification & Mechanical technical specification for detailed
specification)

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5.ELECTRICAL - SCHEDULE OF QUANTITIES

(Clauses mentioned below are referred to the clauses in Electrical technical specification)

S. No. DESCRIPTION UNIT QTY. REMARKS

1. Supply erection and commissioning of 2000

KVA 3.3 KV/433 Volt. DY11, 3 Phase, 50
No. 2
c/s, Power Transformers and associated
minor civil works as per clause-8.

2. Supply erection and commissioning of

3.3KV, 630A VCB to be installed in the
existing module along with transformer No. 2
protective relays (Retro Fitting) as per
clause- 1, 2 & 6.

3. Supply, erection, testing and commissioning

of 250KVA DG set with AMF Panel and No. 1
associated minor civil works as per clause-24.

Supply erection and commissioning of 415V

Power & Motor Control Centers (PMCC, 2
nos. bus sections with bus-coupler) and No. 1
4.
associated minor civil works as per clause-7,
9, 13 & SLD.

Supply, erection and commissioning of 415V

ETP MCC and associated minor civil works No. 1
5.
as per clause- 7, 9,13 & SLD.

Supply, erection and commissioning of 415V

Pump House Panel and associated minor No. 1
6.
civil works as per clause- 7, 9,13 & SLD.

Supply erection and commissioning of

CLASSIII power panel (EMCC) and
No. 1
7. associated minor civil works as per clause-7,
10, 13 & SLD.

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Supply installation and commissioning of 13

Nos. of VFDs for agitator motors enclosed in
No. 1
8. a panel and associated minor civil works as
per clause- 7,15 & SLD.

9. Supply installation and commissioning Class

I load center (110V DCDB) and associated No. 1
minor civil works as per clause- 11.

10. Supply, installation and termination Lights & Lot 1

Light Fittings and associated minor civil
works as per clause-16.

11. Supply of cables

(a) 3.3KV 3Cx300sq.mm armoured FRLS , Mt 1500

XLPE UE aluminum power cable
(approx.4Runs x 375mt)
(b) 415V 2MVA Power Transformer sec.
cable 3Cx400sq.mm armoured FRLS Mt 1360
aluminum power cable (approx.16runs x
85mt)
(c) Other 415 V cables meant for motors,
light fitting and all other electrical loads Lot 1
including EMCC, Chiller, ETP-MCC,
VFD MCC.
(d) Control cable Lot 1

(e) 1.1KV 3 ½ C x 300sq.mm armoured

Mt 180
FRLS, aluminum power cable for
electrode boilers.
(f) 1.1KV 3 ½ C x 300sq.mm armoured Mt 100
FRLS, aluminum power cable for DG set
12. Supply and erection of Cable trays as per
Lot 1
clause no-1&18.

13. Supply and erection of structural steel for

cable tray supports, push button frame, Lot 1
erection of electrical equipment etc..

14. Supply and erection of hume pipes for

cable trench and associated minor civil
Lot 1
works including excavation as per clause no-
18

15. Cable laying and cable termination as per Lot 1

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 Chapter-9 Technical specification

clause no-18.

16. Supply, installation, termination Grounding

Lot 1
& lightning protection as per clause no-19.

17. Building electrification and providing

switches and sockets in plant areas and Lot 1
buildings as per clause no. 21 & 23.

18. Supply and installation of 10 Nos. of 1.5 TR

split AC for Air conditioning of main plant
Lot 1
building and providing adequate ventilation in
plant areas as per clause no-22.

19. Supply and installation of Local Push Button Lot 1

Stations as per Clause no. 23

20. Spares as per clause no-1 & 27. Lot 1

21. Misc. Items not indicated above but required Lot 1

to complete the project.

Note: The qty. indicated as lot in the above table has to be calculated by the EPC contractor during
detailed engineering. Accordingly, schedule for each item to be worked out by EPC contractor and get
them approved by HWB and based on that, detailed final SOQ should be prepared by them. Quantity &
size of items mentioned in this SOQ are not changeable.

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6. INST. & CONTROL - SCHEDULE OF QUANTITIES

S. No. DESCRIPTION QTY.

Configuration, Supply & Installation of DCS system of 1000 I/O’s

including total system Integration, testing and Commissioning as per
specifications mentioned in S. No.- 8 to 9. Including Colour laser
1 1 system
printer for printing document up to A3 size laser (A4 size black &
white) ,Hardwire Alarm system, Printer table & Chairs for operator

Supply and Installation of Operator console with cut out and fixing
2 as per dimension given in Annexure-II of the Inst. & control 3 Nos.
Specification.
25 KVA UPS System as per detailed specification given in electrical
3 1 system
technical specification.
Control Valve
As per specification mentioned in Sl. No. 10 to 11 as list of instruments
4 mentioned in Sl. No. 1 to 7
PTFE lined Control valve with accessories 4
SS Control valve with accessories 16
Level Transmitter
As per specification mentioned in Sl. No. 10 to 11 as list of instruments
mentioned in Sl. No. 1 to 7
5 Radar type 9
Ultrasonic type 1
Remote seal type 3
Non contact type RADAR 6
RTD PT 100(Temp transmitter)
As per specification mentioned in Sl. No. 10 to 11 as list of instruments
6 mentioned in Sl. No. 1 to 7
RTD with SS thermo well( With transmitter) 31
RTD with Hastelloy-C thermo well ( With transmitter) 19
Temperature gauge
7
As per specification mentioned in Sl. No. 10 to 11 as list of instruments 14
mentioned in Sl. No. 1 to 7
Pressure Transmitter
8 As per specification mentioned in Sl. No. 10 to 11 as list of instruments
mentioned in Sl. No. 1 to 7
Normal Pressure Transmitter 4

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 Chapter-9 Technical specification

Pressure Transmitter with diaphragm seal 12

DPT
9
As per specification mentioned in Sl. No. 10 to 11 as list of instruments 2
mentioned in Sl. No. 1 to 7
Solenoid valve SS
10
As per specification mentioned in Sl. No. 10 to 11 as list of instruments 6
mentioned in Sl. No. 1 to 7
Speed transmitter
11
As per specification mentioned in Sl. No. 10 to 11 as list of instruments 7
mentioned in Sl. No. 1 to 7
Flow transmitters
As per specification mentioned in Sl. No. 10 to 11 as list of instruments 36
mentioned in Sl. No. 1 to 7
Hastelloy C Mass flow meter coriolisis 5
12
SS Mass flow meter coriolisis 3
Rotameter with transmitter 14
Rotameter with local indication only 9
Steam mass flow transmitter(Vortex/Orifice) 5
Level switch
13 As per specification mentioned in Sl. No. 10 to 11 as list of instruments
mentioned in Sl. No. 1 to 7
Level switch LG mounted 48
14 Pressure switch 8
Level gauge
As per specification mentioned in Sl. No. 10 to 11 as list of instruments
15 mentioned in Sl. No. 1 to 7
SS 316 21
PTFE lining 16
Pressure gauges
As per specification mentioned in Sl. No. 10 to 11 as list of instruments
16 mentioned in Sl. No. 1 to 7
SS PG 57
PTFE Lining PG 25
Vacuum gauge
As per specification mentioned in Sl. No. 10 to 11 as list of instruments
17 mentioned in Sl. No. 1 to 7
Mccleod 6
Pirani with Transmitter 6
‘pH' Transmitter
18 As per specification mentioned in Sl. No. 10 to 11 as list of instruments 3
mentioned in Sl. No. 1 to 7
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Weight transmitter (Load cell)

19 As per specification mentioned in Sl. No. 10 to 11 as list of instruments 5
mentioned in Sl. No. 1 to 7
Weighing machine
20 3
As per specifications
POCl3 detector
21 As per specification mentioned in Sl. No. 10 to 11 as list of instruments 6
mentioned in Sl. No. 1 to 7
Online HCL monitor
22 As per specification mentioned in Sl. No. 10 to 11 as list of instruments 6
mentioned in Sl. No. 1 to 7
Online Hydrocarbon monitor
23 As per specification mentioned in Sl. No. 10 to 11 as list of instruments 4
mentioned in Sl. No. 1 to 7
Online Hydrogen monitor
24 As per specification mentioned in Sl. No. 10 to 11 as list of instruments 3
mentioned in Sl. No. 1 to 7
UV + IR Flame sensors
25 As per specification mentioned in Sl. No. 10 to 11 as list of instruments 3
mentioned in Sl. No. 1 to 7
1/4" SS Tube meters
26 As per specification mentioned in Sl. No. 12 to 13 as list of instruments lot
mentioned in Sl. No. 1 to 7
1/2" SS Tube meters
27 As per specification mentioned in Sl. No. 12 to 13 as list of instruments lot
mentioned in Sl. No. 1 to 7
Fittings, connectors ,cable glands ,tags and all other required
accessories for tubing
28 lot
As per specification mentioned in Sl. No. 12 to 13 as list of instruments
mentioned in Sl. No. 1 to 7
Multi core Cable(various sizes)
29 As per specification mentioned in Sl. No. 12 to 13 as list of instruments 4000 meters
mentioned in Sl. No. 1 to 7
RTD cable
30 As per specification mentioned in Sl. No. 12 to 13 as list of instruments 3000 meters
mentioned in Sl. No. 1 to 7
Control cable from DCS to MCC Panel
31 As per specification mentioned in Sl. No. 12 to 13 as list of instruments lot
mentioned in Sl. No. 1 to 7
Signal Cable (various sizes)
32 As per specification mentioned in Sl. No. 12 to 13 as list of instruments lot
mentioned in Sl. No. 1 to 7

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 Chapter-9 Technical specification

Cable trays
As per specification mentioned in Sl. No. 12 to 13 as list of instruments
mentioned in Sl. No. 1 to 7
33
100mm/50mm 1000 meters

300mm 500 meters

Junction boxes
34 As per specification mentioned in Sl. No. 12 to 13 as list of instruments 18 nos.
mentioned in Sl. No. 1 to 7
Misc. Items like hard wares , components required for interfacing and
35 1 lot
total system integration.

36 Structural material required for different type supports 1 lot

37 Auxiliary Panels (If required) lot

Spares Required
1
Diaphragm seal type PG 5

2 Without diaphragm PG 5
3 Pressure transmitter 1
4 Pressure Transmitter with diaphragm seal 1
6 PTFE Control valve with accessories 1
7 SS Control valve with accessories 1
8 Electro pneumatic positioner 2
9 Air filter regulator 10
10 LG mounted switch 3
11 Control Valve spares 1 lot 1
12 RADAR LT 1

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Long delivery item of SPP

The Purchase order of the following items shall be issued by the EPC contractor within three
months from the date of issue of work order by HWB.

Process

1. Vacuum system (S.No. 3 as on page CS-10)

2. Chilled water system (S.No. 6 as on page CS-10)
3.

Mechanical :

1. Glass lined reactors ( 43 RV 01,02,03, 44 RV 01,02)

2. Nickel lined reactor (43 RV03)
3. First MTO(Material take off) of Piping(Item no. 92 to 98 on page CS -14)
4. Bulk storage tanks (49 V01,02,03,04,05)
5. Centrifugal pumps (as listed on page no. CS-13 &14)

Electrical :

1. Power Transformer (S. No. 1 as on page CS-16)

2. 3.3KV VCB (S. No. 2 as on page CS-16)
3. 3.3KV HT Cable (S. No. 11a. as on page CS-17)
4. DG Set (S. No. 3 as on page CS-16)
5. MCC Panels(S. No. 4&5 as on page CS-16)
6.

Inst. & Control :

1. DCS system (S. No. 1 as on page CS-19)

2. Operator console(S. No. 1 as on page CS-19)
3. 25 KVA UPS(S. No. 3 as on page CS-19)
4. Multi core Cable (various sizes) (S. No. 29 as on page CS-21)
5. RTD cables(S. No. 30 as on page CS-21)

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TECHNICAL SPECIFICATIONS

PROCESS

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Chapter-9 Technical specification

CONTENT

S.No. DESCRIPTION PAGE NO.

P-3
1 Introduction

2 Scope of Work P-3

P-5
3 Site Description
P-5
4 Process and Plant Description

5 Raw Materials, Utility Systems, Storage & Auxiliaries P-6

P-9
6 Equipment and Machinery List
P-16
7 Process Data Sheets

8 Package Units P-94

P-94
8.1 Specification of Alkali Dissolution Unit (Unit 46)

8.2 Specification of Vacuum & Vent Scrubber Unit (Unit 47) P-96

P-104
8.3 Specification of Electrode Boilers (Unit 48)
P-106
8.4 Specification of Chilled Water System (Unit 50)

8.5 Specification of Cooling Water System (Unit 51) P-108

P-110
9 List of Spares
P-111
10 List of Recommended Vendors

11 List of Drawings P-112

P-113
12 Schedule of Quantities

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1. INTRODUCTION

The following process details has been prepared for carrying out design and detailed
engineering, procurement and construction (EPC) of the Solvent Production Plant(SPP)
facility at HWP (Heavy Water Plant), Tuticorin. SPP is intended to produce various types of
organo phosphorous solvents for captive consumption of Department of Atomic Energy.

The plant will be located in the premises of Heavy Water Plant, Tuticorin in Tamil
Nadu state. The utilities like electrical power, raw water, nitrogen, instrument air, fire water
& DM water (as per requirement) will be tapped from HWP Tuticorin.

2. SCOPE OF WORK

The scope of work of EPC contractor covers residual process design & engineering,
procurement, supply, erection, testing, pre-commissioning, commissioning & documentation
of the auxiliary and package utility system covered under process and mechanical technical
specifications. The Schedule of Quantity (SOQ), process data sheet & technical specification
given in the document is the minimum requirement for the project. The scope of work of EPC
contractor for Process & utility system is given below (but not limited to):

2.1. Review of adequacy of design/ basic engineering:

EPC contractor shall carry out the residual design & detailed engineering for the
following:
a. Hydraulic calculations - adequacy of pump heads and gravity flow lines.
b. Design and sizing of heat exchangers.
c. Sizing of relief valves and rupture disc.
d. Adequacy of sizing of utility & package systems.

2.2. Piping & Instrumentation diagrams:

Tentative P&IDs are given in the tender document. The EPC contractor shall review
P&IDs and conduct HAZOP study for finalization of P&IDs. Detailed final P&IDs with
instrumentation & control logic, head, capacity & power ratings of various machinery,
design documents and HAZOP study report shall be prepared and submitted for approval
of HWB. Process flow diagrams are not included in this tender document and shall be
issued after placement of work order.

2.3. Auxiliary & Package utility systems:

Design, engineering, supply, erection, testing, pre-commissioning, commissioning &
documentation of the auxiliary and utility systems like vacuum system, chilled water
system, vent scrubber system, electrode boiler, cooling tower & alkali dissolution system.
The QAP for auxiliary and utility systems shall be prepared by the EPC contractor and
submitted for approval. Testing/stage inspection of the system at vendor’s works and
performance testing at site shall be witnessed by HWB for acceptance. The list of spares
for auxiliary and utility systems is given in the tender document.

2.4. Design Basis Report:

Preparation and submission of process design basis report including the following :

a. Design & residual engineering

b. Basis for selection of material of construction for equipment, piping & machinery.
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c. Basis of process fluid transportation methodology.

d. Basis of safety system features.

2.5. Cause and Effect diagram:

Preparation and submission of cause and effect diagram for control and interlocks
system.

2.6. List of Piping & equipment:

Preparation and submission of final detailed list of pipelines, equipment, machinery,
instrument, electrical load and valves from the approved P&IDs.

2.7. Technical Specification & Process Data Sheets:

Review of design adequacy and preparation and submission of final technical
specification / design data sheets for pipelines, equipment, machinery, instrument,
electrical equipment, valves, heat exchangers, reactors, agitators, distillation columns,
scrubber, pumps, relief valves, rupture disc etc.

2.8. Equipment layout:

A tentative plant equipment layout and plot plan is given in the tender. Final
equipment layout shall be prepared for review/approval of HWB.

2.9. Documentation:
Preparation and submission of documents for conducting commissioning,
performance testing, schedule of testing, operational procedures and precautions.
Participation in system testing & commissioning as well as plant start-up activities.
Preparation of commissioning reports, test reports and operation manuals shall be carried
out by the EPC contractor.

2.10. Deliverables: The following is the list of deliverables by the EPC contractor:
1. Equipment layouts.
2. Design Basis Report.
3. P&IDS.
4. Equipment list.
5. Machinery list.
6. Line list with consolidated pressure drop tables.
7. Instrument list.
8. Valve list.
9. Electrical load list.
10. Tank datasheets.
11. Machinery datasheets.
12. Reactor datasheets.
13. Heat exchanger datasheets.
14. Datasheets of Safety valves and rupture discs.
15. HAZOP report.
16. Cause and effect diagram.
17. Procedure and schedules for systems/Plant commissioning.
18. Systems/plant test and commissioning reports.
19. Operation manuals for plant equipment, machinery and package systems.

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However, during the execution of the project, minor changes and rectification of
deficiencies arising out of detailed engineering, HAZOP, testing & commissioning shall be in
the scope of EPC contractor.

3. SITE DESCRIPTION

a) Geographical Longitude : 78° - 8’ - 44’’E

b) Geographical Latitude : 8° - 44’- 16’’N
c) Elevation above Sea level : 2.85 m
d) State : Tamil Nadu
e) District : Tuticorin
f) Taluk : Tuticorin
g) Police station : Muthiapuram

Heavy Water Plant is located at a longitude of 78° - 8’ - 44’’E and latitude of 8° - 44’ -
16’’N at an elevation of 2.85m above sea level. The area of the plant is 8.5 hectares. It is
situated at a distance of 14 KM from Tuticorin Railway Station and about 4 KM from
Tuticorin – Thiruchendur high way running on the west side of the plant. On the east lies the
Bay of Bengal about 3 KM away. The fertilizer plant of M/s. SPIC is situated adjacent on the
north side and extends on the east and west side. To the south of the plant, lies an open
lagoon and gypsum yard of M/s Southern Petrochemical Industries Corporation (SPIC).

The general climatic conditions of the site are summarised below:

S. No. Parameter Value

1 Maximum Temperature, °C 38.2
2 Minimum Temperature, °C 19
3 Design Wet Bulb Temperature, °C 28
4 Dry Bulb Temperature Max./Min, °C 38/20
5 Design Ambient Temperature, °C 50
6 Relative Humidity, % 61.9-86
7 Average Rainfall, mm 625
8 Wind Speed, Maximum km/hr 90
9 Wind Speed, Average km/hr 50-60
10 Wind Rose Direction N-W

4. PLANT DESCRIPTION

SPP is intended to produce various solvents in different campaigns in batch mode as per
the requirement. The plant shall be operated in round the clock shift throughout the year. The
process operations shall be carried out in stirred tank jacketed reaction vessels with heating &
cooling for different steps. In view of multiple solvents being produced in the same facility,
the reactors & vessels shall be positively connected or blinded as per the requirement. A
schematic diagram (No: HWB/SPP/PROC/0002, Rev 01 ) of the SPP facility is enclosed in
the tender.
The plant shall consist of equipment viz. reactors, vessels, day tanks, bulk storage tanks,
heat exchangers, columns etc. machinery viz. pumps, agitators, blowers, compressors etc.

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auxiliary and package utility systems. The operating pressure ranges from vacuum to
2
10 kg/cm and temperature ranges from -10 °C to 170 °C. To maintain the above operating
conditions, the main SPP facility shall be installed with required auxiliary units viz. vacuum
system, scrubber system, alkali preparation unit and package utility units namely chiller unit,
steam generation unit and cooling water unit. Other utilities such as power, raw water, DM
water, Instrument Air & nitrogen shall be drawn from HWP. The facility shall also be
provided with bulk storage tanks (5 nos.) for storing n- Butanol, 2 EHA, IAA. These tanks
shall be located at about 300 m away from the SPP plant building and shall be connected to
the appropriate daytank in the main plant of SPP. Other liquid chemicals like PCl3 and POCl3
shall be stored in drums in the dedicated chemical storage building and the other chemicals
like Na2CO3, KOH, NaOH etc. shall be stored in the chemical storage shed.
Various types of Corrosive fluids are to be handled in this facility. The respective
equipment of the facility shall be designed to handle the chemicals namely POCl 3, PCl3,
2Ethyl Hexanol, n- Butanol, Sodium, Magnesium, KOH, n- Hexane, Xylene, THF, Bromo
Octane, aq. HCl, aq. Sodium carbonate & Sodium hydroxide solution, Tri Ethyl Amine, Di
Hexyl Amide, Octyl chloride, Iso Amyl alcohol and intermediate products of acidic &
alkaline nature. Material of Construction for the respective vessels, piping, machinery &
equipment has been suitably selected based on the fluid compatibility.

List of plant units of SPP:

UNIT No. DESCRIPTION

43 Main plant 1
44 Main plant 2
45 Butanol recovery
46 Alkali dissolution
47 Vacuum & Vent scrubber
48 Electrode boiler
49 Bulk storage tanks
50 Chilled water system
51 Cooling water system

5. RAW MATERIALS, UTILITY SYSTEM, STORAGE & AUXILIARIES

List of chemicals used in the facility and broad specification of utility and auxiliary
systems in SPP is given below:

5.1. Chemicals to be used in the facility:

i) POCl3
ii) PCl3
iii) 2 Ethyl Hexanol
iv) n- Butanol
v) Iso Amyl alcohol
vi) Sodium

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vii) Potassium Hydroxide

viii) n- Hexane
ix) Hydro chloric acid
x) Sodium Carbonate
xi) Sodium Hydroxide
xii) Tri Ethyl Amine
xiii) Di Hexyl Amine
xiv) Octonyl Chloride
xv) Bromo Octane
xvi) Xylene
xvii) Tetra Hydro Furan
xviii) Magnesium
xix) Iodine

5.2. Utilities and its Specifications:

Utilities like raw water, Instrument air, Nitrogen & Fire water are available in the
plant. Other utilities like Chilled water, steam, alkali solution are to be generated from
the proposed package system.

Utilities available in the plant & its specification

Raw water:
Turbidity : less than 2 NTU
PH : 7.8-8.0
Total hardness : 184 mg/l as CaCO3
Calcium hardness : 80 mg/l as CaCO3
Total Na + (incl. K+) : 182 mg/l as CaCO3
Total alkalinity : 260 mg/l as CaCO3
P-alkalinity : Nil
Chloride : 95 mg/l as CaCO3
Silica : 26 mg/l as CaCO3
Sulphate : 13 mg/l as CaCO3
Nitrate : nil
COD : less than 2 mg/l as O2

Instrument Air:
Pressure : 6.0 to 7.0 kg/cm2 (g)
Dew point : - 40 °C

Nitrogen:
Pressure : 3 kg/cm2 (g)
Oxygen : 10 - 100 ppm
Oil : nil

Fire Water:
A complete Fire water system consisting of fire hydrant at 7.0 Kg/cm2 (g) pressure is
available in SPP facility.

Utilities & Auxiliaries to be provided by the EPC contractor

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Package Chilled water unit :

120 (60 TR x 2) with a chilled water supply temp. of -5 °C and return at 0 °C.

Package Steam generation unit ( Non IBR electrode Boiler )

Capacity : 800 Kg/hr (400 x 2)
Pressure : 6.0 kg/cm2 (g)

Vent scrubber :
Scrubbing duty :
HCl : 100 Kg/hr
Organics : 1-2 % ( not dissolved )

Alkali solution preparation unit:

2 KL dissolution tank × 2 nos.
Jacketed Vessel with Agitator and 3 nos. of supply pumps

Vacuum System:
Consisting of two trains of vacuum pumps. Each train shall comprise of 1 booster
pump, two Oil Seal Rotary Vacuum (OSRV) pumps and with a chiller trap and a
Knock Out Drum.

Bulk Storage facility:

Type of storage : Dyked CS Horizontal tank

Capacity : 30 KL × 3 nos. and 20 KL × 2 nos.
Storage conditions : Atmospheric temperature & pressure
Fire fighting system : Automatic sprinkler system
Transfer pumps : 7 nos. of Centrifugal pumps outside the dyke

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6. EQUIPMENT & MACHINERY LIST

6.1. List of process vessels of unit 43

Capacity, Pressure, Kg/cm2,a Temperature, °C

S.No Tag No. MOC Service Fluid H/V
m3
Operating Design Operating Design
Day Full
1 43V01 2 SS 304L Tank 2EHA V 0-2 Vac-6 Ambient 100
Feed POCl3/PCl3/TEA/OC/ Full
2 43V02 0.5 MSGL Tank DHA V vac-2 Vac-6 Ambient 100
Feed POCl3/PCl3/TEA/OC/ Full
3 43V03 1 MSGL Tank DHA V vac-2 Vac-6 Ambient 100
Feed POCl3/PCl3/TEA/OC/ Full
4 43V04 0.5 MSGL Tank DHA V vac-2 Vac-6 Ambient 100
Day Full
5 43V05 1 MSGL Tank Hexane Trace HCl V vac-2 Vac-6 Ambient 100
Day Octyl Chloride Trace Full
6 43V06 1 MSGL Tank HCl V vac-2 Vac-6 Ambient 100

Charging Full
7 43V07 1 SS 304L Vessel Na2CO3 (soln.)/KOH V vac-2 Vac-6 Ambient 100

Charging Full
8 43V08 1 SS 304L Vessel Na2CO3 (soln.)/KOH V vac-2 Vac-6 Ambient 100
Day Static
9 43V09 1 PPFRVE Tank HCL Charging Vessel V Atm Fill Ambient 70
Day Full
10 43V10 1 SS 304L Tank DM Water V 0-2 Vac-6 Ambient 100
Product Full
11 43V11 1 MSGL Tank D2EHPA II, DHOA V 0-2 Vac-6 Ambient 100
Full
12 43V12 1 MSGL Receiver Hexane V vac-2 Vac-6 Ambient 100
Full
13 43V13 1 MSGL Receiver RCL+ROH V vac-2 Vac-6 Ambient 100
Full
14 43V14 1 MSGL Receiver Xylene V vac-2 Vac-6 Ambient 100
Full
15 43V15 1 MSGL Receiver RCL+ROH V vac-2 Vac-6 Ambient 100
Excess Full
16 43V16 1 SS 304L Receiver RCL+ROH V vac-2 Vac-6 Ambient 100
POCl3/PCL3/TEA/OC/
Dump DHA/Hexane/. Full
17 43 V 17 2 MSGL Tank Xylene H vac-2 Vac-6 Ambient 100
Drain Static
18 43 V 18 1 PPFRVE Tank Reactor Drain H Atm Fill Ambient 70
Drain Static
19 43 V 19 1 PPFRVE Tank Reactor Drain /H Atm Fill Ambient 70

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6.2. List of heat exchangers of unit 43

Pressure, Kg/cm2,g Temperature, °C

S.No. Tag No. Duty MOC Service Fluid H/V
Operating Design Operating Design

Refer
Data CW Hexane, Process:vac-1 Process:vac-5 Process:150-45
1 43R01 Sheet Graphite Condenser DOP,2EHA,BO V Utility:3 Utility:5 Utility:32-37 180
Refer Process:vac-5
Data CHW Hexane, DOP, Process:vac-1 Utility:5 Process:45-10
2 43R02 Sheet Graphite Condenser 2EHA, BO V Utility:2.5 Utility:-5-0 180
Refer Process:vac-5
Data CW RCl, ROH, Xylene, Process:vac-1 Utility:5 Process:150-45
3 43R03 Sheet Graphite Condenser Hexane V Utility:3 Utility:32-37 180
Refer Process:vac-5
Data CHW RCl, ROH, Xylene, Process:vac-1 Utility:5 Process:45-10
4 43R04 Sheet Graphite Condenser Hexane V Utility:2.5 Utility:-5-0 180
Refer Process:vac-5
Data CW THF, Hexane, Process:vac-1 Utility:5 Process:80-40
5 43R05 Sheet SS 316L Condenser DOP, RCL V Utility:3 Utility:32-37 180
Refer Process:vac-5
Data CHW THF, Hexane, Process:vac-1 Utility:5 Process:40-10
6 43R06 Sheet SS 316L Condenser DOP, RCL V Utility:2.5 Utility:-5-0 180

6.3. List of reactors of unit 43

Design
Design
Capacity, H/ Pressure,
S.No. Tag No. MOC Service Fluid 2 Temperature, °C
m3 V Kg/cm ,a
Process Jacket Process Jacket
Full Full
1 43RV01 2 MSGL Reactor POCl3/PCl3/TEA/OC/DHA/ V Vac-6 Vac-8 200 200
Hexane/Xylene/Sodium/HCl/ Full Full
2 43RV02 2 MSGL Reactor EHA/Na2CO3 (soln.) V Vac-6 Vac-8 200 200

Full Full
3 43RV03 2 CS-Ni Reactor TOP/KOH/Xylene /Sodium V Vac-6 Vac-8 200 200

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6.4. List of process vessels of unit 44

Pressure, Kg/cm2,g Temperature, ° C

Tag Capacity,
S.No. MOC Service Fluid H/V
No. m3
Operating Design Operating Design

1 44 V01 5 SS 304L Day Tank Butanol V 0-2 Full Vac-6 Ambient 100
Charging
2 44 V02 1 MSGL Vessel POCl3 V vac-2 Full Vac-6 Ambient 100
Charging
3 44V03 1 MSGL Vessel POCl3 V vac-2 Full Vac-6 Ambient 100
SS 304L
4 44V04 2 Feed Tank Na2CO3 (soln.) V 0-2 Full Vac-6 Ambient 100
SS 304L
5 44V05 2 Feed Tank Na2CO3 (soln.) V 0-2 Full Vac-6 Ambient 100
6 44V06 4 MSGL Dump Tank Butanol, aq HCl H vac-2 Full Vac-6 Ambient 100
SS 304L
7 44V07 2 Feed Tank Na2CO3 (soln.) V 0-2 Full Vac-6 Ambient 100
SS 304L
8 44V08 3 Storage Tank Impure Butanol V 0-2 Full Vac-6 Ambient 100
9 44V09 2 SS 304L Product Tank Solvent V vac-2 Full Vac-6 Ambient 100
10 44V10 2 PPFRVE Drain Tank Wash Water H atm Static Fill Ambient 60
11 44V11 2 PPFRVE Drain Tank Wash Water H atm Static Fill Ambient 60

6.5. List of heat exchangers of unit 44

Pressure, Kg/cm2,g Temperature, °C

S.No. Tag No. Duty MOC Service Fluid H/V
Operating Design Operating Design

Process: Process
Process: Process: 110-40 :0-150
Refer Data SS Condenser, Butanol + Moisture vac-atm vac-5 Utility: Utility:-
1 44 E 1-A Sheet 304L S&T (3-15 %) v Utility:3.5 Utility:5 -32-37 5-60
Process
Process: Process: Process: :0-150
Refer Data SS Condenser, Butanol + Moisture vac-atm vac-5 40-10 Utility:-
2 44 E 1-B Sheet 304L S&T (3-15 %) V Utility:2.5 Utility:5 Utility: -5 -0 5-60

Process: Process: Process: Process

Cold Trap, Butanol + CO2 vac-atm vac-5 40-0 :0-150
Refer Data SS Double Pipe Utility:2.5 Utility:1 Utility:-5-0 Utility:-
3 44 E3 Sheet 304L Type V 5-60

Process
Cold Trap, Butanol + CO2 Process: Process: Process: :0-150
Refer Data SS Double Pipe vac-atm vac-5 40-0 Utility:- Utility:-
4 44 E4 Sheet 304L Type V Utility:2.5 Utility:5 5-0 5-60

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 Chapter-9 Technical specification

6.6. List of reactors of unit 44

Design Pressure, Design

Capacity, Kg/cm2,a Temperature, °C
S.No. Tag No. MOC Service Fluid H/V
m3
Process Jacket Process Jacket

1 44 RV01 5 MSGL Reactor V Full Vac-6 Full Vac-8 200 200

Butanol+POCl3 +
2 44 RV02 5 MSGL Reactor Na2CO3 (soln.) V Full Vac-6 Full Vac-8 200 200

3 44 RV03 5 MSGL Reactor Butanol + TBP V Full Vac-6 Full Vac-8 200 200

6.7. List of process vessels of unit 45

Pressure, Kg/cm2,a Temperature, °C

Capacity, H/
S.No. Tag No. m3 MOC Service Fluid V Operating Design Operating Design
Feed Butanol+ Full Vac-
1 45 V01 5 SS 304 L Tank Moisture (17 %) V 0-2 6 Ambient 150
Product Butanol+ Full Vac-
2 45 V02 5 SS 304 L Tank Moisture (17 %) V 0-2 6 Ambient 150
Butanol+ Full Vac-
3 45 D01 5 SS 304 L Decanter Water V 0-2 6 Ambient 150
Organic Butanol+ Full Vac-
4 45 C1 - SS 304 L Column Water V 0-2 6 100 200
SA 516 gr
70+1mm Aqueous Butanol+ Full Vac-
5 45 C2 - PTFE lining Column Water V 0-2 6 100 200

6.8. List of heat exchangers of unit 45

Pressure, Kg/cm2,g Temperature, °C

Tag
S.No. Duty MOC Service Fluid H/V
No. Operating Design Operating Design

Organic
1 45 R 1 Refer Data column Butanol Process:2 Process:5 Process:117 Process:200
Sheet SS304L reboiler V Utility:3 Utility:5 Utility:135 Utility:200
Aqueous Process:5
2 45 R 2 Refer Data column Effluent water Process:2 Utility:5 Process:117 Process:200
Sheet Graphite reboiler V Utility:3 Utility:135 Utility:200
Butanol + Process:5
3 45 E 1 Refer Data SS304L Head Water Process:1 Utility:5 Process:93-70 Process:180
Sheet Condenser H Utility:3 Utility:32-37 Utility:50
Process:5 Process:180
SS304L Utility:5 Pure Butanol: Utility:50
4
45 E2 Refer Data + Cooler Butanol Process:1 117-40
Sheet H Utility:3 Utility: 32-37
Process:5 Process:180
5 45 E3 Refer Data Graphite Cooler Effluent water Process:1 Utility:5 Process:117-45 Utility:50
Sheet H Utility:3 Utility:32-37
Butanol + Process:5 Process:180
6 45 E4 Refer Data Graphite Condenser Water Process:1 Utility:5 Process:117-45 Utility:50
Sheet H Utility:3 Utility:32-37

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 Chapter-9 Technical specification

6.9. List of process vessels of unit 49

Pressure, Kg/cm2,g Temperature, °C

Capacity,
S.No. Tag No. MOC Service Fluid H/V
m3
Operating Design Operating Design
Full
1 49 V01 20 A 516 Gr 70 2 EHA Storage Tank H 0-2 Vac-5 Ambient 100
Iso Amyl Full
2 49 V02 20 A 516 Gr 70 Alcohol Storage Tank H 0-2 Vac-5 Ambient 100
Full
3 49V03 30 A 516 Gr 70 Dump Dump H 0-2 Vac-5 Ambient 100
Full
4 49V04 30 A 516 Gr 70 Butanol Storage Tank H 0-2 Vac-5 Ambient 100
Full
5 49V05 30 A 516 Gr 70 Butanol Storage Tank H 0-2 Vac-5 Ambient 100

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 Chapter-9 Technical specification

6.10. List of machinery

Capacity,
S.No. Tag No. m3/hr Head, m Qty. Description Type MOC
Unit - 43
1 43 P01 A/B 5 40 2 2EHA Pump Centrifugal SS 316

2 43 P05 A/B 1.5 15 2 Hexane Pump Diaphragm PP

3 43 P06 A/B 0.5 20 2 RCL Feed Pump Diaphragm PP

4 43 P07 A/B 0.8 15 2 Alkali Charging Pump Centrifugal SS 316

5 43 P08 A 0.8 15 1 Alkali Charging Pump Centrifugal SS 316
6 43 P09 A/B 0.5 15 2 HCL Charging Pump Diaphragm PP

7 43 P10 A/B 2 15 2 DM water Feed Pump Diaphragm SS304L

8 43 P17 A/B 6 25 2 Dump Tank Recirculation Centrifugal PP
9 43 ARV01 --- --- 1 Agitator of RV01 Agitator Glass Lined
10 43 ARV02 --- --- 1 Agitator of RV02 Agitator Glass Lined
Ni clad carbon
11 43 ARV03 --- --- 1 Agitator of RV03 Agitator steel
Unit - 44
1 44 P04 A/B 0.6 25 2 Na2CO3 (aq) Dosing Pump Diaphragm SS304L
2 44 P05 0.6 25 1 Na2CO3 (aq) Dosing Pump Diaphragm SS304L
3 44 P06 A/B 6 25 2 Dump Tank Recirculation Centrifugal PP
4 44 P07 A/B 3 25 2 Na2CO3 (aq) Dosing Pump Diaphragm SS304L
5 44 P08 A/B 5 40 2 I-Butanol Feed Pump Centrifugal SS 316
6 44 ARV01 --- --- 1 Agitator of RV01 Agitator Glass Lined
7 44 ARV02 --- --- 1 Agitator of RV02 Agitator Glass Lined
8 44 ARV03 --- --- 1 Agitator of RV03 Agitator Glass Lined
Unit - 45
1 45 P01 A/B 0.7 40 2 Organic Column Feed Pump Diaphragm SS304L
2 45 P02 0.7 40 1 Purified Butanol Transfer Pump Diaphragm SS304L
3 45 P03 A/B 0.7 40 2 Purified Butanol Pump Diaphragm SS304L
4 45 P04A/B 0.1 40 2 Aqueous Phase Transfer Pump Diaphragm SS304L
5 45 P05 A/B 0.7 40 2 Organic Phase Transfer Pump Diaphragm SS304L
Unit – 46 (Package system)
1 46 P01 A/B/C 5.0 40 3 Alkali Feed Pump Centrifugal SS316
2 46 AG 01/02 2 Agitator of Alkali dissolution Agitator SS304L
Unit – 47(Package system)
1 47 P01A/B 5.0 25 2 NaOH recircualation Pump
700 200 mm Blowers for scrubber column
2 47 K1 A/B Nm3/hr H2O 2 O/L
7500
3 47 P02 A/B m3/hr 2 Booster vacuum pump
47 P03 600
4 A1/B1/A2/B2 m3/hr 4 OSRV

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 Chapter-9 Technical specification

Capacity,
S.No. Tag No. m3/hr Head, m Qty. Description Type MOC
Unit - 48(Package system)
1 48 P01 A/B 5 25 2 Raw water feed Pump Centrifugal

2 48 P02 A/B 1.0 100 2 Boiler feed water Pump Diaphragm

Unit - 49
1 49 P01 A/B 5 40 2 EHA Feed Pump Centrifugal SS 316
2 49 P02 A/B 5 40 2 IAA Feed Pump Centrifugal SS 316
3 49 P03 5 40 1 Dumped Liquid Transfer Pump Centrifugal SS 316
4 49 P03 A/B 5 40 2 N-Butanol Feed Pump Centrifugal SS 316
Unit - 50(Package system)
1 50 P01 A/B/C 50 40 3 Hot well Pump Centrifugal
2 50 P02 A/B/C 50 40 3 Cold well Pump Centrifugal
Semi hermatic
3 50 K1 A/B 2 Chiller compressor (60 TR x 2) screw
Unit - 51(Package system)
1 51 P01 A/B/C 100 40 3 CW Pump Centrifugal
2 51 IDF 1/2 2 ID fan

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Chapter-9 Technical specification

7. PROCESS DATA SHEET

7.1. Process Data Sheets of Unit 43

7.1.1. Tanks

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Chapter-9 Technical specification

PROJECT TITLE : ITEM NO.: 43 V01 QTY

SPP, TUTICORIN FEED TANK SERVICE FLUID: 2-ETHYL HEXYL ONE
ALCOHOL
PROCESS
Process fluid : 2-Ethyl Hexyl Alcohol / Iso-Amyl Process Vol. : 2 m3
Alcohol
Liquid density : 830 kg / m3 Liquid Viscosity : 0.88 cP
Operating Pressure : 0-1 kg / cm2 (g) Design Pressure: Full Vacuum to 5 Kg/cm2(g)
Operating Temperature : 35 °C Design Temperature : 100 °C
MECHANICAL
Design Code : ASME Sec-VIII- Div-I Hydro Test Pressure : As per code
Type Of Shell : Cylindrical Minimum Thickness : 6 mm, Vendor to confirm
Side Dish End (1) : 2:1 Ellipsoidal Side Dish End (2) : 2:1 Ellipsoidal
Dish thickness: 4mm
Type Of Installation : Indoor Radiography : 100 %
Shell Inside Diameter : 1100 mm Orientation: Vertical
TL To TL Length : 2200 mm Material For Shell : SA 240 SS 304 L
Material For End Covers : SA 240 SS 304 L Material For Nozzle Flange : SA 182 SS 304 L
Material For Nozzle Pipe : SA 312 SS 304 L Material For Leg Support : IS-2062
Material For Manhole Flange : SA 240 SS 304 L Manhole Details : 600 mm X 150 lb
Material For Stud Bolts : A-193 Gr-B8M Material For Nuts : A-194 Gr-8M
Type Of Insulation : None Seismic Code : IS 1893
NOZZLE & CONNECTION
Mark No Size Elevation Rating Service
mm mm

N1 1 40 Top 150 lbs Liquid In

N2 1 40 Bottom 150 lbs Liquid Out
N3 1 25 Bottom 150 lbs Drain
N4 1 25 Top 150 lbs Safety Valve
N5A/B 2 25 2150/50 150 lbs LG/LT
N6 1 600 400 150 lbs Manhole
N7 1 25 Top 150 lbs PG
N8 1 25 Top 150 lbs Nitrogen In
N9 1 25 Top 150 lbs Vent
N10 1 50 Top 150 lbs Spare

NOTES :
a) Nozzle elevations are from the bottom tan line.

PROCESS DATA SHEET

43 V01 REV
00

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Chapter-9 Technical specification

PROJECT TITLE : ITEM NO.: 43 V02 QTY

SPP, TUTICORIN FEED TANK SERVICE FLUID: PHOSPORYL ONE
CHLORIDE/ PHOSPHORUS TRI-
CHLORIDE/ TRI-ETHYL AMINE
PROCESS
Process fluid : POCl3/PCl3/(C2H5)3N Process Vol. : 0.5 m3
3
Liquid density : 1200-1600 kg / m Liquid Viscosity : 0.5-1.0 cP
Operating Pressure : 0-1 kg / cm2 (g) Design Pressure : Full Vacuum to 5 Kg/cm2(g)
Operating Temperature : 35 °C Design Temperature : 100 °C
MECHANICAL
Design Code : DIN 28136 manufactured as per Sec- Hydro Test Pressure : As per code
VIII-Div-I
Type Of Shell : Cylindrical Thickness : Vendor to confirm
Side Dish End (1) : 2:1 Ellipsoidal Side Dish End (2) : 2:1 Ellipsoidal
Type Of Installation : Indoor Radiography : 100 %
Shell Inside Diameter : 800 mm Orientation : Vertical
Top TL To Bottom End Length (h1): 1200 mm Material For Shell : : Enamel Quality Steel A 516 M Grade
380
Material For End Covers : Enamel Quality Steel A 516 Material For Nozzle Flange : A 516 M Grade 380
M Grade 380
Material For Nozzle Pipe : : Enamel Quality Forging SA Material For Leg Support : IS-2062
836 Class I /SA 181M Class 60
Material For Manhole Flange : A 516 M Grade 380 Manhole Details :500 mm X 150 lb
Material For Stud Bolts : A-193 Gr-B7 Material For Nuts : A-194 Gr-2H
Glass Lining of Wetted Parts :1.5-2.0 mm Type Of Insulation : None
NOZZLE & CONNECTION
Mark No Size Elevation Rating Service
mm mm

N1 1 25 Top 150 lbs Liquid In

N2 1 25 Bottom 150 lbs Liquid Out
N3 1 25 Top 150 lbs Vent
N4 1 50 Top 150 lbs Safety Valve
N5 1 25 Top 150 lbs LT
N6 1 500 Top 150 lbs Manhole
N7 1 25 Top 150 lbs PG
N8 1 25 Top 150 lbs Nitrogen In
N9 1 25 Top 150 lbs Spare

NOTES :
a) Nozzle elevations are from the bottom tan line.

PROCESS DATA SHEET

43 V02 REV
00

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Chapter-9 Technical specification

TITLE : ITEM NO.: 43 V03 QTY

PROJECT FEED TANK
SPP, TUTICORIN SERVICE FLUID: PHOSPORYL ONE
CHLORIDE/DHA/DOP/BO
PROCESS
Process fluid : POCl3 / DHA / DOP / BO Process Vol. : 1.0 m3
3
Liquid density : 1200-1600 kg / m Liquid Viscosity : 0.5-1.0 cP
Operating Pressure : 0-1 kg / cm2 (g) Design Pressure : Full Vacuum to 5 Kg/cm2(g)
Operating Temperature : 35 °C Design Temperature : 100 °C
MECHANICAL
Design Code : DIN 28136 manufactured as per Sec-VIII- Hydro Test Pressure : As per code
Div-I
Type Of Shell : Cylindrical Thickness : Vendor to confirm
Side Dish End (1) : 2:1 Ellipsoidal Side Dish End (2) : 2:1 Ellipsoidal
Type Of Installation : Indoor Radiography : 100 %
Shell Inside Diameter (d1) : 1000 mm Orientation : Vertical
Top TL To Bottom End Length (h1) : 1800 mm Material For Shell : : Enamel Quality Steel A 516 M
Grade 380
Material For End Covers : Enamel Quality Steel A 516 M Material For Nozzle Flange : A 516 M Grade 380
Grade 380
Material For Nozzle Pipe : : Enamel Quality Forging SA Material For Leg Support : IS-2062
836 Class I /SA 181M Class 60
Material For Manhole Flange : A 516 M Grade 380 Manhole Details :500 mm X 150 lb
Material For Stud Bolts : A-193 Gr-B7 Material For Nuts : A-194 Gr-2H
Glass Lining of Wetted Parts :1.5-2.0 mm Type Of Insulation : None
NOZZLE & CONNECTION
Mark No Size Elevation Rating Service
mm mm

N1 1 25 Top 150 lbs Liquid In

N2 1 25 Bottom 150 lbs Liquid Out
N3 1 25 Top 150 lbs Vent
N4 1 50 Top 150 lbs Safety Valve
N5 1 25 Top 150 lbs LT
N6 1 500 Top 150 lbs Manhole
N7 1 25 Top 150 lbs PG
N8 1 25 Top 150 lbs Nitrogen In
N9 1 25 Top 150 lbs Spare

NOTES :
a) Nozzle elevations are from the bottom tan line.

PROCESS DATA SHEET

43 V03 REV
00

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Chapter-9 Technical specification

PROJECT TITLE : ITEM NO.: 43 V04 QTY

SPP, TUTICORIN FEED TANK SERVICE FLUID: OCTONYL ONE
CHLORIDE / TETRAHYDROFURAN
PROCESS
Process fluid : C8H15OCl /(CH₂)₄O Process Vol. : 0.5 m3
3
Liquid density : 1200-1600 kg / m Liquid Viscosity : 0.5-1.0 cP
2
Operating Pressure : 0-1 kg / cm (g) Design Pressure : Full Vacuum to 5 Kg/cm2(g)
Operating Temperature : 35 °C Design Temperature : 100 °C
MECHANICAL
Design Code : DIN 28136 manufactured as per Hydro Test Pressure : As per code
Sec-VIII-Div-I
Type Of Shell : Cylindrical Thickness : Vendor to confirm
Side Dish End (1) : 2:1 Ellipsoidal Side Dish End (2) : 2:1 Ellipsoidal
Type Of Installation : Indoor Radiography : 100 %
Shell Inside Diameter (d1) : 800 mm Orientation : Vertical
Top TL To Bottom End Length (h1) : 1200 mm Material For Shell : : Enamel Quality Steel A 516 M
Grade 380
Material For End Covers : Enamel Quality Steel A Material For Nozzle Flange : A 516 M Grade 380
516 M Grade 380
Material For Nozzle Pipe : : Enamel Quality Material For Leg Support : IS-2062
Forging SA 836 Class I /SA 181M Class 60
Material For Manhole Flange : A 516 M Grade Manhole Details :500 mm X 150 lb
380
Material For Stud Bolts : A-193 Gr-B7 Material For Nuts : A-194 Gr-2H
Glass Lining of Wetted Parts :1.5-2.0 mm Type Of Insulation : None
NOZZLE & CONNECTION
Mark No Size Elevation Rating Service
mm mm

N1 1 25 Top 150 lbs Liquid In

N2 1 25 Bottom 150 lbs Liquid Out
N3 1 25 Top 150 lbs Vent
N4 1 50 Top 150 lbs Safety Valve
N5 1 25 Top 150 lbs LT
N6 1 500 Top 150 lbs Manhole
N7 1 25 Top 150 lbs PG
N8 1 25 Top 150 lbs Nitrogen In
N9 1 25 Top 150 lbs Spare

NOTES :
a) Nozzle elevations are from the bottom tan line.

PROCESS DATA SHEET

43 V04 REV
00

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Chapter-9 Technical specification

PROJECT TITLE : ITEM NO.: 43 V05 QTY

SPP, TUTICORIN Hexane SERVICE FLUID: Hexane ONE
FEED TANK
PROCESS
Process fluid : n-C6H14 Process Vol. : 1.0 m3
Liquid density : 830-970 kg / m3 Liquid Viscosity : 0.8cP
Operating Pressure : 0-1 kg / cm2 (g) Design Pressure: Full Vacuum to 5 Kg/cm2(g)
Operating Temperature : 35 °C Design Temperature : 100 °C
MECHANICAL
Design Code : DIN 28136 manufactured as per Hydro Test Pressure : As per code
Sec-VIII-Div-I
Type Of Shell : Cylindrical Thickness : Vendor to confirm
Side Dish End (1) : 2:1 Ellipsoidal Side Dish End (2) : 2:1 Ellipsoidal
Type Of Installation : Indoor Radiography : 100 %
Shell Inside Diameter (d1) : 1000 mm Orientation : Vertical
Top TL To Bottom End Length (h1) : 1800 mm Material For Shell : : Enamel Quality Steel A 516 M
Grade 380
Material For End Covers : Enamel Quality Steel A Material For Nozzle Flange : A 516 M Grade 380
516 M Grade 380
Material For Nozzle Pipe : : Enamel Quality Material For Leg Support : IS-2062
Forging SA 836 Class I /SA 181M Class 60
Material For Manhole Flange : A 516 M Grade 380 Manhole Details :500 mm X 150 lb
Material For Stud Bolts : A-193 Gr-B7 Material For Nuts : A-194 Gr-2H
Glass Lining of Wetted Parts :1.5-2.0 mm Type Of Insulation : None
NOZZLE & CONNECTION
Mark No Size Elevation Rating Service
mm mm

N1 1 25 Top 150 lbs Liquid In

N2 1 25 Bottom 150 lbs Liquid Out
N3 1 25 Top 150 lbs Vent
N4 1 50 Top 150 lbs Safety Valve
N5 1 25 Top 150 lbs LT
N6 1 500 Top 150 lbs Manhole
N7 1 25 Top 150 lbs PG
N8 1 25 Top 150 lbs Nitrogen In
N9 1 25 Top 150 lbs Spare

NOTES :
a) Nozzle elevations are from the bottom tan line.

APD PROCESS DATA SHEET

CHKD 43 V05 REV

PRO MEC COO 00
SECTION INST
S H RD

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Chapter-9 Technical specification

PROJECT TITLE : ITEM NO.: 43 V06 QTY

SPP, TUTICORIN RCL & ROH TANK SERVICE FLUID: BUTYL CHLORIDE / ONE
BUTYL ALCOHOL
PROCESS
Process fluid : C4H9Cl / C4H9OH Process Vol. : 1.0 m3
3
Liquid density : 830-970 kg / m Liquid Viscosity : 9.8cP
Operating Pressure : 0-1 kg / cm2 (g) Design Pressure: Full Vacuum to 5 Kg/cm2(g)
Operating Temperature : 35 °C Design Temperature : 100 °C
MECHANICAL
Design Code : DIN 28136 manufactured as per Hydro Test Pressure : As per code
Sec-VIII-Div-I
Type Of Shell : Cylindrical Thickness : Vendor to confirm
Side Dish End (1) : 2:1 Ellipsoidal Side Dish End (2) : 2:1 Ellipsoidal
Type Of Installation : Indoor Radiography : 100 %
Shell Inside Diameter (d1) : 1000 mm Orientation : Vertical
Top TL To Bottom End Length (h1) : 1800 mm Material For Shell : : Enamel Quality Steel A 516 M
Grade 380
Material For End Covers : Enamel Quality Steel A Material For Nozzle Flange : A 516 M Grade 380
516 M Grade 380
Material For Nozzle Pipe : : Enamel Quality Material For Leg Support : IS-2062
Forging SA 836 Class I /SA 181M Class 60
Material For Manhole Flange : A 516 M Grade Manhole Details :500 mm X 150 lb
380
Material For Stud Bolts : A-193 Gr-B7 Material For Nuts : A-194 Gr-2H
Glass Lining of Wetted Parts :1.5-2.0 mm Type Of Insulation : None
NOZZLE & CONNECTION
Mark No Size Elevation Rating Service
mm mm

N1 1 25 Top 150 lbs Liquid In

N2 1 25 Bottom 150 lbs Liquid Out
N3 1 25 Top 150 lbs Vent
N4 1 50 Top 150 lbs Safety Valve
N5 1 25 Top 150 lbs LT
N6 1 500 Top 150 lbs Manhole
N7 1 25 Top 150 lbs PG
N8 1 25 Top 150 lbs Nitrogen In
N9 1 25 Top 150 lbs Spare

NOTES :
a) Nozzle elevations are from the bottom tan line.

PROCESS DATA SHEET

43 V06 REV
00

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Chapter-9 Technical specification

PROJECT TITLE : ITEM NO.: 43 V07 & 43 V08 QTY

ALKALI CHARGING
SPP, TUTICORIN VESSEL SERVICE FLUID: TWO
AQ. SODIUM CARBONATE / AQ.
POTASSIUM HYDROXIDE
PROCESS
Process fluid : Aq. Na2CO3 / KOH Process Vol. : 1 m3
Liquid density : 1100-1200 kg / m3 Liquid Viscosity : 2 cP
Operating Pressure : 0-1 kg / cm2 (g) Design Pressure: Full Vacuum to 5 Kg/cm2(g)
Operating Temperature : 35 °C Design Temperature : 100 °C
MECHANICAL
Design Code : ASME Sec-VIII-Div-I Hydro Test Pressure : As per code
Type Of Shell : Cylindrical Minimum Thickness : 6 mm, Vendor to confirm
Side Dish End (1) : 2:1 Ellipsoidal Side Dish End (2) : 2:1 Ellipsoidal
Dish thickness: 4mm
Type Of Installation : Indoor Radiography : 100 %
Shell Inside Diameter : 900 mm Orientation : Vertical
TL To TL Length : 1800 mm Material For Shell : SA 240 SS 304 L
Material For End Covers : SA 240 SS 304 L Material For Nozzle Flange : SA 182 SS 304 L
Material For Nozzle Pipe : SA 312 SS 304 L Material For Leg Support : IS-2062
Material For Manhole Flange : SA 240 SS 304 L Manhole Details : 600 mm X 150 lb
Material For Stud Bolts : A-193 Gr-B8M Material For Nuts : A-194 Gr-8M
Type Of Insulation : None
NOZZLE & CONNECTION
Mark No Size Elevation Rating Service
mm mm

N1 1 25 Top 150 lbs Alkali In

N2 1 25 Bottom 150 lbs Liquid Out
N3 1 25 Bottom 150 lbs Effluent liquid
& Drain
N4 1 25 Top 150 lbs Safety Valve
N5A/B 2 25 1750/50 150 lbs LG/LT
N6 1 600 400 150 lbs Manhole
N7 1 25 Top 150 lbs PG
N8 1 25 Top 150 lbs DM Water In
N9 1 50 Top 150 lbs Vent
N10 1 50 Top 150 lbs Spare
N11 1 25 1500 150 lbs Balance line
N12 1 25 300 150 lbs Balance line
NOTES :
a) Nozzle elevations are from the bottom tan line.

PROCESS DATA SHEET

43 V07 & 43 V08 REV

00

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Chapter-9 Technical specification

PROJECT TITLE : ITEM NO.: 43 V09 QTY

AQ. HCl FEED TANK
SPP, SERVICE FLUID: ONE
TUTICORIN HYDROCHLORIC ACID
PROCESS
Process fluid: Aq. HCl
Process Vol.: 1 m3
: 950-1050 kg / m3
Liquid density
Dimensions : 1000 mm ID x 1500 mm height cylindrical tank
OPERATING DESIGN
PRESSURE, kg/cm2(g) ATMOSPHERIC Hydrostatic head
TEMPERATURE, °C 35 60
CORROSION ALLOWANCE Nil
INSULATION No
MECHANICAL
MATERIAL OF CONSTRUCTION
SHELL : FRV+ PP HEAD: FLAT BOTTOM: FLAT
NOZZLES & FLANGES : FRV+ PP SUPPORTS: MS with epoxy coating
DESIGN & FABRICATION CODE BS 4994 LATEST
SPARK TEST 20 KVA MINIMUM THICKNESS Vendor to indicate
HYDROSTATIC TEST Water fill up to top flange BOLTING SS 304 L
GASKETS Teflon enveloped CAF SUPPORTS MS with epoxy coating
NOZZLE & CONNECTION
Mark No Size Elevation Rating Service
mm mm

N1 1 25 Top 150 lbs Acid In

N2 1 25 Bottom 150 lbs Liquid Out
N3 1 25 Bottom 150 lbs Effluent liquid
& Drain
N4 1 25 Top 150 lbs Spare
N5A/B 2 25 1750/50 150 lbs LG/LT
N6 1 600 400 150 lbs Manhole
N7 1 25 Top 150 lbs PG
N8 1 25 Top 150 lbs DM Water In
N9 1 50 Top Vent
N10 1 Top Spare

PROCESS DATA SHEET

43 V09 RE
V
00

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Chapter-9 Technical specification

PROJECT TITLE : ITEM NO.: 43 V10 QTY

DM WATER TANK
SPP, TUTICORIN SERVICE FLUID: ONE
DM WATER
PROCESS
Process fluid : Demineralised water Process Vol. : 1 m3
Liquid density : 990-1010 kg / m3 Liquid Viscosity : 1 cP
Operating Pressure : 0-1 kg / cm2 (g) Design Pressure: Full Vacuum to 5 Kg/cm2(g)
Operating Temperature : 35 °C Design Temperature : 200 °C
MECHANICAL
Design Code : ASME Sec-VIII-Div-I Hydro Test Pressure : As per code
Type Of Shell : Cylindrical Minimum Thickness : 6 mm, Vendor to confirm
Side Dish End (1) : 2:1 Ellipsoidal Side Dish End (2) : 2:1 Ellipsoidal
Dish thickness: 4mm
Type Of Installation : Indoor Radiography : 100 %
Shell Inside Diameter : 900 mm Orientation : Vertical
TL To TL Length : 1800 mm Material For Shell : SA 240 SS 304 L
Material For End Covers : SA 240 SS 304 L Material For Nozzle Flange : SA 182 SS 304 L
Material For Nozzle Pipe : SA 312 SS 304 L Material For Leg Support : IS-2062
Material For Manhole Flange : SA 240 SS 304 L Manhole Details : 600 mm X 150 lb
Material For Stud Bolts : A-193 Gr-B8M Material For Nuts : A-194 Gr-8M
Type Of Insulation : None
NOZZLE & CONNECTION
Mark No Size Elevation Rating Service
mm mm

N1 1 25 Top 150 lbs Spare

N2 1 25 Bottom 150 lbs Liquid Out
N3 1 25 Bottom 150 lbs Effluent liquid
& Drain
N4 1 25 Top 150 lbs Safety Valve
N5A/B 2 25 1750/50 150 lbs LG/LT
N6 1 600 400 150 lbs Manhole
N7 1 25 Top 150 lbs PG
N8 1 25 Top 150 lbs DM Water In
N9 1 50 Top 150 lbs Vent
N10 1 50 Top 150 lbs Spare
N11 1 25 1500 150 lbs Balance line
N12 1 25 300 150 lbs Balance line
NOTES :
a) Nozzle elevations are from the bottom tan line.

PROCESS DATA SHEET

43 V10 REV
00

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Chapter-9 Technical specification

PROJECT TITLE : ITEM NO.: 43 V11 QTY

SPP, TUTICORIN PRODUCT TANK SERVICE FLUID: D2EHPA-II / DHOA / ONE
TOPO
PROCESS
Process fluid :D2EHPA-II / DHOA / TOPO Process Vol. : 1.0 m3
3
Liquid density : 830-970 kg / m Liquid Viscosity : 4.0cP
Operating Pressure : 0-1 kg / cm2 (g) Design Pressure: Full Vacuum to 5 Kg/cm2(g)
Operating Temperature : 35 °C Design Temperature : 100 °C
MECHANICAL
Design Code : DIN 28136 manufactured as per Hydro Test Pressure : As per code
Sec-VIII-Div-I
Type Of Shell : Cylindrical Thickness : Vendor to confirm
Side Dish End (1) : 2:1 Ellipsoidal Side Dish End (2) : 2:1 Ellipsoidal
Type Of Installation : Indoor Radiography : 100 %
Shell Inside Diameter (d1) : 1000 mm Orientation : Vertical
Top TL To Bottom End Length (h1) : 1800 mm Material For Shell : : Enamel Quality Steel A 516 M
Grade 380
Material For End Covers : Enamel Quality Steel A Material For Nozzle Flange : A 516 M Grade 380
516 M Grade 380
Material For Nozzle Pipe : : Enamel Quality Material For Leg Support : IS-2062
Forging SA 836 Class I /SA 181M Class 60
Material For Manhole Flange : A 516 M Grade Manhole Details :500 mm X 150 lb
380
Material For Stud Bolts : A-193 Gr-B7 Material For Nuts : A-194 Gr-2H
Glass Lining of Wetted Parts :1.5-2.0 mm Type Of Insulation : None
NOZZLE & CONNECTION
Mark No Size Elevation Rating Service
mm mm

N1 1 50 Top 150 lbs Liquid In

N2 1 25 Bottom 150 lbs Liquid Out
N3 1 25 Top 150 lbs Vent
N4 1 50 Top 150 lbs Safety
Valve
N5 1 25 Top 150 lbs LT
N6 1 500 Top 150 lbs Manhole
N7 1 25 Top 150 lbs PG
N8 1 25 Top 150 lbs Nitrogen In
N9 1 25 Top 150 lbs Spare

NOTES :
a) Nozzle elevations are from the bottom tan line.

PROCESS DATA SHEET

43 V11 REV
00

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Chapter-9 Technical specification

PROJECT TITLE : ITEM NO.: 43 V12, 43 V13, 43 V14, 43 QTY

RECEIVER TANK V15
SPP, TUTICORIN SERVICE FLUID: D2EHPA-II / DHOA / FOUR
TOPO / OCl/ Hexane / RCl / ROH / Xylene
PROCESS
Process fluid :D2EHPA-II / TIAP / DHOA / TOPO/ Process Vol. : 1.0 m3
OCl/ Hexane / RCl / ROH / Xylene
Liquid density : 830-970 kg / m3 Liquid Viscosity : 4.0cP
Operating Pressure : 0-1 kg / cm2 (g) Design Pressure: Full Vacuum to 5 Kg/cm2(g)
Operating Temperature : 35 °C Design Temperature : 100 °C
MECHANICAL
Design Code : DIN 28136 manufactured as per Sec- Hydro Test Pressure : As per code
VIII-Div-I
Type Of Shell : Cylindrical Thickness : Vendor to confirm
Side Dish End (1) : 2:1 Ellipsoidal Side Dish End (2) : 2:1 Ellipsoidal
Type Of Installation : Indoor Radiography : 100 %
Shell Inside Diameter (d1) : 1000 mm Orientation : Vertical
Top TL To Bottom End Length (h1) : 1800 mm Material For Shell : : Enamel Quality Steel A 516 M Grade
380
Material For End Covers : Enamel Quality Steel A Material For Nozzle Flange : A 516 M Grade 380
516 M Grade 380
Material For Nozzle Pipe : : Enamel Quality Forging Material For Leg Support : IS-2062
SA 836 Class I /SA 181M Class 60
Material For Manhole Flange : A 516 M Grade 380 Manhole Details :500 mm X 150 lb
Material For Stud Bolts : A-193 Gr-B7 Material For Nuts : A-194 Gr-2H
Glass Lining of Wetted Parts :1.5-2.0 mm Type Of Insulation : None
NOZZLE & CONNECTION
Mark No Size Elevation Rating Service
mm mm

N1 1 50 Top 150 lbs Liquid In

N2 1 25 Bottom 150 lbs Liquid Out
N3 1 25 Top 150 lbs Vent
N4 1 80 Top 150 lbs Safety Valve
N5 1 25 Top 150 lbs LT
N6 1 500 Top 150 lbs Manhole
N7 1 25 Top 150 lbs PG
N8 1 25 Top 150 lbs Nitrogen In
N9 1 50 Top 150 lbs Balance line

NOTES :
a) Nozzle elevations are from the bottom tan line.

PROCESS DATA SHEET

43 V12, 43 V13, 43 V14, 43 V15 REV
00

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Chapter-9 Technical specification

PROJECT TITLE : ITEM NO.: 43 V16 QTY

RECOVERY TANK
SPP, TUTICORIN SERVICE FLUID: ONE
Hexane / Water
PROCESS
Process fluid : n-C6H14 / H2O Process Vol. : 1 m3
Liquid density : 1000 kg / m3 Liquid Viscosity : 2 cP
Operating Pressure : 0-1 kg / cm2 (g) Design Pressure: Full Vacuum to 5 Kg/cm2(g)
Operating Temperature : 35°C Design Temperature : 100 °C
MECHANICAL
Design Code : ASME Sec-VIII-Div-I Hydro Test Pressure As per code
Type Of Shell : Cylindrical Minimum Thickness : 6 mm, Vendor to confirm
Side Dish End (1) : 2:1 Ellipsoidal Side Dish End (2) : 2:1 Ellipsoidal
Dish thickness: 4mm
Type Of Installation : Indoor Radiography : 100 %
Shell Inside Diameter : 900 mm Orientation : Vertical
TL To TL Length : 1800 mm Material For Shell : SA 240 SS 304 L
Material For End Covers : SA 240 SS 304 L Material For Nozzle Flange : SA 182 SS 304 L
Material For Nozzle Pipe : SA 312 SS 304 L Material For Leg Support : IS-2062
Material For Manhole Flange : SA 240 SS 304 L Manhole Details : 600 mm X 150 lb
Material For Stud Bolts : A-193 Gr-B8M Material For Nuts : A-194 Gr-8M
Type Of Insulation : None
NOZZLE & CONNECTION
Mark No Size Elevation Rating Service
mm mm

N1 1 25 Top 150 lbs Liquid In

N2 1 25 Bottom 150 lbs Liquid Out
N3 1 25 Bottom 150 lbs Drain
N4 1 50 Top 150 lbs Safety Valve
N5A/B 2 25 1750/50 150 lbs LG/LT
N6 1 600 400 150 lbs Manhole
N7 1 25 Top 150 lbs PG
N8 1 50 Top 150 lbs Balance line
N9 1 25 Top 150 lbs Vent
N10 1 25 Top 150 lbs Nitrogen In
N11 1 50 Top 150 lbs Spare

NOTES :
a) Nozzle elevations are from the bottom tan line.

PROCESS DATA SHEET

43 V16 REV
00

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Chapter-9 Technical specification

PROJECT TITLE : ITEM NO.: 43 V17 QTY

SPP, TUTICORIN DUMP TANK SERVICE FLUID: HYDROCHLORIC ONE
ACID / N-BUTANOL / SOLVENTS
PROCESS
Process fluid : Solvents / aq. HCl / n-Butanol Process Vol. : 2 m3
3
Liquid density : 830-970 kg / m Liquid Viscosity : 3.8 cP
2
Operating Pressure : 0-1 kg / cm (g) Design Pressure: Full Vacuum to 5 Kg/cm2(g)
Operating Temperature : 35 °C Design Temperature : 100 °C
MECHANICAL
Design Code : DIN 28136 manufactured as per Sec-VIII- Hydro Test Pressure : As per code
Div-I
Type Of Shell : Cylindrical Thickness : Vendor to confirm
Side Dish End (1) : 2:1 Ellipsoidal Side Dish End (2) : 2:1 Ellipsoidal
Type Of Installation : Indoor Radiography : 100 %
Shell Inside Diameter : 1400 mm Orientation : Horizontal
Horizontal Length : 1725 mm Material For Shell : : Enamel Quality Steel A 516 M
Grade 380
Material For End Covers : Enamel Quality Steel A 516 M Material For Nozzle Flange : A 516 M Grade 380
Grade 380
Material For Nozzle Pipe : : Enamel Quality Forging SA Material For Leg Support : IS-2062
836 Class I /SA 181M Class 60
Material For Manhole Flange : A 516 M Grade 380 Manhole Details :500 mm X 150 lb
Material For Stud Bolts : A-193 Gr-B7 Material For Nuts : A-194 Gr-2H
Glass Lining of Wetted Parts :1.5-2.0 mm Type Of Insulation : None
NOZZLE & CONNECTION
Mark No Size Elevation Rating Service
mm mm

N1 1 50 Top 150 lbs Liquid dumping

N2 1 80 Bottom 150 lbs Liquid Out
N3 1 80 Top 150 lbs Vent
N4 1 50 Top 150 lbs Safety Valve
N5 A/B 2 25 Side 150 lbs Level Gauge
N6 1 600 Top 150 lbs Manhole
N7 1 25 Top 150 lbs Pressure Gauge
N8 1 25 Top 150 lbs Nitrogen In
N9 1 50 Top 150 lbs Spare

NOTES :
a) Nozzle elevations are from the bottom line.

PROCESS DATA SHEET

43 V17 REV
00

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Chapter-9 Technical specification

PROJECT TITLE : ITEM NO.: 43 V18 & 43 V 19 QTY

REACTOR DRAIN TANKS
SPP, SERVICE FLUID: TWO
TUTICORIN DRAIN FLUID
PROCESS
Process fluid: Reactor Drain Fluid
Process Vol.: 1 m3
: 950-1050 kg / m3
Liquid density
Dimensions : 1420 mm ID x710X 1000 mm rectangular tank (LXBXH)
OPERATING DESIGN
PRESSURE, kg/cm2(g) ATMOSPHERIC Hydrostatic head
TEMPERATURE, °C 35 60
CORROSION ALLOWANCE Nil
INSULATION No
MECHANICAL
MATERIAL OF CONSTRUCTION
SHELL : FRV+ PP Rectangular HEAD: OPEN BOTTOM: FLAT
NOZZLES & FLANGES : FRV+ PP SUPPORTS: MS with epoxy coating
DESIGN & FABRICATION CODE BS 4994 LATEST
SPARK TEST 20 KVA MINIMUM THICKNESS Vendor to indicate
HYDROSTATIC TEST Water fill up to top flange BOLTING SS 304 L
GASKETS Teflon enveloped CAF SUPPORTS MS with epoxy coating
NOZZLE & CONNECTION
Mark No Size Elevation Rating Service
mm mm

N1 1 50 Side 150 lbs Aqueous In

N2 1 50 Side 150 lbs Effluent liquid
& Drain
N3 1 50 Side 150 lbs Effluent liquid
& Drain
N4 1 50 Side 150 lbs Effluent liquid
& Drain
N5 1 50 Side 150 lbs Effluent liquid
& Drain
N6 1 50 Side 150 lbs Effluent liquid
& Drain

PROCESS DATA SHEET

43 V18 & 43 V 19 RE
V
00

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Chapter-9 Technical specification

7.1.2 Heat Exchangers and Reactors of Unit 43

DATA SHEET FOR POLY BLOCK TYPE GRAPHITE HEAT EXCHANGER
PROJECT: SPP, TUTICORIN TAG NO.:43R01

1 SERVICE OF UNIT: HEAT EXCHANGER (CONDENSER) DUTY: CONTINUOUS

2 DATE: REV NO.:
3 PERFORMANCE OF ONE UNIT
4 FLUID ALLOCATION PROCESS (TUBE SIDE) SERVICE (SHELL SIDE)
5 FLUID 2 ETHYL HEXYL CHLORIDE AND COOLING WATER
2 ETHYL HEXYL ALCOHOL,
INERTS-5%
6 FLUID QUANTITY (TOTAL) kg/hr 210 ***
7 VAPOR FLOWRATE in/out kg/hr *** *** *** ***
8 LIQUID FLOWRATE in/out kg/hr *** *** *** ***
9 TEMPERATURE in/out °C 150 45 32 37
10 DENSITY Vap/Liq kg/m3
11 SPECIFIC HEAT Vap/Liq Kcal/(kg* ⁰C)
12 THERMAL CONDUCTIVITY Vap/Liq Kcal/(hr*m*⁰C)
13 VISCOCITY Vap/Liq °C ***
14 OPERATING PRESSURE 2 ATA TO 100 TORR 4 ATA
15 PRESSURE DROP calc./perm. bar *** 0.5 *** 0.5
16 VELOCITY calc. m/s *** ***
17 FOULING RESISTANCE m2 *h *°C / kcal *** ***
18 HEAT EXCHANGED kcal/hr 38000*
19 LMTD (CORRECTED) ⁰C ***
20 HEAT TRASFER RATE DIRTY SERVICE CLEAN
21 kcal/(m2*hr*⁰C) *** *** ***
22 AREA CALCULATED / AREA PROVIDED m2 ***
23 SHORT SUMMARY OF PROCESS CALCULATIONS
24 ZONE FOR CONDENSER DESUPERHEATING CONDENSATION VAPOR COOLING LIQUID COOLING
25 PROCESS SIDE
26 REYNOLD NUMBER ***
27 PRANDTL NUMBER ***
28 HTC ***
29 SERVICE SIDE
30 REYNOLD NUMBER ***
31 PRANDTL NUMBER ***
32 HTC ***
33 CONSTRUCTION
34 MODEL *** NO. OF BLOCKS ***
35 SURFACE AREA ***
36 NO. OF PASSES *** ***
37 CONNECTIONS Inlet/Outlet mm *** ***
38 Condensate out mm *** ***
39 RATING
40 DESIGN TEMPERATURE °C 180 50
41 DESIGN/TEST PRESSURE bar (g) VAC - 5 5/5.5
42 MOUNTING VERTICAL
43 MATERIAL
44 BLOCKS IMPREGNATED GRAPHITE
45 END CHAMBER/DOMES IMPREGNATED GRAPHITE
46 SHELL IS 2062 GR A/B
47 SHELL LINING NO GASKETS PTFE EPDM ‘O’ RING, Neoprene
48 CODES APPLICABLE FOR DESIGN
49 PROCESS SIDE
50 SERVICE SIDE/SHELL SIDE ASME SEC VIII DIV 1
51 SPECIAL REQUIREMENTS NO
52 OVERALL DIMENSION IN mm (APPROXIMATE)
53 REMARKS: 1. DATASHEET IS FOR 3 DIFFERENT FLUID & TEMPERATURE CASES; DESIGN IS BASED ON CRITICAL CASE OF HEAT LOAD
2. EXCHANGER SHOULD BE DESIGNED FOR DE-SUPERHEATING, CONDENSATION AND SUBCOOLING.
54 MINIMUM AREA TO BE PROVIDED SHALL BE 14 m2
55 *VENDOR TO CONFIRM; *** VENDOR TO CALCULATE

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Chapter-9 Technical specification

DATA SHEET FOR POLY BLOCK TYPE GRAPHITE HEAT EXCHANGER

PROJECT: SPP, TUTICORIN TAG NO.:43R02

1 SERVICE OF UNIT: CONDENSER (CHILLED WATER) DUTY: CONTINUOUS

2 DATE: REV NO.:
3 PERFORMANCE OF ONE UNIT
4 FLUID ALLOCATION PROCESS (TUBE SIDE) SERVICE (SHELL SIDE)
5 FLUID 2 ETHYL HEXYL CHLORIDE AND CHILLED WATER
2 ETHYL HEXYL ALCOHOL,
INERTS
6 FLUID QUANTITY (TOTAL) kg/hr 50 ***
7 VAPOR FLOWRATE in/out kg/hr *** *** *** ***
8 LIQUID FLOWRATE in/out kg/hr *** *** *** ***
9 TEMPERATURE in/out °C 45 10 -5 0
10 DENSITY Vap/Liq kg/m3
11 SPECIFIC HEAT Vap/Liq Kcal/(kg* ⁰C)
12 THERMAL CONDUCTIVITY Vap/Liq Kcal/(hr*m*⁰C) ***
13 VISCOCITY Vap/Liq ⁰C ***
14 INLET PRESSURE 2 ATA TO 100 TORR 3.5 ATA
15 PRESSURE DROP calc./perm. bar *** 0.5 *** 0.5
16 VELOCITY calc. m/s *** ***
17 FOULING RESISTANCE m2 *hr*⁰C/ kcal *** ***
18 HEAT EXCHANGED kcal/hr 9500*
19 LMTD (CORRECTED) °C ***
20 HEAT TRASFER RATE DIRTY SERVICE CLEAN
21 kcal/(m2*hr*⁰C) *** *** ***
22 AREA CALCULATED / AREA PROVIDED m2 ***
23 SHORT SUMMARY OF PROCESS CALCULATIONS
24 ZONE FOR CONDENSER DESUPERHEATING CONDENSATION VAPOR COOLING LIQUID COOLING
25 PROCESS SIDE
26 REYNOLD NUMBER ***
27 PRANDTL NUMBER ***
28 HTC ***
29 SERVICE SIDE
30 REYNOLD NUMBER ***
31 PRANDTL NUMBER ***
32 HTC ***
33 CONSTRUCTION
34 MODEL *** NO. OF BLOCKS ***
35 SURFACE AREA ***
36 NO. OF PASSES *** ***
37 CONNECTIONS Inlet/Outlet mm *** ***
38 Condensate out mm *** ***
39 RATING
40 DESIGN TEMPERATURE °C 180 50
41 DESIGN/TEST PRESSURE bar (g) VAC -5 5/5.5
42 MOUNTING VERTICAL
43 MATERIAL
44 BLOCKS IMPREGNATED GRAPHITE
45 END CHAMBER/DOMES IMPREGNATED GRAPHITE
46 SHELL IS 2062 GR A/B
47 SHELL LINING NO GASKETS PTFE EPDM ‘O’ RING, Neoprene
48 CODES APPLICABLE FOR DESIGN
49 PROCESS SIDE
50 SERVICE SIDE/SHELL SIDE ASME SEC VIII DIV 1
51 SPECIAL REQUIREMENTS NO
52 OVERALL DIMENSION IN mm (APPROXIMATE)
53 REFER
54 REMARKS: 1. DATASHEET IS FOR 3 DIFFERENT FLUID & TEMPERATURE CASES; DESIGN IS BASED ON CRITICAL CASE OF HEAT LOAD
2. EXCHANGER SHOULD BE DESIGNED FOR DE-SUPERHEATING, CONDENSATION AND SUBCOOLING.
55 MINIMUM AREA TO BE PROVIDED SHALL BE 8 m2
56 *VENDOR TO CONFIRM; *** VENDOR TO CALCULATE

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Chapter-9 Technical specification

DATA SHEET FOR POLY BLOCK TYPE GRAPHITE HEAT EXCHANGER

PROJECT: SPP, TUTICORIN TAG NO.:43R03

1 SERVICE OF UNIT: HEAT EXCHANGER (CONDENSER) DUTY: CONTINUOUS

2 DATE: REV NO.:
3 PERFORMANCE OF ONE UNIT
4 FLUID ALLOCATION PROCESS (TUBE SIDE) SERVICE (SHELL SIDE)
5 FLUID Xylene, INERTS-5% COOLING WATER
6 FLUID QUANTITY (TOTAL) kg/hr 500 ***
7 VAPOR FLOWRATE in/out kg/hr *** *** *** ***
8 LIQUID FLOWRATE in/out kg/hr *** *** *** ***
9 TEMPERATURE in/out °C 150 45 32 37
10 DENSITY Vap/Liq kg/m3
11 SPECIFIC HEAT Vap/Liq Kcal/(kg* °C )
12 THERMAL CONDUCTIVITY Vap/Liq Kcal/(hr*m*°C )
13 VISCOCITY Vap/Liq ⁰C ***
14 OPERATING PRESSURE 2 ATA TO 100 TORR 4 ATA
15 PRESSURE DROP calc./perm. bar *** 0.5 *** 0.5
16 VELOCITY calc. m/s *** ***
17 FOULING RESISTANCE m2 *h *°C / kcal *** ***
18 HEAT EXCHANGED kcal/hr 40000*
19 LMTD (CORRECTED) 0 °C ***
20 HEAT TRASFER RATE DIRTY SERVICE CLEAN
21 kcal/(m2*hr*°C ) *** *** ***
22 AREA CALCULATED / AREA PROVIDED m2 ***
23 SHORT SUMMARY OF PROCESS CALCULATIONS
24 ZONE FOR CONDENSER DESUPERHEATING CONDENSATION VAPOR COOLING LIQUID COOLING
25 PROCESS SIDE
26 REYNOLD NUMBER ***
27 PRANDTL NUMBER ***
28 HTC ***
29 SERVICE SIDE
30 REYNOLD NUMBER ***
31 PRANDTL NUMBER ***
32 HTC ***
33 CONSTRUCTION
34 MODEL *** NO. OF BLOCKS ***
35 SURFACE AREA ***
36 NO. OF PASSES *** ***
37 CONNECTIONS Inlet/Outlet mm *** ***
38 Condensate out mm *** ***
39 RATING
40 DESIGN TEMPERATURE °C 180 50
41 DESIGN/TEST PRESSURE bar (g) VAC -5 5/5.5
42 MOUNTING VERTICAL
43 MATERIAL
44 BLOCKS IMPREGNATED GRAPHITE
45 END CHAMBER/DOMES IMPREGNATED GRAPHITE
46 SHELL IS 2062 GR A/B
47 SHELL LINING NO GASKETS PTFE EPDM ‘O’ RING, Neoprene
48 CODES APPLICABLE FOR DESIGN
49 PROCESS SIDE
50 SERVICE SIDE/SHELL SIDE ASME SEC VIII DIV 1
51 SPECIAL REQUIREMENTS NO
52 OVERALL DIMENSION IN mm (APPROXIMATE)
53 REFER
54 REMARKS: 1. DATASHEET IS FOR 3 DIFFERENT FLUID & TEMPERATURE CASES; DESIGN IS BASED ON CRITICAL CASE OF HEAT LOAD
2. EXCHANGER SHOULD BE DESIGNED FOR DE-SUPERHEATING, CONDENSATION AND SUBCOOLING.
55 MINIMUM AREA TO BE PROVIDED SHALL BE 14 m2
56 *VENDOR TO CONFIRM; *** VENDOR TO CALCULATE

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Chapter-9 Technical specification

DATA SHEET FOR POLY BLOCK TYPE GRAPHITE HEAT EXCHANGER

PROJECT: SPP, TUTICORIN TAG NO.:43R04

1 SERVICE OF UNIT: CONDENSER (CHILLED WATER) DUTY: CONTINUOUS

2 DATE: REV NO.:
3 PERFORMANCE OF ONE UNIT
4 FLUID ALLOCATION PROCESS (TUBE SIDE) SERVICE (SHELL SIDE)
5 FLUID Xylene, INERTS CHILLED WATER
6 FLUID QUANTITY (TOTAL) kg/hr 125
7 VAPOR FLOWRATE in/out kg/hr *** *** *** ***
8 LIQUID FLOWRATE in/out kg/hr *** *** *** ***
9 TEMPERATURE in/out ⁰C 45 10 -5 0
10 DENSITY Vap/Liq kg/m3
11 SPECIFIC HEAT Vap/Liq Kcal/(kg* °C )
12 THERMAL CONDUCTIVITY Vap/Liq Kcal/(hr*m* °C ) ***
13 VISCOCITY Vap/Liq °C ***
14 INLET PRESSURE 2 ATA TO 100 TORR 3.5 ATA
15 PRESSURE DROP calc./perm. bar *** 0.5 *** 0.5
16 VELOCITY calc. m/s *** ***
17 FOULING RESISTANCE m2 *hr*°C / kcal *** ***
18 HEAT EXCHANGED kcal/hr 9500
19 LMTD (CORRECTED) °C ***
20 HEAT TRASFER RATE DIRTY SERVICE CLEAN
21 kcal/(m2*hr*°C ) *** *** ***
22 AREA CALCULATED / AREA PROVIDED m2 ***
23 SHORT SUMMARY OF PROCESS CALCULATIONS
24 ZONE FOR CONDENSER DESUPERHEATING CONDENSATION VAPOR COOLING LIQUID COOLING
25 PROCESS SIDE
26 REYNOLD NUMBER ***
27 PRANDTL NUMBER ***
28 HTC ***
29 SERVICE SIDE
30 REYNOLD NUMBER ***
31 PRANDTL NUMBER ***
32 HTC ***
33 CONSTRUCTION
34 MODEL *** NO. OF BLOCKS ***
35 SURFACE AREA ***
36 NO. OF PASSES *** ***
37 CONNECTIONS Inlet/Outlet mm *** ***
38 Condensate out mm *** ***
39 RATING
40 DESIGN TEMPERATURE °C 180 50
41 DESIGN/TEST PRESSURE bar (g) VAC -5 5/5.5
42 MOUNTING VERTICAL
43 MATERIAL
44 BLOCKS IMPREGNATED GRAPHITE
45 END CHAMBER/DOMES IMPREGNATED GRAPHITE
46 SHELL IS 2062 GR A/B
47 SHELL LINING NO GASKETS PTFE EPDM ‘O’ RING, Neoprene
48 CODES APPLICABLE FOR DESIGN
49 PROCESS SIDE
50 SERVICE SIDE/SHELL SIDE ASME SEC VIII DIV 1
51 SPECIAL REQUIREMENTS NO
52 OVERALL DIMENSION IN mm (APPROXIMATE)
53 REFER
54 REMARKS: 1. DATASHEET IS FOR 3 DIFFERENT FLUID & TEMPERATURE CASES; DESIGN IS BASED ON CRITICAL CASE OF HEAT LOAD
2. EXCHANGER SHOULD BE DESIGNED FOR DE-SUPERHEATING, CONDENSATION AND SUBCOOLING.
55 MINIMUM AREA TO BE PROVIDED SHALL BE 8 m2
*VENDOR TO CONFIRM; *** VENDOR TO CALCULATE

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Chapter-9 Technical specification

1 PROJECT: SPP, TUTICORIN

2 TAG NO.: 43 R5
3 Service of Unit: CODENSER (COOLING WATER)
4 Item No.:
5 Date: Rev No.: Job No.:
6 Size mm Type BEM Vert. Connected in 1 parallel 1 series
7 Surf/Unit(eff.) *** m2 Shells/unit Surf/shell (eff.) *** m2
8 PERFORMANCE OF ONE UNIT
9 Fluid allocation Shell Side Tube Side
10 Fluid name PROCESS FLUID COOLING WATER
11 Fluid quantity, Total kg/hr 420 ***
12 Vapour (In/Out) kg/hr 400 ***
13 Liquid kg/hr *** ***
14 Non condensable kg/s 20 ***
15
16 Temperature (In/Out) °C 80 40 32 37
17 Dew / Bubble point °C *** ***
18 Density kg/m3 *** ***
19 Viscosity cP *** ***
20 Molecular wt, Vap *** ***
21 Molecular wt, NC 28
22 Specific heat kcal/(kg*°C) *** ***
23 Thermal conductivity kcal/(hr*m* °C ) *** ***
24 Latent heat kcal/kg ***
25 Inlet Pressure kgf/cm2a 2 4
26 Velocity m/s *** ***
27 Pressure drop, allow./calc. kgf/cm2 0.2 *** 0.5 ***
2
28 Fouling resist. (min) m *hr*°C /kcal *** ***
29 Heat exchanged kcal/hr *** MTD corrected *** °C
30 Transfer rate kcal/( m2*hr*⁰C) Service *** Dirty *** Clean ***
31 CONSTRUCTION OF ONE SHELL Sketch
32 Shell Side Tube Side
33 Design/Test pressure kgf/cm2a 0-6 6
34 Design temperature °C 180 180
35 Number passes per shell *** ***
36 Corrosion allowance mm *** ***
37 Connections In mm *** ***
38 Size/rating Out mm *** ***
39 Intermediate *** ***
40 Tube No. *** OD *** mm Thks(avg) *** mm Length *** mm Pitch *** mm
41 Tube type PLAIN Material 316L STAINLESS STEEL Tube pattern ***
42 Shell ID *** mm OD mm MOC : SS 316L Shell cover ***
43 Channel or bonnet *** Channel cover ***
44 Tube sheet-stationary *** Tube sheet-floating ***
45 Floating head cover *** Impingement Plate ***
46 Baffle-cross Type *** Cut(%d) *** Spacing: c/c *** mm
47 Baffle-long *** Seal type *** Spacing: Inlet *** mm
48 Supports-tube *** U-bend *** Type ***
49 Bypass seal *** Tube-tube sheet joint ***
50 Expansion joint *** Type ***
51 RhoV2-Inlet nozzle *** Bundle entrance *** Bundle exit *** kg/(m*s2)
52 Gaskets - Shell side *** Tube Side ***
53 Floating head ***
54 Code requirements *** TEMA class R
55 Weight/Shell *** Filled with water *** Bundle *** kg
56 Remarks: EXCHANGER SHOULD BE DESIGNED FOR DE-SUPERHEATING, CONDENSATION AND SUBCOOLING. AS PER TEMA R
57 PROCESS FLUID COMPOSITION : TETRAHYDROFURAN VAPOR, INERTS (NITROGEN)
58 *VENDOR TO CONFIRM; *** VENDOR TO CALCULATE

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Chapter-9 Technical specification

1 PROJECT: SPP, TUTICORIN

2 TAG NO.: 43 R6
3 Service of Unit: CODENSER (CHILLED WATER)
4 Item No.:
5 Date: Rev No.: Job No.:
6 Size mm Type BEM Vert. Connected in 1 parallel 1 series
7 Surf/Unit(eff.) *** m2 Shells/unit Surf/shell (eff.) *** m2
8 PERFORMANCE OF ONE UNIT
9 Fluid allocation Shell Side Tube Side
10 Fluid name PROCESS FLUID CHILLED WATER
11 Fluid quantity, Total kg/hr 100 ***
12 Vapor (In/Out) kg/hr 80 ***
13 Liquid kg/hr *** ***
14 Non-condensable kg/s 20 ***
15
16 Temperature (In/Out) ⁰C 40 10 -5 0
17 Dew / Bubble point ⁰C *** ***
18 Density kg/m3 *** ***
19 Viscosity cP *** ***
20 Molecular wt, Vap *** ***
21 Molecular wt, NC 28
22 Specific heat kcal/(kg*⁰C) *** ***
23 Thermal conductivity kcal/(hr*m*⁰C) *** ***
24 Latent heat kcal/kg ***
25 Inlet Pressure kgf/cm2a 2 3.5
26 Velocity m/s *** ***
27 Pressure drop, allow./calc. kgf/cm2 0.2 *** 0.5 ***
28 Fouling resist. (min) m2*hr*⁰C/kcal *** ***
29 Heat exchanged kcal/hr *** MTD corrected *** ⁰C
30 Transfer rate kcal/( m2*hr*⁰C) Service *** Dirty *** Clean ***
31 CONSTRUCTION OF ONE SHELL Sketch
32 Shell Side Tube Side
33 Design/Test pressure kgf/cm2a 0-6 6
34 Design temperature ⁰C 180 180
35 Number passes per shell *** ***
36 Corrosion allowance mm *** ***
37 Connections In mm *** ***
38 Size/rating Out mm *** ***
39 Intermediate *** ***
40 Tube No. *** OD *** mm Thks (avg) *** mm Length *** mm Pitch *** mm
41 Tube type PLAIN Material 316 STAINLESS STEEL Tube pattern ***
42 Shell ID *** mm OD *** mm MOC : SS 316L Shell cover ***
43 Channel or bonnet *** Channel cover ***
44 Tube sheet-stationary *** Tube sheet-floating ***
45 Floating head cover *** Impingement Plate ***
46 Baffle-cross Type *** Cut(%d) *** Spacing: c/c *** mm
47 Baffle-long *** Seal type *** Spacing: Inlet *** mm
48 Supports-tube *** U-bend *** Type ***
49 Bypass seal *** Tube-tube sheet joint ***
50 Expansion joint *** Type ***
51 RhoV2-Inlet nozzle *** Bundle entrance *** Bundle exit *** kg/(m*s2)
52 Gaskets - Shell side *** Tube Side ***
53 Floating head ***
54 Code requirements *** TEMA class R
55 Weight/Shell *** Filled with water *** Bundle *** kg
56 Remarks: EXCHANGER SHOULD BE DESIGNED FOR DE-SUPERHEATING, CONDENSATION AND SUBCOOLING.
57 PROCESS FLUID COMPOSITION : TETRAHYDROFURAN VAPOR, INERTS (NITROGEN)
58 *VENDOR TO CONFIRM; *** VENDOR TO CALCULATE

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Chapter-9 Technical specification

PROJECT TITLE : ITEM NO.: 43 RV01 QTY

GLASS LINED
SPP, TUTICORIN SERVICE FLUID: PHOSPORYL ONE
REACTOR
CHLORIDE, HCl,
PROCESS
3
Process fluid : Phosphoryl Chloride Process Vol. : 2 m
3
Liquid density : 1645 kg / m Liquid Viscosity : 1.12 cP
2 2
Operating Pressure : 0-2 kg / cm (g) Design Pressure: Full Vacuum to 5 Kg/cm (g)
o o
Operating Temperature : 35 to 170 C Design Temperature : 200 C
MECHANICAL
Design Code : DIN 28136 manufactured as per Hydro Test Pressure : At design pressure
Sec-VIII-Div-I
Type Of Shell : Cylindrical Thickness : Vendor to confirm
Side Dish End (1) : 2:1 Ellipsoidal Side Dish End (2) : 2:1 Ellipsoidal
Type Of Welding : Single V Butt & Fillet Radiography : 100 %
Shell Inside Diameter : 1400 mm Type Of Installation : Vertical
Height : 2010 mm Material For Shell : : Enamel Quality Steel A 516 M
Grade 380
Material For End Covers : Enamel Quality Material For Nozzle Flange : A 516 M Grade 380
Steel A 516 M Grade 380
Material For Nozzle Pipe : : Enamel Quality Material For Leg Support : IS-2062
Forging SA 836 Class I /SA 181M Class 60
Material For Manhole Flange : A 516 M Grade Manhole Details :600 mm X 150 lb
380
Material For Stud Bolts : A-193 Gr-B7 Material For Nuts : A-194 Gr-2H
Glass Lining of Wetted Parts :1.5-2.0 mm Type Of Insulation :Hot
NOZZLE & CONNECTION
Mark No Size Elevation Rating Service
mm mm
N1 1 25 Top 150 Na2CO3(Soln.) In
N2 1 50 Top 150 Reflux
N3 1 150 Top 150 Vapour Out
N4 1 25 Top 150 PCl3 / POCl3 In
N5 2 100 Top 150 Sight Glass
N6 1 50 Top 150 LT
N7 1 * Top 150 Agitator
N8 1 15 Top 150 Presuure Transmitter
N9 1 50 Top 150 Rupture Disc
N10 1 50 Top 150 Safety Valve
N11 1 600 Top 150 Man Hole
N12 1 I/S* Top 150 Temp Element
N13 1 50 Top 150 Spare
N14 0 - Top 150 -
N15 1 50 - 150 CW/Steam In
N16 1 50 S 150 CW/Steam Out
N17 1 S 150 CW/Steam Out
N18 1 50 S 150 Outlet
N19 1 I/S* Bott 150 Temp Element
Accessories
1.A glass lined flush bottom valve for outlet fluid.
2.A tantalum tip with RTD sensor & thermo well from top for temperature
measurement of the bottom most charge of vessel.
3. A tantalum tip with RTD sensor for temperature measurement with
flush bottom valve.
4.A PTFE dip pipe.
5. Safety valve whose MOC shall be PTFE lined for the wetted part
PROCESS DATA SHEET compatible with process fluid & Inconel 600 rupture discs with PTFE
envelopes.
43 RV01
6. Spiral shall be provided in the jacket for distributed utility ( steam,
cooling water, chilled water, etc.) flow in the jacket for heating & cooling.

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Chapter-9 Technical specification

PROJECT TITLE : ITEM NO.: 43 RV02

SPP, TUTICORIN GLASS LINED SERVICE FLUID: PHOSPORYL CHLORIDE,
REACTOR HCl,
PROCESS
3
Process fluid : Phosphoryl Chloride Process Vol. : 2 m
3
Liquid density : 1645 kg / m Liquid Viscosity : 1.12 cP
2 2
Operating Pressure : 0-2 kg / cm (g) Design Pressure: Full Vacuum to 5 Kg/cm (g)
o o
Operating Temperature : 35 to 170 C Design Temperature : 200 C
MECHANICAL
Design Code : DIN 28136 manufactured as per Sec- Hydro Test Pressure : At design pressure
VIII-Div-I
Type Of Shell : Cylindrical Thickness : Vendor to confirm
Side Dish End (1) : 2:1 Ellipsoidal Side Dish End (2) : 2:1 Ellipsoidal
Type Of Welding : Single V Butt & Fillet Radiography : 100 %
Shell Inside Diameter : 1400 mm Type Of Installation : Vertical
Height : 2010 mm Material For Shell : : Enamel Quality Steel A 516 M
Grade 380
Material For End Covers : Enamel Quality Steel A 516 Material For Nozzle Flange : A 516 M Grade 380
M Grade 380
Material For Nozzle Pipe : : Enamel Quality Forging SA Material For Leg Support : IS-2062
836 Class I /SA 181M Class 60
Material For Manhole Flange : A 516 M Grade 380 Manhole Details :500 mm X 150 lb
Material For Stud Bolts : A-193 Gr-B7 Material For Nuts : A-194 Gr-2H
Glass Lining of Wetted Parts :1.5-2.0 mm Type Of Insulation : Hot
NOZZLE & CONNECTION
Mark No Size Elevation Rating Service
mm mm
N1 1 25 Top 150 Na2CO3(Soln.) In
N2 1 50 Top 150 Reflux
N3 1 150 Top 150 Vapour Out
N4 1 25 Top 150 PCl3 / POCl3 In
N5 2 100 Top 150 Sight Glass
N6 1 50 Top 150 LT
N7 1 * Top 150 Agitator
N8 1 15 Top 150 Presuure Transmitter
N9 1 50 Top 150 Rupture Disc
N10 1 50 Top 150 Safety Valve
N11 1 600 Top 150 Man Hole
N12 1 I/S* Top 150 Temp Element
N13 1 50 Top 150 Spare
N14 1 100 Top 150 Sodium In
N15 1 50 - 150 CW Out/Steam In
N16 1 50 S 150 CW Out
N17 1 S 150 CW In/Steam Out
N18 1 50 S 150 Outlet
N19 1 I/S* Bott 150 Temp Element
Accessories
1.A glass lined flush bottom valve for outlet fluid.
2.A tantalum tip with RTD sensor & thermo well from top for temperature
measurement of the bottom most charge of vessel.
3. A tantalum tip with RTD sensor for temperature measurement with flush
bottom valve.
4.A PTFE dip pipe.
PROCESS DATA SHEET 5. Safety valve whose MOC shall be PTFE lined for the wetted part
43 RV02 compatible with process fluid & Inconel 600 rupture discs with PTFE
envelopes.
6. Spiral shall be provided in the jacket for distributed utility ( steam, cooling
water, chilled water, etc.) flow in the jacket for heating & cooling.

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Chapter-9 Technical specification

PROJECT TITLE : ITEM NO.: 43 RV03 QTY

SPP, TUTICORIN CS NICKEL SERVICE FLUID: ONE
CLAD POTASSIUM
REACTOR HYDROXIDE, TOP,
MAGNESIUM
PROCESS
3
Process fluid : Potassium Hydroxide, Mg,TOP, BO Process Vol. : 2 m
3
Liquid density : 1645 kg / m Liquid Viscosity : 1.12 cP
2 2
Operating Pressure : 0-2 kg / cm (g) Design Pressure: Full Vacuum to 5 Kg/cm (g)
o o
Operating Temperature : 35 to 170 C Design Temperature : 200 C
MECHANICAL
Design Code : DIN 28136 manufactured as per Sec- Hydro Test Pressure : At design pressure
VIII-Div-I
Type Of Shell : Cylindrical Thickness : Vendor to confirm
Side Dish End (1) : 2:1 Ellipsoidal Side Dish End (2) : 2:1 Ellipsoidal
Type Of Welding : Single V Butt & Fillet Radiography : 100 %
Shell Inside Diameter : 1400 mm Type Of Installation : Vertical
Height : 2010 mm Material For Shell : : Enamel Quality Steel A 516 M
Grade 380 clad with 2 mm Nickel cladding
Material For End Covers : Enamel Quality Steel A 516 Material For Nozzle Flange : A 516 M Grade 380
M Grade 380
Material For Nozzle Pipe : : Enamel Quality Forging Material For Leg Support : IS-2062
SA 836 Class I /SA 181M Class 60
Material For Manhole Flange : A 516 M Grade 380 Manhole Details :500 mm X 150 lb
Material For Stud Bolts : A-193 Gr-B7 Material For Nuts : A-194 Gr-2H
Nickel Lining of Wetted Parts : 2.0 mm clad Type Of Insulation : Hot
NOZZLE & CONNECTION
Mark No Size Elevation Rating Service
mm mm
N1 1 25 Top 150 KOH (Soln.) In
N2 1 50 Top 150 Reflux
N3 1 150 Top 150 Vapour Out
N4 1 25 Top 150 BO In
N5 2 100 Top 150 Sight Glass
N6 1 50 Top 150 LT
N7 1 * Top 150 Agitator
N8 1 15 Top 150 Presuure Transmitter
N9 1 50 Top 150 Rupture Disc
N10 1 50 Top 150 Safety Valve
N11 1 600 Top 150 Man Hole
N12 1 I/S* Top 150 Temp Element
N13 1 50 Top 150 Spare
N14 1 100 Top 150 Magnesium In
N15 1 50 - 150 CW/Steam In
N16 1 50 S 150 CW/Steam Out
N17 1 S 150 CW/Steam Out
N18 1 50 S 150 Outlet
N19 1 I/S* Bott 150 Temp Element
Accessories
1.A flush bottom valve for outlet fluid.
2.A tantalum tip with RTD sensor & thermo well from top for temperature
measurement of the bottom most charge of vessel.
3. A tantalum tip with RTD sensor for temperature measurement with flush bottom
PROCESS DATA SHEET valve.
43 RV03 4.A PTFE dip pipe.
5. Safety valve whose MOC shall be PTFE lined for the wetted part compatible
with process fluid & Inconel 600 rupture discs with PTFE envelopes.
6. Spiral shall be provided in the jacket for distributed utility ( steam, cooling
water, chilled water, etc.) flow in the jacket for heating & cooling.

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Chapter-9 Technical specification

HWB Specification of Agitators for Reaction Plant :

Mumbai Vessels with Accessories SPP facility HWP, Tuticorin

Service : To carry out chemical Operating drive : Tag No : 43 RV 01/ 02/03 and
reactions / unit operations under Flame proof Motor 44 RV 01/ 02/03
heating and cooling. with VFD for the Agitator No of Equipment : 06

1 Agitating system/Drive Motor Glass lined Impeller type agitators for 43 RV01,2 and 44
RV01,2,3 for agitation of the reactants. For 43 RV03 the MOC
of the shaft shall be ASME SB-160-UNS NO. 2200, MOC of the
impeller shall be ASME SB-162-UNS NO. 2200, for stud SA
193 B7 and nuts SA1942 H drive unit should be adequate for
the above load and consists of an asynchronous three phase
explosion proof Motor, gear box. Lantern stool houses self-
aligning double ball bearing and specially design three piece
muff coupling for perfect alignment.

Drive Motor: 415 V, 3 Phase, 50 HZ, IP enclosure for gas group

IIB, Zone 1, Insulation class F. Make: Crompton/ Kirloskar /
Bharat Bijlee.

Agitator shaft should be provided with double mechanical seal

with thermo siphon cooling system for avoiding leakage and
ingress of air into the system at high vacuum.

2 Agitator speed 1. 0 - 100 rpm for the agitator with VFD for controlling of the
speed.
2. The VFD panel shall be provided in the field control panel
of explosion proof for all agitator motors.
3. Speed control shall be provided both from site as well as
from PLC/DCS control panel.
4. The drive unit is to be designed to facilitate easy and quick
replacement of components without disturbing alignment
or dismantling of major drive components.

3 Gear Box Flange mounted helical gear box of reputed brand like
BONFIGLIOLI.

4 Agitator shaft sealing Double mechanical seal at the shaft with cooling arrangement
( indirect cooling ) for removal of sealing heat

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 Chapter-9 Technical specification

7.1.2. Diaphragm Pumps of Unit 43

HWB, Mumbai Specification of Diaphragm Plant : HWP, Tuticorin

SPP Project pump with Drive Motor
Sheet No : 1 of 1
General
Tag Number : 43 P05 A/B Quantity : 2
Service Fluid :Hexane Type : single acting double diaphragm pump with
Fluid filled intermediate chamber
Location : Indoor Installation : connected to 43 V05
Design Conditions
Capacity ( m3/hr) Head (meters)
Normal: 1.5 Rated:1.7 Minimum: * Suction: Atm.& flooded Differential : 15
Pumping Temperature : 40 °C Density : 650 kg/m3
Design Temperature : 60 °C Design Pressure : 9.0 kg/cm2(g)
Viscosity : 0.8 cP Hydro Test Pressure : 11 kg/cm2(g)
Net Positive Suction Head, (meters) Vapor Pressure : 270 mm Hg
Available : Required : Percentage of Solid : Nil
Mode Of Operation : Intermittent
Number Of stages : 1 Number Of Diaphragm : 2
Material of Construction
Process Chamber : PP Diaphragm : PTFE
Valve Chamber : PP Dampener : PP/FRP
Bolts Nuts : SS 304
Connections
Suction Nozzle: 25 NB Sch. 40/ Bottom Discharge Nozzle : : 25 NB Sch. 40 /Top
Rating : 150 lbs
Motor
Type : TEFC Induction Motor, Flame Proof, Motor Protection : IP 55
Energy Efficient 1
Voltage : 415 Volts Phase : 3
Frequency : 50 Hertz Insulation Class : F
Motor Rating : * RPM : *
Accessories
Anchor Bolt : CS Base Plate : MS Fabricated
Coupling : Jaw Coupling Guard : CI
Oil Side Relief Valve : SS304 L Bearings : Ball Bearings of SKF make
Others
Weight Of Pump : * Weight Of Motor : *
Common Base Frame Size: * Foundation Loading : *
Noise Level : 85 db A (Maximum) from 1m Efficiency : *
Brake Kilo Watt : * Pump Model Number :*
Pump Make :* Capacity Control: By control of stroke length for entire
flow.
Diaphragm Failure features : Diaphragm Failure alarm/indication to be provided at the intermediate of the
two diaphragms.
* Vendor to indicate

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 Chapter-9 Technical specification

HWB, Mumbai Specification of Diaphragm Plant : HWP, Tuticorin

SPP Project pump with Drive Motor
Sheet No : 1 of 1
General
Tag Number : 43 P06 A/B Quantity : 2
Service Fluid :2-Ethyl Hexanol + Hexyl Type : Single Acting Double Diaphragm Pump with
Chloride + HCl Traces Fluid Filled Intermediate Chamber
Location : Indoor Installation : Connected to 43 V06
Design Conditions
Capacity ( m3/hr) Head (meters)
Normal: 0.5 Rated:0.6 Minimum: * Suction: Atm.& flooded Differential : 15
Pumping Temperature : 40 °C Density : 890 kg/m3
Design Temperature : 60 °C Design Pressure : 9.0 kg/cm2(g)
Viscosity : 9.8 cP Hydro Test Pressure : 11 kg/cm2(g)
Net Positive Suction Head, (meters) Vapor Pressure : 0.46 mm Hg
Available : Required : Percentage of Solid : Nil
Mode Of Operation : Intermittent
Number Of stages : 1 Number Of Diaphragm : 2
Material Of Construction
Process Chamber : PP Diaphragm : PTFE
Valve Chamber : PP Dampener : PP/FRP
Bolts Nuts : SS 304
Connections
Suction Nozzle: 25 NB Sch. 40/ Bottom Discharge Nozzle : 25 NB Sch. 40 /Top
Rating : 150 lbs
Motor
Type : TEFC Induction Motor Energy, Flame Motor Protection : IP 55
Proof, Efficient 1
Voltage : 415 Volts Phase : 3
Frequency : 50 Hertz Insulation Class : F
Motor Rating : * RPM : *
Accessories
Anchor Bolt : CS Base Plate : MS Fabricated
Coupling : Jaw Coupling Guard : CI
Oil Side Relief Valve : SS304 L Bearings : Ball Bearings of SKF make
Others
Weight Of Pump : * Weight Of Motor : *
Common Base Frame Size: * Foundation Loading : *
Noise Level : 85 db A (Maximum) from 1m Efficiency : *
Brake Kilo Watt : * Pump Model Number :*
Pump Make :* Capacity Control: By control of stroke length for entire
flow.
Diaphragm Failure features: Diaphragm Failure alarm/indication to be provided at the intermediate of the
two diaphragms.
* Vendor to indicate

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 Chapter-9 Technical specification

HWB, Mumbai Specification of Diaphragm Plant : HWP, Tuticorin

SPP Project pump with Drive Motor
Sheet No : 1 of 1
General
Tag Number : 43 P09 A/B Quantity : 2
Service Fluid :Commercial HCl Type : Single Acting Double Diaphragm Pump with
Fluid Filled Intermediate Chamber
Location : Indoor Installation : Connected to 43 V09
Design Conditions
Capacity (m3/hr) Head (meters)
Normal: 0.5 Rated:0.6 Minimum: * Suction: Atm.& flooded Differential : 15
Pumping Temperature : 40 °C Density : 1200 kg/m3
Design Temperature : 60 °C Design Pressure : 9.0 kg/cm2(g)
Viscosity : 9.8 cP Hydro Test Pressure : 11 kg/cm2(g)
Net Positive Suction Head, (meters) Vapor Pressure : 150 mm Hg
Available : Required : Percentage of Solid : Nil
Mode Of Operation : Intermittent
Number Of stages : 1 Number Of Diaphragm : 2
Material Of Construction
Process Chamber : PP Diaphragm : PTFE
Valve Chamber : PP Dampener : PP/FRP
Bolts Nuts : SS 304
Connections
Suction Nozzle: 25 NB Sch. 40/ Bottom Discharge Nozzle : 25 NB Sch. 40 /Top
Rating : 150 lbs
Motor
Type : TEFC Induction Motor Energy, Flame Motor Protection : IP 55
Proof, Efficient 1
Voltage : 415 Volts Phase : 3
Frequency : 50 Hertz Insulation Class : F
Motor Rating : * RPM : *
Accessories
Anchor Bolt : CS Base Plate : MS Fabricated
Coupling : Jaw Coupling Guard : CI
Oil Side Relief Valve : SS304 L Bearings : Ball Bearings of SKF make
Others
Weight Of Pump : * Weight Of Motor : *
Common Base Frame Size: * Foundation Loading : *
Noise Level : 85 db A (Maximum) from 1m Efficiency : *
Brake Kilo Watt : * Pump Model Number :*
Pump Make :* Capacity Control: By control of stroke length for entire
flow.
Diaphragm Failure features: Diaphragm Failure alarm/indication to be provided at the intermediate of the
two diaphragms.
* Vendor to indicate

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 Chapter-9 Technical specification

HWB, Mumbai Specification of Diaphragm Plant : HWP, Tuticorin

SPP Project pump with Drive Motor
Sheet No : 1 of 1
General
Tag Number : 43 P010 A/B Quantity : 2
Service Fluid :DM-Water Type : Single Acting Double Diaphragm Pump with
Fluid Filled Intermediate Chamber
Location : Indoor Installation : Connected to 43 V010
Design Conditions
Capacity ( m3/hr) Head (meters)
Normal: 2 Rated:2.2 Minimum: * Suction: Atm.& flooded Differential : 15
Pumping Temperature : 40 °C Density : 1000 kg/m3
Design Temperature : 60 °C Design Pressure : 9.0 kg/cm2(g)
Viscosity : 1 cP Hydro Test Pressure : 14 kg/cm2(g)
Net Positive Suction Head, (meters) Vapor Pressure : 33 mm Hg
Available : Required : Percentage of Solid : Nil
Mode Of Operation : Intermittent
Number Of stages : 1 Number Of Diaphragm : 2
Material Of Construction
Process Chamber : SS 304L Diaphragm : PTFE
Valve Chamber : SS 304L Dampener : SS 304
Bolts Nuts : SS 304
Connections
Suction Nozzle: 25 NB Sch. 40/ Bottom Discharge Nozzle : 25 NB Sch. 40 /Top
Rating : 150 lbs
Motor
Type : TEFC Induction Motor Energy, Flame Motor Protection : IP 55
Proof, Efficient 1
Voltage : 415 Volts Phase : 3
Frequency : 50 Hertz Insulation Class : F
Motor Rating : * RPM : *
Accessories
Anchor Bolt : CS Base Plate : MS Fabricated
Coupling : Jaw Coupling Guard : CI
Oil Side Relief Valve : SS304 L Bearings : Ball Bearings of SKF make
Others
Weight Of Pump : * Weight Of Motor : *
Common Base Frame Size: * Foundation Loading : *
Noise Level : 85 db A (Maximum) from 1m Efficiency : *
Brake Kilo Watt : * Pump Model Number :*
Pump Make :* Capacity Control: By control of stroke length for entire
flow.
Diaphragm Failure features: Diaphragm Failure alarm/indication to be provided at the intermediate of the
two diaphragms.
* Vendor to indicate

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7.1.3. Centrifugal Pumps of Unit 43

HWB, Mumbai Specification of Centrifugal pump Plant : HWP, Tuticorin

MSPP Project with Drive Motor
Sheet No : 1 of 1
General
Tag Number : 43 P01 A/B Quantity : 2
Service Fluid : 2-Ethyl Hexanol Type : Horizontal End Suction Back Pull Out
Location : Outdoor Installation : Connected to 43 V01
Design Conditions
Capacity (m3/hr) Head (meters)
Normal: 5 Rated:6 Minimum: Suction: Atm. & Flooded Differential : 40
*
Pumping Temperature : 40 °C Density : 833 kg/m3
Design Temperature : 60 °C Design Pressure : 9.0 kg/cm2(g)
Viscosity : 9.8 cP Hydro Test Pressure : 14 kg/cm2(g)
Net Positive Suction Head, (meters) Vapor Pressure : 0.46 mm Hg
Available : Required : * Percentage of Solid : Nil
Mode Of Operation : Intermittent
Material Of Construction
Casing : SS 316 Shaft : SS 316
Sleeve : SS 316 Impeller : SS 316
Back Plate ; SS316
Connections
Suction Nozzle: 50 NB Sch. 40 Discharge Nozzle : 40 NB Sch. 40
Rating : 150 lbs
Motor
Type : TEFC Induction, Flame Proof, Energy Motor Protection : IP 55
Efficient 1Motor
Voltage : 415 Volts Phase : 3
Frequency : 50 Hertz Insulation Class : F
Motor Rating : * RPM : 2900
Accessories
Anchor Bolt : MS 8.8 Base Plate : MS Fabricated
Coupling : Jaw/Cast Iron Coupling Guard : Aluminum Non-Sparking
Seals : Single SiC vs SiC Bearings : Ball Bearings of SKF make
Others
Weight Of Pump : * Weight Of Motor : *
Common Base Frame Size: * Foundation Loading : *
Noise Level : 85 db A (Maximum) from 1m Efficiency : *
Brake Kilo Watt : * Impeller Diameter :*
Pump Make :* Pump Model Number :*

* Vendor to indicate

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HWB, Mumbai Specification of Centrifugal Plant : HWP, Tuticorin

MSPP Project pump with Drive Motor
Sheet No : 1 of 1
General
Tag Number : 43 P07 A/B Quantity : 2
Service Fluid : Aqueous KOH/ Aqueous Na2CO3 Type : Horizontal End Suction Back Pull Out
Location : Indoor Installation : Connected to 43 V07
Design Conditions
Capacity (m3/hr) Head (meters)
Normal: 0.8 Rated:1.0 Minimum: Suction: Atm. & Flooded Differential : 15
*
Pumping Temperature : 40 °C Density : 1200 kg/m3
Design Temperature : 60 °C Design Pressure : 9.0 kg/cm2(g)
Viscosity : 10 cP Hydro Test Pressure : 14 kg/cm2(g)
Net Positive Suction Head, (meters) Vapor Pressure : 20 mm Hg
Available : Required : * Percentage of Solid : Nil
Mode Of Operation : Intermittent
Material Of Construction
Casing : SS 316 Shaft : SS 316
Sleeve : SS 316 Impeller : SS 316
Back Plate ; SS316
Connections
Suction Nozzle: 50 NB Sch. 40 Discharge Nozzle : 50 NB Sch. 40
Rating : 150 lbs
Motor
Type : TEFC Induction,Flame Proof, Energy Motor Protection : IP 55
Efficient 1Motor
Voltage : 415 Volts Phase : 3
Frequency : 50 Hertz Insulation Class : F
Motor Rating : * RPM : 2900
Accessories
Anchor Bolt : MS 8.8 Base Plate : MS Fabricated
Coupling : Jaw/Cast Iron Coupling Guard : Aluminum Non-Sparking
Seals : Single SiC vs SiC Bearings : Ball Bearings of SKF make
Others
Weight Of Pump : * Weight Of Motor : *
Common Base Frame Size: * Foundation Loading : *
Noise Level : 85 db A (Maximum) from 1m Efficiency : *
Brake Kilo Watt : * Impeller Diameter :*
Pump Make :* Pump Model Number :*

* Vendor to indicate

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HWB, Mumbai Specification of Centrifugal Plant : HWP, Tuticorin

MSPP Project pump with Drive Motor
Sheet No : 1 of 1
General
Tag Number : 43 P08 Quantity : 1
Service Fluid : Aqueous KOH/ Aqueous Na2CO3 Type : Horizontal End Suction Back Pull Out
Location : Indoor Installation : Connected to 43 V08
Design Conditions
Capacity (m3/hr) Head (meters)
Normal: 0.8 Rated:1.0 Minimum: Suction: Atm. & Flooded Differential : 15
*
Pumping Temperature : 40 °C Density : 1200 kg/m3
Design Temperature : 60 °C Design Pressure : 9.0 kg/cm2(g)
Viscosity : 10 cP Hydro Test Pressure : 14 kg/cm2(g)
Net Positive Suction Head, (meters) Vapor Pressure : 20 mm Hg
Available : Required : * Percentage of Solid : Nil
Mode Of Operation : Intermittent
Material Of Construction
Casing : SS 316 Shaft : SS 316
Sleeve : SS 316 Impeller : SS 316
Back Plate ; SS316
Connections
Suction Nozzle: 25 NB Sch. 40 Discharge Nozzle : 25 NB Sch. 40
Rating : 150 lbs
Motor
Type : TEFC Induction,Flame Proof, Energy Motor Protection : IP 55
Efficient 1Motor
Voltage : 415 Volts Phase : 3
Frequency : 50 Hertz Insulation Class : F
Motor Rating : * RPM : 2900
Accessories
Anchor Bolt : MS 8.8 Base Plate : MS Fabricated
Coupling : Jaw/Cast Iron Coupling Guard : Aluminum Non-Sparking
Seals : Single SiC vs SiC Bearings : Ball Bearings of SKF make
Others
Weight Of Pump : * Weight Of Motor : *
Common Base Frame Size: * Foundation Loading : *
Noise Level : 85 db A (Maximum) from 1m Efficiency : *
Brake Kilo Watt : * Impeller Diameter :*
Pump Make :* Pump Model Number :*

* Vendor to indicate

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 Chapter-9 Technical specification

HWB, Mumbai Specification of Centrifugal pump Plant : HWP, Tuticorin

MSPP Project with Drive Motor
Sheet No : 1 of 1
General
Tag Number : 43 P17 A/B Quantity : 2
Service Fluid : N-Butanol+S2+HCl(aq.) Type : Horizontal End Suction Back Pull Out
Location : Indoor Installation : Connected to 43 V17
Design Conditions
Capacity (m3/hr) Head (meters)
Normal: 6 Rated:7 Minimum: Suction: Atm. & Flooded Differential : 25
*
Pumping Temperature : 40 °C Density : 970 kg/m3
Design Temperature : 60 °C Design Pressure : 9.0 kg/cm2(g)
Viscosity : 3.8 cP Hydro Test Pressure : 14 kg/cm2(g)
Net Positive Suction Head, (meters) Vapor Pressure : 38.6 mm Hg
Available : Required : * Percentage of Solid : Nil
Mode Of Operation : Intermittent
Material Of Construction
Casing : PP Shaft : EN8
Sleeve : Ceramic Impeller : PP
Back Plate : PP
Connections
Suction Nozzle: 80 NB Sch. 40 Discharge Nozzle : 25 NB Sch. 40
Rating : 150 lbs
Motor
Type : TEFC Induction,Flame Proof, Energy Motor Protection : IP 55
Efficient 1Motor
Voltage : 415 Volts Phase : 3
Frequency : 50 Hertz Insulation Class : F
Motor Rating : * RPM : 2900
Accessories
Anchor Bolt : MS 8.8 Base Plate : MS Fabricated
Coupling : Jaw/Cast Iron Coupling Guard : Aluminum Non-Sparking
Seals : Single SiC vs SiC Bearings : Ball Bearings of SKF make
Others
Weight Of Pump : * Weight Of Motor : *
Common Base Frame Size: * Foundation Loading : *
Noise Level : 85 db A (Maximum) from 1m Efficiency : *
Brake Kilo Watt : * Impeller Diameter :*
Pump Make :* Pump Model Number :*

* Vendor to indicate

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Chapter-9 Technical specification

7.2. Process Data Sheets of Unit 44

7.2.1. Tanks

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Chapter-9 Technical specification

PROJECT TITLE : ITEM NO.: 44 V01 QTY

SPP, TUTICORIN INTERMEDIATE SERVICE FLUID: N-BUTANOL ONE
STORAGE TANK
PROCESS
Process fluid : N-Butanol Process Vol. : 5 m3
Liquid density : 810 kg / m3 Liquid Viscosity : 3.8 cP
Operating Pressure : 0-1 kg / cm2 (g) Design Pressure: Full Vacuum to 5 Kg/cm2(g)
Operating Temperature : 35 °C Design Temperature : 100 °C
MECHANICAL
Design Code : ASME Sec-VIII-Div-I Hydro Test Pressure : As per code
Type Of Shell : Cylindrical Minimum Thickness : 6 mm, Vendor to confirm
Side Dish End (1) : 2:1 Ellipsoidal Side Dish End (2) : 2:1 Ellipsoidal
Type Of Installation : Indoor Radiography : 100 %
Dish thickness: 4mm
Shell Inside Diameter : 1500 mm Type Of Installation : Vertical
TL To TL Length : 3000 mm Material For Shell : SA 240 SS 304 L
Material For End Covers : SA 240 SS 304 L Material For Nozzle Flange : SA 182 SS 304 L
Material For Nozzle Pipe : SA 312 SS 304 L Material For Leg Support : IS-2062
Material For Manhole Flange : SA 240 SS 304 L Manhole Details : 600 mm X 150 lb
Material For Stud Bolts : A-193 Gr-B8M Material For Nuts : A-194 Gr-8M
Type Of Insulation : None
NOZZLE & CONNECTION
Mark No Size Elevation Rating Service
mm mm

N1 1 40 Top 150 lbs Butanol In

N2 1 40 Bottom 150 lbs Butanol Out
N3 1 40 Bottom 150 lbs Drain
N4 1 50 Top 150 lbs Safety Valve
N5A/B 2 25 2950/50 150 lbs LG/LT
N6 1 600 400 150 lbs Manhole
N7 1 25 Top 150 lbs Pressure
Gauge
N8 1 25 Top 150 lbs Nitrogen In
N9 1 50 Top 150 lbs Spare
N10 1 50 50 150 lbs Thermowell
N11 1 25 Top 150 lbs Vent

NOTES :
a) Nozzle elevations are from the bottom tan line.

APD PROCESS DATA SHEET

CHKD 44 V01 REV

PRO MEC COO 00
SECTION INST
S H RD

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Chapter-9 Technical specification

PROJECT TITLE : ITEM NO.: 44 V02 & 44 V03 QTY

SPP, TUTICORIN CHARGING VESSELS SERVICE FLUID: PHOSPORYL TWO
GLASS LINED CHLORIDE
PROCESS
Process fluid : Phosphoryl Chloride Process Vol. : 1 m3
3
Liquid density : 1645 kg / m Liquid Viscosity : 1.12 cP
Operating Pressure : Full Vacuum--1 kg / cm2 (g) Design Pressure: Full Vacuum to 5 Kg/cm2(g)
Operating Temperature : 35 °C Design Temperature : 100 °C
MECHANICAL
Design Code : DIN 28136 manufactured as per Sec- Hydro Test Pressure : As per code
VIII-Div-I
Type Of Shell : Cylindrical Thickness : Vendor to confirm
Side Dish End (1) : 2:1 Ellipsoidal Side Dish End (2) : 2:1 Ellipsoidal
Type Of Installation : Indoor Radiography : 100 %
Shell Inside Diameter : 1000 mm Type Of Installation : Vertical
TL To TL Length : 1800 mm Material For Shell : : Enamel Quality Steel A 516 M
Grade 380
Material For End Covers : Enamel Quality Steel A 516 Material For Nozzle Flange : A 516 M Grade 380
M Grade 380
Material For Nozzle Pipe : : Enamel Quality Forging SA Material For Leg Support : IS-2062
836 Class I /SA 181M Class 60
Material For Manhole Flange : A 516 M Grade 380 Manhole Details :500 mm X 150 lb
Material For Stud Bolts : A-193 Gr-B7 Material For Nuts : A-194 Gr-2H
Glass Lining of Wetted Parts :1.5-2.0 mm Type Of Insulation : None
NOZZLE & CONNECTION
Mark No Size Elevation Rating Service
mm mm

N1 1 25 Top 150 lbs POCl3 In

N2 1 25 Bottom 150 lbs POCl3 Out
N3 1 25 Top 150 lbs Vent
N4 1 25 Top 150 lbs Safety Valve
N5 1 25 Top 150 lbs LT
N6 1 500 Top 150 lbs Manhole
N7 1 25 Top 150 lbs Pressure
Gauge
N8 1 25 Top 150 lbs Nitrogen In
N9 1 25 Top 150 lbs Spare

NOTES :
a) Nozzle elevations are from the bottom tan line.

APD PROCESS DATA SHEET

CHKD 44 V02 &44 V03 REV

PRO MEC COO 00
SECTION INST
S H RD

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Chapter-9 Technical specification

PROJECT TITLE : ITEM NO.: 44 V04 & 44 V05 QTY

SPP, TUTICORIN CHARGING VESSEL SERVICE FLUID: TWO
AQUEOUS SODIUM CARBONATE
PROCESS
Process fluid : Aqueous Na2CO3 (Conc.) Process Vol. : 2 m3
Liquid density : 1100-1200 kg / m3 Liquid Viscosity : 2 cP
Operating Pressure : Full vacuum-1 kg / cm2 (g) Design Pressure: Full Vacuum to 5 Kg/cm2(g)
Operating Temperature : 35 °C Design Temperature : 100 °C
MECHANICAL
Design Code : ASME Sec-VIII-Div-I Hydro Test Pressure : As per code
Type Of Shell : Cylindrical Minimum Thickness : 6 mm, Vendor to confirm
Side Dish End (1) : 2:1 Ellipsoidal Side Dish End (2) : 2:1 Ellipsoidal
Dish thickness: 4mm
Type Of Installation : Indoor Radiography : 100 %
Shell Inside Diameter : 1100 mm Type Of Installation : Vertical
TL To TL Length : 2200 mm Material For Shell : SA 240 SS 304 L
Material For End Covers : SA 240 SS 304 L Material For Nozzle Flange : SA 182 SS 304 L
Material For Nozzle Pipe : SA 312 SS 304 L Material For Leg Support : IS-2062
Material For Manhole Flange : SA 240 SS 304 L Manhole Details : 600 mm X 150 lb
Material For Stud Bolts : A-193 Gr-B8M Material For Nuts : A-194 Gr-8M
Type Of Insulation : None
NOZZLE & CONNECTION
Mark No Size Elevation Rating Service
mm mm

N1 1 40 Top 150 lbs Alkali In

N2 1 40 Bottom 150 lbs Liquid Out
N3 1 25 Bottom 150 lbs Drain
N4 1 25 Top 150 lbs Safety Valve
N5A/B 2 25 2150/50 150 lbs LG/LT
N6 1 600 400 150 lbs Manhole
N7 1 25 Top 150 lbs Pressure Gauge
N8 1 25 Top 150 lbs Water In
N9 1 50 Top 150 lbs Vent
N10 1 50 Top 150 lbs Spare

NOTES :
a) Nozzle elevations are from the bottom tan line.

APD PROCESS DATA SHEET

CHKD 44 V04 & 44 V05 REV

PRO MEC COO 00
SECTION INST
S H RD

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Chapter-9 Technical specification

PROJECT TITLE : ITEM NO.: 44 V06 QTY

DUMP TANK
SPP, TUTICORIN SERVICE FLUID: HYDROCHLORIC ONE
ACID/ S2/ N-BUTANOL
PROCESS
Process fluid : S2/ aq. HCl/ n-Butanol Process Vol. : 4 m3
3
Liquid density : 830-970 kg / m Liquid Viscosity : 3.8 cP
Operating Pressure : Full vacuum-1 kg / cm2 (g) Design Pressure: Full Vacuum to 5 Kg/cm2(g)
Operating Temperature : 35 °C Design Temperature : 100 °C
MECHANICAL
Design Code : DIN 28136 manufactured as per Sec-VIII- Hydro Test Pressure : As per code
Div-I
Type Of Shell : Cylindrical Thickness : Vendor to confirm
Side Dish End (1) : 2:1 Ellipsoidal Side Dish End (2) : 2:1 Ellipsoidal
Type Of Installation : Indoor Radiography : 100 %
Shell Inside Diameter : 2000 mm Type Of Installation : Horizontal
Horizontal Length : 2125 mm Material For Shell : : Enamel Quality Steel A 516 M
Grade 380
Material For End Covers : Enamel Quality Steel A 516 M Material For Nozzle Flange : A 516 M Grade 380
Grade 380
Material For Nozzle Pipe : : Enamel Quality Forging SA Material For Leg Support : IS-2062
836 Class I /SA 181M Class 60
Material For Manhole Flange : A 516 M Grade 380 Manhole Details :500 mm X 150 lb
Material For Stud Bolts : A-193 Gr-B7 Material For Nuts : A-194 Gr-2H
Glass Lining of Wetted Parts :1.5-2.0 mm Type Of Insulation : None
NOZZLE & CONNECTION
Mark No Size Elevation Rating Service
mm mm

N1 1 50 Top 150 lbs Liquid dumping

N2 1 80 Bottom 150 lbs Liquid Out
N3 1 80 Top 150 lbs Vent
N4 1 50 Top 150 lbs Safety Valve
N5 A/B 2 25 Side 150 lbs Level Gauge
N6 1 600 Top 150 lbs Manhole
N7 1 25 Top 150 lbs Pressure Gauge
N8 1 25 Top 150 lbs Nitrogen In
N9 1 50 Top 150 lbs Spare
N10 1 25 Bottom 150 lbs Drain
N11 1 50 Top 150 lbs Liquid in
N12 1 50 Top 150 lbs Balance line
NOTES :
a) Nozzle elevations are from the bottom line.

APD PROCESS DATA SHEET

CHKD 44 V06 REV

CO 00
PRO MEC
SECTION INST OR
S H
D

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Chapter-9 Technical specification

PROJECT TITLE : ITEM NO.: 44 V07 QTY

SPP, TUTICORIN CHARGING VESSEL SERVICE FLUID: TWO
AQUEOUS SODIUM CARBONATE
PROCESS
Process fluid : Aqueous Na2CO3 (Dilute) Process Vol. : 2 m3
3
Liquid density : 1100-1200 kg / m Liquid Viscosity : 2 cP
Operating Pressure : Full vacuum-1 kg / cm2 (g) Design Pressure: Full Vacuum to 5 Kg/cm2(g)
Operating Temperature : 35 °C Design Temperature : 100 °C
MECHANICAL
Design Code : ASME Sec-VIII-Div-I Hydro Test Pressure : As per code
Type Of Shell : Cylindrical Minimum Thickness : 6 mm, Vendor to confirm
Side Dish End (1) : 2:1 Ellipsoidal Side Dish End (2) : 2:1 Ellipsoidal
Dish thickness: 4mm
Type Of Installation : Indoor Radiography : 100 %
Shell Inside Diameter : 1100 mm Type Of Installation : Vertical
TL To TL Length : 2200 mm Material For Shell : SA 240 SS 304 L
Material For End Covers : SA 240 SS 304 L Material For Nozzle Flange : SA 182 SS 304 L
Material For Nozzle Pipe : SA 312 SS 304 L Material For Leg Support : IS-2062
Material For Manhole Flange : SA 240 SS 304 L Manhole Details : 600 mm X 150 lb
Material For Stud Bolts : A-193 Gr-B8M Material For Nuts : A-194 Gr-8M
Type Of Insulation : None
NOZZLE & CONNECTION
Mark No Size Elevation Rating Service
mm mm

N1 1 40 Top 150 lbs Alkali In

N2 1 40 Bottom 150 lbs Liquid Out
N3 1 25 Bottom 150 lbs Drain
N4 1 25 Top 150 lbs Safety Valve
N5A/B 2 25 2150/50 150 lbs LG/LT
N6 1 600 400 150 lbs Manhole
N7 1 25 Top 150 lbs Pressure Gauge
N8 1 25 Top 150 lbs Water In
N9 1 50 Top 150 lbs Vent
N10 1 50 Top 150 lbs Spare

NOTES :
a) Nozzle elevations are from the bottom tan line.

APD PROCESS DATA SHEET

CHKD 44 V07 REV

PRO MEC COO 00
SECTION INST
S H RD

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Chapter-9 Technical specification

PROJECT TITLE : ITEM NO.: 44 V08 QTY

SPP, TUTICORIN IMPURE BUTANOL SERVICE FLUID: N-BUTANOL ONE
TANK
PROCESS
Process fluid : N-Butanol with 1% moisture Process Vol. : 3 m3
Liquid density : 830-890 kg / m3 Liquid Viscosity : 3.8 cP
Operating Pressure : Full vacuum-1 kg / cm2 (g) Design Pressure: Full Vacuum to 5 Kg/cm2(g)
Operating Temperature : 35 °C Design Temperature : 100 °C
MECHANICAL
Design Code : ASME Sec-VIII-Div-I Hydro Test Pressure : As per code
Type Of Shell : Cylindrical Minimum Thickness : 6 mm, Vendor to confirm
Side Dish End (1) : 2:1 Ellipsoidal Side Dish End (2) : 2:1 Ellipsoidal
Dish thickness: 6mm
Type Of Installation : Indoor Radiography : 100 %
Shell Inside Diameter : 1300 mm Type Of Installation : Vertical
TL To TL Length : 2600 mm Material For Shell : SA 240 SS 304 L
Material For End Covers : SA 240 SS 304 L Material For Nozzle Flange : SA 182 SS 304 L
Material For Nozzle Pipe : SA 312 SS 304 L Material For Leg Support : IS-2062
Material For Manhole Flange : SA 240 SS 304 L Manhole Details : 600 mm X 150 lb
Material For Stud Bolts : A-193 Gr-B8M Material For Nuts : A-194 Gr-8M
Type Of Insulation : None
NOZZLE & CONNECTION
Mark No Size Elevation Rating Service
mm mm

N1 1 50 Top 150 lbs Liquid In

N2 1 40 Bottom 150 lbs Liquid Out
N3 1 25 Bottom 150 lbs Drain
N4 1 50 Top 150 lbs Safety Valve
N5A/B 2 25 2950/50 150 lbs LG/LT
N6 1 600 400 150 lbs Manhole
N7 1 25 Top 150 lbs Pressure
Gauge
N8 1 25 Top 150 lbs Nitrogen In
N9 1 50 Top 150 lbs Spare
N10 1 50 Top 150 lbs Balancing line
N11 1 25 Top 150 lbs Vent

NOTES :
a) Nozzle elevations are from the bottom tan line.
b) Instrumentation to confirm nozzles N5A/B.

APD PROCESS DATA SHEET

CHKD 44 V08 REV

PRO MEC COO 00
SECTION INST
S H RD

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Chapter-9 Technical specification

PROJECT TITLE : ITEM NO.: 44 V09 QTY

SPP, TUTICORIN PRODUCT TANK SERVICE FLUID: TRI-BUTYL ONE
PHOSPHATE
PROCESS
Process fluid : Tri-Butyl Phosphate Process Vol. : 2 m3
Liquid density : 900-970 kg / m3 Liquid Viscosity : 4.0 cP
Operating Pressure : Full vacuum-1 kg / cm2 (g) Design Pressure: Full Vacuum to 5 Kg/cm2(g)
Operating Temperature : 35 °C Design Temperature : 100 °C
MECHANICAL
Design Code : ASME Sec-VIII-Div-I Hydro Test Pressure : As per code
Type Of Shell : Cylindrical Minimum Thickness : 10 mm, Vendor to confirm
Side Dish End (1) : 2:1 Ellipsoidal Side Dish End (2) : 2:1 Ellipsoidal
Type Of Installation : Indoor Radiography : 100 %
Shell Inside Diameter : 1100 mm Type Of Installation : Vertical
TL To TL Length : 2200 mm Material For Shell : SA 240 SS 304 L
Material For End Covers : SA 240 SS 304 L Material For Nozzle Flange : SA 182 SS 304 L
Material For Nozzle Pipe : SA 312 SS 304 L Material For Leg Support : IS-2062
Material For Manhole Flange : SA 240 SS 304 L Manhole Details : 600 mm X 150 lb
Material For Stud Bolts : A-193 Gr-B8M Material For Nuts : A-194 Gr-8M
Type Of Insulation : None
NOZZLE & CONNECTION
Mark No Size Elevation Rating Service
mm mm

N1 1 50 Top 150 lbs Liquid In

N2 1 25 Bottom 150 lbs Liquid Out
N3 1 25 Bottom 150 lbs Drain
N4 1 25 Top 150 lbs Safety Valve
N5A/B 2 25 2150/50 150 lbs LG/LT
N6 1 600 400 150 lbs Manhole
N7 1 25 Top 150 lbs Pressure Gauge
N8 1 25 Top 150 lbs Nitrogen In
N9 1 25 Top 150 lbs Vent
N10 1 50 Top 150 lbs Spare
N11 1 25 Top 150 lbs Spare
N12 1 50 Bottom 150 lbs Spare

NOTES :
a) Nozzle elevations are from the bottom tan line.

APD PROCESS DATA SHEET

CHKD 44 V09 REV

PRO MEC COO 00
SECTION INST
S H RD

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Chapter-9 Technical specification

PROJECT TITLE : ITEM NO.: 44 V10 & 44 V 11 QTY

REACTOR DRAIN TANKS
SPP, SERVICE FLUID: TWO
TUTICORIN DRAIN FLUID
PROCESS
Process fluid: Reactor Drain Fluid
Process Vol.: 2 m3
: 950-1050 kg / m3
Liquid density
Dimensions : 2000 mm ID x1000X 1000 mm rectangular tank (LXBXH)
OPERATING DESIGN
PRESSURE, kg/cm2(g) ATMOSPHERIC Hydrostatic head
TEMPERATURE, °C 35 60
CORROSION ALLOWANCE Nil
INSULATION No
MECHANICAL
MATERIAL OF CONSTRUCTION
SHELL : FRV+ PP Rectangular HEAD: OPEN BOTTOM: FLAT
NOZZLES & FLANGES : FRV+ PP SUPPORTS: MS with epoxy coating
DESIGN & FABRICATION CODE BS 4994 LATEST
SPARK TEST 20 KVA MINIMUM THICKNESS Vendor to indicate
HYDROSTATIC TEST Water fill up to top flange BOLTING SS 304 L
GASKETS Teflon enveloped CAF SUPPORTS MS with epoxy coating
NOZZLE & CONNECTION
Mark No Size Elevation Rating Service
mm mm

N1 1 50 Side 150 lbs Aqueous In

N2 1 50 Side 150 lbs Effluent liquid
& Drain
N3 1 50 Side 150 lbs Effluent liquid
& Drain
N4 1 50 Side 150 lbs Effluent liquid
& Drain
N5 1 50 Side 150 lbs Effluent liquid
& Drain
N6 1 50 Side 150 lbs Effluent liquid
& Drain

PROCESS DATA SHEET

44 V10 & 44 V 11 RE
V
00

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Chapter-9 Technical specification

7.2.2 Heat Exchangers and Reactors of Unit 44

1 PROJECT: SPP, TUTICORIN

2 TAG NO.: 44 E1A
3 Service of Unit: BUTANOL CODENSER (COOLING WATER)
4 Item No.:
5 Date: Rev No.: Job No.:
6 Size mm Type BEM Vert. Connected in 1 parallel 1 series
7 Surf/Unit(eff.) *** m2 Shells/unit Surf/shell (eff.) *** m2
8 PERFORMANCE OF ONE UNIT
9 Fluid allocation Shell Side Tube Side
10 Fluid name PROCESS FLUID COOLING WATER
11 Fluid quantity, Total kg/hr 560 ***
12 Vapor (In/Out) kg/hr *** ***
13 Liquid kg/hr *** ***
14 Non-condensable kg/s *** ***
15
16 Temperature (In/Out) °C 110 40 32 37
17 Dew / Bubble point °C *** ***
18 Density kg/m3 *** ***
19 Viscosity cP *** ***
20 Molecular wt, Vap 78 & 18 *** ***
21 Molecular wt, NC 28
22 Specific heat kcal/(kg*°C) *** ***
23 Thermal conductivity kcal/(hr*m*°C) *** ***
24 Latent heat kcal/kg ***
25 Inlet Pressure kgf/cm2a 0 to 1 4
26 Velocity m/s *** ***
27 Pressure drop, allow./calc. kgf/cm2 0.2 *** 0.5 ***
2
28 Fouling resist. (min) m *hr*°C /kcal *** ***
29 Heat exchanged kcal/hr *** MTD corrected *** °C
30 Transfer rate kcal/( m2*hr*⁰C) Service *** Dirty *** Clean ***
31 CONSTRUCTION OF ONE SHELL Sketch
32 Shell Side Tube Side
33 Design/Test pressure kgf/cm2a 0 to 6 6
34 Design temperature °C 150 -5 to 60
35 Number passes per shell *** ***
36 Corrosion allowance mm *** ***
37 Connections In mm *** ***
38 Size/rating Out mm *** ***
39 Intermediate *** ***
40 Tube No. *** OD *** mm Thks(avg) *** mm Length *** mm Pitch *** mm
41 Tube type PLAIN Material SA 249 TP 304 L Tube pattern ***
42 Shell ID *** mm OD mm *** Material SS 304L Shell cover ***
43 Channel or bonnet *** Channel cover ***
44 Tube-sheet-stationary *** Tube-sheet-floating ***
45 Floating head cover *** Impingement Plate ***
46 Baffle-cross Type *** Cut(%d) *** Spacing: c/c *** mm
47 Baffle-long *** Seal type *** Spacing: Inlet *** mm
48 Supports-tube *** U-bend *** Type ***
49 Bypass seal *** Tube-tube-sheet joint ***
50 Expansion joint *** Type ***
51 RhoV2-Inlet nozzle *** Bundle entrance *** Bundle exit *** kg/(m*s2)
52 Gaskets - Shell side *** Tube Side ***
53 Floating head ***
54 Code requirements *** TEMA class R
55 Weight/Shell *** Filled with water *** Bundle *** kg
56 Remarks: EXCHANGER SHALL BE DESIGNED FOR DE-SUPERHEATING, CONDENSATION AND SUBCOOLING.
57 PROCESS FLUID COMPOSITION : n-BUTANOL VAPOR SATURATED WITH WATER VAPOR, INERTS (NITROGEN)-5%
58 *VENDOR TO CONFIRM; *** VENDOR TO CALCULATE

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Chapter-9 Technical specification

1 PROJECT: SPP, TUTICORIN

2 TAG NO.: 44 E1B
3 Service of Unit: BUTANOL CODENSER (CHILLED WATER)
4 Item No.:
5 Date: Rev No.: Job No.:
6 Size mm Type BEM Vert. Connected in 1 parallel 1 series
7 Surf/Unit(eff.) *** m2 Shells/unit Surf/shell (eff.) *** m2
8 PERFORMANCE OF ONE UNIT
9 Fluid allocation Shell Side Tube Side
10 Fluid name PROCESS FLUID CHILLED WATER
11 Fluid quantity, Total kg/hr 270 ***
12 Vapor (In/Out) kg/hr *** ***
13 Liquid kg/hr *** ***
14 Non-condensable kg/s *** ***
15
16 Temperature (In/Out) °C 40 10 -5 0
17 Dew / Bubble point °C *** ***
18 Density kg/m3 *** ***
19 Viscosity cP *** ***
20 Molecular wt, Vap 78 & 18 *** ***
21 Molecular wt, NC 28
22 Specific heat kcal/(kg*°C) *** ***
23 Thermal conductivity kcal/(hr*m* °C) *** ***
24 Latent heat kcal/kg ***
25 Inlet Pressure kgf/cm2a 0 to 1 3.5
26 Velocity m/s *** ***
27 Pressure drop, allow./calc. kgf/cm2 0.2 *** 0.5 ***
28 Fouling resist. (min) m2*hr*°C /kcal *** ***
29 Heat exchanged kcal/hr *** MTD corrected *** °C
30 Transfer rate kcal/( m2*hr*⁰C) Service *** Dirty *** Clean ***
31 CONSTRUCTION OF ONE SHELL Sketch
32 Shell Side Tube Side
33 Design/Test pressure kgf/cm2a 0 to 6 6
34 Design temperature °C 150 -5 to 60
35 Number passes per shell *** ***
36 Corrosion allowance mm *** ***
37 Connections In mm *** ***
38 Size/rating Out mm *** ***
39 Intermediate *** ***
40 Tube No. *** OD *** mm Thks(avg) *** mm Length *** mm Pitch *** mm
41 Tube type PLAIN Material SA 249 TP 304 L Tube pattern ***
42 Shell ID *** mm OD mm Material SS 304L Shell cover ***
43 Channel or bonnet *** Channel cover ***
44 Tube sheet-stationary *** Tube sheet-floating ***
45 Floating head cover *** Impingement Plate ***
46 Baffle-cross Type *** Cut(%d) *** Spacing: c/c *** mm
47 Baffle-long *** Seal type *** Spacing: Inlet *** mm
48 Supports-tube *** U-bend *** Type ***
49 Bypass seal *** Tube-tube sheet joint ***
50 Expansion joint *** Type ***
51 RhoV2-Inlet nozzle *** Bundle entrance *** Bundle exit *** kg/(m*s2)
52 Gaskets - Shell side *** Tube Side ***
53 Floating head ***
54 Code requirements *** TEMA class R
55 Weight/Shell *** Filled with water *** Bundle *** kg
56 Remarks: EXCHANGER SHOULD BE DESIGNED FOR DE-SUPERHEATING, CONDENSATION AND SUBCOOLING.
57 PROCESS FLUID COMPOSITION : n-BUTANOL VAPOR SATURATED WITH WATER VAPOR, INERTS (NITROGEN)-5%
58 *VENDOR TO CONFIRM; *** VENDOR TO CALCULATE

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Chapter-9 Technical specification

1 PROJECT: SPP, TUTICORIN

2 TAG NO.: 44 E3 & 44 E4
3 Service of Unit: VENT TRAPS (CHILLED WATER) (2 Nos.)
4 Item No.:
5 Date: Rev No.: Job No.:
6 Size mm Type Double Pipe Connected in 1 parallel 1 series
7 Surf/Unit(eff.) *** m2 Shells/unit Surf (eff.) *** m2
8 PERFORMANCE OF ONE UNIT
9 Fluid allocation Inner Pipe Outer Pipe
10 Fluid name PROCESS FLUID CHILLED WATER
11 Fluid quantity, Total kg/hr 50 ***
12 Vapor (In/Out) kg/hr *** ***
13 Liquid kg/hr *** ***
14 Non-condensable kg/s *** ***
15
16 Temperature (In/Out) °C 40 0 -5 0
17 Dew / Bubble point °C *** ***
3
18 Density kg/m *** ***
19 Viscosity cP *** ***
20 Molecular wt, Vap 78 & 18 *** ***
21 Molecular wt, NC 28
22 Specific heat kcal/(kg*°C) *** ***
23 Thermal conductivity kcal/(hr*m*°C) *** ***
24 Latent heat kcal/kg ***
25 Inlet Pressure kgf/cm2a 0 to 1 3.5
26 Velocity m/s *** ***
27 Pressure drop, allow./calc. kgf/cm2 0.2 *** 0.5 ***
28 Fouling resist. (min) m2*hr*°C /kcal *** ***
29 Heat exchanged kcal/hr *** MTD corrected *** °C
30 Transfer rate kcal/( m2*hr*⁰C) Service *** Dirty *** Clean ***
31 CONSTRUCTION Sketch
32 Inner pipe Outer Pipe
33 Design/Test pressure kgf/cm2A 0 to 6 6
34 Design temperature °C 0 to 150 -5 to 60
35 Corrosion allowance mm *** ***
36 Connections In mm *** ***
37 Size/rating Out mm *** ***
38 Intermediate *** ***
39 Material 304L STAINLESS STEEL
40 Remarks: EXCHANGER SHOULD BE DESIGNED FOR DE-SUPERHEATING, CONDENSATION AND SUBCOOLING.
41 PROCESS FLUID COMPOSITION : CARBON DIOXIDE SATURATED WITH n-BUTANOL AT INLET AND OUTLET
42 *VENDOR TO CONFIRM; *** VENDOR TO CALCULATE

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 Chapter-9 Technical specification

PROJECT TITLE : ITEM NO.: 44 RV01 & 44 QTY

GLASS LINED RV02
SPP, TUTICORIN REACTORS SERVICE FLUID: TWO
PHOSPORYL
CHLORIDE, HCl,
PROCESS
Process fluid : Phosphoryl Chloride Process Vol. : 5 m3
Liquid density : 1645 kg / m3 Liquid Viscosity : 1.12 cP
Operating Pressure : 0-1 kg / cm2 (g) Design Pressure: Full Vacuum to 5 Kg/cm2(g)
Operating Temperature : 35 to 170 °C Design Temperature : 200 °C
MECHANICAL
Design Code : DIN 28136 manufactured as per Sec-VIII-Div-I Hydro Test Pressure : As per code
Type Of Shell : Cylindrical Thickness : Vendor to confirm
Side Dish End (1) : 2:1 Ellipsoidal Side Dish End (2) : 2:1 Ellipsoidal
Type Of Welding : Single V Butt & Fillet Radiography : 100 %
Shell Inside Diameter : 2000 mm Type Of Installation : Vertical
Height : 2560 mm Material For Shell : : Enamel Quality Steel A 516 M
Grade 380
Material For End Covers : Enamel Quality Steel A 516 M Grade 380 Material For Nozzle Flange : A 516 M Grade 380

Material For Nozzle Pipe : : Enamel Quality Forging SA 836 Class I /SA Material For Leg Support : IS-2062
181M Class 60
Material For Manhole Flange : A 516 M Grade 380 Manhole Details :500 mm X 150 lb
Material For Stud Bolts : A-193 Gr-B7 Material For Nuts : A-194 Gr-2H
Glass Lining of Wetted Parts :1.5-2.0 mm Type Of Insulation : None
NOZZLE & CONNECTION
Mark No Size Elevation Rating Service
mm mm
N1 2 100 Top 150 Sight Glass
N2 1 40 Top 150 Butanol In
N3 1 40 Top 150 Na2CO3 (soln.) In
N4 1 25 Top 150 POCl3 In
N5 1 600 Top 150 Man Hole
N6 1 50 Top 150 Safety Valve
N7 1 50 Top 150 Rupture Disc
N8 1 100 Top 150 Vapour Out
N9 1 50 Top 150 Level Transmitter
N10 1 I/S* Top 150 Temp Element
N11 1 15 Top 150 Presuure Transmitter
N12 1 * Top 150 Agitator
N13 1 50 Top 150 Spare
N14 1 50 S 150 CW In
N15 1 50 S 150 CW Out
N16 1 50 S 150 CW Out
N17 1 50 B 150 Outlet
N18 1 I/S* Bott 150 Temp Element
Accessories
1.A flush bottom valve for outlet fluid.
2.A tantalum tip with RTD sensor & thermo well from top for temperature
measurement of the bottom most charge of vessel.
3. A tantalum tip with RTD sensor for temperature measurement with flush bottom
valve.
4.A PTFE dip pipe.
5. Safety valve whose MOC shall be PTFE lined for the wetted part compatible with
PROCESS DATA SHEET process fluid & Inconel 600 rupture discs with PTFE envelopes.
44 RV01 & 44 RV02 6. .Spiral shall be provided in the jacket for distributed utility ( steam, cooling
water, chilled water, etc.) flow in the jacket for heating & cooling.

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Chapter-9 Technical specification

PROJECT TITLE : ITEM NO.: 44 RV03 QTY

SPP, TUTICORIN GLASS LINED SERVICE FLUID: TRI BUTYL ONE
REACTOR PHOSPHATE
PROCESS
Process fluid : Phosphoryl Chloride Process Vol. : 5 m3
Liquid density : 1645 kg / m3 Liquid Viscosity : 1.12 cP
Operating Pressure : 0-1 kg / cm2 (g) Design Pressure: Full Vacuum to 5 Kg/cm2(g)
Operating Temperature : 35 to 170 °C Design Temperature : 200 °C
MECHANICAL
Design Code : DIN 28136 manufactured as per Sec-VIII- Hydro Test Pressure : As per code
Div-I
Type Of Shell : Cylindrical Thickness : Vendor to confirm
Side Dish End (1) : 2:1 Ellipsoidal Side Dish End (2) : 2:1 Ellipsoidal
Type Of Welding : Single V Butt & Fillet Radiography : 100 %
Shell Inside Diameter : 2000 mm Type Of Installation : Vertical
Height : 2560 mm Material For Shell : : Enamel Quality Steel A 516 M Grade
380
Material For End Covers : Enamel Quality Steel A 516 M Material For Nozzle Flange : A 516 M Grade 380
Grade 380
Material For Nozzle Pipe : : Enamel Quality Forging SA Material For Leg Support : IS-2062
836 Class I /SA 181M Class 60
Material For Manhole Flange : A 516 M Grade 380 Manhole Details :500 mm X 150 lb

Material For Stud Bolts : A-193 Gr-B7 Material For Nuts : A-194 Gr-2H
Glass Lining of Wetted Parts :1.5-2.0 mm Type Of Insulation : None
NOZZLE & CONNECTION
Mark No Size Elevation Rating Service
mm mm

N1 2 100 Top 150 Sight Glass

N2 1 50 Top 150 From RV01 & RV02
N3 1 50 Top 150 Na2CO3 (soln.) In
N4 1 50 Top 150 Spare
N5 1 600 Top 150 Man Hole
N6 1 50 Top 150 Safety Valve
N7 1 50 Top 150 Rupture Disc
N8 1 250 Top 150 Vapour Out
N9 1 50 Top 150 Level Transmitter
N10 1 I/S* Top 150 Temp Element
N11 1 15 Top 150 Presuure
Transmitter
N12 1 * Top 150 Agitator
N14 1 50 S 150 CW In
N15 1 50 S 150 CW Out
N16 1 50 S 150 CW Out
N17 1 50 B 150 Outlet
N18 1 I/S* Bott 150 Temp Element
Accessories
1.A flush bottom valve for outlet fluid.
2.A tantalum tip with RTD sensor & thermo well from top for temperature
measurement of the bottom most charge of vessel.
3. A tantalum tip with RTD sensor for temperature measurement with flush bottom
PROCESS DATA SHEET valve.
44 RV03 4.A PTFE dip pipe.
5. Safety valve whose MOC shall be PTFE lined for the wetted part compatible with
process fluid & Inconel 600 rupture discs with PTFE envelopes.
6. Spiral shall be provided in the jacket for distributed utility ( steam, cooling water,
chilled water, etc.) flow in the jacket for heating & cooling.

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 Chapter-9 Technical specification

7.2.3 Diaphragm Pumps of Unit 44

HWB, Mumbai Specification of Diaphragm Plant : HWP, Tuticorin

SPP Project pump with Drive Motor
Sheet No : 1 of 1
General
Tag Number : 44 P04 A/B Quantity : 2
Service Fluid :Aqueous Na2CO3 Type : Single Acting Double Diaphragm Pump with
Fluid Filled Intermediate Chamber
Location : Indoor Installation : Connected to 44 V04
Design Conditions
Capacity (m3/hr) Head (meters)
Normal: 0.6 Rated: 1.0 Minimum: * Suction: Atm.& flooded Differential : 25
Pumping Temperature : 40 °C Density : 1200 kg/m3
Design Temperature : 60 °C Design Pressure : 9.0 kg/cm2(g)
Viscosity : 2.0 cP Hydro Test Pressure : 14 kg/cm2(g)
Net Positive Suction Head, (meters) Vapour Pressure : 20 mm Hg
Available : Required : Percentage of Solid : Nil
Mode Of Operation : Intermittent
Number Of stages : 1 Number Of Diaphragm : 2
Material Of Construction
Process Chamber : SS 304L Diaphragm : PTFE
Valve Chamber : SS 304L Dampener : SS 304
Bolts Nuts : SS 304
Connections
Suction Nozzle: 40 NB Sch. 40/ Bottom Discharge Nozzle : 25 NB Sch. 40 /Top
Rating : 150 lbs
Motor
Type : TEFC Induction Motor Energy, Flame Motor Protection : IP 55
Proof, Efficient 1
Voltage : 415 Volts Phase : 3
Frequency : 50 Hertz Insulation Class : F
Motor Rating : * RPM : *
Accessories
Anchor Bolt : CS Base Plate : MS Fabricated
Coupling : Jaw Coupling Guard : CI
Oil Side Relief Valve : SS304 L Bearings : Ball Bearings of SKF make
Others
Weight Of Pump : * Weight Of Motor : *
Common Base Frame Size: * Foundation Loading : *
Noise Level : 85 db A (Maximum) from 1m Efficiency : *
Brake Kilo Watt : * Pump Model Number :*
Pump Make :* Capacity Control: By control of stroke length for entire
flow.
Diaphragm Failure features: Diaphragm Failure alarm/indication to be provided at the intermediate of the
two diaphragms.
* Vendor to indicate

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 Chapter-9 Technical specification

HWB, Mumbai Specification of Diaphragm Plant : HWP, Tuticorin

SPP Project pump with Drive Motor
Sheet No : 1 of 1
General
Tag Number : 44 P05 Quantity : 1
Service Fluid :Aqueous Na2CO3 Type : Single Acting Double Diaphragm Pump with
Fluid Filled Intermediate Chamber
Location : Indoor Installation : Connected to 44 V04
Design Conditions
Capacity (m3/hr) Head (meters)
Normal: 0.6 Rated: 1.0 Minimum: * Suction: Atm.& flooded Differential : 25
Pumping Temperature : 40 °C Density : 1200 kg/m3
Design Temperature : 60 °C Design Pressure : 9.0 kg/cm2(g)
Viscosity : 2.0 cP Hydro Test Pressure : 14 kg/cm2(g)
Net Positive Suction Head, (meters) Vapour Pressure : 20 mm Hg
Available : Required : Percentage of Solid : Nil
Mode Of Operation : Intermittent
Number Of stages : 1 Number Of Diaphragm : 2
Material Of Construction
Process Chamber : SS 304L Diaphragm : PTFE
Valve Chamber : SS 304L Dampener : SS 304
Bolts Nuts : SS 304
Connections
Suction Nozzle: 40 NB Sch. 40/ Bottom Discharge Nozzle : 25 NB Sch. 40 /Top
Rating : 150 lbs
Motor
Type : TEFC Induction Motor Energy, Flame Motor Protection : IP 55
Proof, Efficient 1
Voltage : 415 Volts Phase : 3
Frequency : 50 Hertz Insulation Class : F
Motor Rating : * RPM : *
Accessories
Anchor Bolt : CS Base Plate : MS Fabricated
Coupling : Jaw Coupling Guard : CI
Oil Side Relief Valve : SS304 L Bearings : Ball Bearings of SKF make
Others
Weight Of Pump : * Weight Of Motor : *
Common Base Frame Size: * Foundation Loading : *
Noise Level : 85 db A (Maximum) from 1m Efficiency : *
Brake Kilo Watt : * Pump Model Number :*
Pump Make :* Capacity Control: By control of stroke length for entire
flow.
Diaphragm Failure features : Diaphragm Failure alarm/indication to be provided at the intermediate of the
two diaphragms.

* Vendor to indicate

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 Chapter-9 Technical specification

HWB, Mumbai Specification of Diaphragm Plant : HWP, Tuticorin

SPP Project pump with Drive Motor
Sheet No : 1 of 1
General
Tag Number : 44 P07 A/B Quantity : 2
Service Fluid :Aqueous Na2CO3 Type : Single Acting Double Diaphragm Pump with
Fluid Filled Intermediate Chamber
Location : Indoor Installation : Connected to 44 V05
Design Conditions
Capacity (m3/hr) Head (meters)
Normal: 3.0 Rated: 4.0 Minimum: * Suction: Atm.& flooded Differential : 25
Pumping Temperature : 40 °C Density : 1200 kg/m3
Design Temperature : 60 °C Design Pressure : 9.0 kg/cm2(g)
Viscosity : 2.0 cP Hydro Test Pressure : 14 kg/cm2(g)
Net Positive Suction Head, (meters) Vapour Pressure : 20 mm Hg
Available : Required : Percentage of Solid : Nil
Mode Of Operation : Intermittent
Number Of stages : 1 Number Of Diaphragm : 2
Material Of Construction
Process Chamber : SS 304L Diaphragm : PTFE
Valve Chamber : SS 304L Dampener : SS 304
Bolts Nuts : SS 304
Connections
Suction Nozzle: 40 NB Sch. 40/ Bottom Discharge Nozzle : 25 NB Sch. 40 /Top
Rating : 150 lbs
Motor
Type : TEFC Induction Motor Energy, Flame Motor Protection : IP 55
Proof, Efficient 1
Voltage : 415 Volts Phase : 3
Frequency : 50 Hertz Insulation Class : F
Motor Rating : * RPM : *
Accessories
Anchor Bolt : CS Base Plate : MS Fabricated
Coupling : Jaw Coupling Guard : CI
Oil Side Relief Valve : SS304 L Bearings : Ball Bearings of SKF make
Others
Weight Of Pump : * Weight Of Motor : *
Common Base Frame Size: * Foundation Loading : *
Noise Level : 85 db A (Maximum) from 1m Efficiency : *
Brake Kilo Watt : * Pump Model Number :*
Pump Make :* Capacity Control: By control of stroke length for entire
flow.
Diaphragm Failure features : Diaphragm Failure alarm/indication to be provided at the intermediate of the
two diaphragms.
* Vendor to indicate

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 Chapter-9 Technical specification

7.2.4 Centrifugal Pumps of Unit 44

HWB, Mumbai Specification of Centrifugal pump Plant : HWP, Tuticorin

SPP Project with Drive Motor
Sheet No : 1 of 1
General
Tag Number : 44 P06 A/B Quantity : 2
Service Fluid : N-Butanol+S2+HCl(aq.) Type : Horizontal End Suction Back Pull Out
Location : Indoor Installation : Connected to 44 V06
Design Conditions
Capacity (m3/hr) Head (meters)
Normal: 6 Rated:7 Minimum: Suction: Atm. & Flooded Differential : 25
*
Pumping Temperature : 40 °C Density : 970 kg/m3
Design Temperature : 60 °C Design Pressure : 9.0 kg/cm2(g)
Viscosity : 3.8 cP Hydro Test Pressure : 14 kg/cm2(g)
Net Positive Suction Head, (meters) Vapour Pressure : 38.6 mm Hg
Available : Required : * Percentage of Solid : Nil
Mode Of Operation : Intermittent
Material Of Construction
Casing : PP Shaft : EN8
Sleeve : Ceramic Impeller : PP
Back Plate : PP
Connections
Suction Nozzle: 80 NB Sch. 40 Discharge Nozzle : 25 NB Sch. 40
Rating : 150 lbs
Motor
Type : TEFC Induction,Flame Proof, Energy Motor Protection : IP 55
Efficient 1Motor
Voltage : 415 Volts Phase : 3
Frequency : 50 Hertz Insulation Class : F
Motor Rating : * RPM : 2900
Accessories
Anchor Bolt : MS 8.8 Base Plate : MS Fabricated
Coupling : Jaw/Cast Iron Coupling Guard : Aluminum Non-Sparking
Seals : Single SiC vs SiC Bearings : Ball Bearings of SKF make
Others
Weight Of Pump : * Weight Of Motor : *
Common Base Frame Size: * Foundation Loading : *
Noise Level : 85 db A (Maximum) from 1m Efficiency : *
Brake Kilo Watt : * Impeller Diameter :*
Pump Make :* Pump Model Number :*

* Vendor to indicate

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 Chapter-9 Technical specification

HWB, Mumbai Specification of Centrifugal pump Plant : HWP, Tuticorin

SPP Project with Drive Motor
Sheet No : 1 of 1
General
Tag Number : 44 P08 A/B Quantity : 2
Service Fluid : N-Butanol Type : Horizontal End Suction Back Pull Out
Location : Indoor Installation : Connected to 44 V08
Design Conditions
Capacity (m3/hr) Head (meters)
Normal: 5 Rated:6 Minimum: Suction: Atm. & Flooded Differential : 40
*
Pumping Temperature : 40 °C Density : 810 kg/m3
Design Temperature : 60 °C Design Pressure : 9.0 kg/cm2(g)
Viscosity : 3.8 cP Hydro Test Pressure : 14 kg/cm2(g)
Net Positive Suction Head, (meters) Vapour Pressure : 38.6 mm Hg
Available : Required : * Percentage of Solid : Nil
Mode Of Operation : Intermittent
Material Of Construction
Casing : SS 316 Shaft : SS 316
Sleeve : SS 316 Impeller : SS 316
Back Plate ; SS316
Connections
Suction Nozzle: 40 NB Sch. 40 Discharge Nozzle : 25 NB Sch. 40
Rating : 150 lbs
Motor
Type : TEFC Induction, Flame Proof, Energy Motor Protection : IP 55
Efficient 1Motor
Voltage : 415 Volts Phase : 3
Frequency : 50 Hertz Insulation Class : F
Motor Rating : * RPM : 2900
Accessories
Anchor Bolt : MS 8.8 Base Plate : MS Fabricated
Coupling : Jaw/Cast Iron Coupling Guard : Aluminum Non-Sparking
Seals : Single SiC vs SiC Bearings : Ball Bearings of SKF make
Others
Weight Of Pump : * Weight Of Motor : *
Common Base Frame Size: * Foundation Loading : *
Noise Level : 85 db A (Maximum) from 1m Efficiency : *
Brake Kilo Watt : * Impeller Diameter :*
Pump Make :* Pump Model Number :*

* Vendor to indicate

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Chapter-9 Technical specification

7.3. Process Data Sheets of Unit 45

7.3.1. Columns &Tanks

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Chapter-9 Technical specification
PROJECT TITLE : ITEM NO.: 45 C01 QTY
SPP, TUTICORIN ORGANIC PHASE DISTILLATION SERVICE FLUID: ONE
COLUMN N-BUTANOL
PROCESS
Process fluid : N-Butanol Sump/Column Vol. : 0.44 m3 / 1.9 m3
Liquid density : 810 kg / m3 Liquid Viscosity : 3.8 cP
Operating Pressure : 0-2 kg / cm2 (a) Design Pressure: Full Vacuum to 5 Kg/cm2(g) + 2 Kg/cm2
(Static head)
Operating Temperature : 100 °C Design Temperature : 200 °C
MECHANICAL
Design Code : ASME Sec-VIII-Div-I-2004: IS-875 Minimum Thickness : 8mm
Type Of Sump : Cylindrical
Construction : Vertical cylindrical shell with top and bottom dish end
Dish thickness: 6mm
Type Of Installation : Single V Butt & Fillet Radiography : 100 %
Sump Inside Diameter : 500 mm Sump TL To TL Length : 2200 mm
Column Inside Diameter : 400 mm Column TL To TL Length : 14870 mm
Orientation : Vertical Material For Shell : SA 516 GR 70
Material For End Covers : SA 240 SS 304 L Material For Nozzle Flange : SA 182 SS 304 L
Material For Nozzle Pipe : SA312 SS 304 L Material For Leg Support : IS-2062
Material For Manhole Flange : SA 240 SS 304 L Manhole Details : 600 mm X 150 lb
Material For Stud Bolts : A-193 Gr-B8M Material For Nuts : A-194 Gr-8M
Type Of Insulation : Hot Packing : SS 304 L structured packing
NOZZLE & CONNECTION
Mark No Size Elev Rating Service
mm mm
N1 1 50 Top 150 lbs Nitrogen in
N2 1 50 Top 150 lbs PSV
N3 1 50 Top 150 lbs Butanol vapor out
N4 1 50 Top 150 lbs Spare
N5 1 25 Hold 150 lbs Butanol in
N6 1 25 Hold 150 lbs Butanol in
N7 A/B/C 3 25 Hold 150 lbs Temp. gauges
N8 1 600 Hold 150 lbs Manhole
N9 A/B 1 25 Hold 150 lbs Sump LT
N10 1 25 Bot. 150 lbs Pure butanol out
N11 1 25 Bot. 150 lbs Drain
N12 1 50 Hold 150 lbs Temp. Element
N13 A/B 2 25 Hold 150 lbs Sump LG
N14 1 100 Hold 150 lbs Butanol in
N15 1 25 Hold 150 lbs Pure butanol out
N16 A/B/C 3 25 Hold 150 lbs DPT

NOTES :
a) Nozzle elevations are from the bottom tan line.
b) 3 sctions of SS 304 lstructured packing each of height 4000mm .with all
accessories like distributers, redistributers, packing support trays,
collecors etc.

APD PROCESS DATA SHEET

CHKD 45 C01 REV
PRO MEC COO 00
SECTION INST
S H RD

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Chapter-9 Technical specification

PROJECT TITLE : ITEM NO.: 45 C02 QTY

SPP, TUTICORIN AQUEOUS PHASE DISTILLATION SERVICE FLUID: ONE
COLUMN N-BUTANOL
PROCESS
Process fluid : N-Butanol Sump/Column Vol. : 0.22 m3 /0.31 m3
Liquid density : 810 kg / m3 Liquid Viscosity : 3.8 cP
Operating Pressure : 0-2 kg / cm2 (a) Design Pressure: Full Vacuum to 5 Kg/cm2(g) + 2 Kg/cm2
(Static head)
Operating Temperature : 100 °C Design Temperature : 200 °C
MECHANICAL
Design Code : ASME Sec-VIII-Div-I-2004: IS-875 Minimum Thickness : 6mm
Type Of Sump : Cylindrical Hydro-test : As per code
Construction : Vertical cylindrical shell with top and bottom dish end
Dish thickness: 4mm
Type Of Installation : Single V Butt & Fillet Radiography : 100 %
Sump Inside Diameter : 300 mm Sump TL To TL Length : 3000 mm
Column Inside Diameter : 200 mm Column TL To TL Length : 9620 mm
Orientation : Vertical Material For Shell : SA 516 GR 70
Material For End Covers : SA 516 GR 70 Material For Nozzle Flange : SA 516 GR 70
Material For Nozzle Pipe : SA 516 GR 70 Material For Leg Support : IS-2062
Material For Manhole Flange : SA 516 GR 70 Manhole Details : 600 mm X 150 lb
Material For Stud Bolts : A-193 Gr-B8M Material For Nuts : A-194 Gr-8M
Type Of Insulation : Hot Packing : 1’’ Ceramic pall rings randomly packed
NOZZLE & CONNECTION
Mark No Size Elev Rating Service
mm mm
N1 1 50 Top 150 lbs Nitrogen in
N2 1 50 Top 150 lbs PSV
N3 1 50 Top 150 lbs Butanol vapor out
N4 1 50 Top 150 lbs Temp. gauge
N5 1 25 Hold 150 lbs Butanol in
N6 1 25 Hold 150 lbs Temp. gauge
N7 3 25 Hold 150 lbs Sump vapor
N8 1 600 Hold 150 lbs Manhole
N9 A/B 1 25 Hold 150 lbs Sump LT
N10 1 25 Bot. 150 lbs Pure butanol out
N11 1 25 Bot. 150 lbs Drain
N12 1 50 Hold 150 lbs Temp. Element
N13 A/B 2 25 Hold 150 lbs Sump LG
N14 1 100 Hold 150 lbs Liqiud to reboiler
N15 1 25 Hold 150 lbs Liquid from reboiler
N16 A/B/C 3 25 Hold 150 lbs DPT

NOTES :
a) Nozzle elevations are from the bottom tan line.
b) SA 516 Gr 70 to have 1 mm PTFE lining wetted parts.
c) 2 sctions of random packing (1’’ ceramic pall rings) 0f 4000 mm each.
with all accessories like distributers, redistributers, packing support trays,
collecors etc.

APD PROCESS DATA SHEET

CHKD 45 C02 REV
PRO MEC COO 00
SECTION INST
S H RD

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Chapter-9 Technical specification

PROJECT TITLE : ITEM NO.: 45 V01 QTY

ORGANIC COLUMN
SPP, TUTICORIN FEED TANK SERVICE FLUID:IMPURE N- ONE
BUTANOL
PROCESS
Process fluid : N-Butanol +Water Process Vol. : 5 m3
3
Liquid density : 810 kg / m Liquid Viscosity : 3.8 cP
Operating Pressure : 0-2 kg / cm2 (a) Design Pressure: Full Vacuum to 5 Kg/cm2(g)
Operating Temperature : 35 °C Design Temperature : 150°C
MECHANICAL
Design Code : ASME Sec-VIII-Div-I Hydro Test Pressure : As per code
Type Of Shell : Cylindrical Minimum Thickness : 10 mm, Vendor to confirm
Side Dish End (1) : 2:1 Ellipsoidal Side Dish End (2) : 2:1 Ellipsoidal
Type Of Installation : Outdoor Radiography : 100 %
Shell Inside Diameter : 1500 mm Type Of Orientation : Vertical
TL To TL Length : 3000 mm Material For Shell : : SA 240 SS 304 L
Material For End Covers : : SA 240 SS 304 L Material For Nozzle Flange : : SA 182 SS 304 L
Material For Nozzle Pipe : : SA 312 SS 304 L Material For Leg Support : IS-2062
Material For Manhole Flange : : SA 240 SS 304 L Manhole Details : 600 mm X 150 lb
Material For Stud Bolts : A-193 Gr-B8M Material For Nuts : A-194 Gr-8M
Type Of Insulation : None
NOZZLE & CONNECTION
Mark No Size Elevation Rating Service
mm mm

N1 1 25 Top 150 lbs Butanol In

N2 1 25 Bottom 150 lbs Butanol Out
N3 1 40 Bottom 150 lbs Drain
N4 1 50 Top 150 lbs Safety Valve
N5A/B 2 25 2950/50 150 lbs LG/LT
N6 1 600 400 150 lbs Manhole
N7 1 15 Top 150 lbs Pressure Gauge
N8 1 25 Top 150 lbs Nitrogen In
N9 1 50 Top 150 lbs Spare
N10 1 50 Top 150 lbs Recirculation

N11 1 50 Top 150 lbs Vent

NOTES :
a) Nozzle elevations are from the bottom tan line.

APD PROCESS DATA SHEET

CHKD 45 V01 REV

PRO MEC COO 00
SECTION INST
S H RD

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Chapter-9 Technical specification

PROJECT TITLE : ITEM NO.: 45 V02 QTY

SPP, TUTICORIN PURIFIED BUTANOL SERVICE FLUID:IMPURE N- ONE
TANK BUTANOL
PROCESS
Process fluid : N-Butanol Process Vol. : 5 m3
Liquid density : 810 kg / m3 Liquid Viscosity : 3.8 cP
Operating Pressure : 0-2 kg / cm2 (a) Design Pressure: Full Vacuum to 5 Kg/cm2(g)
Operating Temperature : 35 °C Design Temperature : 150 °C
MECHANICAL
Design Code : ASME Sec-VIII-Div-I Hydro Test Pressure : As per code
Type Of Shell : Cylindrical Minimum Thickness : 10 mm, Vendor to confirm
Side Dish End (1) : 2:1 Ellipsoidal Side Dish End (2) : 2:1 Ellipsoidal
Type Of Installation : Outdoor Radiography : 100 %
Shell Inside Diameter : 1500 mm Type Of Orientation : Vertical
TL To TL Length : 3000 mm Material For Shell : : SA 240 SS 304 L
Material For End Covers : : SA 240 SS 304 L Material For Nozzle Flange : : SA 182 SS 304 L
Material For Nozzle Pipe : : SA 312 SS 304 L Material For Leg Support : IS-2062
Material For Manhole Flange : : SA 240 SS 304 L Manhole Details : 600 mm X 150 lb
Material For Stud Bolts : A-193 Gr-B8M Material For Nuts : A-194 Gr-8M
Type Of Insulation : None
NOZZLE & CONNECTION
Mark No Size Elevation Rating Service
mm mm

N1 1 25 Top 150 lbs Butanol In

N2 1 25 Bottom 150 lbs Butanol Out
N3 1 40 Bottom 150 lbs Drain
N4 1 50 Top 150 lbs Safety Valve
N5A/B 2 25 2950/50 150 lbs LG/LT
N6 1 600 400 150 lbs Manhole
N7 1 15 Top 150 lbs Pressure
Gauge
N8 1 25 Top 150 lbs Nitrogen In
N9 1 50 Top 150 lbs Spare
N10 1 50 Top 150 lbs Vent
NOTES :
a) Nozzle elevations are from the bottom tan line

APD PROCESS DATA SHEET

CHKD 45 V02 REV

PRO MEC COO 00
SECTION INST
S H RD

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Chapter-9 Technical specification

PROJECT TITLE : ITEM NO.: 45 D01 QTY

DECANTER
SPP, TUTICORIN SERVICE FLUID:IMPURE N- ONE
BUTANOL & WATER
PROCESS
Process fluid : N-Butanol Process Vol. : 5 m3
Liquid density : 810 kg / m3 Liquid Viscosity : 3.8 cP
Operating Pressure : 0-2 kg / cm2 (a) Design Pressure: Full Vacuum to 5 Kg/cm2(g)
Operating Temperature : 35 °C Design Temperature : 150 °C
MECHANICAL
Design Code : ASME Sec-VIII-Div-I Hydro Test Pressure As per code
Type Of Shell : Cylindrical Minimum Thickness : 10 mm, Vendor to confirm
Side Dish End (1) : 2:1 Ellipsoidal Side Dish End (2) : 2:1 Ellipsoidal
Type Of Installation : Outdoor Radiography : 100 %
Shell Inside Diameter : 1500 mm Type Of Orientation : Vertical
TL To TL Length : 3000 mm Material For Shell : : SA 240 SS 304 L
Material For End Covers : : SA 240 SS 304 L Material For Nozzle Flange : : SA 182 SS 304 L
Material For Nozzle Pipe : : SA 312 SS 304 L Material For Leg Support : IS-2062
Material For Manhole Flange : : SA 240 SS 304 L Manhole Details : 600 mm X 150 lb
Material For Stud Bolts : A-193 Gr-B8M Material For Nuts : A-194 Gr-8M
Type Of Insulation : None
NOZZLE & CONNECTION
Mark No Size Elevation Rating Service
mm mm

N1 1 50 Top 150 lbs Butanol In

N2 1 25 Top 150 lbs Butanol In
N3 1 25 Top 150 lbs Recirculation
In
N4 1 25 Top 150 lbs LS Hi
N5 2 25 Top 150 lbs Vapour
Balance
N6 A/B 2 25 HOLD(s) 150 lbs LS Lo
N7 1 600 400 150 lbs Manhole
N8 1 25 HOLD(S) 150 lbs Pump Suction
N9 1 50 HOLD(S) 150 lbs Drain
N10 1 50 Bottom 150 lbs Drain
N11 1 25 Bottom 150 lbs Drain
N12 A/B 2 25 HOLD(s) 150 lbs LS Lo
NOTES :
a) Nozzle elevations are from the bottom tan line.
b) Sight glass shall be orovided on opposite sides for visual indication of
the interface.

APD PROCESS DATA SHEET

CHKD 45 D01 REV

PRO MEC COO 00
SECTION INST
S H RD

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Chapter-9 Technical specification

7.3.2 Diaphragm Pumps of Unit 45

HWB, Mumbai Specification of Diaphragm Plant : HWP, Tuticorin
SPP Project pump with Drive Motor
Sheet No : 1 of 1
General
Tag Number : 45 P01 A/B Quantity : 2
Service Fluid :N-Butanol + Water Type : Single Acting Double Diaphragm Pump with
Fluid Filled Intermediate Chamber
Location : Outdoor Installation : Connected to 45 V01
Design Conditions
Capacity ( m3/hr) Head (meters)
Normal: 0.7 Rated: 1.0 Minimum: * Suction: Atm.& flooded Differential : 40
Pumping Temperature : 40 °C Density : 810 kg/m3
Design Temperature : 60 °C Design Pressure : 9.0 kg/cm2(g)
Viscosity : 3.8 cP Hydro Test Pressure : 14 kg/cm2(g)
Net Positive Suction Head, (meters) Vapour Pressure : 38.6 mm Hg
Available : Required : Percentage of Solid : Nil
Mode Of Operation : Intermittent
Number Of stages : 1 Number Of Diaphragm : 2
Material Of Construction
Process Chamber : SS 304L Diaphragm : PTFE
Valve Chamber : SS 304L Dampener : SS 304
Bolts Nuts : SS 304
Connections
Suction Nozzle: 25 NB Sch. 40/ Bottom Discharge Nozzle : 25 NB Sch. 40 /Top
Rating : 150 lbs
Motor
Type : TEFC Induction Motor, Flame Proof, Motor Protection : IP 55
Energy Efficient 1, VFD Compatible.
Voltage : 415 Volts Phase : 3
Frequency : 50 Hertz Insulation Class : F
Motor Rating : * RPM : *
Accessories
Anchor Bolt : CS Base Plate : MS Fabricated
Coupling : Jaw Coupling Guard : CI
Oil Side Relief Valve : SS304 L Bearings : Ball Bearings of SKF make
Others
Weight Of Pump : * Weight Of Motor : *
Common Base Frame Size: * Foundation Loading : *
Noise Level : 85 db A (Maximum) from 1m Efficiency : *
Brake Kilo Watt : * Pump Model Number :*
Pump Make :* Capacity Control: By control of motor RPM.
Diaphragm Failure features: Diaphragm Failure alarm/indication to be provided at the intermediate of the
two diaphragms.
* Vendor to indicate

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 Chapter-9 Technical specification

HWB, Mumbai Specification of Diaphragm Plant : HWP, Tuticorin

SPP Project pump with Drive Motor
Sheet No : 1 of 1
General
Tag Number : 45 P02 Quantity : 1
Service Fluid :N-Butanol Type : Single Acting Double Diaphragm Pump with
Fluid Filled Intermediate Chamber
Location : Outdoor Installation : Connected to 45 V02
Design Conditions
Capacity (m3/hr) Head (meters)
Normal: 0.7 Rated: 1.0 Minimum: * Suction: Atm.& flooded Differential : 40
Pumping Temperature : 40 °C Density : 810 kg/m3
Design Temperature : 60 °C Design Pressure : 9.0 kg/cm2(g)
Viscosity : 3.8 cP Hydro Test Pressure : 14 kg/cm2(g)
Net Positive Suction Head, (meters) Vapour Pressure : 38.6 mm Hg
Available : Required : Percentage of Solid : Nil
Mode Of Operation : Intermittent
Number Of stages : 1 Number Of Diaphragm : 2
Material Of Construction
Process Chamber : SS 304L Diaphragm : PTFE
Valve Chamber : SS 304L Dampener : SS 304
Bolts Nuts : SS 304
Connections
Suction Nozzle: 25 NB Sch. 40/ Bottom Discharge Nozzle : 25 NB Sch. 40 /Top
Rating : 150 lbs
Motor
Type : TEFC Induction Motor, Flame Proof, Motor Protection : IP 55
Energy Efficient 1 VFD Compatible.
Voltage : 415 Volts Phase : 3
Frequency : 50 Hertz Insulation Class : F
Motor Rating : * RPM : *
Accessories
Anchor Bolt : CS Base Plate : MS Fabricated
Coupling : Jaw Coupling Guard : CI
Oil Side Relief Valve : SS304 L Bearings : Ball Bearings of SKF make
Others
Weight Of Pump : * Weight Of Motor : *
Common Base Frame Size: * Foundation Loading : *
Noise Level : 85 db A (Maximum) from 1m Efficiency : *
Brake Kilo Watt : * Pump Model Number :*
Pump Make :* Capacity Control: By control of motor RPM.
Diaphragm Failure features : Diaphragm Failure alarm/indication to be provided at the intermediate of the
two diaphragms.
* Vendor to indicate

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 Chapter-9 Technical specification

HWB, Mumbai Specification of Diaphragm Plant : HWP, Tuticorin

SPP Project pump with Drive Motor
Sheet No : 1 of 1
General
Tag Number : 45 P03 A/B Quantity : 2
Service Fluid :N-Butanol Type : Single Acting Double Diaphragm Pump with
Fluid Filled Intermediate Chamber
Location : Outdoor Installation : Connected to 45 C 1
Design Conditions
Capacity (m3/hr) Head (meters)
Normal: 0.7 Rated: 1.0 Minimum: * Suction: Atm.& flooded Differential : 40
Pumping Temperature : 40 °C Density : 810 kg/m3
Design Temperature : 60 °C Design Pressure : 9.0 kg/cm2(g)
Viscosity : 3.8 cP Hydro Test Pressure : 14 kg/cm2(g)
Net Positive Suction Head, (meters) Vapour Pressure : 38.6 mm Hg
Available : Required : Percentage of Solid : Nil
Mode Of Operation : Intermittent
Number Of stages : 1 Number Of Diaphragm : 2
Material Of Construction
Process Chamber : SS 304L Diaphragm : PTFE
Valve Chamber : SS 304L Dampener : SS 304
Bolts Nuts : SS 304
Connections
Suction Nozzle: 25 NB Sch. 40/ Bottom Discharge Nozzle : 25 NB Sch. 40 /Top
Rating : 150 lbs
Motor
Type : TEFC Induction Motor, Flame Proof, Motor Protection : IP 55
Energy Efficient 1 VFD Compatible.
Voltage : 415 Volts Phase : 3
Frequency : 50 Hertz Insulation Class : F
Motor Rating : * RPM : *
Accessories
Anchor Bolt : CS Base Plate : MS Fabricated
Coupling : Jaw Coupling Guard : CI
Oil Side Relief Valve : SS304 L Bearings : Ball Bearings of SKF make
Others
Weight Of Pump : * Weight Of Motor : *
Common Base Frame Size: * Foundation Loading : *
Noise Level : 85 db A (Maximum) from 1m Efficiency : *
Brake Kilo Watt : * Pump Model Number :*
Pump Make :* Capacity Control: By control of motor RPM.
Diaphragm Failure features : Diaphragm Failure alarm/indication to be provided at the intermediate of the
two diaphragms.
* Vendor to indicate

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Chapter-9 Technical specification

HWB, Mumbai Specification of Diaphragm Plant : HWP, Tuticorin

SPP Project pump with Drive Motor
Sheet No : 1 of 1
General
Tag Number : 45 P04 A/B Quantity : 2
Service Fluid :N-Butanol + Water Type : Single Acting Double Diaphragm Pump with
Fluid Filled Intermediate Chamber
Location : Outdoor Installation : Connected to 45 D 1
Design Conditions
Capacity ( m3/hr) Head (meters)
Normal: 0.15 Rated: 0.2 Minimum: * Suction: Atm.& flooded Differential : 40
Pumping Temperature : 40 °C Density : 830 kg/m3
Design Temperature : 60 °C Design Pressure : 9.0 kg/cm2(g)
Viscosity : 3.8 cP Hydro Test Pressure : 14 kg/cm2(g)
Net Positive Suction Head, (meters) Vapour Pressure : 38.6 mm Hg
Available : Required : Percentage of Solid : Nil
Mode Of Operation : Intermittent
Number Of stages : 1 Number Of Diaphragm : 2
Material Of Construction
Process Chamber : SS 304L Diaphragm : PTFE
Valve Chamber : SS 304L Dampener : SS 304
Bolts Nuts : SS 304
Connections
Suction Nozzle: 25 NB Sch. 40/ Bottom Discharge Nozzle : 25 NB Sch. 40 /Top
Rating : 150 lbs
Motor
Type : TEFC Induction Motor, Flame Proof, Motor Protection : IP 55
Energy Efficient 1 VFD Compatible.
Voltage : 415 Volts Phase : 3
Frequency : 50 Hertz Insulation Class : F
Motor Rating : * RPM : *
Accessories
Anchor Bolt : CS Base Plate : MS Fabricated
Coupling : Jaw Coupling Guard : CI
Oil Side Relief Valve : SS304 L Bearings : Ball Bearings of SKF make
Others
Weight Of Pump : * Weight Of Motor : *
Common Base Frame Size: * Foundation Loading : *
Noise Level : 85 db A (Maximum) from 1m Efficiency : *
Brake Kilo Watt : * Pump Model Number :*
Pump Make :* Capacity Control: By control of motor RPM.
Diaphragm Failure features : Diaphragm Failure alarm/indication to be provided at the intermediate of the
two diaphragms.
* Vendor to indicate

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 Chapter-9 Technical specification

HWB, Mumbai Specification of Diaphragm Plant : HWP, Tuticorin

SPP Project pump with Drive Motor
Sheet No : 1 of 1
General
Tag Number : 45 P05 A/B Quantity : 2
Service Fluid :N-Butanol + Water Type : Single Acting Double Diaphragm Pump with
Fluid Filled Intermediate Chamber
Location : Outdoor Installation : Connected to 45 D 1
Design Conditions
Capacity (m3/hr) Head (meters)
Normal: 0.7 Rated: 1.0 Minimum: * Suction: Atm.& flooded Differential : 40
Pumping Temperature : 40 °C Density : 830 kg/m3
Design Temperature : 60 °C Design Pressure : 9.0 kg/cm2(g)
Viscosity : 3.8 cP Hydro Test Pressure : 14 kg/cm2(g)
Net Positive Suction Head, (meters) Vapour Pressure : 38.6 mm Hg
Available : Required : Percentage of Solid : Nil
Mode Of Operation : Intermittent
Number Of stages : 1 Number Of Diaphragm : 2
Material Of Construction
Process Chamber : SS 304L Diaphragm : PTFE
Valve Chamber : SS 304L Dampener : SS 304
Bolts Nuts : SS 304
Connections
Suction Nozzle: 25 NB Sch. 40/ Bottom Discharge Nozzle : 25 NB Sch. 40 /Top
Rating : 150 lbs
Motor
Type : TEFC Induction Motor, Flame Proof, Motor Protection : IP 55
Energy Efficient 1 VFD Compatible.
Voltage : 415 Volts Phase : 3
Frequency : 50 Hertz Insulation Class : F
Motor Rating : * RPM : *
Accessories
Anchor Bolt : CS Base Plate : MS Fabricated
Coupling : Jaw Coupling Guard : CI
Oil Side Relief Valve : SS304 L Bearings : Ball Bearings of SKF make
Others
Weight Of Pump : * Weight Of Motor : *
Common Base Frame Size: * Foundation Loading : *
Noise Level : 85 db A (Maximum) from 1m Efficiency : *
Brake Kilo Watt : * Pump Model Number :*
Pump Make :* Capacity Control: By control of motor RPM.
Diaphragm Failure features : Diaphragm Failure alarm/indication to be provided at the intermediate of the
two diaphragms.
* Vendor to indicate

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Chapter-9 Technical specification

7.3.3 Heat Exchangers of Unit 45

HEAT EXCHANGER SPECIFICATION SHEET
1 PROJECT: SPP, TUTICORIN
2 TAG NO.: 45 E1
3 Service of Unit: HEAD CONDENSER (COOLING WATER)OF ORGANIC PHASE DISTILLATION COLUMN
4 Item No.:
5 Date: Rev No.: Job No.:
6 Size mm Type BEM Hori. Connected in 1 parallel 1 series
7 Surf/Unit(eff.) *** m2 Shells/unit Surf/shell (eff.) *** m2
8 PERFORMANCE OF ONE UNIT
9 Fluid allocation Shell Side Tube Side
10 Fluid name PROCESS FLUID COOLING WATER
11 Fluid quantity, Total kg/hr 275 ***
12 Vapor (In/Out) kg/hr *** ***
13 Liquid kg/hr *** ***
14 Non-condensable kg/s *** ***
15
16 Temperature (In/Out) °C 93 70 32 37
17 Dew / Bubble point °C *** ***
18 Density kg/m3 *** ***
19 Viscosity cP *** ***
20 Molecular wt, Vap 78 & 18 *** ***
21 Molecular wt, NC 28
22 Specific heat kcal/(kg*°C) *** ***
23 Thermal conductivity kcal/(hr*m* °C) *** ***
24 Latent heat kcal/kg ***
25 Inlet Pressure kgf/cm2A 2 4
26 Velocity m/s *** ***
27 Pressure drop, allow./calc. kgf/cm2 0.2 *** 0.5 ***
2
28 Fouling resist. m *hr*°C /kcal *** ***
29 Heat exchanged kcal/hr * MTD corrected *** ⁰C
30 Transfer rate kcal/( m2*hr*⁰C) Service *** Dirty *** Clean ***
31 CONSTRUCTION OF ONE SHELL Sketch
32 Shell Side Tube Side
33 Design/Test pressure kgf/cm2A 6 6
34 Design temperature °C 180 180
35 Number passes per shell *** ***
36 Corrosion allowance mm *** ***
37 Connections In mm *** ***
38 Size/rating Out mm *** ***
39 Intermediate *** ***
40 Tube No. *** OD *** mm Thks(avg) *** mm Length *** mm Pitch *** mm
41 Tube type PLAIN Material SA 249 TP 304 L Tube pattern ***
42 Shell ID *** mm OD mm Material SS 304 L Shell cover ***
43 Channel or bonnet *** Channel cover ***
44 Tube-sheet-stationary *** Tube-sheet-floating ***
45 Floating head cover *** Impingement Plate ***
46 Baffle-cross Type *** Cut(%d) *** Spacing: c/c *** mm
47 Baffle-long *** Seal type *** Spacing: Inlet *** mm
48 Supports-tube *** U-bend *** Type ***
49 Bypass seal *** Tube-tube-sheet joint ***
50 Expansion joint *** Type ***
51 RhoV2-Inlet nozzle *** Bundle entrance *** Bundle exit *** kg/(m*s2)
52 Gaskets - Shell side *** Tube Side ***
53 Floating head ***
54 Code requirements *** TEMA class R
55 Weight/Shell *** Filled with water *** Bundle *** kg
56 Remarks: EXCHANGER SHOULD BE DESIGNED FOR DE-SUPERHEATING, CONDENSATION AND SUBCOOLING.
57 PROCESS FLUID COMPOSITION : n-BUTANOL(57.7 %) VAPOUR, INERTS (NITROGEN-5%) WATER VAPOUR
58 *VENDOR TO CONFIRM; *** VENDOR TO CALCULATE

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Chapter-9 Technical specification

HEAT EXCHANGER SPECIFICATION SHEET

1 PROJECT: SPP, TUTICORIN
2 TAG NO.: 45 E2
3 Service of Unit: BUTANOL COOLER
4 Item No.:
5 Date: Rev No.: Job No.:
6 Size mm Type BEM Hori. Connected in 1 parallel 1 series
7 Surf/Unit(eff.) *** m2 Shells/unit Surf/shell (eff.) *** m2
8 PERFORMANCE OF ONE UNIT
9 Fluid allocation Shell Side Tube Side
10 Fluid name n-BUTANOL COOLING WATER
11 Fluid quantity, Total kg/hr 361 ***
12 Vapor (In/Out) kg/hr *** ***
13 Liquid kg/hr *** ***
14 Non-condensable kg/s *** ***
15
16 Temperature (In/Out) °C 117 40 32 37
17 Dew / Bubble point °C *** ***
18 Density kg/m3 *** ***
19 Viscosity cP *** ***
20 Molecular wt, Vap *** ***
21 Molecular wt, NC 28
22 Specific heat kcal/(kg*°C) *** ***
23 Thermal conductivity kcal/(hr*m*°C) *** ***
24 Latent heat kcal/kg ***
25 Inlet Pressure kgf/cm2A 2 3
26 Velocity m/s *** ***
27 Pressure drop, allow./calc. kgf/cm2 0.2 *** 0.5 ***
2
28 Fouling resist. m *hr*°C /kcal *** ***
29 Heat exchanged kcal/hr *** MTD corrected *** °C
30 Transfer rate kcal/( m2*hr*⁰C) Service *** Dirty *** Clean ***
31 CONSTRUCTION OF ONE SHELL Sketch
32 Shell Side Tube Side
33 Design/Test pressure kgf/cm2A 6 6
34 Design temperature °C 180 180
35 Number passes per shell *** ***
36 Corrosion allowance mm *** ***
37 Connections In mm *** ***
38 Size/rating Out mm *** ***
39 Intermediate *** ***
40 Tube No. *** OD *** mm Thks(avg) *** mm Length *** mm Pitch *** mm
41 Tube type PLAIN Material SA 249 TP 304 L Tube pattern ***
42 Shell ID *** mm OD *** mm Material SS 304L Shell cover ***
43 Channel or bonnet *** Channel cover ***
44 Tube-sheet-stationary *** Tube-sheet-floating ***
45 Floating head cover *** Impingement Plate ***
46 Baffle-cross Type *** Cut(%d) *** Spacing: c/c *** mm
47 Baffle-long *** Seal type *** Spacing: Inlet *** mm
48 Supports-tube *** U-bend *** Type ***
49 Bypass seal *** Tube-tube-sheet joint ***
50 Expansion joint *** Type ***
51 RhoV2-Inlet nozzle *** Bundle entrance *** Bundle exit *** kg/(m*s2)
52 Gaskets - Shell side *** Tube Side ***
53 Floating head ***
54 Code requirements *** TEMA class R
55 Weight/Shell *** Filled with water *** Bundle *** kg
56 Remarks:
57
58 *VENDOR TO CONFIRM; *** VENDOR TO CALCULATE

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Chapter-9 Technical specification

HEAT EXCHANGER SPECIFICATION SHEET

1 PROJECT: SPP, TUTICORIN
2 TAG NO.: 45 R1
3 Service of Unit: ORGANIC PHASE DISTILLATION COLUMN THERMOSYPHON REBOILER
4 Item No.:
5 Date: Rev No.: Job No.:
6 Size mm Type BEM Vert. Connected in 1 parallel 1 series
7 Surf/Unit(eff.) *** m2 Shells/unit Surf/shell (eff.) *** m2
8 PERFORMANCE OF ONE UNIT
9 Fluid allocation Shell Side Tube Side
10 Fluid name PROCESS FLUID STEAM
11 Fluid quantity, Total kg/hr 1077 ***
12 Vapor (In/Out) kg/hr *** 715***
13 Liquid(In/Out) kg/hr 1077*** 362***
14 Non-condensable kg/s *** ***
15
16 Temperature (In/Out) °C 117 120 145 135
17 Dew / Bubble point °C *** ***
18 Density kg/m3 *** ***
19 Viscosity cP *** ***
20 Molecular wt, Vap *** ***
21 Molecular wt, NC 28
22 Specific heat kcal/(kg*°C) *** ***
23 Thermal conductivity kcal/(hr*m*°C) *** ***
24 Latent heat kcal/kg ***
25 Inlet Pressure kgf/cm2A 3* (at bubble point) 4* (super heat of 12 degrees )
26 Velocity m/s *** ***
27 Pressure drop, allow./calc. kgf/cm2 0.2 *** 0.5 ***
28 Fouling resist. (min) m2*hr*°C /kcal *** ***
29 Heat exchanged kcal/hr 110000* MTD corrected *** °C
30 Transfer rate kcal/( m2*hr*⁰C) Service *** Dirty *** Clean ***
31 CONSTRUCTION OF ONE SHELL Sketch
32 Shell Side Tube Side
33 Design/Test pressure kgf/cm2A 6 6
34 Design temperature °C 200 200
35 Number passes per shell *** ***
36 Corrosion allowance mm *** ***
37 Connections In mm *** ***
38 Size/rating Out mm *** ***
39 Intermediate *** ***
40 Tube No. *** OD *** mm Thks(avg) *** mm Length *** mm Pitch *** mm
41 Tube type PLAIN Material SA 249 TP 304 L Tube pattern ***
42 Shell ID *** mm OD *** mm Material SS 304L Shell cover ***
43 Channel or bonnet *** Channel cover ***
44 Tube-sheet-stationary *** Tube-sheet-floating ***
45 Floating head cover *** Impingement Plate ***
46 Baffle-cross Type *** Cut(%d) *** Spacing: c/c *** mm
47 Baffle-long *** Seal type *** Spacing: Inlet *** mm
48 Supports-tube *** U-bend *** Type ***
49 Bypass seal *** Tube-tube-sheet joint ***
50 Expansion joint *** Type ***
51 RhoV2-Inlet nozzle *** Bundle entrance *** Bundle exit *** kg/(m*s2)
52 Gaskets - Shell side *** Tube Side ***
53 Floating head ***
54 Code requirements *** TEMA class R
55 Weight/Shell *** Filled with water *** Bundle *** kg
56 Remarks
57 PROCESS FLUID COMPOSITION : n-BUTANOL WITH WATER
58 *VENDOR TO CONFIRM; *** VENDOR TO CALCULATE

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Chapter-9 Technical specification

DATA SHEET FOR POLY BLOCK TYPE GRAPHITE HEAT EXCHANGER

PROJECT: SPP, TUTICORIN TAG NO.:45 E3

8 SERVICE OF UNIT: AQUEOUS EFFLUENT HEAT EXCHANGER DUTY: CONTINUOUS

9 DATE: REV NO.:
10 PERFORMANCE OF ONE UNIT
11 FLUID ALLOCATION PROCESS (TUBE SIDE) SERVICE (SHELL SIDE)
12 FLUID PROCESS WATER COOLING WATER
13 FLUID QUANTITY (TOTAL) kg/hr 150 ***
14 VAPOR FLOWRATE in/out kg/hr *** *** *** ***
15 LIQUID FLOWRATE in/out kg/hr *** ***
16 TEMPERATURE in/out ⁰C 117 45 32 37
17 DENSITY Vap/Liq kg/m3 *** ***
18 SPECIFIC HEAT Vap/Liq Kcal/(kg* °C ) *** ***
19 THERMAL CONDUCTIVITY Vap/Liq Kcal/(hr*m*°C) *** ***
20 VISCOCITY Vap/Liq °C *** *** ***
21 OPERATING PRESSURE bar (g) 1 3
22 PRESSURE DROP calc./perm. bar *** 0.1 *** 0.5
23 VELOCITY calc. m/s *** ***
24 FOULING RESISTANCE m2 *h *°C / kcal *** ***
25 HEAT EXCHANGED kcal/hr 7000*
26 LMTD (CORRECTED) °C ***
27 HEAT TRASFER RATE DIRTY SERVICE CLEAN
28 kcal/(m2*hr*⁰C) *** *** ***
29 AREA CALCULATED / AREA PROVIDED m2 ***
30 SHORT SUMMARY OF PROCESS CALCULATIONS
31 ZONE FOR CONDENSER DESUPERHEATING CONDENSATION VAPOR COOLING LIQUID COOLING
32 PROCESS SIDE
33 REYNOLD NUMBER ***
34 PRANDTL NUMBER ***
35 HTC ***
36 SERVICE SIDE
37 REYNOLD NUMBER ***
38 PRANDTL NUMBER ***
39 HTC ***
40 CONSTRUCTION
41 MODEL *** NO. OF BLOCKS ***
42 SURFACE AREA ***
43 NO. OF PASSES *** ***
44 CONNECTIONS Inlet/Outlet mm *** ***
45 Condensate out mm *** ***
46 RATING
47 DESIGN TEMPERATURE °C 180 50
48 DESIGN/TEST PRESSURE bar (g) VAC -5 5/5.5
49 MOUNTING VERTICAL*
50 MATERIAL
51 BLOCKS IMPREGNATED GRAPHITE
52 END CHAMBER/DOMES IMPREGNATED GRAPHITE
53 SHELL IS 2062 GR A/B
54 SHELL LINING NO GASKETS PTFE EPDM ‘O’ RING, Neoprene
55 CODES APPLICABLE FOR DESIGN
56 PROCESS SIDE
57 SERVICE SIDE/SHELL SIDE ASME SEC VIII DIV 1
58 SPECIAL REQUIREMENTS NO
59 OVERALL DIMENSION IN mm (APPROXIMATE)
60 REFER
61 REMARKS:
62 *VENDOR TO CONFIRM; *** VENDOR TO CALCULATE

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Chapter-9 Technical specification

DATA SHEET FOR POLY BLOCK TYPE GRAPHITE HEAT EXCHANGER

PROJECT: SPP, TUTICORIN TAG NO.:45 E4

8 SERVICE OF UNIT: AQ. COLUMN HEAD CONDENSER DUTY: CONTINUOUS

9 DATE: REV NO.:
10 PERFORMANCE OF ONE UNIT
11 FLUID ALLOCATION PROCESS (TUBE SIDE) SERVICE (SHELL SIDE)
12 FLUID n-BUTANOL (55%), WATER COOLING WATER
(40%), INERT (N2)
13 FLUID QUANTITY (TOTAL) kg/hr 50 ***
14 VAPOR FLOWRATE in/out kg/hr *** *** *** ***
15 LIQUID FLOWRATE in/out kg/hr *** *** *** ***
16 TEMPERATURE in/out °C 95 70 33 38
17 DENSITY Vap/Liq kg/m3 *** ***
18 SPECIFIC HEAT Vap/Liq Kcal/(kg* ⁰C) *** ***
19 THERMAL CONDUCTIVITY Vap/Liq Kcal/(hr*m*⁰C) *** ***
20 VISCOCITY Vap/Liq °C *** *** ***
21 OPERATING PRESSURE bar (g) 1 3.5
22 PRESSURE DROP calc./perm. bar *** 0.1 *** 0.5
23 VELOCITY calc. m/s *** ***
24 FOULING RESISTANCE m2 *h *°C / kcal *** ***
25 HEAT EXCHANGED kcal/hr 1100*
26 LMTD (CORRECTED) °C ***
27 HEAT TRASFER RATE DIRTY SERVICE CLEAN
28 kcal/(m2*hr*⁰C) *** *** ***
29 AREA CALCULATED / AREA PROVIDED m2 ***
30 SHORT SUMMARY OF PROCESS CALCULATIONS
31 ZONE FOR CONDENSER DESUPERHEATING CONDENSATION VAPOR COOLING LIQUID COOLING
32 PROCESS SIDE
33 REYNOLD NUMBER ***
34 PRANDTL NUMBER ***
35 HTC ***
36 SERVICE SIDE
37 REYNOLD NUMBER ***
38 PRANDTL NUMBER ***
39 HTC ***
40 CONSTRUCTION
41 MODEL *** NO. OF BLOCKS ***
42 SURFACE AREA ***
43 NO. OF PASSES *** ***
44 CONNECTIONS Inlet/Outlet mm *** ***
45 Condensate out mm *** ***
46 RATING
47 DESIGN TEMPERATURE °C 180 50
48 DESIGN/TEST PRESSURE bar (g) VAC - 6 5/5.5
49 MOUNTING VERTICAL
50 MATERIAL
51 BLOCKS IMPREGNATED GRAPHITE
52 END CHAMBER/DOMES IMPREGNATED GRAPHITE
53 SHELL IS 2062 GR A/B
54 SHELL LINING NO GASKETS PTFE EPDM ‘O’ RING, Neoprene
55 CODES APPLICABLE FOR DESIGN
56 PROCESS SIDE
57 SERVICE SIDE/SHELL SIDE ASME SEC VIII DIV 1
58 SPECIAL REQUIREMENTS NO
59 OVERALL DIMENSION IN mm (APPROXIMATE)
60 REFER : EXCHANGER SHOULD BE DESIGNED FOR DE-SUPERHEATING, CONDENSATION AND SUBCOOLING.
61 REMARKS: DATASHEET IS FOR 3 DIFFERENT FLUID & TEMPERATURE CASES; DESIGN IS BASED ON CRITICAL CASE OF HEAT LOAD
62 *VENDOR TO CONFIRM; *** VENDOR TO CALCULATE

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Chapter-9 Technical specification

DATA SHEET FOR POLY BLOCK TYPE GRAPHITE HEAT EXCHANGER

PROJECT: SPP, TUTICORIN TAG NO.:45 R2

8 SERVICE OF UNIT: AQUEOUS PHASE DIST. COL. REBOILER DUTY: CONTINUOUS

9 DATE: REV NO.:
10 PERFORMANCE OF ONE UNIT
11 FLUID ALLOCATION PROCESS (TUBE SIDE) SERVICE (SHELL SIDE)
12 FLUID WATER STEAM
13 FLUID QUANTITY (TOTAL) kg/hr 30 ***
14 VAPOR FLOWRATE in/out kg/hr *** *** *** ***
15 LIQUID FLOWRATE in/out kg/hr *** *** *** ***
16 TEMPERATURE in/out °C 95 105 135* 135*
17 DENSITY Vap/Liq kg/m3 *** ***
18 SPECIFIC HEAT Vap/Liq Kcal/(kg* °C) *** ***
19 THERMAL CONDUCTIVITY Vap/Liq Kcal/(hr*m*°C) *** ***
20 VISCOCITY Vap/Liq °C *** *** ***
21 OPERATING PRESSURE bar (g) 0.1 3*
22 PRESSURE DROP calc./perm. bar *** 0.1 *** 0.5
23 VELOCITY calc. m/s *** ***
24 FOULING RESISTANCE m2 *h *°C / kcal *** ***
25 HEAT EXCHANGED kcal/hr 10000*
26 LMTD (CORRECTED) °C ***
27 HEAT TRASFER RATE DIRTY SERVICE CLEAN
28 kcal/(m2*hr*⁰C) *** *** ***
29 AREA CALCULATED / AREA PROVIDED m2 ***
30 SHORT SUMMARY OF PROCESS CALCULATIONS
31 ZONE FOR CONDENSER DESUPERHEATING CONDENSATION VAPOR COOLING LIQUID COOLING
32 PROCESS SIDE
33 REYNOLD NUMBER ***
34 PRANDTL NUMBER ***
35 HTC ***
36 SERVICE SIDE
37 REYNOLD NUMBER ***
38 PRANDTL NUMBER ***
39 HTC ***
40 CONSTRUCTION
41 MODEL *** NO. OF BLOCKS ***
42 SURFACE AREA ***
43 NO. OF PASSES *** ***
44 CONNECTIONS Inlet/Outlet mm *** ***
45 Condensate out mm *** ***
46 RATING
47 DESIGN TEMPERATURE °C 180 180
48 DESIGN/TEST PRESSURE bar (g) VAC - 5 5/5.5
49 MOUNTING VERTICAL*
50 MATERIAL
51 BLOCKS IMPREGNATED GRAPHITE
52 END CHAMBER/DOMES IMPREGNATED GRAPHITE
53 SHELL IS 2062 GR A/B
54 SHELL LINING NO GASKETS PTFE EPDM ‘O’ RING, Neoprene
55 CODES APPLICABLE FOR DESIGN
56 PROCESS SIDE
57 SERVICE SIDE/SHELL SIDE ASME SEC VIII DIV 1
58 SPECIAL REQUIREMENTS NO
59 OVERALL DIMENSION IN mm (APPROXIMATE)
60 REFER
61 REMARKS:
62 *VENDOR TO CONFIRM; *** VENDOR TO CALCULATE

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7.4. Process Data Sheets of Unit 49

7.4.1. Tanks

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Chapter-9 Technical specification

PROJECT TITLE : ITEM NO.: 49 V01 QTY

2-EHA STORAGE TANK
SPP, TUTICORIN SERVICE FLUID: ONE
2-ETHYL HEXANOL
PROCESS
Process fluid : 2-Ethyl Hexanol (C8H17OH) Process Vol. : 20 m3
Liquid density : 833 kg / m3 Liquid Viscosity : 9.8 cP
Operating Pressure : 0-1 kg / cm2 (g) Design Pressure: Full Vacuum to 5 Kg/cm2(g)
Operating Temperature : 35 °C Design Temperature : 100 °C
MECHANICAL
Design Code : ASME Sec-VIII-Div-I Hydro Test Pressure : As per code
Type Of Shell : Cylindrical Minimum Thickness : 10mm, Vendor to confirm
Side Dish End (1) : 2:1 Ellipsoidal Side Dish End (2) : 2:1 Ellipsoidal
Dish thickness: 8mm
Type Of Installation : Outdoor Radiography : 100 %
Shell Inside Diameter : 2335 mm Orientation : Horizontal
TL To TL Length : 4670 mm Material For Shell : SA-516 Gr 70
Material For End Covers : SA-516 Gr 70 Material For Nozzle Flange : SA-105
Material For Nozzle Pipe : SA-106 Gr B Material For Saddle Support : IS-2062
Material For Manhole Flange : SA-105 Manhole Details : 600 mm X 150 lb
Material For Stud Bolts : A-193 Gr-B8M Material For Nuts : A-194 Gr-8M
Type Of Insulation : None
NOZZLE & CONNECTION
Mark No Size Elevation Rating Service
mm mm

N1 1 25 Top 150 lbs Nitrogen in

N2 1 50 Top 150 lbs RD
N3 1 50 Top 150 lbs PSV
N4 1 50 Top 150 lbs Vent
N5 2 600 Top 150 lbs Manhole
N6 1 50 Top 150 lbs LT
N7 1 50 Top 150 lbs Spare
N8 1 25 Top 150 lbs PT
N9 1 50 Top 150 lbs Liquid in
N10 1 25 Top 150 lbs PG
N11 2 50 Side 150 lbs LG-01 (Top)
A/B
N12 2 50 Side 150 lbs LG-02 (Bottom)
A/B
N13 1 25 Bottom 150 lbs Drain
N14 1 50 Bottom 150 lbs Liquid out
N15 1 50 Side 150 lbs Thermowell
NOTES :
a) Nozzle elevations are from the bottom line.

APD PROCESS DATA SHEET

CHKD 49 V01 REV

PRO MEC COO 00
SECTION INST
S H RD

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Chapter-9 Technical specification
PROJECT TITLE : ITEM NO.: 49 V02 QTY
SPP, TUTICORIN IAA STORAGE TANK SERVICE FLUID: ONE
ISO-AMYL ALCOHOL
PROCESS
Process fluid : Iso-Amyl Alcohol Process Vol. : 20 m3
Liquid density : 810 kg / m3 Liquid Viscosity : 3.8 cP
Operating Pressure : 0-1 kg / cm2 (g) Design Pressure: Full Vacuum to 5 Kg/cm2(g)
Operating Temperature : 35 °C Design Temperature : 100 °C
MECHANICAL
Design Code : ASME Sec-VIII-Div-I Hydro Test Pressure : As per code
Type Of Shell : Cylindrical Minimum Thickness : 10mm, Vendor to confirm
Side Dish End (1) : 2:1 Ellipsoidal Side Dish End (2) : 2:1 Ellipsoidal
Dish thickness: 8mm
Type Of Installation : Outdoor Radiography : 100 %
Shell Inside Diameter : 2335 mm Orientation : Horizontal
TL To TL Length : 4670 mm Material For Shell : SA-516 Gr 70
Material For End Covers : SA-516 Gr 70 Material For Nozzle Flange : SA-105
Material For Nozzle Pipe : SA-106 Gr B Material For Saddle Support : IS-2062
Material For Manhole Flange : SA-105 Manhole Details : 600 mm X 150 lb
Material For Stud Bolts : A-193 Gr-B8M Material For Nuts : A-194 Gr-8M
Type Of Insulation : None
NOZZLE & CONNECTION
Mark No Size Elevation Rating Service
mm mm

N1 1 25 Top 150 lbs Nitrogen in

N2 1 50 Top 150 lbs RD
N3 1 50 Top 150 lbs PSV
N4 1 50 Top 150 lbs Vent
N5 2 600 Top 150 lbs Manhole
N6 1 50 Top 150 lbs LT
N7 1 50 Top 150 lbs Spare
N8 1 25 Top 150 lbs PT
N9 1 50 Top 150 lbs Liquid in
N10 1 25 Top 150 lbs PG
N11 A/B 2 50 Side 150 lbs LG-01 (Top)
N12 A/B 2 50 Side 150 lbs LG-02 (Bottom)
N13 1 25 Bottom 150 lbs Drain
N14 1 50 Bottom 150 lbs Liquid out
N15 1 50 Side 150 lbs Thermowell
NOTES :
a) Nozzle elevations are from the bottom line.
b) Instrumentation to confirm nozzles
APD PROCESS DATA SHEET

CHKD 49 V02 REV

PRO MEC COO 00
SECTION INST
S H RD

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Chapter-9 Technical specification

PROJECT TITLE : ITEM NO.: 49 V03 QTY

DUMP TANK
SPP, TUTICORIN SERVICE FLUID:Dumped Alcohol ONE

PROCESS
Process fluid : Dumped Alcohol Process Vol. : 30 m3
3
Liquid density : 833 kg/m Liquid Viscosity : 9.8 cP
Operating Pressure : 0-1 kg / cm2 (g) Design Pressure: Full Vacuum to 5 Kg/cm2(g)
Operating Temperature : 35 °C Design Temperature : 100 °C
MECHANICAL
Design Code : ASME Sec-VIII-Div-I Hydro Test Pressure : As per code
Type Of Shell : Cylindrical Minimum Thickness : 10 mm, Vendor to confirm
Side Dish End (1) : 2:1 Ellipsoidal Side Dish End (2) : 2:1 Ellipsoidal
Dish thickness: 8mm
Type Of Installation : Outdoor Radiography : 100 %
Shell Inside Diameter : 2675 mm Orientation : Horizontal
TL To TL Length : 5350 mm Material For Shell : SA-516 Gr 70
Material For End Covers : SA-516 Gr 70 Material For Nozzle Flange : SA-105
Material For Nozzle Pipe : SA-106 Gr B Material For Saddle Support : IS-2062
Material For Manhole Flange : SA-105 Manhole Details : 600 mm X 150 lb
Material For Stud Bolts : A-193 Gr-B8M Material For Nuts : A-194 Gr-8M
Type Of Insulation : None
NOZZLE & CONNECTION
Mark No Size Elevation Rating Service
mm mm

N1 1 25 Top 150 lbs Nitrogen in

N2 1 50 Top 150 lbs RD
N3 1 50 Top 150 lbs PSV
N4 1 50 Top 150 lbs Vent
N5 2 600 Top 150 lbs Manhole
N6 1 50 Top 150 lbs LT
N7 1 50 Top 150 lbs Spare
N8 1 25 Top 150 lbs PT
N9 1 50 Top 150 lbs Liquid in
N10 1 25 Top 150 lbs PG
N11 A/B 2 50 Side 150 lbs LG-01 (Top)
N12 A/B 2 50 Side 150 lbs LG-02 (Bottom)
N13 1 25 Bottom 150 lbs Drain
N14 1 50 Bottom 150 lbs Liquid out
N15 1 50 Side 150 lbs Thermowell
NOTES :
a) Nozzle elevations are from the bottom line.

APD PROCESS DATA SHEET

CHKD 49 V03 REV

PRO MEC COO 00
SECTION INST
S H RD

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Chapter-9 Technical specification

PROJECT TITLE : ITEM NO.: 49 V04 & 49 V05 QTY

SPP, TUTICORIN BUTANOL SERVICE FLUID: TWO
STORAGE TANK BUTANOL
PROCESS
Process fluid : Butanol (C4H9OH) Process Vol. : 30 m3
Liquid density : 810 kg / m3 Liquid Viscosity : 3.8 cP
Operating Pressure : 0-1 kg / cm2 (g) Design Pressure: Full Vacuum to 5 Kg/cm2(g)
Operating Temperature : 35 °C Design Temperature : 100 °C
MECHANICAL
Design Code : ASME Sec-VIII-Div-I Hydro Test Pressure : As per code
Type Of Shell : Cylindrical Minimum Thickness : 10mm, Vendor to confirm
Side Dish End (1) : 2:1 Ellipsoidal Side Dish End (2) : 2:1 Ellipsoidal
Dish thickness: 8mm
Type Of Installation : Outdoor Radiography : 100 %
Shell Inside Diameter : 2675 mm Orientation : Horizontal
TL To TL Length : 5350 mm Material For Shell : SA-516 Gr 70
Material For End Covers : SA-516 Gr 70 Material For Nozzle Flange : SA-105
Material For Nozzle Pipe : SA-106 Gr B Material For Saddle Support : IS-2062
Material For Manhole Flange : SA-105 Manhole Details : 600 mm X 150 lb
Material For Stud Bolts : A-193 Gr-B8M Material For Nuts : A-194 Gr-8M
Type Of Insulation : None
NOZZLE & CONNECTION
Mark No Size Elevation Rating Service
mm mm

N1 1 25 Top 150 lbs Nitrogen in

N2 1 50 Top 150 lbs RD
N3 1 50 Top 150 lbs PSV
N4 1 50 Top 150 lbs Vent
N5 2 600 Top 150 lbs Manhole
N6 1 50 Top 150 lbs LT
N7 1 50 Top 150 lbs Spare
N8 1 25 Top 150 lbs PT
N9 1 50 Top 150 lbs Liquid in
N10 1 25 Top 150 lbs PG
N11 2 50 Side 150 lbs LG-01 (Top)
A/B
N12 2 50 Side 150 lbs LG-02 (Bottom)
A/B
N13 1 25 Bottom 150 lbs Drain
N14 1 50 Bottom 150 lbs Liquid out
N15 1 50 Side 150 lbs Thermowell
NOTES :
a) Nozzle elevations are from the bottom line.
APD PROCESS DATA SHEET

CHKD 49 V04 & 49 V05 REV

PRO MEC COO 00
SECTION INST
S H RD

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7.4.2 Centrifugal Pumps of Unit 49

HWB, Mumbai Specification of Centrifugal pump Plant : HWP, Tuticorin

SPP Project with Drive Motor
Sheet No : 1 of 1
General
Tag Number : 49 P01 A/B Quantity : 2
Service Fluid : 2-Ethyl Hexanol Type : Horizontal End Suction Back Pull Out
Location : Outdoor Installation : Connected to 49 V01
Design Conditions
Capacity (m3/hr) Head (meters)
Normal: 5 Rated:6 Minimum: Suction: Atm. & Flooded Differential : 40
*
Pumping Temperature : 40 °C Density : 833 kg/m3
Design Temperature : 60 °C Design Pressure : 9.0 kg/cm2(g)
Viscosity : 9.8 cP Hydro Test Pressure : 14 kg/cm2(g)
Net Positive Suction Head, (meters) Vapour Pressure : 0.46 mm Hg
Available : Required : * Percentage of Solid : Nil
Mode Of Operation : Intermittent
Material Of Construction
Casing : SS 316 Shaft : SS 316
Sleeve : SS 316 Impeller : SS 316
Back Plate ; SS316
Connections
Suction Nozzle: 50 NB Sch. 40 Discharge Nozzle : 40 NB Sch. 40
Rating : 150 lbs
Motor
Type : TEFC Induction, Flame Proof, Energy Motor Protection : IP 55
Efficient 1Motor
Voltage : 415 Volts Phase : 3
Frequency : 50 Hertz Insulation Class : F
Motor Rating : * RPM : 2900
Accessories
Anchor Bolt : MS 8.8 Base Plate : MS Fabricated
Coupling : Jaw/Cast Iron Coupling Guard : Aluminum Non-Sparking
Seals : Single SiC vs SiC Bearings : Ball Bearings of SKF make
Others
Weight Of Pump : * Weight Of Motor : *
Common Base Frame Size: * Foundation Loading : *
Noise Level : 85 db A (Maximum) from 1m Efficiency : *
Brake Kilo Watt : * Impeller Diameter :*
Pump Make :* Pump Model Number :*

* Vendor to indicate

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 Chapter-9 Technical specification

HWB, Mumbai Specification of Centrifugal pump Plant : HWP, Tuticorin

SPP Project with Drive Motor
Sheet No : 1 of 1
General
Tag Number : 49 P02 A/B Quantity : 2
Service Fluid : Iso Amyl Alcohol Type : Horizontal End Suction Back Pull Out
Location : Outdoor Installation : Connected to 49 V02
Design Conditions
Capacity (m3/hr) Head (meters)
Normal: 5 Rated:6 Minimum: Suction: Atm. & Flooded Differential : 40
*
Pumping Temperature : 40 °C Density : 810 kg/m3
Design Temperature : 60 °C Design Pressure : 9.0 kg/cm2(g)
Viscosity : 3.8 cP Hydro Test Pressure : 14 kg/cm2(g)
Net Positive Suction Head, (meters) Vapour Pressure : 100 mm Hg
Available : Required : * Percentage of Solid : Nil
Mode Of Operation : Intermittent
Material Of Construction
Casing : SS 316 Shaft : SS 316
Sleeve : SS 316 Impeller : SS 316
Back Plate ; SS316
Connections
Suction Nozzle: 50 NB Sch. 40 Discharge Nozzle : 40 NB Sch. 40
Rating : 150 lbs
Motor
Type : TEFC Induction, Flame Proof, Energy Motor Protection : IP 55
Efficient 1Motor
Voltage : 415 Volts Phase : 3
Frequency : 50 Hertz Insulation Class : F
Motor Rating : * RPM : 2900
Accessories
Anchor Bolt : MS 8.8 Base Plate : MS Fabricated
Coupling : Jaw/Cast Iron Coupling Guard : Aluminum Non-Sparking
Seals : Single SiC vs SiC Bearings : Ball Bearings of SKF make
Others
Weight Of Pump : * Weight Of Motor : *
Common Base Frame Size: * Foundation Loading : *
Noise Level : 85 db A (Maximum) from 1m Efficiency : *
Brake Kilo Watt : * Impeller Diameter :*
Pump Make :* Pump Model Number :*

* Vendor to indicate

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 Chapter-9 Technical specification

HWB, Mumbai Specification of Centrifugal pump Plant : HWP, Tuticorin

SPP Project with Drive Motor
Sheet No : 1 of 1
General
Tag Number : 49 P03 Quantity : 1
Service Fluid : Dumped Alcohol Type : Horizontal End Suction Back Pull Out
Location : Outdoor Installation : Connected to 49 V03
Design Conditions
Capacity (m3/hr) Head (meters)
Normal: 5 Rated:6 Minimum: Suction: Atm. & Flooded Differential : 40
*
Pumping Temperature : 40 °C Density : 833 kg/m3
Design Temperature : 60 °C Design Pressure : 9.0 kg/cm2(g)
Viscosity : 9.8 cP Hydro Test Pressure : 14 kg/cm2(g)
Net Positive Suction Head, (meters) Vapour Pressure : 100 mm Hg
Available : Required : * Percentage of Solid : Nil
Mode Of Operation : Intermittent
Material Of Construction
Casing : SS 316 Shaft : SS 316
Sleeve : SS 316 Impeller : SS 316
Back Plate ; SS316
Connections
Suction Nozzle: 50 NB Sch. 40 Discharge Nozzle : 40 NB Sch. 40
Rating : 150 lbs
Motor
Type : TEFC Induction, Flame Proof, Energy Motor Protection : IP 55
Efficient 1Motor
Voltage : 415 Volts Phase : 3
Frequency : 50 Hertz Insulation Class : F
Motor Rating : * RPM : 2900
Accessories
Anchor Bolt : MS 8.8 Base Plate : MS Fabricated
Coupling : Jaw/Cast Iron Coupling Guard : Aluminum Non-Sparking
Seals : Single SiC vs SiC Bearings : Ball Bearings of SKF make
Others
Weight Of Pump : * Weight Of Motor : *
Common Base Frame Size: * Foundation Loading : *
Noise Level : 85 db A (Maximum) from 1m Efficiency : *
Brake Kilo Watt : * Impeller Diameter :*
Pump Make :* Pump Model Number :*

* Vendor to indicate

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 Chapter-9 Technical specification

HWB, Mumbai Specification of Centrifugal pump Plant : HWP, Tuticorin

SPP Project with Drive Motor
Sheet No : 1 of 1
General
Tag Number : 49 P04 A/B Quantity : 2
Service Fluid : N-Butanol Type : Horizontal End Suction Back Pull Out
Location : Indoor Installation : Connected to 49 V04 & 49 V05
Design Conditions
Capacity (m3/hr) Head (meters)
Normal: 5 Rated:6 Minimum: Suction: Atm. & Flooded Differential : 40
*
Pumping Temperature : 40 °C Density : 810 kg/m3
Design Temperature : 60 °C Design Pressure : 9.0 kg/cm2(g)
Viscosity : 3.8 cP Hydro Test Pressure : 14 kg/cm2(g)
Net Positive Suction Head, (meters) Vapour Pressure : 38.6 mm Hg
Available : Required : * Percentage of Solid : Nil
Mode Of Operation : Intermittent
Material Of Construction
Casing : SS 316 Shaft : SS 316
Sleeve : SS 316 Impeller : SS 316
Back Plate ; SS316
Connections
Suction Nozzle: 40 NB Sch. 40 Discharge Nozzle : 40 NB Sch. 40
Rating : 150 lbs
Motor
Type : TEFC Induction,Flame Proof, Energy Motor Protection : IP 55
Efficient 1Motor
Voltage : 415 Volts Phase : 3
Frequency : 50 Hertz Insulation Class : F
Motor Rating : * RPM : 2900
Accessories
Anchor Bolt : MS 8.8 Base Plate : MS Fabricated
Coupling : Jaw/Cast Iron Coupling Guard : Aluminum Non-Sparking
Seals : Single SiC vs SiC Bearings : Ball Bearings of SKF make
Others
Weight Of Pump : * Weight Of Motor : *
Common Base Frame Size: * Foundation Loading : *
Noise Level : 85 db A (Maximum) from 1m Efficiency : *
Brake Kilo Watt : * Impeller Diameter :*
Pump Make :* Pump Model Number :*

* Vendor to indicate

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8. PACKAGE UNITS

8.1 Specification of Alkali dissolution unit (Unit 46)

Scope: Design, manufacture, inspection, testing, supply, erection & commissioning.

OPERATING CONDITIONS
1 Service required Preparation of aqueous Na2CO3, NaOH and KOH solution ( different
batches ) at different concentration level .
Alkali solution shall be prepared in 2 number of jacketed stirred tank
by mixing of Na2CO3 or NaOH or KOH in the form of flakes or
powder and water under stirring. The mixed charge shall be stirred
with a electric motor operated agitator fitted with this tank. The heat
generated in the system shall be removed by cooling with cooling
water to be circulated through the spiral jacket of the stirred tank.
The agitator shall be of overhung design. It’s RPM shall be 105. The
in-line-helical gearboxes shall be of Bonfiglioli make.

2 System configuration The agitator motors shall be 415 V/ 3 phase/50 hertz/4 pole/TEFC
induction type. Local Start/Stop push button station to be provided in
the field.

Required Na2CO3 or NaOH or KOH shall be fed into the tank by a

lifting of 50 Kg bags and automatic filling system. Three centrifugal
pumps of capacity 5 m3/hr and 40 m head shall be provided in the
system for transportation of the alkali solution to the main system of
the plant. A recirculation line will also be provided for close loop
circulation of the solution if required. The transfer line shall be
provided with a steam tracing jacket to keep the line under heating
by hot water (condensate from the plant).

3 Capacity of the tanks 2 KL x 2 ( nominal volume ) with standard baffling, for preparation
of about 1600 lit of alkali solution at a time.
1) The reactors shall be provided with a 3 bladed hydrofoil impeller
Agitator (with non-flame proof electric motor), local temperature
indicator ( bi-metallic ), Level gauge. Alkali feed port at top (for
filling system as well as manual).

2) Cooling water/steam supply & return line for the jacket with
valves.

3) A view point at the top of tank (removable opening for periodic

inspection & cleaning).
4 Accessories
4) Steam tracer jacket on alkali solution transfer line.

5) Three numbers (one stand-by ) of single mechanically sealed

alkali transfer pumps along with their baseplates (SS 316 material)
along with their baseplates and non-flameproof motor for transfer of
alkali to the main plant from the tank @5.0 m3/hr / 40 m head. Local
Start/Stop push button station to be provided in the field.

6) A 50 Kg Alkali bag lifting and filling system for filling of the

alkali into the tank.

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7) Process water filling line at top of the tank

8) Inter connected piping (2” SS 304L Sch.40, 100 °C) for the pumps
& drains, process water and cooling water feed lines up to battery
limit, valves, strainers, NRV and other pipe fittings.

9) PG for the pumps (at discharge).

5 Type of Installation Indoor. Steel required for structural work and support during
erection shall be in scope of the vendor.
6 Operation mode The Unit will be operated intermittently as and when required basis.
Therefore flushing lines shall be provided to flush the entire suction
& discharge line after the unit is taken shutdown for larger time
period.
7 Operating temperature 50- 70 °C
8 Operating pressure Atmospheric
9 Design temperature 150 °C
10 Design pressure 2.0 Kg/cm2 g (sufficient to take dynamic and static load of the
charge). It is the contractor’s scope to decide for the design pressure
under this static and dynamic load condition.
11 Material of MOC of the jacket shall be IS-2062 Gr A/B. Pumps: SS 316.
Construction ( MOC ) 2 KLVessel-SS 304L.
Pipes valves fittings agitator and agitator shaft : SS 304.
Cooling Water : Pressure : 3.0 Kg/cm2 (g)
Temperature: :Supply:32°C,
:Return : 37°C
Nitrogen : Max. at the rate of 40 Nm3/hr
12
Utility available at site Instrument Air : Pressure : 6.5 Kg/cm2(g)
Electrical Power: 415 V, 50 Hz with emergency backup
feeder of 250 KW load .
Hot water : Steam condensate at 75 – 90 °C
Instrumentation 3 no. of pressure gauges & 3 no. of pressure transmitter, 2 no. of
13
Level gauges, 2 nos. of local temperature indicator
Electrical 3 no. of pump motors & 2 no. of agitator motors with VFD including
14
cabling from the MCC located 60 metre away from the unit.
15 Civil Foundation for 2 nos.of 2 KL vessel and 3 no. of pumps

Following documents shall be submitted during detailed engineering:

 P&I diagram, GA drawing, equipment lay out indicating the space requirement,
total weight of the system, utilities needed for this, electrical power requirement, etc.
 Equipment data sheets of pumps, agitators, tanks.
 Electrical / Instrument control logic diagram.
 Specification/make/model of instruments, pumps, agitators and tanks.
 QAP & delivery schedule.
Note:
1. Recommended spares for the trouble free operation for a period of 2 years shall be supplied.
2. Vendor shall take reference of the schematic drawing for meeting the minimum requirement of the
system.
3. Final QA plan including stage inspection shall be submitted for our approval prior to
manufacture.
4. Four sets of operation and maintenance manual of the Alkali dissolution system along with a CD
containing one set of the above mentioned documents shall be submitted.
5. Material Test certificate, Equipment Internal Performance test report, etc. shall be sent along
with the consignment.
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 Chapter-9 Technical specification

8.2. Specification of Vacuum & Vent Scrubber Unit (Unit 47)

8.2.1. Scrubber
Scope: Design, manufacture, inspection, testing, supply, erection & commissioning

S.No. Requirement Description

1
Service required Scrubbing of HCl, POCl3 along with organics ( 1-5 % ) and inerts (nitrogen &
leakage air ) at a temperature of 40°C. Scrubbing medium is 10-25% NaOH
solution. The reacted solution from scrubber will be disposed to effluent tank.

-Alkali scrubber consisting a packed column with internals like liquid

distributors, redistributors, packing supporting plates etc. The following
dimensions are to be considered for the scrubber column.
(i) Height of column : 6000 mm
(ii) Packing height : 3700mm
(iii) Dia. of the column : 500 mm
(iv) Dia. of the sump : 1000 mm
(v) Height of the sump : 1200 mm

- A water cooler is to be provided in the alkali recirculation line between sump

of the scrubber column and its top, to remove the heat of scrubbing /
System neutralization.
2 configuration - Two blowers shall be provided at the vent outlet of scrubber.
- The outlet of the vent pipe of the scrubber shall be at least 12 m height from
the ground.
- Two pumps shall be provided for caustic recirculation through the scrubber.

Note:

All lining and equipment design, fabrication & inspection shall be as per BS
4994 code of practice and fabrication drawing for all these components is to be
submitted to the Department for verification and final clearance before
fabrication of the same .
While designing, general safety aspect shall be considered with respect to use
of the item in hazardous chemicals and conditions.
A schematic diagram of the unit is enclosed. However the successful vendor
shall subsequently submit a detailed P&ID.

3 Capacity To scrub HCL @ 100 Kg/hr (1-5 % of Hexane, 2Ethyl hexanol, iso-amyl
alcohol, xylene, etc). HCL traces in scrubber outlet shall be nil.

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Chapter-9 Technical specification

(i) Scrubber coumn as per the dimension above.

(ii) The packing type is Raschig rings(1”). (Vedor to provide performance test
certificate for this type of packing and ensure extra quantity as required for
commissioning)
(iii) Two nos. circulating pumps along with their motors, baseplate assembly.
Normally one pump will be in service.
Capacity of each pump: 5 m3/hr,
Head: 25 m,
Sealing: single mechanical seal.
Local Start/Stop push button station to be provided in the field.
4 Accessories
(iv) Graphite water cooler in Alkali circulation line for removal of heat of
neutralization/absorption (5m3/hr of 20% NaCl solution shall be cooled from
65 to 40 °C by cooling water supply 32 °C and return 37 °C).

(v) Two blowers along with their motors (capacity: 700 Nm3/hr; Head: 200 mm
water column) Local Start/Stop push button station to be provided in the field.

(vi) Connected piping –for liquid piping and for column inlet and outlet
vapour.

(vii) Valves & Fittings.

(viii) Instruments such as gauges and transmitter for level measurement of the
column sump, flow measurement for the liquid circulation, compound pressure
gauges on the column inlet and pump discharges, delta pressure transmitter
across the column, vacuum gauges on blower suction, temperature indicators
for of the column sump. The system shall be operated from the field and DCS.
All logics and interlocks shall be configured though the DCS.

(ix) All other accessories as required for smooth operation of the unit to be
designed by the supplier.

(x) Structural steel required for erection and supports shall be in the scope of
the vendor.

5 Type of Outdoor
Installation
6 Operation mode Continuous
7 Operating 40- 70 °C
temperature
8 Operating Atmospheric
pressure
9 Design 70 °C
temperature
10 Design pressure Vacuum of 350 mm WC to atmospheric
Pressure drop across the column: 50 mm of water column maximum
Hydro test pressure: Water Filled

11 Material of Column: PP lined FRP ( min. 2 mm thick )

Construction Pumps: PP
( MOC ) Pipe, pipe fitting, valves : CPCV, 3 piece valve with flanged ends, ANSI B
16.5, 150# 5
Packing : Ceramic raschig ring
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Water cooler : Graphite

Gasket: PTFE
Fasteners: A193B7/A1942H
Blower – PP FRP
Gland packing

12 Utility available Cooling Water : Pressure : 3.0 Kg/cm2 g

at site Temperature : Supply : 32 °C
Return : 37 °C
Nitrogen : Max. at the rate of 40 Nm3/hr
Oxygen : around 500 ppm
Dew point : -20 °C
Instrument Air : Pressure : 4.8-5.2 Kg/cm2g
Dew point : -40 °C
Electrical Power : 415 V, 50 Hz

13 Instrumentation 2 no. of pressure gauges, 1 no. of Temp. Indicator, 1 no. of Level gauge, 1 no.
of HCl monitor & 1 no. of H2 monitor with DCS connectivity and necessary
cabling.
14 Electrical 2 no. of alkali circulation pumps motors & 2 no. of blower motors with
cabling from MCC located 60 metre away from the unit.
15 Civil Foundation for one Scrubber column, one Heat exchange and 2 no. of
circulation pumps.

Following documents shall be submitted during detailed engineering:

 P&I diagram, GA drawing, equipment lay out indicating the space requirement,
total weight of the system, utilities needed for this, electrical power requirement, etc.
 Equipment data sheets of pumps, agitators, tanks.
 Electrical / Instrument control logic diagram.
 Specification/make/model of instruments, pumps, agitators and tanks.
 QAP & delivery schedule.

Note:
1. Recommended spares for the trouble free operation for a period of 2 years shall be supplied.
2. Vendor shall take reference of the schematic drawing for meeting the minimum requirement of
the system.
3. Final QA plan including stage inspection shall be submitted for HWB’s approval prior to
manufacture.
4. Guarantee test runs shall be carried out for final acceptability. Guarantee test runs shall be carried
5. out for final acceptability. Test conditions shall be approved by HWB prior to placement of order.
6. 5. Four sets of Operation and maintenance manual of the equipment and machinery along with a CD
7. containing one set of the above mentioned documents shall be submitted.
8. 6. Material Test certificate, Equipment Internal Performance test report, etc. shall be sent along with
9. the consignment.

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8.2.2 Vacuum pumping system with Drive Specification

Scope: Design, manufacture, inspection, testing, supply, erection & commissioning

S.No. Requirement Description

1
Service required 1. Evacuation of Reaction vessel along with condensers and receivers.
Service fluid: 2 Ethyl Hexanol, Iso amyl alcohol, Di hexyl
Amine,Tri ethyl Amine, Octonyl chloride, n-
Hexane, water. vapor, HCl, POCl3 & PCl3 vapour.
Density of the fluid : 0.006 – 0.01 gms/cc.

1. Two number of skid mounted Vacuum system should be able to

evacuate the connected system to the ultimate vacuum level of 0.01 Torr
from atmospheric pressure. For operational flexibility/redundancy both the
systems shall be interconnected.

2. One supplied system consists of :

i) A mechanical booster pump backed up by two Oil seal rotary

vacuum pump suitable for the above service.

ii) Interconnected chiller traps/ vessels (as required for the system),
piping, fittings, valves, Instrumentation & controls,accessories and
2 System spares suitable for the hazardous area.
configuration
iii) A 1 m3 SS304 L suction buffer vessel designed for full vacuum and
5 kg/cm2 (g).

3. All the above equipment shall be skid mounted on common base frame
and inter-connecting piping & bellows shall be provided in between the
equipment.
4. Necessary Electrical and Instrumentation cabling shall be in vendors
scope. The MCC is located 60 metre away from the unit.

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At 0.1 Torr : 6500 m3/hr

Ultimate vacuum with gas ballast closed : 0.001 Torr.
Ultimate vacuum with gas ballast open : 0.01 Torr.
Vacuum inlet port : 150 mm.
Booster pump cut in pressure : 10 Torr.
Individual capacities of vacuum pumps
1. Each Mechanical Booster Pump :
Capacity :7500 to 8000 m3/hr.
3 Capacity 2. Each Oil seal Rotary Vacuum Pump :
Type : Oil seal Rotary vane type.
Stage : double.
Ultimate vacuum : 0.005 mm of Hg with gas ballast closed
and 0.1 mm of Hg with gas ballast open.
Free Air displacement : 600 m3/Hr.
Note: Proper sealing to be designed for no leakage and with the material
suitable for handling the fluid mentioned above.

Intermediate Chiller Trap with condensate tank

Chiller trap type: Shell and tube condenser
For trapping moisture along with traces of vapour. The condensate tank
shall be provided with level indicator, manual drain valve, vacuum relief
valve and isolation valve.

Other Accessories
1.Electropneumatic operated high vacuum valves at different isolation
points of the system like suction, discharge, bypass etc.( 6” size )
2. Vacuum measuring instruments – i) Pirani gauge. ii) Mcleod gauge
3. Interconnected piping along with required equipment within the system.
4. Bellows for connecting the rotary and stationary items of the system.
5. Other equipment like intermediate vessels as required in the system.
Accessories
4 6. Necessary spares to be indicated and supplied by the supplier for five
years of trouble free operation.
7. Chilled water trap
8. Condensate tank with level indicator,
9. Air & electrical operated Admittance valves
10. Non return valves
11. Vacuum switch, Temperature switch
12. 1 m3 suction knock out drum.

5 Type of Installation In door, Hazardous area.

6 Operation mode Continuous
7 Operating -5 to +170 °C
temperature
8 Design pressure Absolute vacuum to 6.0 Kg/cm2 a

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Mechanical Booster pump

Pump Impellers / Shafts : Ductile Iron Cast Integrally with shaft
Pump Casing, Head plates: Finegrained Cast Iron BS 1452.
Intermediate vessels : SS316L
End cover: Grade 220 Impregnated for high vacuum service
Interconnected pipelines: SS 316L
Gears :High grade carbon steel BS 970 Grade 817M40 Hardened and
Ground

Oil seal Rotary vane vacuum pumps

Material of Pump parts :Cast Iron IS 210 FG 220
9 Construction Body & jacket : A 516 Gr. 70
( MOC ) End Shaft of the rotor :AISI 4140/EN 24

Electro pneumatic operated High vacuum valves

Body :SS 304 L
Seat : SS 304 L having “O” ring groove
“O” ring:PTFE

Connected piping: SS 304 L

Skid : CS/MS

Cooling water :
Pressure : 3.5 Kg/cm2 g ;
Temperature : In/Out : 32 °C /37 °C
Pressure drop allowed: 0.2 Kg/cm2 (max.)
10 Utility available at Chilled water :
site Pressure : 3.0 Kg/cm2 g ;
Temperature : In/Out : -5°C / 0 °C
Nitrogen : At 2.0 kg/cm2 g
Instrument Air: at 6.5 Kg/cm2g

11 Other details
Electric Motor -Explosion/Flame proof VFD compatible Motor
-Suitable power rating for the continuous duty
- Powers supply :415 V, 3 Phase, 50 Hz.
- IP 55 for gas group II B, Zone 1,
Insulation class : F,
Make: Crompton/Kirloskar/BharatBijlee/ABB/
Siemens

System Controls The system shall be configured with the DCS. It shall be provided with all
interlocks for automatic starting/stopping of Booster pumps,VFD control,
By-pass valves, Booster Suction/Discharge isolation valves, Booster High
Temperature Tripping and Overload tripping of boosters and OSRVs with
indications in the DCS.

External surface Painting with Epoxy Red oxide primer and final painting by polyurethane
preparation paint.

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Instrumentation & Supplier to provide all necessary Instrumentation & Control items
Control compatible with Gas group IIB, Zone 1 for smooth operation and safety of
the system. Apart from the others following should be provided :

i) Frequency convertor of Telemechanic/ABB/L&T – equivalent

ii) Electro-pneumatic operated Booster suction, discharge and bypass
valves-butterfly type as required.
iii) Electro-pneumatic operated OSRV suction, valves-butterfly type as
required.
iv) Air admittance valves for admitting air in OSRV.
v) Temp switch & vacuum Switch along with interlock systems.
vi) Start and stop push button stations along with ammeters.
vii) Temp. switch.
viii) Vacuum measurement ( local ) : mercury McLeod Gauge &
Compound Bourdon gauge.
ix) Vacuum meter(control panel indication) : Pirani gauge.
x) Interlocks to be provided for automatic starting & stopping of booster.
pump along with bypass /suction/discharge valves by sensing pressure and
tripping of booster & Oil seal rotary vacuum pumps on high temperature
& overload.
xi) Necessary cabling for DCS connectivity.

12 Test to be carried
out
Details of Test Test to be carried out by To be witnessed by
Pumping capacity Manufacturer Department
and other
functional test for
checking of all the
interlocks.
Hydro test for the Manufacturer Department
Intermediate
equipment and
pipelines at 9 ata
Other NDT test as Manufacturer Department
specified in
standard code of
practice.
Material test Mil test certificate Review
13 Electrical 2 no. of Booster pump motors through VFD, 4 no. of OSRV pump motors.
The two VFDs shall be housed in one panel in MCC located 60 metre
away from the unit.
14 Civil Foundation for 2 no. of vacuum suction buffer vessel(Knock out drum), 2
no. of Intermediate condensers, 2 no. of Booster pumps & 4 no. of OSRV
pumps.

General specification for vacuum pumps :

1. The above data is the basis for procurement of the item. However it is the scope under the EPC
contract to prepare a detail technical sheet and obtaining approval from the department to
facilitate manufacturing of the item. The Supplier should submit detail design data for all the
related Machineries/ Equipment.

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2. In case the item requires outsourcing by the party, for safeguard of the item and interest of the
Department the same should be procured from a reputed Manufacturer or it’s Authorized agencies
in this field (Preferably from M/S Hick Hargreeves U.K, Hind Hivac, Precise vacuum, J.B.
Sawant, or it’s authorised agency), having experience in manufacturing and supplying the item at
least 3 to 5 Industries in last five years. The list of such Manufacturers along with their design
details should be submitted to the department for issuing final clearance for
manufacturing/procurement of the item.
3. While detail designing of the item general safety aspect should be considered.
4. Following documents shall be submitted during detailed engineering:

 P&I diagram, GA drawing, equipment lay out indicating the space requirement,
total weight of the system, utilities needed for this, electrical power requirement, etc.
 Equipment data sheets of pumps, agitators, tanks.
 Electrical / Instrument control logic diagram.
 Specification/make/model of instruments, pumps, agitators and tanks.
 QAP & delivery schedule.

Note:
1. Recommended spares for the trouble free operation for a period of 2 Years shall be supplied.
2. Vendor shall take reference of the schematic drawing for meeting the minimum requirement of the
system
3. Final QA plan including stage inspection plan shall be submitted for HWB’s approval prior to
manufacture/procurement.
4. Guarantee test runs shall be carried out for final acceptability.
5. Four sets of Operation and maintenance manual of the vacuum system along with a CD containing
one set of the above mentioned documents shall be submitted.
6. Material Test certificate, Equipment Internal Performance test report, etc. shall be sent along with
the consignment.

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8.3. Specification of Electrode Boilers (Unit 48)

Scope: Design, manufacture, inspection, testing, supply, erection & commissioning

S. No Parameters Description
Quantity: 2nos.(sets)
1. System configuration - Complete skid mounted package unit
- Fully automatic operation ( auto start & stop for capacity control
with ampere based water level controller, pressure controller and
blow down
- Non IBR type
- Automatic blow down and cleaning system
- Automatic blow down and pressure control Operation / fault
status of the units shall be available in the DCS.
2. Steam quality Super-heated steam ( 5-100C )
Press : 6.0 kg/ cm2 g
2 a) Steam generation capacity 400 Kg/ hr from each boiler
3. Type of system Non IBR; Electrode type of boilers

4. Accessories to supply - Water feed tank with level gauge and necessary valves
- Motorized Water feed pump with valves
- All valves including manual & auto valves for blow down
- Steam stop valve.
- Safety valves
- Steam pressure control valves
- Pressure gauges & switches
- Pressure controller
- All field instruments & control system
- Control panel
- Cabling for Electrical & Instrumentation.
- All insulation
- connected pipe, pipe fittings & valves
- Water softener(one softener for both units) from process water
- feed water day tank (one tank for both units) with valves
- Pre-wired control panel (one panel for both units) complete with
contactors, overload relay, Ampere controller, indicating lamps,
cam switches, ammeters, voltmeters, selector switches, switches
and indication lamps for pumps heaters pressure controllers fuses
etc.
- Isolation transformer: For electrode boiler one no. of suitable
415V/415V isolation transformer of 500KVA rating (continuous
rating) is to be supplied with each set.. The transformer should be
dry type with natural air cooling. The class of insulation of
transformer should be class H. The purpose of isolation
transformer is to isolate main system from the neutral voltage
variation which is likely to arise during the operation of electrode
boiler.
- Boiler vessel seamless fitted with special alloy electrodes, Teflon
insulators, neutral shiel
5. MOC - A106 Gr B piping
- Valve body: A 105 gr II
- Stem: A 182 Gr 304
6. Special features - Fully automatic ampere-based water level controller
- Quick steaming

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7. Instrumentation - 4 no. of pressure gauges, 1 no. of Pressure switch & pressure

gauges at the steam generator.
8. Electrical - 2 no. of raw water feed pump motors & 2 no. of Boiler feed
water pump motors. Cabling shall be in the vendor scope.it may
be noted that the MCC is located 60 metre away from the unit.
9. Civil - Foundation for 2 no. of raw water feed pumps & 2 no. of
Boiler feed water pumps and 2 no. of boiler unit skid.

Following documents shall be submitted during detailed engineering:

 P&I diagram, GA drawing, equipment lay out indicating the space requirement,
total weight of the system, utilities needed for this, electrical power requirement, etc.
 Equipment data sheets of pumps, agitators, tanks.
 Electrical / Instrument control logic diagram.
 Specification/make/model of instruments, pumps, agitators and tanks.
 QAP & delivery schedule.

Note:
1. Recommended spares for the trouble free operation for a period of 2 Years shall be supplied.
2. Vendor shall take reference of the schematic drawing for meeting the minimum requirement of the system
3. Final QA plan including stage inspection plan shall be submitted for HWB’s approval prior to
manufacture/procurement.
4. Guarantee test runs shall be carried out for final acceptability.
5. Four sets of Operation and maintenance manual of the system along with a CD containing one set
of the above mentioned documents shall be submitted.
6. Material Test certificate, Equipment Internal Performance test report, etc. shall be sent along with
the consignment.

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8.4. Specification of Chilled Water System (Unit 50)

Scope : Design, manufacture, inspection, testing, supply, erection & commissioning

Basis Of Design :

Capacity : 60 TR x 2
Flow rate (within chiller unit) : as reqd.
Supply Water/Brine Temp. : -5°C.
Return Water/Brine Temp. : 0°C.
Supply Water/Brine Flow : 40 m3/hr.
Supply Water/Brine pr. : 3 Kg /cm2
Type of system : Skid mounted water cooled Chilling system
Refrigerant : R- 134a / 404a (CFC free refrigerant )
Location : HWP, Tuticorin

TECHNICAL SPECIFICATIONS:

S.No Item Description

1 Type 2 nos. skid mounted vapour compression refrigeration system for generation of
chilled water.
2 System Each system consisting of vapour compression refrigeration system with
configuration compressor along with motors, condenser, receiver, evaporator, expansion valves,
interlock instruments, piping, safety systems.
However, the systems shall include one common storage tank (hot & cold wells), 3
Primary pumps and 3 Secondary pumps along with its motors.
1 Compressor Semi hermetic screw compressors along with motor designed to run with R-
134a/404a (CFC Free Refrigerant) & Each Giving 60 TR output at -10°C
Evaporating temperature & +40°C Condensing temperature. Local start/stop push
button station along with ammeters shall be field mounted.
2 Condenser Shell & Tube type condenser, MOC: Tubes –SS 316 integrally finned, rest of all
CS. Design code: TEMA class-C & ASME section VIII Div.1
3 Receiver Suitable for 120 TR capacity
4 Evaporator Shell & Tube type, MOC: Tubes – SS 316, rest of all CS.
Design code: TEMA class-C & ASME section VIII Div. 1
5 Refrigeration Thermostatic Expansion Valve
Controls Catch all drier/strainer
Sight glass Isolation Valves
Suction-discharge Pressure Gauges
6 Safety Controls Antifreeze thermostat,
HP/LP & Oil Cut out safety switch
Low water level controller
Single Phase preventer
Pressure Relief Valve
Flow switch
7 Body Structure Common MS structure duly painted. Designed and installed for easy approach with
respect to servicing and maintenance.
8 Refgt. Piping Interconnecting seamless SS 304L piping with fittings.
9 Gas & Oil First charge of refrigerant R-134 a /R 404a gas & required suitable oil.
10 Storage Tank Capacity : 4000 litre each (total 8000 lts.)
(Hot & Cold) Tank shall be divided into two parts with centre insulated partition to make hot and
cold well.
Inner skin: SS-304 X 16 gauge.
Outer skin: GI painted X 18 gauge insulated with 60 mm thick PUF insulation.

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injected on all sides.

11 Insulation Elastomeric nitrile rubber foam insulation to chiller & suction line and primary
line.
12 Pumps with Centrifugal pumps with single mechanical seal (SiC vs SiC); and baseplate.
motors Capacity: each 40000 LPH at 30 m Head.
Primary pumps (3 no.; 2 running, 1 standby) (within Chiller unit).
Secondary pumps (3 no.; 2 running, 1 standby) (for chilled water supply to plant).
Pumps should be sourced from approved vendors. Local start/stop push button
station along with ammeters shall be field mounted.
13 Accessories 1) Pressure gauges on the refrigerant (at compressor suction, discharge) line and
water line (pumps discharge).
2) Temp. gauges in the tanks and supply & return chilled water lines.
3) Suction filter at pump suction.
4) Flow meter on chilled water supply.
5) Interlock instruments for safe operation of the unit.
6) Refrigerant Charging valves.
14 Water piping Primary interconnecting piping with required controls, fittings & insulation (A-106
Gr B) as indicated in the schematic.
15 System controls The system shall be configured with the DCS. All start up, interlocks, capacity
control, shutdowns of the system shall be done through the DCS.
16 Power supply 415 V, Three Phase, AC with neutral & earth.
available
17 Testing Hydro testing & other NDT test as per standard at manufacturer’s work shop.
18 Instrumentation As indicated in accessories with necessary cabling.
19 Electrical 2 no. of chiller compressor motors & 6 no. of Chilled water pump motors with
necessary cabling to the MCC located 60 metre away from the unit.
20 Civil Foundation for 2 no. of chiller compressor , 6 no. of Chilled water pumps, 1 no. of
Hot & Cold well, Evaporator & condenser

Following documents shall be submitted during detailed engineering:

 P&I diagram, GA drawing, equipment lay out indicating the space requirement,
total weight of the system, utilities needed for this, electrical power requirement, etc.
 Equipment data sheets of pumps, agitators, tanks.
 Electrical / Instrument control logic diagram.
 Specification/make/model of instruments, pumps, agitators and tanks.
 QAP & delivery schedule.

Note:

1 Recommended spares for the trouble free operation for a period of 2 Years shall be supplied.
2 Vendor shall take reference of the schematic drawing for meeting the minimum requirement of the system.
3 Final QA plan including stage inspection plan shall be submitted for HWB’s approval prior to
manufacture/procurement.
4 Guarantee test runs shall be carried out for final acceptability. Test conditions shall be approved by HWB
prior to placement of order.
5 Four sets of Operation and maintenance manual of the chilled water system along with a CD containing one
set of the above mentioned documents shall be submitted.

6 Material Test certificate, equipment internal performance test report, etc. shall be sent along with the
consignment.

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8.5. Specification of Cooling Water System (Unit 51)

Scope: Design, manufacture, Inspection, testing, supply, erection & commissioning and
guarantee of Induced draft counter flow cooling tower along with its cooling water
supply pumps.

S. No Description Specification

1 System Complete package unit of FRP Cooling Tower consisting of its casing (shell),
configuration fills, water distribution header with spray nozzles, fan with motor & guard in
each cell, drift eliminator and air Intake mesh and supporting structures for
erection of entire cooling tower unit. Which will be erected in the existing hot
well of HWP, Tuticorin. The system shall also consist of 3 nos. of cooling
water supply pumps along with it’s suction and discharge isolation & non-
return valves and piping.
2 Technical Specification
2.1. Type FRP induced draft counter flow cooling tower
2.2. No. of cell 2 Nos.
2.3. Water Circulating 200 m3/hr i.e. 100 m3 / hr through each cell
Rate
2.4. Inlet Water 42 °C
Temperature
2.5. Outlet Water 32 °C
Temperature
2.6. Wet Bulb 28 °C
Temperature
2.7. Approach 4 °C
2.8. Fan Axial Flow, Multi blade direct mounted/ belt driven, adjustable pitch
Galvanised steel hub with S.S. 304 Clamps, Bolts & Nuts., EN 8 shaft.
2.9. Pump Centrifugal, Flow -100 m3/hr/ Head -40 m 3 nos. of pumps along with base
plates supply as per approved vendors list for pumps.
MOC casing SA 216, Gr WCB, Shaft SS410, Graphoil packing
2.10. Motor Squirrel cage TEFC weather proof induction motor, IP-55, Class F Insulation,
415 V, 3 phase, 50 Hz –supply as per approved vendors list for motors.
3 Scope of supply and material specification
3.1. Casing (shell) FRP ( minimum 3mm thick)
3.2. Fan Cylinder FRP ( minimum 3mm thick)
3.3. Fan Blades Al Alloy
3.4. Fan Guard SS 304
4.5. Fan Hub Galvanised steel hub with S.S. 304 Clamps, Bolts & Nuts.
4.6. Fan shaft EN 8
4.7. Fills and Spray Honey comb PVC
Nozzles
4.8. Drift Eliminator PVC
4.9. Water Galvanised Steel.
Distribution
Headers
4.10. Fasteners, Bolts, S.S. 304
Nuts and
miscellaneous
hardware
4.11. Pipes supports & S.S. 304
Clamps

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4.12. Frame work, Galvanised steel

Approach ladder
to fan deck floor
4.13. Number of 3
centrifugal pumps
with motors
4.14. Casing SA 216 Gr WCB
4.15. Impeller SA 351 Gr CF 8
4.16. Shaft SS 410
4.17. Coupling Guard CI/Non sparking
4.18. Base Frame MS fabricated
4.19. Pump Piping A -106 Gr B Sch 40 150 NB
Suction &
Discharge
4 Instrumentation 3 no. of pressure gauges, 2 no. of Temp. Indicator for Hot water & cold water
with necessary cabling.
5 Electrical 3 no. of CW pump motors, 2 no. of ID fans with necessary cabling to MCC
located 250 metre away from the unit..
6 Civil Foundation for Cooling tower cells by making partition in the existing Hot
well and 3 no. of CW pumps.

Following documents shall be submitted during detailed engineering:

 Dimensions indicating the space requirement, height, electrical power, foundation details,
operating weights of the cooling tower along with its accessories, GA drawing and operating
weight of the centrifugal pumps.
 Four sets of operation and maintenance manual of the cooling tower including pumps along
with a CD containing one set of the above mentioned documents shall be submitted.
 Material test certificates, performance and test reports.
 Pre dispatch inspection shall be carried out by HWB or their authorized representative at the
supplier’s works. All arrangements shall be made at no extra cost.
 The cooling tower shall be erected in a concrete sump having a depth of 2 m. The support
required for installing the same has to be provided with the cooling tower.
 Performance test of the cooling tower shall be conducted at site and the test conditions shall
be approved by HWB prior to placement of order.

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9. LIST OF SPARES

S.No. Unit Spares

1 Alkali Dissolution 1. Bearing -2 nos
System 2. Motor oil seals -1 set
2 Vacuum & Vent Booster Pump Spares
OSRV
Scrubber Unit
1. Spec. on bearing -1 nos 1. Oil Seal-1 set
2. Lock Plate-2 nos. 2. Oil Rings-1 set
3. Ball Bearing-4 nos. 3. Gasket-1 Set
4. Lip Seal-1 nos. 4. Valve-springs-1 set
5. Retainer-2 nos. 5. Exhaust valve plate-1
6. Timing Gear Shim-1 set
Set 6. Bearings-1 set
7. Gear Key-2 nos. 7. Rotor assembly along
8. Roller Bearing-1 nos. with casing-1 set
9. Lab Seal-4 nos.
10. Mechanical Seal-5 nos.
11. Locking Tab-4 nos.
12. Cap Screw-4 nos.
13. Roll Pin-4 nos.
14. O Ring-16 nos.

3 Electrode Boiler 1. Electrode-2 Sets (6nos.) 6 TIC-1 nos.

2. Ampere Controller- 1 nos.
3. Glass Tubes-1 nos.
4. Indicating Bulbs-4 nos.
5. Steam Gasket Set-4 nos.
6. TIC-1 nos.
7. Steam Safety Valve-1 nos.
8. Pressure Switch-1 nos.
9.Feed Water Piston Pump-1 nos
4 Chilled Water 1. Flow Switch-2 nos
System 2. Drier Core-2 nos
3. Thermostatic Expansion valves-2 nos.
4. Main Pilot Solenoid Valve-1 nos.
5. Compressor capacity control solenoid valve coil—2 nos.
6. PLC base unit without display-1 nos.
7. Pressure Transducers-2 nos.
8. Temperature sensors-4 nos.
9. Pressure gauges for water-4 nos.
10. Indicating lamps with special LED types-4 nos.
11. Flare Nuts-”-30 nos.
12. Charging valves-4 nos
13. Flaring Tool Kit-1 nos.
14. Refrigerant -1 cylinder
5 Cooling Tower 1. Fan Assembly-1 nos.
2. Spray Nozzles-50 nos.
3. Fan Motor-1 nos.

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10. LIST OF RECOMMENDED VENDORS

S.No. Unit Recommended Vendor

1 Alkali Dissolution 1. Iyengar Engineers, Bengaluru
System 2. Unique Chemo plant Equipment’s, Mumbai
2 Vacuum System 1. JB Sawant Engineering Private Limited, Mumbai (For vacuum
system)
2. Hind High Vacuum Company Private Limited, Bengaluru (For
vacuum system)
3. Crompton Greaves, Aurangabad.

3 Vent Scrubber Unit 1. Coroseal Chemical Equipment Private Limited, Mumbai. (For
scrubber system)
2. Jr Fibreglass Industries Private Limited, Mumbai (For
scrubber system)

3 Electrode Boiler 1. Ascent Machineries & Engg. Services, Mumbai

2. Double Ace, Engineers, Mumbai
4 Chilled Water 1.Bright HVAC Engineers Pvt. Ltd., Mumbai
System 2 Voltas Limited, Mumbai

5 Cooling Tower 1. Wet Bulb Cooling Towers, Mumbai.

2. Bright HVAC Engineers Pvt. Ltd., Mumbai

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10. LIST OF DRAWING

Following drawings are enclosed in the tender under the respective Annexures :

No.
Annexures Unit
Drawing Number Description Of
No.
sheets

PROCESS SCHEMATIC
P1 HWB/SPP(T)/PROC/0002, REV 01 DIAGRAM FOR SPP 43 & 44 1
SITE PLOT PLAN FOR SPP AT
HWB, TUTICORIN
P II HWB/SPP(T)/CIVIL/0001, REV.00 - 1
PIII EQUIPMENT LAY OUT UNIT
HWB/SPP(T)/MECH/ 0003,REV.00 43 & UNIT 44 43 & 44 1
P IV HWB/SPP(T)/PROC/0010,REV0 P&ID OF MAIN PLANT 43 3
PV HWB/SPP(T)/PROC/0011,REV0 P&ID OF MAIN PLANT 44 2
P&ID OF BUTANOL
P VI HWB/SPP(T)/PROC/0012,REV0 RECOVERY UNIT 45 2
P VII HWB/SPP(T)/PROC/0016,REV0 P&ID OF STORAGE TANKS 49 1
SCHEMATIC OF UNIT 46(
PVIII HWB/SPP(T)/PROC/0013,REV0 ALKALI DISSOLUTION) -46 1
SCHEMATIC OF UNIT 47(
VACUUM & VENT
P IX HWB/SPP(T)/PROC/0014,REV0 SCRUBBER) -47 1
SCHEMATIC OF UNIT
48(ELECTRIC BOILER
P-X HWB/SPP(T)/PROC/0015,REV0 PACKAGE UNIT) -48 1
SCHEMATIC OF UNIT
P-XI HWB/SPP(T)/PROC/0017,REV0 50(CHILLER PACKAGE UNIT) -50 1
SCHEMATIC OF UNIT
P-XII HWB/SPP(T)/PROC/0018,REV0 51(COOLING TOWER UNIT) -51 1

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11. SCHEDULE OF QUANTITY

S. No. Description Quantity

1. Alkali Dissolution Unit
1.1. Jacketed Tanks SS 304 L – Capacity 2 kL 2
Jacket –IS 2062 Gr A/B
SS 304L Agitators( shaft + hydrofoil impeller) 2
1.2. Gear Boxes 2
1.3. Agitator Motor 415 V/3 phase/ 50 Hz/4 Pole/TEFC/Induction along along with stop start 2
button post along with neccessary cabling.
1.4. SS 316 Pumps 5 m3/hr capacity, 40 m Head single mechanically sealed SiC/SiC along 3
with the baseplate
1.5. Pump motors non –flame proof along with stop start button post along with necessary 3
cabling
1.6. 50 kg bag lifting and filling system along with its start stop switch 1
1.7. Local Temperature gauges for jacketed tanks 2
1.8. Level Gauges for the jacketed tanks 2
1.9. Pressure Gauges at pump discharge 3
1.10. 2” SS 304 L Sch 40 piping for pump suction discharge, interconnection and recirculation 1 lot
with steam tracing jacket
1.11. 1’’ SS 304 L Sch 40 piping for water make up 1 lot
1.12. SS 304 Isolation and non-return Valves as indicated in the schematic As per
schematic
1.13. Skids/ structures/supports duly painted for the entire system 1 lot
1.14. Supply, Erection, Testing & Commissioning 1 lot
2 Vent Scrubber Unit
2.1. PPFRVE Scrubber Column inclusive of distributor, re-distributors, packing support 1
plates. Column diameter shall be 500 mm and column height shall be 6000 mm.
2.2. PPFRVE Scrubber sump integral with the column as in 2.10 dimensions of the sump 1
shall be height=1200mm and diameter=500mm
2.3. 1” ceramic pall rashig packing for 3700 mm height of the scrubber column+ 10 % excess 1 lot
2.4. PP Pumps 5 m3/hr capacity, 15 m Head single mechanically sealed SiC/SiC. Pump shall 2
be capable of handling 20 % caustic or sodium chloride solution
2.5. Bonded Poly-block graphite Heat Exchanger for cooling 20 % sodium chloride solution 1
from 65 to 40 o C using cooling water
2.6. Interconnected piping valves and fittings in CPVC 1 lot
2.7. Blowers 700Nm3/hr capacity, 200 mm Head of water column + Motors along with stop 2+2
start button post with necessary cabling.
2.8. Level Gauge for Sump 1
2.9. Level Transmitter Delta Pressure Type for sump with necessary cabling. 1
2.10. Rotameter at Pump discharge with necessary cabling. 1
2.11. Compound Pressure Gauges at Pump discharge and column inlet 3
2.12. Delta Pressure Transmitter across column with necessary cabling. 1
2.13. Vacuum Pressure Gauges at blower suction 2
2.14. Temperature Indicator For Column Sump. 1
2.15. 12 meter length vent pipe CPVC(200 mm dia ) 1 lot
2.16. All valves as indicated in the schematic and compatible with the piping As per
schematic
2.17. Skids/ structures/supports duly painted for the entire system 1 lot
2.18. Supply, Erection, Testing & Commissioning 1 lot

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 Chapter-9 Technical specification

Serial Description Quantity

No.
3. Vacuum Unit
3.1. SS 304 l Suction Knock Out Drum 1m3 from full vacuum to 5 bar gauge 2
3.2. Mechanical Booster Pump along with vfd compatible electric motors along with stop start 2+2
button post with necessary cabling.
3.3. VFD/Frequency convertor along with VFD panel. 2 +1
3.4. Oil Seal Rotary Vane Pump along with electric motors along with stop start button post 4+4
with necessary cabling.
3.5. Intermediate Chilled Trap with condensate tank in SS304L 2
3.6. Temperature Switches 2
3.7. Mercury Mcleod vacuum gauge Rangw 10 to 10-3 mm of Hg with isolation valve 2
3.8. Vacuum Meters (Pirani) with isolation valve 2
3.9. Bourdon Vacuum Gauge 0 to 760 mm Hg with isolation valve 4
3.10. Temperature Gauges 0 to 200°C range 4
3.11. Booster By-Pass butterfly valve 2
Size: 150NB, Operation : Electro-pneumatic, Actuators : Schrader bellows/Rotex/
Equivalent Body : SS 304 L, Seat: SS 304 L having “O” Ring Groove O Ring : PTFE
Solenoid : Schrader bellows/Avcon (FLP) at supply voltage of 230 V,Single phase 50 Hz.
3.12. Booster Suction/Discharge butterfly valve 4
Size: 300 NB, Operation : Electro-pneumatic, Actuators : Schrader bellows/Rotex/
Equivalent Body : SS 304 L, Seat: SS 304 L having “O” Ring Groove O Ring : PTFE
Solenoid : Schrader bellows/Avcon (FLP) at supply voltage of 230 V,Single phase 50 Hz.
3.13. OSRV Suction butterfly valve 4
Size: 80 NB, Operation : Electro-pneumatic, Actuators : Schrader bellows/Rotex/
Equivalent Body : SS 304 L, Seat: SS 304 L having “O” Ring Groove O Ring : PTFE
Solenoid : Schrader bellows/Avcon (FLP) at supply voltage of 230 V,Single phase 50 Hz.
3.13. Air admittance valve 4
3.14. Interconnected piping, valves, fittings SS 304L 1 lot
3.15. Necessary cabling for DCS connectivity 1 lot
3.16. Skid –carbon steel duly painted 2 lots
3.17. Supply, Erection, Testing & Commissioning 1 lot
4 Electrode Boiler
4.1 Steam Chambers insulated along with electrodes with necessary cabling. 2
4.2. Feed Pumps along with it’ motors with necessary cabling. 2
4.3. Steam Stop Valves 2
4.4. Air vent valve/auxiliary valve 2
4.5. Safety Valves 2
4.6. Non-Return valves 2
4.7. Blow Down Valves 2
4.8. Water level gauge 2
4.9. 4” dial type pressure gauge with syphon and cock 2
4.10. Magnetic Water level controller 2
4.11. Pressure Switches 2
4.12. AMS controller 2
4.13. Control Panel with necessary cabling. 1
4.14. Water Softeners 1
4.15. Feed Water Tank of capacity 2 m3 SS 304L 1
4.16. A 106 Gr B piping along with isolation valves and fittings 1 lot
4.17. Pressure gauges on water feed line 2
4.18. Isolation Transformer 415 V/415 V Dry Type (natural cooling) 2
4.19. Pressure Control Valve 2
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 Chapter-9 Technical specification

4.20. Pressure Indicator cum controller 2

4.21. Skids/ structures/supports duly painted for the entire system 1 lot
4.22. Supply, Erection, Testing & Commissioning 1 lot
Chilled Water System
5.1 Semi Hermetic screw compressors -60 TR along with motors along with stop start button 2+2
post with necessary cabling.
5.2. Initial charge of refrigerant and oil 1 lot
5.3. Shell and tube condensers 2
5.4. Evaporator 2
5.5. Centrifugal Pumps along with motors along with stop start button post with necessary 6+6
cabling.
5.6. Insulated Hot-Cold well (8 m3) 1
5.7. Thermostatic Expansion Valves 2
5.8. Catch all drier strainer 2
5.9. Sight Glass Isolation Valves 2
5.10. Suction Discharge Pressure Transmitters for DCS display 4
5.11. Antifreeze Temperature sensor( DCS display) 2
5.12. HP/LP & Oil cut out switches (through pressure transducers to DCS) 6
5.13. Pressure Relief valves 4
5.14. Flow switches 2
5.15. Refrigerant Receivers 1
5.16. Level Transmitters of refrigerant receivers–DCS display 2
5.17. A-106 Gr B Chilled/cooling water piping along with insulation, valves and fittings 1 lot
5.18. Temperature transmitters on chilled water supply and return lines–DCS display with 2
necessary cabling.
5.19. Flow transmitter on chilled water supply lines –DCS display with necessary cabling. 1
5.20. Skids/ structures/supports duly painted for the entire system 1 lot
5.21. Supply, Erection, Testing & Commissioning 1 lot
6 Cooling Water System
6.1 Cells including spray nozzles, water distribution headers, drift eliminators, FRP shell, pvc 2 Lots
fills, and isolation valves
6.2. Fans including guard, blades, cylinder, hub, shaft and motors along with stop start button 2
post with necessary cabling.
6.3. SA 216 Gr WCB centrifugal pumps with motors base plate along with stop start button 3
post with necessary cabling.
6.4. Piping A 106 GR B along with valves and fittings 1 lot
6.5. Skids/ structures/supports duly painted for the entire system 1 lot
6.6. Supply, Erection, Testing & Commissioning 1 lot

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 Chapter-9 Technical specification

TECHNICAL SPECIFICATIONS

MECHANICAL

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 Chapter-9 Technical specification
S. No. Description Page No.
M-I Mechanical Technical Specifications M-5
1.1 Scope Of Work M-5
1.2 Engineering Documentation M-8
1.3 Quality Surveillance M-9
1.4 Progress Report M-9
1.5 Code Requirements M-9
1.6 General Services M-9
1.7 HWB’s Scope M-10
1.8 Special Note M-10
1.9 System Description M-11
1.10 Design Basis Of Mechanical Systems M-12
1.11 Layout Considerations M-15
1.11.1 Equipment And Piping Clearance M-16
1.11.2 Accessibility Of Valves And Instruments: M-19
M – II Mechanical Technical Specification For Equipments M-21
2.1 Specification For Process Equipment (Fabricated) M-21
2.1A. Specifications For Stainless Steel / Carbon Steel Equipment M-21
2.1.1 Equipment Design, Fabrication, Testing & Supply M-22
2.1.2 Design M-22
2.1.3 Materials M-23
2.1.4 Accessories / Attachments / Spares M-23
2.1.5 Equipment Fabrication M-23
2.1.6 Inspecion And Testing Of Equipments At Supplier’s Work M-25
2.1.7 Technical Specifications For Shell & Tube Type Heat M-26
Exchanger
2.1.8 Cleaning, Painting And Despatch From Supplier’s Works: M-27
2.1.9 Documentation Of Fabricated Equipments: M-28
2.1B. Specifications For HDPE Equipment M-29
2.1C. Specifications For Glass Lined Equipment M-30
2.1D Technical Specifications For PP-FRV Vessels M-31
M – III Technical Specifications For Piping, Site Fabrication & M-33
Erection
3 A. Piping Technical Specification M-33
3.1 Scope M-33
3.1.1 Piping And Fittings M-34
3.1.2 Bends, Miters And Reducers Fabricated From Pipe M-34
3.1.3 Flanges M-34
3.1.4 Thread Sealant (Wherever Unavoidable On Utility Lines) M-35
3.1.5 Valves M-35
3.1.6 Relief & Safety Valves M-36
3 B. Equipment And Piping Layout Requirements M-36
3 C. Site Erection & Testing Of Equipment & Piping M-43

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 Chapter-9 Technical specification

3.3.1 Erection Of Static Equipments (Vessels, Tanks, Columns) M-43

3.3.2 Scope Of Work And Technical Specifications For Erection M-44
Of Piping System (Above Ground)
3.3.3 Testing & Inspection At Site M-46
3.3.4 Radiographic Examination Of Welds: M-47
3.3.5 Weld Repair & Extent Of Examination On Repaired Weld: M-48
3.3.6 Visual Examination: M-48
3.3.7 Cleaning Requirement & Procedure M-50
3.3.8 Inspection During Pressure Testing Of Piping M-53
3.3.9 System Leak Test - Inspection Specification M-55

M – IV a Technical Specification For Centrifugal Pumps M-56

4.1 General Requirements M-56
4.2 Coupling M-57
4.3 Bearings M-57
4.4 Impeller And Shafts M-57
4.5 Pressure Casing M-57
4.6 Base Plate M-57
4.7 Materials M-57
4.8 Shop Inspection & Tests M-58
4.9 Preparation For Shipment M-58
M – IV b Technical Specification For Diaphragm Pumps M-60
M – IV c. Technical Specification For Agitators M-61
M–V Technical Specification For Thermal Insulation M-68
5.1 Scope: M-68
5.2 Reference Standards: M-68
5.3 Deviations: M-68
5.4 Limitations: M-68
5.5 General Requirements: M-68
5.6 Insulation Supports (Cleats) To Be Provided By Equipment M-69
Contractor
5.7 Material Requirements M-69
5.8 Inspection M-70
5.9 Application M-70
5.10 Measurement Of Insulation Work M-73
5.11 Guarantee M-73
5.12 Thermal Insulation – Hot Service M-73
5.12.1 General M-73
5.12.2 Material Requirements M-74
5.12.3 Application Of Insulation M-77

M – VI Technical Specifications For Eot Crane M-80

6.1 Detailed Specification Of The EOT Crane M-80

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 Chapter-9 Technical specification

6.2 Special Requirements For Motors & Other Electrical Items: M-81
M – VII Specification For Painting: Piping & Equipment M-84
7.1 General M-84
7.2 Scope M-84
7.3 Extent Of Work M-84
7.4 Codes & Standards M-85
7.5 Equipment M-85
7.6 Surface Preparation, Non Compatible Shop Primer, Coating M-86
Procedure, Application & Repair And Documentation
7.7 Paint Materials M-93

7.8 Painting System M-94

7.9 Piping Colour Code M-95
7.10 Identification Of Vessels, Pumps, Piping Etc. M-95
7.11 Primer Application M-95

M – VIII Mechanical Specification For Graphite Heat Exchangers, M-98

Condensers & Coolers
8.1 Scope Of Work M-98
8.2 Design M-98
8.3 Materials M-98
8.4 Testing And Inspection M-98
8.5 Spares M-99

M – IX Piping Specifications M-100

9.1 SS Piping Specification M-100
9.2 CS Piping Specification M-104
9.3 Glass Lined Piping Specification M-108
9.4 Non-Metallic Piping Specification M-109
M–X Quality Assurance Plans
10.1 QAP For Equipment M-110
10.2 QAP For Piping M-114
10.3 QAP For Glass Lined Reactors M-115
10.4 QAP For Heat Exchangers M-117
10.5 QAP For Graphite Heat Exchangers M-119
10.6 QAP For Centrifugal / Diaphragm Pump M-121
M – XI List Of Applicable Codes & Standards M-123
M – XII Schedule Of Quantities M-126
M – XIII List Of Spares M-133
M – XIV Recommended Vendor’s List M-134-136
Annex-I Drawing No. HWB/SPP(T)/CIVIL/0001 M-137
Annex-II Drawing No. HWB/SPP(T)/PROC/0021 M-138

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 Chapter-9 Technical specification

M – I. MECHANICAL TECHNICAL SPECIFICATIONS

1.1 SCOPE OF WORK

The entire scope of work for the Design & Engineering, Supply, Fabrication, Site Erection, and
Inspection & Testing, commissioning of Mechanical Items for this tender shall be as under:
1) Equipment: Mechanical Design and detailed engineering, procurement of all the raw
materials and spare parts, fabrication/ Manufacture, testing, inspection, supply & safe
delivery to HWB’s site, storage of the vessels & equipment for erection at HWB’s premises,
erection of equipment, piping hooking up and commissioning of the equipments. Basic
details of the equipment including MOC, technical specifications, and process data sheets
are given elsewhere in the tender.
2) Rotating / Reciprocating Machines: Design and engineering, supply, procurement of
items including spare parts, testing, inspection, safe delivery to HWB’s site, storage,
erection at HWB’s premises, piping hooking up and commissioning of the machineries.
Basic details of the machineries including MOC, technical specifications and process data
sheets are given elsewhere in the tender.
3) Piping: Design and engineering, supply of pipes, fittings, flanges, valves as per approved
isometric drawings & P&ID. Fabrication, erection including suitable supporting, testing and
inspection, commissioning of all the piping as per piping technical specifications given in
the tender.
4) Structural Steel: Supply of all the structural steel required during erection of (i)
Equipment, (ii) Rotating / Reciprocating machineries, (iii) Package / Utility Systems (iv)
Piping including supports (v) platforms, walkways/stairs and access to equipment for safe
operation and maintenance as included in the scope of the tender.
5) EOT Crane: Supply, erection and commissioning of EOT Crane as per the technical
specifications given in the tender.
6) Spares: Supply of all spares required for commissioning and maintenance of equipment &
machineries as listed in tender document.
7) Project Management: Activity scheduling, work progress monitoring, variance reports,
milestones status, constraints, rescheduling of activities, catch-up plan, implication of
rescheduling on expenditure pattern, final project completion reports, cost statements etc.
PRIMAVERA or equivalent tool may be employed
8) Site Execution: Selection of work method, schedule for the construction and erection, field
co-ordination, field engineering, construction and installation supervision, field inspection
and verification, review of change notices, quantity certification etc. Deployment of
manpower (resident engineers at site, qualified engineers, safety officer, supervisors, skilled
and un-skilled), personal protective appliances, tools & tackles, consumables etc. Obtaining
necessary work permit from EIC as per safety procedures of the plant. Preparation of
Material Accounting Statement & return of left over materials to stores with proper return
vouchers.
9) Battery Limit: Battery limit for the present tender is indicated by hatched portion of
drawing no. HWB/SPP(T)/CIVIL/0001. External piping beyond battery limit (Drg No.
HWB/SPP(T)/PROC/0021) is excluded from the scope of the contractor.
10) Quality Assurance Plan: Preparation of detailed QAPs for fabrication of equipment, piping
and bought out items based on the tentative QAPs included in the tender. Submission of
QAPs to the HWB for approval before fabrication, placement of orders. QAP shall include
quality assurance for raw material / bought out items, fabrication / welding (including WPS,
PQR & Welder Qualification), erection tolerances, testing procedures, acceptance standards
and extent of testing / stage inspection required indicating involvement of contractor, Third

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 Chapter-9 Technical specification

party Inspection / HWB etc. All testing procedures shall be prepared and submitted for
HWB’s approval.
11) Preparation of Equipment & Piping Layout: Preparation of Equipment & Piping Layout
based on the tentative plant layout as given in the tender. Based on the tentative layout, the
contractor shall carry out following activities for preparing final layout:
a. Develop the layout in 3-D using PDMS, PDS or equivalent layout software.
b. Equipment Layout Drawings, piping GA drawings Isometric Drawings shall be
extracted from 3 D layout with full details indicating Supports, Weld Joints, Bill of
Material etc.
c. Modify the 3-D Model at the end to incorporate “As-Built” Drawings for Equipment
Layout, Piping GA and Piping Isometrics (for all pipe sizes).
d. Submit the “Navis Works” or equivalent walk through model to HWB for future
references.
The final layout & Bill of Material shall be submitted to HWB for approval prior to
preparation of final Material Take Off.
12) Piping Stress Analysis: Contractor shall carry out the Flexibility & Code analysis for entire
piping & submit the design & analysis for HWB’s approval prior to commencement of
piping fabrication. Supports are also required to be considered / provided for ease of
maintenance.
13) Ducting: Design & Supply of entire material, fabrication & erection for non-metallic hoods
& ducting, supports required to complete the job, if any.
14) Miscellaneous Items: Supply of gaskets, O-Rings, grout materials of various categories, as
required. Supply of shims of stainless steel required for leveling / aligning of rotating /
reciprocating equipment on foundations is in the scope of the contractor.
15) Machineries, Tools & Tackles for Erection: Arrangement of required machinery like
master level, theodolite, dumpy level, torque wrench, electric welding sets and diesel
generator welding sets, diesel and electrically operated dewatering pumps, Hydro-testing
pumps, air compressors, winches, wooden sleepers, derricks, crane and other lifting tackles,
tractors and trailers, etc. as required for erection. Arrangement of all necessary scaffolding
required for all the jobs including erection of piping, equipment, inspection, testing etc. is
also included in the scope of the contractor.
16) Transportation of Material at Site: Sorting of pipes and piping materials from stores,
Withdrawal of equipment / associated piping and structure and any other material within
factory site, visual checking and reporting of the condition of the equipment, transportation
of the same at work site including handling, unloading, loading, unpacking etc. till erection
is completed and accepted by owner.
17) Prefabrication: Prefabrication of the piping system as per isometrics / layout drawings and
as per instructions given by HWB. Modification / rectifications if required to suit site
conditions shall be done by contractor.
18) Erection: Erection including grouting (which includes excavation of earth work, providing
concrete pedestal/ footings etc.) if any, pipe supports including spring supports, Fabrication
and / or erection of equipment, piping etc. This includes alignment, leveling, grouting of
structures viz. platforms, ladders, railing, walkways, staircases, gratings etc. Fabrication &
Erection of piping, supports, temporary supports in addition to permanent supports where
ever required for testing and other purpose. Erection including placement on foundations
and / or structures, drilling of holes on structure for equipment bolting, finishing, fitting,
assembling etc. of all equipment like vessel, tanks, columns, heat exchangers, condensers
etc. and piping erection. Cutting of transportation cleats provided on inside / outside of the
equipment and grind off irregularities.

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 Chapter-9 Technical specification

19) Pipe Laying: Cutting / chipping of floor and making of holes / cut-outs in the walls to
facilitate pipe-laying. Chipping the wall to expose reinforcement and welding insert plates.
Deviations in piping to suit equipment position and marking of offsets if required.
20) Branching: Stub in connections i.e. making of all unequal branches from the main headers.
21) WPQ / WPS: Welder's qualification and weld procedure qualification tests shall be carried
out by the EPC contractor before fabrication of piping.
22) Stress relieving, Pre and post weld Heat Treatment.
23) Testing of Piping: Hydro / Pneumatic testing for each loop after installation. It includes
spool pieces, instruments, drain / vent valves, control valves, safety valves, orifice plates
etc. removal and reinstallation, flushing.
24) Installation of Piping: Installation of all piping elements including isolation valves,
regulating valves, control valves, vent valves, drain valves, sample valves, line filters and
strainers etc. wherever required as per drawing / instruction of HWB. Valve installation,
includes handling, rigging, lifting placing in position, final alignment, bolting up to
companion flanges or making of weld joint/ screw joint after and preparation etc.
25) Tapping Points: Forming of tapping points for instruments and samples lines.
26) Testing and Inspection: Stage and final inspection and testing at manufacturer’s works and
at site ensuring quality assurance of supply items as well as site fabrication, erection, and
assembly work. Arrangement for special tests at site (eg. DP Test, radiography as per the
approved QA plan). It includes arrangement of inspection tools as recommended in
equipment manufacturer's manual, scaffoldings, calibrated instruments and temporary
lighting etc. for carrying out the inspection. Maintaining records of all the works and
inspection reports
27) Passivation & Cleaning: All SS lines shall be properly cleaned and passivated, where ever
required, Acid cleaning for process piping and all equipment before erection, detergent
cleaning for utility piping and local passivation, cleaning of the piping after assembly by air.
During the course of such cleaning all the control valves, safety valves, orifice plates, flow
nozzles and other in-line instruments installed shall be removed except for such items,
which are directly welded with the pipelines and reinstalled after cleaning. Cleaning of
pipes as required above shall be done after hydraulic testing / pneumatic testing
28) Pre-commissioning, Commissioning and Testing: All equipment/ systems/ packages &
interfaces. Purging of equipment / machinery by nitrogen gas. Preservation after erection, as
per directions of owner/ equipment manufacturer.
29) Insulation: Design & application of Insulation (Cold and Hot as required) and Painting as
specified in the tender.
30) Documentation: Prepare & supply of all documents, as built drawings and imparting of
training to Employer’s personnel.
31) Security: Arrangement of security for contractor's office and stores, distribution of
electricity and water from supply point to work spots, floodlights and other facilities for
working on round the clock basis.
32) Good Practice: Requirements arising due to good engineering practice shall be followed.
33) Hook-Up: Final hook up of the joints within the battery limits of various headers or any
other equipment (wherever applicable).
34) Co-ordination with other contractor's works as required by owner.
35) Safety & Cleanliness: Maintaining safety, cleanliness, security, hygiene, accessibility to
work place, clearing of site after completion of work.
36) Specific Facility: No equipment / facility whatsoever will be provided by owner unless
specifically provided for in the tender.
37) Protection to Facility: There shall be no damage to the existing facility during the
execution of the contract. Repairs required, if any, and painting etc for protection /
aesthetics purpose.

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38) Compliance: Compliance of entire installation to relevant standards, Acts, Rules,

Regulations, etc. as applicable.

1.2 ENGINEERING DOCUMENTATION

Contractors shall be required to submit following documents/ drawings:

a. Detailed technical specification of all items, engineering drawings, Design calculations,

Data sheets prior to placement of purchase orders / fabrication.
b. Item-wise QAP for various stage inspection, extent of testing, inspection agency &
Testing Procedures prior to placement of purchase orders / fabrication.
c. Equipment drawings (G.A & Fabrication), Layout drawings, Piping flexibility analysis
reports, Isometrics, Bill of Material before piping fabrication & erection.
d. Structural/fabrication drawing for equipment support, crane/gantries etc. before
erection.
e. Inspection test and performance reports prior to acceptance of the system.
f. Operation and maintenance manuals of equipment, items and various systems after
mechanical completion.
g. As Built Drawings after final fabrication & erection.
h. Site test report on Erection & Commissioning.
i. Any other drawing/document required.
 The Contractor shall forward Four (4) sets of all drawings and parts list and specifications
along with a soft copy on CD for Employer's review/ approval. Drawings and parts list
when found satisfactory for approval on the first submission will be so noted and signed and
one copy of the signed prints would be returned. Drawings not found satisfactory
for approval on the first submission will have changes/ notes etc. noted on the prints, one of
which will be returned to the Contractor for resubmission. A print with such additions shall
not be interpreted by the contractor to be "Approved as noted” unless specifically so noted
above on approving signature. Any shop work done prior to the approval of drawings will
be at the Contractor's risk. The Contractor shall make changes in the design which are
considered necessary to make the equipment conform to the provisions and intent of the
specification and information regarding same shall be furnished to Employer for
approval. These changes shall be carried out without any additional cost and time overrun
to the Employer.
 All drawings, parts list, assembly procedures etc. shall bear a readily identified drawing
number and each subsequent revision or addition to the drawing or procedure shall be
identified by a revision number or issue number.
 The checking and approval of the above documents by the Employer is for the benefit of the
Employer and shall not relieve the contractor from full responsibility for ensuring
correct interpretation of design drawings and specifications or for the completeness and
accuracy of the shop drawings and relevant specifications.
 The Contractor shall record all deviations, concessions, omissions, changes etc. occurring
throughout the manufacturing, assembly and testing phases and submit two sets of 'As-
Built' drawings in reproducible form along with a soft copy in the form of CD within thirty
(30) days of the date the equipment is considered to be placed in satisfactory operating
condition.
 All drawings shall be clearly marked as “SPP-Tuticorin” and the title block shall describe
Drawing title, Drawing No. and revision No.
 In addition to the drawings specified above, the contractor shall supply Four (4) manuals
containing all drawings and documents generated during detailed engineering as listed

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under scope of work in reduced form together with descriptive data on the equipment,
quality control plan, component and equipment test reports, complete instructions for
installation, recommended settings, operation and maintenance of the equipment and parts
catalogue. The manuals shall be specific to the equipment furnished and not of a general
nature. The instructions for assembly and installation shall show the identification part
numbers of the dismantled apparatus or equipment. Four (4) copies of the above in draft
form shall be submitted for approval. After acceptance of the draft, Contractor shall supply
six (6) hard copies in bound form along with a soft copy on CD.

1.3 QUALITY SURVEILLANCE:

The successful contractor shall prepare detailed quality control plan based on the guidelines
indicated in the technical specifications and submit for approval at appropriate stages. It shall
cover all stages of fabrication, raw material / accessories procurement, details of stage
inspection, final assembly, testing, packing dispatch, storage and receipt at site, erection and
commissioning checks etc. Suggested QAP is enclosed in the document, which should form the
basis for developing the final QAP for individual equipment / machines / component. Reference
document, witness, review, hold points, drawing numbers with Rev No. etc., shall be indicated
for each and every activity.

1.4 PROGRESS REPORT:

1. The Contractor shall submit four (4) copies of a monthly detailed progress report.
2. Detailed execution schedule shall be prepared and submitted covering at least following
major activities:
a) Design and detailed engineering work.
b) Tendering, evaluation and order placement.
c) Drawing, design approval and manufacture.
d) Assembly and testing.
e) Packing, shipping and transportation.
f) Erection
g) Pre-commissioning and Commissioning
h) Performance testing

1.5 CODE REQUIREMENTS:

1. It shall be the responsibility of the successful contractor to ensure that the
material requirement covered by the specification conform to all statutory /
regulatory requirements & applicable codes / standards etc.
2. It shall be the responsibility of the successful contractor to rectify / replace in
reasonable time all material and equipment found to be not meeting specified
code requirements at no extra cost to the Employer.

1.6 GENERAL SERVICES:

The contractor shall render the following general services:-
1. Arrange for inspection and obtain the approval from statutory bodies,
wherever required.
2. The contractor shall fully comply with the relevant statutory acts, rules and
regulation pertaining to contracts.
3. All bidders are advised to visit the site and familiarize themselves with site
conditions before submitting their tender. Non-familiarity with site conditions
will not be considered a reason either for extra claims or for not carrying out
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the work in strict conformity with drawings and specification.

1.7 HWB’S SCOPE:

1) Space for the site office. However, contractor shall make his own arrangements
for temporary construction of the office.
2) Construction power & water on chargeable basis shall be provided by HWB site.

1.8 SPECIAL NOTE:

1) It is not the intent to specify completely the scope of work here. The scope of
work in general gets covered by the drawings and Equipment list and systems
indicated elsewhere in the tender.
2) The plant shall be designed, engineered and manufactured as per
high standard of Engineering, design and workmanship and be capable of
performing in continuous operation in a manner acceptable to the Employer as
per Indian, International standards and codes, good engineering practices.
3) Drawings enclosed give the basic details and contractor would be required to
develop the detailed drawings based on the requirements indicated and as per the
good engineering practices, codes and standards.
4) All the designs, QAPs, Procedures, documents and drawings have to be got duly
approved from the Employer and the work should be executed as per the
approved documents.
5) Any contradictory information / discrepancy in the document shall be clarified
from the HWB. Further, conflict between the requirement of any two clauses or
documents forming a part of this specification the more stringent requirements
shall apply unless otherwise confirmed by the HWB in writing. In these regards,
decision of the HWB shall be final and binding on the contractor. The same shall
be executed at no additional cost.
6) Exclusions, if any, from the scope shall be specifically brought out by the bidder
in his offer failing which it shall be assumed that the entire scope of work is
included in the bid.

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1.9 SYSTEM DESCRIPTION

The Solvent Production Plant is being built for the synthesis of variety of solvents. The plant is
coming in the premises of Heavy Water Plant, Tuticorin. The detailed process description of the
project is indicated in other part of this tender.
With reference to Mechanical, the system of the plant may be divided into two parts:
1) Main Process System
2) Utilities
The Main Process System consists of the following units
SN Unit No. Description
1. Unit 43 & Unit 44 Solvent(s) Production Unit
2. Unit 45 Butanol Recovery Unit
3. Unit 46 Alkali Dissolution Unit
4. Unit 47 Vacuum & Vent Scrubber Unit
5. Unit 49 Bulk Storage Unit

The Utility System of the plant consists of the following units

SN Unit No. Description
1. Unit 48 Electrode Boiler Unit
2. Unit 50 Chilled Water Unit
3. Unit 51 Cooling Water Unit

For Units 43 & 44 Glass Lined –Carbon Steel and Nickel Cladded Carbon Steel Reactors are
envisaged for the project. The connecting lines, fittings, diaphragm valves for these units are
also to be glass lined.
Stainless Steel Tanks and Carbon Steel tanks and vessels are considered for other units. Butanol
recovery unit has PTFE Lined Carbon Steel Columns. Butanol Bulk Storage Unit has 5 nos. of
Carbon Steel tanks of varied capacities. Process piping are generally SS 304 piping. Non-
metallic (HDPE & PP-FRVE) tanks are also considered. Non-metallic HDPE piping, PP Ball
Valves and PP-FRVE duct are also required in the system.
Detailed specifications, requirements and process parameters are given in other parts of this
tender.

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1.10 DESIGN BASIS OF MECHANICAL SYSTEMS

This document indicates major consideration and basis which are to be used while
designing the systems. Though the detailed specifications, requirements and considerations
are indicated in the Process Data Sheet, Technical Specifications, Quality Assuarance Plans
given in the tender of this chapter serves to give a broad requirement for carrying out the
design for mechanical system of the plant.

1. Codes & Standards for Mechanical Systems:

Mechanical Components for main process as well as utility mainly comprise of the
following:
a. Tanks & Vessels
b. Piping
c. Pumps
d. EOT Crane
Relevant Codes & Standards for the above items are as follows:

A. Tanks & Vessels

 Design, Fabrication, Acceptance – ASME Sec VIII Div 1.
 For Seismic Design – IS 1893 Part1 & 4.
 Nozzles - WRC 297 / WRC 107
 Welding – ASME Sec IX
 Non-Destructive Testing (NDT) – ASME Sec V
 DVS Codes for design of Non-metallic components.
 For PP-FRV Vessels – BS 4994
B. Piping
 Design, Fabrication, Acceptance Code – ANSI B 31.3 Category M Fluid. Steam
Piping is considered as Process Piping for which the design code is ANSI B
31.3. For piping carrying steam, water, alcohol, alkali, nitrogen design code shall
be ANSI B 31.3.
 DVS Codes for Non-Metallic piping
 Seismic Design – IS 1893 Part1 & 4
 Welding ASME Sec IX
 NDT - ASME Sec V.
C. Pumps
 Process Pumps – As per manufacturer’s standard.
 Utility Pumps (Chilled Water, Cooling Water) - IS 5120.
 Diaphragm Pump – Generally as per API 675
D. EOT Crane
 Design, Erection & Testing (Structural Portion) - IS 807
 Design, Erection & Testing (Other than Structural Portion) -IS 3177
E. Piping Components
 Valves – ANSI B 16.34
 Fittings – ANSI B 16.9
 Flanges – ANSI B 16.5

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2. Material of Construction (MOC): Following major material of construction is envisaged

for the plant:

SN MOC Equipment / Machineries Service

1. Glass Lined-Carbon Reactors and Tanks, Piping, Corrosive Fluid
Steel flanges, fittings, glass lined
diaphragm valves for
interconnecting piping between
glass lined-CS Reactors /
Vessels
2. Nickel Cladded CS Reactor Corrosive Fluid
3. Austenitic Stainless Process Equipment & heat Alkali Service
Steel SS 304 L exchangers, Pumps & Valves
Body Castings, Piping, Fittings,
Flanges, Fasteners
4. Carbon Steel Bulk Storage Tank - SA 516 Gr Alcohol & General
70, Carbon Steel Pipe – A 106
Gr B, Fittings – A105 / A 234
WPB, Flanges – A 105,
Valves – A 105 / A 216 WCB,
Pumps – A 216 WCB,
Bolts & Nuts – A 193 B 7 / A
194 Gr 2H)
5. Graphite Heat Exchangers Corrosive Fluid
6. Non Metallic Tanks, piping, ducting, valves Effluent
(HDPE, PP, PP-
FRP)
7. CAF with PTFE Gaskets General
enveloped with SS
inserts
8. Neoprene O-Rings General

3. Quality Assurance: Tentative Quality Assurance Plans are included in the tender with
following considerations:
RECORDS / DOCUMENTS:
A. Approved QAP
B. Approved WPS, PQR, Welder Qualification.
C. Approved Test Procedures (Wherever required)
D. Records of Stage and Final Inspection & Testing
E. Original Material Test Certificates
F. Radiographs
MAJOR TESTS: Major tests which are indicated in the QAP consist of the
following
A. DP – 100%
B. Radiography for Butt-Weld joints – Process Lines - 100%, Utility Lines – 10%.
C. Leak Test - Soap Bubble.
D. Hydro-test.
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E. Original Mill Test Certificates.

F. Positive Material Identification for SS Components
G. Performance Tests for Pumps

4. Salient Design / Constructional Features of Tanks, Columns, Vessels & Lining:

A. For Vacuum Design, stiffeners (if any) outside the tank.
B. Manhole – 24” wherever equipment size permits otherwise hand-hole of suitable
size or Flanged covers at the end.
C. Internals would be removable from man-hole unless vessel has flanged
construction.
D. Dished ends – Tori-spherical, No Petal Construction, no hot forming. Solution
Annealing to achieve hardness < 200BHN.
5. Salient Design / Constructional Features of Pumps, Fans & Blowers
A. Process Pumps - Single Mechanical Seal. Seal element - Silicon carbide.
B. PTFE Elastomer in mechanical seals.
C. Closed/ Semi-Closed impeller for slurry service.
D. Dynamic balancing - ISO 1940 Gr 6.3 or better.
E. Diaphragm Type metering pump.
6. Piping
A. Pipe Flanges & Valves Rating – 150#
B. Corrosion Allowance for CS line – 3 mm, SS line – 1mm.
C. Miters – not permitted for process piping.
D. No. Of cycles < 7000; Stress Range reduction factor = 1
E. Joints : Nozzle to Pipe, Valve to Pipe, Pipe to Pipe etc. – Welded joints on small
bore lines otherwise flange Joints.

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1.11 LAYOUT CONSIDERATIONS

The final equipment and piping layouts shall be prepared by the EPC contractor based
on the tentative equipment & Site plot Plant lay out given in the tender document and
get it approved by the department . Equipment lay out shall be prepared in accordance
with good engineering practices and international codes and standards. The layout
should provide for ease of operation and maintenance and adequate platforms and
staircases (two opposite sides) shall be provided. Suitable provisions shall be made for
overhead clearance for erection and maintenance of equipment. In general, as otherwise
as per discussion after completion of detailed engineering by the EPC contractor,
following shall be considered while developing layouts.
 Spacing shall be such that at least two escapes are available from any part for
operating personnel.
 Maintenance methods for each item of equipment shall be determined so that
equipment requiring maintenance will be easily accessible.
 Equipment and structures shall be arranged to permit free access of lifting device
for all equipment i.e. service vessels, reaction vessels, condensers, vacuum
pump, pumps etc.
 All equipment shall have proper approachability and handling facilities for their
easy removal and reinstallation.
 Heat exchangers for same service shall be stacked one above another wherever
possible.
 Space shall be provided for removal of exchangers, & tube bundle.
 Sample points shall be clubbed together at one place as far as possible and
service water shall be provided at liquid sampling stations.
 Suitable slopes to be provided where complete draining of line is required.
 Isometrics shall be prepared for all process and utilities lines in line with above
requirement. Piping layouts shall be prepared for all lines and to be got approved
from department. While preparing piping layout, three dimensional views of
piping system, equipment, structures, platform, etc. shall be considered to avoid
fouling and to meet the minimum space requirement, accessibility, etc. as
mentioned elsewhere in the specification using Auto CAD and other applicable
software.
 Piping layouts shall be prepared for underground piping.

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1.11.1 EQUIPMENT AND PIPING CLEARANCE:

Unless otherwise noted, following minimum clearance shall be maintained. However this may
be reviewed depending upon final equipment lay out which is to be prepared by the EPC
contractor based on the tentative equipment & Site plot Plant lay out given in the tender
document and get it approved by the department :
Piping Overhead Clearances:

Description Clearance
Over rail roads, top of rail to bottom of any obstruction. 7M
Over Plant roads for major mobile equipment 6M
Over secondary roads (Bottom of pipe or structure) & Access ways for 5M
mobile equipment
Over grades and bottom of pipe or structure (inside battery limit) at pump 3M
row access way.
Over walk ways, pass way and platform to nearest obstruction and inside 2.2 M
building
Over exchangers at grade, shell cover and channel. 1.5 M

Piping Horizontal Clearances:

Description Clearance

Between Exchangers (Aisle between piping) 0.9 M

Around Pumps (Aisle between piping) 0.9 M

At driver end of pumps, where truck access is required 1.3 M

At driver end of pumps, where truck access is not required 1.8 M

At shell cover end of exchangers at grade for access way 1.3 M

Between shells of adjacent vessel 1.2 M

Clear space centrally under main pipe rack both vertically and 3M
horizontally for mobile equipment to service pumps

Pipe berthing Under Ground minimum clear gap between pipes 0.3 M

Pipe Berthing (Above ground) clear gap between same lines carrying 0.75 M
clear and contaminated fluid

Minimum clearance between finished grade/ pavement level and lowest 0.3 M
piping item (drip legs, drains etc.)

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Equipment Spacing:

Equipment Spacing
Small Pumps (3.75 KW & Less) Common
foundation

Minimum clear aisle for Medium Pumps (22.5 KW & Less) 900 mm
Minimum clear aisle for Exchangers and other equipment on structure 900 mm
From edge of equipment to wall (as per vendor recommendation) 750 mm
Electrical motors from walls 750 mm

Platforms: Towers, Vertical & Horizontal vessels:

Distance of platform below centerline of manhole flange side 900-1050

platform. mm

Widths of manhole platform from manhole cover to outside edge 900 mm

of platform, side platform.

Platform extension beyond centerline of manhole side platform. 900 mm

Distance of platform below underside of flange head platform. 175 mm

Width of platform from three sides of manhole head platform. 750 mm

Horizontal Exchanger:

Clearance in front of channel or bonnet flange. 1200 mm

Heat exchanger tube bundle Bundle length + 1000 mm

Minimum clearance from edge of flanges 300 mm

Vertical Exchanger:
Distance of platform below top flange of channel or 1500 mm
bonnet.
Width of platform from three sides of flange 900 mm

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Operating Aisles:

At grate 750 mm Minimum

On structure 750 mm Minimum

On vessels 750 mm Minimum

communicating 600 Minimum

Operating Clearances: (Indoor)

Switch Gear Front (Minimum) Rear (Minimum)

High Voltage 1500 mm 1500 mm

Low Voltage 1200 mm 1000 mm

Motor Starters 1000 mm ----

Motor Control Centers 1000 mm 1000 mm

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1.11.2 ACCESSIBILITY OF VALVES AND INSTRUMENTS:

Valves, Instruments and Center line of item to Center line of item to be

equipments to be operated be operated, located operated, located more than
less than 3.6 M above 3.6 M above grate, 2.75 M
grate, 2.75 M above above floor or platform, 1.8
floor or platform, 1.8 M M above wing platform.
above wing platform.

Exchanger heads grate Platform

Open valves 2” & smaller Fixed ladder Fixed ladder

Open valves 3” and above Platform Platform

Motor operated valves Platform Platform

Control valves Platform (edge) Platform

Relief valve 2” & smaller Fixed ladder Fixed ladder

Relief valve 2” & above Platform Platform

Block valves & battery limit Portable ladder Platform

valves – 2” & smaller

Block valves & battery limit Platform Platform

valves – 2” & larger

Pressure instruments Portable ladder/ fixed Fixed ladder

ladder if above 2.2 m ht.

Temperature instruments Portable ladder/ fixed Fixed ladder

ladder if above 2.2 m ht.

Sample points Platform Platform

Test valves Fixed ladder Fixed ladder

Gauge glasses Fixed ladder Fixed ladder

Level controllers Platform Platform

Process blinds & spades except at Up to 3” portable ladder Platform

battery limits above 3” platform

Manholes/ man ways Platform Platform

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Hand holes Platform Platform

Nozzles No access required No access required

Vessel vents Portable ladder Fixed ladder

Line drains & vents No access required Access required

Approach to spring hanger Ladder Platform

supports

Orifice flanges Portable ladder Portable ladder

Centerline of block valves located above 2.0 meter from the operating floor which are required
for normal operation shall be provided with chain Wheels. Chain wheel operation shall not be
used on screwed valves and on pump discharge lines. The use of chain operation shall be kept
to a minimum.

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M – II TECHNICAL SPECIFICATION FOR EQUIPMENTS

2.1 SPECIFICATION FOR PROCESS EQUIPMENT (FABRICATED)

Present tender includes the scope for the fabrication of equipment with MOC of Stainless Steel
/ Carbon Steel, Glass Lined and HDPE. Thus, the technical specifications for vessel of each
MOC are described separately in this Technical Specifications.
2.1.A. SPECIFICATIONS FOR STAINLESS STEEL / CARBON STEEL EQUIPMENT

i. Mechanical Design, Fabrication, Testing, Inspection and Supply of Stainless steel

vessels as per specification and drawings listed out in this document. The table is
given elsewhere in the tender indicating the list of the process equipments for
fabrication.
ii. Contractor to prepare “General Arrangement Drawings” for carrying out further work
related to Mechanical Design, submission of design calculations, fabrication drawing,
fabrication, inspection & testing as per following Codes:
iii. Carry out mechanical design and develop GA drawing, fabrication drawing based on
the date sheets attached with the tender document and various mechanical design
considerations as per the following codes:
 Design Life : 40 years
 Seismic Design : IS 1893 (Par 1 & 4)
 Wind Design : IS 875
 Code for design & Fabrication : ASME Section VIII Div 1 (Not before 2010
Ed.)
 Nozzles : WRC 107 / WRC 297
 Ferrous Materials : ASME SEC II A
 Inspection & Testing : ASME SEC V
 Welding Electrodes : ASME SEC II C
 Valves : B 16.34
 Flanges : B 16.5
 Fittings : B 16.9
iv. Submit the fabrication drawing to HWB’s approval & incorporate the comments in
the drawing, if any, made by the HWB and resubmit for approval.
iii. Prepare complete Bill of Material (BOM) required for the job and procure all the raw
material required to complete the job.
iv. Based on the tentative Quality Assurance Plan of the tender enclosed, prepare &
submit detailed Quality Assurance Plan (QAP) for HWB’s approval. Incorporate
the comments in the QAP, if any made by the HWB and resubmit for approval.
v. Fabricate the equipments as per the technical specification of this tender. Codes /
Standards indicated in the tender and good engineering practice.
vi. Offer stage inspection and final testing inspection to the HWB / Third Party
Inspection Agency (TP) as per approved QAP.
vii. Pack the equipments properly & ensure its delivery at site without any damage
during transit. Unloading responsibility of the consignment, at HWB’ site is in the
scope of the bidder. Equipments should be delivered in the minimum possible time
(in a dedicated / chartered transport arrangement) on door delivery basis, at site (as
has been indicated elsewhere in the tender).

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2.1.1 EQUIPMENT DESIGN, FABRICATION, TESTING & SUPPLY:

This specification defines minimum requirements relating to complete procurement of all
the raw materials, mechanical design, fabrication, inspection, testing, painting, packing
and dispatch / delivery etc. for the process equipment to HWB’s premises. This
specification shall be read in conjunction with code, data sheets and other inquiry
documents etc. In case of any conflict between code and inquiry documents the matter
shall be referred to owner for clarification and owner’s views shall be binding.
2.1.2 DESIGN:
a) Carrying out Complete mechanical design, submission of such calculations for
HWB’s review & approval, detailing of equipment as per latest code of design /
construction shall be the responsibility of the Contractor. Strict compliance with the
requirement datasheets, this specification, equipment standards and any other referred
document shall be fully ensured.
b) Detailed design calculations for adequacy of strength of all individual parts shall be
made and submitted to purchaser for comments and approval. After receipt of approval
from purchaser the design of equipment shall be considered as final. Any
change/comment made on design calculations to satisfy the requirements to code /
specifications shall have to be incorporated. For vessel design calculation, PV Elite
(Latest Version) may be used.
c) Wind Design: Most of the equipment for this plant are placed inside a Civil Building.
For all such equipment, wind loads are not required to be considered. However, for the
equipment which are located outdoor, Wind Design shall be carried out as per IS-875.
Equipment Data Sheet indicated the location of the equipment.
d) Corrosion Allowance (CA): The minimum thickness of the vessel indicated in the data
sheet for the equipment is the thickness excluding the corrosion allowance. It is
required that for Stainless Steel Vessels, CA of 1mm shall be used and for Carbon
Steel Vessels CA of 2mm shall be used.
e) For designing the equipment for seismic forces, the maximum ground motion
corresponding to the site of installation shall be taken from IS 1893, unless otherwise
stated. Detailed vibration analysis under seismic forces shall be submitted along with
the design calculations. For the design consideration seismic forces shall be increased
by 30% to cater for the effect of piping system, platforms and ladders etc.
f) For the static design, if the liquid is required inside the vessel as per the process, the
static design shall consider the vessel to be completely filled with the process fluid.
g) Nozzles of size => 50 NB shall be analyzed for loads coming on to the nozzles due to
piping with the code WRC 107 / WRC 297.
h) Characteristic strength of foundation concrete shall be taken as M20, unless
specifically confirmed. Project site soil shall be taken as medium type and back filled
soil shear strength shall be considered as only 20 MT/m2.
i) All removable internals shall be designed so as to pass freely through inside diameter
of vessel manholes unless shell is of flanged construction. Fasteners for fixing internals
shall be of 18/8 S.S., if not specified otherwise.
j) Dished ends – Only Tori-spherical, No Petal Construction, no hot forming, solution
annealed, hardness<200BHN.
k) Circumferential joints between shell & dished end shall be fully radiographed (unless
specified otherwise).
l) All fitting lug fillets joints shall be 100% DP checked. Fillet size shall not be less than
8 mm.

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2.1.3 MATERIALS:
a) All materials, whatsoever, required to complete the supplies shall be procured by the
supplier and all such materials shall be covered with due identifiable material test
certificates. If required, the HWB may ask for retesting of the raw materials for
verification, through Govt. approved test laboratories and it shall be carried out by the
contractor at no extra cost.
b) Materials indicated in data sheets are required for the specified service conditions.
Supplier however may use better or equivalent material with prior approval of
purchaser.
c) Equipment Material Specification: The material of construction of equipment shall be
as per the equipment data sheets / drawings.

2.1.4 ACCESSORIES / ATTACHMENTS / SPARES:

1. Unless otherwise specified, the main equipment and their various components as
specified in drawings and inquiry documents shall be included in contractor’s scope of
supply.
2. Scope of supply shall also include but not limited to the following :
a. Companion flanges with bolting and gaskets as specified.
b. Cover flanges, for manholes, hand holes and inspection openings etc. with
bolting and gaskets. Manhole Covers shall be provided with davit for opening /
closing the cover.
c. Test blind flanges / caps / blinds.
d. All internals complete with supports and fasteners.
e. Manhole blind covers having class ratings as of Manhole forging & has to be
rated for design pressure. Davits for manholes are also required to be provided.
f. All external welded attachments like insulation & ladder cleats etc.
g. The spacing between insulation cleats shall not be more than 2000 mm.
h. Equipments specific stool, if any.
i. Minimum two Lifting lugs / erection lugs as specified.
j. Template for skirt supports of equipment.
k. Cleats for earthing connections, Cleats shall have female fitting, with internal
threads suiting ½” NB BSP ends.
l. Name plate with brackets.
m. Support stools / pedestal.
n. Agitator with reduction gear & its drive along with supporting arrangements etc.,
if any.
o. Welding wire / rods for welding and sealing gaskets.
p. Special tools, tackles if any.
q. Filter elements at pump suction.

2.1.5 EQUIPMENT FABRICATION:

a) The manufacturer of the equipment shall comply in all respects with the provisions of
the applicable code and specifications including such jobs as welding, fabrication,
forming of heads etc., radiography, heat treatment, inspection, testing and quality
control unless otherwise specified. Quality assurance plan must be got approved from
purchasers & authorized inspecting authority before starting jobs. Among others, the
QAP shall include the equipment specific QAP enclosed.
b) Plates of different thickness shall be aligned along with their inner surface of
equipment unless otherwise stated. A suitable transition length shall be provided, by

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grinding to ensure smooth & gradual change in thickness. Such length of transition
shall not be less than 4 times the difference in thicknesses.
c) Production control coupons when required as per code & specification shall be
subjected to all tests like impact test for Inter Granular Corrosion Test for austenitic
S.S. material in addition to Mechanical test required as per material specification. In
case of heat treated equipment, test coupons shall be given similar heat treatment as
proposed for the equipment.
d) All welding neck flanges shall be bored to suit nozzle I.D. Flange facing shall have
suitable concentric serrations for gasket seating in case of plain, male, female & raised
faces. In case of spiral wound gaskets no serrations are to be provided on gasket
seating faces, however, suitable nubbin/raised face shall be provided. Surface finish
shall be 125 RMS.
e) All nozzles reinforcing pads shall be tested by using pneumatic pressure of 2.0 kg /
cm2 (g) pressure with soap solution on attachment welds. Each reinforcement pad shall
be provided with minimum two tell-tales holes (⅛” NB BSP female threads) and shall
be plugged by using removable type threaded S.S. Plugs.
f) All nozzles shall be tagged as per the “functional tag” indicated in the data sheets.
g) All internals fabricated in pieces shall be shop assembled and properly match marked
for easy assembly at site.
h) In case of equipment involving site assembly / fabrication the entire site job including
fabrication, radiography, heat treatment, inspection, testing and transportation to site
shall be in supplier’s scope of work.
i) All flange bolts & skirt bolts shall be either in vertical or in horizontal plane unless
otherwise stated.
j) All nozzles less than or equal to 40 NB shall be stiffened with three equi-spaced ribs
of the same material as that of shell / nozzle. For all nozzles ≥ 50 NB shall be provided
with reinforcement pad having OD equal to twice the OD of nozzle.
k) For the studs to be tightened with hydraulic tensioner, removal type caps shall be
provided for protection.
l) DP examination shall be carried out on all weld overlays and weld seam of alloy
lining and to ensure / show that no evidence of any crack and surface defects, exist.
m) DP examination shall be carried out on welds attached nozzle to shell, nozzle to
flange, flange to shell and supports like skirts, lugs, brackets etc. to shell and non-
pressure parts to pressure parts. Dissimilar weld shall be avoided in pressure parts.
n) DP examination shall be carried out on all weld chamfers and reverse side of double
welded joint after back gouging.
o) DP examination of finished welds, wherever specified shall be carried out after heat
treatment and such examination shall cover base metal adjacent to weld.
p) In the absence of radiography or ultrasonic examination, D.P. check shall be carried
out progressively at the lesser of One third of thickness of weld joint or 10 mm weld
deposit.
q) D.P. Examination shall be carried out on all flange faces and gasket faces.
r) Coil to coil, coil to bend joints and nozzle to shell joints shall be of full penetration
weld.
s) All butt weld joints shall be 100% radiographed.
t) DP examination shall be carried out after forming of fittings to check for cracks.
u) Radiography examination shall be carried out as specified in the respective drawing.

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2.1.6 INSPECTION AND TESTING OF EQUIPMENTS AT SUPPLIER’S WORK:

a) All raw materials shall be inspected by third party inspection Agency or by DAE
Engineer, at source and test certificates are to endorsed by him to enable proper
identifications.
b) All equipment shall be inspected during various stages of manufacture starting from
identification of raw materials to completion. The equipment shall be considered
acceptable for dispatch only after final certification for acceptance is issued by the
inspector.
c) Bought out items or items sub-contracted to other sub-suppliers shall also be inspected
by the same inspection agency at the sub-supplier’s works. However, standard items
like bolts, nuts, ordinary gaskets etc. may be exempted from the inspection with
specific approval from HWB or may be sample checked.
d) Inspection by HWB and/or third party, if any, will be arranged by HWB (probable
vendors for such inspection work shall be like Lloyds, BV, ABS industrial
Verification, DNV, EIL, PDIL or SGS etc. and all cost of inspection shall be borne by
contractor. It shall be the responsibility of the contractor to make available to the
inspector all the new/revised drawings, calculations and other enquiry documents and
purchase order copies.
e) Inspection order on third party shall also include specific instructions for making
copies of all correspondences from inspecting authorities to the owner and
expediting/reporting monthly progress of the order to purchaser. Complete
responsibility of getting approval of drawings/calculations and documents from
inspecting authority shall also be that of the supplier.
f) Leak test (Soap Bubble) shall be carried out with permissible leak rate of 1.25 x 10-3
std CC/sec unless or otherwise stated differently in data sheet/tender drawing.
g) Dimensional measurement of vessel shall be carried out before and after hydraulic test
including inside diameter wherever possible.
h) Brinnel hardness shall be measured inside and outside joints where welding and heat
treatment are done before and after heat treatment.
i) Straightness of vessel shall be measured.
j) In case of flanged construction, the tightness of flanged joint shall be thoroughly
checked and gap between matching parts shall be measured.
k) All the measurements as above shall be carried out in presence of inspecting authority
and results shall be reported in the inspection certificate for record.
l) All measurements taken shall confirm to equipment drawing and tolerance
requirements as specified.
m) Pneumatic testing shall be carried out for specific equipment as mentioned in the Data
Sheets.
n) Tare & operating weight of various equipment, given elsewhere in the tender, are
indicative only. For designing the working platform and foundation, additional loads
due to piping & valves, live loads of personnel etc. need to be considered.
o) For equipments “As-Built” fabrication drawings shall be prepared and submitted to
purchaser after due verification by the appointed third party inspection agency.

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2.1.7 Technical Specifications for Shell & Tube Type Heat Exchangers
A. Scope
 Supply of all materials, fabrication, inspection and testing as per technical specifications
and enclosed drawings shall be in the scope of contractor.
 All required materials such as pipes, tubes, pipe fittings, welding consumables, tube
sheet, flanges, fasteners, partition plate, tie rod etc. shall be procured by the supplier
from reputed manufacturers.
 Fabrication, inspection & testing shall be as per ASME Sec VIII . Div – I and TEMA
class – B / R .
 Design Calculation and the GA drawings shall be submitted for the approval of the
HWB.

B. Material of Construction :
All material of construction shall be as per the data sheet. If not otherwise mentioned,
following M.O.C may be used corresponding to Stainless Steel
Shell: SA240 type 304L
Tube sheet and Flanges: SA182 type 304 L
Nozzle pipe: A312 type 304L seamless
Tube: confirming to A213 type 304L. Tube shall be cold drawn and annealed. All
tubes shall be 100% eddy current and hydrostatically tested.
Pass partition plate: SA 240 type 304L
Fasteners : Studs with two nuts – SA 193 Gr B7M / SA 194 Gr 2HM
Gasket : PTFE enveloped CAF with corrugated metal ring.
All the test details for mechanical tests and chemical composition, NDE procedure,
mock up test, personnel qualification and performance qualification for welding shall
be made available to the purchaser.

C. Fabrication:
 Fabrication generally shall meet code requirement of ASME Sec. VIII-Div.1 and TEMA
CLASS-A / B.
 Welding procedure and welder qualification shall be as per ASME section IX.
 All NDE requirements shall be carried out by qualified personnel in level not less than
ISNT/ASNT Level 2.
 The gasket surface also shall have smooth matching finish.
 Number of nozzles and its orientation shall be as per the enclosed tender drawings.
 No carbon steel to Stainless steel welding is permitted. Any CS welding to
shell/channel shall be through a pad plate.
 Tube holes shall be made with two grooves in the tube sheet as per TEMA standard.
Tube shall be extended for a length equal to total tube sheet thickness minus 3mm.
After completion of expansion, tube ends shall be seal welded with tube sheet as per
TEMA standard.
 Procedure shall be established for tube to tube sheet joint and the pull out test shall be
conducted in the presence of HWP inspection agency to establish the procedure. Mock
up test shall be done in presence of purchaser/authorized agency. Mock up test shall be
done as per ASME sec.VIII division 1 and pull out strength shall meet the code
requirement.
 Procedure as established in mock up test for tube to tube sheet joint and shall be
deployed in production weld of tube to tube sheet joint.
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 Tube sheet flange gasket face shall be lapped to have perfect, 100% blue matching, with
gasket. This has to be established before hydro test.
 All the welding consumables used shall have proper test certificates. TIG welding shall
be having inert gas back up and no oxidation shall occur.
 The production of weld coupon shall be attached with the shell and tested (one tensile
test and two numbers of face bend and root bend each). Hardness survey shall be carried
out on the production coupon on parent metals HAZ and on welds.
 All the fasteners shall be of very good quality capable of withstanding the service
conditions and shall be procured form manufacturer only. All test certificates having
material composition, mechanical properties like T.S., Yield strength, hardness,
elongation, etc. shall be furnished with necessary correlation.
 Prior approval of the department shall be taken by the supplier for any deviation in the
materials, during fabrication and also for sub-contracting.
 No repair will be permitted without the approval of purchaser / authorized inspector.
 Liquid penetrant examination shall be carried out on the edges of all the joints to be
welded at root weld and on final welds. While doing one inch on either side of weld
shall be checked with D.P. D.P. test shall be conducted for all tube to tube sheet joints
also. The materials used for DP shall not contain free halogen or sulphur in excess of 26
ppm.
 Fabrication shall be done in dust free atmosphere.
 Complete work shall have good workmanship. The stainless steel weld shall be
passivated after welding.
 A tentative Quality Assurance Plan is given in the tender. Detailed QA plan shall be
submitted by the contractor for the approval of the HWB.

D. HYDRO TEST:
 Tube to tube sheet joints: After completion of expansion and seal welding, tube to tube
sheet joints shall be subjected to hydro-test to test integrity and leak tightness.
Necessary fixtures shall be fabricated to conduct shell side hydro-test to check the
integrity of the leaking tube. This test shall be conducted as per the codal requirement.
 Pneumatic test: Shall be conducted to identify leak tightness of tube to tube sheet joints.
This test shall be conducted at 2 kg/cm2.
 Shell side hydro-test: To check the integrity of all gasket joints, welded joints on shell
side in final test assembled condition, testing shall be done at a pressure as per the
requirement of the code.
 Tube side hydro test: To conduct hydro test on tube side after completion of final
assembly. Testing shall be done as per the requirement of the code.
 Preservation, Packing and transportation:
 After completion of final hydro test both shell and tube side, Exchanger shall be drained
thoroughly and flushed with moisture free air. Exchanger shall be charged with N2 (on
both shell and tube sides) at a pressure of 1 kg/cm2. All nozzle flanges shall be blinded
with SS flanges and gasket. Pressure gauge shall be provided on both shell and tube
side in order to indicate the pressure.

2.1.8 CLEANING, PAINTING AND DESPATCH FROM SUPPLIER’S WORKS:

a) After hydraulic testing, the equipment shall be dried, thoroughly, cleaned from inside
and outside and shall be free of all dusts and foreign materials. All S.S. vessels shall be
thoroughly pickled and passivated by using appropriate hot acids & stabilizers.
b) After Hydraulic testing, all SS parts and equipments shall be pickled.

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c) Equipments shall be dispatched with N2 filling at 0.5 kg / cm2 (g). Nitrogen filling
arrangement drawing to be supplied for approval.
d) Cleaning and Sand Blasting shall be carried out as specified in drawing / data sheet.

2.1.9 DOCUMENTATION OF FABRICATED EQUIPMENTS:

a) The contractor shall provide the following documents to the purchaser. The documents
not mentioned below but relevant are also to be supplied on demand.

Documents for review:

The following table refers to the requirements:

SN Documents No. of copies

1 Detailed fabrication drawing for each equipment 4

2 Mechanical Design Calculation of Equipment 2

3 Quality Assurance Program of the fabricators for each 4

equipment

4 Welding procedures and performance records received from the 4

fabricators

5 Procedure for Hydraulic / pneumatic test and Heat Treatment 4

6 NDT Procedures for approval 4

Documents along with equipment.:

The following table refers the requirements:

SN Documents No. of Copies

1 As-built drawing of each equipment 6
2 Record of Dimensional Measurements certified by 6
Inspection Agency
3 Records of NDT tests e.g. radiography, Ultrasonic test, 6
Die-penetrate test, Magnetic test, Hardness test etc.
4 Post weld Heat treatment chart 6
5 Hydraulic, Pneumatic and leak test reports 6
6 Inspector’s final certificates 6
7 Supplier’s guarantee certificate 6
8 Material test certificates duly stamped by inspecting 6
authority
9 Copies of report pertaining to various steps of QAP 2

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2.1.B. Specifications for HDPE Equipment

For Design, Fabrication, Inspection & Testing of HDPE Equipment, following codes shall be
used:

SN DVS Code No. Description

Design Calculations for containers and

DVS 2205-1 (along with
1. apparatus made from thermoplastics –
Supplement-1)
Characteristic Values

Calculation-of-Thermoplastic-Tanks-and-
2. DVS-2205-2-1997 Appatatus-Vertical-Cylindrical-Non-
pressurised-Tanks

Welding of Thermoplastics – Heated Tool

3. DVS 2207-1 Welding of Pipes, Pipelines, Components,
Sheets made from PE-HD

Testing of welded joints of thermoplastic

4. DVS 2203 -2
materials – Tensile Test

Testing of welded joints of thermoplastic

5. DVS 2203-4
tubes and plates – Tensile Creep Test

Industrial Pipelines Made of

6. DVS 2210-1 Thermoplastics – Planning & Execution,
Above ground Pipe Systems.

Industrial Pipelines Made of

Thermoplastics – Design & Execution,
7. DVS 2210-1 (Supplement 2) Above ground Pipe Systems –
Recommendations for the Internal Pressure
& Leak Test

Imperfections in Thermoplastic Welding

8. DVS 2202-1
Joints- features, descriptions & evaluations

Plastic Welding Personnel - Qualification

9. DIN EN-13067 2003
Testing of Welders

1. HDPE material used for the equipment shall be virgin HDPE without any fillers. Use of
recycled HDPE is strictly prohibited.
2. Design & the construction for the vessel shall be above mentioned code DVS 2205.
3. Hydro test for the vessel shall be conducted as per DVS 2210-1 (Supplement 2)

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2.1.C. SPECIFICATIONS FOR GLASS LINED EQUIPMENT

GLASS CHARACTERISTICS
 Glass lining thickness : 1 mm to 2 mm
 Thermal Conductivity : 1.2 W/mK
 Density : 2.5 gms/cc
 Softening temperature : 5700 C
 Compressive strength : 900 N/mm2
 Tensile strength : 80N/mm2
 Hardness : 600 Vickers
 Dielectric strength : 20 – 30 kv/mm
 Modulus of elasticity : 75000 N/mm2
 Electrical Resistivity : 1013ohm/cm
 Specific heat : 0.835 KJ/kgK
 Surface roughness : 0.08 – 0.18 micrometers
 Surface resistance : 5 x 109 ohms
 Elongation : 0.1 %
 Adhesion strength : > 100 N/mm2 (Glass on steel)
 Thermal shock resistance : 1500 C (minimum)
(Temp. difference)
 Linear co-eff. of expansion : 88 x 10-7/C

1. Spark Test for Glass Lining shall be conducted as High voltage test shall be carried out as
per DIN ISO 2746 at 10,000 Volts after glass lining, to establish the integrity of glass
lining. Lining thickness test and dimensional test shall be carried out during final
inspection.
1. The tank shall be designed, fabricated and hydro tested as ASME Sec VIII Div 1.
2. Quality Assurance Plan for the Glass Lined Vessels is attached with this specification.
3. Reactor shall be designed for operating under pressure and full vacuum.
4. Reactor shall be hydro tested before and after glass lining.
5. Reactor and Jacket shall be designed independently for maximum pressure.

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2.1.D. TECHNICAL SPECIFICATIONS FOR PP-FRVE VESSELS

The plant consists of few vessels made out of PP-FRVE. This specification defines
specifications for the fabrication of these vessels.

D.1 Codes:

SN Code No. Description

1. BS-4994 Specification for the design and

construction of vessels and storage tanks in
reinforced plastics.
2. DIN 16966-4 Glass fibre reinforced polyester resin (UP-
GF) pipe fittings and joints; Tees, Nozzles,
Dimensions.
3. BS-7159: 1989 Design & Construction of Glass Reinforced
plastics (GRP) piping systems for
individual plants or sites.
4. BS-6464 Specifications for reinforced plastic pipes,
fittings and joints for process plants.

D.2 General Conditions:

 Detailed process conditions are mentioned in the data sheet attached elsewhere in the
tender.
 Only PPGL sheets shall be used for PP-FRP vessels. The thickness shall be decided as per
the Codes. Thickness calculation for both FRV and PP shall be submitted for HWB
approval.
 Polypropylene welding shall be done by the hot gas filler technique. In that case inert gas to
be used which is free from moisture.
 Electrodes to be used shall meet the minimum requirements of applicable code. HWB shall
approve the vendors for the procurement of electrodes for which a list of manufacturer of
electrodes shall be submitted. Approved Test procedures by HWB shall be carried out by
the contractor.
 Welders engaged in the PP fabrication shall carry out specified approval test before
commencement of fabrication.
 The flange shall be square to the axis of the branch to within 1º up to 100 mm diameters
and to within 0.5º above 100 mm diameter.
 The stub ends and full face flanged pipe connection and bolting shall be designed to
connect Class 150 of ANSI 16.5.
 FRP lining shall be carried out by using Vinyl ester resin (UV resistant). Grey pigment
shall be added with the resin in order to have aesthetic look. Final layer of FRP shall be
carried out with smooth FRP mat.
 The resin mix including catalyst, hardeners or any other ingredient to be used shall be of
suitable commercial grade, which should meet the minimum requirements of BS 3532. The
same shall be clearly mentioned in the offer and in the drawing. Approval of resin mix by
HWB shall be based on lab coupon test to be conducted by HWB.

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 The recommendation of resin suppliers for the usage of hardener, catalysts and accelerators
shall be strictly followed.
 The requisite amount of resin, catalyst or hardener and any other ingredient, such as
accelerator or permitted filler shall be accurately measured and thoroughly mixed. The
amount of mixed resin and reinforcement used in each layer of the laminate and the number
and types of layers applied shall be recorded.
 Consistency in both material and fabrication shall be ensured and appropriate supervision
shall be provided all stages of manufacturing.
 Outer layer shall be FRP as per BS4994 standard and minimum 3mm thickness shall be
maintained.
 The equipment shall be subjected to the inspection and test as per Section V of BS 4994.
 All surfaces shall be smooth, continuous and irregularities which may cause high local loads
shall be repaired. There shall be adhesion between PP and FRP layers.
 After completion of all fabrication equipment shall be cleaned from inside to be free of all
traces of release agents, fibers, dust and other foreign matters.
 Copy of Material test certificate for PP and FR shall be submitted along with the materials.
 For final acceptance, hydro test /water fill test shall be carried out at the pressure stipulated
by the code. Any joint, nozzle or fittings found leaking during hydro test will be welded at
free of cost and hydro tested again.
 Welding shall be done in an open space or well ventilated room.
 Regular welding/jointing will be done after establishing a welding procedure at site.
 PTFE gaskets resistant to the process fluid are to be provided in between the stub ended
flanges.

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M-III TECHNICAL SPECIFICATIONS FOR PIPING, SITE

FABRICATION & ERECTION

3 A. PIPING TECHNICAL SPECIFICATION

3.1 SCOPE
a) Leak Tightness: Majority of process equipment handle toxic gases whose leakage to
atmosphere is detrimental to operational safety. Therefore maintaining the leak tightness
shall be technical essence of this contract.
b) Specific requirements arising due to a particular service and not covered in this
specification shall be prepared accordingly and with the approval of “HWB” may be
included as a part of this specification.
c) IBR Certification: Materials meant for steam service shall be with Indian Boiler
Regulation form IIIC duly signed by competent authority for the specified working
conditions. (IBR certification is depend on the type of boiler selection. Boiler selection is
not spelt out in the tender. Electrode boiler is not is a non IBR boiler and IBR certification
is not involved. So this clause may be deleted.)
d) Original Mill Test certificates are mandatorily required. Wherever Original Mill Test
certificates cannot be provided then check test shall be carried out.
e) Required job of the Tender involves the following :
i. 3-D Model & Drawing Preparation :
(A) As a first step, a 3-D Model of the plant shall be made by the contractor with the
help of competent engineering software packages like PDMS, PDS or equivalent. The
package shall be capable of “Walk-through”. Further, the 3-D model prepared by the
software should be available and accessible for browsing by the HWB without requiring
the software in which the model is prepared. For this purpose, contractor may note that
the HWB is equipped with “AutoCAD”. 3-D Model shall include Structures,
Equipments, Machines, Piping / Ducting, Electrical & Instrumentation, Pipe & Cable
Racks, Trenches / Drainage, SS Lining etc. 3-D Model is intended for the following
requirement: (a) Optimum utilization space, (b) Detect fouling, (c) decision on
clearances for ease of operation & maintenance, (d) ease of man-material movement, (e)
optimum routing with respect to quantity, pressure drop etc.
(B) Drawings (layout, isometrics, etc) shall be extracted from the 3-D Model.
Contractor shall prepare Equipment & Piping Layout Drawing and Isometric Drawing
with support details based on the tentative plant layout enclosed with the tender
document and in consultation with EIC at site and submit for approval by the HWB. 3-D
Model shall be modified at the end to incorporate “As-Built” Drawings.
ii. Incorporate the comments in the drawing, if any made by the HWB and resubmit For
approval.
iii. Prepare complete Bill of Material (BOM) required for the job, procure the entire raw
material required to complete the job however with required Quality Assurance.
iv. Based on the tentative QAP of the tender, prepare & submit QAP for HWB’s approval.
The QAP shall include quality assurance for raw material / bought out items,
fabrication/welding (including WPS, PQR & Welder Qualification), erection tolerances,
testing procedures, acceptance standards and extent of testing/ inspection required.
Incorporate the comments in the QAP, if any made by the HWB and resubmit for
approval.
v. Wherever necessary, prepare testing procedure and submit for HWB’s approval.
vi. Obtain necessary work permit from EIC as per safety procedures of the plant.

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vii. Supply structural steel and fabricate & erect the structures required for erection of
equipment & piping along with necessary platforms and ladders etc. The platform and
foundation shall be designed considering operating weight, live load, load of various
attachments to the equipment etc.
viii. Fabricate the piping & its supports. Carry out erection and testing of equipments and
piping as per the technical specification of this tender, Codes/Standards indicated in the
tender and good engineering practice. The testing includes system leak test. The
contractor shall make good all leaky joints to achieve desired leak tightness.
ix. The contractor shall carry out prefabrication of the piping system as per the
isometric / layout drawing and as per instructions given by the owner. Modification /
rectifications if required to suit site conditions, shall be done by contractor.
x. Offer stage inspection & finial testing / inspection to the HWB as per approved QAP.
xi. On satisfactory fabrication and erection of the piping, obtain final hydro testing
clearance from the Engineer-in-Charge (EIC).
xii. Prepare “As-Built” / “As-Erected” Drawings and submit to owner.
xiii. On satisfactory completion of work, obtain necessary certificate of completion from the
EIC.
xiv. After completion of work, statement for material accounting, if any, shall be prepared
by the contractor. The statement shall be submitted to the EIC for his review and
approval.
xv. Carry out design and detailing of working platform based on the equipment layout
drawing, submit the design calculation and BOM for the structural steel, plates etc. for
review of purchaser.

3.1.1 PIPING AND FITTINGS

a) Threaded joint may be used for instrument connections. Socket welded joint is used up
1½” NB pipes as per plant piping specification.
b) Dimensions of Butt fittings for Stainless Steel shall conform to ANSI B 16.9.

3.1.2 BENDS, MITERS AND REDUCERS FABRICATED FROM PIPE

a) Bends with a bend radius of 5 times nominal pipe diameter may be used in case of non-
availability of prefabricated elbows on all lines up to and including 1 ½” pipe size.
b) Miters and fabricated elbows / Reducers constructed of pipe are not permitted for
process piping.
c) 450 elbows to be used for ‘HT–GS’ type of lines whenever possible.

3.1.3 FLANGES
a) Flanges shall be in accordance with ANSI B 16.5. However for achieving leak
tightness, special consideration will have to be made with respect design,
manufacturing, installation and testing. To achieve leak tightness, special arrangement
may have to be incorporated at certain places.
b) Minimum Brinell Hardness for ring joint facing shall be as follows. Hardness shall be
measured as near to the groove as practicable without spoiling the flange.
c)
Type 304 or 316 180

Type 304L or 316L 140

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d) Spectacle Blinds, Blinds and Spacers to be as per respective standard.

3.1.4 THREAD SEALANT (WHEREVER UNAVOIDABLE ON UTILITY LINES)

a) Up to 200ºC, threaded joints shall be made with 1” wide PTFE jointing tape.
b) Above 200ºC, threaded joints shall be seal welded with a full strength fillet weld.

3.1.5 VALVES
a) All high points and low points in piping shall be provided with vents and drains to be
used during start up, shut down or test operations. All process vents and drains shall be
as per process and utility piping respectively as called out in piping specification. All
vents & drains in process / steam lines shall be provided with valve and blind flange.
b) Vent at high points and drains at low points shall be shown on the piping isometrics for
line size 2” NB and above. For line size 1 ½” NB and below if isometric is not
available, contractor shall provide the same at field in accordance with the piping
specifications. Vents and drains valves & its hardware/fittings shall be indicated in the
piping material lists.

c) General :
 Valve types are specified in P&IDs.
 The valves should be designed, preferably, to ANSI-B-16.34 & 16.10 and tested as
per API-598. End connections shall be maintained as per HWB’s requirements as
specified against each item.
 Extended stem for valves (if asked for in case of very high temperature lines) shall
be provided.

d) Design and Construction :

 Bonnet flange bolting shall be of the stud-bolt type threaded full length with two
nuts each. Flanged bonnet joints shall be of the enclosed gasket type (male &
female or tongue & groove). Screwed Bonnets shall be of the union type and it
shall be for small bore valves only.
 Valves shall be provided with back seating arrangement to keep valve tight in open
position and to permit packing replacement under operating pressure condition.
Back seat should be suitable for full operating & test pressure.
 Flanged valves shall have flanges integral with the body. Flanges shall be machine-
finished on the joint side and on the back side fully machined or spot faced.
 Hand wheels shall be of spoke design, preferably with not more than six spokes.
 Webbed or disk hand wheels shall not be used.
 Valve parts shall be designed and manufactured with tolerances set to allow
interchangeability between units of the same size, rating and type from any one
manufacturer.
 Globe and check valves shall be suitable for installation in both horizontal and
vertical pipelines.

e) Material:

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I. Material types used for the valve shall be as specified in the individual valve specification
sheets.
II. MARKING: Valves shall be marked on the body with Primary pressure rating in kg/cm2 (g)
or lbs as the case may be. Material identification, Melt identification (Cast number shall
also be indicated). Nominal size in inches (a raised arrow marking on the body to
indicate direction of flow for globe and check valves) and the valve Tag No.

3.1.6 RELIEF & SAFETY VALVES

 Relief valves on process systems shall be connected to a vent or other disposal system
so indicated on the applicable P&I Diagrams.
 Relief valve outlet is connected with vent header and no flare is involved in this plant.
 Relief valves shall have a minimum length of piping between the protected line or
equipment and the valve inlet.
 Relief valves/Safety valve & Rupture disc are to be designed as per standard
engineering code for capacity estimation and construction. MOC for the wetted part
shall be suitable to handle fluids of the respective vessels which are as follows :
 All reactors (RV01/RV02/RV03/) : PCl3 , POCl3 , HCL , KOH , Na2CO3 ,
Alcohols , Tri Ethyl Amine ,
 Feed Vessels ( SS Vessels ) : 43 V01 / V07, V08,V10 : Alcohols, Alkali , DM water
 Feed Vessels ( MSGL vessels ) : 43 V02/43V03/V04/V05/V06/V09/V11 : Alcohols
with traces of HCl
 All Receivers (MSGL vessels ) : Alcohols with traces of HCl
 MOC for wetted part of the relief valves shall be PTFE lined for all the reactors and
vessels handling PCl3, POCl3,HCl, TEA. The rupture discs for the same shall be
Inconel 600 with PTFE lining.
 Design data sheet and process calculation for sizing of safety valves & rupture disc
are to be submitted for review and approval.

3 B. EQUIPMENT AND PIPING LAYOUT REQUIREMENTS

3.2.1 General
a) The equipment and piping layouts shall be prepared in accordance with good
engineering practices and international codes and standards. The layout should provide
for ease of operation and maintenance and adequate platforms and staircases shall be
provided. Suitable provisions shall be made for overhead crane for erection and
maintenance of equipment. Following shall be considered while developing layouts.
b) Spacing shall be such that at least two escapes are available from any part for operating
personnel.
c) Maintenance methods for each item of equipment shall be determined so that equipment
requiring maintenance will be easily accessible.
d) Equipment and structures shall be arranged to permit crane access.
e) All equipment shall have proper approachability and handling facilities for their easy
removal and reinstallation.
f) Suitable slopes to be provided where complete draining of line is required.
g) Isometrics shall preferably made for all process lines.

3.2.2 Flexibility in Layout

Piping must have sufficient flexibility to prevent failure of piping system due to thermal
expansion. All piping shall take care of expansion under start up, operation and shut
down conditions without over stressing the piping, valves and equipment. In the process

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piping adequate flexibility shall be provided by the use of bends, loops etc. Use of
expansion joint shall be avoided (except for vibrating equipment). The Flexibility
Analysis shall be carried out as per ANSI B 31.3 Category M Fluid. For Flexibility
Analysis CAEPIPE software may be used.

3.2.3 Important Consideration For Piping General Arrangement

a) All piping shall be routed for the shortest possible run with minimum number of fittings
consistent with provision for expansion and flexibility. The assembly, removal and
support of piping and equipment shall also be taken into consideration.
b) All lines within battery limits, except drain and sewer lines and other special use lines
shall be run side by side on overhead pipe supports.
c) Bottoms of all lines insulated for heat conservation, which are run on overhead supports
shall generally be supported on steel shoes.
d) Change in line diameter to be incorporated by using Eccentric Reducers in liquid lines.
e) Un-insulated lines shall not be supported on steel shoes, but generally be carried at a
common elevation of bottom of piping or shoes when there is a change in direction.
f) Thermal expansion of all pipe lines shall be contained within the system and within the
battery limit. Expansion from all causes shall be absorbed by piping configuration.
g) Lines containing corrosive fluid shall not be laid near hot lines or other heat sources
unless corrosion rate does not increase with temperature.
h) Lines shall be so erected to avoid pocket formation.

i) Steam Piping System :

 All lines shall be down pitched for full draining.
 All branch connections from steam header shall generally be taken from the top of the
header. Single isolation valves shall be provided in branches adjacent to the headers.
 Steam and condensate lines shall generally not be buried.
 Steam traps and drain valves shall discharge to ditches or other suitable location unless
otherwise indicated on the applicable P&I diagram. Each steam trap station shall consist
of one root isolation valve near main header, trap isolation valve and by-pass valve. All
valves shall be of gate valve to get full opening and no regulation is involved.)

3.2.4 Piping Supports

a) Piping supports shall be generally as per standard support which shall be provided
during execution of the job. All piping shall be adequately supported, guided or
anchored so as to prevent undue vibration, deflection or loads on connected equipment
and piping and leakage at joints.
b) Piping at valves and equipment such as pumps, requiring periodic maintenance, shall
be supported so that valves and equipment can be removed with a minimum necessity
of installing temporary pipe supports.
c) Gas line supports shall be designed for hydro test condition. Friction shall be
considered in calculation of terminal forces.

3.2.5 Drain and Vent

a) All high points and low points in piping shall be provided with vents and drains to be
used during start up, shut down or test operations. All process vents and drains shall be
as per P&IDs vents & drains in process/steam lines shall be provided with valve and
blind flange whereas all utility line vents and drains shall be blind flanged without the
provision of valve. Smaller lines will have line size drains and vents.

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b) Vent at high points and drains at low points shall be shown on the piping isometrics for
line size 2” NB and above. For line size 1½” NB and below if isometric is not
available, contractor shall prepare field sketches in accordance with the specification.
However, considering the requirement of a compact layout, isometrics may preferably
be generated for all sizes upto ½”. Vents and drains details shall be as specified in the
piping material specifications.

3.2.6 Important Considerations For Piping Fabrication

a) Weld Joints
i. Entire welding shall be carried out as per ASME Section IX and fabrication shall be
as per the stipulation of ANSI B31.3 (Category M).
ii. WPS, PQR and Welder Qualification shall be carried out as per ASME Section IX
requirement.
iii. Before welding all piping material shall be thoroughly cleaned of rust, oil, grease
and any other chemical / foreign material which may affect the welding. Edge preparation
shall be as per applicable code / Piping Material Specification.
iv. Root run and subsequent runs of process lines shall be by TIG process with “Argon”
shielding irrespective of the material i.e. Stainless Steel or Carbon Steel. Subsequent
runs for Carbon Steel may be done by SMAW/SAW as per qualified welding
process but for Stainless Steel entire welding shall be by TIG process with “Argon”
shielding.
v. Root and final run of all process piping shall be D.P. examined. All process weld
joints shall be radio-graphed after welding as per piping specification. While
welding SS joints Argon shielding and back-up shall be provided.
vi. Jointing in all piping systems shall be accomplished by butt welding.
vii. Branch connections shall be made with forged tees and weldolets. Section will be
governed by piping material specifications.
viii. The specified weld joint designs shall only be employed joint designs. Other than
those specified may only be employed after obtaining prior written approval of the
consultant.
ix. Cutting of stainless steel shall be carried out by using of Nylon grinders / cutters.
Edge preparation of all pipes and fittings shall be carried out by suitable Edge-
Beveling machines.
x. Coated electrodes and filter wires for welding of various types of piping materials
shall be selected by contractor from the HWB approved list of manufacturers.
xi. All electrodes and filter rods, must be stored in dry condition with original tags and
original cartons.
xii. Electrodes shall be heated before use at approximately 250-300ºC and shall be kept
in drying oven at approximately 40-50ºC.
xiii. Oils, greases and paints shall not be stored where the electrodes and filter metals
have been stored.
xiv. Only a few electrodes shall be taken out from the drying oven at a time for
immediate use.
xv. No welding shall be performed when ambient conditions are likely to upset perfect
weld quality. During period of rainy or stormy weather welding tents shall be used
for shielding the work place. During winter when the ambient temperature is about
5ºC all piping elements which are normally not preheated shall be dried. In case wall
thickness of piping above 6 mm on an area 200-300 mm in width shall be heated to
about 50ºC prior to welding and after every interruption.

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xvi. The welding end dimensions shall be checked to meet the requirements of Code /
Standard. Groove / Edge face shall be free from oil, paint, dust. rust & other
detrimental materials to welding.
xvii. The welding conditions such as voltages, current & speed shall be checked to meet
the requirement of approved WPS.

xviii. Welders Qualifications:

Welder employed by the contractor shall be well experienced and duly qualified,
wherever required possessing valid certificates recognized by a competent authority.
All welders employed shall have to undergo welder’s qualification tests as per
ASME Codes sec IX. Preparation of test pieces, consumables and other materials in
welding and testing should be arranged by the contractor.
Owner may, at its discretion, subject any welder to test, who in its opinion is not
producing finished welds of the required quality. The contractor shall have to
replace any welder found unqualified or incompetent to do the job as per
requirements.
All the welding work undertaken by the Contractor will be subjected to suitable tests
to the satisfaction of owner. Any defect indicated by test reports shall be made good
by the contractor to the satisfaction of Engineer-in-charge. Welding procedure shall
also be qualified as per ASME Code.
b) Screwed Joints
Screwed Joints to be used as indicated in the piping specifications of the plant.

c) Bending and Forming

i. All piping if required shall be bent cold by bending machine, to produce bends free from
wrinkles, bulges and kinks.
ii. Flattening of bends, as measured by difference between the nominal outside diameter
and minimum or maximum diameter at any cross section shall not exceed 5% of
nominal thickness of pipe.
iii. Reduction in wall thickness Reduction of wall thickness of a bend, as measured by
difference between nominal thickness and minimum thickness shall not exceed 12½ %
of nominal thickness of pipes.

3.2.7 Pump Piping Installation

a) Suction lines to pumps shall be designed for supports to avoid trips and pockets.
Horizontal suction lines from towers shall be designed to avoid pockets resulting from
thermal expansion of vertical lines.
b) Suction and discharge lines of pump shall be drained through drains located at the low
point of the pump casing whenever possible.
c) Pump suction piping shall be so arranged that flow is non turbulent as practicable at
pump suction nozzle. To accomplish this use of tees, branch connections short radius
elbows etc. shall be avoided very close to suction nozzle.
d) Suction pipe shall not contain pockets where there is a chance of gas accumulation.
Eccentric reducer with belly down shall be used at pump suction to avoid pocket
formation.
e) Reducer, if any, on the Discharge Line should preferably be Concentric Reducer type.
f) Check Valves shall be located in the vertical line whenever practical and shall be
towards the pump.

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3.2.8 Non-Metallic Piping

Following codes shall be followed for HDPE & PP-FRVE Piping
SN DVS Code No. Description

Welding of Thermoplastics – Heated Tool

1. DVS 2207-1 Welding of Pipes, Pipelines, Components, Sheets
made from PE-HD

Testing of welded joints of thermoplastic materials

2. DVS 2203 -2
– Tensile Test

Testing of welded joints of thermoplastic tubes and

3. DVS 2203-4
plates – Tensile Creep Test

Industrial Pipelines Made of Thermoplastics –

4. DVS 2210-1 Planning & Execution, Above ground Pipe
Systems.

Industrial Pipelines Made of Thermoplastics –

Design & Execution, Above ground Pipe Systems
5. DVS 2210-1 (Supplement 2)
– Recommendations for the Internal Pressure &
Leak Test

Imperfections in Thermoplastic Welding Joints-

6. DVS 2202-1
features, descriptions & evaluations

Plastic Welding Personnel - Qualification Testing

7. DIN EN-13067 2003
of Welders

Design & Construction of Glass Reinforced

8. BS 7159 : 1989 Plastics (GRP) Piping Systems for individual
plants or sites.

Reinforced-Plastics-Pipes-Fittings-and-Joints-for-
9. BS 6464: 1984
Process-Plants

a) HDPE Pipes as per IS 4984 – 1995 & material grade PE – 100, PN-16 to with stand a
pressure of 16 kg/cm2(g) shall be supplied.
b) HDPE pipe and pipe fittings shall be of M/s. Reliance/ M/s Nocil / M/s. Masti brands as
per following data sheet and technical specifications.
c) HDPE flanges shall confirm to the dimension of #150 ANSI B 16.5 and provide with
10mm thick metallic back up flange from IS 2062 MS plate.
d) Miter bend and stubbed TEES are not permitted.
e) PP Ball Valves shall be of reputed brand only.
f) HDPE welding shall be done by the Hot Plate Butt Welding and by hot gas filler
technique for fillet joints. In that case inert gas to be used which is free from moisture.

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g) Electrodes to be used shall meet the minimum requirements of applicable code. HWB
shall approve the vendors for the procurement of electrodes for which a list of
manufacturer of electrodes shall be submitted. Approved Test procedures by HWB
shall be carried out by you.
h) Welders engaged in the HDPE fabrication shall carry out specified approval test before
commencement of fabrication.
i) The flange shall be square to the axis of the branch to within 1º up to 100 mm diameters
and to within 0.5º above 100 mm diameter.
j) The stub ends and full face flanged pipe connection and bolting shall be designed to
connect Class 150 of ANSI 16.5.
k) Consistency in both material and fabrication shall be ensured and appropriate
supervision shall be provided all stages of manufacturing.
l) All surfaces shall be smooth, continuous and irregularities which may cause high local
loads shall be repaired.
m) After completion of all fabrication pipes shall be cleaned inside to be free of all traces of
release agents, fibers, dust and other foreign matters.
n) Copy of Material test certificate for HDPE shall be submitted along with the materials.
o) HWB reserves the right to check the HDPE material by FTIR and Thermogravimetric
Analysis. HDPE used for pipes and fittings shall be pure and there shall be no addition
of fillers etc.

3.2.9 Spares to be Supplied

PIPING MATERIAL

NB 300 &
NB<40 NB 50 TO 100 NB 100 TO 250
OVER

Min Max Min Max Min Max Min Max

% % % %
Nos Nos Nos Nos Nos Nos Nos Nos

Pipes 20 15 10 5

Fittings 20 100 500 15 50 200 10 50 100 5 25 50

Flanges 15 20 200 15 39 100 10 10 20 5 850 10

Bolting 20 40 400 25 25 200 15 40 200 25 10 200

Gaskets 25 25 100 25 10 100 20 10 100 50 1 100

Valves 20 10 20 15 5 10 10 2 5 10 1 3

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SPARES FOR VALVE

NB<40 NB 50 TO 250 NB 300 & OVER

Min Max Min Max Min Max

%
Nos Nos Nos Nos Nos Nos

Stem 20 5 50 2 25 1 10

Plug/ gate 20 5 50 2 25 1 10

Gland follower 10 5 20 2 10 1 5

Packing 50 20 100 10 50 5 20

Stem Nut 20 5 50 5 20 2 5

Bonnet Gasket 25 10 50 5 25 5 15

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3 C. SITE ERECTION & TESTING OF EQUIPMENT & PIPING

3.3.1 Erection of Static Equipments (Vessels, Tanks, Columns)

a) Scope of Work For Equipment Erection

i. The scope of work shall include but not be limited to the following (All necessary
arrangements including men, materials, lifting tools and tackles, trailers (if any) and
consumable etc. shall be supplied by contractor at his cost, except where otherwise
specified).
ii. Withdrawal of equipment/associated piping and structure and any other material to be
supplied by owner from Owner’s / Consultant’s stores/storage yard within factory site,
visual checking and reporting of the condition of the equipment, transportation of the
same to contractor’s storage or to work site and vice versa including handling,
unloading, loading, unpacking etc. required till erection is completed and accepted by
owner.
iii. Erection including placement on foundations and / or structures, drilling of holes in
structure, aligning, leveling, floor finishing, grouting, finishing, fitting, assembling etc.
of all equipment like vessel, tanks columns, heat exchangers, condensers etc. and
erection of prefabricated piping, supplied as part of equipment, All grout materials of
various categories, if any, are included in Contractor’s Scope of Supply. Drilling of
holes on structures for equipment bolting shall be the responsibility of the Contractor.
iv. Fabrication and /or erection, alignment, leveling, grouting of structures viz. platforms,
ladders, railing, walkways, staircase, grating etc.
v. Erection of prefabricated piping received along with the equipment.
vi. Cutting of transportation cleats provided on inside / outside of the equipment and grind
off irregularities.
vii. Purging of equipment / machinery by nitrogen gas. Preservation after erection, as per
directions of owner. Nitrogen gas as required shall only be supplied by owner free of
cost.

b) Technical Specifications
i. The complete job shall be executed in accordance with latest relevant drawings.
ii. Co-ordinates of foundations / supporting structures/pockets etc. shall be checked with
respect to general layout drawings.
iii. Orientation of all foundations, elevations, depth and orientation of anchor bolt holes for
supports / saddle foundations etc. shall be checked by the contractor well in advance and
minor rectification as may be necessary shall be carried out free of cost by him after
obtaining approval of the owner. Before equipment is placed on foundations, orientation
shall be checked with respect to drawings.
iv. After erection, the equipment shall be leveled and aligned with packing materials,
shims etc. which shall be supplied by the contractor. Vessels shall be plumbed to the
tolerances indicated in the drawings/standards and as per the instructions of owner. The
equipment shall be set level and square so that pipe connections can be made without
strain. If required provision for free expansion of vessels shall be kept as per drawings
and specifications. After approval from the owner, the contractor shall carry out
grouting and final finishing of the foundation base. The anchor bolt for the sliding
saddle shall be kept in the middle of slotted hole. The nuts for the sliding saddle are
loosened approx. 3 mm and the counter nuts are blocked.

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v. Wherever grouting is required, grouting of anchor bolt pockets and under base plates of
equipment will be carried out. All grouting shall be properly cured so as to achieve full
strength and grouting shall be done only after Owner’s written clearance. Max. grouting
flange faces of nozzle shall be checked for level with precision level.
c) Inspection & Acceptance Limits for Level & Alignment
i. Verticality of the columns shall be checked with theodolite. Elevation of equipment
shall be checked by means of `U’ tube at Four Corners with respect to standard
benchmark. The machined flange faces of nozzle shall be checked for level with
precision level.
ii. Permissible limits for level and alignment shall be in accordance with the values
given in standards / sketches. Levels shall also be checked with respect to standard
benchmark.
iii. Specification for Fabrication / Erection of structures i.e. Ladder & Platforms, Stairs,
Handrails, Gratings, Davits & Columns / Trusses etc.
iv. Fabrication of above items shall be in accordance with IS:800 and standard
fabrication practices approved by the owner.
v. Fabrication shall be done in accordance with fabrication drawings approved by
owner. The connections shall be welded or bolted as per design drawings.
vi. Welding shall be carried out by trained and experienced welders duly approved by
the owners.
vii. Erection of structures shall be done in accordance with IS:800 and relevant drawings
with approval of owner.
viii. The erection work shall be permitted only after the foundations or other structure
over which the steel work will be erected, is accepted and is ready for erection.
ix. The contractor shall satisfy himself about the levels, alignment etc. for foundations
in advance before taking up erection. Defects / Discrepancies if any shall be pointed
out to the owner in time. However minor rectification shall be carried out by the
contractor at his cost.
x. Grouting of foundation bolt’s pockets and below base plates shall be done.
xi. Maximum tolerance for line and level of steel work shall be + 3mm on any part of
the structure. The structure shall not be of plumb more than 3.5 mm on each 10-
meter section of height and not more than 7 mm per 30M Section height. Verticality
of columns shall be checked with theodolite and the verticality shall be achieved
within 1 mm/meter or better on cumulative basis.
NOTE: The above mentioned tolerances apply to all parts of the structure unless the drawings
issued indicate otherwise.

3.3.2 Scope of Work and Technical Specifications for Erection of Piping System
(Above Ground)
a) Sorting of pipes and piping materials from owner’s stores. Return of left over pieces,
left over fittings and valves and other materials etc. to stores with proper return
vouchers.
b) Transportation of pipes and piping materials such as pipes, fittings, valves and all other
materials required in the fabrication, erection, testing and pre-commissioning, from
owner’s stores/storage yard within factory site to work site and /or contractor’s stores
required till erection is completed and accepted by owner.
c) Pre-fabrication piping system including all type of fittings viz. flanges, elbows,
reducers, tees, reinforcement ring/pads., caps, couplings etc. as per drawings and
reference standards.
d) Pre and post heating where specified/required as per code, as per reference standards,
drawings and technical specifications.
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e) Hydro / Pneumatic testing in the presence of owner for each loop after installation.
During testing of pipes some direct in line instruments, control valves, safety valves,
orifice plates etc. may be required to be removed and reinstalled after testing and
flushing. Spool pieces to facilitate hydro-test shall also have to be provided. Spool
pieces shall be fabricated from off-cuts and waste pieces available. All pressure gauges
for hydro-test shall also be arranged by contractor after due calibration and certification
by owner. All test loops shall be prepared in consultation with owner. Wherever drain /
vent valves are to be installed to facilitate hydro-test (not shown in the drawings) same
shall be done by the contractor free of charge. Any flange joint on valves or equipment
found leaking during the test shall be rectified and the complete system shall be re-
tested till all leakage in such system are arrested to the satisfaction of the owner.
f) Installation of isolation valves, regulating valves, control valves, vent valves, drain
valves, sample valves, line filters and strainers etc. wherever required as per drawing /
instruction of owner.
g) Cleaning of the piping after assembly by air shall be done. During the course of such
cleaning all the control valves, safety valves, orifice plates, flow nozzles and other in-
line instruments installed shall be removed except for such items which are directly
welded with the pipe lines and reinstalled after cleaning. Cleaning of pipes as required
above shall be done after hydraulic testing / pneumatic testing. During cleaning,
temporary connections and spool pieces / test pieces, shall be provided by contractor.
h) Preparation of connection details, fabrication and erection of piping supports as per bill
of quantities in accordance with drawing sketches, with materials including bolts, nuts.
Washers, supplied by owner as free issue. For small bore pipes below 2” requirement
i.e. location and type of pipe supports shall be decided by the contractors in
consultation with Owner.
i) Erection, including grouting if any of all type of pre-fabricated pipe supports including
spring supports. All grouting materials as required shall be arranged by the contractor.
Contractor shall have to provide without any extra cost temporary supports in place of
permanent supports. All spring supports shall be adjusted after hydro-test to the
required setting after removal of present pin.
j) Chipping of piping supports foundation up to required level wherever required to the
extent of 50 mm only.
k) Cutting/chipping of floor and making of holes/cut-outs in the walls to facilitate pipe-
laying shall be done by the contractor. Chipping the wall to expose reinforcement and
welding inert plates is also to be done, when required.
l) Forming of tapping points for instruments and samples lines inclusive of installation of
first isolation valves on all piping networks.
m) Stub in connections i.e. making of all unequal branches from the main headers in
accordance with reference standards.
n) Pipe end machining for preparation of weld and also pipe end machining and lapping
the same to form lens gaskets facing, lapping of flanges supplied by owner.
o) All machined seats metallic rings/lens gaskets shall be properly lapped on mating
surfaces with the corresponding gaskets, if required.
p) Pickling and passivation of outer surface including inner surfaces, wherever accessible,
of welded-joints on SS pipes in accordance for such work shall be carried out by
contractor at his own cost.
q) Edge preparation of pipes with dissimilar thickness for proper I.D. matching.
r) Cutting of gaskets from Asbestos sheets, PTFE.
s) Deviations in piping to suit equipment position and marking of offsets if required.
t) During erection of piping, the contractor shall install proper size of bolts and nuts as per
drawings and specifications. The contractor shall provide approved quality grease
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mixed with graphite powder thoroughly on all the bolts, nuts and washers during
storage in his stores and immediately after erection and when the flanges are opened for
purpose like hydro-test, flushing and seal test, alignment with equipment etc. to prevent
rusting. The grease and graphite powder shall be supplied by contractor for piping
work.
w) Submission of drawings and documents.
x) Valve installation, including handling, rigging, lifting placing in position, final
alignment, bolting p to companion flanges or making of weld joint/screw joint after and
preparation etc. valves include all type of valves, line filters, and strainers of any
rating and construction.
y) The pipes and fittings tack welded shall be offered for inspection to check proper gap,
beveling and other surface defects.

3.3.3 Testing & Inspection at Site

a) The entire work covered by this contract shall be subject to stage inspection as well as
final inspection /certification by owner.
b) The contractor shall arrange and provide to the owner all necessary facilities, i.e.
inspection tools as recommended in equipment manufacturer’s manual, scaffolding and
temporary lighting etc. required for carrying out the inspection.
c) Welder’s qualification and weld procedure qualification tests shall be carried out in
accordance with provisions of ASME code section IX (latest edition) in the presence of
owner.
d) Arrangement of required tools and tackles, machinery like master level, theodolite,
dumpy level, torque wrench, electric welding sets and diesel generator welding sets,
Gas cutting sets, Extension Boards with sufficient length of electric cables, diesel and
electrically operated dewatering pumps, Hydro-testing pumps, air compressors,
winches, wooden sleepers, crane and other lifting tackles, tractors and trailers,
consumables like welding electrodes, industrial gases, etc. No tools / tackles / derricks /
cranes, whatsoever will be provided by owner unless specifically provided for in the
tender.
e) Supply of all supervisory staff, skilled and unskilled labor force as required for timely
completion of the entire job.
f) Arrangement for distribution of electricity and water from supply point to work spots.
g) Arrangements of necessary metallic blinds, gaskets on nozzles/piping and necessary
temporary connections, including Hydraulic test pump, Pressure Gauges etc. for
carrying out hydraulic testing.
h) Maintaining records of all the works and inspection reports as per the advice of owner.
i) Co-ordination with other contractor’s works as required by owner.
j) Security arrangement for contractor’s office and stores to ensure safety of all equipment.
k) Cleaning of site after completion of work.
l) Return of owner’s surplus and leftover materials to owner’s stores.
m) Arrangement of necessary flood lights and other facilities.
n) Arrangement of necessary shims of stainless steel required for leveling/ aligning of
rotating / reciprocating equipment on foundations.
o) Testing shall mean hydraulic / pneumatic / system leak/vacuum holding testing of the
pipes and seal testing of the piping system which shall be done as per standard.
p) Water for hydro testing and oil free air if required for pneumatic testing shall be
supplied by owner.
q) Cleaning/blowing/flushing of the erected piping system shall be carried out as per
approved procedure.

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r) Rectification of any work or re-testing, after such rectification shall also be carried out
the satisfaction of owner. Test pressure for different piping network shall be as
specified, if the erected piping or any portion there of before or after trial runs is found
defective or inferior in quality or workmanship, the contractor shall be responsible to
make the defects good. All blanks, nuts and bolts, hydro test pumps, pressure gauges
for hydro/pneumatic test shall be arranged by contractor, blanking arrangement shall
also be removed by the contractor after hydro/pneumatic testing is completed. Such
open ends of pipes will be plugged with suitable wooden plugs, which will be left in
position till the ends are hooked up with equipment required for the trial runs to attend
piping leakages. The Contractor shall have to stay during start up and commissioning of
plant and take up maintenance jobs on the piping erected by him. The contractor shall at
all time during commissioning make available the maintenance staff as required by
owner.

s) Following tests & inspection shall be performed :

SN Timing Inspection & Items

1 Before starting the job Material Electrodes, Material TC

2 Before welding operation WPS/PQR, Welders performance test,

Grooves/Welding end preparations. Shape &
dimensions of pipe ends. Alignment of pipe
ends. Fit-up. Cleanliness of the joint. Cold pull.

3 During welding Preheating. Welding condition. Confirmation of

welder’s performance.

4 After completion of Welding Post-weld heat treatment, if any. Visual

operation examination.

Non-destructive inspection : Magnetic

Particle/Liquid Penetrate test Radiography
Hydrostatic & Pneumatic pressure tests Leak
Test

3.3.4 Radiographic Examination of Welds:

i. The radiography procedure shall be approved by Engineer-in-charge. The
procedure and quality of Radiographic examination, limit of capability, repair and
removed of defects shall be as per ASME Sec V & ANSI B 31.3.
ii. Radiographic inspection of welds shall preferably be made with Gamma rays.
Iridium 192 / Cobalt 60 isotopes may be used with the approval of the owner. For
double will thickness more than 65 mm Co-60 Gamma rays to be used.

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iii. Wherever less than 100% radiography is stipulated, the joints as well as location of
welds for radiography shall be selected by Engineer-in-Charge at his sole
discretion and shall be performed in his presence, if desired and contractor shall
submit the radiographs along with their interpretation immediately to Engineer-in-
Charge who shall evaluate the same and communicate the results to contractor for
needful.
iv. All tools & tackles, films etc. dark room with the required facilities, scaffolding,
approaches, personnel etc. shall be arranged by contractor.
v. The contractor shall be required to fulfill all the statutory safety requirements in
handling the X-ray and/or Gamma-ray equipment.
vi. The full radiography shall be performed for weld to the extent shown.
vii. Number of welds to be radiographed shall not be less than one as minimum
irrespective of percentage shown.
viii. The radiography and acceptance criteria shall be as per ANSI B31.3 standard.
ix. Full care & precautions shall be taken for management of radiation by establishing
hazardous area depending on results of measurement of scattered radiation. Use of
source of radiation shall be subject of agreement with HWB.
x. Liquid penetrates examination after completion of the root run shall be done as per
ANSI B31.3. Liquid Penetrant Examination is sufficient.
xi. Number of radiographs per one circumferential weld shall be as follows :

Nominal Pipe
Film Length (mm) No. of Radiographs (no. of film)
Size (mm)
Up to 75 150 2
100 - 150 300 3

3.3.5 Weld Repair & Extent of Examination on Repaired Weld:

i. In case of 100% inspection, all unacceptable weld shall be repaired and re-inspected.
ii. In case where less than 100% examination reveals unacceptable defects in weld or
welds, two additional welds per defective weld shall be inspected for any group made
by same welding procedure or welder or both. If the test of these welds, reveal no
unacceptable defects, the defects in the first weld or welds shall be repaired and re-
tested.
iii. The welds rejected by radiography and other non-destructive inspection shall be
repaired and re-inspected in accordance with this specification. More than 2 weld repair
shall not be permitted.

3.3.6 Visual Examination:

i. All finished welds shall be visually examined 100% to check for profile, smoothness,
root penetration etc. in accordance with the following requirement.
ii. Internal misalignment: (a) Maximum permissible offset due to misalignment shall
be 0.5 mm or less for wall thickness up to 20 mm & 1 mm for wall thickness above
20 mm.
iii. External misalignment: 3.0 mm or less
iv. Internal weld protrusion:
Nominal pipe size (mm) Maximum Maximum Restriction in
Penetration in bore
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(mm) bore (mm)

15 1.6 1.6

15 - 50 3.2 3.2

Above 50 3.2 4.8

1 Weld ripples irregularly 2.5 mm or less

2 Lack of uniformity in bead width 2.5 mm or less

3 Lack of uniformity in leg length 2.5 mm or less

4 Unevenness of bead 2.0 mm or less

5 Maximum Weld undercutting Weld undercutting shall be limited

to 20% of pipe thickness or 0.8 mm

6 Over lap 1.5 mm or less

7 Bead Deflection 2.5 mm or less

v. Thickness of weld reinforcement:

Component wall thickness mm) Reinforcement thickness (mm)

Up to 12 1.6

Over 12 to 25 2.4

Over 25 to 50 3.2

Over 50 4.0

vi. Throat thickness of fillet welds: Nominal thickness of thinner component x 0.7 or
more.
Weld having any imperfection which exceeds the items specified above shall be
repaired by welding, grinding or overlaying etc. The maximum numbers of times of
such repairs shall be restricted to 1.

vii. Workmanship:
Unless otherwise specifically mentioned, dimensional tolerance for various piping
assembled in a shop or in the field shall be as specified below:

1 Length + 30 mm

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2 Inclination of flange face, the angle + 0.50 but not exceeding 1.0 mm at
between pipe axis & flange face flange end

3 Perpendicularly 2/1000

4 Horizontality 2/1000

5 Misalignment between pipe centre 1.6 mm

and flange centre

6 Rotation of flanges + 1.5 mm

7 Flattening of pipe 1% of less of calculated inside

diameter of pipe at cross section but
its length shall not exceed ½ of
outside diameter.

8 Depression depth of pipe 6.0 mm

9 Tolerance for connecting with Tolerance of piping which connects

machinery with machines such as pumps etc.
shall be in accordance with
requirements for each machine.

3.3.7 CLEANING REQUIREMENT & PROCEDURE

Cleaning requirement for inspection of piping system during construction:
General Requirement:
i. Plastics caps, covering ends of piping components shall not be removed during
fabrication and installation. In case the end covers of the pipe, valves, fittings is found to
be missing during erection, the inside of the piping component shall be thoroughly
examined and cleaned by blowing with compressed air or flushed with water before
installation.
ii. Inside and outside surface of fabricated piping at site shall be cleaned to remove slag,
dirt, scale and other foreign matter. Cleaning of pipe lines shall be done by grinding,
wire brushing, sand blasting etc. and then pipes shall be air blown. The ends of the
piping shall be covered with plastic caps till the erection.
iii. Safety rules and precautions shall be observed during cleaning / blowing operation of
pipes.
a) Procedure of Cleaning :
i. The cleaning procedure shall be as follows :
Instrument Air, Process Air, Gas & Fluid lines for ND Air Blowing
50 & below

Instrument Air, Process Air, Gas and fluid lines above Card Board Bursting
ND 50

Cooling Water, Wash Water and Flushing Water Water Flushing

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Lines

Steam and Boiler Feed Water Steam Blowing

Gas Piping Inter Stage and within Battery Limits Preferably pickling/ blowing with
air or steam

b) Preliminary Steps:
i. The following shall be ensured before cleaning operation:
1. Completion of erection of piping including pipe supports.
2. Completion of hydraulic testing.
3. Completion of insulation of lines which are to be steam blown.
4. Process instruments connected to the piping shall be blanked or removed. Control
valves on the line shall be removed, control valves with butt-welding ends shall
be installed after cleaning operation.
5. Connected equipment shall be isolated by means of suitable blind.
6. Necessary piping for cleaning operation is completed.
7. Necessary instruments like pressure gauges, temperature indicators etc. shall be
installed at suitable location.

c) Water Cleaning:
i. Service water, Steam condensate, process water etc. shall be used. Sea water shall not be
used for cleaning, if use of sea water is unavoidable, piping shall be washed with water
at least twice to prevent corrosion. In no case, chloride content of water shall exceed 5
ppm for austenitic stainless steel.
ii. All cooling water lines shall be flushed with water after installation during cooling
water pumps commissioning. The process of water flushing shall continue till the clean
water starts coming from the open end.
iii. After cleaning operation is over, pipes shall be dried by blowing compressed air or for
natural drying.

d) Air Cleaning:
i. Air cleaning shall be performed by blowing pressurized air.
ii. Pipe line below ND 50 shall be simply blown with compressed air. The pipelines above
ND 50 and up to ND 800 shall be blown with air by card board bursting or by sudden
opening of a globe valve of ND 50 provided at the outlet.

f) Card Board Bursting:

i. This effective method of pipe cleaning uses high velocity of over 30 meter/second
created due to bursting of card board and consequent release of built up pressure inside
the pipe line. The escaping high velocity air will carry along dirt, loose welding slag,
small pieces of electrodes, rust particles etc.
ii. After removing valves, control valves etc. inside of pipe is checked for any material left
inside the pipe by mistake like nut, bolt, fabrication tools and tackles.
iii. One end of pipe is bolted with ordinary flange with 4 to 5 layers of card board cut out
blind gaskets with bolt holes. Thickness and number of card board layers shall be so
chosen that bursting takes place at about 5 to 6 kg/cm2 pressure. Other end is closed

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with a blind flange having one nozzle for air inlet from compressor and other for
pressure gauge mounting.
iv. Gradually air pressure is increase till card board bursts and loose materials are carried
along with high velocity escaping in air. This procedure is to be repeated 3 or 4 more
times till no more dirt or loose matter comes out. Light hammering of the weld joins and
along the entire pipe length hastens the removal of scales.

e) Steam Blowing:
i. The quantity of steam required for effective steam blowing should be calculated. It shall
be ensured that blowing pressure and temperature do not exceed the design pressure and
temperature. The blowing pressure shall normally be 50% of the operating pressure.

ii. The blowing operation shall consist of three steps.

a. Heating
b. Blowing
c. Cooling

1. Heating:
Initial heating of pipe line shall be done at 30˚ C/hr up to working temperature. During
heating up flange connections, pipe hangers, movable and fixed supports shall be checked.
Further heating rate for blowing after intermittent cooling shall be 4˚ c/minute for alloy steel
lines.
2. Blowing:
Increase the pressure in the Boiler to the normal working pressure and temperature. The
temperature of the pipe line at the blowing end should be equal to the normal temperature of
the steam in the line. The blowing shall be started by opening the outlet isolation valves till
50% of the normal working pressure is attained. This slow heating can be achieved by the
either controlled firing of the boiler or by throttling the bypass valve of main steam line.
The rate of pressure reduction in the boiler shall not be more than 1 kg/cm2/minute. The
steam flow shall be measured from the consumption of boiler feed water if the steam flow
meter is not lined (orifice plate is removed). Blowing shall be continued for 20-30 minutes
and then stopped by closing the isolation valve. The test plate with aluminum foil shall be
put at the steam outlet during blowing and after each cycle of blowing shall be examined for
indents.
3. Cooling:
Pipe line shall be allowed to cool to a temperature of 150˚ C and then the second blowing
cycle shall be started. The process of blowing shall be continued till the test plate is found
without any indent or impression on it. Light scratch mark with maximum depth of 0.2 mm
is acceptable.
The temporary blow off line shall be properly supported and shall be designed for the steam
blowing pressure and temperature.
The test plate shall be thin copper/aluminum plate backed by support in a frame and could
be mounted on the blow off at a distance of 200 mm from the open.
On completion of each blowing operation the drain valve at the bottom most point in the
circuit shall be operated to drain of condensates and then closed before starting the next
blowing off operation.

3.3.8 INSPECTION DURING PRESSURE TESTING OF PIPING

a) Scope :

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All installed piping, prior to initial operation shall be pressure tested in accordance with
the requirements of this specification. However, piping built in conformance with the
ASME code or Indian Boiler Regulation etc. shall be pressure tested in compliance of
such code or regulations.
Piping systems open to atmosphere, such as drains, vents, outlet piping for relief valve
discharging to atmosphere and underground sewers shall not require any pressure
testing. These lines hall be examined to determine that all joints are properly made up.
b) Test Methods:
The following test methods are included in this specification:
i. Hydrostatic Testing
ii. Pneumatic Testing

c) Test preparation and necessary precautions:

i. All joints, including welds shall be left un-insulated and exposed for examination
during the test.
ii. Major equipment, such as pumps, vessels etc. shall be isolated from pipeline during
hydrostatic test. When necessary for practicability, vessels may be included with the
connected piping provided the piping test pressure is within the allowable cold
pressure limits of the equipment.
iii. Air present in the system, to be tested, shall be vented while admitting the test fluid.
iv. Piping designed for vapour and gas shall be provided with additional temporary
supports, if tested hydraulically.
v. Instruments, expansion joints, filters etc. for which the maximum permissible cold
test pressures are lower than the specified hydrostatic test pressure shall be isolated
as excluded from the test.
vi. Lines containing check valves shall give source of test pressure on the up-stream
side. Valves shall not be subjected to a test pressure in excess of manufacturers
allowable test rating. When permitted, the installed valves shall be kept open. Relief
valves shall be excluded of the test and shall be suitably blanked off. Control valves
shall not be field tested.
vii. All flanged control valves shall be removed before hydraulic test, cleaning and
blowing.
viii. Instrument take-of piping up to the first block valve shall be tested with piping to
which it is connected. Testing of remaining of lead line up to instrument can also be
done at the same time provided instruments are blocked off from source of pressure
and vented to atmosphere.
ix. Indicating pressure gauge mounted locally may be tested with the lines, provided the
test pressure is not in excess of their scale ratings.
x. The test shall be carried at ambient temperature and the water temperature shall be
limited between 5º C and 38ºC.
xi. Flanged joints at which blinds are inserted to blank off other equipment during the
test need not be tested.
xii. All vent valves during filling up as well as during draining must be fully open and it
should be ensured that these overflow at the time of their closure.

d) Test Fluid:
Test fluid shall normally be water.
Hydraulic testing of austenitic material shall preferably be carried out using normal
water.

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e) Period between the start of testing and drying:

The period between the start of testing and drying a component shall not be longer than
48 hours in case of inhibited water and 4 hours in case of uninhibited water. Where
difficulty may be experienced in draining and therefore in achieving the drying specified
above, drying shall be accomplished in as short time as is practicable.
f) Test Pressure :
i. The test pressure shall be as per the relevant design code.
ii. The maximum working pressure is the pressure representing the most severe condition
of coincident pressure and temperature expected in normal operation considering fluid
head, set pressure of safety valves in the line and pump shut off head.
iii. Tested and properly calibrated pressure gauge shall be used and appropriate corrections
shall be made during the test for any static heads in any component of the piping under
test. The range of the pressure gauge shall not be more than 1.7 times the test pressure
and the error of the pressure gauge shall not be more than 1% of the range.
iv. If the pipelines are to be tested along with the equipment the test pressure shall not
exceed the equipment test pressure. However, it shall be checked that stress due to
testing does not exceed 90% of yield stress.

g) Lines at atmospheric pressure:

i. All gas lines at atmospheric pressure or < 1 kg/cm2(g) shall be tested pneumatically at
0.5 kg/cm2(g) in accordance with ASME Sec-5.
ii. All liquid lines at atmospheric pressure or 1 kg/cm2(g) shall be tested hydrostatically at
1.3 kg/cm2(g).

h) Pneumatic Testing :
Piping may be tested pneumatically if these cannot be safety filed with water, or where
traces of water cannot be tolerated or if these have been preciously tested hydrostatically.
i. Pneumatic test pressure and procedure:

The test pressure for piping shall be 110% of maximum working pressure. Any pneumatic
test shall include a preliminary check at not more than 2 kg/cm2 (g) for detection of any
major leaks. The pressure subsequently shall be increased gradually in steps to the
specified test pressure, providing sufficient time to allow the piping to equalize the strains
during the test and to check for leakage. After reaching maximum test pressure, pressure
shall be reduced to design pressure and kept for sufficient time to inspect the piping.
Hammering is strictly prohibited in case of Pneumatic tests.
i) Retest :
Any leaks shall be repaired and the system retested to the extent required by the
provisions of this standard.
j) Duration of Test :
Test pressure shall be maintained for half an hour or the time taken for inspection
whichever is more.

l) Test Records:
Records shall be made of each piping installation during the testing. These records
shall include:
i. Date of test
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ii. Identification of the piping tested

iii. Test Method
iv. Test Pressure and duration
v. Approval by the Inspector
3.3.9 SYSTEM LEAK TEST - INSPECTION SPECIFICATION
a) Scope :
The system leak test is necessary to be conducted on some critical systems (as identified in
the tender document) for the purpose of this test is to ensure that all points and sealing
surfaces are in perfect operating condition and if system is charged with operating gas there
will be no leakage to outside or inside as the case may be. This test shall be done with air
at operating pressure. Pressure drop over a period of 24 hours shall not exceed the amount
specified. In the absence of specified leakage rate, 3% pressure drop shall be allowed for
operating pressures in this case.

b) Procedure :
i. For the sake of early detection of gross defect or leaky paths, like left out weld joint,
gasket or un-blanked tapping and consequent saving in time and labour, test is done
two or more stages.
ii. In first stage whole system is pressurized to 5 kg/cm2 (g) or operating pressure
(whichever is lower) and checked for leak tightness. Defects if any rectified and
system is again pressurized to 5 kg/cm2 (g) or operating pressure shall be gradually
raised to the operating pressure and pressure retained for 24 hours. Pressure drop shall
be noted and checked against the permissible pressure. Exceed pressure drop indicates
leakages taking place from the system. Various sealing surfaces, valve glands and
isolating valves, including those of drains and vent lines shall be checked for leakages.
After rectification of the leaky-joints, system shall be again pressurized and checked.
iii. Ensure use of more than two calibrated pressure gauges for monitoring pressures as
well as to arrive at the extent of leakages. Start & finish pressures, at the end of
pressure test, shall be considered at same time of the day or night to avoid
environment’s temperature differences.

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M-IV A. TECHNICAL SPECIFICATION FOR CENTRIFUGAL PUMPS

4.1 GENERAL REQUIREMENTS

a) Pump and Driving Motor set along with accessories shall be supplied as per this
technical specification / Data Sheet given elsewhere in the tender specification.
b) This specification together with the pump and motor data sheets and attachments defines
the minimum requirements for Horizontal Centrifugal Pump, Driver (electric motor),
accessories and spares.
c) ASME B 73.1 / ISO 5199 may be used as the Design & Construction Code for the
Pumps.
d) No deviations or exceptions from this specification shall be permitted without written
approval of employer. Intended deviations shall be separately listed with supporting
reasons, for consideration by the Employer.
e) Motor shall be sized at 125% of rated input power or at the end of the curve whichever
is higher.
f) Compliance with this specification shall not relieve the contractor of the responsibility
of furnishing equipment and accessories of proper design, materials and workmanship to
meet the specified operating conditions.
g) Static Seal Element of the shaft for Centrifugal Pump shall be of Teflon.
h) Pump shall have stable performance characteristics requiring that at the rated speed over
the whole flow range it shall have a continuously rising curve i.e. the developed head
shall continuously increase with decreasing flow up to shut off head. There shall be no
inflection point at any partial load in the Head-Capacity curve.
i) Pump-Motor assembly shall be capable of starting with full valve open condition.
j) Impeller diameter corresponding to the operating condition shall not exceed 97.5% of
the maximum possible diameter of the impeller at speed specified on the bidder’s
performance curve for the type of pump offered. Impellers with minimum impeller
diameter for the casing model shall not be used.
k) First critical speed of rotating assembly shall be at least 30% higher than the operating
speed.
l) Pumping unit and auxiliary equipment shall be designed and constructed for safe
operation at full load duty and continuous service. The pumps shall be of robust
construction, suitable for long periods of maintenance-free service. Units shall be of a
design proven in similar service with excellent track record.
m) All electrical and mechanical equipment shall be designed and manufactured so that no
damage results from inland transportation and during storage, installation and operation
of equipment under the climatic conditions to which it will be subjected.
n) Manufacturing Experience and Past Performance Requirements: Pumps shall be
procured from the reputed manufacturer.
o) Pump and Motor assembly shall be designed to permit ease of access during inspection,
maintenance and repair.
p) Clamps, lifting lugs and eyebolts of adequate capacity shall be provided to ensure safe
and easy handling of the pumps and motors.
q) Unit shall be provided with proper doweling between pump and motor for ease of
assembly.
r) Pump shall be completely assembled at manufacturer's shop and mating parts shall be
match-marked for ease of assembly at site. This is applicable for spare rotating assembly
also, if any.
s) The effect of earthquake loading shall be considered for design of pump, pump supports
& restraints.

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t) Copy of Technical Purchase Order shall be submitted.

4.2 COUPLING
a) Connection between pump and driver shall be of reputed make.
b) Mesh type removable coupling guard shall be supplied and mounted so that they cover
rotating parts within 1/2" of stationary housing.
c) Coupling shall be of flexible and spacer type statically and dynamically balanced.

4.3 BEARINGS
a) Anti-friction bearings shall be standard type and shall be selected for minimum L-10
rating. The bearings should be selected to give 3 years (25,000 hrs) life with continuous
operation at rated operating conditions but not less than 16,000 hrs at maximum axial
and radial loads at rated speed.
b) The rise in bearing grease / oil temperature with continuous running of the pump shall
be within the allowable limit which shall not exceed 20 deg. C for grease and 30C for
oil lubricated bearing above ambient. Cooling arrangements shall be provided, if
required. Bearings shall be equipped with constant level sight feed oilers.
c) LUBRICATION and COOLING:
i. Pump shall be suitable for dry start under normal condition.
ii. All instruments required for lubrication system and cooling system shall be
provided by contractor.
d) Bearing in the pump shall be arranged so as to permit measurement of shaft vibration
adjacent to at least one bearing.

4.4 IMPELLER AND SHAFTS

a) Impeller shall be made in one piece.
b) Rotor assembly including impeller, shaft etc. shall be statically and dynamically
balanced as per respective code requirement. Wherever such requirement is not
specified by the governing code then, as a minimum requirement, the dynamic
balancing shall be carried out as per ISO 1940 Gr 6.3.

4.5 PRESSURE CASING

a) Wear Rings: Replaceable type wear rings shall be provided. The rings shall be so fitted
as to prevent turning.
b) Mechanical Seals: The Mechanical Seals shall be supplied of reputed make like Eagle
Poonawala / Burgmann or equivalent.

4.6 BASE PLATE

a) Machined base plate of rigid construction shall be provided.

4.7 MATERIALS
a) The material of construction of parts shall be as per the data sheets.
b) Only the best quality and type of material shall be used. Castings used for any part shall
be sound, free from shrink or blow-holes, scale, blisters etc. Similarly forgings shall be
free from flaw and objectionable imperfections, machined true and in a workman like
manner.
c) Welding of fabricated part shall be entrusted to only qualified welders.

4.8 SHOP INSPECTION & TESTS

a) General Requirements:

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i. Unless otherwise specified, all pumps shall be inspected and testing witnessed
by the employer / third party inspection agency or their authorized
representative.
ii. Employer or their authorized representative shall have access to the plant
including sub-vendor's plants where work is being carried out, or testing of,
equipment is being performed.
iii. No surfaces of parts of pumps are to be painted until the inspection is completed.
iv. Contractor shall give to the Employer at least 5 days’ notice prior to
commencement of testing. Contractor shall carry out all running test and
mechanical test and satisfy himself prior to Employer's arrival for inspection and
shall maintain desired log of tests.
v. Acceptance of shop test shall not constitute the waiver of requirement to meet
field test under operating conditions, nor does inspection relieve the Contractor
of his responsibility in any way whatsoever.

b) Testing Requirements:
As a minimum, following tests shall be performed. The basic reference standard shall
be as per the data sheet. Pump shall be shop tested with job motor.
i. HYDROSTATIC TEST
ii. PERFORMANCE TEST
iii. NPSH TEST
iv. VIBRATION MEASUREMENT
v. STRIP TEST

c) Final Inspection:
i. The pump will be checked for visual inspection.
ii. As a result of any or all of the above tests, if dismantling is necessitated
requirement of retest shall be at the discretion of the employer.
iii. Various tests carried out as described above shall be properly recorded, plotted
and shall be extrapolated for speed, specific gravity, viscosity, etc. Such
documents duly signed by contractor's inspector and Employer's inspector shall
be submitted to the employer with requisite number of sets for their record.

4.9 PREPARATION FOR SHIPMENT

a) All flanges, nozzles and any other openings shall be blanked-off (capped or blind
flanged). All untapped openings shall be provided with substantial wood or metal
closure. The ends of small piping may be sealed with tape.
b) The Pump shall be supplied with a Nameplate as per relevant standard containing all the
information required by the code. However following information must be incorporated
in the Nameplate even if it is not required by the code:
i. Employer's Name & Item No.(Tag no.)
ii. Type and Serial No.
iii. Speed
iv. Kilowatt Rating
v. Capacity
vi. Head
c) The nameplate shall be of stainless steel and relevant information shall be punched into
the same.
d) All auxiliaries, dismantled and packed separately, shall be properly marked with the
Item No., for which it is intended, by means of metal tag.

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e) Pump with auxiliaries, shall be suitably packed, fastened to avoid damage during transit
and crated for shipment and storage for a period of 6 months. Lifting, unpacking and
handling instructions shall be securely attached to the exterior of the largest packing in a
well-marked, weather proof container. The up-right position of lifting points, gross
weights and dimensions shall be clearly marked on each package. Each Package shall
clearly identify the equipment contained therein.

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M IV B. SPECIFICATION FOR DIAPHARGM PUMP

4B.1 This specification covers the design, manufacture, inspection, testing and supply of
Metering Pumps with drive.
4B.2 Process parameters and other requirements (MOC etc.) are mentioned elsewhere in the
tender. If the data sheet for the pump is not enclosed, the same shall be decided during the
detailed engineering.
4B.3 Except as modified herein, the pumps shall be designed, fabricated, tested and supplied
in accordance with API (675-Positive displacement pump-Controlled volume-1980 edition.
4B.4 Positive displacement controlled volume pumps shall conform to API standard 675-
1980 edition, except as modified in this section.
Reference is made in this section only to those paragraphs of API-675-1980 where additions
or modifications are made and to wholly new paragraphs which are inserted in
alphanumeric order in API-675-1980. Other paragraphs of API 675-1980 which are not
mentioned in this section are to be followed without change
4B.5 Inspection and tests shall be conducted under witness of HWB, Mumbai. For this
purpose, QAP shall be submitted along with technical officer.
4B.6 Performance Guarantee
 Vendor shall guarantee the performance of the equipment as below:
 Pump Head and capacity at rated point without negative tolerance
 Any shortfall in performance shall be rectified by the vendor within a reasonable
time mutually agreed, free of cost, to Purchaser. If the defects are not rectified
within the agree time, Purchaser shall have the right to carry out the necessary
modifications at the risk and cost of vendor.
 Guarantee shall be for 18 months from date of supply or 12 months from the
date of commissioning whichever is earlier.
4B.7 Vendor shall quote for spares for the equipment for two years normal operation and
commissioning spares. Item-wise list with price shall be furnished along with the officer
(suggested list of spares for two years operation is indicated in the spares list).
4B.8 Vendor shall quote per item rates for supervision of erection/commissioning of the
equipment at site. Total estimated number of stay of vendor’s serviceman shall be
indicated.
4B.9 Companion flanges along with gaskets and fasteners shall be supplied for non standard
nozzles sizes.
4B.10 Pump shall be tested at shop with job motor
4B.11 Base plate shall cover full length of pump and motor
4B.12 Equipment shall be dispatched to site in fully assembled and aligned condition
4B.13 Compliance Statement, duly filled in, shall be furnished along with the quotation.
4B.14 Unless otherwise specified, equipment shall be suitable for outdoor installation, without
roof.
4B.15 Unless otherwise specified, pump flow rate shall be adjustable over a range of 10% to
100% of rated capacity, while the pump is running.
4B.16 Pump rated capacity shall be equal to the maximum capacity specified by the purchaser.
The liquid cylinder design shall be based on volumetric efficiency of 90% or less.
4B.17 Inlet and outlet connections shall be flanged connections suitable for maximum
allowable working pressure.

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M4C. SPECIFICATION FOR AGITATOR

DESIGN AND CONSTRUCTION

4C.01 Mechanical agitators and auxiliaries, as indicated in the detailed specifications, are
required to be supplied and shall be suitable for continuous full load duty for at least two
years of operation. These equipments shall be suitable for outdoor (unsheltered)
installation, unless otherwise specified.

4C.02 Motors shall be IP-55 type & shall have horsepower ratings at least equal to the
following percentage of agitator brake horsepower including all the transmission losses.
Gear horsepower ratings shall be at least equal to driver ratings.
Motor name plate rating, KW Percentage of BHP

18.5 and below 125

Above 18.5 and below 75 115

Above 75 110

4C.03 In case of liquid - liquid mixing and slightly contaminated liquid, bending moment
calculation for the power shaft should be based on 2.5 times the maximum horsepower
of the driving unit. But in case of slurry service, the bending moment calculation must
be based on 3.5 times the maximum HP of the driving unit and gearbox be selected
accordingly.

4C.04 Vendor shall guarantee the horsepower requirements for operation at specified speed
when mixing fluid or fluids of the specified specific gravity.

4C.05 The corrosion allowance for the agitator components (wetted parts) shall be equal to the
corrosion allowance of the related vessel but shall be minimum 3.0 mm.

4C.06 Other general Mechanical components of the agitator assembly shall be designed
considering the operating duty as 150% of the indicated rated load, to take care of any
fluctuations.

4C.07 Assembly and disassembly

 Replacement of bearings, shaft sealing devices, gear unit and driver shall be possible
without dismantling other major parts of the unit and without emptying or
depressurizing the vessel.
 Component parts shall be designed to ensure accuracy of realignment during
reassembly.

4C.08 Bearings & Bearing housing

 Oil lubricated bearing shall be equipped with ‘constant level oiler’. Sufficiently large
oil sumps may be fitted with an oil level indicating gauge. A threaded oil filling
connection shall be furnished in addition to a constant level oiler. Recommended oil
level shall be clearly marked.
 Sleeve bearings shall be renewable insert type.

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 If lubrication is pressurized type, the furnished system shall include the oil reservoir,
pump, coolers, strainer, necessary controls and instruments. Preferably, the oil pump
should be driven by a direct connection from main agitator drive.
 Antifriction bearing shall be of standard type and selected to give minimum 3 years
(25000 hr) rating life.
 Peak-to-peak vibration measured on bearing housing shall be less than 75 microns.

4C.09 Shafts, shaft sleeves and mixing element

 Unless otherwise specified, a solid constant diameter one piece shafting of cantilever
design without steady bearing shall be supplied.
 Shaft shall be designed for jamming/locked rotor conditions, assuming at jamming
conditions maximum forces will act at a point 0.75r from the centre (where r is radius
of impeller). Unless otherwise specified a safety factor of 2.5 shall be taken on motor
rating while calculating the stress as per max. Shear energy theory. The maximum
stress thus calculated shall be limited to yield point stress of the shaft material.
 Shaft and shaft sleeves shall be accurately machined throughout the entire length and
property finished at the bearing and seal surface such that under the service
conditions, those shall resist wear, corrosion and erosion particularly in the area of the
packing.
 Shaft sleeves shall be locked to the shaft and sealed at one end
 The end of the shaft sleeve shall extend beyond the outer face of the packing gland so
that any leakage between the shaft and the sleeves cannot become confused with
leakage through stuffing box packing.
 Unless otherwise specified, impeller hub shall be removable type & to be of keyed
connection. Blades shall be welded or bolted as specified depending on use in open or
closed tank service. Shaft shall be designed for minimum run out and diameter
carefully selected to avoid critical speeds. Stabilizer ring are to be considered in
preference to step bearing. Vendor shall advise where step bearings are necessary.
 Sleeve nuts, if used, shall be made of material to withstand external corrosion.
 All impellers and shaft assemblies shall be statically balanced. In addition, the
impellers shall be dynamically balanced if impeller speed is equal to or more than
1000 rpm. When dynamic balancing is proposed, the vendor shall indicate the limits
of acceptable unbalance.

4C.010 Shaft sealing and lubrication

 External lubrication shall be provided for any shaft seal operating in a gas zone of a
vessel or in the liquid zone of a vessel containing non-lubricating fluids.
 Lubrication facilities or devices shall be automatic and shall have a lubrication
capacity for a minimum of one week without refilling.

4C.011 Mechanical shaft seals

 When mechanical seal is specified, the seal shall be a double type, positioned as
closely as possible to the lower output shaft bearing to ensure minimum shaft run out
and deflection.
 When mechanical shaft seal is used, all seal parts including non-metallic parts shall be
resistant to the fluids being mixed and to any lubricant. The gasket materials shall be
Teflon or equivalent for mixing temperatures from 60°C to 250°C
 Hydraulically balanced type mechanical seal shall be used for sealing pressure above
5.0 Kg/cm2(g).
4C.012 Conventional packing
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 When stuffing boxes are required and specified as for pressure or vacuum service, the
assembly shall be designed with split gland and large accessible opening to stuffing
box. Two extra sets of packing shall be included.
 In case of conventional packing, stuffing boxes shall be preferably integral with the
cover. If bolted stuffing boxes are used, those shall be constructed to maintain
alignment.
 Stuffing boxes shall be provided with connections for the introduction of a cooling
medium or lubricant.
 Ample space shall be provided for the packing replacement without removing or
dismantling any part other than the gland and the seal cage.
 Stuffing boxes shall have not less than six rings of packing plus seal cage. The
minimum packing size permitted shall be 6 mm square; however 10 mm square or
larger is preferred.
 Glands shall be designed so that the bolts cannot slip off, if the packing becomes
loose. Where split glands are used, the halves shall be bolted together.
 Drains shall be provided to remove stuffing box leakage.

4C.013 Bellow seals

 Bellow shaft seals shall be provided if specified on the data sheet.

4C.014 Critical speed

 First critical speed shall be greater than 125% of the maximum operating speed or
shall be less than 75% of the minimum operating speed.

4C.015 Couplings
 Flexible steel couplings shall be furnished between motor and reducer and rigid
coupling between the agitator shaft and driver.
 Couplings shall be properly keyed in place and cylindrical interference fits shall be
light enough to permit easy and rapid removal of the hub without the need for heating
above 120°C.
 When a solid shaft drive unit is used on vertical units, a spacer type coupling shall be
provided for units equipped with mechanical seals. The spacer shall be sufficient
length to permit replacement of the seal assembly without removing the drives.
 Couplings shall be as per vendors standard, unless otherwise specified. Flexible
coupling shall be selected with a min. service factor of > 2.

4C.016 Agitator bed plate

 The agitator shall be mounted on a suitable bed plate or pedestal/mounting stool as
required for specified service. Bed plate shall be rigid enough to withstand all stresses
caused by impeller and shaft. If pedestal type support is specified, access holes shall
be provided to reach couplings or seals. Bolt holes shall be provided as required.

4C.017 Gear reducers

 Gear units shall be designed for agitator duty. Gearing shall be enclosed in rugged
heavy duty housing (close grained Cast body or weldment). The unit shall be designed
so that no significant gear deflection shall result from impeller over hung loads or
shaft thrust loads. If required, the gearing should be so arranged to provide speed
adjustment with change gears between reasonable change ratios.

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 A dependable lubrication system shall furnish lubrication to all bearings and gears and
provide for an oil reservoir of sufficient capacity to prevent overheating including
means for cooling, if necessary.
 The lower output shaft bearing may be grease lubricated but shall have a high quality
lip type seal to prevent any possible grease leakage or contaminated from external
sources.
 Following service factors shall be applied to motor horsepower in fixing the agitator
gear assembly.
Class of equipment
Load Hours / day
Gear motor Speed reducer

10 1.0 1.0
Uniform
24 1.4 1.25

10 1.4 1.25
Moderate shock
24 2.0 1.5

10 2.0 1.75
Heavy shock
24 2.0 1.75

4C.018 Guards
 Guards shall be provided by vendor for couplings to prevent any safety hazard to
personnel by accidental contact or due to any flying pieces in case of failure. Guards
for outdoor service shall be weather proof. All such guards shall be bolt-able with the
equipment base frame.

4C.019 Drive motor

 The motor shall be sized as specified in Para.2.1.2. Motor speed and horse power shall
be based on 415 volts, 3 phase, 50 Hz power. Motors shall be outdoor installation &
continuous duty type with at least four ‘hot start’ facilities. D.O.L. Starter shall be
provided with each Motor-Unit.

4C.020 Tools
 The vendor shall furnish all specials tools necessary to service the shaft sealing
devices and to dismantle and assemble the unit.

4C.021 Materials
 Purchaser shall specify the materials of the shafts, shaft sleeves and mixing element
on the data sheet.
 Materials of the vendor’s standards suitable for the specified operating conditions are
acceptable, if materials are not specified on the data sheet.

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 Unless otherwise specified on the data sheet, material test certificates (chemical
analysis and mechanical properties) shall be supplied for impeller, shaft, mounting
stool, mounting flange, auxiliary tank coupling, spacer coupling and shaft coupling.

4C.022 INSPECTION AND TESTS

 Inspection by purchaser
 Stage inspections by the Purchaser or through their authorized representative would be
necessary. Purchaser and/or their designated representative shall have the right to visit
the manufacturing works of the Supplier & witness any pre-defined inspection-stages
and tests to be performed by vendor and to review vendor’s records and data.
 Purchaser’s inspector shall have free entry to vendor’s shop while work is on or testing
of the equipment is being performed.
 Vendor shall notify purchaser sufficiently in advance of the witnessed inspection and
test operations to permit purchaser’s inspector to arrive at the vendor’s shop.
 Inspection by purchaser’s inspector shall in no way relieve vendor of his responsibility
to meet all requirements of the purchase order.
 A general arrangement drawing (in four sets) detailing various components of the
equipment being offered shall be submitted for ‘approval in principle’ from the
Purchaser.

4C.023 INSPECTIONL AND TEST RECORDS

4C.024 Records and data required

a. The complete records, as outlined in para ‘2’ of inspection and tests shall be
supplied by vendor to purchaser after completion of all inspection and tests.
b. The complete records shall include (where applicable)
1. Material certificates
2. Dimensional inspection records
3. Running test records.

4C.025 Procedures and acceptance standard.

a. Unless otherwise specified, all agitators, agitator parts and accessories shall be
inspected and tested in accordance with the corresponding paragraphs of this
section.
b. Running tests will be witnessed by purchaser’s inspector.

4C.026 Material inspection

a. Material certificates shall be furnished for the following parts. The material
certificates shall state the results of chemical analysis and physical tests and heat
treatment(if any) given to the materials.
1. Shafts
2. Mixing elements
3. Mounting stool
4. Mounting flange
5. Couplings

4C.027 Visual and dimensional inspection

a. Machined surfaces of the parts shall be carefully checked for finishing.
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b. Dimensional inspection shall comprise check on the following during

assembling or upon completion.
1. Dimensions of base flange, including size and location of bolt holes.
2. Dimensions of the mixer such as length, diameter, deflection and run out
of the shaft, mixing element diameter, etc.

c. Completed unit shall be subjected to a visual inspection to check for:

1. Rotational direction
2. Nameplate description
3. Cleanliness
4. Auxiliary piping arrangement
5. Accessories, spare parts, etc.
6. Painting

4C.028 Running test

1. Unless otherwise specified, all agitators shall be given a mechanical running test and load
test in water for a sufficient period ( at least 1 hour) to obtain complete test data using
vendor’s testing facilities
2. Mechanical Run Test Each agitator unit shall be given mechanical run test in air at
vendor’s shop. Agitator unit shall be mounted in the same manner as it will operate in the
field. During this test, the following shall be noted and recorded
a. The deflection of the shaft end shall be measured by a dial indicator when the
agitator is turned by hand. The total indicator reading shall not exceed 0.05% of the
shaft length.
b. The shaft or shaft sleeve run out shall be measured immediately above the stuffing
box or mechanical seal by a dial indicator when the agitator is turned by hand. The
total indicator reading shall not exceed the following limits.

Seal type Limits (Microns)

Mechanical shaft seal 50

Packing and other 100

c. The bearing temperatures shall be measured on the bearing housings until they reach
almost constant value during the running test. The bearing temperatures shall n ot
exceed ambient temperature plus 40oC or 70oC whichever is less.
d. The temperature of gear box oil shall not exceed ambient plus 40oC.
e. Bearing housing vibrations (by a seismic probe) shall not exceed 50 microns.
f. Vibration of agitator unit at any point shall not exceed 80 microns.
g. Noise levels shall be checked and recorded.
h. Agitator shall RPM and motor RPM.
i. During the shop run checking for oil leaks shall be made. Any indicated leaks shall
be corrected.

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3. Load Test in Water

If specified in the data sheets, the agitator unit shall be given a load test in water at the
vendor’s shop unless agreed otherwise between the purchaser and the vendor. The
following parameters shall be recorded during the test.

a. The shaft or shaft sleeve run out shall be measured immediately above the stuffing
box or mechanical seal by a dial indicator when the agitator is turned by hand. The
total indicator reading shall not exceed the limits mentioned earlier.
b. The bearing temperatures shall be measured on the bearing housings until they reach
almost constant value during the running test. The bearing temperatures shall not
exceed ambient temperature plus 40°C or 70°C whichever is less.
c. The temperature of gear box oil shall not exceed ambient plus 45°C
d. Bearing housing vibration shall not exceed 60 microns.
e. Vibration of agitator unit at any point shall not exceed 100 microns.
f. Noise measurements shall be made all around the agitator during the running test
with a calibrated sound level meter. The microphone shall be located at the distance
of 1.0m from the nearest surfaces of the agitator and at the height of about 1.0m
above the floor.
g. Ampere, voltage and power consumption shall be measured.
h. Agitator shaft RPM and motor RPM.
i. Check of satisfactory operation of shaft and retracting arrangements.
j. Gear ratio shall be confirmed by measuring input and output shaft rotational speed.
k. Unusual sound arising from gearing shall be checked with sound detector.
l. The mechanical shaft seals shall be checked for tightness.

4. After completion of the running tests, all mech. Shaft seals shall be removed and
inspected and reassembled in the agitator.
5. If dismantling is necessitated for some corrections such as improvement of mechanical
or performance deficiencies, the initial tests will not be acceptable and the final shop
tests shall be done after such corrections are made.
6. Each pressure part like stuffing box housing or oil reservoir of a pressurized lubrication
system etc. shall be hydrostatically tested with water at a pressure not less than one and
half time the max. operating pressure. The duration of the test shall be 30 minutes.
Criteria for acceptance shall be ‘no leaks’.
7. Acceptance of shop tests shall not constitute a waiver of requirements to meet field tests
under specified operating conditions, nor does inspection relieve the manufacturer of his
responsibilities in any way whatsoever.

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M - V. TECHNICAL SPECIFICATION FOR THERMAL INSULATION

GENERAL

5.1 Scope:
This standard covers the requirement for supply and application of the materials for thermal
insulation of equipment, piping and other items.

5.2 Reference Standards:

IS 7413 Code of Practices for Industrial Application and finishing of thermal insulation
materials at temperatures above 40° C and up to 700° C.
IS 737 Wrought Aluminum and Aluminum alloys, sheet, strip (for general engineering
purpose)
IS 1254 Specification for corrugated aluminum sheet.

5.3 Deviations:
i. Should unforeseen difficulties arise to comply with requirements of the standard.
ii. Alternative materials and application techniques superior to the requirements of this
standard be submitted with complete details for approval of owner.

5.4 Limitations:

i. TEMPERATURE LIMITS
This standard deals with insulations applied externally on piping, equipments etc. as
per the table below:
SN Maximum Operating Temperature Type of Insulation

1 60°C to 800°C for C.S, A.S. & S.S. HOT

5.5 General Requirements:

i. INFORMATION TO BE SUPPLIED TO CONTRACTOR
1. Material of construction/dimension of equipments/pipes required to be insulated.
2. Temperature
3. Location of equipment (Indoor/Outdoor/Elevation)
4. Requirement of removable box type insulation, if any
5. Special requirements if any regarding type of insulation material and other
properties.
6. These information shall be supplied during detail engineering.

ii. STORES OF MATERIAL

Insulation material shall at no time be stacked directly on the ground; instead it will
be stored at a level higher than ground level. It should not only be covered by
tarpaulins but other effective protection against weather is also to be provided. The
contractor shall provide a properly covered storage to the satisfaction of engineer-in-
charge.

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iii. HYDROSTATIC TEST FOR PIPES

Before taking up insulation job on piping or vessels it shall be ensured that
hydrostatic test of the concerned equipment/piping is completed. Where it is felt
necessary to take up the insulation job before such testing are performed all welded
and mechanical joints shall be left un-insulated for a length of at least 400mm on
either side of the joint.

iv. PROTECTION OF INCOMPLETE JOBS

Any part of insulation job which is not provided with final weather proofing will be
adequately protected by means of tarpaulins and other aids. After the day’s work
similar protection should be provided for the partially completed jobs to be
continued the next day to avoid any absorption of rain/moisture during the night.

5.6 INSULATION SUPPORTS (CLEATS) TO BE PROVIDED BY EQUIPMENT

CONTRACTOR
Suitable supports (cleats) in the form of rings, lugs, studs or pins shall be provided on
equipment. However, should any additional supports or anchorage be felt necessary by
the insulation contractor the same will be recommended by them to the Engineer-in-
charge for his approval before installations. These will be installed by the contractor free
of any extra cost.

5.7 MATERIAL REQUIREMENTS

a) Insulation Materials:
i. GENERAL
1. Whenever reference to any standard is made it is presumed that the latest
revision as on date should be considered.
2. When blankets are to be used on piping up to 300mm diameter they shall be
backed on both sides with wire netting when un-bonded mineral wool mattresses
are used.

b) Auxiliary Materials For Jacketing:

i. ALUMINUM JACKET

1. Horizontal Vessels:
99% pure aluminum sheet as per IS-737 shall be used for jacketing insulation on
overall piping, vessel and equipment. The thickness will be as follows:
Jacket Insulation
Insulatio Over rigid Over resin bonded
Over unbounded
n O.D insulation like mattresses
mattresses
(mm) Calcium Silicate (Semi rigid)
Less 28 SWG (0.38 mm) 26 SWG (0.46 mm)
24SWG(0.56mm)
than 325
325 to 26 SWG (0.46 mm)
24 SWG (0.56 mm) 22SWG(0.71mm)
900
More
24 SWG (0.56 mm) 22 SWG (0.71 mm) 20SWG(0.91mm)
than 900

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2. Vertical Vessels:
Jacket material for vessels with insulation O.D 900 mm and less shall be the same
as for pipes. For vessels above 900 mm insulation O.D. 22 SWG corrugated
aluminum sheet to IS: 1254 with deep corrugation may be used for vertical
installations only.
ii. SCREWS
Screws used with aluminum sheeting shall be of self-tapping type, ½” No.7 of high
quality.
iii. S-CLIPS
Aluminum, 20x1.5 mm bent to form a shape of to provide a minimum lap of 50
mm.
iv. BANDS FOR SECURING JACKET
Aluminum of dimensions 20mm width x 0.5 mm thick.
v. QUICK RELEASE CLIPS FOR REMOVABLE COVERS
Suitable quick release clips will be made as per standard arrangement from 20mm
width x 20 SWG aluminum sheet and some suitable rectangular ring.

5.8 INSPECTION
a) All insulation materials shall be subject to inspection by owner before application. In
case of doubt Owner’s representative will have the liberty to get the material tested by
the contractor at any approved test laboratory. Any material not meeting specified
requirement will be rejected and the rejected material shall have to be replaced by the
contractor with materials of specified type and quality. Insulation found to be
improperly installed shall be removed and reinstalled properly.
b) Inspection of materials and/or installation by owner shall not relieve the contractor of
his responsibility to ensure that finished insulation conform to specified requirements
and is free from defects. Contractor shall correct and defects due to poor workmanship.
c) Tests for thickness shall be carried out after application. Thickness at any point shall not
be less than indicated thickness and shall not be more than 115% of the specified
thickness.
d) Testing of Bulk density of the insulating materials shall be carried out before the
application of insulation. This should be within +/- 15% of the specified value. Test
location shall be selected by owner and its repair shall be done by contractor.

5.9 APPLICATION
a) Insulation thickness shall be as specified in the insulation schedule
/specification/isometric drawings prepared for equipments / piping. Wherever the
thickness is not indicated the same may be selected from Specification for Hot.

b) No. of Layers:
When insulation thickness exceeds 80 mm, the insulation shall be applied in multi-
layers with all joints staggered. Each layer will be separately secured with metallic
bands/wires.

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No. of layers shall be as follows:

Insulation Thickness No. of layers

Up to 80 mm 1 Layer

80 to 160 mm 2 Layers

160 mm and above 3 Layers

c) General requirements:
i. SURFACE PREPARATION
1. Surface to be insulated shall be cleaned of all dirt, oil, loose scale etc. by wire
brushing. All insulation shall be applied at ambient temperature and both the
metal surface and insulation material shall be dry prior to application of
insulation.
2. The surface for cold insulation shall be then coated with a bitumen emulsion.
3. If the vessel is made of stainless shall steel, it shall be wire-brushed with
stainless steel wire brush.
ii. EXPANSION/CONTRACTION JOINT
1. Depending on the type of insulation used the operating temperatures and the
nature of material, it may be necessary to provide expansion/contraction joints
on vessels or pipes to prevent the insulation from rupturing/buckling when the
surface expands/contracts.
2. It is recommended that expansion joints will be provided in the intervals as
follows:
Temperature Intervals Remarks

201° to 300°C 4M interval This is not required

where flexible wool is
301° to 400°C 3M interval
used as insulation
401°C & above 2M interval

3. Expansion joints in horizontal vessel insulation shall be close to fixed support

saddle (s).
4. At the expansion joint there shall be a complete cut through the insulation.
5. On piping, expansion joints shall be provided on both sides and within 900 mm
of each band (within the above guide line for interval).
6. The cut out in insulation shall be at least 25 mm wide and dry filled with loose
insulation. Density of the loose insulation shall be equal to that of the blanket.
7. The expansion joint wherever necessary shall be insulated by over-lapping the
metal sheet as per standard practice, wherever it coincides with the
circumferential overlap of sheeting. In case of vertical piping the upper
insulation sheeting shall be provided at spacer rings only, by anchoring the inner
sheeting and leaving the outer sheeting free with grooving.

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iii. FILLING OF VOIDS

All voids, irregularities and joints shall be packed with loose insulation
material/insulation cement trowelled smooth whichever is applicable.

d) Insulation Procedure:
Insulation procedure shall be as per Specification for Hot service.

e) Metal Jacketing:
i. GENERAL
1. All joints shall have minimum 75 mm overlap arranged such as to shed water.
For horizontal vessels and pipes, horizontal overlap shall be installed within 5-6-
7’O-clock.
2. Jacket shall be secured to the spacer rings and to itself by self-tapping screws,
described earlier, at a pitch of 150 mm for longitudinal joints and 100 mm for
circumferential joints or by metal bands.
3. All outlets and cut outs shall be cut as close as possible to nozzles, manholes,
supports, branch connections etc. and sealed to be weather proof.
4. At all joints, edges of the jacket will be grooved.
5. All openings through insulation finish shall be flashed weather tight by vapour
seal mastic, particularly where connections are not insulated.
6. Insulation of flange assemblies, valves, manholes, hand-holes, removable heads
of heat exchangers etc. shall be of removable type.
ii. HORIZONTAL VESSELS
Jacketing for dished heads shall be fabricated in form with the radial overlapped
joint (with adequate overlap) secured by self-taping screws 100 mm pitch where it is
not possible, suitable metal bands shall be provided as approved by Engineer-in-
charge. The ends shall be secured to the vessels surface (Cylindrical shell) by
circumferentially tensioned bands and reinforced by self-tapping screws set at 150
mm pitch.
iii. VERTICAL VESSEL
1. Corrugated aluminum sheeting shall be adequately rolled and installed parallel to
the axis of the vessels and shall be secured to the insulation supports available on
the vessels. Otherwise they shall be secured to themselves and rings provided by
the contractor by self-tapping screws. All individual sheets shall be overlapped
by at least 75 mm on longitudinal joints and two corrugations on circumferential
joints, to shed water wherever possible. All joints shall be staggered.
2. Circumferential end laps shall be supported with S-clips so that top section can
rest on the lower one and top section.
Heads: Guide lines for horizontal vessels will be followed.

vi. TANKS
Corrugated aluminum sheet shall be fixed with the help of suitable pop rivets on the
sides of the tank. Flat sheet will be used for top of tank. Sheet to sheet longitudinal
joints shall be sealed only with pop rivets and no screws shall be used.
Circumferential joints need not be riveted.

vii. HEAT EXCHANGERS

Guide line for vessels shall be followed.

viii. MACHINERIES LIKE PUMPS, TURBINES, COMPRESSORS ETC

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Whenever sheeting will be required it will be specifically asked for and contractor
shall submit his proposed details for each equipment for approval of the Engineer-
in-charge.

ix. SPHERICAL VESSELS

Guide line for vessels will be followed.

x. PIPING ITEMS
1. Elbows/Bends:
 On piping, jacketing shall be supplied with longitudinal and circumferential
laps of 50 mm and secured by aluminum bands spaced 300 mm centers or by
aluminum self-tapping screws at 150 mm centers. Longitudinal laps on
horizontal pipes shall be arranged minimum 300 mm below the horizontal
centers line to shed water. Circumferential lap joints should be sealed with
suitable adhesive sealer.
 Jacketing of insulation over large bends shall be as per standard practice.
Jacketing of insulation over elbows shall be spun aluminum jacket and the
joint with jacketing of adjacent straight pipe shall be flashed and banded.
2. Valves & Flanges:
 Where flanges and valves are not insulated, the end of insulation on both
sides shall be suitably covered. When these are required to be insulated they
will have removable box insulation.

5.10 MEASUREMENT OF INSULATION WORK

a) Measurement of insulation works shall be as per IS: 7413.

5.11 GUARANTEE
a) Contractor shall produce 12 copies of test certificates as per relevant IS/ASTM
Standard. Contractor shall certify that
i. All materials are new and unused and are as per specifications called for in this
standard.
ii. The thermal conductivity shall be as specified
iii. The workmanship shall be in accordance with good practice
Other terms & conditions of the guarantee clause shall be as per Work Order.

5.12 THERMAL INSULATION – HOT SERVICE

5.12.1 GENERAL
a) Scope:
This standard covers the requirement for supply and application of the materials for
thermal insulation of equipment, piping and other items for Hot Service.
b) Reference Standards:
IS 3690 Specification for Glass wool mats for Thermal Insulation

IS 3677 Specification for un-bonded Rock and Slag wool for thermal
insulation.

IS 7413 Code of Practices for Industrial Application and finishing of

thermal insulation materials at temperatures above 40° C and

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up to 700° C

IS 8183 Specification for bonded mineral wool

BS: 3958 (Part-5) Specification-----do----

IS 9842 Specification for preformed fibrous pipe insulation

ASTM C 547 Mineral fiber preformed pipe insulation

ASTM C 592 Mineral fiber blanket insulation and blanket type pipe insulation
(Metal mesh covered) (industrial type)

IS 8154 / IS:9428 Calcium Silicate pipe sections & blocks

c) Deviations:
i. Should unforeseen difficulties arise to comply with requirements of the standard.
ii. Alternative materials and application techniques superior to the requirements of this
standard be submitted with complete details for approval.
d) Limitations:
i. TEMPERATURE LIMITS
This standard deals with insulations applied externally on piping/equipments etc. for
temperature ranging from 60°C to 800°C.
e) General Requirements:
i. PERSONNEL PROTECTION (PP)
Insulation for personnel protection is usually called for when the surface
temperature is above 65°C and process requirements does not necessitates any
insulation. Wherever, requirement of such insulation for P.P. is indicated, extent of
insulation will be as follows:
1. Insulate all such portions of the surface which could be touched in the course of
normal operating/maintenance duties.
2. Insulate up to a height of 2.5 M above grade level/working platform level.
3. Insulate all portions of the surface within a distance of 600 mm from the edge of
any walkway/operating platform/ladder.
ii. Application of rigid insulation like calcium silicate may be considered for vibration
prone pipelines / equipment and where foot traffic is expected over the insulation
surface.

5.12.2 MATERIAL REQUIREMENTS

a) Insulation Materials:
i. GENERAL
1. Whenever reference to any standard is made it is presumed that the latest
revision as on date should be considered.
2. When blankets are to be used on piping up to 300 mm diameters they shall be
backed on both sides with wire netting when un-bonded mineral wool mattresses
are used.

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Max.
Applied
Service
Composition, Shape & Thermal
Density in Remarks
Specification Cond. in
Kg/m3
mw/cm OC

Factory made, machine laid or

and machine stitched un-
Hot bonded mineral wool 120 for 0.51 at No chloride and or alkali
mattresses direct as per 100OC meancontent is permitted for
O
IS:3677 type 2 or ASTM-592 T≤ 500 C temp. direct application on SS
A type 2 or material as per surfaces. However
BS:3958 part 5 OR calcium silicate
P insulation with chloride
Factory made machine laid content up to 10 ppm but
P and machine stitched lightly having suitable corrosion
bonded mineral wool mattress 100 as per inhibitor (Sodium
L as per IS-8183 (the amount of group-I of -- do -- Silicate) is also
I resin being added between 1 IS-8183 acceptable for direct
to 3% by Wt.) up to a application over SS. A
C temperature of 250OC only max. of 100 ppm
A Preformed resin bonded pipe leachable chlorides may
sections (for pipes) and radial 100 as per 0.52 at be permitted for
T segments (for vessels & group-I of 100OC mean application on CS & AS
equipments) as per ASTM C- IS-8183 temp. surfaces and for
I application on SS
547 or IS-9842 Group-2 or 3
surface after covering it
O
Calcium Silicate pipe sections with Aluminum foil (as
0.82 at
N & blocks as per IS-8154/IS- per Clause 6.3.5).
250 300OC mean
9428 for temperature above
temp.
300OC.

b) Auxiliary Materials:
i. PAINTS
Heat resisting (for application on surfaces Hot Service.)

Type Single pack

Composition Silicon resin based with aluminum flakes as

pigment.

Dry film thickness 20 microns/coat (minimum)

No. of coats 2 coats

Other requirement The paint shall be suitable to withstand

temperatures up to 600°C

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ii. INSULATION CEMENT

This is used for filling voids & surface irregularities. This shall be high grade
mineral wool/calcium silicate plastic composition based cement having a volumetric
shrinkage not exceeding 20% of wet coverage and with a max. Thermal conductivity
of 0.01 mW/Cm°C at 205°C mean temperature.
iii. HARD SETTING PLASTER
Hard setting plaster shall be a mixture of cement sand or cement asbestos or plaster
of a Paris-asbestos. This will be applied over the specified wire netting.
iv. WIRE (FOR NETTING, LACING OR STITCHING)
Wire netting for machine stitched mattresses shall be galvanized steel wire of
diameter 0.56 mm (minimum) making 25 mm hexagon mesh. Lacing wire to bind
the ends of wire netting shall be galvanized steel wire of minimum diameter 0.56
mm. Stitching wire for machine stitching shall be 0.4 mm diameter(minimum)
v. BANDING WIRE
Wire for securing insulating blankets or section shall be galvanized soft, annealed
steel wire of 1.625 mm diameter for pipes and mm diameter for vessels.
vi. BANDS FOR SECURING INSULATION MATERIAL
Aluminum or S.S., 20 x 0.5mm. For spherical surfaces only S.S. bands will be used.

vii. FOIL FOR WRAPPING S.S SURFACES

Aluminum foil of 0.1 mm thickness, free from pin holes.

viii. SPACER RINGS

1. Spacer rings shall be provided when mattress insulation is used to provide frame
work on which aluminum sheeting, used for protecting the insulation, is cladded.
These rings shall be fabricated from 25 x 3 mm MS flats. Spacer rings are not
needed in calcium silicate rigid sections. The outside diameter of these rings
shall be equivalent to the diameter of the pipes/vessels measured over the
insulation. Spacer rings shall not be required when insulation in the form of
preformed pipe sections is used.
2. Spacer rings may not be used for pipes where insulation 0.D. is less than 200
mm.
3. Spacer rings shall be provided with ‘Z’ shaped stays fabricated from the same
size MS flats. Stays shall be provided at intervals of not more than 300 mm
along the circumference of the insulation, subject to a minimum of 3 stays
Spacer rings shall be provided to the pipes at a pitch of not more than 900 mm.
4. To minimize direct heat conduction through the stays, a packing of 2 sheets of 3
mm thick asbestos mill board shall be provided at the joints of the stays and
pipes, while the joints of stays and MS rings shall be riveted by 6 mm diameter
MS rivets with 2 sheets of 3 mm thick asbestos mill board interposed.

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5.12.3 APPLICATION OF INSULATION

a) Insulation thickness shall be calculated by the contractor for equipments/piping. These
calculations shall be submitted to the HWB for approval.
b) General Requirement:
i. EXTENT OF INSULATION
1. All steam-traced lines, steam jacketed piping and vessels shall be insulated.
2. Steam trap and piping downstream of it shall not be insulated.
3. Turbines, pumps and compressors operating below 120°C shall not be insulated
unless otherwise specified.
4. Flanges & flanged valves on lines operating above 0°C but below 200°C shall
normally not be insulated excepting for personnel protection. In such cases,
insulation shall terminate at such a distance from the joints as to provide
sufficient space for removal of belts.
5. Drain and vent piping for hot service up to the first valve on insulated equipment
shall be insulated with similar type of insulation and finish as the equipment to
which attached.
6. Steam supply headers, and tracer lines used for steam tracing as shown on steam
trap hook-ups shall be insulated.
7. All instruments which are steam traced shall be insulated for heat conservation.
8. All samples connections and drains on steam lines shall be insulated.
9. All name plates and vessel markings should remain visible.

ii. INSULATION OF S.S. SURFACE

1. To avoid stress corrosion cracking of stainless steels it is imperative that if
mineral wool/calcium silicate insulation contains any Chlorine or alkali, it
should be ensured that it never comes in contact with the stainless steel surfaces.
2. For operating temperatures up to 450°C the stainless steel surfaces shall be
wrapped with 0.1mm thick aluminum foil with 50mm overlap at longitudinal
and circumferential joints before application of insulation. All joints of the
aluminum foil shall have barium chromate primer interposed. Aluminum foil
shall be firmly secured on to the stainless surfaces by aluminum bands at a pitch
of 450 mm. Care shall be taken while applying aluminum foil over the pipes to
ensure that the foil is not punctured at any place during wrapping and clapping
with aluminum bands. For operating temperatures from 451°C to 600°C, the
stainless steel surfaces shall be painted with two coats of heat resistant paint
before application of insulation. When the paint becomes dry, the painted
surfaces shall show no discontinuity.
c) Insulation Procedure:
The application procedure described is for mineral wool. For other insulation, the
application procedure shall be submitted by the tenders.
i. VESSELS AND COLUMNS
1. General:
 Insulation blankets shall be applied with the retaining wire mesh exposed on the
outside. The edges of blankets shall be well butted up to each other and laced
together with galvanized wire and secured to the vessel with circumferential bands.

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When the layers are to be applied the first layer may be secured by means of
galvanized wire in lieu of the bands.
 On flat surfaces, blanket-blocks shall be applied by impaling them over 9 gauge
galvanized wire pins welded perpendicular to the surface. The extending ends of the
wires shall than be bent upward at right angles and pressed into the blanket. The
edges of blankets shall be tightly butted and laced together with galvanized wire,
where more than one layer of insulation is applied; securing bands of the layers shall
not coincide with each other. All joints in successive layer shall be staggered.
2. Vessel heads:
 Insulation on heads shall be secured by radial bands from a floating ring (made by 2-
3 loops of wire) centered at the crown of head and tied to a circumferential band
placed approx 300mm inside the tangent line on insulation O.D. On to heads of
vertical vessels, these radial bands protecting the blanket insulation shall be
provided with distance pins placed every 300mm and of length equal to insulation
thickness. The pins shall be welded or riveted to the strip steel.
 For bottom heads, in all skirt supported vessels insulation supports are provided
inside the skirt as indicated in the equipment drawings. Floating rings or wire loops
around the nozzle and bands may be used to support downward facing of insulation.
Such a floating ring may be supported from the lagging support ring fixed inside the
skirt. Blanket shall be shaped and secured on to the head by means of bands
stretched across the floating ring and insulation support rings. The netting firmly
laced together and secured in place. All wire ends shall be cut short and turned into
the insulation.
 For vertical vessels having temperatures more than or equal to 450°C, the upper
600mm of the supporting skirt shall be insulated both on inside and outside.
ii. TANKS
1. Mineral wool mattresses faced with galvanized iron wire netting shall be pressed
onto the supporting pins of 8SWG GI. Wire. All joints shall be closely butted.
2. For the top of tank the following procedure shall be adopted where angle
supports/wire lugs are not provided by fabricator. All these will be supplied by
insulation contractor.
3. Laying of central and peripheral angle rings.
4. Welding M6 studs of length T + 6 mm (Where T= thickness of insulation) at
300mm pitch to MS flats (15x6mm) on ground. The flats shall then be laid on
the tank top connecting the central and peripheral rings riveted/welded at both
ends. Fix the 15x6mm flat cross stiffeners with the stud welded.
5. Fix resin bonded mineral wool slabs of required thickness by pressing on to the
studs.
6. Stretch 20 SWG chain link mesh, anchoring it to the M.S. studs by means of
speed washers.
7. Apply approx 19 mm thick hard setting plaster trowelled to a smooth and even
finish.

iii. HEAT EXCHANGERS

Exchangers shall be insulated with insulation mattresses as specified for vessel.
Channels and channel covers will be insulated with removable aluminum covers
lined with insulation. Unless otherwise mentioned flanges bolting shall be left un-
insulated for hot service.
iv. MACHINERIES LIKE PUMPS TURBINES COMPRESSORS ETC

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In general these will be insulated in such a way that the same is of removable type to
allow easy maintenance. The contractor shall supply insulation detail to engineer-in-
charge for approval.

v. PIPING
1. General:
 Vertical lines shall be provided with welded support rings spaced at approximately
4000mm. Expansion/contraction joints shall be provided under each support ring for
hot/cold service.
 Insulation around support shoes etc. shall be trimmed closely and thoroughly sealed
with vapor seal mastic. For hanger support special care shall be given for weather
proofing jacket and sealing mastic.
2. Hot Services:
 The blankets shall be wrapped round the pipe closely, completely covering the outer
surface. Edges shall be tightly butted and laced with galvanized wire. The blankets
shall be secured in place with galvanized bands/wires spaced at 300 mm. Ends of the
wire loops shall be twisted and pressed back into the insulation. All voids,
irregularities and joints shall be painted up and trowelled smooth with insulating
cement. Longitudinal joints on horizontal pipes shall be located 30°below centerline
of pipe
 In consideration of possible pipe line movement with change in fluid temperature
different pipes should be separately insulated.
 Flanges, valves & Expansion joints shall be insulated with removable type
arrangement as per requirements of Clause 6.1.

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M-VI. TECHNICAL SPECIFICATIONS FOR EOT CRANE

6.1 Detailed Specification of the EOT Crane

Structure mounted EOT crane shall be designed, manufactured & tested as per applicable
IS-Codes (IS-807 & IS-3177). Contractor shall arrange erection of this hoist at the location
decided during detailed engineering. Contractor shall indicate the guaranteed Electric Power
consumption of the crane motor during idle run as well as during full load operation. Crane
motors are to be tested at contractor’s works for routine tests. Contractor shall ensure major
parameters for site conditions also. Thorough Load testing of the Crane shall be conducted
by the contractor at site. Required test load shall be arranged by the contractor. (Concrete
test loads are available at site and can be spared for testing)
Prior to placement of order on Crane contractor by the EPC contractor, response to the
technical stipulations of the Check List (at the end of this spec) shall be submitted to the
employer for their review / approval.
a) Safe Working Load, Travel Length, Hoisting-Length & Quantities: Safe Working
Load of the crane shall be 10 Ton. However, it is to be decided based on maximum
weight of an individual component which is required to be handled during maintenance.
Other details are to be decided during detailed engineering.
b) Travel: Total travel length of EOT shall be between the terminal stoppers, with stopper
cum shock absorbers at both terminals of both the Beam. Trolley track wheel alignment
shall be within 2 mm & straightness of the Beam shall be within  2 mm over a length
of 3 M, after installation at Site.
c) Hook Pulley Arrangement: Each hook shall have in built sling locking facility. Hook
body shall be of forged construction, 360O rotating type with suitable thrust bearing.
Multiple pulley arrangement shall be provided for maximum mechanical advantage.
d) Rails: These shall be made from high quality steel (EN-8 material), duly Impact
tested for a maximum load situation.
e) Crane Hook Raising / Lowering Height: Each Crane Hook shall have travel from
floor level when rope is in 90% of fully wound position (Limit switch activated
condition) to the specified height. The rope drum centre line shall be accordingly fixed.
However there shall be at least 03 rounds of rope left on the respective Rope drum when
any one of the Hoist hook touches the floor of the building, during lowering operation.
f) Hoist ropes & Rope Drum: Wire ropes shall be well lubricated with Cardium
compound and shall be kink free type. Drum shall be round in construction with
multiple Sheaves/groves on it for guiding the hoist rope correctly during winding. Rope
shall be joint less, multiple strands type and free end suitably held, to prevent unwinding
of strands. Wire rope shall be rust free and of suitable diameter for the Design/Test load.
Size of Pulley grooves/sheaves shall be such that it exactly matches with the rope
diameter. Rope alignment shall be as straight as possible. Rope drum shall be made of
M.S. seamless construction & shall meet requirements of IS-3177. All gear boxes shall
be totally enclosed splash lubricated type. Gears shall be made from EN-8 material and
properly heat treated. Flexible couplings shall be provided for Torque transmission.
g) Travel Speed: Travel speed of the crane shall not exceed 12 M/Minute. Wire ropes
hoisting/lowering speed, with full load on-hook, shall not exceed 6 M/Minute. Torque
checking of the base bolts of the Hoist components shall be demonstrated by the
Contractor at installation site.

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h) Brake Arrangement: The Crane shall be provided with Fail-safe type hoisting/lowering
brake arrangement. Electric power should be required to release the brake against spring
pressure. Thruster type brake arrangement is preferable for Hoist. Solenoid braking
arrangement shall be provided in Trolley travel.
i) Capacity Name Plate: Safe Working Load (SWL) Capacity shall be displayed over the
Hoist body/Girder by writing on a name plate (300 mm long x 150 mm wide x 3 mm
thick M.S. plate duly painted) and fixed at a conspicuously visible location on the main
body of the hoist. This name-plate shall also show Date of Installation, Date of next
Load test due.
j) Power supply & Pendant: 415 V 10 %, 3-phase, 3-wire, A.C 50 Hz 3% Electric
power supply should be used for the main power supply. There shall be a Pendant-panel
hanging from the hoist crab-unit, with moveable wire sling for sliding the pendant
across the Cross travel span. Height of the Pendant Panel shall be 1.25 M above the
floor. The Pendant shall have a suitable hand grip arrangement & should be suitably
earthed.
It must have following push buttons: (a) Trolley motor “ON” (b) Trolley motor
“OFF” (c) Main Power Supply “ON” (d) Main Power supply “OFF”. All such push
buttons shall have lamp indications also, just adjacent to the respective push buttons.
k) Safety features: Trolley travel shall be fitted with limit switches at either ends of the
travel. Hoisting & lowering of the Hook, under load, shall have inching provision in
both directions. There shall be limit switches in hoisting operation as well as in lowering
operation. All limit switches shall automatically get activated & cut off power supply to
the respective motors.
l) Slings: Wire Slings shall have thimbles at both ends, well lubricated with Cardium
compound and shall be kink free type. Slings shall be round in construction with
multiple strands. It shall be joint less and free end suitably held by a metallic socket, to
prevent unwinding of strands. Slings shall be rust free, lengths suitably matched and
sling capacity punched on the Metallic Socket.
m) Class Designation – Class 4.
n) Slings & D-Shackles : Following lifting accessories are required to be supplied along
with each hoist (Slings shall be in matched pairs) :
1. 2 M long metallic thimbles (both ends) slings.
2. D-shackles --- 02 Nos.
o) Pre-dispatch Inspection: Pre-dispatch inspection at contractor’s works is mandatory.
p) Operators’ training: Contractor shall ensure that the Crane Contractor sends
experienced service Engineer/personnel to installation site, for providing operational
training, on this hoist, to departmental operators. Such training shall be imparted after
commissioning the hoist for three days or more (which will be mutually decided by
contractor / employer).
q) Recommended Contractors for bought out items:
a) Thruster Brake (A. C. disc type): Electromag make or equivalent,
b) Limit Switches (roller lever type): Siemens make or equivalent,
c) Limit Switches (Gravity type): Electromag make or equivalent.
r) Technical Confirmation: Contractor must fill up the technical confirmations sheet and
submit to employer for approval before placement of order.

6.2 Special requirements for Motors & other Electrical items:

Hoist motors shall be for heavy duty, continuous rated having maximum rating factor of
85%. Separate contactors shall be provided for movement in each direction e.g. Main
hoist Up, Main hoist down, forward, reverse etc. The control wiring shall be of 110 Volts
A.C. supply. Suitable capacity double copper wound, resin cast, class-F insulated control
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transformer shall be provided for getting control supply from main 415 Volts supply. The
transformer shall be provided with suitable rating fuse switches separately on primary &
secondary winding.
The motor control wiring shall be done with interlocks wired up in opposite direction
movements. Also the interlocks for limit switches shall be wired up. Similar interlocks to
prevent operation in opposite direction shall also be wired up in pendant push buttons &
testing push button station to be installed over the Hoist girders. A push button station for
testing purpose, from the hoist, shall be provided along the side of control panel for the
purpose of testing the movements of hoist on board. A selector switch wired up in control
supply for testing push button station & pendant push button unit at the testing push
button station on board of the hoist. Intrinsically safe circuit shall be provided for the
testing push button station and pendant push button.
The hoist shall be supplied with fail-safe brakes for all the motors. For hoist, in addition
to the conventional rack & pinion operated limit switch, separate limit switch with
operating device near the hook shall be provided for protection of wire rope. The hoist is
to be provided complete with required cables, flexible cables, trailing cable &
arrangement with rail & rollers for trolley travel. All the cables shall be 1100 Volts rated.
The trailing cables shall be multistrand copper conductor with galvanized screen wire
armored & overall FRLS sheathed.
The rollers shall be provided with clamping arrangement for the power & control cables
separately. The rollers shall move over the rails smoothly. A multistrand wire rope to be
provided between the rollers for to & fro movement & rollers are pulled by wire rope and
not by the cables.
The cables to be provided on fixed parts shall also be 1100 Volts rated, galvanized round
wire armored, FRLS overall sheathed. The control wiring shall be suitably numbered &
ferrule to be provided for convenience of trouble-shooting. The control panel doors,
components, terminals, push buttons shall be suitably labeled for easy identification.

A complete wiring diagram shall be sent along with the offer with full technical
particulars, details of electrical equipment e.g. motors, Limit switches, brakes, push
buttons, control panel, fuse switch units, contactors, thermal overload relays, timers,
indicating lamps, terminals etc. giving type, make, capacity, rating, confirming whether
these are according to any IS-specification numbers or not etc. T-track current collection
system to be supplied with necessary cable looping (cable shall be total length of travel +
6 m extra).

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CHECK-LIST FOR TECHNICAL REQUIREMENT

Bidder’s
SN Technical Requirement
Response
01 Trolley Girder Beam (ISMB-250) of M.S. construction
02 Trolley Travel length as decided during detail engineering.
03 Rail alignment is within 2 mm & Straightness =  2 mm
04 Hoist hook to have sling locking facility
05 Hook shall have thrust bearings fitted
06 Hoist wheels to be designed for the maximum design load.
Hoisting length, as specified in table, under 90 % of fully wound-rope-drum
07
condition
Hoist shall have minimum three round of rope left on rope drum when hook
08
touches floor level
09 Hoist wire rope as well as Slings to be lubricated with Cardium compound
Material of rail, wheels, gear boxes shall be EN-8 in duly heat treated
10
condition
Rope drum shall be of M.S. construction (seamless) and meets IS-3177
11
requirement & gear boxes enclosed type
Trolley travel speed shall be equal to 12 M/minute & Hoisting speed shall be
12
6 M/minute, under full load condition
Painting of hoist with a base coat of red oxide primer followed by two coats of
13
synthetic enamel paint, yellow in shade (total DFT = 120 micron)
14 Name plate shall be provided as described
15 All Electric components shall meet the specifications as described
Trolley Travel, Hoisting / lowering shall be provided with limit switches &
16
travel ends with Safety Bumpers
Wire Slings shall have metallic thimbles at both ends, kink free ropes, joint
17
less, multiple strands type, capacity marked on metallic socket
Complete wiring diagram is sent with the offer with full technical particulars of
motors, limit switches, brakes, push buttons, control panel, fuse switch units,
18
contactors, thermal overload relays, timers, indicating lamps, terminals etc,
along with there IS-numbers
19 List of deviations have been clearly brought out in separate annexure

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M-VII. SPECIFICATION FOR PAINTING: PIPING & EQUIPMENT

7.1 General

7.1.1 This technical specification shall be applicable for the work covered by the contract, and
without prejudice to the various codes of practice, standard specifications etc. It is
understood that contractor shall carry out the work in all respects with the best quality of
materials and workmanship and in accordance with the best engineering practice and
instructions of Company Site Representative.
7.1.2 Wherever it is stated in the specification that a specific material is to be supplied or a
specific work is to be done, it shall be deemed that the same shall be supplied or carried
out by the contractor. Any deviation from this standard without written deviation permit
from appropriate authority will result in rejection of job.

7.2 Scope
7.2.1 Scope of work covered in the specification shall include, without being limited to the
following.
7.2.2 This specification defines the requirements for surface preparation, selection and
application of paints on external surfaces of piping, vessels, etc. The items listed in the
heading of tables of paint systems is indicative only, however the contractor is fully
responsible for supply of all paint materials, carrying out all the necessary painting,
coating and lining on external and internal surfaces as per the tender requirement.

7.3 Extent of Work

7.3.1 The following surfaces and materials shall require shop, pre-erection and field painting:
a) All uninsulated carbon steel piping fittings and valves (including painting of
identification marks), furnace, ducts and stacks.
b) All uninsulated C.S. equipment like columns, vessels, drums, heat exchangers, pumps,
compressors, electrical panels and motors etc.
c) All items contained in a package unit as necessary.
d) All structural steel work, pipe, structural steel supports, Equipment like Pump etc;
walkways, handrails, ladders, Platforms etc.
e) Identification colour bands on all piping as required including insulated aluminium clad,
Galvanized and nonferrous piping.
f) Identification lettering / numbering on all painted surfaces of piping insulated
aluminium clad, galvanized and non-ferrous piping.

g) Marking / identification signs on painted surfaces of piping Hazardous service.

h) Supply of all primers, paints and all other materials required for painting other than
Owner's supply.
i) Over insulation surface of pipes wherever required.
j) Painting under insulation for carbon steel as specified.
k) Repair work of damaged / pre-erection / fabrication shop primer and weld joints at
field.

7.3.2 The following surfaces and materials shall not require painting in general. However, if
there are any specific requirements by the owner, the same shall be painted as per the relevant
specifications:

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a. Plastic and / or plastic coated materials

c. Non-ferrous materials like aluminum etc.
7.3.3 Unless otherwise instructed final painting on pre-erection / shop primed pipes shall be
painted in the field, only after the mechanical completion, testing on systems are completed as
well as after completion of steam purging wherever required.
7.3.4 Changes and deviations required for any specific job due to HWB requirement or
otherwise shall be referred to Company for deviation permit.

7.4 Codes & Standards

7.4.1 Without prejudice to the provision of Clause 1.1 above and the detailed specifications of
the contract, the following codes and standards shall be followed for the work covered by this
contract.
IS-5, 2004 Ed. : Paint Colour Code for Piping
IS- Methods of test for ready mixed paints and
101, : enamels.

ASA 13.1-1981 : Scheme for identification of piping systems:

American National Standards Institution.
Indian Standard for Pipeline Identification-Colour
IS 2379-1990 : Code.

7.4.2 Surface Preparation Standards

Following standards shall be followed for surface preparations:
 Swedish Standard - SIS-05 5900-1967 (Surface preparations standards for
Painting Steel Surfaces).
 This standard contains photographs of the various standards on four different
degrees of rusted steel and as such is preferable for inspection purpose by the
Company Site Representative.
 Steel Structures Painting Council, U.S.A. (Surface Preparation Specifications
(SSPC-SP).
 British Standards (Surface Finish of Blast-cleaned for Painting) BS-4232.
 National Association of Corrosion Engineers, U.S.A., (NACE).
 The contractor shall arrange, at his own cost, to keep a set of latest edition of
above standards and codes at site.

7.4.3 The paint manufacturer's instructions shall be followed as far as practicable at all times.
Particular attention shall be paid to the following:
 Instructions for storage to avoid exposure as well as extremes of temperature.
 Surface preparation prior to painting.
 Mixing and thinning.
 Application of paints and recommended limit on time intervals between coats.

7.5 Equipment
 All tools, brushes, rollers, spray Guns, blast material, hand power tools for
cleaning and all equipments, scaffolding materials, shot / sand blasting
equipments & air compressors etc. required to be used shall be suitable for the
work and all in good order and shall be arranged by the contractor at site and in
sufficient quantity.
 Mechanical mixing shall be used for paint mixing operations in case of two pack
systems except that the Company Site Representative may allow the hand mixing

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of small quantities at his discretion.

7.6 Surface Preparation, Non Compatible Shop Primer, Coating Procedure, Application
& Repair and Documentation
7.6.1 General
 In order to achieve the maximum durability, one or more of following methods of
surface preparation shall be followed, depending on condition of steel surface and as
instructed by Company Site Representative. Adhesion of the paint film to surface
depends largely on the degree of cleanliness of the metal surface. Proper surface
preparation contributes more to the success of the paint protective system.
a. Manual or hand tool cleaning.
b. Mechanical or power tool cleaning.

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f.

 Surface shall not be coated in rain, wind or in environment where injurious

airborne elements exists, when the steel surface temperature is less than 5˚F
above dew point when the relative humidity is greater than 85% or when the
temperature is below 40°F. De-humidifier equipment shall be used to control the

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RH and Dew point for proper curing of internal coating of storage tanks.
 Blast cleaned surface shall be coated with one complete application of primer as
soon as practicable but in no case later than 4 hrs. the same day.
 To the maximum extent practicable, each coat of material shall be applied as a
continuous film uniform thickness free of probes. Any spots or areas missed in
application shall be recoated and permitted to dry before the next coat is applied.
Applied paint should have the desired wet film thickness.
 Each coat shall be in proper state of cure or dryness before the application of
succeeding coat. Material shall be considered dry for recoating when an
additional coat can be applied without the development of any detrimental film
irregularities, such as lifting or loss of adhesion of the under coat. Manufacturer
instruction shall be followed for inter coat interval.
 When the successive coat of the same colour have been specified, alternate coat
shall be tinted, when practical, sufficiently to produce enough contrast to
indicate complete coverage of the surface. The tinting material shall be
compatible with the material and not detrimental to its service life.
 Air spray application shall be in accordance with the following:
 The equipment used shall be suitable for the intended purpose, shall be
capable of properly atomizing the paint to be applied, and shall be
equipped with suitable pressure regulators and gauges. The air caps,
nozzles, and needles shall be those recommended by the manufacturer of
the equipment for the material being sprayed. The equipment shall be
kept in satisfactory condition to permit proper paint application.
 Traps or separators shall be provided to remove oil and condensed water
from the air. These traps or separators must be of adequate size and must
be drained periodically during operations. The air from the spray gun
impinging against the surface shall show no condensed water or oil.
 Ingredients shall be kept properly mixed in the spray pots or containers
during application by continuous mechanical agitation.
 The pressure on the material in the pot and of the air at the gun shall be
adjusted for optimum spraying effectiveness. The pressure on the material
in the pot shall be adjusted when necessary for changes in elevation of the
gun above the pot. The atomizing air pressure at the gun shall be high
enough to properly atomize the paint but not so high as to cause excessive
fogging of paint, excessive evaporation of solvent, or less by over spray
 Spray equipment shall be kept sufficiently clean so that dirt, dried paint,
and other foreign materials are not deposited in the paint film. Any
solvents left in the equipment shall be completely removed before
applying paint to the surface being painted.
 Paint shall be applied in a uniform layer, with overlapping at the edge of
the spray pattern. The spray patterns shall be adjusted so that the paint is
deposited uniformly. During application, the gun shall be held
perpendicular to the surface and at a distance, which will ensure that a
wet layer of paint is deposited on the surface. The trigger of the gun
should be released at the end of each stroke.
 All runs and sags shall be brushed out immediately or the paint shall be
removed and the surface repainted.
 Areas inaccessible to the spray gun shall be painted by brush; if not
accessible by brush, daubers or sheepskins shall be used.
 All nameplates, manufacturer’s identification tags, finished flange faces,
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control valve items and similar items shall be masked to prohibit coating
deposition. If these surfaces are coated, the component shall be cleaned
and resorted to its original condition.
 Edges of structural shapes and irregular coated surfaces shall be coated
first and an extra pass made later.

 If spray gun shows choking, immediately de-choking procedure shall be

followed.

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 No coat shall be applied until the preceding coat dries off completely. The
material shall be considered dry for re-coating when another coat can be applied
without the development of any film irregularities such as lifting or loss of
adhesion of undercoats. Drying time of the applied coat should not exceed
maximum specified for it as a first coat; if it exceeds the paint material has
possibly deteriorated or mixing is faulty.
 No paint shall be force dried under conditions, which will cause cracking,
wrinkling, blistering formation of pores, or detrimentally affect the conditions of
the paint.
 No drier shall be added to paint on the job unless specifically called for in the
manufacturer’s specification for the paint.
 Paint shall be protected from rain, condensation, contamination, snow and
freezing until dry to the fullest extent practicable.

Where paint has been damaged in handling and in transportation, the repair of
damaged coating of pre-erection/fabrication shall be as given below.
 Repair of damaged inorganic zinc silicate primer or Etch Primer after
erection/welding:
 Quickly remove the primer from damaged area by mechanical scraping and
emery paper to expose the white metal. Blast cleans the surface if possible.
Feather the primer over the intact adjacent surface surrounding the damaged area
by emery paper.
 Repair of damaged pre-erection and shop priming in the design temperature
range of -90° C to 300° C.





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7.7 Paint Materials

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7.8 Painting System

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7.9 Piping Colour Code

7.10 Identification of Vessels, Pumps, Piping etc.

7.11 Primer Application



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Notes:
1. Application and arrangement of colour bands shall be as per IS 2379 – 1990.
2. Color Code for other process services shall be decided during detailed engineering.
3. Service wise selection of colour is as per IS 2379 – 1990, colour shades as per IS - 5

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M-VIII. Mechanical Specification for Graphite Heat exchangers, Condensers

& coolers

8.1 Scope of work

The scope of work includes but not limited to following:

8.1.1 The entire comprising of Graphite (Block Type) comes under vendor scope.
8.1.2 Design/selection, fabrication & supply, inspection & testing, erection & assembly at site
and guarantee run of the entire system based on the P& ID, data sheets & specifications
and the location plan listed in the “Attachments” sheet.
8.1.3 Detailed engineering of entire system is in vendor’s scope.
8.1.4 Submission of Calculations, Drawings/documents as per the QAP attached.
8.1.5 The Graphite Plate Heat Exchanger shall be Box Type heat exchanger suitable for the
service conditions mentioned in the heat exchanger data sheet.
8.1.6 Preparation and obtaining approval of welding Procedure Specification and Procedure
Qualification record.
8.1.7 Inspection and testing of all components of the system. The detailed quality Assurance
plan shall be submitted to the HWB for the approval. Pre-dispatch inspection of critical
bought-out items such as the graphite plate heat exchanger, condensers and coolers etc.
shall be carried out at the manufacturer’s works. All inspection should be witnessed by
HWB.
8.1.8 Quality assurance plan for site activities shall be submitted separately to HWB for
approval.
8.1.9 Non-Destructive testing of the equipment / component of the system as per relevant
code requirements/ good engineering practice.

8.2 Design
8.2.1 The vendor shall do the design and detailed engineering of the entire system. Vendor
shall obtain purchaser’s approval for the mechanical design calculations before starting
fabrication.
8.2.2 The layout plan and the piping isometric shall be submitted to HWB sufficiently for
approval. Foundation loadings and foundation details shall be submitted HWB
sufficiently in advance.
8.2.3 Submission of manufacturer’s design calculations and fabrication drawings of the
Graphite Plate Heat Exchanger for review by HWB.

8.3 Materials
8.3.1 MOC of the items shall be as per the relevant equipment data sheet attached with the
TPS.
8.3.2 Vendor shall furnish complete, Item wise MTO in the in the drawing.
8.3.3 Structural steel shall conform to IS 2062 or equivalent of weldable quality.
8.3.4 All material including structurals supplied by the vendor shall meet the requirements of
codes and standards.
8.3.5 Test certificate for the materials shall be submitted to RCF for review and approval.
8.3.6 Prior written permission shall be obtained from HWB for any change in material
specification.

8.4 Testing and Inspection

8.4.1 HWB or their representatives shall carry out inspection at various stages of fabrication /
procurement, including bought-out items and raw material identification. Vendor shall
submit a detailed plan for review and approval by HWB.

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8.4.2 Approval of work by HWB shall in no way relieve the vendor of his responsibility in
meeting all the provisions of the Enquiry conditions.

8.5 Spares
The following spares are included in the vendor’s scope of supply.
a. 200% gasket for every type installed
b. 10% bolts / nuts / washers / clamps (minimum 2 Nos. of each size).

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Chapter-9 Technical specification

M-IX PIPING SPECIFICATIONS

9.1 SS Piping Specifications

ANSI COROSSION DESIGN TEMPERATURE ºC 150

CLASS ALLOWANCE DESIGN PRESSURE Kg/cm2 10
150 # 0 mm (g)
SERVICE : All Services as indicated in P&ID with SS
1. ALL WELDS SHALL HAVE 100% VISUAL EXAMINATION.
NOTES

2. RADIOGRAPHIC EXAMINATION OF BW SHALL BE 100%.

3. 100% FOR WELDED JOINTS DP / MP CHECKED.
4. ROOT RUN BY GTAW PROCESS. ROOT WELDS TO BE 100% DP TESTED.

ITEM SIZE DESCRIPTION

MAINTENANCE ALL FLANGED (BUT TO BE KEPT MINIMUM)
JOINTS

PIPE JOINTS All BUTT WELDED

DRAINS LINES ≤ 1 LINE SIZE

½”
>1 MIN. 1 ½” OR AS PER P & ID
½”

VENTS LINES ≤ ¾” LINE SIZE

> ¾” OR AS PER P&ID
¾”

TEMP. CONN. 1 ½” OR AS FLANGED

PER P&ID
ORIFICE TAPS 1 ½” OR AS TAPS ON LINE WITH FLANGED PLUG VALVE
PER P&ID
PRESSURE GAUGE 1 ½” OR AS WITH FLANGED PLUG VALVE
CONN. PER P&ID

NOTE HEAVY WATER BOARD, 5TH FLOOR, V.S.

BHAVAN, MUMBAI 400094
Prepared PROJECT: SPP
by SS
Reviewed PIPING TECHNICAL
by SPECIFICATION
Approved SHEET 1 OF 4
by

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Chapter-9 Technical specification

FACE DIMENSION MATERIAL

S.NO.
ITEM TYPE END/ DIAMETER RANGE SCH / FINISH/ STANDARD
FACING LOW HIGH THK / RADIUS DESCRIPTION NOTE
RATING
Inch Inch
SEAMLESS PE 0.5 1.0 40 S ANSI B – 36.19 A 312 TP 304 L
PIPE

SEAMLESS BE Above 1” 40 S ANSI B – 36.19 A 312 TP 304 L

WN / Slip-On RF All Sizes 150 # 63-85 RMS ANSI B – 16.5 A 182 F 304 L
FLANGES

BLIND RF All Sizes 150 # 63-85 RMS ANSI B – 16.5 A 182 F 304 L

ALL FITTINGS BW 0.5 1.0 3000 # ANSI B – 16.11 A 182 F 304 L

FITTINGS

BW 1.5” AND ABOVE 40 S R= 1.50 ANSI B – 16.9 A 403 WP 304 L

NOTE HEAVY WATER BOARD, 5TH FLOOR, V.S. BHAVAN, MUMBAI 400094
Prepared by PROJECT: SPP
Reviewed by PIPING TECHNICAL SPECIFICATION SS
Approved by SHEET 2 OF 4

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Chapter-9 Technical specification
FACE DIMENSION MATERIAL

ITEM

NO.
TYPE END/ DIAMETER RANGE SCH / FINISH/ STANDARD

NO.
SR.

EM
FACING LOW HIGH THK / RADIUS DESCRIPTION NOTE
RATING
Inch Inch
GATE BW 0.5 1.5 800 API – 602 A 182 F 304 L
GLOBE BW 0.5 1.5 800 BS – 2995 TRIM HARDNESS
35 HRC
CHECK BW 0.5 1.5 800 BS – 2995
VALVES

BALL BW 0.5 1.5 800 ANSI B 16.34

BELLOW SEAL BW 0.5 1.5 800 ANSI B 16.34
BUTTERFLY BW 0.5 1.5 800 IS 5155
GATE FF 2.0 12.0 150 API - 600
GLOBE FF 2.0 12.0 150 63-85 RMS BS - 1873 A 351 GR CF 8
TRIM HARDNESS
CHECK FF 2.0 12.0 150 BS – 1868
35 HRC
PLUG FF 0.5 4.0 150 BS 5353
BALL FF 2.0 12.0 150 ANSI B 16.34
BELLOW SEAL FF 2.0 12.0 150 ANSI B 16.34
BUTTERFLY FF 2.0 12.0 150 IS 5155
STUD (FULLY THREADED) ANSI B – 18.2 BOLT: A 193
BOLTI

WITH 2 NUTS Gr B7M

NG

M/C BOLT WITH 1 NUT ANSI B – 18.2 NUT: A 194 Gr

2HM
SKE
GA

ANSI B – 16.21
T

CAF with PTFE Enveloped 0.5 12.0 3 mm

with SS
TRAP FLANGED 0.5 1.5 150 # THERMODYNAMIC MNF’S
MISC

STD A 351 GR CF 8
STRAINER BW 0.5 1.0 150 # Y-TYPE MNF’S STD TRIM HARDNESS
STRAINER FLANGED 1.5 12.0 150 # Y-TYPE MNF’S STD 35 HRC
NOTE HEAVY WATER BOARD, 5TH FLOOR, V.S. BHAVAN, MUMBAI 400094
Prepared by PROJECT: SPP
Reviewed by PIPING TECHNICAL SPECIFICATION SS
Approved by SHEET 3 OF 4

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Chapter-9 Technical specification

BRANCH CONNECTIONS TABLE

24
20
18
16
14
E B.W. TEES
B H BW HALF COUPLING
E 12 R
10
P PIPE TO PIPE
E E A R REINFORCED
E E E 8 N
6
T BW TEES
E E E E C W WELDOLETS
E E E E W 5 H
E E E E W W 4

E E E E W W W 3 P
E E E W W W W W 2 I
½
E E E E W W W W W 2 P
T E E E E W H H H H 1 E
½
T T E E H H H H H H H 1

T T E H H H H H H H H H ¾

T T T H H H H H H H H H H ½
½ ¾ 1 1 2 2 3 4 5 6 8 10 12 14 16 18 20 24
½ ½
RUN PIPE

NOTE HEAVY WATER BOARD, 5TH FLOOR, V.S. BHAVAN, MUMBAI 400094
Prepared by PROJECT: SPP
Reviewed by PIPING TECHNICAL SPECIFICATION SS
Approved by SHEET 4 OF 4

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Chapter-9 Technical specification

9.2 CS Piping Specifications

ANSI CLASS COROSSION ALLOWANCE DESIGN TEMPERATURE ºC 150
150 # 1.5 mm
DESIGN PRESSURE Kg/Cm2 g 10
SERVICE : For all services as indicate in the P&ID
1. ALL WELDS SHALL HAVE 100% VISUAL EXAMINATION.
2. RADIOGRAPHIC EXAMINATION OF BW SHALL BE 10%.
NOTES

3. SW TO BE DP / MP CHECKED.
4. SW BALL VALVES SHALL HAVE 150 MM LONG SMLS. NIPPLES WELDED TO THE BOTH ENDS OF THE VALVE.

ITEM SIZE DESCRIPTION

MAINTENANCE JOINTS ALL FLANGED (BUT TO BE KEPT MINIMUM)

PIPE JOINTS 1 ½” & BELOW 3000 lbs SW FULL COUPLING

2” & ABOVE BUTT WELDED

DRAINS LINES ≤ ¾” LINE SIZE

> ¾” ¾” OR AS PER P & ID

VENTS LINES ≤ ¾” LINE SIZE

> ¾” ¾” OR AS PER P&ID

TEMP. CONN. 1 ½” FLANGED

ORIFICE TAPS ½” FLANGED TAPS ONLY
PRESSURE GAUGE CONN ½” SW SCH.80, 80mm LONG NIPPLE WITH GATE VALVE
NOTE HEAVY WATER BOARD, 5TH FLOOR, V.S. BHAVAN, MUMBAI 400094
Prepared by PROJECT: SPP CS
Reviewed by PIPING TECHNICAL SPECIFICATION
Approved by SHEET 1 OF 4

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Chapter-9 Technical specification

M-9.2 CS Piping Specification

FACE DIMENSION MATERIAL

ITEM

S.NO.

TYPE END/ DIAMETER RANGE SCH / FINISH/ STANDARD

FACING THK / RADIUS
LOW HIGH DESCRIPTION COD
RATING
E
Inch Inch
SEAMLESS PE 0.5 1.5 SCH 80 ANSI B – 36.10 A 106 GR.B
PIPE

SEAMLESS BE 2.0 6.0 SCH 40 ANSI B – 36.10 A 106 GR.B

SW RF 0.5 1.5 150 # SERR. FIN ANSI B – 16.5 A 105

SO RF 2.0 6.0 150 # SERR.FIN ANSI B – 16.5 A 105
FLANGES

BLIND RF 0.5 6.0 150 # SERR.FIN ANSI B – 16.5 A 105

ALL SW 0.5 1.5 3000 # ANSI B – 16.11 A 105

FITTINGS

FITTINGS
BW 2.0 6.0 SCH 40 R= 1.50 ANSI B – 16.9 A234 GR.WPB

NOTE HEAVY WATER BOARD, 5TH FLOOR, V.S. BHAVAN, MUMBAI 400094
Prepared by PROJECT: SPP
Reviewed by PIPING TECHNICAL SPECIFICATION CS
Approved by SHEET 2 OF 4

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Chapter-9 Technical specification

FACE DIMENSION MATERIAL

ITEM

S.NO. TYPE END/ DIAMETER RANGE SCH / FINISH/ STANDARD

FACING LOW HIGH THK / RADIUS DESCRIPTION CODE
RATING
Inch Inch
GATE SW 0.5 1.5 800 API – 602
GLOBE SW 0.5 1.5 800 BS – 2995 A105;
VALVES

CHECK SW 0.5 1.5 800 BS – 2995 13% CR TRIM

BALL SW 0.5 1.5 800 BS – 5351
GATE RF 2.0 6.0 150 API - 600
GLOBE RF 2.0 6.0 150 SERRATE BS - 1873 A216 GR.WCB;
CHECK RF 2.0 6.0 150 D BS – 1868 13% CR TRIM
BALL RF 2.0 6.0 150 FINISH BS – 5351
STUD (FULLY ANSI B – 18.2 BOLT: A 193 Gr
BOLTIN

THREADED) WITH 2 B7
NUTS
G

M/C BOLT WITH 1 NUT ANSI B – 18.2 NUT: A 194 Gr 2H

KET
GAS

CAF RING 0.5 6.0 3 mm ANSI B – 16.21 IS 2712 Gr 0/1

MISC

STRAINER FLANGED 2.0 6.0 150 # Y-TYPE BODY CS + TRIM

/ INTERNAL SS
304
NOTE HEAVY WATER BOARD, 5TH FLOOR, V.S. BHAVAN, MUMBAI 400094
Prepared by PROJECT: SPP
Reviewed by PIPING TECHNICAL SPECIFICATION CS
Approved by SHEET 3 OF 4

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BRANCH CONNECTIONS TABLE

24
20
18

E 16
14
E B.W. TEES
E W B H SW HALF COUPLING
E W W 12 R
10
P PIPE TO PIPE
E W W W A R REINFORCED
E W W W W 8 N
6
S SOCKETLETS
E W W W W W C T SW TEES
E W W W W W W 5 H
4
W WELDOLETS
E W W W W W W W
E W W W W W W W W 3 P
E W W W W W W W W W 2½ I
E W W W W W W W W W W 2 P
T E E H H H H H H H H H 1½ E
T T H H H H H H H H H H H 1

T T T H H H H H H H H H H H ¾

T T T T H H H H H H H H H H H ½
½ ¾ 1 1½ 2 2½ 3 4 5 6 8 10 12 14 16 18 20 24
RUN PIPE

NOTE HEAVY WATER BOARD, 5TH FLOOR, V.S. BHAVAN, MUMBAI 400094
Prepared by PROJECT: SPP
Reviewed by PIPING TECHNICAL SPECIFICATION CS
Approved by SHEET 4 OF 4

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9.3 MSGL Piping Specs

Service Process fluid in glass lined;

Fluid handled:
n-Hexane (liquid and vapour)
xylene (liquid and vapour)
2-Ethyl Hexyl Alcohol (liquid)
HCl gas & Cl2 gas
PCl3 & POCl3
Triethyl amine
Octonyl cholirde
16 % NaOH solution
Design Pressure 6.0 kg/cm2g
Design Temperature Min.00 C; max. 2000 C
Hydro Test Pressure 9.0 kg/cm2g before lining and 6.0 kg/cm2g after lining
S.No Description of Item Size NB Description
1 Pipe All A106 Gr.B sch.80 seamless glass lined
2 Design Code B31.3
3 Flanges All A 105, 150# rating as per ANSI B 16.5 LJF
Stub end All A105 Sch.80
4
Fittings (Elbows, 15 - 25 A 105, 3000# rating
5 Tees, Reducers, etc) 40 & A 105, Sch.80
Above
6 Gasket All CAF with SS corrugated ring and PTFE envelope

7 Bolting All Carbon steel studs ASTM A 193 Gr.B7 with

hexagonal head nuts to ASTM A 194 Gr.2H and
washer all galvanized.
8 Construction All
9 Valves
Diaphragm All Cast Steel body bolted bonnet ASTM A 216
Gr.WCB with flange ends confirming to ANSI
B16.5; glass lined diaphragm valve with PTFE
diaphragm

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9.4. Non-Metallic Piping Specifications

Service Vacuum header

Design Pressure 10.0 kg/cm2 (g)
Design Temperature 0 to 50 deg. C.
Hydro Test Pressure 10.0 kg/cm2 (g)
Slno Description of Item Size NB Description
1 Pipe and fittings All PP with FRP; Fittings shall be butt welded ends
as per DIN 16962 and injection molded.
2 Flanges All PP confirming to 150# ANSI 16.5
3 Stub end All Long neck PP stub end
4 Gasket All PTFE (soft Teflon)
5 Bolting All Carbon steel studs ASTM A 193 Gr.B7 with
hexagonal head nuts to ASTM A 194 Gr.2H and
washer all galvanized.
6 Valves
Ball valves All 3 piece design, reinforced ball, teflon seated, full
bore, flanged ends as per ANSI 16.5, 150#
Check valve All Ball type check valve with flanged ends as per
ANSI 16.5, 150#

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Chapter-9 Technical specification

M-X QUALITY ASSURANCE PLANS

10.1 QUALITY ASSURANCE PLAN FOR EQUIPMENT

1) SCOPE & PURPOSE:

The purpose of this Typical Quality Assurance Plan is to describe general practices and sequence of activities (such as
inspection, testing, control etc.) to be performed during the execution of the project. This is a typical QAP and should
be customized by suitable modifications keeping in mind tender specification requirements, codes, standards and
vendor/sub-vendor practices.
2) ABBREVIATIONS & DEFINITIONS:
Description Abbreviations Description Abbreviations
Performed By P Transfer Of Identification Mark TRA
Witnessed By W Longitudinal Weld LSEAM
Reviewed By R Circumferential Weld CSEAM
Customer Hold Point CHP Root Run Weld ROOT
HWB/DAE 1 OR CL Test Certificates Verification TC VER
Third Party Inspection Agency 2 Radiographs / Charts Review RVW
Contractor 3 OR CT Visual Check VIS
Sub-vendor 4 Measurement MEAS
External Laboratory / Agency 5 Extent of Check 100% / 10%
Dimensional Check DIM Approved Drawing APD DWG
Orientation Check ORI Material Specification MTL SPEC
Magnetic Particle Test MPT Test Certificates TC
Liquid Penetrant Test LPT Machined Component M/C
Radiography Test RT Nondestructive Testing NDT
Ultrasonic Test UST Approved Procedure APD PRO
Pneumatic Test PNE 100% Check 100%
Leak Test LEAK Inspection Reports REP
Post-weld Heat Treatment /Stress Relieving HT Machined Component M/C
Fit-up Check FIT Material Identification ID

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Chapter-9 Technical specification

EQUIPMENTS
Reference Agency
Sr. Quantum of Format of
Component & Type of Document
Characteristics
Operation Check Acceptance
No. Check Records P W R
Criteria

1 2 3 4 5 6 7 8 9 10

Chemical Verify TC+Sample TC 4/5 4/5 1/2/3

Plates For Shell, Mechanical Verify TC+Sample TC 4/5 1/2/3 1/2/3

1
Dish end Etc.
Measure/
DIM & VIS 100% Report 4 1/2/3 1/2
VIS

Chemical Verify TC+Sample TC 4/5 3/4/5 1/2/3

Mechanical Verify TC+Sample TC 4/5 1/2/3 1/2/3

Bought Out APD DWG /
Forgings, MPT/LPT (M/C) NDT 100% Report 4 1/2/3 1/2
2
Fittings, Pipes, APD PRO /
Bars, Etc. UST (M/C) NDT 100% Report 4 1/2/3 1/2
Material
Measure/ Specification /
DIM & VIS 100% Report 4 1/2/3 1/2
Visual.
ASME Code
3 Welding WPS/PQR/WPQ Verify 100% PQR & TC 3,4 1/2/3 1/2

ID & TRA ID VIS 100% Report 3,4 1/2/3 1/2

Fabrication Edge & Fit-Ups, Measure/

100% List 3,4 1/2/3 1/2
Shell, Dish end Orientation Visual.
4
Nozzle &
Pressure Parts MPT/LPT/UST/RT of
NDT 100% Report / RVW 4 1/2/3 1/2
L-Seam, C-Seam, Root

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Chapter-9 Technical specification

Measure/ Report
Fit-Ups, 100% 3,4 3 1/2
Support, Lugs, Visual.
5
Cleats Etc Report
LPT NDT 100% 3,4 1/2/3 1/2
PWHT, Sol.
6 Heat Cycle Visual 100% HT Chart 3 1/2/3 1/2
Annealing
TRA ID Visual 100% Report 3,4 1/2/3 1/2
HT VIS 100% HT Chart 3 1/2
RVW
RT NDT 100% 4 1/2/3 1/2
Formed
7
Components Report
Knuckle LPT NDT 100% 4 1/2/3 1/2
APD DWG /
Measure/ Report
DIM & VIS 100% APD PRO / 4 1/2/3 1/2
Visual.
Report
TRA ID Visual 100% Material 3,4 1/2/3 1/2
Measure/ Specification /
Assembly of Dish- FIT-UPS, Orientation 100% List 3,4 1/2/3 1/2
Visual.
8 End, Shell, Nozzle, ASME Code Report
Supports Etc. LPT Root & Final NDT 100% 4 1/2/3 1/2
RVW
RT NDT 100% 4 1/2/3 1/2
Measure/
DIM, Visual, Helium Leak Report
9 Final Inspection Visual, 100% 3 1, 2 1,2
Test & Hydraulic, RVW
Integrity
Surface Prep,
Report
10 Painting, Stamping, Visual, ID Visual 100% 3 1, 2 1,2
N2 Filling
Final Doc. & Verify,
11 Verify 100% Report 3 1,2
Release Compilation

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Chapter-9 Technical specification

TYPE OF WELDS AND CLASSIFICATION OF EXAMINATION LEVELS

Sr.
Type Of Weld Examination Level
No.
Root Pass 100% Visual + 100% Supplementary Exam. (LPT On Others)
1 Butt Completed 100% Visual + 100% Supplementary Exam. (LPT On Others) + 100%
Welds Weld Radiographic Examination
Root Pass 100% Visual + 100% Supplementary Exam. (LPT On Others)
Nozzle
2 Completed 100% Visual + 100% Supplementary Exam. (LPT On Others) + 100%
Welds
Weld Radiographic Examination
Seal First Pass 100% Visual + 100% Supplementary Exam. (LPT On Others)
3
Welds Final Pass 100% Visual + 100% Supplementary Exam. (LPT On Others)
Socket Welds / Slip First Pass 100% Visual + 100% Supplementary Exam. (LPT On Others)
4
On Flange Joints Final Pass 100% Visual + 100% Supplementary Exam. (LPT On Others)
Structural First Pass 100% Visual + 100% Supplementary Exam. (LPT On Others)
5
Attachment Welds Final Pass 100% Visual + 100% Supplementary Exam. (LPT On Others)
Hanger & Support First Pass 100% Visual + 100% Supplementary Exam. (LPT On Others)
6
Welds Final Pass 100% Visual + 100% Supplementary Exam. (LPT On Others)

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Chapter-9 Technical specification

10.2 QAP FOR PIPING

PIPING FABRICATION & PIPING AND EQUIPMENT ERECTION
SN Component & Characteristics Type Quantum Reference Format
Operation Of Of Document Of
Check Check Acceptance Records
Criteria
1 2 3 4 5 6 7
Chemical Verify TC+Sample TC
1 Items Procured by Mechanical Verify TC+Sample TC
the Contractor)
Other Code Requirements Verify TC+Sample APD DWG / TC
APD PRO /
DIM & VIS Measure/ 100% Tender Report
Vis. Specification
/
2 Welding WPS/PQR/WPQ VIS Specimen ASME Code / PQR &
ANSI Code TC
Edge & Fit-Ups, Measure/ 100% List
3 Pre-Fabrication Orientation Vis.
MPT/LPT/ of Root NDT 100% Report

Radiography (Process NDT 100% Film

Line)
Radiography (Utility Line) NDT 10% Film

4 Supports Fit-Ups, Measure/ 100% Report

Vis.
LPT NDT 100% Report

5 Erection Erection Tolerances Measure/ 100% Report

Vis.
6 Final Inspection DIM, Visual, Helium Measure/ 100% Report
Leak Test, Vacuum Hold Vis.,
Test & Hydraulic Integrity

7 Final Doc. & Verify, Verify 100% Report

Release Compilation

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Chapter-9 Technical specification

10.3 QAP for MSGL Reactors

Characteristics Endorsement
SrNo Activity Reference back-up document
to be checked Supplier TPI /HWB
Visual & Dimensions, Physical /Chemical
1 Material Inspection Properties of MTC. Refer MTCs H R

In-process Inspection of Equipment:

Set up examination of back chippedarea.
2 Weld Fit up like Shell L/S, C/S between Dishto Refer Log sheet H R
Surveillance of WPS/WPQ & weld visuals.
Shell & Nozzle to Dish Set up,etc.
3 NDT of inner vessel (On accessible joints) Weld defect NDT UT Report H R

4 Release of Equipment for Glass lining Visual &Dimension Fabrication inspection Report H R
In-process Inspection at Jacket Fitting Section:
Fit-up exam. i.e. Root Gap,Offset,
Weld fit up of Jacket, Jacket Nozzles,Side
5 Dimensions. Refer Log sheet H R
Brackets, Earthing Cleats, N/P Bracket,Overall
Surveillance of WPS/WPQ & weld visuals
Dimension.
6 Visual Inspection before Final Testing Visual Final Dimension inspection Report H W

Hydro test of Equipment*, Jacket* & Bottom Outlet Factory Acceptance Test
7 Water tightening + deformation (if any) H W
Valve (After Glassing Operation) Certificate
Factory Acceptance Test
8 Running Trial Test of Equipment Alignment, Current, RPM,Temperature. H W
Certificate
Spark test at 10 KVA & GL Thicknessas Factory Acceptance Test
9 Glass Lining & Inside Visual Inspection H W
per DIN 28721-1 (2011)Std. Certificate

Issuing Final Inspection Release Note /Dispatch Factory Certificate & Bought outTest Factory Acceptance Test
10 H W
clearance Certificates Certificate

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Chapter-9 Technical specification

Explanation of Abbreviations:

H=Hold Point:
Stage shall be kept hold until respective agencies have accepted and cleared the stage for
further processing.

R=ReviewPoint:Work can proceed after carrying out the inspection activity and
documenting the results.

W=WitnessPoint:TPI/Client shall be intimated for the inspection of a

stage.Work can proceed further,if TPI/Client is not able to attend the inspection
within a day.

TPI:Third PartyInspection-Respective Inspection Agency as mentioned by the client.

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Chapter-9 Technical specification

10.4 QAP for Heat Exchangers

Stages Type of check Quantity Specification / Reference / Records / Vendor TPI HWB Remarks QAP
Acceptance norms Documents Compliance
1.1 Inspection: Check

1.2 Raw
Material Review of certificates
-Material test 100% As per applicable ASTM Mill test reports, R R - -
certificates( standard/PO requirements dimensional
Review of
Chemical and check reports,
certificates
mechanical) HT charts, NDT
-Heat treatment reports reports
-NDT reports
-Hydro test reports
-Identification &
correlation/transfer of
markings.
2.0 Finished Chemical Testing:
Tubes Chemical analysis Sampling as As per applicable Test/ P&W R - -
per ASTM standard / PO Analysis
applicable requirements report/PO
ASTM
standard
(Min. 1 No.
Per each
heat)

PMI check 100% -do- PMI report P&W RW - -

Mechanical
Properties:

A. Tensile test Sampling as per -do- Test reports P&W R - -

applicable ASTM
Standard (Min.1
No. per each
heat)`
B. Hardness Test -do- -do- -do- P&W RW - -

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Chapter-9 Technical specification
Stages Type of check Quantity Specification / Records / Vendor TPI HWB Remarks QAP
Reference / Documents Compliance
Check
Acceptance norms
C. Flattening -do- As per applicable Test reports P&W R - -
ASTM standard / PO
requirements

D. Flaring -do- -do- -do- P&W R - -

E. Heat Treatment of 100% -do- -do- P&W R - Review

The tubes after forming Of HT
As applicable charts
2.1 NDT
NDE:
A. Visual inspection & 100% P.O .,App. Drawing Inspection P&W RW - -
Dimensional check. & as per applicable reports
ASTM standard.
B. DPT of ‘U’ section 100% -do- -do- P&W RW - -
Of tubes (for U tubes)

C. ECT of tubes 100% -do- ECT reports P&W RW - -

3.0 Hydrostatic test Hydro test 100% As per applicable ASTM Test P&W RW -
standard / PO certificate
requirements
4.0 Drying and Drying by air blowing 100% As per standard - P&W W R
preservation Cleanliness & proper practice
preservation
5.0
Documentation Verification for 100% PO/QAP Final report P&W R - -
completeness, compilation
of inspection test records
of TPI certified documents
for submission to
customer

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Chapter-9 Technical specification

M - 10.5 Quality Assurance Plan for Impregnated Graphite Condenser

Sr. ACTIVITY CHECK PROCEDURE/ ACCEPTANCE DOCUMENT INSPECTION

No. POINTS DRAWING CRITERIA GENERATED REQUIREMENT
SPECIFICATION MFR TPI
A. For Graphite
Components

1. Raw Material Basic / Manufacturer’s Manufacturer’s Declaration for P R

-Impervious Physical Specifications Specifications impregnated
Graphite Properties Graphite
a .Circular & Sq. Properties
Rod
2. Inprocess a.Visual Manufacturer’s a.No chip-off, W --
Check Specifications good finish etc. Inprocess
Inspection
b.Dimension b. Acceptance Report W --
within tolerance
limit
3. Imperviousness Pneumatic Manufacturer’s No leakage at Declaration for W R
Testing Specifications rated pressure as Imperviousnes
per GA Drawing s Testing
(Blocks & End
Chambers)

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Chapter-9 Technical specification

B. STEEL PARTS

MATERIAL
IDENTIFICATION Material as per Manufacturer’s Material as per Declaration for P R
1.
drawing drawing drawing fabricated
specification specification components

2. Inprocess a.Fitup Manufacturer’s Weld preparation -- W --

or drawing and root gap as
Back chip per drawing
D.P. of root W --
run
3. Final Fabricated a.Final, Visual Drawing No visual defect, W R
Component & General Specifications good
Workmanship workmanship Final
components
b.Dimensions declaration for
& Pressure As per fabricated
Test Manufacturer’s component W R
detail component
drawing
C. Final Assembly a.Overall a. As per W W
dimensions Manufacturer’s Final
b.Hydrotest Manufacturer’s GA drawing Inspection
(Pressure side GA drawing b.No leakage and Report.
& Service pressure drop W W
side) during the test
D. Painting Uniformity of
layer, no roll
down, good Manufacturer’s Manufacturer’s -- W --
finish, DFT as GA drawing GA drawing
per drawing.
Inspection Activities:
R = Review, W = Witness, P = Perform

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Chapter-9 Technical specification

M - 10.6 Quality Assurance Plan for Centrifugal Pump / Diaphragm Pump

STAGE INSPN DESCRPTION CHARACTERISTICS CLASS TYPE OF QUANTUM REFERENCE ACCEPTANCE FORMAT OF Agency
CHECK OF CHECK DOCUMENT NORMS RECORDS
VQ C
RAW MATERIAL Casings, Piston, Chemical Composition Critical Reviewing of 100 % 1 Per Material as per Relevant Standard Foundry T C V V
CASTINGS Plunger Foundry TC , Heat specification
Mechanical sheet
Mechanical properties Test & V V
Heat Treatment Chemical V V
Surface Defects Analysis W -
Dimensional Check Major Measurement 100 % Vendor Drg . Vendor Drg . W -
PMI Wetted part with Mechanical properties Major Chemical 100% ASME material Relevant Standard PMI W W
stainless steel as composition code W W
MOC
WROUGHT Major parts such Chemical Composition Major Chemical 1 NO / Batch Relevant Relevant Standard Vendor T C W V
as casing, shaft, Analysis Standard
impeller,
Connecting rod
Mechanical properties Mechanical
Crank shaft (as
Test
applicable)
IN PROCESS Dimension of Dimension Check / Major Mechanical / 100 % Vendor Drg . Vendor Drg . Inspection Report W -
Components Cleaning & Deburring Visual
listed above
ASSEMBLY Casings Hydro Test ( Pressure Major Visual 100 % As per code No leakage Vendor T C W W
&TESTING test)

ERFORMANCE Pump Assembly Q Vs Stroke Length (for Critical Performance 100 % Pump Datasheet Pump Datasheet Performance Test W W
TEST WITH SHOP diaphargm) Test with test Report
CALIBRATED bed motor
MOTOR Q Vs H, NPSH (for
centrifugal pump)
Vibration Noise Level
Bearing Oil Temperature

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Chapter-9 Technical specification

Strip Test Major Visual 100 % No Brushing of W W

Inspection of internal Parts
wear parts

FINAL Pump Assembly Overall Dimensions & Major Measurement & 100 % Approved Drgs. Approved Drgs. Vendor Drg. W W
Workmanship

Painting & Packing Major Visual 100 % Vendor Standard Vendor Standard - W -

V -Vendor, C-Client, W- Witness , V -Verification of Records

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Chapter-9 Technical specification

M - X1. LIST OF APPLICABLE STANDARDS AND CODES

Following is the recommended List of Codes which may be used for design, fabrication,
installation or testing purpose. Where the codes are mandatory, the same have been mentioned
in the technical specifications. The contractor may also suggest codes other than those listed
subjected to the approval of the HWB.

SN CODE NUMBER CODE DESCRIPTION

1. ASME SEC II Part A Ferrous Material Specifications

2. ASME SEC II Part C Specifications for Welding Rods, Electrodes and Filler
Metals

3. ASME SEC II Part D Material Properties

4. ASME Sec V Non Destructive Examination

5. ASME Sec VIII Div 1 Rules for Construction of Pressure Vessels

6. ASME Sec IX Qualification Standard for Welding & Brazing

Procedures

7. WRC 107 Local Stresses In Spherical And Cylindrical Shells Due

To External Loadings

8. WRC 297 Local Stresses In Cylindrical Shells Due To External

Loadings On Nozzles-
Supplement to WRC Bulletin No. 107 (Revision I)

9. IS 1893 Part 1 Criteria for Earthquake Resistant Design of Structures,

Part 1: General Provisions and Buildings

10. IS 1893 Part 4 Criteria for Earthquake Resistant Design of Structures,

Part 4: Industrial Structures Including Stack-Like
Structures

11. IS 875 Part 3 Code of Practice for Design Loads for (Other Than
Earthquake) Buildings and Structures.

12. ANSI B 31.3 Process Piping

13. ASME B 16.5 Pipe Flanges and Flanged Fittings

14. ASME B 16.9 Factory-Made Wrought Butt-welding Fittings

15. ASME B 16.11 Forged Fittings, Socket-Welding and Threaded

16. ASME B 16.20 Metallic Gaskets for Pipe Flanges

17. ASME B 16.21 Nonmetallic Flat Gaskets for Pipe Flanges

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Chapter-9 Technical specification

18. ASME B 16.25 Butt Welding Ends

19. ASME B 16.34 Valves—Flanged, Threaded, and Welding End

20. IS 2102 Part 1 General Tolerances - Part 1: Tolerances For Linear And
Angular Dimensions Without Individual Tolerance
Indications

21. IS 807 Design, erection and testing (structural portion) of

cranes and hoists - Code of practice

22. IS 3177 Code of Practice for Electric Overhead Travelling

Cranes and Gantry Cranes other than Steel Work
Cranes
23. IS 2379 Color code for identification of pipe lines

24. TEMA Tubular Exchanger Manufacturers Association

25. ANSI B 36.10 Welded & Seamless Wrought Steel Pipe

26. ANSI B 36.19 Stainless Steel Pipe

27. API STD 675 Positive Displacement Pumps - Controlled Volume for
Petroleum, Chemical, and Gas Industry Services

28. ASME B 73.1M Specification for Horizontal End Suction Centrifugal

Pumps for Chemical Process

29. IS 5120 Technical requirements for rotodynamic special

purpose pumps

30. ASME PTC 25 Pressure Relief Devices

31. API 520 Sizing, Selection & Installation of Pressure Relieving

Devices

32. API 521 Pressure-relieving and Depressurizing Systems

33. API 526 Flanged Steel Pressure-relief Valves

34. API 527 Seal Tightness of Pressure Relief Valves

35. DIN ISO 2746 Vitreous and porcelain enamels -- Enameled articles for
service under highly corrosive conditions - High
voltage test

36. BS 4994 Specification for the design

and construction of vessels and storage tanks in
reinforced plastics

37. DVS 2205-1 (along with Design Calculations for containers and apparatus made
Supplement-1) from thermoplastics – Characteristic Values

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Chapter-9 Technical specification

38. DVS-2205-2-1997 Calculation-of-Thermoplastic-Tanks-and-Appatatus-

Vertical-Cylindrical-Non-pressurised-Tanks

39. DVS 2207-1 Welding of Thermoplastics – Heated Tool Welding of

Pipes, Pipelines, Components, Sheets made from PE-
HD

40. DVS 2203 -2 Testing of welded joints of thermoplastic materials –

Tensile Test

41. DVS 2203-4 Testing of welded joints of thermoplastic tubes and

plates – Tensile Creep Test

42. DVS 2210-1 Industrial Pipelines Made of Thermoplastics – Planning

& Execution, Above ground Pipe Systems.

43. DVS 2210-1 (Supplement Industrial Pipelines Made of Thermoplastics – Design

2) & Execution, Above ground Pipe Systems –
Recommendations for the Internal Pressure & Leak
Test

44. DVS 2202-1 Imperfections in Thermoplastic Welding Joints-

features, descriptions & evaluations

45. DIN EN-13067 2003 Plastic Welding Personnel - Qualification Testing of

Welders

46. BS 3505 PVC Pipes

47. BS 7159 : 1989 Design & Construction of Glass Reinforced Plastics

(GRP) Piping Systems for individual plants or sites.

48. BS 6464: 1984 Reinforced-Plastics-Pipes-Fittings-and-Joints-for-

Process-Plants

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 Chapter-9 Technical specification

M-XII SCHEDULE OF QUANTITIES FOR MECHANICAL

The Schedule of Quantities is given herewith to indicate an overall scope regarding

Mechanical activities required to be executed for the Plant by the Contractor. The
quantity of the Process Vessels & EOT Crane indicated in the list shall remain firm.
However, quantities indicated at I-A (B1), I-A (B2) & F1 of the list are only tentative.
Bidders to note that quantities of items may change after detailed engineering and any
addition / deletion of item shall not have any impact on overall cost of the tender.

S. No. DESCRIPTION TAG QTY CAPACITY MOC REMARKS

NO. (m3)
I SUPPLY
A Design (including approval of design calculation and fabrication drawing), raw material
procurement, fabrication, inspection & testing as per approved QAP, painting (Carbon
Steel vessels) transportation, safe delivery at Client's premises & supply of following
equipment as per tender specifications & drawing

(i) Process Vessels

1 Day Tank 43V01 1 2 SS 304L

2 Feed Tank 43V02 1 0.5 MSGL
3 Feed Tank 43V03 1 1 MSGL
4 Feed Tank 43V04 1 0.5 MSGL
5 Day Tank 43V05 1 1 MSGL
6 Day Tank 43V06 1 1 MSGL
7 Charging Vessel 43V07 1 1 SS 304L
8 Charging Vessel 43V08 1 1 SS 304 L
9 Day Tank 43V09 1 1 PPFRVE
10 Day Tank 43V10 1 1 SS 304L
11 Product Tank 43V11 1 1 MSGL
12 Receiver 43V12 1 1 MSGL
13 Receiver 43V13 1 1 MSGL
14 Receiver 43V14 1 1 MSGL
15 Receiver 43V15 1 1 MSGL
16 Excess Receiver 43V16 1 1 SS 304L
17 Dump Tank 43 V 17 1 2 MSGL
18 Drain Tank 43 V 18 1 1 PPFRVE
19 Drain Tank 43 V 19 1 1 PPFRVE
20 Day Tank 44V01 1 5 SS 304L
21 Charging Vessel 44V02 1 1 MSGL
22 Charging Vessel 44V03 1 1 MSGL

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 Chapter-9 Technical specification

TAG CAPACITY
S. No. DESCRIPTION QTY MOC
NO. (m3)
23 Feed Tank 44V04 1 2 SS 304L
24 Feed Tank 44V05 1 2 SS 304L
25 Dump Tank 44V06 1 4 MSGL
26 Feed Tank 44V07 1 2 SS 304L
27 Storage Tank 44V08 1 3 SS 304L
28 Product Tank 44V09 1 2 SS 304L
29 Drain Tank 44V10 1 2 PPFRVE
30 Drain Tank 44V11 1 2 PPFRVE
31 Feed Tank 45 V01 1 5 SS 304 L
32 Product Tank 45 V02 1 5 SS 304 L
33 Decanter 45 D01 1 5 SS 304 L
34 Organic Column 45 C1 1 - SS 304 L
SA 516 gr
35 Aqueous Column 45 C2 1 - 70+1mm
PTFE lining
36 Storage Tank 49 V01 1 20 A 516 Gr 70
37 Storage Tank 49 V02 1 20 A 516 Gr 70
38 Dump Tank 49V03 1 30 A 516 Gr 70
39 Storage Tank 49V04 1 30 A 516 Gr 70
40 Storage Tank 49V05 1 30 A 516 Gr 70
(ii)
Heat Exchangers
As per
Cooling Water
41 43R01 1 Process Data Graphite
Condenser
Sheet
As per
Chilled Water
42 43R02 1 Process Data Graphite
Condenser
Sheet
As per
Cooling Water
44 43R03 1 Process Data Graphite
Condenser
Sheet
As per
Chilled Water
45 43R04 1 Process Data Graphite
Condenser
Sheet
As per
Cooling Water
46 43R05 1 Process Data SS 316L
Condenser
Sheet
As per
Chilled Water
47 43R06 1 Process Data SS 316L
Condenser
Sheet

TAG CAPACITY
S. No. DESCRIPTION QTY MOC
NO. (m3)
48 Condenser, S&T 44 E 1-A 1 Refer Data SS 304L

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 Chapter-9 Technical specification

Sheet
Refer Data
49 Condenser, S&T 44 E 1-B 1 SS 304L
Sheet
Cold Trap,
Refer Data
50 Double Pipe 44 E3 1 SS 304L
Sheet
Type
Cold Trap, Refer Data
51 44 E4 1 SS 304L
Double Pipe Type Sheet
Organic column Refer Data
52 45 R 1 1 SS 304L
reboiler Sheet
Aqueous column Refer Data
53 45 R 2 1 Graphite
reboiler Sheet
Refer Data
54 Head Condenser 45 E 1 1 SS 304L
Sheet
Refer Data
55 Cooler 45 E2 1 SS 304L
Sheet
Refer Data
56 Cooler 45 E3 1 Graphite
Sheet
Refer Data
57 Condenser 45 E4 1 Graphite
Sheet

(iv) Reactors
58 Jacketed Reactors 43RV01 1 2 MSGL
with Agitator &
59 Motor and Flush 43RV02 1 2 MSGL
Bottom valves
Jacketed
60 Reactor with 43RV03 1 2 CS-Ni
Agitator & Motor
61 Reactor 44 RV01 1 5 MSGL
62 Reactor 44 RV02 1 5 MSGL
63 Reactor 44 RV03 1 5 MSGL

(v) Rotating Machinery

43 P01 As per Data
64 2
2EHA Pump A/B Sheet SS 316
43 P05 As per Data
65 2
HEXANE Pump A/B Sheet PP
43 P06 As per Data
66 2
RCL Feed Pump A/B Sheet PP

TAG CAPACITY
S. No. DESCRIPTION QTY MOC
NO. (m3)

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Alkali Charging 43 P07 As per Data

67 2 SS 316
Pump A/B Sheet
Alkali Charging As per Data
68 1 SS 316
Pump 43 P08 A Sheet
HCL Charging 43 P09 As per Data
69 2 PP
Pump A/B Sheet
DM WATER 43 P10 As per Data
70 2 SS 304 L
Feed Pump A/B Sheet
Dump Tank 43 P17 As per Data
71 2 PP
Recirculation A/B Sheet
43 Glass
72 1 -
Agitator of RV01 ARV01 Lined
43 As per Data Glass
73 1
Agitator of RV02 ARV02 Sheet Lined
Ni clad
74 43 1 - carbon
Agitator of RV03 ARV03 steel
Na2CO3(aq) 44 P04 As per Data
75 2 SS304L
Dosing Pump A/B Sheet
Na2CO3(aq) As per Data
76 1 SS304L
Dosing Pump 44 P05 Sheet
Dump Tank 44 P06 As per Data
77 2 PP
Recirculation A/B Sheet

Na2CO3(aq) 44 P07 As per Data

78 2 SS304L
Dosing Pump A/B Sheet

I-Butanol Feed 44 P08 As per Data

79 2 SS 316
Pump A/B Sheet
44 As per Data Glass
80 1
Agitator of RV01 ARV01 Sheet Lined
44 Glass
81 1 -
Agitator of RV02 ARV02 Lined
44 Glass
82 1 -
Agitator of RV03 ARV03 Lined
Organic Column 45 P01 As per Data
83 2 SS 304L
Feed Pump A/B Sheet
Purified Butanol As per Data
84 1 SS 304L
Transfer Pump 45 P02 Sheet
Purified Butanol 45 P03 As per Data
85 2 SS 304L
Pump A/B Sheet
Aqueous Phase 45 As per Data
86 2 SS 304L
Transfer Pump P04A/B Sheet
Organic Phase 45 P05 As per Data
87 2 SS 304L
Transfer Pump A/B Sheet

TAG CAPACITY
S. No. DESCRIPTION QTY MOC
NO. (m3)
49 P01 As per Data
88 EHA Feed Pump 2 SS 316
A/B Sheet
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49 P02 As per Data

89 IAA Feed Pump 2 SS 316
A/B Sheet
Dumped Liquid As per Data
90 49 P03 1 SS 316
Transfer Pump Sheet
N-Butanol Feed 49 P04 As per Data
91 2 SS 316
Pump A/B Sheet

S. No. DESCRIPTION SIZE QTY CAPACITY MOC

B Procurement, inspection & testing as per approved QAP, transportation, safe delivery at
Client's premises & supply of following Piping and its accessories as per tender specifications
& data sheets
MSGL

SS 304 L
1. 0.5”-10” As per Piping
A 106 Gr B
Specifications
Pipes 4.0-4.5km
HDPE
(Approx)
Pipe Fittings MSGL
(Elbows, Tees,
SS 304 L
Flanges,
2. Reducers & 0.5”-10” As per Piping A 106 Gr B
other Specifications
2500 Nos HDPE
miscellaneous
(Approx)
fittings)
Diaphragm As per MSGL
3.
Valves P&ID
As per As per Piping PP
As per P&ID Specifications SS
4.
Ball Valves P&ID
CS
As per PP
5. P&ID SS
NRV CS
SS
As per As per As per Piping
6. Gate Valve CS
P&ID P&ID Specifications
7. As per SS

Globe Valve P&ID CS

S. NO. DESCRIPTION SIZE QTY CAPACITY MOC

C. Procurement, inspection & testing as per approved QAP, transportation, safe delivery at
Client's premises & supply of EOT Crane along with its Erection & Commissioning

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 Chapter-9 Technical specification

As per
As per Tender
1. EOT Crane Tech 1 10 Tons
Specifications
Specs

D. Procurement, inspection & testing as per approved QAP, transportation, safe delivery at
Client's premises & supply of Spares of various equipment & machines

1. Spares As per LOT As per Specifications

Tech
Specs

E. Procurement, transportation, safe delivery at Client's premises & supply of Hot & Cold
Insulation

1. Hot & Cold As per LOT As per Specifications

Insulation Tech
Specs

F. Supply of Structural Steel for supports, equipment platforms, Columns supports etc

1. Structural Steel To be 15 Tons As per detailed Engineering

decided
during
detailed
engg.

II Fabrication of Stainless Steel, Carbon Steel, MSGL, HDPE, PP-FRVE Piping along with
provision of Piping supports as per approved Isometrics, painting of Carbon Steel Piping,
Supports, Structures, Inspection & Testing including application of insulation etc.

1 SS Piping 0.5”-10”

2 CS Piping

3 MSGL Piping As per SN

I(A) &
4 HDPE Piping I(B) above As per Technical Specifications,
drawings etc.
5 PP-FRVE Piping

SN DESCRIPTION Size QTY CAPACITY

III Erection of Stainless Steel, Carbon Steel, MSGL, HDPE, PP-FRVE Piping along with
provision of Piping supports as per approved Isometrics, Inspection & Testing including
hydro testing & application of insulation etc

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1 SS Piping 0.5”-10”

2 CS Piping

3 MSGL Piping As per SN

I(A) &
4 HDPE Piping I(B) above As per Technical Specifications,
drawings etc.
5 PP-FRVE Piping

IV Erection of Stainless Steel, Carbon Steel, MSGL, HDPE, PP-FRVE equipment and rotating
machineries as indicated in SN I(A) & I(B), inspection and testing along with providing
insulation, structural supports, platforms etc

1 SS Equipment & As per

Column the data
sheets
2 CS Equipment
As per SN
3 MSGL Reactors I(A) &
& Vessels I(B) above As per Technical Specifications,
drawings etc.
4 HDPE Tanks

5 PP-FRVE Tank

V Commissioning Lot As per technical specifications

Sub Total ( I to Rs
V)

Taxes for Rs
Supply Part

Taxes for Rs
Service Part

GRAND Rs
TOTAL
(VI+VII)

M - XIII. LIST OF SPARES

CENTRIFUGAL PUMP - Spare for each

1 Wear rings 1 set

2 Bearings 1 set

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3 Throat Bushings 1 set

4 Set of Gaskets / Packing rings of special 2 set
type
Metering Pumps - Spare for each

1 Bearings 1 set
2 Bushings 1 set
3 Set of Gaskets /Packing rings of special type 2set
4 Piston Rings 1 set
Valves - Spare for each type

Items NB ≤ 40 NB 50 to 250 NB ≥300

Nos. Nos. Nos.
1 Stem 25 20 1
2 Plug/Gate/Ball 20 20 1
3 Gland Follower 15 10 1
4 Packings 50 50 5
5 Stem Nut 10 10 2
6 Bonnet Gaskets 50 25 5
7 Bearings 20 10 2
8 Gasket 300%
Piping / Tubing
Items
NB ≤ 40 NB 50 to NB 150 to 250 NB 300 & Over
100
% % % %
1 Fittings 10 10 10 10
2 Flanges 10 10 10 10
3 Bolting 20 20 20 20
4 Gaskets 20 20 20 20
5 Valves 5% of total 3% of total 1 in each 1 in each
Valves qty qty category category
of each type of each
(Min 1 No.) type
(Min 1 No.)

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M - XIV RECOMMENDED VENDOR’S LIST

The recommended sub-vendors and sub-suppliers are given in the technical specification of the
respective items and below . However contractor can suggest and supply from other reputed sub
vendors, or where sub-vendors are not indicated , subject to prior approval from the department
which shall be reviewed and approved by the department as per the criteria given elsewhere in
the tender specification .

1) For Glass Lined Reactors, Glass lined Vessels and Glass lined Piping, Valves :
a) M/S GMM PFAUDLER LTD. Vithal Udyonagar, Karamsad, Gujarat
b) M/S SWISS GLASS COAT EQUIPMENT LTD. Vithal Udyognagar, Anand, Gujarat
c) De-Dietrich Process System, Andheri, Mumbai
2) For Cs-Ni cladded reactor
a) M/s Tinita Engineering (P) Ltd., Mumbai
b) M/s Dynatherm Alloys (P) Ltd., Chennai
c) M/s Titanium (P) Ltd. Chennai

3) For FRP & HDPE Storage Tanks

a) M/S Thermoset Poly Products (I) Pvt. Ltd., Navi Mumbai
b) M/S Polyplast, Mumbai
c) M/S Coroseal, Mumbai
d) M/s J.R. Fibre Glass
4) For Graphite Condensers
a) M/S GRAPHITE INDIA LTD. Nasik
b) M/s BLAST CARBOBLOCKS PVT. LTD. , NAVI MUMBAI
c) M/S SGL CARBON GROUP , PUNE

5) CS SEAMLESS PIPES
a) BHEL (Valves division)
b) Maharastra seamless Ltd.
c) The Indian seamless metal tubes Ltd.
d) TISCO (tube divn.)

6) SS SEAMLESS PIPES
a) Choksi tube company Ltd.
b) Nuclear fuel complex
c) Ratnamani metals & tubes Ltd.

7) PIPE FITTINGS(C.S & S.S)

a) Echjay industry
b) Excel hydro-pneumatics Pvt. Ltd.
c) Micro precision products
d) EBY industries
e) Technomatic (I) Pvt. Ltd.
f) M/s Siddharth & Gautam, Faridabad

8) COMPRESSION FITTINGS
a) Baldota valve & fitting Co. Pvt. LTd.
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b) Excel hydro-pneumatics Pvt. Ltd.

c) Exclesior engg. Works
d) Reliance engg. & electrical Corn.
e) Vikas industrial products
f) Swagelok fluid system components Pvt. Ltd.

9) FABRICATION OF EQUIPMENTS (STORAGE TANKS AND PROCESS

VESSELS)
a) M/s. BHEL
b) M/s. BHPV, Vishakapatinam
c) M/s Hindustan Dorr Oliver, Ahmedabad
d) M/s. Larsen & Toubro Ltd., Mumbai
e) M/s. ISGEC, Yamunanagar, Haryana.
f) M/s. Walchandnagar Industries Ltd., Pune.
g) M/s. Godrej & Boyce Mfg., Mumbai.
h) M/s. G. R. Engineering, Mumbai
i) M/s. Gansons, Nagpur
j) M/s Thermotech engineering, Pune
k) M/s. R & C Ltd., Mumbai.
l) M/s. Everest Engineering, Coimbatore.
m) M/s. Gujarat Machinery Mfg. Ltd., Karamsad, Gujarat.
n) M/s. Kavery Engg. Industries Ltd., Tiruchirapalli.
o) M/s. Testeels Ltd., Ahmedabad
p) M/s. Anup Engineering Ltd., Ahmedabad.
q) M/s. Lloyds Steel Industries Ltd., Mumbai.
r) M/s. Novatech Process Eqpt. Pvt. Ltd., Thane (only for pressure vessel & tanks).
s) M/s. Chemi plants engineering co., Ankleshwar, Bharuch, Gujarat
t) M/s Thermax Ltd., Pune
u) Vivid Highfab, Baroda
v) Perfect Engineering, Baroda

10) VALVES (GATE, GLOBE, CHECK, BALL & BUTTERFLY VALVES)

a) M/s. KSB Pumps, Coimbatore.
b) M/s. BHEL, Tiruchirapalli
c) M/s. Audco India Ltd., Chennai
d) M/s. BDK Industries, Hubli
e) M/s. Dewarence Macneil
f) M/s. Fouress
g) M/s. Saunders
h) M/s. Kirloskar Brothers.
i) M/s Parth Plastic Indutries, Ahmedabad (For PP valves)

11) Centrifugal Pumps

a) M/s. Microfinish Pumps, Hubli Karnataka
b) M/s Sulzer Pumps, Mumbai
c) M/s KBL Pumps, Pune

12) EOT Crane

a) Aditya Cranes Pvt. Ltd., Mumbai
b) Smaco Engineering Pvt. Ltd., Rabale, Navi Mumbai

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13) Diaphragm Pumps

a) M/s Shapo Tools, Mumbai
b) M/s Grossvenor Pumps, Mumbai
c) V.K. Pumps

14) HDPE Pipes & Fittings

a) M/s Sangir Plastics, Vapi

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ANNEXURE – I

DRAWING FOR BATTERY LIMIT (HATCHED PORTION ARE IN BATTERY LIMIT FOR MECHANICAL)

DRAWING NO. HWB/SPP(T)/CIVIL/0001

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ANNEXURE-2

DRAWING FOR INTERCONNECTING PIPELINES (EXCLUDED FROM PRESENT SCOPE OF WORK)

DRG NO. HWB/SPP(T)/PROC/0021

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 Chapter-9 Technical specification

TECHNICAL SPECIFICATIONS

ELECTRICAL

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CONTENT

S. No. Description Page No.

1. Scope E-4

2. General design basis E-6

3. Schedule of quantities for Electrical system E-9

4. Documentation E-12

5. Electrical System E-13

6. Battery Limit E-14

7. Plant loads E-14

8. Power Transformers E-19

9. Class – IV PMCC & ETP MCC E-19

10. Class – III (EMCC) E-20

11. Class – I DC System E-20

12. Special Electrical equipment E-21

13. Breakers E-21

14. Motors E-21

15. VFD’S for agitators motor & its panel E-22

16. Lighting System E-23

17. Cables E-25

18. Cable laying and Termination E-26

19. Grounding & Lightning Protection E-27

20. Protection System E-28

21. Building Electrification and Power supply arrangement E-30

22. Air conditioning and Plant ventilation E-30

23. Power switches, sockets and Push Button Station E-30

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24. DG set E-31

25. UPS System E-31

26. List of applicable Standards/ Codes E-32

27. List of Spares E-38

28. List of Recommended Vendors E-41

29. Annexure-I : Tech Spec for Transformer E-45

30. Annexure-II : Tech Spec for PMCC E-55

31. Annexure-III : Tech Spec for EMCC E-64

32. Annexure-IV : Tech Spec for VCB E-71

33. Annexure-V : Tech Spec for VFD MCC E-79

34. Annexure-VI : Tech Spec for Cables E-92

35. Annexure-VII : Tech Spec for DG Set E-96

36. Annexure-VIII : Tech Spec for UPS E-103

37. Quality Assurance Plan for Electrical System E-114

38. List of Drawings (Tentative SLD) E-125

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1. SCOPE:

This part of specification covers the requirement of design, detailed engineering,

fabrication/manufacture, inspection & testing at manufactures works, supply, transportation
to site, erection, pre commissioning test and commissioning of electrical equipment/systems
like Transformers, PMCC, EMCC, ETP MCC, VCB, VFD, Cables, Cable trays, DG Set,
UPS, Class-I Load Centre, Light fittings, Pump House panel, Air conditioners, Junction
Boxes for DCS interface etc. The Technical specifications, Quality Assurance Plan etc.
attached in this document are indicative. The EPC contractor has to carry out detailed
engineering, prepare SLD, Technical Specifications, Data Sheets, Quality Assurance Plan
and obtain approval from HWB for completeness of the electrical system for the SPP plant
at site of Heavy water plant, Tuticorin. The Electrical system shall be integrated with the
present system at HWP Tuticorin in such a way that it shall work as intended through this
Engineering, Procurement and Construction (EPC) contract.

1.1 Scope of work:

The scope of work for electrical package to be carried out by EPC contractor is listed below
but not limited to:

i) Design and Detailed Engineering: The EPC contractor has to carry out design and
detailed engineering for all the electrical equipment listed under the scope of supply.
Adequate margin shall be kept in all parameters to sustain operation during fluctuation
in the system, grid, emergencies etc. All the equipment shall conform in all respect to
high standard of engineering design and workmanship and shall be capable of
performing continuous operation in a manner acceptable to HWB. EPC contractor has
to prepare detailed Technical specification, data sheets, QAP; detailed drawings etc.
based on the information given in this tender document and obtain approval of HWB
prior to procurement /manufacture. All electrical items should comply with relevant
latest IS.

ii) Selection of equipment: Selection of electrical equipment shall be done by EPC

contractor to satisfy the specified service requirements, suitable for the environmental
conditions prevailing at site as mentioned elsewhere and corrosive/hazardous
atmosphere in the plant.

iii) Factory Acceptance Test (FAT): EPC contractor shall carry out Factory Acceptance
Test i.e. Inspection and Testing at supplier’s works for all the equipment as per
approved QAP in presence of HWB or third party inspector (TPI) appointed by HWB.

iv) Supply & Storage at Site: EPC contractor has to supply all the items to SPP site in a
safe manner without any damage. Items shall be packed with suitable materials to
prevent damage in the transit. EPC contractor has to ensure safe transportation to SPP

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site and storage of all the equipment at SPP site.

v) Erection: EPC contractor has to carry out erection of all the equipment under the
scope of supply including cable laying & termination, mounting of push button etc. as
mentioned in this tender in a safe manner as per standard engineering practices and
manufacturer’s guide lines. Erection and commissioning activities should be carried
out by the licensed Electrical personnel as per safety procedures prevailing at HWP
site.

vi) Site Acceptance Test: The EPC contractor has carry out pre-commissioning test,
commissioning test at site as per approved QAP & check list of each equipment.

vii) Clearance from Regulatory Authorities: EPC contractor has to obtain clearance
from regulatory authorities like State / Central Electricity Authority, as applicable
before taking the electrical system into service. However formal application will be
submitted by the owner.

viii) Commissioning: The EPC contractor has to submit check list/procedure for pre-
commissioning test, commissioning test and charging the equipment or taking it into
service as per the technical specification and get them approved from the HWB. After
safe erection of the equipment, EPC contractor shall carry out pre-commissioning and
commissioning test as applicable as per the approved check list/procedure.

ix) Charging and handing over: The EPC contractor has to hand over the equipment to
HWB after satisfactory completion of commissioning and performance tests
acceptable to the HWB.

x) Retrofitting of 3.3KV feeders: Electrical power for SPP plant is to be tapped from
two dummy panels available in the existing 3.3KV switchgear at HWP site. 2 nos. of
3.3KV VCB of 630A rating are to be supplied by the EPC contractor as per the
technical specification and to be retrofitted in the existing dummy panel of 3.3KV
feeder along with measuring and protective CT, PT etc. and necessary wiring shall be
done. Detailed Technical specification for 3.3 KV Breaker is given in Annexure – IV.

xi) Cabling: Supply, laying & termination of all cables, cable trays, support structures,
underground trenches shall be carried out by EPC contractor. Supply, laying &
termination of 3.3KV cable from existing 3.3KV substation located at HWP site to
SPP transformers. 415V Cabling from SPP transformer secondary terminal box to
PMCC and to other MCC/panel, motors located in SPP main plant & utility area, DG
set to EMCC, panels to light fitting/AC/fans/sockets etc. are to be carried out by EPC
contractor. Cabling from MCC located in SPP to all the motors of distant units
(outside of main plant building) like SPP pump house panel, Bulk storage tanks, PCl3
storage area, ETP etc. For tapping class – I power supply, cable to be laid from
existing class I power source of HWP site to SPP class-I power distribution board.

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xii) Associated Minor Civil Works: All the equipment shall be erected in the existing
RCC room in the SPP main plant building by the EPC contractor. Major civil works
like foundation of transformer, DG set, soak pit, etc. are not included in the scope of
this tender. However EPC contractor has to submit foundation/GA/lay out drawing for
required civil jobs. Associated minor civil works like chipping, grouting etc. are in the
scope of this tender and to be carried out by the EPC contractor. Supply of Hume pipe
for underground cabling, preparation of trench, construction of Earth Pit and
associated minor civil works is also included in the scope of EPC contractor.

xiii) Structural requirements: The EPC contractor has to supply the structural steel for
providing support for installation of electrical equipment, cable trays, wherever
required for successful completion of erection of entire system.

xiv) Drawings: After design and detailed engineering, the data sheets & drawings have to
be duly approved by the HWB and all the work should be executed as per the
approved Data Sheet and drawings.

xv) Spare parts: Spare parts shall be supplied as per the list enclosed with the tender.

xvi) Tools & tackles: Sufficient Tools & tackles, testing equipment for Transformers,
Motors, cables, etc. required for successful erection, commissioning and making the
equipment operational are to be brought by the vendor.

2. GENERAL DESIGN BASIS:

i) Field electrical equipment shall confirm to the hazardous area classification of the plant
(Zone-2).
ii) The plant lighting shall have 30% lighting on class-III and remaining lighting on class-
IV.
iii) Adequate panic lights in control room and stair case of the plant shall be on class-I
supply.
iv) The motor selection shall be based on 80% of full load as normal operating load.
v) The dedicated earth pits shall be provided for control system, power system &
equipment/ vessels body earth. Adequate nos. of earth pits shall be provided on each of
above as per relevant IS.
vi) Protection against static electricity shall be provided by bonding flanges of metallic
pipelines and by connecting vessels/ equipment with earth grid.
vii) Adequate passive fire protection shall be provided to cables with the help of fire
barriers and fire breaks at zone crossover.
viii) The various load requirements have been divided into four classes of power as follows:
a. Class IV Supply: Majority of loads on 415V and all the loads on 3.3 KV bus
may be interrupted on the loss of power supply from TNEB Grid.

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b. Class III Supply: Loads which are required for emergency operation of plant
but may be interrupted for briefly for less than 30 seconds duration. These
loads shall be supplied through the new 250KVA Diesel Generator during
normal supply failure.
c. Class II Supply: The most essential control and instrumentation loads needing
AC supply which must not be interrupted. These loads are very critical for
plant safety and operation. These loads shall be supplied through an un-
interruptible power supply (UPS).
d. Class I Supply: Essential DC loads where no interruption can be tolerated shall
be supplied through class-I, 110V DC supply. Class-I power to be extended
from existing rectifier backed up through dedicated battery bank.

2.1 Electrical system for SPP plant shall be designed taking into consideration
tapping of power as mentioned below:

i. Class IV power supply from existing 3.3 KV Bus, through new separate VCB for
plant load and lighting requirement.
ii. Class III supply for critical plant load and lighting will be from the new DG (3ph,
415V 250KVA) which is to be procured and installed under this tender.
iii. Class II supply (110V 50Hz AC) - to be supplied and installed by the EPC
contractor.
iv. Class I supply (110V DC) from the existing Class-I DC Bus as indicated in the single
line diagram for control requirement.

Equipment selection shall be done keeping in view of hazardous nature of POCl 3, PCl3, Iso-
amyl alcohol, 2 ethyl hexane , hexane , xylene , RCL, ROH and other chemicals being
handled in the plant after carrying out necessary studies for hazardous area classification.

Cable and equipment shall be selected after considering voltage drop up to 15% at equipment
terminals during start-up of biggest motor with the maximum base load on the transformer.
Size of cable shall be done to ensure that the voltage drop in operating condition shall not be
more than 3% of rated voltage at the terminals of the equipment. Voltage drop for the
lighting circuit shall be restricted to 1 volt + 2% of the supply voltage as per IEE Regulation
No. 204. Direct –on-line starting feature shall be incorporated in the motors of rating less
than 37 kW and Star Delta starter shall be provided for all motors of 37kW rating and above
except for VFD driven motors.

Distribution of loads on 415V bus shall be done in a manner to provide adequate redundancy
for plant operation. Short circuit impedance of the transformers shall be kept such that the
short circuit current and voltage spared at output terminals should remain within permissible
limits.

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Short circuit calculations for the system shall be carried out based on IS-13234 or equipment
standards. Existing fault level on 3.3 KV bus is 200 MVA.

2nos. of power transformers of 2000 KVA capacity each shall be supplied under this tender
for bringing down the voltage level from 3.3 KV to 415 Volt for utilization loads.

2nos of 3.3KV VCB 630A are to be supplied by EPC Contractor and shall be fixed
(retrofitting) in the existing dummy panel of 3.3KV feeder along with measuring and
protective CT, PT, relay, meter and necessary wiring shall be done.
Detailed Technical specification for 3.3 KV Breaker is given in Annexure-IV.

A DG set of 250KVA shall be supplied along with AMF control panel with change over
contact and the same shall be installed by the party.

The plant grounding system design has been based on the recommendation of IEEE-80
and has been designed with the following objective:

i. To limit the touch and step potentials between the different non-current carrying parts
and earth to a safe value under all normal and abnormal conditions.

ii. To provide low impedance path for the earth fault current so that it is of sufficient
magnitude to operate the protective relays.
iii. To effectively discharge the accumulation of static charge.
iv. All flanges of pipe lines which carry chemicals shall be provided with earth brides.
v. All electrical equipment, vessels, power panels, shall be provided with double
earthing by GI flats as per relevant IS.
vi. Lighting spike shall be provided in main plant building and vent scrubber stack. This
shall be connected to earth through copper flats as per relevant IS.
EPC Contractor shall design the grounding system for SPP plant for achieving above
objectives.
Plant site may get polluted with POCl3, PCL3, Iso-amyl alcohol, 2 ethyl hexane, hexane,
xylene, RCL, ROH and other chemicals through leakages or due to accidental release.
Equipment is to be selected, keeping in view of hazardous nature of these chemicals.

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3. SCHEDULE OF QUANTITIES FOR ELECTRICAL SYSTEM

Sl. No. Item Description Unit Qty. Remark(s)

1. Supply, erection and commissioning
of 2000 KVA 3.3 KV/433 Volt.
DY11, 3 Phase, 50 c/s, Power No. 2
Transformers and associated minor
civil works as per clause-8.
2. Supply, erection and commissioning
of 3.3KV, 630A VCB to be installed
in the existing module along with No. 2
transformer protective relays (Retro
Fitting) as per clause- 1, 2 & 6.
3. Supply, erection, testing and
commissioning of 250KVA DG set
No. 1
with AMF Panel and associated minor
civil works as per clause-24.
Supply erection and commissioning of
415V Power & Motor Control
Centers (PMCC, 2 nos. bus sections
4. No 1
with bus-coupler) and associated
minor civil works as per clause-7, 9,
13 & SLD.
Supply, erection and commissioning
of 415V ETP MCC and associated
5. No 1
minor civil works as per clause- 7, 9,
13 & SLD.
Supply, erection and commissioning
of 415V Pump House Panel and
6. No 1
associated minor civil works as per
clause- 7, 9, 13 & SLD.
Supply erection and commissioning of
CLASSIII power panel (EMCC) and
7. No 1
associated minor civil works as per
clause-7, 10, 13 & SLD.
Supply installation and
commissioning of 13 Nos. of VFDs
8. for agitator motors enclosed in a panel No 1
and associated minor civil works as
per clause- 7, 15 & SLD.
9. Supply installation and
No 1
commissioning Class I load center

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(110V DCDB) and associated minor

civil works as per clause- 11.
10. Supply, installation and termination of Lot 1
Lights & Light Fittings and
associated minor civil works as per
clause -16.
11. Supply of cables as per Clause -17
(a) 3.3KV 3Cx300sq.mm armoured
Mt 1500
FRLS , XLPE UE aluminum
power cable (4Runs x 375mt)
(b) 415V 2MVA Power Transformer
sec. cable 3Cx400sq.mm
Mt 1360
armoured FRLS aluminum power
cable (16runs x 85mt)
(c) Other 415 V cables meant for
motors, light fitting and all other
electrical loads including EMCC, Lot 1
Chiller, ETP-MCC, VFD MCC
etc.
(d) Control cables. Lot 1
(e) 1.1KV 31/2 Cx300sq.mm armoured
FRLS, aluminum power cable for Mt 180
Electrode Boilers.
(f) 1.1KV 31/2 Cx400sq.mm armoured
FRLS, aluminum power cable for Mt 100
DG Set.
12. Supply and erection of Cable trays
Lot 1
as per clause no-1 & 18.
13. Supply and erection of structural steel
for cable tray supports, push button
Lot 1
frame, erection of electrical equipment
etc. as per clause No-1
14. Supply and erection of hume pipes
for cable trench and associated minor
Lot 1
civil works including excavation as
per clause no-18
15. Cable laying and cable termination as
Lot 1
per clause no-18.
16. Supply, installation, termination
Grounding & lightning protection Lot 1
as per clause no-19.
17. Building electrification and
Lot 1
providing switches and sockets in
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plant areas and buildings as per clause

no. 21 & 23.
18. Supply and installation of 10 Nos. of
1.5 TR split AC for Air conditioning
of main plant building and providing Lot 1
adequate ventilation in plant areas as
per clause no-22.
19. Supply and installation of Local Push Lot 1
Button Stations as per Clause no. 23
20. Spares as per clause no-1 & 27. Lot 1
21. Misc. Items not indicated above but Lot 1
required to complete the project

Note: The qty. indicated as lot in the above table has to be calculated by the EPC contractor
during detailed engineering. Accordingly schedule for each item to be worked out by EPC
contractor and get them approved by HWB and based on that detailed final SOQ should be
prepared by them. Quantity and size of items mentioned in this SOQ are not changeable.

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4. DOCUMENTATION
4.1 Documents to be submitted with bid: Following document are to be submitted along
with the bid;

i) The single line diagram furnished in this document is tentative. The bidder has to
prepare and submit actual Single Line Diagram (SLD) for Class -I, II, III & IV power
supply system with their interconnections.

ii) Make, model, catalogue and manufacturer’s data sheet for all the electrical equipment
for the scope of supply like Transformer, HT Panel, Protective relays VCB, LT Panel,
ACB, Variable Frequency Drive, Motor, UPS, Battery bank, DG Set, Light fittings ,
Push button station, Cables, Air Conditioners and other auxiliaries as applicable.
Make of the equipment shall be one among the recommended EPC contractor list.

iii) Confirmation of technical specification of electrical equipment based on filled up data

sheet as given in tender document.

iv) All the filled up datasheets, Single Line Diagrams for class-IV, class-III, Class-II
power supply & class-I power supply, load lists etc. shall be submitted along with
bid.

v) Load list given in this document is tentative. Based on approved P&ID EPC
contractor has to prepare appropriate load list for class- I, II, III & IV loads (including
VFD feeders for class-III) with spare feeders showing typical Bill of Material of each
type of feeder. Supply of equipment like pump and motors of ETP is not included in
the scope of this tender but supply, erection, commissioning of ETP MCC, supply and
installation of local push button stations and cabling from ETP MCC to motors and
push button station of ETP and termination are in the scope of this tender.

vi) The EPC contractor shall submit all supporting information and technical
data as requested in tender so that employer can make detailed technical comparison
and evaluation of the offers without the need of request for further information from
the EPC contractor.

vii) Deviation statement: Bidder has to submit deviation statement if any.

4.2 Documents to be submitted by EPC contractor after award of contract for approval
before manufacturing:

Detailed single line diagram with all the feeders and bill of material for each type of
feeder

Cable schedule (power & control)

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Over all cable lay out (for all class of power supply)

Cable tray lay out with support

Electrical equipment lay out

Earthing & lightning protection lay out

Over all lighting layout

Class-III load

Interconnection drawing

In addition to the documents mentioned here all other documents as mentioned in respective
Technical Specifications for each equipment shall be supplied by the EPC contractor for
approval before manufacture.

4.3 Calculations to be submitted by contractor after placement of order for approval:

Short Circuit Analysis/Fault Level calculations, Arc Flash Analysis, Sizing calculation
for cables, Earthing calculation , Lighting calculation of different area, Sizing calculation
for battery banks, Capacity calculation for air-conditioners, Basis for selection of KW
rating of motors, Sizing calculation of PMCC bus bar , Size of earthing strip & pits for
lightening protection, Setting value of relay, Selection of VFD rating.

4.4 Specifications and data sheet to be submitted by contractor after placement of order
for approval: After placement of order, documents are to be supplied as listed here and
elsewhere of this document. The contractor may, in addition furnish any other supporting
information, technical data, drawing or catalogue which, in his view, are necessary to
assist the HWB to make a detailed technical evaluation of his offer.

Technical Specifications, detailed data sheet, QAP, guide lines for erection of electrical
equipment, pre-commissioning check list, final testing and commissioning procedure for
Transformer, DG set, VCB, LT Switch board, ACB, cable (LT/HT power & control)
cable tray, LT motor, LT push button station, lighting earthing & lightning protection,
lighting distribution board, VFD, ups & battery, battery banks, fire sealing & fire breaks,
lamp and light fittings, etc. are to be furnished by the contractor.

4.5 Foundation drawings of the equipment: The EPC contractor has to submit detailed
foundation drawings for all electrical equipment for approval from the HWB.

5. ELECTRICAL SYSTEM:
Heavy Water Plant, Tuticorin is receiving power from Muthiapuram 110 KV Auto sub-station
through a single 110 KV feeder, ‘DOG’ ACSR conductor has been used for incoming feeder and

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in HWP switchyard ‘PANTHER’ ASCR conductor has been used for inter-connection of 2 nos.
of 10 MVA power transformers through two separate 110 KV MOCBs.

In existing plant power utilization levels for the various types of loads are as follows:

3.3 KV, 3 Phase, 3-wire, 50 cycles, high voltage distribution and power supply for motors over
200 KW and up to 2600 KW.
415V, 3 phase, 4 wire, 50 cycle medium voltage plant power for the following:
Motors – over fraction KW to 200 KW.
Miscellaneous individual loads.
Motor Control Centers.
Lighting Loads
Un-interruptible Power Supply distribution boards.
DC distribution boards.

6. BATTERY LIMIT:
Battery limit for erection and commissioning of the electrical equipment are given below.
i) Retrofitting of 3.3 KV feeders with VCB in existing 3.3KV switchgear in Main plant.
HT, control and other associated cables are to be laid from these feeders to
Transformers to be installed in SPP. Detailed Technical specification for 3.3 KV
Breaker is given in Annexure-IV.
ii) Class-I power to be tapped from existing class-I power supply panel located in 3.3KV
substation. Associated cables are to be laid from existing Class-I power supply panel
to DCDB to be installed in SPP.
iii) Pump house panel to be installed in existing cooling water pump house near cooling
tower for SPP. Associated cables are to be laid from PMCC to be installed in SPP
MCC Panel Room to Pump house panel and from this panel to the motors.
iv) Transfer pumps will be located near Bulk storage tank and PCl3/POCl3 storage Tanks.
Associated power and the control cables are to be laid for the pumps.
v) Supply of equipment like pump and motors of ETP is not included in the scope of this
tender but supply, erection, commissioning of ETP MCC, supply and installation of
local push button stations and cabling from ETP MCC to motors and push button
station of ETP equipment and termination are in the scope of this tender.
vi) All the above mentioned locations are marked as hatched in the attached plot plan
drawing No. HWB/SPP(T)/CIVIL/0001.

7. PLANT LOADS:

A. EXISTING LOADS:

At Present plant loads being fed through 2 nos. of 10MVA, 110/3.45 KV transformers
are as below:
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(i) 20K41,42, compressor each of 800 kW rating

(ii) Booster compressor AGB 101 of 2600 KW rating and refrigeration compressor
AGC 101 of 2450 KW rating.
(iii) Cold water pump 1,2 & 3 each rating 300 KW
(iv) 2nos. of 2 MVA, 3.3/0.433 KV, power transformer
(v) 1 no of 500 KVA, 3.3/0.433 KV transformer for Class IV Lighting.
Existing plant operating load is near about 7 MW

B. SPP LOADS: SPP Plant shall have following loads and any other loads that may be
required for consideration after detailed engineering. Feeders of adequate capacity shall
be provided to feed power to UPS, Class-1 system and other panels as required

Elect. Power
Equipment
S. No. Name (Tentative) Remark(s)
Tag No.
(KW)
LIST OF MACHINERY OF UNIT 43
1. 43 P01 A 2EHA Pump 2.2
2. 43 P01 B 2EHA Pump 2.2
3. 43 P05 A Hexane Pump 0.75
4. 43 P05 B Hexane Pump 0.75
5. 43 P06 A RCL Feed Pump 0.75
6. 43 P06 B RCL Feed Pump 0.75
7. 43 P07 A Alkali Charging Pump 0.75
8. 43 P07 B Alkali Charging Pump 0.75
9. 43 P08 A Alkali Charging Pump 0.75
10. 43 P09 A HCL Charging Pump 0.75
11. 43 P09 B HCL Charging Pump 0.75
12. 43 P10 A DM WATER Feed Pump 0.75
13. 43 P10 B DM WATER Feed Pump 0.75
14. 43P17 A Dump liquid recycle pump 0.75
15. 43P17 B Dump liquid recycle pump 0.75
16. 43 AG01 Agitator of RV01 5.5 To be provided
17. 43 AG02 Agitator of RV02 5.5 with 7.5KW
VFD. To be
18. 43 AG03 Agitator of RV03 5.5 connected to class
III supply
Equipment Tag Elect. Power
S. No. Name Remark(s)
No. (KW)
LIST OF MACHINERY OF UNIT 44
Conc. Sod. Carbonate charging
19. 44 P04 A 0.75
pump.
Conc. Sod. Carbonate charging
20. 44 P04 B 0.75
pump.
Conc. Sod. Carbonate charging
21. 44 P05 A 0.75
pump
22. 44 P06 A Dump liquid recycle pump 2.2

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23. 44 P06 B Dump liquid recycle pump 2.2

Dil. Sod. Carbonate charging
24. 44 P07 A 1.5
pump
Dil. Sod. Carbonate charging
25. 44 P07 B 1.5
pump
26. 44 P08 A Impure Butanol transfer pump 2.2
27. 44 P08 B Impure Butanol transfer pump 2.2
28. 44 AG01 Agitator of RV01 7.5 To be provided
with 10KW
29. 44 AG02 Agitator of RV02 7.5 VFD. To be
connected to class
30. 44 AG03 Agitator of RV03 7.5
III supply

Equipment Elect. Power

Name Remark(s)
S. No. Tag No. (KW)
LIST OF MACHINERY OF UNIT 45
31. 45 P01 A Organic Column Feed Pump 0.75
32. 45 P01 B Organic Column Feed Pump 0.75
33. 45 P02 Purified Butanol Transfer Pump 0.75
34. 45 P03 A Purified Butanol Pump 0.75
35. 45 P03 B Purified Butanol Pump 0.75
36. 45 P04 A Aq. Phase transfer pump 0.75
37. 45 P04 B Aq. Phase transfer pump 0.75
38. 45 P05 A Purified Butanol Transfer Pump 0.75
39. 45 P05 B Purified Butanol Transfer Pump 0.75
Equipment Tag Elect. Power
S. N o. Name Remark(s)
No. (KW)
LIST OF MACHINERY OF UNIT 46
40. 46 P01 A Na2CO3(aq)Dosing Pump 1.5
41. 46 P01 B Na2CO3(aq)Dosing Pump 1.5
42. 46 P01 C Na2CO3(aq)Dosing Pump 1.5
43. 46 AG01 Dissolution Tank Agitator 1.1 To be provided with 2.2KW
44. VFD. To be connected to
46 AG02 Dissolution Tank Agitator 1.1
class III supply
Equipment Tag Elect. Power
S. No. Name Remark(s)
No. (KW)
LIST OF MACHINERY OF UNIT 47
45. 47 P01 A NaOH recirculation pump 0.75
46. 47 P01 B NaOH recirculation pump 0.75
47. 47 P02A Booster Vacuum Pump 20
48. 47 P02B Booster Vacuum Pump 20
49. 47 P03A1 OSRV Vacuum Pump 20
50. 47 P03A2 OSRV Vacuum Pump 20
51. 47 P03B1 OSRV Vacuum Pump 20
52. 47 P03B2 OSRV Vacuum Pump 20

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Equipment Tag Elect. Power

S. No. Name Remark(s)
No. (KW)
LIST OF MACHINERY OF UNIT 48
53. 48 P01 A Raw Water Pump 1.5
54. 48 P01 B Raw Water Pump 1.5
55. 48 P02 A Boiler Feed Water Pump 1.1
56. 48 P02 B Boiler Feed Water Pump 1.1
Equipment Tag Elect. Power
S. No. Name Remark(s)
No. (KW)
LIST OF MACHINERY OF UNIT 49

57. 49 P01 A EHA 2.2

58. 49 P01 B EHA 2.2
59. 49 P02 A IAA 2.2
60. 49 P02 B IAA 2.2
61. 49 P03 Dump tank pump 2.2
62. 49 P04 A N-Butanol Feed Pump 2.2
63. 49 P04 B N-Butanol Feed Pump 2.2
Equipment Tag Elect. Power
S. No. Name Remark(s)
No. (KW)
LIST OF MACHINERY OF UNIT 50
64. 50 P01 A Hot Well Pump 12
65. 50 P01 B Hot Well Pump 12
66. 50 P01 C Hot Well Pump 12
67. 50 P02 A Cold Well Pump 12
68. 50 P02 B Cold Well Pump 12
69. 50 P02 C Cold Well Pump 12
Star / Delta
70. 50 K1 A Refrigeration Compressor 75
Starter
Star / Delta
71. 50 K1 B Refrigeration Compressor 75
Starter
S. Equipment Tag Elect. Power
Name Remark(s)
No. No. (KW)
OTHER ELECTRICAL LOADS
72. CW Pump-1 CW circulation 20
73. CW Pump-2 CW circulation 20
74. CW Pump-3 CW circulation 20
Electrode
75. Steam generation 300 415V ACB, 800A
boiler
Electrode
76. Steam generation 300 415V ACB, 800A
boiler
77. ID fans 15
78. ID fans 15
79. EOT crane 10
80. Lighting loads 50
Fire water
81. 0
supply
82. ETP 135

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Other
83. unexpected 50
Loads

Equipment Elect. Power

S. No. Name Remark(s)
Tag No. (KW)
LIST OF MACHINERY OF ETP
84. 53 P 31 NaOH transfer pump 0.75
85. 53 P 32 NaOH transfer pump 0.75
86. 53 P 21 HCl transfer pump 0.75
87. 53 P 22 HCl transfer pump 0.75
88. 53 P 41 FeCl3 Dosing pump 1.10
89. 53 P 42 FeCl3 Dosing pump 1.10
90. 53 P 11 Effluent Transfer pump 2.20
91. 53 P 12 Effluent Transfer pump 2.20
92. 53 P 51 Slurry Acidic 3.50
93. 53 P 52 Slurry Acidic 3.50
94. 53 P 61 Slurry alkaline 3.50
95. 53 P 62 Slurry alkaline 3.50
96. 53 P 91 Acidic filtrate 3.50
97. 53 P 92 Acidic filtrate 3.50
98. 53 P 93 Alkaline filtrate 3.50
99. 53 P 94 Alkaline filtrate 3.50
100. 53 VP 11 Vacuum pump for RVDF 15
101. 53 VP 12 Vacuum pump for RVDF 15
102. 53 VP 13 Vacuum pump for RVDF 15
103. 53 VP 14 Vacuum pump for RVDF 15
AGIGATOR OF 53V 02
104. 53 –AG-1-V2 5.0
FeCl3
105. 53-AG-5-R-11 AGIGATOR OF 53 R 11 5.0 To be provided
106. 53-AG-6-R12 AGIGATOR OF 53 R 12 5.0 7.5KW VFD. To
107. 53-AG-7-R21 AGIGATOR OF 53 R 21 5.0 be connected to
class III supply
108. 53-AG-8-R-22 AGIGATOR OF 53 R 22 5.0
109. 53 RVF11 Rotary vacuum filter 5.0
110. 53RVF/AG11 RVF –vat agitator 1.5
111. 53 RVF12 Rotary vacuum filter 5.0
112. 53RVF/AG12 RVF –vat agitator 1.5

Total 1600.25
 All the ratings given in this document are tentative in nature, EPC contractor has
to calculate actual rating based on process design and submit for approval before
manufacture.
 Total power requirement for entire new system may be of the order of 1800 KW.
 Other feeders are to be provided as per plant requirement.
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 Spare feeders are to be provided in every panel as indicated in Single Line

Diagram.
 Supply of equipment like pump and motors of ETP is not included in the scope of
this tender but supply, erection, commissioning of ETP MCC, supply and
installation of local push button stations and cabling from ETP MCC to motors
and push button station of ETP and termination are in the scope of this tender.

8. POWER TRANSFORMER
2 Nos. of power transformer of 2000 KVA capacity shall be provided for bringing down the
voltage level from 3.3.KV to 0.433KV. Transformer shall be two winding, three phase,
Dy11 vector group with secondary neutral solidly grounded. The transformer shall be
designed and manufactured as per relevant standards for the ambient conditions specified in
the tender document. Transformer shall have Off Load Tap Changer for making correction
of output voltage from +5% to -5% through 5 tap positions. Percentage impedance shall be
selected such that biggest motor connected at output terminal can start smoothly in direct-
on-line (DOL) mode with maximum permissible base loads. Transformers shall be oil filled
and shall have ONAN type cooling. 2MVA transformer protective relay shall be provided in
the existing 3.3KV panel.
DETAILED TECHNICAL SPECIFICATION FOR TRANSFORMER AND
PROACTIVE RELAYS IS GIVEN IN ANNEXURE-I.

1. Along with the power cable 2 Nos. of 24 c x 2.5 sq.mm, of length 375mtrs copper
armoured cables to be laid from existing 3.3KV substation to SPP MCC for providing
tripping provisions.
2. 2 nos. of 24c x 1.5 Sq.mm of length 80mtrs copper armoured cables to be laid from SPP
transformer to SPP MCC panel.
9. CLASS-IV POWER & MOTOR CONTROLCENTER and ETP MCC

The Power & motor control centers (PMCCs) are planned to cater to various motors (fraction
KW to 75 KW), electrode boiler (300KW), chiller (75KW), vacuum pump (50KW) and
lighting loads. The short circuit rating of the PMCCs shall be 50 KA (sym) and making
current as 125KA (peak). The PMCCs shall be totally enclosed in modular construction. It
shall have out going feeders as per SLD and load list given in this document. Given SLD and
load list are tentative, EPC contractor has to prepare final load list required for completeness
of the project. Direct –on-line starting feature shall be incorporated in the motors of rating
less than 37 kW and Star Delta starter shall be provided for all motors of 37kW rating and
above.

Each electrical Panel shall be provided with specially compounded Insulation Electrical
Safety Mats by the EPC Contractor suitable as per their voltage rating.

ETP MCC panel shall have 26 feeders of rating from fraction KW to 15KW. Each feeder
shall consist of fuse, CT, Contactor, Overload relay, as per the motor rating. The panel should
have power cable camber and control cable chamber. The panel shall be provided with a main
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incoming 400A isolator. Panel construction and indications shall be as per Class-IV PMCC
panel.

Pump house panel shall have incomer and outgoing feeders as given in SLD. Its
constructional features shall be in line with that of PMCC. Required protections shall be
incorporated in the up stream breaker.

Control supply for the PMCCs shall be fed though separate 415/110 volts AC transformer
mounted in a separate module.

Every feeder shall have SERVICE / ISOLATE / TEST positions, and current indications.
Cable entry shall be from top. Link type HRC fuses (having dual characteristics), Over
Load Relays with resetting provision through “push –button” & single-phase prevention
feature shall be used for motors 40KW and above. Enough potential free contacts shall be
provided for interlocking. Selection of HRC fuses, OLR relays shall be done to ensure full
protection to motor and smooth starting.

PMCC shall be fed & controlled through manual ACBs in 415 volts switch gear.
Electrode boiler 300KW rating each shall be provided with 415Volts 800A ACBs.
PMCC shall be indoor and draw-out type, double front execution to suit operation and
optimum space requirements. The PMCC shall be dust proof & vermin proof and shall
conform to requirements of degree of protection of IP42.

Annunciation panel with hooter shall be provided in 415V Incomer-I and II panel.
The switchgear components like ACBs, Contactors, Thermal overload relays, CTs, Fuse
switch units etc shall of make one among the vendor list given in this document.
DETAILED SPECIFICATION FOR PMCC PANEL IS GIVEN IN ANNEXURE-II.

10. CLASS III LOAD CENTRE, EMCC FOR EMERGENCY LIGHTING AND
CERTAIN MACHINERIES :
The class III load center shall be designed to feed the essential lighting loads VFD panel
meant for agitator and also certain machineries. Loads on Class III bus shall include
emergency lighting, instrument supply, agitator motors, cooling water pumps etc... Class III
bus shall be fed from class-IV MCC and during normal power failure the EMCC panel will
be fed by the 250KVA DG set to be installed at SPP through change over contact.
DETAILED SPECIFICATION FOR EMCC PANEL IS GIVEN IN ANNEXURE-III.

11. CLASS I DC SUPPLY SYSTEM FOR CONTROL SUPPLY OF ELECTRICAL

PANEL
The class I Load Centre shall be metal enclosed it shall accommodate 10Nos of isolators of
1KW each. Isolator shall be given back-up protection through HRC fuses. The class I load
Centre shall have 11 Nos. outgoing feeders including 3 nos. Spares. The Class I load centre
will be located in SPP MCC room and suitable cable for connecting DCDB at SPP and
rectifier unit installed at 3.3KV substation shall be laid. It is proposed 1 Nos. of 3 c 185
sq.mm 415 V cables will be laid from existing class I load centre located at the existing sub-
station. Approximate length is 500 meters
Class I load centre shall be fed from existing Battery bank / Battery charger for class I
supply.
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Remarks: All the cables meant for 3.3 KV supply and class I supply can be laid on
existing cable trays from existing sub-station to chemical lab. From the road it is to be
brought by underground up to the MCC room as well as transformers. All civil jobs
involved in this job are under the scope of contractor.

12. SPECIAL ELECTRICAL EQUIPMENT :

Various Organic chemicals such as POCl3, PCL3, Iso amyl alcohol, 2 ethyl hexane , hexane ,
xylene, RCL, ROH and other chemicals used in process form explosive mixture with air and
as such is a fire and explosive hazard. The points of potential leakage are valve packing,
valve seat, flanges, leaking piston packing, compressor seals etc.. The possibility of
explosion exists mainly in the case of fault or disturbances in the process and prevails mainly
in the plant areas.
Selection of equipment in the plant areas such as motors, local push button stations, local
control panel, light fittings, cables, cable glands, instruments etc.. shall be done considering
the above fire hazard in this area. Classification studies and shall be as per relevant
national/international codes.

13. BREAKERS:
The panel at SPP shall be provided with the flowing Air Circuit breakers 3phase 415V
ACBs.
1. INCOMERS : 3200A rating : 2 Nos.
2. BUS COUPLER : 3200A Rating : 1 No.
3. EMCC INCOMER : 800A Rating : 2 Nos.
4. Electrode Boiler : 800A Rating : 2 Nos.
5. Pump House : 400A Rating : 1 No.
6. Incoming from DG Set : 800A Rating : 1 Nos

All ACBs shall be of drawn out type and it shall be provided with manual and
electrical operation.
Every breaker should have service/ Isolate/ Test positions.
In case of any fault it has to trip.
Overload trip provision shall be provided with trip current adjustment.
Breaker should ON and TRIP by using 110V DC Class-I supply.
ON indication, OFF indication and TRIP indication shall be provided.
Single phasing, under voltage protection shall be provided.
Electrical interlock shall be provided in-between Incomer breakers (3200A) and Bus
coupler (3200A).

14. MOTORS :

Since chemicals used are highly corrosive, all the motors shall be with die cast
aluminum rotor or copper bar rotor brazed with phosphorous free alloy. In view of
high ambient conditions at site all the motors shall have class “F” insulation but the
temperature rise in the motor shall be restricted to the temperature rise permissible for
class “B” insulation. All the motors should be rated for continuous duty i.e. “S1”
duty. All the motors shall be of flameproof construction in Main Plant area, chemical
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storage area, and chemical handling area and in Effluent treatment plant. They should
be suitable for gas group IIB , Zone I and Temperature class T-3. The remaining
areas motor suitable for Zone II areas can be selected i.e. Increased safety type motors
can be selected.

All the motors shall have terminal box of adequate size to accommodate the cable
terminal comfortably and without causing undue stress on the motor terminals.
Enough space inside the terminal box shall be available for ventilation. All motors
shall have external provision for of grease nipples for greasing of the bearings.
However for small motors it is not applicable as they may be fitted with sealed
bearings. Space heaters shall be provided for motors having 30 KW and above rating.

Motors shall have TEFC enclosures and having IP55 degree of protection. Windings
insulation shall be given anti corrosive treatment.
Motor rating for centrifugal pumps and compressor shall be sized as per
recommendation of relevant API codes.
Motors for operation with VFD shall be compatible for running at different
speed/VFD.

All Motors shall be high efficiency type (IE2) conforming to IS 12615 (2011).
Specification and requirement of canned motor pumps, if any, may be referred in
mechanical part of this document.
EPC Contractor has to prepare checklist for Pre-Commissioning test, commissioning
and performance tests and get them approved from HWB. This list should include the
following;
A visual check to be carried out to verify is any damage has occurred and free
rotation of the motor.
 The motor body should have its body paint intact.
 The motor if put in long storage the motor; moisture should be removed from the
motor. Before putting the electric motor in to operation the motor is to be checked for
the healthiness of its insulation by the help of 500V megger.
 Check the name plate details of the motors and that should match the approved
specifications

15. VFD’S FOR AGITATOR MOTORS AND ITS PANEL:

For all 12 Nos. of agitators suitable VFDs are to be provided. In total 12 Nos. of
VFDs to be provided (11 Nos. – 1 for each agitator + 1 No. spare). These VFDs
should be enclosed in a separate panel with adequate ventilation. All VFDs should
have standard features and they should be operable through external 0-10V& 4-20mA
signal for speed variation. All VFDs should have under current features as in-built
protection. All drives shall be fixed inside the panel and HMI control/display shall be
mounted in front side of the panel for monitoring / controlling / setting. Power cable
and control should have separate compartment and the cable entry to the panel is from
top.
The VFD panel shall be mounted with suitable 415V bus bar along with neutral and
earth bus. The panel should be of dust / vermi proof.

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Each VFD feeder shall have

1. 3Ph. 415V Isolator.

2. ON /OFF/Trip indication.
3. ON /OFF/reset push buttons.
4. MCB for control supply isolation.
5. Speed control using suitable potentiometer.
All the above items shall be mounted in front of the panel.
In each VFD feeder shall be mounted with suitable exhaust fan with air filter which
would be supplied by the EPC Contractor.
Isolator shall be lockable type.

The VFD shall be provided with suitable choke filters at incoming and outgoing.
Each VFD feeder shall be provided with suitable space heater and 4/5W LED lamp
with separate switch control.
For controlling and monitoring of the agitators motor speed RPM meter shall be fixed
in control room.

Detailed Technical Specification of VFD panel is enclosed in Annexure-V.

16. LIGHTING SYSTEM:

Adequate illumination shall be provided in the plant areas and buildings. Emergency
lighting will be provided near the critical equipment / machines (Reactor, Vacuum
system, package units of Chiller unit, boiler unit, storage tank, and chemical store)
sub-station, control rooms as well as in the escape route. All the light fittings, junction
boxes, motors, switches used shall be of flameproof construction in Main Plant area,
chemical storage area, chemical handling area and in Effluent treatment plant. They
should be suitable for gas group IIB and Zone I. The remaining areas light fittings
suitable for Zone II areas can be selected i.e. Increased safety type fittings can be
selected. Other non-hazardous areas weather proof light fittings should be provided.

The emergency lighting shall be provided from Class III switchgears. In addition 110
VDC panic lamps should be provided in main plant, ETP, Recovery unit, control
room, MCC room, escape routes and stair cases.

The illumination levels for the various area shall be maintained as follows:

Location Illumination level required in lux

Main operating 100

platforms( reactors &
feed vessels )
Ordinary platforms 100-150
Path way & ground 100-150
floor machineries
Stairways and ladders 50

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frequently used
Other stairways 20
All the RCC rooms 100
connected with main
SPP plant ( to be
constructed under this
EPC contract )
The general lighting in the plant is broadly divided into three categories
a) Street lighting
b) Indoor lighting
c) Outdoor lighting
The fixtures are of two categories, flame proof and non-flame proof.

a) Street lighting :

The basis of the lighting design shall be to obtain an illumination level of 8 to 10 lux
on streets. Mercury, LED Lights of suitable rating shall used for street lighting. The
street light poles will be of swaged poles as per IS 2713(P-III)-1980. The height of
the poles should be of 8 meters.

b) Indoor Lighting:

The indoor lighting design shall be based on IS:3646 – Part II. The fittings of
fluorescent industrial type or LED type shall be used in the general plant area and
decorative type in offices and other areas. Lighting in office shall be decorative type
recessed in false ceiling and shall have efficient fluorescent lamp or equivalent LED.
Compact fluorescent type lamps or equivalent LED shall be used in corridor areas.
30% of the light provide in plant, control room, etc are to be connected to class-III
supply.
All plant light and building lights (class-IV & Class-III) are connected from MCC and
EMCC panel through suitable isolator and MCB.
Panic lamps are connected from 110V DCDB.

c) Outdoor Lighting :

High pressure mercury vapour (HPMV) 125 Watts lamp or equivalent LED fixtures
shall be used for plant areas. Increased safety type /Flameproof type shall be used in
main plant areas. As explained above, all the light fittings, cable gland, junction
boxes, switches used shall be of flameproof construction in Main Plant area, chemical
storage area, chemical handling area and in Effluent treatment plant. They should be
suitable for gas group IIB and Zone I. The remaining areas light fittings suitable for
Zone II areas can be selected i.e. Increased safety type fittings can be selected.

Other non-hazardous areas weather proof light fittings should be provided. In the
transformer yard of sub-station, weatherproof 125W HPMV shall be provided. While
general lighting is planned to be provided by flood light fittings mounted on towers,
local fittings will be provided wherever required along the railings and on structures/
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platforms at suitable locations. Yard lighting shall be provided, flood lights as well as
post top lanterns. The light fittings in crucial areas shall be fed from the A.C.
emergency lighting system. All the light fittings shall be as per area classification and
shall be weather proof.
17. CABLES

a) 3.3. KV Cables :

The incoming HT cable for each transformer shall be supplied and laid from the
existing 3.3 KV switch-gears in the existing sub-station at HWP Site. The
approximate distance between existing substation and SPP is around 375mts. In total
4 Nos. (4run x 375M length) of 3.3 KV, 3Core x 300 sq.mm Aluminum armoured
FRLS; XLPE cables are to be laid from the existing 3.3KV sub-station. Hence the
total length of the cable will be around 1500 mts.
General specification of Cables is enclosed in Annexure-VI.

b) L.V Cables :
Cables shall comply with the requirements laid down in the latest issues of relevant
standards wherever applicable along with other related standards.

(i) Power cable :

All cables shall be HR-PVC insulated, PVC sheathed, armoured, Fire Resistant Low
Smoke (FRLS), 1.1 KV grade, multi-stranded type. Minimum size for Aluminium
cable shall be 16 sq.mm, below which copper cable shall be used. Minimum size of
Copper cable shall be of 4 sqmm. The selection of cable sizes is to be done by EPC
Contractor based on required current capacity, voltage drop and de-rating due for
higher ambient, grouping etc as per prevailing site condition mentioned elsewhere.
Cables are to be laid from the SPP PMCC, EMCC, ETP MCC Panel to the individual
motors and loads with the proper selection of cable size and length. For all motors
cable should be selected such that the voltage drop at the motor terminals shall not be
more than 15% during starting and 3% during running.

While in the lower sizes (Up to 70 sq.mm) the predominant criterion has been to limit
the voltage drop at motor terminals, for higher sizes above 70 sq.mm de-rating for a
higher ambient of 45 °C (0.9) and due to grouping (0.7) about 30 cables touching each
other will be predominant.
Cables of suitable size to be supplied and laid between existing class-I DC power
source to the DCDB to be installed at SPP and there from to the respective loads.
Similarly cables of suitable size and length to be laid from UPS Panel to respective
loads e.g. DCS, etc

Power cables of size 3Cx400sq.mm Aluminum armoured cable of length (16runs

x 85mtrs) from Transformer secondary terminal box to SPP incomer panel for
low voltage power distribution.

For the plant lighting, plant power supply and building electrification proper cabling is
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to be done from their respective feeders to the distribution board/switch board. For
lighting, ACs and power sockets, copper cables/wires should be used. They will be of
PVC insulated and FRLS cables.

ii) Control Cables :

1. Along with the power cable 2 Nos. of 24 c x 2.5 sq.mm, of length 375mtrs copper
armoured cables to be laid from existing 3.3KV substation to SPP MCC for providing
tripping provisions.
2. 2 nos. of 24c x 1.5 Sq.mm of length 80mtrs copper armoured cables to be laid from
SPP transformer to SPP MCC panel.
3. Multicore copper conductor 1100 volts, PVC insulated PVC sheathed armoured Fire
Resistant Low Smoke (FRLS) cables are shall be used for control, indication,
annunciation, interlocking, logic circuitry, connection with Local Push Button
Stations, PMCC/MCC/Panels to JB for interfacing with DCS etc. Individual multicore
cables shall be used between central control panel, local control stations and
interconnection of Electrical Panels and DCS.
4. Cabling for lighting, ACs and power sockets are also included in the scope.
Tests: Routine & Acceptance shall be carried out on cables for FRLS and other
property as per relevant IS in presence of HWB representative and report shall be
submitted by EPC contractor. Type test shall be carried out or report shall be submitted
as per relevant IS.

18. CABLE LAYING AND TERMINATION:

CABLE LAYING:

Supply of required cable trays and their erection for successful completion of the
project is in the scope of EPC Contractor. All the cables for 3.3KV and class-I
supply shall be laid over the existing cable tray (i.e. from 3.3KV substation to
chemical lab) and to be clamped properly. Cable from chemical lab to SPP
Transformer is to be laid in trenches. Excavation and trench preparation jobs required
for this cable and other cable are in the scope of the EPC Contractor. Pump house
cable from SPP MCC shall be laid over the existing tray from chemical lab to pump
house. Wherever cable tray is not existing trenches/trays are to be constructed by EPC
Contractor for cable laying. The cables shall be properly fixed and dressed. Where
ever road crossing is involved Hume pipe shall be laid so as to accommodate the
power and control cables and clearance shall be there for laying cables in future. The
materials required for the job is in scope of contractor.

Cables, other than ancillary buildings shall be routed in overhead cable trays
(Slotted GI Tray) throughout the plant area. The cable tray arrangement shall be
based on cable de-rating factors under normal operating condition and overall
economy.

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Cables in ancillary buildings area (i.e. off-site facilities) shall be laid in trenches with
sand bedding and filling and layer of bricks on top and depths between 1500 mm to
750 mm depending on cable sizes and their voltage grades. Power cables of various
voltage level i.e. 3.3. kV, 415 volts, 110 volts etc and control cables shall be separated
from each other by brick barriers. Due consideration should be taken for economical
selection of cables while planning the cable arrangements in the trenches.

Cables for the plant area shall be arranged in trays with recommended spacing
between them. 3.3. kV, 415 volts and 110 volts shall be laid in the separate trays.
Cable trays shall be arranged in multi-tiers with control cable trays normally at top
except for 3.3.kV cable trays which shall be laid at top.

Vertical spacing between cable trays shall be maintained at 300 mm (minimum)

inside buildings and plant areas and at 450 mm while routing over pipe racks for
interplant run. In general, cable trays shall be supported on pipe racks approximately
at every two meters and they run above pipes with a clearance of one meter.

Sizes of cable trays shall be standardize as 500 mm, 300 mm 150 mm 75mm and
50mm wide with 2400 mm in length. Cable trays including fasteners shall be of GI.
The thickness galvanization shall not be less than 75 micron. Various standard
fittings e.g. tee, cross, reducer, elbows (vertical and horizontal) shall be used to suit
the routing.

Structural design to support cable trays will be based on two columns with a top
beam, when the supports for cable trays at different levels (for multi-tier
arrangements) will be provided to suit the required cable tray arrangements.
Similarly, for intermediate supports of cable trays (i.e. @ 2 metre between two rows
of columns) the structural design will provide a top beam only.
Cable laying for street lights to be done by the contractor.

CABLE TERMINATION:

1. All the termination of cables in motors, transformers, switch gear will be in

contractor’s scope. For termination of cables in motors, junction boxes, switches, etc
in Main Plant double compression glands only should be used. In other areas normal
glands are permitted. Similarly, all the terminal lugs, connectors, etc which are
required for termination are in the scope of the contractor it should be taken care
while quoting. Terminations of HT cable on both sides are in the scope of EPC
Contractor.

19. GROUNDING & LIGHTNING PROTECTION:

The grounding/Earthing electrodes shall be provided at various areas within the plant
area and these electrodes shall be inter-connected to bring down the earth resistance.
Electrodes for boiler grounding should be separate. Each electrode boiler shall be
provided with double earthing.

Power transformer (2MVA) shall be provided with separate earthing. Each

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transformer shall be provided with three earth pits apart from neutral earthing pit. All
body earthing shall be linked using GI Flats as per relevant IS. Neutral earthing shall
be of copper flats as per relevant IS.

Power transformer neutral earthing and Electrode boiler earthing should not be linked.
Both power transformer body earthing shall be linked.250KVA DG set shall be
provided with separate grounding. Separate neutral grounding shall be done for the
new 250KVA DG set.

The earthing design should be done in such a way that the system resistance should be
less than 1ohm.

Separate earth pits shall be made for instrumentation / DCS system with adequate
numbers of earth pits.

The structures will be grounded by low resistance conductors to the grounding

electrode and steel structures and vessels which are accessible to personnel and which
enclose support or are in the vicinity of the electrical equipment such as monorails etc
will be connected to the grounding system through low resistance GI flats. Cable trays
will be bonded at intervals and will be connected to the earth through a flat laid in one
of the trays. Electrical motors will be connected to the earth grid by two distinct
earth connections. The internal grounding bus in each electrical equipment will be
connected at both ends to the earth. The frames of all junction boxes and other control
panels will also be connected to the earth. All non-current carrying parts of the
electrical equipment shall be doubly grounded at two distinct places diagonally
opposite to each other. Size of earthing conductor shall be sufficient in all respect.

The lightning protection for the various structures in the plant and other buildings of
the plant shall be based on IS 2309.

The existing earthing system in the main plant.

(Neutral points of the 3.3. KV winding of the 10 MVA, 110 KV /3.3kv main power
transformers are solidly grounded. For the 3.3. KV/433 volts load center transformer,
the neutral of the secondary star connected winding will be solidly grounded. The
neutral of the star connected winding of the existing diesel generator is also to be
solidly grounded. Class II / I supply is floating in respect of earth.)
All the metallic pipe flanges shall be bonded by flexible conductor which is known as
flange shunting braids for protection from static electricity. All the vessels to be
earthed (with double earth)
20. PROTECTION SYSTEM :

(i) General Requirements:

All fault detecting relays are equipped with operation indicators. Annunciation and
alarm circuits are generally initiated from a contact which opens when an abnormal
condition is detected. Tripping and other control circuits for Breaker are to be fed
from a 110 volts DC source and control supply for all other feeders shall be of 110 V
AC to be tapped through control transformers. In each MCC two control transformers
shall be provided. All fault detecting relays shall be supplied in draw-out cases for

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flush mounting or rigid steel panels. Control power monitoring shall be provided.
Annunciation and indicating panel should be provided in the MCC itself.

(ii) 3.3KV/433 V 2 MVA TRANSFORMER PROTECTION :

Each of the transformer should have the following protections:
(iii) The gas detecting Buchholz relay (63) for internal faults, oil temperature high trip and
alarm, winding temperature high trip and alarm and magnetic oil gauge shall be
provided for each transformer. Protective relays such as over current and earth fault
(IDMT), instantaneous earth fault for both HT and LT winding; REF for LT winding
and differential protection shall be provided for the transformers. All of these
protection/relays are to be provided in HT panel. Each of these above relays during
respective fault will initiate a high-speed tripping relay along with auxiliary relays. 24
c x 2.5 sq.mm armoured copper cable shall be laid between 3.3KV Panels and PMCC
for incorporating the trip signal. This tripping signal will trip the 3.3 KV breakers in
the sub-station. Inter-trip facility shall be incorporated between HT and LT Breaker.
Annunciation panel with hooter shall be provided in 3.3KV Annunciation panel.
Under voltage of control circuit shall be monitored with suitable relay (27T).
EPC contractor has to do the detail engineering for these protections and get them
approved.
(iii) 415 VOLTS SWITCHGEAR

(a) 415 V ACBS FOR INCOMER (2 NOS), BUS COUPLER, ELECTRODE

BOILER AND PUMPHOUSE.

Each of the above circuit breaker shall be protected with combined inverse time over
current (51) and earth fault (64) relay.
The breakers shall also be provided with under voltage protection scheme.
Suitable multifunction meter shall be provided in each breaker.

(b) MOTOR FEEDERS:

Each motor shall be provided with a multi-purpose relay to provide comprehensive
protection of motor under various fault conditions.

(i) Motors feeders below 37 KW rating shall have following protection:

 Short circuit protection through HRC fuses.
 Overload and single phasing protection through thermal bi-metal relays with
manual resetting feature.
 Under voltage protection through suitable scheme.

(ii)Motors feeders of 37 KW rating and above shall have following protection:

Motor protection Relay with overload, short circuit, earth fault, single phasing
(unbalancing) etc. Relay operation will trip the contactor, the lock-out relay will
initiate an alarm and will signal for starting of standby motor.

Each motor should be provide with local push button station in field with ON and
OFF facility, local push button station should be fixed in vicinity to the motor and
shall be of flame proof type.

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Each feeder panel shall have ON/OFF/Over Load indication. Analog Ammeter of
suitable range shall be provided. Each feeder panel shall have OVER LOAD reset
push button. Each panel shall be provided with local remote switch. Philosophy for
controlling each motor from local, electrical panel and DCS is to be prepared by EPC
contractor and submit for approval from HWB.

21. BUILDING ELECTRIFICATION AND POWER SUPPLY ARRANGEMENT

Electrification of all the buildings including installation of light fittings, ceiling fan,
exhaust fan, power sockets, etc is in the scope of the contractor. For control room,
MCC room I & II, UPS room, Engineers room and conference room the wiring should
be done as a concealed wiring. For other areas in Main plant, utility, ETP, Recovery
unit, chemical storage shed etc. open type cable wiring is to be done. All the items
required for the above electrification is in the scope of contractor. Scheme for Local
distribution for lighting, Air conditioners etc is to be configured by the EPC
Contractor and get it approved from HWB.
22. AIR CONDITIONING AND PLANT VENTILATION
Air-conditioning of control room, UPS room, conference room is in the scope of
contractor. For this purpose 10Nos. of 1.5 TR, split ACs are to be supplied and
installed at location as per direction of Engineer in charge. In case of surplus or
shortfall owner will take care.
As the plant is handling highly volatile substances a proper fume extraction system
needs to be installed in all the buildings. For this purpose, sufficient numbers of
exhaust fans to be installed to maintain air changes of at least 6 changes per hour
needs to be installed in all the buildings. In addition, mobile fume extractors approx.
of rating of 3000 m3 per hour capacity with FRP construction for the blower shall be
supplied at least 4 Nos. These fume extractors can be utilized in all the buildings
whenever required.
23. POWER SWITCHES, SOCKETS and PUSH BUTTON STATION

In addition to lighting, in each building sufficient numbers of 3 phase 63 A Power

sockets and single phase 32 A Power sockets needs to be installed. In Main Plant
area, charging room, ETP, chemical storage area, etc. it is proposed to install two
numbers of 3 phase 63 Amps. Power sockets and 2 nos. of 32 Amp power socket in
each building. These should be of flameproof type whereas in other areas such as
utility shed, MCC room, etc.. 1 no. of 63 Amp. 3 phase power socket and 2 nos. of 32
Amp. Single phase power socket may please be provided. This can be of
weatherproof type. For all power sockets ELCB to be provided. VFD room shall be
adequately ventilated to maintain VFD temperature within allowable limit.

Local Push Button Stations:

EPC contractor have to supply and erect Local Push Button Stations in field for each
motor of SPP equipments and also for motors of equipments installed in ETP; List of
such equipments are mentioned in the load list. Each Push Button station should have
ON/OFF push buttons, terminals for cable, opening for cable entry and should be
fixed on a stand near motor. Push Button Stations shall be of normal and flame proof
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type as per plant requirement. Each Push Button should have 1 NO+1 NC Contact.
All the push buttons will be suitable for 230V. Material of Construction should be
suitable for the corrosive environment prevailing at the site. Enclosure should be
PP/FRP/Aluminium Alloy etc of proper thickness. For Flameproof Push Button
Station CMRI certificates should be submitted. Vendor has to work out quantity of
Flameproof and Non-Flameproof PBS required for completeness of the system. The
push button station shall have provision of cable gland at the bottom. Non Flameproof
PBS shall have proper ingress protection. Name plate, legend, wiring diagram should
be provided on each push button station.
24. D.G SET

The SPP facility will be having a CLASS-III load of 150KW approx. So for meeting
the CLASS-III power requirement of SPP a new 415V, 250KVA DG set is to be
supplied, installed, tested and commissioned. For operation and control of DG set one
AMF (Auto Mains Failure) panel is to be procured and installed along with change
over switch by the EPC contractor.
AMF PANEL:
AMF panel should have incomer breaker and change over contactor.
The change over contact should operate automatically when CLASS-IV supply fails
and vice versa when CLASS-IV supply resumes. When class-IV supply fails DG set
should feed power to EMCC panel through Change over contactor.
The change over contactor shall be provided with electrical interlocks.
AMF panel shall have all the indications control of DG set Energy meter, Running
hour meter, battery charger, and ammeter, voltmeter, and DG protective relays.
DG set shall be supplied, installed, tested and commissioned along with AMF panel,
battery charger, battery, power and control cables for connecting AMF panel are in
the scope of contractor.
Associated minor civil works involved for erection of DG and AMF panel is under the
scope of the EPC contractor.

THE DETAILED SPECIFICATION OF 415V 250KVA DG SET IS GIVEN IN

ANNEXURE-VII.

25. UNINTERRUPTED POWER SUPPLY SYSTEM:

The UPS system shall be an integrated system comprising static rectifier, battery
bank, static inverters, static switches, manual bypass switch, AC distribution board,
voltage stabilizer in bypass, isolating and protection devices and all other
equipment/accessories required for completeness of the system.

The UPS system shall be suitable to feed all loads connected to output which are
primarily DCS & instruments. The UPS system shall be complete in every respect
and shall comprise following major sections.

DETAILED SPECIFICATIONS OF UPS SYSTEM IS GIVEN IN ANNEXURE-

VIII.

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26. LIST OF APPLICABLE ELECTRICAL STANDARDS:

General Requirements:
IS 732 Code of practice for electrical wiring installations (system voltage not expending
650 Volts).
IS 900 Code of practice for installation and maintenance of Induction Motors.
IS 1271 Classification of insulating materials for electrical machinery and apparatus in
relation to their thermal stability in service.
IS 1646 Code of practice for fire safety of buildings (general)
- Electrical installation
IS 1866 Code of practice for maintenance of insulating oil.
IS 1882 Code of practice for outdoor installation of public address systems.
IS 1886 Code of practice for installation and maintenance of transformers.
IS 1931 General and safety requirements of electric lighting fittings.
IS 2032 Graphical symbols used in electric technology.
IS 2148 Flame proof enclosure for electrical apparatus.
IS 2165 Guide for insulation coordination.
IS 2274 Code of practice for electrical wiring installations (system voltage exceeding 650
volts).
IS 2309 Code of practice for protection of buildings and allied structures against lighting.
IS 3034 Code of practice for fire safety of industrial buildings – electrical generating and
distributing stations.
IS 3043 Code of practice for earthing.
IS 3072 Code of practice for installation and maintenance of switchgear (system voltage
Part-I not exceeding 1000 volts)
IS 3106 Code of practice for selection, installation and maintenance of fuses (voltage not
exceeding 650Volts)
IS 3638 Application guide for gas-operated relays.
IS 3646 Code of practice for interior illumination.
IS 3716 Application guide for insulation coordination – equipment located in hazardous
situations.
IS 3842 Application guide for electrical relays for AC system.
IS 4004 Application guide for non-linear resisted type lightning arrestors for AC system.
IS 4146 Application guide for voltage transformers
IS 4201 Application guide for current transformers.
IS 5571 Guide for selection of electrical equipment in hazardous area.
IS 5572 Classification of hazardous areas for electrical installations.
IS 5780 Intrinsically safe electrical apparatus and circuits.
IS 5908 Method of measurement of electrical installations in buildings.
IS 13346 General requirement for enclosures for electrical apparatus for explosive gas
atmosphere.

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II – EQUIPMENT:

2. Switchgear:
(a) General:

IS 375 Marking and arrangement for switchgear bus-bars, main connections and
auxiliary winding.
IS 694 Part-I PVC insulated cables (for voltages up to 100V) with Copper Conductors.
IS – 1248 Direct acting electrical indicating instruments.
IS 13947 Degree of protection provided for enclosures for low voltage switchgear
and control gear.
IS 2208 HRC cartridge fuse links up to 650V.
IS 2705 Part – I, II & III – Current transformers
IS 3156 Part-I, II & III voltage transformers.
IS 3202 Code of practice for climate proofing of electrical equipment.
IS 3231 Electrical relays for power system protection.
IS 4047 Heavy duty air break switches and composite units of air break switches
and fuses for voltages not exceeding 1000 Volts.
IS 4237 General requirements for switchgear for switchgear and control gear for
voltages not exceeding 1000V
IS 5987 Code of practice for selection of switches (voltage not exceeding 1000V).

(b) 3.3KV

IS 2516 Part I – Sec. 2 and Part II – sec. 2 – Alternating current circuit breakers –
Requirements and tests for voltage ranges 1000 to 11000 volts.
IS 3427 Metal enclosed switchgear and control gear for voltages above 1000V but
not exceeding 11000V.

(c) 415 Volts:

IS 722 AC electricity meters.

IS 1951 PVC sleeving for electrical purposes.
IS 2419 Dimensions of electrical indicating instruments.
BS 4752 Circuit breakers of rated voltage up to and including 1000Volts and 1200
volts DC.
BS 6231 PVC insulated cables for switchgear wiring.
IEC 157 Low voltage distribution switchgear circuit breakers.

(d) M.C.C:

IS 1554 Part I – PVC insulated (heavy duty) electric cables for working voltages
up to and including 1100 Volts.
IS 1822 AC motor starters of voltage not exceeding 1000 Volts.
IS 2959 AC contactors of voltage not exceeding 1000V.
IS 3961 Part-II – Recommended current ratings for PVC insulated and PVC

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sheathed cables.
IS 5124 Code of practice for installation and maintenance of AC induction motor
starters (voltage not exceeding 1000V).
IS 13947 (Part 3 & 4) LV switchgear and control gear.
IS 8544 (Part I & II) motor starter.
IS 12640 Residual current operated CBs.

(e) PMCC and EMCC:

IS 12021 Control transformers for switchgear and control gear for voltages not
exceeding 1000V AC.
IS 13947 Low voltage switchgear and control gear
IS 722 Specification for AC Electricity meter.
IS 1248 Direct acting electrical indicating analogue electrical measuring
Instruments and their accessories.
IS 2705 Current Transformers
IS 3156 Voltage Transformers
IS 3231 Electrical relays for power systems protection
IS 3043 Code of practice for earthing
IS 5082 Wrought aluminium and aluminium alloy bars, rods, tubes and sections
for electrical purposes.
IS 5578 Guide for marking of insulated conductor
IS 8623 Low voltage switchgear and control gear assemblies
IS 11353 Guide for uniform system marking and identification conductors and
apparatus terminals
IS 375 Marking and arrangement for switchgear bus bars, main conductor and
auxiliary wiring.
IS 3072 Code of practice for installation and maintenance of Switchgear
IS 1897 Copper strips for electrical purposes.
IS 2147 Degrees of protection provided by enclosures for low voltage switchgear
and control gear.
IS 2516 AC circuit breaker requirements-voltages not exceeding 1000V
IS 4064 Specifications for air break switches, air break dis connectors, air break
switch dis connectors and fuse combination units for voltages not
exceeding 1000V
IS 4237 General requirements for switchgear and control gear for voltages not
exceeding 1000V AC.
IS 6875 Control switches for voltages up to and including 1000V AC and 1200V
DC.
IS 10118 Code of practice for selection, installation and maintenance of switchgear
and control gear
IS 15652 Insulating Mats for Electrical Purposes

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(f) Vacuum Circuit Breaker:

IS 14697 AC Static Energy meters.

IS 996 Single phase small AC and universal electrical motors.
Direct Acting indicating analogue electrical measuring Instruments and
IS 1248
Accessories.
Degree of protection provided by enclosures for low Voltage switchgear and
IS 13947
control gear.
Porcelain post insulators for systems with nominal voltages greater than
IS 2544
1000 Volts.
IS 2705 Current transformers.
IS 3156 Voltage Transformers
IS 6005 Code of practice for phosphating of iron and steel.
IS 3427 Metal enclosed switchgear and control gear
Specification for wrought aluminium and aluminium alloy bars, rods, tubes
IS 5082
and selections for electrical purposes.
IEC 61850 Communication Standard for Numerical relays
IEC 61131‐3 Automation Standard for Numerical relays
AC contactors for voltages above 1000 volts and up to and including 11000
IS 9046
Volts.
IS 13703 Low voltage fuses
IS 9385 HV fuses
Specification for indoor post insulators of organic material for system with
IS 9431
nominal voltages greater than 1000 volts up to and including 300 kV.
A.C. dis connectors (isolators) and Earthing switches for voltages above
IS 9921
1000 V
Guide for uniform system of marking and identification of conductors and
IS 11353
apparatus terminals.
IS 13118 Specification for high voltage AC circuit breakers.
IEC 60099‐4 Metal oxide surge arrestor without gap for AC system
IEC 62271‐100 High voltage alternating current circuit breakers.
IEC 62271‐200 High voltage metal enclosed switchgear and control gear.
IEC 60947‐7‐1 Terminal blocks for copper conductors
IS 513 (2008) Cold Rolled Low Carbon Steel Sheets and Strips

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(g) Variable Frequency Drive:

IEEE 519 Harmonic control and reactive compensation of static power converters.

IS-3700
Essential ratings and characteristic of semi conductor Devices.
IS-3715
Letter symbols for semi conducting devices
IS-4411
Code of designation of Semi-conducting devices
IS-5001
Guide for preparation of drawings for semi conductor devices
IS-5469
Code of practice for the use of Semi-conducting Junction devices
IS-13947
Low voltage switch gear and control gear: General rules
IEC-146
Semi conducting converter
IEC-297
Dimensions of panels and racks
IEC - 326 General requirements and measuring methods for printed wiring boards

IEC-352
Solder less wrapped connection
IEEE 44
Protection standards for converter

(h) Uninterrupted Power Supply

IS 13947 Specification for low voltage switch gear and control gear

IEC 146
Semi-conductor converters
IS 3700 Essential rating and characteristic of Semi-conductor Device

IS 16242 Un-interruptible power system

IS 4411 Code of designation of Semi-conductor Device

IS 5001 Guide for preparation of drawing for Semi-conductor Device

IS 5469 Code of practice for the use of Semi-conductor Junction device

IS 13947 L.V. switch-gear and control-gear

IS 2147 Degree of protection provided

IS 7204 Stabilised power supply D.C output

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IS 13314 Solid state inverters run from storage battery

(i) Transformers:

IS 335 Insulating oil for transformers and switchgear.

IS 2026 Power transformers.
IS 2099 High voltage porcelain bushings.
IS 3070 Lightning arrestors for AC systems.
IS 3637 Gas operated relays.
IS 3639 Fittings and accessories for power transformers.

(j) Motors:

IS 325 Three phase induction motors.

IS 4691 Degree of protection provided by enclosures for rotating electrical machinery.
IS 4722 Rotating electrical machines.

(k) Cables:

IS 1554 Part I&II – PVC insulated (heavy duty) electric cables for working voltages
up to and including 110 Volts and from 3.3 KV to 11 KV.
IS 1753 Aluminium conductors for insulated cables.
IS 3961 Part-II – Recommended current ratings for cables.
IS 3975 Mild steel wires, strips and tapes for armouring cables.
IS 5819 Recommended short-circuit ratings of high voltage cables.
IS 5831 PVC insulation and sheathed of electric cables.
IS 7098 Cross linked Polyethylene Insulated (Part I & II) PVC Sheathed Cables
IS 694 PVC Insulated Cables for working voltage upto and including 1100V.
IS 10418 Drums for Electric Cables
IS 8130 Conductors for insulated electric cables and flexible cords
IS 10810 Methods of testing for cables

(l) DG Set
BS 649 Diesel engines for general purpose
IS-10000 Methods of test for internal combustion engine
ASM E codes(applicable to Diesel Generator)
IS 4722 Rotating Electrical Machines
Oil coolers as per TEMA class “C”

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BS : 2623 Alternator
IS: 1460 Diesel Fuels
IS: 4691 degrees of protection provided by enclosures for rotating electrical
machinery
IS 10002 Performance requirements of Diesel Engine for General purpose above 20
KW o Indian Electricity Act & Rules.

27. LIST OF SPARES

Description Quantity
A. Spares For MCC Nos.
1 Selector Switch 2 Nos. Of Each Type
2 Indicting Lamps 5 Nos. Of Each Colour
3 Control Fuses 5 Nos. Of Each Type
4 Push Button 2 Nos. Of Each Type
5 Overload Relay 2 Nos. Of Each Type
6 Power Contractor 2 Nos. Of Each Type
7 Aux. Contractor 6 Nos.
8 Power Fuses 5 Nos. Of Each Rating
9 Power Fuses For Incoming 6 Nos.
B Lighting Distribution Board
1 MCB 5 Nos. Of Each Type
2 HRC Fuses 5 Nos. Of Each Type
5% spares Push Button Station of each type
and 10% push buttons with contacts of each
C Local push Button Station type
D Motor
1 Bearings 2 Set (DE & NDE SIDE) For Each Frame Size
2 Cooling Fan with end cover 1 Nos Of Each Frame Size
2 Nos. Of Each Type For Indoor Lighting
E Lighting Fittings Of Hpmv Lamps
2 Nos. Of Lighting Fittings On Class I & III
1 Lighting Fitting Supply
2 Lighting Fitting 2 Nos. Of Street Lighting
3 Bulb 5 Nos. Of Each Type Installed
F Ups (Class - II) Power
1 System Card 1 No. Of Each Type
2 Buffer Card 1 No. Of Each Type
3 Inverter 1 No. Of Each Type
4 Charger Thyristor 1 No. Of Each Type
5 Spare Battery Cell 2 Nos.

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6 Indicating Lamps 5 Nos.

7 Reset Push Button 2 Nos.
8 Hooter 1 No. Of Each Type
Fast Acting Semi Conductor Fuses (For 10 No. Of Total Inventory Used Of Each
9 Full Bridge) Rating
10 Control Fuses 20 Nos.
10 No. Of Total Inventory Used Of Each
11 HRC Fuses Rating
12 Cooling Fan 2 Nos.
13 MCB 10 No. Of Each Type

Sr.
Item Description Qty.
No.
G. Spares for VCB
1 Closing coil 2
2 Tripping coil 2
3 Auxiliary contact switch 2
4 Spring charging motor 2
5 Consumables like washer, pin etc.. 4 set
6 Handling trolley suitable for VCB 1 no

H Spares for ACB

1 Closing coil 2
2 Tripping coil 2
3 Auxiliary contact switch 2
4 Spring charging motor 2
5 Consumables like washer, pin etc.. 4 set
6 Indication lamp 12
7 Ammeter 2
8 Auxiliary contactor 4
9 Handling trolley suitable for ACB 1

Sr.
Item Description Quantity
No.
I. Spares for Diesel Generator Set
1 All Engine Bearings/Bushes 1 Set
Piston Assembly including piston rings, connecting rods, bolts
2 2 Nos.
etc.
3 Piston rings(all types)- 1 Set
4 Inlet valve and exhaust valve 1 Set

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5 Main lub. oil pump assembly 1 Nos.

6 Fuel Injection pump- 1 Nos.
7 Gaskets and O rings 1 Set
8 Turbo Charger assembly 1 Nos.
9 Coupling assembly complete 1 Nos.
Lube Oil Filters
10 Filter Cartridge/Elements 1 Set
11 Cartridge Guide 2 Nos.
12 Set of filter gaskets/O rings 1 Nos.
Fuel Oil Filters
13 Filter Cartridge/Elements 1 Set
14 Cartridge Guide 2 Nos.
15 Set of filter gaskets/O rings 1 Set
Aux Lube Oil pump
16 Pump Assembly with motor & coupling 1 Nos.
17 Set of bearings/Sleeve 1 Nos.
18 Mechanical shaft, Seal 1 Nos.
19 Set of gaskets/O rings 1 Nos.
Electrical Alternator
20 Set of bearings 1 set
21 Rotating Diode assembly 1 set
22 Diode Fuse 20% of total qty.
23 AVR cards 1 Nos.
24 Governor Controller 1 Nos.
25 Potential transformer one of each type 1 Nos.
26 Current Transformer one of each type 1 Nos.
27 Control transformers one of each type 1 Nos.
Instrumentation
28 10 % of spare instruments or 1 of each type 1 Set

Sr.
Item Description
No.
J. Spares for Transformers
1 HT Bushing 1 Set
2 LT Bushing 1 Set
3 Temperature gauges cum Protection Relay 1 Set
4 Magnetic Oil Gauge 1 Set
5 Silica Gel 1 Set
6 Safety Relief Valve 1 Set
7 Drain Plug 1 Set

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LIST OF RECOMMENDED VENDOR:

A) SWITCH GEAR:

1. Voltech Manufacturing Company Limited

2. Alstom T & D India Ltd
3. L&T Electrical and Automation
4. Siemens Limited
5. ABB Limited
6. Schneider
7. C&S Switchgear
8. Kirloskar Electric
9. Asahi Switchgear

B) TRANSFORMER

1. M/S ROWSONS MARKETING PRIVATE LIMITED.

2. EMCO TRANSFORMERS LIMITED.
3. VOLTAMP TRANSFORMERS LIMITED
4. ABB LIMITED
5. PETE TRANSFORMERS
6. VOLTECH TRANSFORMERS
7. CGL
8. RAYCHEM
9. BHARAT BIJLEE

C) WIRES & CABLES:

1. M/S Polycab cables Private Limited
2. M/S Universal Cables Ltd.
3. RPG Cables Limited
4. Finecab Wires and Cables
5. Gem Cables & Conductors Ltd
6. Havells Cables
7. KEI cables

D) DG SET
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1. M/s Kirloskar
2. CUMMINS
3. MTU
4. CATERPILAR
E) VACUUM CIRCUIT BREAKER:

1. M/s. Schneider Electric Infrastructure Ltd. (Energy Business)

2. M/s Voltech Manufacturing Company Limited
3. M/s Kirloskar-electric Limited
4. M/s Jyoti Limited
5. M/s Crompton Greaves
6. M/s ABB
7. Siemens
8. M/s Alstom
9. L&T
10. BHEL
F) AIR CIRCUIT BREAKER
1. ABB
2. Siemens
3. Schneider
4. AREVA
5. L&T
G) VARIABLE FREQUENCY DRIVES:
1. ABB,
2. Toshiba.
3. Siemens
4. Hitachi
5. Danfoss
6. Vacon
H) LIGHT FTTING AND FIXTURES
1. L&T
2. Legrand
3. Schneider
4. Havells

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5. Philips
6. Crompton Greaves Limited
7. GE
I) MICROPROCESSOR RELAY
1. L&T
2. Schneider
3. Siemens
4. Areva
5. GE
6. ABB
J) ANALOG METERS
1. AE
2. Conzerv
3. Secure
4. L&T
5. Rishabh
6. MECO
K) INSTRUMENT TRANSFORMERS AND CONTROL TRANSFORMERS
1. Kappa
2. Silicon
3. Prayog
4. Pragati
5. AE
L) CONTROL TERMINALS
1. Elemex
2. ConnectWell
M) MULTI-FUNCTION METER
1. Swift-Encore
2. Siemens
3. HPL-Socomec
4. Merlin Gerin
5. MECO
6. Rishabh

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7. Secure
N) GLANDS AND LUGS
1. Dowells
2. Comet
3. Braco

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29.

ANNEXURE – I

29. TECHNICAL SPECIFICATION

FOR 3.3KV/433V of 2MVA
OUT DOOR POWER TRANSFORMER

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TECHNICAL SPECIFICATIONS (OUT DOOR TRANSFORMER (OFTC) - OIL

TYPE):
1.0. SCOPE:
Design, manufacture, testing, supply, installation and commissioning of 3.3 KV / 433V
distribution transformer complete with all the accessories and fittings for efficient and trouble
free operation.

2.0. STANDARDS:
2.1 The equipment and accessories covered by this specification shall be designed,
manufactured and tested in compliance with the latest relevant standards published by the
Indian Standards institution wherever available in order that specific aspects under Indian
conditions are taken care of.
2.2 The equipment and accessories for which Indian Standards are not available shall be
designed, manufactured and tested in accordance with the latest standards published by any
other recognized national standards institution.
2.3 The equipment shall also conform to the latest Indian Electricity Rules as regards safety,
earthing and other essential provisions specified therein for installation and operation of
electrical plants.

3.0. GENERAL DESIGN AND CONSTRUCTIONAL FEATURES:

3.1 All mechanisms shall be of stainless steel, brass, gunmetal, or other suitable material to
prevent sticking due to rust or corrosion.
3.2 TANK:

3.2.1 The transformer tank shall be made of steel plate, shaped in such a way that
minimum of welding is required. The tank shall be electrically welded and all welding
stresses shall be properly relieved. Tank walls shall be reinforced by adequate stiffeners
to ensure mechanical rigidity permitting hoisting of complete transformers filled with oil
and also to damp transformer noise.

3.2.2 Tank cover shall be bolted on to the flanged rim of the tank with a suitable weather-
proof, hot-oil-resistant gasket in between for oil tightness
3.2.3 The exterior of tank and other steel surface exposed to the weather shall be
thoroughly cleaned and have a priming coat of zinc chromate applied. The second coat
shall be of an oil and weather resistant nature preferably of distinct colour from the prime
and finish coats. The final coat shall be of glossy, oil and weather resisting non-fading
paint of specified shade. The interior of the tank shall be cleaned by shot blasting and
painted with two coats of heat resistant and oil insoluble paint.
3.2.4 Steel bolts and nuts exposed to atmosphere shall be galvanized however; surfaces of
the transformer or other parts of the transformer or auxiliary equipment which are in
contact with oil shall not be galvanized.
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3.3 CORE:
3.3.1 The magnetic circuit shall be built of transformer grade cold rolled grain oriented
low loss steel stampings having high permeability and conforming to adopted standards.
Stampings shall be insulated from each other with material having high inter-lamination
insulation resistance and rust inhibiting property and also capable of withstanding
pressure, mechanical vibration and action of heat and oil, thus reducing the possibility of
sludge formation to a minimum.
3.3.2 The framework, clamping arrangement and general structure of the cores of each
transformer shall be of robust construction and shall be capable of withstanding any
shock to which they may be subjected during transport, installation and service. The
assembled core shall be securely clamped, on the limbs and the yoke, to build up a rigid
structure. The clamping pressure shall be uniform over the whole of the core and so
adjusted as to minimize noise and vibration in the core when the transformer is in service.
The framework and the core bolts shall be efficiently insulated from the core so as to
reduce the circulating currents to a minimum.
3.3.4 An approved type of core grounding system shall be used; the grounding
connections being located at the top of the core for easy access from the inspection hole.
3.4 WINDING:
3.4.1 The coils used for transformer winding shall be circular in shape, made of paper
insulated, continuous and smooth, tinned or enamelled electrolytic copper conductors of
high conductivity.
3.4.2 The end turns on the high voltage winding shall have reinforced insulation to take
care of the voltage surges likely to occur during switching or any other abnormal system
condition.
3.5 INSULATING MATERIALS:
3.5.1 The insulating oil shall conform to IS-335 and shall be suitable in all respects for
operating the transformer at the rating and under conditions specified in the main
equipment specification. Sufficient oil shall be supplied for the first filling of transformer,
the oil circulating equipment and the tank containing tap-changing mechanism and an
extra 10% shall be supplied in non-returnable drums. The tender shall contain information
about the grades of oil recommended by the transformer manufacturer for use in the
transformer. Test certificates for the oil shall be furnished before dispatch of transformer
and acceptance by owner.
3.5.2 “Class A” insulating materials specified in latest IS shall be used. Paper insulation
shall be new and free from punctures. Wood insulation, where used shall be well
seasoned and treated.
3.6 COOLING EQUIPMENT:
3.6.1 Natural cooling by means of banks of detachable type radiators made from
pressed/round tubes around transformer tank shall be provided. The tubes shall be of
seamless mild steel sheet with clean bright internal surface and shall be suitably braced to
protect them from shock.

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3.6.2 The radiators shall be provided with butterfly type of shut off valves.
3.6.3 Cooling tubes/radiators shall permit every part of the cooling surface to be cleaned
by hand.
3.7 TERMINAL ARRANGEMENT
3.7.1 High Voltage Side (3.3 KV)
Cable box shall be provided suitable for terminating two runs 3C x 300 sq.mm FRLS,
XLPE insulated armoured 3.3 KV UE cable complete with disconnecting chamber,
compression glands, tinned copper lugs, Armour earth clamp and body earth terminal.
Cable box shall be fitted with bushing insulators for H.T. cable termination side.
3.7.2 Low Voltage Side (433V)
Secondary terminal box shall accommodate 8 runs of 3Cx400sq.mm FRLS aluminium
armoured cable. (Seven runs of cable for 3phase and one run cable for neutral).
Secondary terminal box should be weather proof and vermin proof. Suitable
disconnecting arrangements should be available in the terminal Box to remove
transformer without disconnecting cable.
3.7.3 Bushing:
Bushings shall confirm to IS: 2099 and other relevant standards.
Bushings shall be supplied with terminal connector clamp suitable for connecting the
bushing terminal to the owner's conductor.
Creepage distance of bushing shall be (41mm/kv phase ground) adequately.
3.8 MARSHALLING BOX
3.8.1 The supplier shall provide temperature indicators, with auxiliary contacts; Buchholz
Relay and CT's are to be connected to Marshalling box. Contacts terminals of all other
electrical devices mounted on the transformer shall be connected to Marshalling box.
Steps shall be incorporated to prevent open circuit of CT.
a) The interconnection cabling between the Marshalling box and the accessory devices
either by PVC insulated copper wire in G.I. conduits or PVC insulated copper conductor
armoured cables.
b) Necessary compression type brass cable glands at the Marshalling box for above
cables.
3.8.2 The Marshalling box shall be tank mounted, water/dust tight sheet steel (2mm thick)
enclosed with hinged door having padlocking facility. All doors, covers and plates shall
be fitted with neoprene gaskets. Top surface shall be sloped and bottom shall be at least
600mm from floor and provided with gland plate and cable glands as required.
3.8.3 Terminals shall be clip on type rated for 10A. All contacts for alarm/trip indication
shall be potential free, wired up to the terminal block. Wiring shall be done with stranded

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copper conductor wires of sizes not less than 1.5 sq.mm for control and 2.5 sq.mm for CT
circuits.
4.0. SPECIFICATION FOR 3.3 KV /433V of 2MVA OUT DOOR POWER
Transformer (OFTC TYPE)
Capacity : 2000 KVA
Voltage No load HT : 3300 V
Voltage No load LT : 433 V
Ampere HT : 320 A
Ampere LT : 2666 A
Phase :3
Frequency : 50 Hz
Vector Group : Dyn11
Maximum Temp. Raise : 45oC
Type of cooling : ONAN
Mounting : Outdoor on Rail.
TYPE : OFTC
IS ref. : IS 2026/1962 or latest edition
The transformer should be provided with the following:

 Off load tap changer preferably (Range 5 Steps -5% to +5%).

 Double float Buchholz Relay
 Dial Type Thermometer
 Winding Temperature Indicator
 Magnetic Oil Gauge
 Cooling Fins
 Breathers
 Explosion Vent
 Primary terminal box shall accommodate 2 runs of 3Cx300sq.mm FRLS XLPE
aluminium armoured cable.
 Secondary terminal box shall accommodate 8 runs of 3Cx400sq.mm FRLS
aluminium armoured cable. (Seven runs of cable for 3phase and one run cable for
neutral).

5.0. ELECTRICAL & PERFORMANCE REQUIREMENT:

a) Transformer shall be designed for 110% continuous over fluxing withstand capability.

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b) The neutral terminals of the winding with star connection shall be designed for the highest
over current that can flow through the winding.
Transformer should conform to overloading requirement as specified in relevant IS
c) Temperature Rise shall be continuously rated for full load. The temperature rise shall not
exceed 45 °C by thermometer in oil or 55 °C by resistance over an ambient temperature.

6.0. EARTHING:
6.1 Two separate earthing terminals to be provided at the bottom of the tank on opposite
sides. The terminals shall be of clamp type suitable for connection to earth grid.
6.2 Internal Earthing:
The frame work and clamping arrangements of core and oil shall be securely earthed inside
the tank by adequately sized copper strip connections to the tank.

7.0. FITTINGS AND ACCESSORIES:

The transformer shall be provided with all standard fittings and accessories specified in the
applicable standard for the size and type of transformer concerned. The accessories and
fittings shall generally be as specified below:
- Lifting Lugs:
The arrangement for lifting the active part out of the transformer tank along with the cover by
means of lifting lugs without disturbing the connections.
- Rollers:
The transformer to be provided with 4 No’s Bi-Directional rollers fitted on cross channels to
facilitate the movement of the transformer in both directions.
For the free movement transformers suitable rail arrangement shall be made by contractor.
- Oil Conservator:
The transformer to be provided with an oil conservator with welded end plates. It is to be
bolted to the cover and can be dismounted for purpose of transport. It has to be provided with
magnetic oil level gauge and an oil filling hole 1 1/4” BSF size with a cap, which can be used
for filtering oil. For draining purpose a plug shall be provided. A connection pipe between the
conservator and the main tank is to be provided which projects inside the conservator and the
main tank is to be provided which projects inside the conservator.
- Air release Valve:
An air release valve is to be provided on the top of the tank cover to facilitate the release of
the entrapped air and filling of oil.
- Breather:
The transformer to be provided with an indicating dehydrating silica gel breather of sufficient
capacity.

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- Drain-cum-oil Filter Valves:

The transformer to be provided with a drain-cum-oil filter valve of 1 1/4” BSF size at the
bottom of the tank.
-Soak Pit
EPC contractor has to submit detailed drawing for soak pit and foundation of the
Transformer.
Associated minor civil works like grouting, chipping, fixing rail, GI fencing, earth pits are
also included in the scope.

- Diagram and rating plate:

Diagram and rating plate shall be provided indicating all major parameters of transformer
including connection diagram, vector group, impedance, tap changing diagram etc.
- Dial type thermometer (150 mm dia.) with maximum set pointer at 75 ° C and electrical
contacts for electrical alarm at high temperature.
- Winding temperature indication and electrical contacts for trip / alarm.
- Buchholz relay of double float type with electrical contacts for low oil level alarm and high
gas pressure trip suitable for 110 volts DC supply.
- Filter valve of 1 1/4” BSF at top.
- Explosion vent.
- Repeater for Oil and Winding Alarm and Trip for BMS connection.
- RTD for temperature signal to BMS.
- Surge Relay

Maximum allowable Power losses:-

Transformer Maximum Allowable Maximum Allowable

Capacity KVA losses at 50% KVA or losses at full load/Rated
load KVA
2000 0.64% 0.98%

The offered Transformer should comply with the above.

8.0. TECHNICAL DATA SHEET FOR OUT DOOR TYPE TRANSFORMER (OFTC)

8.1. Data Sheet to be submitted along with Bid

Sl. Particulars of Equipment Unit Purchaser requirement Bidder’s Response

No
1. Quantity Nos. 2

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2. Manufacturer VTS
3. Type of Transformer Oil Type
4. Type of Cooling ONAN
5. Rating KVA 2000
6. Primary Voltage KV 3.3
7. Secondary Voltage KV 0.433
8. No of Phases 3
9. Frequency Hz 50
10. Vector Group Dyn11
11. Location Outdoor
12. Cable Entry Bottom
13. Secondary Neutral Earthing Solid
14. Winding material Copper
15. Degree of Protection VTS
16. Off Load Tap Changer +/- 5%, 5 Taps
17. Compliance to Tech Specs As per Tender
in the Transformer
18. Ref Standard IS 2026

8.2. EPC Contractor prepare detailed data sheet and submit to HWB for
approval before manufacturing

9.0. DRAWINGS AND DOCUMENTS:

9.1. Following shall be submitted along with the offer:

a) The enclosed Data Sheet filled up completely

b) Clause – wise deviation, if any other wise nil deviation statement to be
submitted.
9.2. EPC Contractor has to submit following documents/drawings for approval
from HWB before manufacturing:

Technical data sheet, overall General Arrangement Drawing clearly showing

accessories, termination details, foundation details with roller arrangement, BOM etc.
a) Original equipment manufacturer certificate for core and winding material
b) Foundation Drawings
c) General Arrangement of Marshalling Box.
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d) Rating & Diagram Plate Drawing.

e) Cable Box Arrangement Drawing.
f) Loss flux density, heat dissipation calculation sheet
g) GA drawing for tap changer.
h) Bushing/ Insulator Drawings.
i) Wiring Diagrams
j) Type test certificates

9.3.Along with the above documents/drawings, the EPC Contractor has to submit
the following documents after commissioning :
 Manual with complete, operation, maintenance and repairs circuit diagrams,
foundation and trenching details shall be provided with the transformers. List of
spare parts shall also be indicated. O & M manuals which broadly includes
following minimum information:
o General description of equipment
o Approved Technical Data Sheet
o Salient constructional features
o Technical leaflets of fittings/ important parts
o All drawings
o Type and routine test certificates
o Commissioning Reports
o Withdrawal arrangement/ material handling instructions
o Operation instructions
o Maintenance instructions.
o Trouble-shooting.
o Safety instructions.
o Maintenance schedule
 Reproducible copy of the above drawings for records
 Test Reports

The final set of various drawings/ documents shall be submitted in triplicate.

10.0. PRE-COMMISSIONING AND COMMISSIONING CHECKS

EPC Contractor has to prepare checklist for Pre-Commissioning test, commissioning and
performance tests and get them approved from HWB. This list should include the
following;

 Insulation Test and Polarization Index Test: The power transformer the 2500V
megger will be used to check the insulation healthiness of the windings. The values
will be checked for each winding to winding, windings to transformer body.
 Voltage ratio/ Turns ratio test will be performed on each winding.
 Vector Group Test
 Magnetic balance/Core balance test to be carried out.
 Before the topping up of the oil the Transformer should totally dried up and be fitted
with all the gauges, valves, thermometers etc.. The oil should be filled up to proper
marking.

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 Functional checks shall be carried out on all Protection relays and report to be
submitted. CT secondary injection test, Polarity test etc. to be carried out.
 Buchholz relay contacts/trips should be thoroughly checked before mounting it in the
transformer.

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30.
ANNEXURE-II

30. TECHNICAL SPECIFICATIONS

FOR
POWER & MOTOR CONTROL CENTRE (PMCC)

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TECHNICAL SPECIFICATIONS FOR LT 415V POWER & MOTOR CONTROL

CENTRE (PMCC)

1. SCOPE
This specification covers the Design, manufacture, testing, supply, installation
and commissioning of Low voltage power control centre along with supply of
spares as specified. Scope also includes supply, installation and commissioning of
Junction Box for interfacing with DCS.

2. GENERAL REQUIREMENT OF PANEL:

a. The low voltage power control centre shall be metal clad, enclosed CRCA
sheet steel cubicles and compartmentalized, modular / fixed type, double
front., floor mounted.
b. The Panel to be suitable for Three Phase Neutral 415V AC. Control supply
for breaker shall be of 110V DC and 110V AC for all other feeders .
c. LT switchboard shall be dust and vermin proof and provided with a degree of
protection not less than IP-42. The switchboard shall be assembled out of
vertical sections of uniform height not exceeding 2300mm.Operating height
should not be more than 2100mm
d. The LV Switchboard shall be designed to fulfil the following design
parameters:
i. Rated Voltage – 415 V
ii. Rated Frequency – 50 Hz
iii. Rated insulation level :
a. For power ckt. – 2.5KV for 1 minute
b. For control Ckt. – 1.5 KV for 1 Minute
iv. Rated cont. current rating of main bus bar 3000 A.
v. Fault level - 50 KA for 1 Sec.
e. The main I/ C supply shall be fed through cable only. No bus duct shall be
used.
f. It should contain aluminium bus bar (current density 0.78A/sq mm).
g. Individual feeder panel suitable for operation from front side..
Thickness of sheet steel shall be as follows:
i. Load bearing member – 2 mm
ii. Covers & partition – 1.6 mm
iii. Gland plate – 2 mm
h. The design and construction of each panel shall be such as to allow extension
at either end.
i. Cubicles should have individual front doors with sturdy hinges and fitted with
special non-deteriorating neoprene gasket. Similar gaskets should be provided
between all joints as required. Lifting lugs should be provided on the top of
panel.
j. If louvers are provided, they shall be backed up by fine wire mesh.
k. Each vertical section of panel and feeder compartment shall be constructed,
such that failure of one equipment does not affect the adjacent units. Between

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bus compartment and breaker compartment & breaker compartment and cable
compartment, non-perforated flame retardant partitions shall be provided.
l. Suitable GI strip should be provided on the backside of the panel with
adequate holes (13mm dia. each) with nuts, bolts and washers for making
earth connections for all panels and cables. Length of GI strip should be same
as panel length. Zinc plated and passivated double earthing studs with nuts,
bolts and washers should be provided on the earthing strips.
m. Danger plates (415 VAC) should be fixed on both front and rear of panel
including the busbar chambers.
n. The panel should be suitable for ambient temp and relative humidity 95%.
Panel should be of IP-42 protection.
o. Relays, meters and control switches shall be located at height which shall be
convenient for monitoring and operating. Relays shall be selected to ensure
proper coordination with upstream relays.
p. Shrouding shall be done in the front and top of the terminal of each feeder.
q. Bolted doors to cover front and back of busbar alley shall also be provided.
Busbar alley shall be covered with screwed perforated sheet to avoid direct
access to the vertical bus bars on opening of the busbar alley door. Doors of
bus bar alley shall be fitted to board frame with special screw / bolts such that
same can be opened with special key only. Vertical cable alley covering the
entire height with hinged door shall be provided.
r. Continuous current rating of various switchgear components/ busbars is in
panel rating at full load condition for design ambient temperature and site
conditions. All hardware shall be zinc-passivated or cadmium plated.
s. All hinged doors should be earthed with copper flexible loops / braids as per
IS-3043.
t. All the hardware should be of high tensile steel duly zinc passivated for
corrosion protection & fitted with proper sized heavy duty spring washer &
two nos. heavy duty flat washers.

3. DETAILED DESCRIPTION OF PANEL

a. Incomer

i. The panel should house three nos. of 3200 amps ACB (Incomer-I, Incomer-II,
Bus coupler). There will be 1(one) incomer (draw out type) in each bus, with 3
pole, with neutral link, 3200A, 415V +/-10%, 50 kA breaking capacity rated
ACB with inbuilt thermal magnetic release protection. In addition each breaker
should have separate microprocessor based relays with over current, short-
circuit and earth fault protection with distinct fault indication The ACBs should
conform to IEC60947-2/IS 13947-2, tropicalized to Class-II (high humidity);
breaking capacity 50 KA at rated service voltage; the overload (long time), short
circuit (short time) and earth fault current settings should be selectable including
individual time settings.
ii. All incoming and outgoing terminals of ACB should be fitted with spreader
links supplied by ACB manufacturer or brought out phase & neutral links of
aluminum in rectangular sections with hole. Zinc passivated nut bolts with flat
and spring washers for connection should be provided for cable termination The
Neutral link rating should be 100% of the phase bar rating.

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iii. Metering/ Instrumentation for each Incomer:

 Digital multifunction meter indicating Voltage, Current, Frequency, Power
factor, Power and Energy with RS-485 capability
 Transformer protection relays
 Current transformer of appropriate rating for metering and control. CTs should
be provided with link to short Circuit.
 LED indication lamps for indication of ‘ Mains Supply ON’ (for R/Y/B
phases), ‘CB Off, CB-On,; DC-ON, DC Fail, Trip Circuit Healthy, As
required- Moulded HRC fuse holders with suitably rated fuse links for control
circuit and instrument circuit protection; make GE/ Telemecanique/ Bussman.

Any other required materials for completeness of the system

b. O/G Feeders

i. T-2 section of PMCC will have ACB Outgoing feeder of 800 amps to feed
power to EMCC PMCC shall also have 2 Nos ACB outgoing feeders of 630
Amps; One in T1-sec and other in T2-sec for feeding power to Electrode
Boilers. All other feeders shall be of DOL type of Star Delta Type as indicated
in Tentative SLD and Load list.
ii. Motor feeders shall be provided in the panel as given in Load list/ SLD with
proper protection for O/C, E/F & S/C fault.

 Each motor feeder shall be provided with Switch Disconnector Fuse Unit
(SDFU) of minimum 25 amps rating, Contactor minimum 16 amps rating,
Over Load relay/intelligent relay with resetting provision on panel, Ammeter
with CT and auxiliary relay as required for indication and feedback in DCS.
 Secondary current of all CT shall be same and primary current shall be in
grouped in different ranges.
 Feeders shall be of DOL, Star/Delta or VFD type as indicated in load list &
SLD.
 Duty of the contactor shall be as per process requirement.
 Control supply shall be of 110 V AC tapped through transformer with
redundancy.

iii. Main components of individual ACB feeder panels:

 All ACBs should be of draw out type and should be housed in individual
cubicles.
 ACB with micro processor based relay with protection features for O/C,
E/F & S/C fault
 01 no.- Digital multifunction meter indicating Voltage, Current,
Frequency, Power factor, Power and Energy with RS-485 capability. RS
485 port.
 CTs for metering & protection as per feeder capacity.

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 LED indication lamps for ON, OFF and TRIP on Panel.

 Suitable single pole MCB for Control Supply.

c. Air Circuit Breakers Panels

i. Each breaker shall be provided with emergency manual trip device, mechanical
‘ON-OFF’ indicators, operation counter, spring ‘CHARGED-DISCHARGED’
indicators, manual spring charging facility with manual ‘close’ push button.
Manual ‘Close’ push button shall be accessible after opening the front door.
ii. Each breaker shall have three (3) positions – SERVICE, TEST and
DISCONNECTED with mechanical indication.
iii. The ACB should have operational safety interlock of shutter, front cover, breaker
closing and tripping mechanism at service, test and isolate position viz.
mechanical interlock for preventing breaker movement in ‘ON’ condition from
service to test and test to service.
iv. Earthing of circuit breaker carriage before the main circuit breaker contacts are
plugged into the stationary contacts. Positive earthing of the circuit breaker truck
shall be maintained in the connected position.
v. To prevent compartment door from being opened if the breaker is in closed
position. Interlock defeat to be provided.
vi. Spring charging supply for ACB shall be of 230V AC.

d. Busbars:

i. The main busbars shall be of high conductivity aluminium (E91E) & of

uniform cross–section throughout their length. The standard busbars and
supporting arrangement shall be designed and tested to withstand a short
circuit fault level of 50 kA for 1 second.
ii. Current density for bus bars shall be 0.78A/sq. mm.
iii. The busbars should consist of 1 set of hard drawn, high conductivity, TPN
(neutral equally rated to phase bars), electrolytic grade, aluminium bars
rated minimum 3000Amps
iv. The maximum operating temperature of busbars including joints, at design
ambient temperature shall not exceed 95ºC for normal operating condition
& 200ºC for short circuit condition.
v. Only high tensile electro galvanized cadmium plated bolts, nuts and
washers shall be used. The washers shall be spring and plain type. Both
vertical and horizontal busbars shall be capable of withstanding dynamic
& thermal stresses of specified short circuit currents for 1 sec.
vi. Bus chamber should be steel clad having front and rear bolted covers.
vii. The Bus bar supported at sufficient intervals on non-hygroscopic, non-
inflammable SMC supports.
viii. All bus bars shall be encased throughout with colour coded insulated
sleeving and joints shall be fitted with insulated shrouds. Red, yellow &
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blue colour shall be used for phase busbars and black colour shall be used
for neutral busbars Main busbars should be full length of the panel.
ix. Vertical bus bars for feeding individual feeder should be full height of the
panel. Sufficient clearance should be maintained in the bus chamber for
proper cooling of the busbar. Busbar should be extensible type to facilitate
future extensions.
x. Removable links shall be provided on feeders to permit isolation of the
neutral bus bar.
xi. A separate Cu / GI horizontal earth bar of adequate cross section shall be
provided all along the length of the switchboard with necessary
terminating arrangement for connecting external earth conductor. The
earth bus shall be rated for faults withstand capacity of 50KA for 1 sec.
xii. Auxiliary busbars each of minimum size 18mm² copper shall be provided
for control supply of 110 V DC for ACB. And 110V AC bus for other
feeders.
xiii. The control busbars shall be insulated. The busbars shall run horizontally
in a separate compartment or in the same compartment of power busbars.
Necessary Tee off connectors shall be used for distributing auxiliary
supply to each vertical panel. Rubber grommets shall be used for all wire
entries to make the entries and vermin proof.

e. Panel wiring:

i. Control wiring shall be carried out with flexible heat resistant switchboard
wires (standard type) of minimum size 1.5 mm² for control circuits and 2.5
mm² for CT circuits preferably be enclosed in plastic channels or neatly
bunched together. The wiring shall with proper lugs. All wires and cable
should have proper ferrule numbers for easy identification.
ii. All wire termination except for Elmex type terminal blocks shall be made
with ring/fork tongue compression type connectors. Wires shall not be
tapped in between terminal points. Type of lug shall suit relevant
application. All wires for connecting with DCS and local push button
station shall be terminals box from where it is to be connected to junction
Box
iii. The terminal block shall be grouped and segregated according to circuit
functions and different voltage levels, and shall have 20% spare terminals.
Individual terminals in each block in each group shall be serially
numbered in accordance with the drawings. Such numbering shall be
legible, permanent and indelible. Terminal block for CTs shall be provided
with drop out facility for testing purposes for shorting and shall be
segregated from other terminals. Sufficient clear space shall be provided
between gland plate and terminal blocks.

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f. Earthing

i. All cubicles shall be connected to an earth bus bar running throughout the
length of the switchboard. The earth bus bar size shall be minimum 50x6
mm² aluminum. Provision shall be made to connect the same to the plant
earthing grid at two ends.
ii. Vertical earth bus shall be provided for earthing of all feeders.
iii. All doors are movable parts shall be connected to the earth bus with
flexible copper connections.
iv. All non-current carrying metallic parts of the equipment and components
shall be earthed.

g. Space heaters
i. Each switchboard panels shall be provided with space heaters with
thermister to prevent moisture condensation.
ii. The space heaters shall be located at the bottom of the switchboards, and
shall be controlled through a thermostat with an adjustable setting and a
manually operated switch. The thermostat shall preferably be located in
the metering or relay chamber.

h. Painting
LT switchboards shall be painted using standard 7 – tank process. Unless
otherwise specified, the finishing shade shall be light grey having shade no. 631 as
per IS: 5.

4. INTERFACING OF PMCC WITH DCS

Junction Box (JB) shall be installed in PMCC room for interfacing with DCS. In one
side of JB, cable from each motor feeder shall be connected for ON/OFF & Trip Feed
Back, signaling and control from DCS and in other side multicore cable shall be
connected up to DCS. Supply, laying, termination of this multicore cable shall be in
scope of instrumentation section. Junction Box shall be provided with 20% spare
terminal blocks. Scheme for control from DCS, Local and panel shall be designed by
EPC contractor and approval to be obtained from HWB.

5. DATA SHEET
5.1 Data Sheet to be submitted along with Bid:

Sl. Particulars of Equipment Unit Purchaser requirement Bidder’s Response

No
1. Panel
2. Make/Manufacturer
3. Power Supply Volts
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4. Control Supply Volts

5. Degree of Protection
6. Maximum Vertical Height mm
7. Material of Construction CRCA Sheet
8. Thickness of Sheet metal mm
9. Type of feeder Draw-out
10. Bus bars Aluminium
(Electrolytic Grade)
11. Earthing Busbar Material Aluminium (100%)
12. Busbar Sleeve Phase Colour Coded
(PVC)
13. Air Circuit Breaker
14. Nominal Current Rating A 3200 (3 Nos.)
15. Nominal Current Rating A 800A (3 Nos.)
16. Make/Manufacturer
17. Pole Nos. 3
18. Voltage V 415
19. Compliance to Tech Specs As per Tender
in the Transformer
20. Ref Standard IS 13947

5.2 Detailed Data Sheet to be prepared and submitted by EPC contractor for
approval before manufacturing.

6. DOCUMENTATION
6.1. Following shall be submitted along with the offer:
i. The enclosed Data Sheet filled up completely
ii. Clause – wise deviation, if any other wise nil deviation statement to be
submitted.

6.2. EPC Contractor has to submit following documents/drawings for approval

from HWB before manufacturing:
a. Technical data sheet, overall General Arrangement Drawing clearly
showing accessories, termination details, foundation details, BOM etc.
b. Original equipment manufacturer certificate
c. Wiring Diagrams of power and Control circuit indicating control
interlocks etc.

6.3. Along with the above documents/drawings, the EPC Contractor has to
submit the following documents after commissioning :
 Manual with complete, operation, maintenance and repairs circuit diagrams. O &
M manuals which broadly includes following minimum information:

o General description of equipment

o Approved Technical Data Sheet

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o Salient constructional features

o Technical leaflets of fittings/ important parts
o All drawings
o Type and routine test certificates
o Commissioning Reports
o Withdrawal arrangement/ material handling instructions
o Operation instructions
o Maintenance instructions.
o Trouble-shooting.
o Safety instructions.
o Maintenance schedule
 Reproducible copy of the above drawings for records
 Test Reports

The final set of various drawings/ documents shall be submitted in triplicate.

7. PRE-COMMISSIONING AND COMMISSIONING CHECKS:

EPC Contractor has to prepare checklist for Pre-Commissioning test,

commissioning and performance tests and get them approved from HWB. This list
should include the following:

 Visual check to be carried out on all the electrical equipment to determine if

any transit damage/erection damage has occurred.
 All relays will be visually checked if there is no dirt, packing loss, metal chips
etc.
For all the installations the CTs will be checked for short circuit of secondary.
 IR value of the busbars, circuit breakers, incoming and outgoing terminals,
 The busbar surface should be smooth to have a proper electrical connection.
Conductive jelly should be applied at the bolted contacts to avoid any corrosion.
All the enclosure fittings should be tightened with the torque wrench.
 Functional checks to be carried out for all the protective relays. Secondary
injection test to be carried out.

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31.
ANNEXURE-III

31. TECHNICAL SPECIFICATIONS

FOR
EMERGENCY MOTOR CONTROL CENTRE (EMCC)

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TECHNICAL SPECIFICATIONS FOR LT 415V EMERGENCY CONTROL PANEL

1. SCOPE:
This specification covers the Design, manufacture, testing, supply, installation and
commissioning of Low voltage power control centre along with supply spares as
specified. Scope also includes supply, installation and commissioning of Junction Box
for interfacing with DCS.

2. GENERAL REQUIREMENT OF PANEL:

General requirements for this panel shall be in line with that of PMCC.

3. DETAILED DESCRIPTION OF PANEL:

a. Incomer:

i.There will be 1(one) incomer (draw out type), with 3 pole, 800A, 415V +/-10%, 50
kA breaking capacity rated ACB with inbuilt thermal magnetic release protection. In
addition each breaker should have separate microprocessor based relays with over
current, short-circuit and earth fault protection with distinct fault indication The ACBs
should conform to IEC60947-2/IS 13947-2, tropicalized to Class-II (high humidity);
breaking capacity 50 KA at rated service voltage; the overload (long time), short
circuit (short time) and earth fault current settings should be selectable including
individual time settings.
ii. All incoming and outgoing terminals of ACB should be fitted with spreader links
supplied by ACB manufacturer or brought out phase & neutral links of aluminum in
rectangular sections with hole. Zinc passivated nut bolts with flat and spring washers
for connection should be provided for cable termination The Neutral link rating
should be 100% of the phase bar rating.
iii. The change over contact should operate automatically when CLASS-IV supply fails
and vice versa when CLASS-IV supply resumes. When class-IV supply fails DG set
should feed power to EMCC panel through Change over contactor. The change over
contactor shall be provided with electrical interlocks.
iv. Scheme incorporating the required features for supply from DG set and PCC has to be
prepared by EPC Contractor and get it approved from HWB
b. Metering/ Instrumentation for the Incomer:
i. 02 no.- Digital multifunction meter indicating Voltage, Current, Frequency, Power
factor, Power and Energy with RS-485 capability
ii. Current transformer of appropriate rating for metering and control.
iii. LED indication lamps for indication of ‘Supply ON’ (for R/Y/B phases), ‘CB Off/CB
On/Trip-OC/Trip-SC/Trip-EF’; As required- Moulded HRC fuse holders with suitably
rated fuse links for control circuit and instrument circuit protection; make GE/
Telemecanique/ Bussman.
iv. Any other required materials.

c. O/G Feeders
i. The panel should house one nos. of 400 amps ACB (three pole). It shall be of draw
out type and should be housed in individual cubicles. It shall be provided with
proper protection for O/C, E/F & S/C fault.
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Main components of ACB feeder panels:

• ACB with micro processor based protection features for O/C, E/F & S/C fault-
 01 no of digital energy meter of class-1, with RS 485 port.
 01 of Analog voltmeter (0-500V AC) with selector switch.
 01 no of Analog ammeter of suitable range. Make-AE/Conzerv in each outgoing
feeder
 CTs for metering & protection as per feeder capacity. Make-AE/KAPPA
 LED indication lamps for ON/OFF.
 Suitable single pole MCB.
 01 no.- Digital multifunction meter indicating Voltage, Current, Frequency, Power
factor, Power and Energy with RS-485 capability.

ii. Motor feeders shall be provided in the panel as given in Load list/ SLD with proper
protection for O/C, E/F & S/C fault.
 Each motor feeder shall be provided with Switch Disconnector Fuse Unit (SDFU),
Contactor, Over Load relay/intelligent relay with resetting provision on panel,
Ammeter with CT and auxiliary relay as required for indication and feedback in
DCS.
 Secondary current of all CT shall be same and primary current shall be in grouped in
different ranges.
 Feeders shall be of DOL, Star/Delta or VFD type as indicated in load list & SLD.
 Minimum rating of the power contactor shall be 16 A.
 Duty of the contactor shall be as per process requirement.
 Control supply shall be of 110 V AC tapped through transformer with redundancy.

d. Air Circuit Breakers (ACB)

i. Circuit breakers shall be of proven design.
ii. Each breaker shall be provided with emergency manual trip device, mechanical
‘ON-OFF’ indicators, operation counter, spring ‘CHARGED-DISCHARGED’
indicators, manual spring charging facility with manual ‘close’ push button. Manual
‘Close’ push button shall be accessible after opening the front door.
iii. Each breaker shall have three (3) positions – SERVICE, TEST and
DISCONNECTED with mechanical indication.
iv. The ACB should have operational safety interlock of shutter, front cover, breaker
closing and tripping mechanism at service, test and isolate position viz. mechanical
interlock for preventing breaker movement in ‘ON’ condition from service to test
and test to service.
v. Earthing of circuit breaker carriage before the main circuit breaker contacts are
plugged into the stationary contacts. Positive earthing of the circuit breaker truck
shall be maintained in the connected position.
vi. To prevent compartment door from being opened if the breaker is in closed position.
Interlock defeat to be provided.
vii. Spring charging supply for ACB shall be 230V AC.

e. Busbars

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i. The main busbars shall be of high conductivity aluminium (E91E) & of uniform
cross–section throughout their length. The standard busbars and supporting
arrangement shall be designed and tested to withstand a short circuit fault level of
50 kA for 1 second.
ii. Current density for bus bars shall be 0.78A/sq. mm.
iii. The busbars should consist of 1 set of hard drawn, high conductivity, TPN (neutral
equally rated to phase bars), electrolytic grade, aluminium bars rated minimum 800
Amps
iv. The maximum operating temperature of busbars including joints, at design ambient
temperature shall not exceed 95ºC for normal operating condition & 200ºC for short
circuit condition.
v. The bus bars shall be rigidly supported at equal intervals to withstand the stresses
due to full short circuit and also to take care of thermal expansion.
vi. Only high tensile electro galvanized cadmium plated bolts, nuts and washers shall
be used. The washers shall be spring and plain type. Both vertical and horizontal
busbars shall be capable of withstanding dynamic & thermal stresses of specified
short circuit currents for 1 sec.
vii. Bus chamber should be steel clad having front and rear bolted covers.
viii. The Bus bar supported at sufficient intervals on non-hygroscopic, non-inflammable
SMC supports.
ix. All bus bars shall be encased throughout with colour coded insulated sleeving and
joints shall be fitted with insulated shrouds. Red, yellow & blue colour shall be used
for phase busbars and black colour shall be used for neutral busbars Main busbars
should be full length of the panel.
x. Vertical bus bars for feeding individual feeder should be full height of the panel.
Sufficient clearance should be maintained in the bus chamber for proper cooling of
the busbar. Busbar should be extensible type to facilitate future extensions.
xi. Removable links shall be provided on feeders to permit isolation of the neutral bus
bar.
xii. A separate Cu / GI horizontal earth bar of adequate cross section shall be provided
all along the length of the switchboard with necessary terminating arrangement for
connecting external earth conductor. The earth bus shall be rated for faults
withstand capacity of 50KA for 1 sec.
xiii. Auxiliary busbars each of minimum size 18mm² copper shall be provided for
control supply of 110 V DC for ACB and 110V AC for other feeders.
xiv. The control busbars shall be insulated. The busbars shall run horizontally in a
separate compartment or in the same compartment of power busbars. Necessary Tee
off connectors shall be used for distributing auxiliary supply to each vertical panel.
Rubber grommets shall be used for all wire entries to make the entries and vermin
proof.

f. Panel wiring:
i. Control wiring shall be carried out with flexible heat resistant switchboard wires
(standard type) of minimum size 1.5 mm² for control circuits and 2.5 mm² for CT
circuits preferably be enclosed in plastic channels or neatly bunched together. The
wiring shall with proper lugs. All wires and cable should have proper ferrule
numbers for easy identification.
ii. All wire termination except for Elmex type terminal blocks shall be made with
ring/fork tongue compression type connectors. Wires shall not be tapped in between
terminal points. Type of lug shall suit relevant application.
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iii. The terminal block shall be grouped and segregated according to circuit functions
and different voltage levels, and shall have 20% spare terminals. Individual
terminals in each block in each group shall be serially numbered in accordance with
the drawings. Such numbering shall be legible, permanent and indelible. Terminal
block for CTs shall be provided with drop out facility for testing purposes for
shorting and shall be segregated from other terminals. Sufficient clear space shall be
provided between gland plate and terminal blocks.

g. Earthing
i. All cubicles shall be connected to an earth bus bar running throughout the length of
the switchboard. The earth bus bar size shall be minimum 50x6 mm² aluminum.
Provision shall be made to connect the same to the plant earthing grid at two ends.
ii. Vertical earth bus shall be provided for earthing of all feeders.
iii. All doors are movable parts shall be connected to the earth bus with flexible copper
connections.
iv. All non-current carrying metallic parts of the equipment and components shall be
earthed.

h. Space heaters
i. Each switchboard panels shall be provided with space heaters with thermister to
prevent moisture condensation.
ii. The space heaters shall be located at the bottom of the switchboards, and shall be
controlled through a thermostat with an adjustable setting and a manually operated
switch. The thermostat shall preferably be located in the metering or relay chamber.

i. Painting
LT switchboards shall be painted using standard 7 – tank process. Unless otherwise
specified, the finishing shade shall be light grey having shade no. 631 as per IS: 5.

4. INTERFACING OF EMCC WITH DCS

Junction Box (JB) shall be installed in PMCC room for interfacing with DCS. In one
side of JB, cable from each motor feeder shall be connected for ON/OFF & Trip Feed
Back, signalling and control from DCS and in other side multicore cable shall be
connected up to DCS. Supply, laying, termination of this multicore cable shall be in
scope of instrumentation section. Junction Box shall be provided with 20% spare
terminal blocks. Scheme for control from DCS, Local and panel shall be designed by
EPC contractor and approval to be obtained from HWB.

5. DATA SHEET
A. Data Sheet to be submitted along with Bid:

Sl. Particulars of Equipment Unit Purchaser requirement Bidder’s

No Response
1. Panel EMCC
Make/Manufacturer
Power Supply Volts 415
Control Supply Volts
Degree of Protection
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Maximum Vertical Height mm

Material of Construction CRCA Sheet
Thickness of Sheet metal mm
Type of feeder Draw-out
Bus bars Aluminium (Electrolytic
Grade), 800A
Earthing Busbar Material Aluminium (100%)
Busbar Sleeve Phase Colour Coded
(PVC)
2 Air Circuit Breaker
Nominal Current Rating A 800A (1 Nos.)
Make/Manufacturer VTS
Pole Nos. 3
Voltage V 415
Compliance to Tech Specs As per Tender
in the Transformer
Ref Standard IS 13947

B. Detailed Data Sheet to be prepared and submitted by EPC contractor for

approval before manufacturing.

6. DOCUMENTATION
A. Following shall be submitted along with the offer:

i. The enclosed Data Sheet filled up completely

ii. Clause – wise deviation, if any other wise nil deviation statement to be
submitted.

B. EPC Contractor has to submit following documents/drawings for approval from

HWB before manufacturing:
a. Technical data sheet, overall General Arrangement Drawing clearly
showing accessories, termination details, foundation details, BOM etc.
b. Original equipment manufacturer certificate
c. Wiring Diagrams of power and Control circuit indicating control
interlocks etc.

C. Along with the above documents/drawings, the EPC Contractor has to submit
the following documents after commissioning :
 Manual with complete, operation, maintenance and repairs circuit diagrams. O &
M manuals which broadly includes following minimum information:

o General description of equipment

o Approved Technical Data Sheet
o Salient constructional features
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o Technical leaflets of fittings/ important parts

o All drawings
o Type and routine test certificates
o Commissioning Reports
o Withdrawal arrangement/ material handling instructions
o Operation instructions
o Maintenance instructions.
o Trouble-shooting.
o Safety instructions.
o Maintenance schedule
 Reproducible copy of the above drawings for records
 Test Reports
 The final set of various drawings/ documents shall be submitted in triplicate.

7. PRE-COMMISSIONING AND COMMISSIONING CHECKS:

EPC Contractor has to prepare checklist for Pre-Commissioning test, commissioning and
performance tests and get them approved from HWB. This list should include the following;

 Visual check to be carried out on all the electrical equipment to determine if any
transit damage/erection damage has occurred.
 All relays will be visually checked if there is no dirt, packing loss, metal chips etc.
 For all the installations the CTs will be checked for short circuit of secondary.
 IR value of the busbars, circuit breakers, incoming and outgoing terminals,
 The busbar surface should be smooth to have a proper electrical connection.
Conductive jelly should be applied at the bolted contacts to avoid any corrosion. All
the enclosure fittings should be tightened with the torque wrench.
 Functional checks to be carried out for all the protective relays. Secondary injection
test to be carried out.

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32.
ANNEXURE-IV

32. TECHNICAL SPECIFICATION

FOR 3.3 KV VCB
(To be retrofitted in the existing panel)

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1. SCOPE :
i. The scope of this specification is to define the requirements of supply, testing (pre
dispatch), proper packing, safe delivery, installation, commissioning, pre & post
commissioning test at site and guarantee of indoor type 3.3KV, 630A, 250MVA VCB
(Vacuum Circuit Breakers) to be retrofitted in the existing panel. Scope also include
supply, installation and commissioning of protective relays along with CT, PT, surge
suppressor etc. for transformers as mentioned in clause no. 20. Termination of HT
cable on both sides are in the scope of EPC Contractor.
ii. It is not the intent to specify herein all the details of design & manufacture. However,
the equipment shall conform in all respect to high standards of design engineering and
workmanship and shall be capable of performing in continuous efficient operation and
confirming to all relevant standards.

2. TECHNICAL PARTICULARS OF VCB:

The breakers shall have the following ratings.

1 Type Vacuum Type

2 Service type Indoor, draw out type

3 Nominal System voltage 3.3 kV

4 Highest System voltage 3.7 kV

5 Rated Frequency 50 Hz +/- 3%

Rated Continuous current at ambient

6 temperature as specified in IS:13118- 630A
1991

7 Number of phases/ poles per breaker Three

8 System neutral earthing Solidly Earthed

9 Rated short circuit capacity 250MVA

10 Maximum break time 3 cycle

11 Standard operating duty O – 0.3 Sec – CO – 3 min - CO

12 Trip and closing coils 110 V DC

13 Spring charging motor 110 V DC

14 Space heaters 240 V AC

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3. GENERAL REQUIREMENT:

1. The VCB panel along with CT, PT, Control, indication, meter & relay shall be
suitable for indoor Installations with vacuum as interrupting media incorporating
separate interrupters of 630 A rating for each phase mounted on single frame.
There shall be a common drive mechanism actuating for interrupters, which must
work in synchronism. These breakers shall be provided with suitable local control
while provision shall be made for remote control.
2. The operating mechanism of the circuit breaker shall be motor wound spring
charged type. It shall be electrically and mechanically trip free with anti-pumping
device. All working parts in the mechanism shall be of corrosion resistant
material. Self-lubricating, wearing resistant bearings shall be provided in the
mechanism.
3. The mechanism shall fully close the circuit breaker and sustain it in the closed
position against the forces of the rated making current and shall fully open the
circuit breaker without undue contact bounce at a speed commensurate with that
shown by tests to be necessary to achieve the rated breaking capacity in
accordance with IEC:56 or IS:13118. The mechanism shall be capable of being
locked in either the open or closed position. The mechanism shall be capable of
fully closing and opening again after the auto-reclose time interval specified as 0.3
second in this specification
4. The entire circuit breaker with its operating mechanism shall be mounted on a
horizontal draw out type trolley. This circuit breaker trolley has to be retrofitted in
the existing panel which would be suitable for withstanding electromagnetic/
electro-dynamic forces of both symmetrical and asymmetrical faults. It shall have
plug-in off load type isolating main and auxiliary contacts with all necessary
safety features, door limit switch etc..
5. The VCB shall be provided with three distinct positions namely service, Test and
Isolate in the panel and in all the position VCB should remain in the cubicle.
6. A mechanically operated circuit breaker position indicator shall be provided in a
location visible from the operating side of the breaker without the necessity to
open the mechanism door. The word ‘OFF’ in white letter on green background
shall be used to indicate that the breaker is in the opening position and the word
‘ON’ in white letters on a red background to indicate that the breaker is in the
closed position. These indications are in addition to the electrical indication.
7. The state of charge of the operating springs shall be indicated by a mechanical
device showing ‘SPRING CHARGED’ when closing spring is fully charged and
operation is permissible and ‘SPRING FREE’ when closing spring is not fully
charged.

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8. Mechanical counters to record the number of closing operations shall be provided

for circuit breaker.
9. ON/NEUTRAL/ OFF control switch with rear terminal connections to be
provided for breaker operation from panel.
10. MECHANICAL EMERGENCY TRIP DEVICE: suitable for manual operation in
the event of failure of electrical supplies. The device shall be accessible without
opening any access doors and distinctly labelled. It shall be shrouded and
protected against inadvertent operation.
11. The base channel shall be provided for installation of the panel.
12. . CURRENT TRANSFORMERS
a. Current transformers, shall be of indoor, single phase, resin cast and shall
comply with IS:2705, suitable for operation in hot and humid atmospheric
conditions. They shall be mounted inside the panel.
b. High grad non- ageing cold rolled grain oriented (CRGO M4 or better grade)
silicon steel of low hysteresis loss and permeability shall be used for the core
so as to ensure specified accuracy at both normal and over currents. The flux
density shall be limited to ensure that there is no saturation during normal
service.
c. Secondary windings of current transformers shall be used for metering,
instrumentation and protection and shall be rated for continuous current of
120% of normal rated current of primary winding. The CT VA rating should
be suitable for connected instrument, meter but in any case it should not be
less than 5 VA.
d. The accuracy for metering CT core should be 0.2 and protection CT for O/C
and E/F 5 P 20.
13. POTENTIAL TRANSFORMER:
a. The single phase PTs (for all the three phases), resin cast type, are to be
provided for metering the rated Pr. Voltage 3.3 KV / sqrt 3 and rated
secondary voltage 110 V/ sqrt 3. With class of accuracy 0.5.
b. The Primary winding shall be protected by HRC Fuses in suitable holder
designed by the manufacturers. The secondary windings shall be protected
by HRC cartridge fuses in fuse holder consisting of carriers and bases. The
carriers and bases.
14. PROTECTIVE RELAY & CONTROL PANEL
a. The CR Panel (Instrument Chamber) should be mounted on top of the
VCB Panel. Control panel (inbuilt) with protective relay and meter shall be
provided for breakers. The equipment shall have protection scheme with
the following minimum relays:

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i. Numerical/Microprocessor communicable relay over current &

S,C (2Nos) & Earth fault (1No),
ii. Auxiliary relays for transformer fault like Buchholz, winding
temperature & oil temperature etc...
iii. Master trip relay and lock out for inter tripping (electro mechanical
type)
iv. Trip circuit supervision relay(electro mechanical type)
v. Anti-pumping relay (electro mechanical type)
b. The voltmeter and ammeter with selector switch to be provided.
c. Indication lamp like ON, OFF, Trip, TC healthy, Spring charging, test
position, service position, R, Y, B, etc. are to be provided.
d. One multi-function meter to be provided.
e. Panel wiring shall be suitably bunched and clamp for neat appearance. The
conductors used for wiring purpose shall be PVC insulated 1100 volt grade
semi flexible heat resistant, flame retardant and vermin proof electrolytic
copper cable conforming to IEC:227, 502 or IS:1554. The wiring shall be
securely supported and taken though PVC through PVC troughs. Each
wire shall be continuous from end to end without any joint in between.
f. In general, fuses and MCBs shall be limited to the minimum required for
safety. The protection scheme shall include fuses for VT secondary
circuits and DC supply to each panel and fuses for MCB for spring
charging motor and incoming AC supply.
15. SWGR. CUBICLE CONSTRUCTIONAL REQUIREMENTS

1 Colour finish IS:5 shade 631

2 Cable entry

a Power Cables I/C and O/G Bottom

b Control Cables Bottom

16. Equipment shall be installed in a neat workman‐like‐manner so that it is levelled,

plumbed, squared and properly aligned and oriented. Tolerances shall be as
established on Contractor’s drawings or as stipulated by Employer. No equipment
shall be permanently bolted down / tag welded to foundation until the alignment
has been checked and found acceptable by the Engineer. Contractor shall furnish
all supervision labour, tools, equipment rigging materials, bolts, wedges, anchors,
concrete inserts etc.. in proper time, required to completely install, test and
commission the equipment.

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17. Manufacturers and Employer’s instructions and recommendations shall be

correctly followed in handling, erection, testing and commissioning of all
equipment.
18. VCB panel shall be installed on finished surfaces, concrete or steel sills.
Successful bidder shall be required to install and align any channel sills which
form part of foundations. Power bus enclosure, ground and control splices of
conventional nature shall be cleaned and bolted together with torque wrench of
proper size or by other approved means. Tape or compound shall be applied where
called for in drawings. Contractor shall take utmost care in handling instruments,
relays and other delicate mechanisms. Wherever the instruments and relays are
supplied loose along with switchgear, they shall be mounted only after the
associated switchgear panels have been erected and aligned. The blocking
materials, employed for safe transit of instrument and relays shall be removed
after ensuring that panels have been completely installed and no further movement
of the same would be necessary. Any damage shall be immediately reported to
Engineer.

4. DATA SHEET

4.1 Data Sheet to be submitted along with the Bid:

S.No Description Qty/ Rating/others

1. Circuit Breaker
Quantity
Manufacturer
Service type
Current Rating
Interrupter
Nominal System Voltage
Retrofitting in Existing Panel
No. of phases/Poles
No.
Operating Duty
System Neutral Earthing
2 Current Transformer
Manufacturer
Construction
3 Potential Transformer
Manufacturer
Construction
4 Relays
Make/Manufacturer
Types
Compliance to Tech Specs in As per Tender
the Transformer
Ref Standard IS 13118 & others

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4.2 Detailed Data Sheet to be prepared and submitted by EPC contractor for
approval before manufacturing.

5. DOCUMENTATION

5.1. Following shall be submitted along with the offer:

i. The enclosed Data Sheet filled up completely
ii. Clause – wise deviation, if any other wise nil deviation statement to be
submitted.

5.2. EPC Contractor has to submit following documents/drawings for approval

from HWB before manufacturing:
5.3. Technical data sheet, overall General Arrangement Drawing clearly showing
accessories, termination details, foundation details, BOM etc.
5.4. Original equipment manufacturer certificate
5.5. Wiring Diagrams of power and Control circuit indicating control interlocks
etc.

5.6. Along with the above documents/drawings, the EPC Contractor has to
submit the following documents after commissioning :
 Manual with complete, operation, maintenance and repairs circuit diagrams. O &
M manuals which broadly includes following minimum information:

o General description of equipment

o Approved Technical Data Sheet
o Salient constructional features
o Technical leaflets of fittings/ important parts
o All drawings
o Type and routine test certificates
o Commissioning Reports
o Withdrawal arrangement/ material handling instructions
o Operation instructions
o Maintenance instructions.
o Trouble-shooting.
o Safety instructions.
o Maintenance schedule
 Reproducible copy of the above drawings for records
 Test Reports

The final set of various drawings/ documents shall be submitted in triplicate.

6. PRE-COMMISSIONING AND COMMISSIONING CHECKS

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EPC Contractor has to prepare checklist for Pre-Commissioning test, commissioning

and performance tests and get them approved from HWB. This list should include the
following;

 Visual check to be carried out for any transit damage/erection damage has
occurred and all items, components, accessories etc are conforming to the
technical Specifications
 Perform startup tests in accordance to the manufacturers instruction manual
 Tripping on protections as given in this document

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ANNEXURE-V

33.TECHNICAL SPECIFICATION
FOR
VFD MCC

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SPECIFICATION FOR VARIABLE FREQUENCY DRIVE (VFD) SYSTEM FOR

AGITATOR MOTORS

1.0 SCOPE

The scope of this specification is to define the requirements of design, manufacture,

testing at works, packing, site delivery, erection and commissioning at site of 13 Nos. of
AC Variable Frequency (speed) Drive (VFD) system to run 13 Nos. of agitator motors
and 1 drive to be kept as spare. The VFD should be suitably selected to the designed
agitator motor power. It is estimated that the agitator will consume 7.5 KW of power.
However, it is to be confirmed after freezing the design data of the agitator motor.
Scope also covers supply of harmonic filter circuits, MCCB or over load for individual
motor along with associated auxiliaries.
1.1 The EPC contractor shall be responsible for engineering and functioning of
complete system fully meeting the intent and requirement of this specification
attached sheets and drawings.
1.2 Each VFD shall be capable of running a single agitator motor at required speed.
1.3 All the VFDs, MCCB/OVERLOAD shall be provided CRCA sheet panel of
suitable size having standard size with IP-42 protection.

2.0 GENERAL REQUIREMENT OF PANEL

General requirements and constructional features for this panel shall be in line with that
of PMCC. Special requirements for VFDs like facility for Cooling shall be provided.
VFD MCC incoming shall be provided with MCCB of required capacity.

3.0 GENERAL PERFORMANCE REQUIREMENTS

3.1 The system shall be suitable for the load characteristics and the operational duty of
the driven equipment. It shall be capable of withstanding the thermal and dynamic
stresses and the transient mechanical torques resulting from short circuit. Any damage
resulting from such a short circuit or internal fault shall be limited to the component
concerned.
3.2 The system shall be SPEED-CONTROLLED as dictated by the user. The system
shall be suitable for continuous speed control of the motors with a soft start feature
facility to reduce disturbance in the electrical system
3.3 The drive shall have sufficient number of digital and analog input and output ports/
terminals for the feedback like ON, OFF, TRIP, RPM reading etc., speed control from
DCS as per process requirement.
3.4 The drive shall be able to accelerate the load over the full speed range of the speed -
torque curves and with incoming line voltage regulation of ± 10 %.
3.5 The system shall be suitable for range of speed variation of 0 % -100 %. The static
speed control error shall be in the range of ± 0.1% to ± 0.5% of motor nominal
speed and dynamic speed control error shall be ± 0.4% at 100% load torque step.

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3.6 The frequency regulation shall be ±0.02% of rated maximum frequency under
steady state and ±5% during transient condition.
3.7 It shall operate on constant V/F supply with required voltage boost
capability in low frequency mode of operation. Short time voltage dips up to 80%
of nominal system voltage shall not cause the control to stop
functioning.
3.8 The system shall be suitable for 3 cold / 2 hot start for the motor without
affecting the performance and life of controller.
3.9 The system shall be regulated to always start the motor in the forward direction.
Logic shall be provided to prevent the motor from being started in the reverse
direction. The length of power cable from the system to motor shall be assumed
as 50 meters and system shall be designed accordingly so as to avoid voltage surges
etc..
3.10 It shall be possible to vary the speed of the drive either manually or in auto mode.
3.11 The drive shall be self-cooled.
3.12 The starting, operating and stopping logic of the system shall produce potential
free contacts, required for owner's use.
3.13 The drive system shall have the following additional features:

4.0 EQUIPMENT SPECIFICATION

4.1 Power Converter
4.1.1 The controller shall be microprocessor based, digital with state of art
technology. The controller shall be vector controlled, sensor less drive with
pulse width modulation (PWM) and shall be voltage source inverter.
4.1.2 The rectifier shall make use of three phase rectified bridge for power
conversion from AC to DC. The inverter section shall use latest IGBT
(insulated gate bipolar transistor) Technology for minimal loss, high speed
switching and very low harmonics.
4.2.3 The converter and inverter shall be able to withstand a three phase short
circuit current/ let through energy until interrupted by protective device.
4.2.4 The drive cooling system, if provided, shall be monitored and alarmed before
any damage occurs to the power controller devices.
4.2.5 Logic shall be provided to restrict the no. of HOT/COLD start of motor as
specified elsewhere.
4.2.6 All the power controller devices shall be protected with fast acting
semiconductor grade fuse. The particulars of the power controller devices
and fuses shall be supplied along with the calculations in support of the
selection of fuses.

4.2 HARMONIC FILTERS

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4.2.1 Harmonic filters shall be provided at the supply side of the drive system on the
maximum allowable level of current and voltage distortion as stated below.
4.2.1.1 Current Harmonics
Based on the short circuit capacity of the supply system, the percentage
of the individual harmonics in the line current shall be limited to maximum
allowable value as specified in IEEE-519.
4.4.1.2 Voltage Harmonics
Based on the short circuit capacity of the supply system, the percentage of
the individual harmonics in the line voltage shall be limited to maximum
allowable value as specified in IEEE-519.

5.0 CONSTRUCTION DETAILS OF PANELS

5.1 The converter and inverter section shall be suitably housed in sheet steel panels and
shall be fabricated with 3mm thick cold rolled closed annealed (CRCA) sheet steel and
structural steel. The panel shall be suitable for indoor installation. It shall be able to
perform satisfactorily at an ambient temperature. The panel shall be free standing, dust
and vermin proof and degree of protection IP - 42.
5.2 The cable entry shall be from the top of the panel and a removable bolted undrilled
gland shall be provided with single compression type cable gland. Clamp type terminals
shall be used for connection of all wires up to 10 mm2 and terminal for higher sizes shall
be bolted type suitable for cable lugs.
5.3 Bus bars shall be of aluminium having black mat finish and colour coded. All the wire
parts shall be shrouded to ensure complete safety to personnel intending routine
inspection by opening the panel doors. All the equipment inside the panel and on the
doors shall be ferruled and terminals shall be properly numbered, min 20% spare
terminals shall be provided.
5.4 All the fuses shall be fast acting semi conducting type and mounted inside the panel.
All the power and control switches shall be mounted on the door operable externally.
All the instruments shall be switch board type, back connected, 72 X 72 mm. having
accuracy class 1.0. Scale shall have red mark indicating maximum permissible operation
rating. Separate test terminals shall be provided for measuring and testing of the
equipment to check the performance.
5.5 Each panel shall be provided with illuminating lamp with switch and fuse. 5/15A,
240V power socket with switch and fuse shall be provided. Each panel shall have
space heater with switch fuse and variable setting thermostat.
5.6 All the non-current carrying metallic components/parts shall be connected to the
main earth bus bar running at the bottom of the panel and of min. 50X 6 mm Cu or
equivalent. All Earth bus bar shall be provided with provision for connection to plant
earth grid.
5.7 Panel enclosure and structure supports shall be thoroughly cleaned and degreased to
remove mill-scale and rust etc. External surfaces shall be prepared for final painting of

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shade, as specified elsewhere.

5.8 All panels shall be of same height so as to form a bank which shall give good aesthetic
appearance.
5.9 All the control wiring shall preferably be enclosed in plastic channel. Each wire shall be
identified at both ends by self-sticking wire marker tapes or PVC ferrules. Ferruling of
wires shall be as per relevant IS.
5.10 Power and control wiring inside the panel shall be done with PVC insulated copper
conductor. 1.5 mm size wire shall normally be used provided the control fuse rating is
10 Amps or less and 2.5mm size for control fuse rating above 16A.
5.11 All transistor / thyristor modules and components shall be accessible from front of
panel only. Modular plug-in/draw out assemblies for both the system control
electronic equipment and power electronic equipment shall be used. In case rear access
being a must, it shall be indicated clearly in the bid.
5.12 Suitable removable type hooks (Eye-bolts) shall be provided for lifting the panel.
6.0 SYSTEM COMPONENTS
6.1 The panel shall include suitable isolating devices i.e. isolators/circuit breakers (if
specified), diodes (converter)/IGBT (inverter) modules with protective devices,
reactors for suppressing commutating notches, control circuit, control accessories,
MCCB or OVERLOAD for each agitator motors, indication and annunciation etc..
6.2 Main isolating device shall be suitably rated and operating handle should be
accessible from outside the panel and lockable in OFF position.
6.3 All electronic components shall be of solid state type. All power diodes shall
be of silicon type. All electronic components shall be suitably de-rated to
withstand high temperature inside the panel.
6.4 The contactor, if used, shall be air break type with required no. of auxiliary
contacts for interlocking.
6.5 Current transformer shall conform to accuracy class 1.0 and metering instrument
shall conform to relevant IS.

7.0 PROTECTION, CONTROL, METERING AND INDICATION/

ANNUNURATION REQUIREMENTS.
7.1 The manufacturer shall provide all the system control, protection, alarm
equipment and metering for the entire drive system and its ancillary equipment
and its description shall be furnished along with the offer including the details of
the system built up.
7.2 Automatic sequence control shall include start-up of cooling system, interlock
checking, automatic start and run-up of drive, planned and emergency shutdown,
the same shall preferably be processed through microprocessor based system.
7.3 Alphanumeric display and keypad control panel shall be provided for mounting on

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the drive panel. The display of fault diagnostic in plain English instead of fault
codes shall be preferred. Fault history for at least 10 faults shall be stored in
memory in the operator keypad so that it can be retrieved, whenever required.
For annunciations a solid state hooter along with accept, test and reset push
buttons shall be provided on front of the panel only.
7.4 Provision for auto start and run up to required speed for stand by pump shall be
made in the system. The auto/manual selection shall be from local/Remote. The
required inter facing with existing system is in the scope of EPC contractor.
7.5 PROTECTION REQUIREMENT
The system offered shall incorporate adequate protection and alarms properly
coordinated by the EPC contractor for the drive control and for motor but not
limited to the following.
7.5.1 FOR MAIN DRIVE MOTOR AND SUPPLY CABLES.
a) Over current
b) Over voltage Short circuit
c) Phase unbalance/single phasing
d) Earth fault
e) Locked rotor
f) Phase reversal

g) Over speed-105%
h) Incoming supply breaker trip.
i) Speed deviation
j) Speed reference loss
k) Under current
7.5.2 FOR CONVERTER
a) Loss of incoming line voltage
b) Transient voltage fluctuations
c) DC link over voltage
d) Loss of control voltage
e) Earth fault
f) High temperature inside enclosure (value to be specified by bidder)
g) Over current

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h) Deviation from set point (value to be specified by bidder)

i) Cooling medium temperature high(value to be specified by bidder)
j) Loss of one cooling system
k) Single device failure
l) Multiple device failure

7.6 Following minimum control are envisaged on front of panel unless otherwise
specified:
a) Start/Stop
b) Speed control -raise / Lower
c) Local/Remote Selector
d) Acknowledge/accept/test push buttons for annunciator
e) Emergency stop
f) Trip remote breaker
h) Bypass starter, if specified,

7.7 The system shall monitor the status of following and provide indications:
a) Drive On (two LEDs shall be used)
b) Drive Off( two LEDs shall be used)
c) Motor over speed
d) AC mains ON
e) Rectifier output ON
f) System ready to start
g) Motor zero speed
h) Remote breaker trip

7.8 Fault annunciation for clause 7.5.2 and following shall be provided.
Alarm shall also be annunciated through solid state hooter. Display of minimum
five most recent faults shall also be provided.
a) Rectifier fuse failure
b) Main AC failure
c) Inverter overload

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d) Inverter high temperature

e) No cooling of panel/motor
f) Motor failed to start.
Potential free contact for above and clause 7.5.1 shall be provided and
wired up to terminal block for owner's use.
7.9 The following readings should be available on operator panel.
a) Input AC voltmeter
b) Input AC Ammeter
c) Input AC frequency meter
d) Output voltmeter
e) Output ammeter
f) Motor speed
g) Motor energy meter
h) DC Amps
i) DC volts

8.0 PAINTING
All metal surfaces shall be thoroughly cleaned and degreased. Fabricated
structure shall be pickled and then rinsed to remove any trace of acid. The under
surface shall be prepared by applying a coat of paint and coat of yellow zinc chromate
primer.
After preparation of the under surface, the board shall be spray painted with two coats
of final paint. Colour shade of final paint shall be grey shade 693 as per IS 5. The
finished panels shall be dried and baked in ovens in dust free atmosphere. Panel
finish shall be free from imperfection like pin holes, orange peel, run off paints
etc. All unpainted steel parts shall be cadmium plated or suitably treated to prevent
rust formation.

9.0 INTERFACING OF VFD WITH DCS

Junction Box (JB) shall be installed in VFD MCC room for interfacing with DCS. In
one side of JB, cable from each motor feeder shall be connected for ON/OFF & Trip
Feed Back, signaling and control from DCS and in other side multicore cable shall be
connected up to DCS. Supply, laying, glanding and termination of this multicore
cable should be in scope of instrumentation section. Junction Box shall be provided
with 20% spare terminal blocks. Scheme for control from DCS, Local and panel shall
be designed by EPC contractor and approval to be obtained from HWB.

10.0 DRAWINGS & DATA SHEETS

10.1The bidder shall furnish the following drawing and data along with the offer:

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a) Technical particulars/catalogues for the offered system & detailed description of the
system. The description should be self-explanatory with required sketches/diagrams and
prove the technical competence of the item offered. For this purpose the bidder can
give, if so desired, a brief detail/ history of various technology used for VFD
systems with their merits and demerits. Bidder shall also explain clearly how the system
offered, shall be able to drive the equipment from zero speed and during coasting down
period without affecting life of driven equipment.
b) Block diagram of the system with technical particulars of equipment
and with brief write up on various interlocks and logics.
c) Complete filled in data sheet for all equipment
d) Clause wise deviations if any to the technical specification
e) Reference list of clients to whom such system has been supplied.
f) Copy of Type tests carried out on similar system.
g) Recommended list of spares for two years of normal operation
h) Tentative layout showing the overall dimensional requirement.
i) Detailed list of tests to be carried out at various stages i.e. tests during
manufacturing, routine tests with complete system before dispatch, pre
commissioning tests, tests for performance guarantee etc..
10.2 The successful bidder shall submit the following drawings and data for
approval/review.
a) Block diagram along with write up for the system.
b) Single line diagram and control schematic showing equipment rating and
interlocks and wiring details for interfacing with existing system. Control schematic
for interfacing with existing system shall be submitted for approval by HWB.
c) GA drawing showing overall dimension with cut out details for all equipment.
d) Technical particular as per data sheet
e) Bill of material
f) Technical details of individual items/ equipment along with the quality control
plan/inspection schedule to be followed during manufacture/assembly of VFD
and the details of subsequent tests to be conducted at works/site.
g) Protection coordination diagram
h) Torque/speed current/power factor of the system under various operating
condition.

10.3 DATA SHEET (PART-I)

Data sheet to be submitted along with offer
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Make:
Manufacturer's reference/Model:

10.3.1. INPUT POWER SUPPLY SYSTEM CONDITIONS

a) No. of phases : 3
b) AC input voltage : 415V
c) Voltage fluctuation : +/-I0%
d) System voltage : 415V, 3 phase with neutral earthed at transformer end
e) Rated frequency : 50 Hz
f) Frequency fluctuation : +/- 5%
g) System fault level : 31 MVA

10.3.2 RATED OUTPUT CAPACITY : as per load list (Suitable for three phase
induction motors)
10.3.3. MOTOR DETAILS

a) Drive system : Single VFD shall be suitable single motor

b) Type of motor : 3 Phase, Squirrel cage induction, IP-55,
Insulation class F, Continuous duty type.
c) KW rating : VTS
d) No. of motor : A per SLD/Load list
e) Starting condition : as per process requirement
f) Frequency range : 50 Hz +/- 5%
g) Voltage rating : 3 phase, 415V +/- 10%
h) Full load current : As Applicable
i) Starting current : 2 times of full load current
j) Short Term O/C capacity : 150% for 1 minute
k) Starting torque : 1.2 times of full load torque
l) Acceleration time : As per requirement
m) Rated speed : VTS

NOTE: Speed - torque characteristics curve and tech. details of the motor are for
general 3-phase, 415V motors.

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10.4 DATA SHEET (PART-II)

a) Speed range required : 0%-100%

b) Adjustment of speed : Auto & Manual both
c) Reference Signal : 4-20 mA/0-10V -
d) Soft start feature
e) Starting current : By EPC contractor
f) Isolator at incoming side of VFD : Yes
g) Acceleration time : By EPC contractor
h) Short time voltage dip : 20%
i) Harmonic limit on input (THD) : <5%
j) Auto start feature for standby
equipment : Required
k) Hot/Cold stand by requirement : Hot standby
I) Remote facility requirement
Manual start :
Manual speed variation :
Auto start
Auto speed control :
10.5 MOTOR PROTECTION - All the protection shall be provided for motors like
overload, short circuit, single phasing etc.
Type of equipment : Agitator motor
Make : Siemens /CGL/ABB
Type : Induction motors
No. : 1
Capacity : As per requirement
Speed : As per requirement
Frequency : 50 +/- 5% Hz
Compliance to Tech Specs in the Transformer : As per Tender

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Ref Standard : IS 13947

10.6 Detailed Data Sheet to be prepared and submitted by EPC contractor for
approval before manufacturing.

11. DOCUMENTATION

11.1 Following shall be submitted along with the offer:

i. The enclosed Data Sheet filled up completely
ii. Clause – wise deviation, if any other wise nil deviation statement to
be submitted.

11.2 EPC Contractor has to submit following documents/drawings for approval from
HWB before manufacturing:
11.3 Technical data sheet, overall General Arrangement Drawing clearly showing
accessories, termination details, foundation details, BOM etc.
11.4 Original equipment manufacturer certificate
11.5 Wiring Diagrams of power and Control circuit indicating control interlocks etc.

11.6 Along with the above documents/drawings, the EPC Contractor has to submit the
following documents after commissioning :
 Manual with complete, operation, maintenance and repairs circuit diagrams. O &
M manuals which broadly includes following minimum information:

o General description of equipment

o Approved Technical Data Sheet
o Salient constructional features
o Technical leaflets of fittings/ important parts
o All drawings
o Type and routine test certificates
o Commissioning Reports
o Withdrawal arrangement/ material handling instructions
o Operation instructions
o Maintenance instructions.
o Trouble-shooting.
o Safety instructions.
o Maintenance schedule
 Reproducible copy of the above drawings for records
 Test Reports

The final set of various drawings/ documents shall be submitted.

12. PRE-COMMISSIONING AND COMMISSIONING CHECKS:

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EPC Contractor has to prepare checklist for Pre-Commissioning test, commissioning

and performance tests and get them approved from HWB. This list should include the
following;
 Functional Checks
 Digital/Analog input and Output, Source and Sink Feedbacks
 Operation of VFD in integration with DCS
 Operation in Auto Mode

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33.
ANNEXURE-VI

34. TECHNICAL SPECIFICATION

FOR
3.3 KV (UE) XLPE, FRLS
POWER CABLE

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POWER CABLES
1. SCOPE

This specification covers the requirement of fabrication/ manufacture, inspection and testing at
manufacturer works, transportation to site, testing installation and commissioning of cable for
3.3 KV system for supplying power from 3.3KV substation located at main plant of HWP
(Tuticorin) to Transformers of SPP unit.

2. TECHNICAL SPECIFICATION

2.1 Supplier’s qualification criteria:

a. Cables shall be supplied either from OEM or their authorized dealer and submit the
relevant document.
b. The EPC contractor should submit the documentary evidence from supplier for
manufacture and supply of same size or higher size cable (300 sq. mm or above for 3
core, 3.3 KV (UE)) of length 15 Km (may be in multiple order) during last five year
for offered make. In case of authorized dealer the documentary evidence of OEM can
be considered.
2.2 Core Identification
Core identification for three core shall be followed as per IS-7098-2
2.3 Length of Cable Required and Drum Length
a. Total length requirement is around 1500 meters.
b. There should not be any cable joint in between Single length of cable (i.e. each drum)
should not be less than 750 mtr, however variation in length + / - 5 % in each drum is
acceptable.
2.4 Marking :-
On the outer sheath, following marking shall be given by embossing.
a. size 3 core x 300 Sq.mm.
b. 3.3 KV ( UE ).
c. FRLS
d. ISI mark
e. Length at every meter shall be printed
f. Manufacturing Company Name
g. Manufacturing Year
2.5 Tolerances
Tolerances on thickness and other parameters shall be within the permissible limit of IS :
7098-2.

3. DATA SHEET
3.1 Data sheet to be submitted along with Bid

S. No. Description To be filled by bidders

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1. Manufacturer
2. Type of cable with
3. Insulation material
4. FRLS properties categories
5. ELECTRICAL PARAMETERS
6. Rated voltage of Cable.
7. Test Voltage.
8. Conformity to IS

3.2 Detailed Data Sheet to be prepared and submitted by EPC contractor for
approval before manufacturing.

4. PRE COMMISSIONING AND COMMISSIONING CHECKS:

EPC Contractor has to prepare checklist for Pre-Commissioning test, commissioning and
performance tests and get them approved from HWB. The cable, conductors and wires are to
be checked for visible damage to impair safety. All live conductors and their methods of
insulation, in relation to design currents of circuits and to the operating currents of the
protective devices, are properly selected and erected. All conductors are correctly and
securely connected and identified. Armoured cables properly terminated to metal casing or
trunking by proper cable glands. Cables and ductings adequately supported. Cables at
distribution board or busbar terminated with cable lugs. Cables protected against mechanical
damage and suitably supported. All exposed metal parts including the armour effectively
Earthed. This list should include the following tests:

 Conductor Resistance Test

 Insulation resistance Test
 Sequence Impedance Tests
 Sheath integrity Test
 Polarization Test
 The cable delivered to the site will be checked for its integrity of the sheath, screen
 length/running meter mark at regular intervals
 diameter of the cable, insulation and conductor thickness

5. DOCUMENTATION
5.1 Following shall be submitted along with the offer:
i. The enclosed Data Sheet filled up completely
ii. Clause – wise deviation, if any other wise nil deviation statement to be
submitted.

5.2 EPC Contractor has to submit following documents/drawings for approval from
HWB before manufacturing:
i. Technical data sheet,
ii. Original manufacturer certificate
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5.3 Along with the above documents/drawings, the EPC Contractor has to submit the
following documents after commissioning :

o Approved Technical Data Sheet

o Type and routine test certificates
o Commissioning Reports
 Reproducible copy of the above drawings for records
 Test Reports
 The final set of various drawings/ documents shall be submitted.

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34.
ANNEXURE-VII

35. TECHNICAL SPECIFICATIONS

FOR
250KVA DG SET

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1. SCOPE:

This Scope covers the requirements of design, manufacture, assembly, shop testing,
supply, delivery to project site, installation & commissioning of 1 Nos. 250 KVA/
200 KW Diesel Generating Set along with Acoustic enclosure and all other related
accessories with AMF Panel and change over switch.
This specification covers the technical requirements of design, engineering manufacture,
assembly, testing at works and delivery in well packed condition of silent type diesel
generator set CPCB compliant complete with all required accessories and control
equipment to supply continuous electrical power. The scope shall also include provision
of associated AMF panel and supply of mandatory spares as per List of Spares.
This standard shall be read in conjunction with job schedule.

2. GENERAL DESIGN & CONSTRUCTIONAL FEATURES

(a) Diesel engine (complete with all the required accessories and
components)

(b) Generator set for operation with the above diesel engine, complete
with all the required accessories and components.

(c) Fuel oil system comprising of fuel oil tank, supply pump, filter,
piping, valves fittings etc.

(d) Air intake system comprising of air blower, air filter, turbo charger
etc..

(e) Lubrication oil system comprising of lube oil pump, filter, cooler,
piping, valves fittings etc.

(f) Jacket cooling system comprising of radiator, water circulation

pump, necessary piping and fittings etc.

(g) Starting system complete with battery, battery charger, starter

motor, control system etc.

(h) All inter connecting piping, valves, fittings etc.

(i) Torsional vibration damper at the free end of the crank shaft.

(j) Speed regulation system.

(k) A common base frame suitable for assembly of engine, radiator

and alternator with their accessories. Anti-vibration mounting pad
shall also be supplied.

(l) Exhaust manifold complete with silencers, asbestos lagging,

metallic expansion bellows and piping.

(m) All necessary instruments for monitoring and safe starting, running
and stopping of the D.G. set their auxiliaries complete with tubing

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and cabling.

(n) All safety and protective devices.

(o) Cabling material between control & protection panel and all
equipment within the battery limit including cables, racks, earthing
terminating materials etc.

(p) Acoustic enclosure (Central Pollution Control Board approved)

made of 14 SWG,CRCA sheet steel.

(q) All other items not specified here but, necessary for safe,
satisfactory and uninterrupted operation of D.G. set.

(r) Set of special tools and tackles required for installation and
maintenance.

(s) All other services for making DG set with its control and
protection features complete in all respect.

(t) Auto Mains Failure and Auto Synchronizing.

(u) Necessary interlocks between class-IV incomer and incomer from

DG Set.

3. SPECIFICATION

ENGINE Direct injection, water cooled engine, rated at 1500 RPM, conforming to
ISO 3046 / BS 5514 has the following specifications:

Digital Electronic Governor (*)

> In-line fuel pump

> Optimized turbocharger

> Stainless steel exhaust flexible coupling

> Silencer

> Radiator

> Coolant inhibitor

> Plate-type lube oil cooler

> Spin-on filters – coolant, fuel & lube oil

> Dry-type, heavy duty replaceable paper element air cleaner with restriction
indicator

> Flywheel housing and flywheel to suit single bearing alternator

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> Electrical starter motor

>Battery charging alternator

> First fill lube oil

> Alternator: Brushless alternator

Self-excited, self-regulated, Output Voltage (415V, 3Phase, 50Hz)

Class „H‟ insulation
Salient pole revolving field
Single bearing
Digital automatic voltage regulator
Auto-Mains Failure feature

 The DG supplier to ensure that in the guarantee period all required accessories and
components that are required for a fully functional power generating station are
available at site.
 The scope shall include supply, design, supervision and commissioning of efficient
acoustic enclosure to the D.G sets in such a manner that the sound levels with all
the D.G sets operating simultaneously will be less than 75 dB within 1 mtr. At
nearest boundary of the DG set during day time. Bidder shall note that the specified
acoustic performance shall be guaranteed by him.

The D. G. Sets shall be rated for 24 hours continuous duty.
The D.G. Sets shall be capable of generating a power output of 250 KVA at 0.8
PF on continuous operation under the environmental conditions prevailing at site
as mentioned elsewhere. All engine driven auxiliaries should run to their full
capacity.
Engine de ratings from the standard (N.T.P.) rating to obtain site rating shall be
carried out in accordance with latest edition of BS-5514.

 The Diesel Engine and Alternator field characteristics shall be suitable for
facilitating parallel operation of similar Diesel Generating Sets with equal load
distribution.
 Since the Diesel Generating Sets will be utilized for emergency services, it shall be
designed without any limitation on the number and frequency of starts in any given
period.

4. OPERATIONAL PHILOSOPHY

The specified DG Set is required for Emergency Power Supply requirement. These
DG set shall start automatically upon failure of the normal power supply and also
stopped automatically in case of restoration of EB supply after the mandatory checking
of the supply parameters. The DG sets shall also be able to start & stop manually
through a push button.
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5. ACCESSORIES

 DG Control panel with AMF panel.

 Battery charger panel
a) Self-excited, self-regulated excitation system along with fast response
governor shall ensure that the set dependably comes to full speed and
delivers rated output at 415 V, 50 Hz within 15 seconds after getting the
starting signal.
b) Under steady state condition, the electronic voltage regulator shall keep the
voltage constant within ± 0.5 % of the rated voltage with full load at
constant speed (with power factor varying between 0.8 lag to unity).
Further adjusting the set voltage up to ± 5% of rated voltage shall be
possible by the potentiometer provided for the purpose.
c) Under transient operating condition, the time of return to within ±3% of
steady state voltage when permitted step down load is suddenly applied
shall be less than one second (assuming speed to be constant). Further the
speed drop due to such loading shall be corrected to ensure 50 Hz 1% Hz
within less than 3 seconds (momentary fluctuation in frequency shall be
less than ± 1 Hz). Governing system shall ensure minimum fluctuation
during load changes. Inertia constant of the rotating system shall aid the
governing system. Class A11 governing system preferably using wood
ward PSG governor shall be offered. Speed drop shall be continuously
adjustable.
d) D G set shall meet the DOL starting requirement of induction motors and
Constant UPS load. Machine shall develop symmetrical balanced sine wave
voltage. Irregularities in waveform shall not cause objectionable
interference to other adjacent circuits. Total harmonic factor (THF) as
found by type tests shall be less than 5% (per IS 4722).

6. DATA SHEET
6.1 Data Sheet to be submitted along with Bid

Sl. Particulars of Equipment Unit Purchaser requirement Bidder’s Response

No
Engine
Quantity Nos. 01
Manufacturer
Type of Diesel Engine
Type of Cooling
Location Outdoor
Alternator
Rating KVA 250 at 0.8 pf
Voltage Volts 415
No of Phases 3
Frequency Hz 50
Excitation VTS
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Battery and Charger details VTS

Cable Entry VTS

Protection Over speed, Under
voltage, Overload,
Short Ckt., Earth Fault,
etc.
Neutral Earthing Separate earthing
(VTS)
Winding material Copper
Degree of Protection VTS
Ambient Temperature °C 50
Physical mm3
Dimensions(LxBxH)
Starting Auto Mains Failure
Panel

6.2 Detailed Data Sheet to be prepared and submitted by EPC contractor after
award of contract for approval before manufacturing.
7. DOCUMENTATION:

7.1 Drawing and Data:-

Within two weeks of award of contract, 4 copies each of the following drawings shall be
submitted by contractor for approval. Subsequently 4 sets of the revised drawings
together with 1 set of reproducible incorporating HWB's comments shall be furnished for
reference and records as "Final Drawings".
General arrangement drawing showing overall dimensions, equipment arrangement and
details and arrangement of terminals including weight of the entire set and static and
dynamic load.
Recommended general arrangement drawing for Acoustic enclosure with all it
accessories indicating therein civil requirements of the including cable and pipe trenches
etc.. Equipment foundation drawing for DG set and accessories.
Piping drawing including support details.
General arrangement drawing of the DG AMF Panel showing the various components
mounted therein, foundation details, cable terminals, overall dimensions, etc..
Wiring diagram of the AMF panel.
Before dispatch of the D.G. Set, 4 set of erection, operation and maintenance instruction
manual along with all above drawings, test certificates; spare parts list etc.. shall be
furnished.

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7.2 Along with the above documents/drawings, the EPC Contractor has to submit the
following documents after commissioning:

 Manual with complete information for operation, maintenance and repair circuit
diagrams, foundation and trenching details etc. O & M manuals which broadly
includes following minimum information:

o General description of equipment

o Approved Technical Data Sheet
o Salient constructional features
o Technical leaflets of fittings/ important parts
o All drawings
o Type and routine test certificates
o Special test reports like compliance to emission norms.
o Commissioning Reports
o Withdrawal arrangement/ material handling instructions
o Operation instructions
o Maintenance instructions.
o Trouble-shooting.
o Safety instructions.
o Maintenance schedule
 Reproducible copy of the above drawings for records

The final set of various drawings/ documents shall be submitted in triplicate.

8. PRE-COMMISSIONING AND COMMISSIONING CHECKS:

EPC Contractor has to prepare checklist for Pre-Commissioning test, commissioning and
performance tests and get them approved from HWB. This list should include the following;
 A visual check will be carried out to ensure that no damage has occurred in transit.
 Ensure that the diesel generator installation is complete and mechanical completion is
approved
 Ensure that no damage has occurred in between mechanical installation and pre-
commissioning
 Check for the proper installations of vibration isolators.
 Ensure that the air intake system of the DG set, exhaust system, fuel oil system
including fuel pimping, fuel pump and filter is complete and approved
 Ensure all the ducting, piping, conduiting to the generator are done properly to avoid
the transmission of the vibration and heat from the engine
 Ensure that the power cable and the control cables to the AMF panel and the EMCC
Panel, Protection system, and generator sensing panel are properly terminated with
sleeves for protection from the high temperatures as per the approved drawing, logic
and circuit diagram
 Check proper earthing of the generator and connection to the existing system earthing
 Ensure that the battery charger functioning and batteries are properly terminated to the
starter.

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ANNEXURE-VIII
35.

36. TECHNICAL SPECIFICATIONS

FOR
UNINTERRUPTED POWER SUPPLY SYSTEM

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1.0 SCOPE
Design, manufacture, supply, testing and commissioning of complete system 110V,
50Hz, 25 KVA Uninterrupted Power System (UPS) along by pass transformer &
stabilizer, as per applicable standards and specifications. The offered system shall
comply with all the requirements, technical specifications and data sheets given in this
document.

2.0 GENERAL REQUIREMENTS

2.1 The UPS system shall be an integrated system comprising static rectifier,
battery bank, static inverters, static switches, manual bypass switch, AC
distribution board, voltage stabilizer in bypass, isolating and protection
devices and all other equipment/accessories required for completeness of the
system.
2.2 The UPS system shall be suitable to feed all loads connected to output which
are primarily instruments.
2.3 The UPS system shall be complete in every respect and shall comprise
following major sections.
Rectifier : 1 Nos. suitable for float/boost charging.
Inverter : 1 Nos. 25 KVA, 50 Hz, 110 V inverters.
Battery Bank : 1 No. Lead-Acid battery bank, back up time 60
minutes minimum.
AC Distribution Board : 1 No., 110V, 50 Hz,
By Pass Transformer : 1 No., 415/110V, 50 Hz, 30KVA Transformer.
Make before break Switch : 1 No. make before break switch
for manually by-passing the inverters.
Voltage Stabilizer : 1 No. Static Voltage Stabilizer.

Static Switch : 2 Nos.

All other accessories including protection, monitoring and control system are in
EPC contractor's scope.

3.0 TECHNICAL REQUIREMENTS :

3.1 Input power supply:
The UPS shall be suitable for 3-phase, 415 V+/-10%, 50Hz+/-5% input power
supply. In addition to above variations, the input voltage may be subjected to
transients such as voltage dip up to 80% of normal voltage during motor
start-up and voltage interruption during short circuit. UPS system shall be
designed to operate satisfactorily even with input power from an emergency

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diesel generator set. UPS system shall also operate satisfactorily on input
power supply having, the ratio of negative to the positive sequence
components not exceeding 5% and total harmonic distortion not more than
5%.
3.2 The incoming power supply to UPS will be provided by 2 Nos. of feeders.
One feeder shall feed the rectifier(s) while other shall supply power to
stabilized bypass supply.

3.3 UPS configuration & operational requirements:

The UPS shall have following basic configurations.
3.3.1 UPS with bypass facility:
In UPS system shall have rectifier to feed DC power simultaneously to the
inverter and float/boost charging of the battery bank to its rated capacity from
full discharge within 10 hrs. under normal conditions. In case of failure/faults
of rectifier or main power supply failure, the battery bank shall feed the
inverter and inverter will feed entire load without any interruption. In case of
resumption of normal 415V supply rectifier will feed the load and battery bank
automatically. Rectifier shall be equipped with automatic ‘On line’ as well as
manual charging facility with selector switch for float/boost charging selection
mode.
3.3.2 Normally inverter will be in synchronized mode with stabilized bypass
supply and will feed the entire load. In case the inverter develop a fault, the
complete load shall get transferred to stabilized bypass supply through the
static switch and re-transfer of load from stabilized bypass to the inverter shall
only be in manual mode. Transfer of load shall be achieved through solid state
switching within less than ¼ cycle.
3.3.3 Asynchronous mode operation: In the synchronous mode the inverter
frequency shall follow the frequency of the main/bypass supply as long as the
later is within +/- 3% of the rated frequency (50 Hz) for enabling
synchronized uninterrupted transfer of load between inverter and bypass
supply. In case main power supply/bypass supply frequency goes beyond +/-
3%, UPS shall get de-linked and will operate in free run mode and it will
maintain rated output voltage & frequency and will return back to
synchronous mode once the frequencies are within the above limits. The
frequency changes shall take place smoothly without any break in supply or
transients. Facility for manual adjustment of synchronized mode frequency
range shall be provided to vary from +/-1% to +/-4%.
3.3.4 The facility for uninterrupted manual transfer in either direction through
static switches shall also be provided.
3.3.5 For ease of maintenance, facility shall be provided to isolate inverter and
static switch and transfer load to stabilized bypass system without any
disturbance through manually operated make before break switches.

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3.4 UPS design & performance requirements:

RECTIFIER:
3.4.1 Incoming AC supply shall be converted to DC through three phase full
wave controlled rectifiers. The rectifiers shall operate according to the
constant voltage current limiting principle and shall incorporate a “Soft
Start” feature to gradually accept load on initial energizing.
3.4.2 The rectifier section of the UPS system shall be capable of precise
regulation to prevent damage to the battery. The output voltage of
rectifier’s DC bus without the battery shall be stabilized to within +/- 2%
of set value during load variation between 0 to 100% and specified
mains input supply voltage variation.
3.4.3 Suitable protection shall be provided in the control circuits to guard
against instability of phase controlled rectifiers due to electrical
oscillations which may be present in the input supply as caused by
emergency DG set.
3.4.4 An R.F. Filter shall be provided at the input and output of UPS to
suppress the ratio frequency interference to permissible limits as
specified in IEC.
3.4.5 Transient/surge protection circuit shall be provided in the input circuit to
rectifiers to protect the UPS from surges & voltage spikes.
3.4.6 The UPS system shall be designed to draw power from mains supply at a
minimum power factor of 0.85 while working at rated load in normal
operating.
3.4.7 Facility for initial charging of batteries shall also be provided. The
inverters shall be disconnected during initial charging of the battery.
3.4.8 The rectifiers/chargers shall be designed to completely charge the battery
in a maximum time of 10 hours after complete discharge. Facilities shall
be provided to initiate battery rapid charge operation by Manual &
Automatic means. An auto charging sequence should be provided for the
boost and float charging based on current sensing. In addition to above,
the charging shall be transferred from boost to float mode after a pre-set
time adjustable through 0-24 hours timer.
3.4.9 The battery may be taken out of service for maintenance, during which
period it shall be possible for the inverter to continue operation by
drawing power from the rectifier. Ripple content at the DC link shall not
exceed 5% even with battery disconnected.

INVERTER:
3.4.10 The inverter shall be suitable for supplying power to the loads
specified for the UPS.

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3.4.11 The inverter shall be able to operate satisfactorily on rated load (25
KVA) with power factors in the range of 0.6 lag to 1.0. The overall
efficiency of the UPS system shall not be less than 80% at rated load and
0.8 p.f.
3.4.12 The inverter shall be of pulse width modulation type and shall consist of
IGBT based circuits as specified in the data sheet.

3.4.13 It shall be possible to vary the inverter output voltage steplessly within
+/- 5% of the specified output voltage. This adjustment shall be possible
to be made when the inverter is in operation.
3.4.14 The steady state output voltage and frequency (free running) variation of
inverters shall not exceed +/- 1% from the set value for specified input
power supply conditions from no load to full load condition and load
power factor variation from 0.6 lag to 1.0.
3.4.15 The UPS output voltage waveform shall be sinusoidal. The total
harmonic content in the output be limited to 3%.
3.4.16 The UPS shall have capacity to deliver a minimum overload of 10%
continuously, 25 % for 10 minutes & 50% for 10 sec. UPS shall be
provided with current limit circuit to avoid excessive loading beyond its
permissible overload withstand capability.
3.4.17 Facility shall be provided to manually and automatically initiate transfer
of the load from inverters to the stabilized bypass supply and manually
from stabilized bypass supply to the inverters. Under voltage and over
voltage sensing levels to initiate transfer shall be adjustable. The
maximum transfer time between inverters and bypass supply shall be
within ¼ cycle in synchronous.
3.4.18 All breakers shall be adequately rated for continuous rating as well as
breaking capacity as applicable. All output isolating device shall be
double pole type.
3.4.19 All electronic power devices including transistors, diodes etc.. shall be
rated under operating conditions for approximately 200% of the
maximum current carried by the device. All other electrical components
such as transformers, reactors, breakers, contractors, switches, bus bars
etc.. shall be rated for at least 125% of the maximum required rating.
3.4.20 All the diodes and other electronic devices of UPS shall be protected
with high speed semiconductor fuses.
3.4.21 Each inverter shall be designed to clear a fault in any of the branch
circuits up to a maximum rating of 20% of the system capacity without
the assistance of the stabilized bypass supply. In case of any fault in
branch circuits, the load connected to the healthy circuits shall not get
affected. The fault clearing time shall be less than 4 milli second.

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3.4.22 All PCBs shall be provided with a transparent epoxy coating for
environmental protection and tropicalisation. They shall be suitably
located away from heat sources.
3.4.23 All electronic control and monitoring printed circuit cards shall be
suitable for easy replacement. Monitoring points shall be provided on
each of the PCBs and the PCB shall be firmly clamped in position so that
vibration or long usage do not result in loose contacts. All PCBs shall be
placed in a manner to avoid replacement of a PCB with a wrong spare
PCB. Failure of each PCB shall be indicated by visual alarms. Visual
fault diagnostics shall preferably identify faults up to various sections in
the card.
3.4.24 Forced ventilation of panel, if provided, shall be supplemented by 100%
redundant fans. In normal operation, normal & redundant fans shall run
together. The power supply for the fans shall be tapped from the inverter
output. However, the rating of the UPS as specified in the data sheet
shall be the net output of UPS after deducting power consumption for
fans etc.. However, in case of non-operation of 50% of running fans the
UPS output shall not get effected. The fan shall be arranged to facilitate
removal of faulty fan for maintenance without taking system shutdown.
3.4.25 Maximum noise level from UPS system at 1 metre distance, under rated
load with all normal cooling fans shall be as per relevant code.

4.0 Construction
4.1 Rectifier/charger and inverter, stabilized bypass supply and static switch
sections shall be suitably housed in sheet steel panels complete with all
interconnections. The panels shall be fabricated with 3 mm. thick cold
rolled sheet steel for structural support and gland plate. Doors and side
wall shall be fabricated out 2.0 mm CRSS.
4.2 The panels shall be free standing, fitted with suitable louvers for
ventilation and cooling fans as required. Hinged doors shall be
provided at the front and back with dust tight gaskets. Inter panels sheet
steel barriers shall be used. The enclosure shall provide minimum IP-52
degree of protection. The maximum and minimum operating height of
the switches shall be 1800 mm and 300 mm respectively.
4.3 Power cables above 16 sq. mm size shall be of aluminium conductors
and up to 6 sq mm shall be of Cu conductor, multi-strand shall be used.
Control cables shall be of copper conductor, multi-strand type. All the
cable connections shall be from bottom of the panel. A removable
bolted gland plate shall be provided along with double compression type
nickel plated brass cable glands for external cable connections. Clamp
type terminals shall be used for connection of all wires up to 10 sq. mm.
Bolted type terminals suitable for cable lugs shall be provided for wire
size above this. Copper lugs for all external connections shall be
provided with the panels.

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4.4 Inside the panels, the control connections shall be done with 660V grade
PVC insulated wires having stranded copper conductors. 1.5 mm2 size
wire shall normally be used for circuits with control fuse rating of 10
Amp. or less. For circuit control fuse of 16 Amps., 2.5 mm2 size wire
shall be used. Wire size of 0.75 mm2 may be used for wiring to
electronic components.
4.5 Bus bars shall be colour coded and live parts shall be shrouded to ensure
complete safety to personnel intending routine inspection by opening the
panel doors. All the equipment inside the panel and on the doors shall
have suitable name plate and device tag numbers. All wires shall be
ferruled and terminals shall be numbered.
4.6 All power MCCB/MCB/switches will be mounted inside the panel
(accessible after opening the door) except those in ACDB. 100W
incandescent lamps shall be provided in each panel.
4.7 The outgoing feeders of ACDB shall be provided with MCB of suitable
capacity.
4.8 A suitably sized earth bus shall be provided at the bottom of the panels
including ACDB running through the panels with provision for earth
connection at both ends to the main earth grid. All potential free metallic
parts of various equipment shall be earthed suitably to ensure safety.
4.9 All panels shall be of same height so as to form a panel line up which
shall have good aesthetic appearance.
4.10 All control wiring shall preferably be enclosed in plastic channels or
otherwise neatly bunched together. Each wire shall be identified at both
ends by PVC ferrules. Ferruling of wires shall be as per relevant IS.
4.11 All metal surfaces shall be thoroughly cleaned and de-greased to remove
mill scale, rust, grease and dirt. Fabricated structures shall be pickled
and then rinsed to remove any trace of acid. The under-surface shall be
prepared by applying a coat of phosphate paint and a coat of yellow zinc
chromate primer. The under surface shall be made free from all
imperfections before undertaking the finished coat.
4.12 After preparation of the under-surface, the panels shall be spray painted
with two coats of epoxy and final paint or shall be powder coated. The
colour shade of the final paint shall be shade 631 (light grey) as per IS:5
unless otherwise specified. Spray painted finished panels shall be dried
in storing ovens in a dust free atmosphere. Panel finish shall be free
from imperfection like pinholes, orange peels, runoff paint etc.

5.0 Battery Bank:

5.1 The battery shall be suitable for the satisfactory operation of the UPS
system at rated capacity for 1 hour. It shall be of the type specified in the
data sheet and shall conform to the standards applicable.
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5.2 While sizing the battery capacity, factors such as aging, temperature,
inverter efficiency, and de rating of nominal capacity on higher
discharges, etc. shall be taken into consideration to have adequate
margin on the capacity. Complete calculation for battery sizing
supported by curves, tables etc. for arriving at capacity factor shall be
furnished.
5.3 The battery shall have adequate short time current rating to meet the short
time current duty of inverter specified in the data sheet.
5.4 The battery shall be complete with inter-cell, inter-row, inter-tier
connections and end take off. Interconnecting cables from battery to
UPS panels are to be supplied along with battery if so specified in the
data sheet.
5.5 The lead-acid batteries shall be supplied in dry uncharged condition with
necessary quantities of electrolyte and distilled water in separate sealed
containers.

5.6 Charging of the battery must be affected automatically by the battery

charger. The relevant IS/IEC Standard Specification for battery shall
be applicable for Lead Acid..

5.7 The battery shall be complete with all accessories and devices as
specified in data sheet.

6. A.C. Distribution Board

Sheet steel enclosed AC distribution board shall be provided as part of the complete
UPS package. They shall accommodate AC feeders. The distribution board shall be
floor mounted, fixed type with compartmentalized construction, having horizontal and
vertical bus-bars. All bus bars shall be PVC sleeved. It shall be possible to operate
the switches without opening the doors. Switches shall be provided with door
interlock. Vertical cable alley shall be provided for the termination of outgoing
cables. Suitable supports shall be provided for supporting incoming and outgoing
cables. All outgoing switches shall be of MCB type. Cable entry shall be from
bottom. The gland plate of the distribution board shall be non-magnetic type.

7. Alarm, Control, Indication, Metering and protection Requirements

Alarm and annunciation shall be provided for deviation of all major parameters like
Voltage and frequency at input, Inverter output, DC Voltage, failure of
rectifier/inverter/cooling fans, Temperature rise etc. as given in data sheet. An
illuminated one line diagram indicating operational status shall be provided on the
front of the panel.
8. Measuring instruments: Analog or digital meters shall be provided for measuring
voltage, current & Frequency at main supply inputs (2 nos.), Rectifier output, Inverter
output, bypass supply output, ACDB and battery bank input. Separate meter shall be
used for each parameter. All instruments shall be switchboard type, back connected.
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72x 72 mm. square of reputed make & analogue/digital type. Analogue instruments
scale shall have red mark indicating maximum permissible operating rating. Separate
test terminals shall be provided for measuring and testing of the equipment to check
the performance.
9. Protection: UPS supply and battery bank shall be provided with separate sensitive
earth leakage protections.

10. Pre Commissioning Checks

EPC Contractor has to prepare checklist for Pre-Commissioning test, commissioning and
performance tests and get them approved from HWB. This list should include the following;
 Functional Checks
 Transformer Insulation Resistance Checks
 Rectifier Voltage
 Inverter Voltage
 Performance with Input Voltage Variation
 Tracking with input Frequency
 Load test of Bypass
 Transfer from Inverter Mode to bypass mode and vice versa

11. Bidder has to submit Manufacturer Make and other features of UPS as given
below along with offer.

S. Descriptions Purchaser Requirement Bidder’s

No. Response
1.0 UPS- GENERAL
1.1 Output Voltage with regulation 110V AC  2%
Output free running frequency 50 Hz ± 1%
1.2 with regulation
50Hz ± 3%
Asynchronous mode
1.3 No. of phase / wires at output Single Phase, 2 wire

Continuous output rating

1.4 25kVA at 0.8PF lag
(KVA)
1.5 Duty (Back up time) 60 Minutes (Minimum)
1.6 No. of sets required One
1.7 No. of inverters required per set One
2.0 RECTIFIER SECTION
Whether separate float and
2.1 Combined Float and Boost Charger
boost chargers are required?
3.0 INVERTER SECTION
3.1 Semiconductor power control IGBT
device

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110% continuous, 125% for 10

3.2 Overload capacity
minutes, 150% for 10 seconds and
STATIC SWITCH Transfer & 200% Manualforand
10 cycles
automatic with selector
3.3
retransfer facility switch
4.0 COOLING ARRANGEMENT
5.0 Special requirements ,if any? Cooling fans if any provided shall
have 100% redundancy.
Battery voltage
Inverter DC voltage
Load bus AC voltage
Bypass line (voltage stabilizer
output) AC current
UPS output voltage Low
6 BATTERY
6.1 Type Tubular type Lead Acid
6.2 Construction Tubular type Lead Acid
6.3 Standard Applicable IS:10918 / International standards
6.4 Set Voltage EPC contractor to specify
6.5 Ampere hour capacity at 27 EPC contractor to specify
6.6 C
Number of cells EPC contractor to specify
Whether interconnecting
6.7 cable from battery to UPS Yes
panels to be supplied
All necessary accessories including
Accessories to be supplied
the following, but not limited to
along with battery
them shall be included in the scope
of
Onesupply.
numbers hydrometers for
specific gravity measurement
One numbers thermometers
One numbers specific gravity
correction scale
One numbers cell testing
7.0 voltmeters complete with leads
One number acid resisting funnel
One number acid resisting jug
Required quantity of electrolyte for
initial filling of the battery set with
10% extra in non returnable
containers
One set of cell number plates and
fixing pins
Necessary connectors

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12. DATA SHEET:

Detailed Data Sheet to be prepared and submitted by EPC contractor after award of
contract for approval before manufacturing.

Battery Room lighting and exhaust arrangement are in the scope of the EPC contractor.
These should be of flameproof type.

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36.

37. QUALITY ASSURANCE PLAN

FOR
ELECTRICAL SYSTEM

NOTE:
1. Tentative, broad QAP for important electrical items is enclosed herewith.
However, successful EPC contractor should submit detailed QAP for each
electrical item for approval of HWB before commencing manufacturing.
2. All type of test reports wherever asked shall not be more than five years
old.

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QAP-1 for
2000KVA 3.3KV/ 433V TRANSFORMER
1. QUALITY ASSURANCE, TESTING & INSPECTION

a) Bidder shall furnish valid type Test certificates as per relevant IS already carried out
on similar transformers from a government recognised institute. If certificate for heat
run test/Temperature rise test is not available for similar transformer this test to be
carried out on one of the transformer.
b) All routine tests shall be carried out as per latest relevant standards (IS 2026) in
presence of HWB representative.
c) In addition to above the EPC Contractor has to carry out other tests/acceptance test
to meet the specifications given in this document.

d) QAP for Transformer

Sr. Inspection Activity Test Particulars Reference Acceptance

No. Document W-Witness
R-reports
1 Type Test for All test as per IS IS-2026 & R
Transformer Relevant IS.
2 Routine Tests for All test as per IS IS-2026 & W
Transformer Relevant IS.

3 Type Test for oil All test as per IS IS-335 & R

Relevant IS.
4 Routine Tests for oil All test as per IS IS-335 & W
Relevant IS.
5 Acceptance/Other Core dimensions R
Tests Core Lamination R
dimensions
Conductor Size R
Bushing size R
Thickness of sheet R
metal of transformer
Radiator Dimensions R
Physical Conductor Tensile R
strength
Torque tests for R
terminal connections
Moisture in Oil R
Moisture in Paper R
Radiator leakage test R
Radiator valve test R
Electrical Conductor resistivity R
test
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Tap Changer ratio test R

QAP-II
QUALITY ASSURANCE PLAN FOR
PMCC, EMCC AND OTHER MCC PANEL

INSPECTION, TESTS AND ACCEPTANCE

The successful bidder has to submit the QAP for the approval of the HWB before startup the
manufacturing process. Tests shall be carried out at the manufacturer’s works before
dispatch. During fabrication, the switchboard shall be subjected to inspection by HWB to
assess the progress of work, as well as to ascertain that only quality raw material is used

i. Type Tests: Type test certificates for the switchgear panel and circuit breakers shall be
furnished during detailed engineering.
ii. Routine Tests :All routine tests as specified by the applicable codes and standards shall
be conducted
iii. Acceptance and other tests: Acceptance and other tests shall be carried out to comply
with the technical specifications given in this document along with the tests listed below
at manufacturer’s works.

a. Panel: During fabrication, the switchboard shall be subjected to inspection by

HWB to assess the type of metal sheet used, smoothness of surface, weld finish,
lifting facility, cable entry, paint finish and paint thickness, degree of protection,
neoprene gaskets dimensional conformity, earthing and dimensional thickness of
the whole panel to ascertain that only quality raw material is used. Insulation
resistance of the main and auxiliary circuits shall be checked before and after the
high voltage withstand test.
b. Busbar: The power and control busbar shall be tested for its dimensions (size and
cross section), type of conductor used; color sleeving, sleeve insulation, support
arrangements, resistivity and conductivity, tensile strength etc. Dry insulation test
with power frequency voltage shall be conducted for the main and auxiliary
circuits.
c. Hardware: The nut, bolts, washers shall have the dimensional conformity and
proper passivity. The correct size, integrity, resistance, connecting arrangement of
terminals used for the power and control connectivity.
d. Conductor: The colour, grade of the conductor used, cross section, thickness of
the wires, clamping, ferruling, proper connection of lugs, and other components
used in the panel shall be inspected. The continuity test shall be conducted in the
final inspection.
e. Air Circuit Breaker: The current rating, verification of the voltage grade,
mounting and support arrangement, setting of drawing out, release and making of

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contacts , mechanical and electrical operation, voltage rating of the closing coil,
antipump feature etc.
f. Protecting and isolating devices: The voltage and the current rating, Mounting
and support arrangement, number of contacts, electrical and mechanical operation
(wherever applicable) for HRC fuse, SDFU, Protective relays etc. The protective
relays shall be checked for the current rating, resetting and different contact
arrangements
g. Instrument Transformers: The mounting and support details, dimensions, Ratio,
ratings, class of accuracy, verification of polarity of CTs and PTs in the panel is to
be checked.

Acceptance tests shall be as follows:

A general visual check shall be carried out for the verification of the panel and
cubicle/module for the implementation of the work as per GA drawing and given circuit
diagram. The name plate of the components in the panel shall be clearly visible. This shall
cover measurement of overall dimensions, verification of BOM, colour coding of the
different phases, location, number and type of devices, terminal boxes, location and
connection of terminals etc.

Tentative Table for QAP

Sr. Inspection Test Reference Acceptance

No Activity/Description Particulars Document
R-Record
W-Witness

1. Type Test All Test as per IS-13947 & R

IS Relevant IS.

2. Routine Test All Test as per IS-13947 & W

IS Relevant IS.

3. Acceptance and other As given above Relevant IS. W

Test

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QAP-III
QUALITY ASSURANCE PLAN For HT & LT Cables
a) The successful bidder shall submit the QAP for HWB’s approval. There shall be no
commercial implication to HWB on account of QAP approval.
b) All materials, components and accessories of the cable shall be procured,
manufactured, inspected and tested by EPC contractor/ sub-EPC contractor as per
approved quality plan.
c) All routine tests on each cable as per relevant standards (IS 7098 part-2) and
specification shall be carried out in presence of HWB’s representative. Charges for all
these tests for all the equipment & components shall be deemed to be included in the
bid price.
d) Bidder shall furnish valid type Test certificates already carried out on similar cables
from a reputed institute (other than bidder) along with offer. This Test certificates shall
not be older than 5 years. In absence of this certificate the offer is liable to be rejected.

QAP for Cable

Sr. Inspection Test Particulars Reference Acceptance

No Activity/Description Document
R-Record
W-Witness

1 Type Test All Test as per IS IS-7098 & R

Relevant IS.

2 Routine Test All Test as per IS IS-7098 & W

Relevant IS.

3 Acceptance Test As given above Relevant IS. W

3.1 Visual/ Dimensional Cable Relevant IS

Check Construction(conductor
diameter)

Colour identification Relevant IS

Cable Dimensions Relevant IS

3.2 Physical Tests Insulation / Relevant IS

Sheath/armour

 Type of
insulation
 Sheath
thickness
 Screen

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Thickness
 Armour
material
 Zinc Coating

Thermal Tests on PVC Relevant IS

Capacitance/Inductance Relevant IS

3.3 Special Tests Temperature index/LOI Relevant IS

Smoke emission Relevant IS

Low halogen acid Relevant IS

Flame retardant test Relevant IS

Signal to Noise ratio Relevant IS

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QAP-IV for Vacuum Circuit Breaker

Sr. Inspection Activity Test Particulars Reference Acceptance

No. Document R-Record
W-Witness
1 Type Test All Test as per IS IS-13118 R
& Relevant
IS.

2 Routine Test All Test as per IS IS-13118 W

& Relevant
IS.

3 Acceptance and As given above Relevant W

other Test IS.

3.1 Visual/Dimensional Trolley dimensions R

Vacuum interrupter R
Conductor Size R
3.2 Physical Mechanical Endurance R
Test for trolley
Mechanical endurance R
test for interrupter
Door and hinges R
operation for opening
and closing
Self-alignment R
Guider operation R
Metal Barrier R
dimensions
Mechanical R
Interlocking
3.3 Electrical Bolted electrical R
contact resistance
Contact resistance test R
Anti-pump feature R
First Pole to clear R
factor
Sequence Tests for R
Control Circuit
Space Heater R
Operation

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QAP-V for DG Set

Sr. Inspection Test Particulars Reference Acceptance
No. Activity Document
1 Type Test All Test as per IS IS-10000, R
10002 &
Relevant
IS.

2 Routine Test All Test as per IS IS-10000, W

10002 &
Relevant
IS.

Acceptance and As given above Relevant W

3 other Test IS.

3.1 Visual/Dimensional Leakage W

Bill of
material/Accessories
Mechanical
Imperfections
3.2 Physical Fuel hose integrity
Lube oil pipe integrity
Temperature Rise Tests
 Enclosure
 Exhaust
 Water
 Lube Oil
Noise Level
Lube Oil Pressure
Vibration Levels
Fuel Consumption Tests
3.3 Electrical Endurance Test
 100% load at 0.8pf
for 8hrs
 75% load at 0.8pf
for 2 hrs
 75% load at unity
pf for 2 hrs
 25% load at 0.8 pf
for 1 hr
 110% load at 0.8 pf
for 1 hr
Generator Efficiency at
 25% at 0.8pf
 50% at 0.8pf
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 75% at 0.8pf
 100% at 0.8pf

Alternator conductor
insulation test
Control Cable, Circuit
insulation Test, Busbar
trunking
AVR Response Test
 Voltage stability
test
 Voltage Regulation
tests
Phase rotation Tests
Injections Tests
Protection logic and
Circuits
Droop characteristics
Transient dip in
 Voltage
 Frequency
Recovery Time
Operational tests
 Auto Mode
 Manual Mode
Meter Performance
Charging of Batteries
3.4 Chemical Tests Quality of exhaust as
per emission norms

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QAP-VI for VFD

Sr. Inspection Test Reference Acceptance

No Activity/Description Particulars Document
R-Record
W-Witness

1. Type Test All Test as per IS-3700, 5469, R

IS IEEE-519 &
Relevant IS.

2. Routine Test All Test as per IS-3700, 5469, W

IS IEEE-519 &
Relevant IS.

3. Acceptance Test As required to Relevant IS. W

comply with
Tech Spec.

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 Chapter-9 Technical specification

QAP-VII for UPS

Sr. Inspection Test Reference Acceptance

No Activity/Description Particulars Document
R-Record
W-Witness

1. Type Test All Test as per IS-16242, R

IS 3700, 5469,
IEEE-519 &
Relevant IS.

2. Routine Test All Test as per IS-16242, W

IS 3700, 5469,
IEEE-519 &
Relevant IS.

3. Acceptance Test As required to Relevant IS. W

comply with
Tech Spec.

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 Chapter-9 Technical specification

2.

38. LIST OF DRAWINGS

The following Single Line Diagrams (SLD) are enclosed with this document. These SLD
are tentative with minimum numbers of feeders. EPC contractor have to prepare exact SLD
based on P&ID, actual load list etc. and get them approved from.

1. Single Line Diagram-over view of electrical system of SPP-Tuticorin

2. SLD for T-1 section of PMCC
3. SLD for T-2 section of PMCC
4. SLD for EMCC
5. SLD for VFD panel
6. SLD for ETP MCC
7. SLD for Pump House Panel
8. SLD for Lighting Distribution Board- II
9. SLD for Power Distribution Board-II
10. SLD for Power Distribution Board-I
11. SLD for Lighting Distribution Board-I
12. SLD for Lighting Distribution Board- Class-III
13. SLD for Direct Current Distribution Board

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TECHNICAL SPECIFICATIONS

INSTRUMENTATION AND CONTROL

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 Chapter-9 Technical specification

C O N TE N T S

S. No. DESCRIPTION PAGE NO

Scope IC-04

1 Scope of Work IC 05

2 Battery limit under the scope of contract IC 10

3 Confirmation and documents to be submitted at time of bid IC 11

4 Schedule Of Quantity (SOQ) and associated items with spares IC 12

System overview IC-17

5 System description IC 18

6 Plant operation and Control philosophy IC19

7 Instrument system and philosophy IC20

DCS IC– 27

8 DCS design basis IC28

9 DCS Specifications IC 35

Field Instruments IC– 60

10 Design basis for field instruments IC 61

11 Specifications of Field Instrument IC 65

Cabling & Tubing IC 77

12 Basis of cable & cable trays selection IC 78

Specification of cables, cable trays, air tubes to be used for
13 IC 78
instrumentation and automation system

Inspection and Testing IC 83

14 Inspection and testing of field instruments. IC 84

15 Inspection and testing of DCS IC 85

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 Chapter-9 Technical specification

16 Recommended QAP IC 89

Documentation IC 95

17 Submission of documents for approval IC 96

18 Technical documents to be supplied for the system IC 96

19 Point wise Clarification / Deviation IC 97

20 List of recommended EPC contractor s IC 107

Standards and Drawings IC 109

21 Recommended Standards IC 110

Drawings IC 112–IC 114

Annexure I IC 112
22
Annexure II IC 113

Annexure III IC 114

23 List of Instruments with process parameters IC 115–IC 164

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 Chapter-9 Technical specification

SCOPE OF
INSTRUMENTATION JOB

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 Chapter-9 Technical specification

1.0 SCOPE OF WORK

It covers Design, Engineering, Procurement, Supply, Erection, Cabling, Calibration,
Testing, Pre-commissioning, Commissioning, Documentation & Training of the
Instrumentation and automation system for complete SPP project. The Schedule of
Quantity (SOQ) mentioned in SL.No. 04 is the minimum requirement for the project.
However, during the execution of the project, if any minor instruments and associated
components required for total system integration for commissioning of the plant, but
not mentioned explicitly in the tender document are in the scope of EPC contractor.
Distributed Control System (DCS) shall be used for process control, monitoring,
process inter-locks/trip logic, data logging, trending, history, report generation &
alarms etc. with compatible field instrumentation.
The scope of work of EPC contractor for Instrumentation and automation package is
listed below but not limited to:

1.1 Detailed Engineering: EPC contractor shall carryout the design, detailed engineering
(including making of logics and control schemes as per HWB’s approved
specifications, drawing and incorporating the same in DCS), preparation of data
sheets & schematics of the instrumentation systems & Associated auxiliary systems
required to complete entire instrumentation and automation system for the plant as per
details indicated in the control philosophy and SOQ are in the scope of work.
1.2 Supply, installation, pre-commissioning, commissioning & documentation of
DCS system and all associated panels
Supply and installation of DCS system, associated panels in control room including
power distribution panel, operator consoles, remote consoles, engineering
workstation, printers as per detailed specifications and Hookup with MCC, VFD,
UPS, field instrumentation, all utility systems (vacuum system, package utility,
auxiliary units, scrubber unit, underground effluent pit, Effluent treatment unit ( ETP),
PCl3/POCl3 storage unit, Bulk storage unit, Butanol purification unit and sub-systems
etc.), Calibration, Testing, Total system integration, Pre-commissioning,
Commissioning and documentation etc.

Supply & installation of Auxiliary Console/Operator console/Auxiliary panel.

Hookup with DCS and field instrumentation, Pre-commissioning, Commissioning.
The function of auxiliary panel shall be to provide facility of annunciation of few
critical alarms including reset and bypass facility. Similarly few critical pumps and
valves shall also be started and stopped from this auxiliary panel with help of self-
illuminated pushbuttons any command from the panel will override in case both s/w
as well as h/w actuation is done simultaneously.

1.3 Supply & Installation of complete field instrumentation and all associated
components.
Supply, installation, cabling and hookup with pipes / vessels/ pumps and all other
equipment. The instrument shall be mounted with suitable isolation valves, drain
valves, bleeders and manifolds after first root valves.

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 Chapter-9 Technical specification

1.4 Selection criteria of instrumentation system: All the instruments and automation
system are as per the schematics of various systems and package units referred in the
tender document are in the scope of EPC contractor. Hence systems to be supplied as
per the detailed engineering for monitoring, controlling and interlocking of the
parameters, based on DCS. The DCS shall have upward communication facility for
communicating with other systems for all parameters to repeat information by open
collector method (4 to 20 mA) without conditioning the signal. Selection of DCS &
field instrumentation shall be done based on the detailed engineering to satisfy the
specified control philosophy, service requirements & suitability for the
environmental conditions(corrosive/hazardous) prevailing at site as mentioned
elsewhere in the tender document.

1.5 Schedule of Quantity for supply of instrumentation and control system:

Technical Specification given in the document covers the basic requirements for the
selection, design and application of process instrumentation and control systems. As
per S. No. 4, in the Schedule of Quantity (SOQ), overall quantity for item is given as
total number/ lot, which is a combination of different sizes, ranges & lengths etc.,
Hence EPC contractor shall carryout estimation and segregate the complete
instrumentation items and their specifications while quoting in the technical bid.
1.6 Submission & approval of Documents: EPC contractor has to submit detailed
specification, DCS of all instruments & accessories, layout drawings, installation
drawing, wiring diagram, loop schematics, QAP & other required documents
mentioned in the Sl. No. 16 to 19 of the tender document and get them approved from
HWB before placing order for supply/manufacture.
1.7 QAP (Quality Assurance Plan): Preparation of detailed QAP & submission for
client’s approval. QAP shall include quality assurance for bought out items,
fabrication / erection tolerances, testing procedures, acceptance standards and extent
of testing /stage inspection required indicating involvement of contractor, client etc..
Wherever necessary, prepare testing procedure and submit for client’s approval.
Suggested QAP is enclosed in the document, which should form the basis for
developing the final QAP for individual field instrument, DCS and other components.
Based on the tentative Quality Assurance Plan of the tender enclosed, prepare &
submit detailed Quality Assurance Plan (QAP) for HWB’s approval. Incorporate the
comments in the QAP, if any made by HWB and resubmit for approval.
1.8 Factory Acceptance Test (FAT): EPC contractor shall carry out Factory Acceptance
Test i.e. Inspection and Testing at supplier’s works for all the instruments and DCS as
per approved QAP in presence of HWB’s representative. Throughout the factory
acceptance test, contractor shall provide all necessary test equipments and
consumables and shall make all necessary connection to all hardwires as required. All
the FAT reports to be signed by EPC contractor’s representative and HWB’s
representative.

1.9 Site Acceptance Test (SAT): After installation of total instrumentation and control
system including filed instruments and DCS, end to end checking will be carried out
jointly. All the SAT reports to be signed by EPC contractor’s representative and
HWB’s representative.

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1.10 Functional testing: Functional testing will be carried out jointly with contractor for
all the instrumentation and associated components. HWB shall carry out 100%
functional checking of all hardware/software modules.
1.11 Total system integration: Total system integration will be checked after
commissioning of the system to verify the specified control philosophy and system
integrity. Contractor to co-ordinate with sub-contractors/manufacturers of all items for
system integration.
1.12 Safe transportation to SPP site and Storage: EPC contractor has to supply all the
items to SPP site in a safe manner without any damage. Items shall be packed with
suitable materials to prevent damage in the transit and also ensure safe transportation
and storage of all the equipments at the SPP site. Each package shall be limited to size
and weight that are permissible under the existing rail and road limitations . All lifting
points shall be clearly marked

1.13 Site Execution: EPC contractor shall depute suitable authorized Supervisor/Engineers
and staff at site for erection, pre-commissioning checks, commissioning of total
system. Adequate Supervision for Safe working by bidder’s personnel is to be
ensured. All Safety & Security rules in vogue at HWP-Tuticorin site shall be
complied during the execution of work at Site. Execution of instrumentation work at
site shall be as per the drawings and documents prepared by the contractor &
approved by the HWB. Scope of site execution work by the EPC contractor shall
cover but not limited to the following:
- Unloading, Unpacking, Assorting, Physical checking, Cleaning and drawal of
instruments accessories and erection material, safe storage at contractors own risk.
- Transportation and handling of instruments, instruments accessories and erection
materials from stores / or from places of storage to work site.
- To make arrangements and supply of consumables like welding electrodes,
industrial gases, cleaning fluids such as (CTC, Rustolene and Kerosene), primer for
structural, Teflon tapes, insulation tape, sealing compound, all clamping materials
(for cables, tubes, trays, racks), screws, strips, washers, GI nuts of different sizes,
cable lugs, all other identification ferrules for cables /wires, structural of MS/CS.
- Supply and cutting gaskets of various materials like PTFE, Neoprene, CAF etc. to
suitable sizes including making additional cut-outs on panel or any other supports
and accessories.
- Supply of structural steel & fabrication of frames, supports, mounting, stands,
clamps, brackets, cable racks and corners, tees and crossing etc.
- Minor civil jobs like grouting, chipping, fixing involved in the installation of
conduits for cables, Cable trays, supports, mounting etc.
- Laying and supporting of multi core and single core electrical cables, multi core &
single core signal cables and any other special cables.
- Supply of stainless steel material, fabrication and laying of distributing air headers
(air distribution pots and lines) fixing distribution air headers lines and its testing ,
cleaning and blowing of all distribution lines , pneumatic tubing impulse tubing.
- Supply of alloy aluminum cable trays, fabrication and erection of cable trays for
above ground and underground cabling (trenches).

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- All steel structures shall be painted with one coat of red oxide zinc chromates
primer to IS: 2074 ( 25 Microns) and two coats of synthetics enamel paint to IS :
2932 ( 50 Microns)
- Supply & installation of fire barriers at all the instrument cable entry points to
Control Room etc..
- Supply & installation of Auxiliary Console.
- Testing, calibration, functional checking of instruments, accessories control and
sequence logic loops to the satisfaction of the HWB.
- Sealing of cables entries to control room / control panel.
- Minor modifications in erection arising out of rerouting, relocation etc. in panel or
in field during testing and calibration and functional testing, if any.
- Trench cutting (Wherever applicable)
Trench cutting, refilling and closing after cable lying as per details given below if
overhead rack is not available for instrumentation cable trays and pipes.
Excavating trenches suitable for cable laying with HDP pipe including excavation
for sockets and dressing of sides ramming of bottoms, depth up to 1.5 meter,
including getting out excavated soil and then returning the soil as required brick
work with common burnt clay modular bricks class designation 7.5 in layers not
exceeding 20 cm depth, including consolidating each deposited layer by ramming,
watering etc., and disposing surplus excavated soil as directed within a lead of
50m. Supply of sand and bricks required for filling are in the scope of the vender.
Cable marker shall be provided throughout the cable route from the auxiliary unit
to main plant ( SPP).
- The network components lay out and Site Plot plan is tentative which may require
minor change as per detailed engineering of the work which is the contractor’s
scope. This minor change shall be considered during execution of the job without
any financial impact of the work.
- Carryout minor modification at no extra cost as suggested by the Purchaser for
completion of entire project.
- Parts found unsatisfactory either due to workmanship or materials shall be removed
by the Contractor and replaced by parts, which are satisfactory, with no extra cost
to be paid by the Purchaser.
- Any components damaged/consumed during testing (before mechanical completion
and final acceptance) shall be borne by the contractor.
- The Contractor shall submit a monthly detailed progress report on the design,
detailed engineering, tendering & ordering, manufacture/assembly or erection and
commissioning of all equipment covered by these tender documents in the
Contractor’s or Sub-Contractor’s work. Detailed erection schedule shall be
prepared and submitted covering following or any other major activity:
a) Design and detailed engineering work.
b) Tendering, evaluation and order placement.
c) Drawing, design approval and manufacture.
d) Assembly and testing.
e) Packing, shipping and transportation.
f) Erection & commissioning.

1.14 Supply of all types of gaskets required for installation: EPC contractor shall supply
all types of gaskets, O-rings of various sizes suitable to process parameters such as

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 Chapter-9 Technical specification

Teflon and rubber gaskets, O-rings, spiral wound asbestos filled and O-rings of
special material (Neoprene, Viton, EPDM) etc..
1.15 Earth pit: Supply of items pertaining to earth pit & Earth pit preparation for system
earth, panel earth and instrument earth as per IS 3043.Testing, pre-commissioning and
commissioning of earth pit.

1.16 Commissioning: The EPC contractor has to prepare and submit check list/procedure
for pre-commissioning test, commissioning test and charging the equipment or taking
it into service and get them approved from HWB. After safe erection of the
equipments, EPC contractor shall carry out pre-commissioning and commissioning
test as applicable as per the approved check list/procedure. Calibration before and
after installation, Commissioning, loop checking of Instruments which include
sensors/final control elements of package plants also. All the documents related to
erection (2 sets of Hard copy and one set of soft copy) will have to be submitted.
Documents shall be approved by HWB before the work is taken up.
1.17 System handing over after commissioning: The EPC contractor has to hand over
the Instrumentation system after successful completion of commissioning and
performance tests acceptable to the purchaser or as per approved commissioning
procedure/manufacturer guidelines. The EPC contractor has to ensure that all the
Instruments can be taken into service.
1.18 Associated Minor Civil Works: All the instruments, cables, cable trays and DCS
system shall be erected in the existing RCC room by the EPC contractor. Associated
minor civil works are to be carried out by the EPC contractor like chipping, grouting
etc.
1.19 As Built Drawings: Preparation of “As Built” drgs. for following (but not limited to)
shall be provided to the client in 3 sets of hard copy & 2 set of CD after erection job is
over. Installation drawings for all the type of instruments also showing the complete
BOM. Instrument Bulk Material list, Cable schedule drawing, Typical Installation of
Instrument supports, Electrical connection, Pneumatic connection, Air supply network
drawings, Isometric showing mainly the installation of instruments, Loop drawings
from filed up to cabinets in control room showing all the termination details, Loop
drawing from Cabinets to DCS/ showing terminations at all the levels such as
Isolators, relays etc., Power supply distribution drawings, Typical Loop drawings,
Earthing network schematics, Isometric showing mainly the installation of
instruments.GA drawing for Panels, Panel Foundation details, Any other drawing
related to erection of the system, Power supply distribution drawings (generated from
soft model) shall be provided.
1.20 Training: The EPC contractor shall arrange for in-depth training on operation and
maintenance/trouble shooting/ calibration of all types of instruments by experts from
respective instrument manufacturer. The training shall be imparted at site to at least 4
numbers of representatives of the client and the duration of the training shall be at
least 5 days. The contractor shall also arrange for comprehensive training on both
hardware and software of DCS system by experts of the manufacturer of DCS system.
The details of the same are mentioned in the specifications of DCS.

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1.21 Supply of Spares: EPC contractor shall supply the list of spares mentioned in the
SOQ Sl.no - 4. In addition to above, the recommended list of spares required for 15
years of maintenance shall be indicated in the offer.

1.22 Laying of cables: Sizing, supply & laying of signal cables and power cables (110V
A.C/DC) from Field to DCS through JB and Marshalling panel , UPS to DCS panel
for distribution of the same in DCS panels, DCS panel to MCC panel and other
required laying of cables to auxiliary panel are in the scope of vendor. The cables
covered under this enquiry shall be used in hazardous plants instrumentation job. The
cable shall be laid on the open trays and shall be exposed to direct sun light, heat, rain
and seasonal changes. The area is wet tropical coastal climate and shall be as per
specifications mentioned in sl. no 12.

1.23 Auxiliary systems / Panels: Supply, installation, commissioning and connection with
main DCS of all the auxiliary panels such as Hardwired Alarm panel, Local panels
and panels for package units etc.

1.24 Guarantee: Guarantee should be given by the vender that the DCS system along with
accessories and instruments shall perform as per the design intent of accuracies,
performances as specified etc. as per the codes and practices indicated earlier. In
absence of the relevant codes in the area if any, the manufacturer’s specification shall
be complied with to the satisfaction of purchaser. If any deviation is noticed, the EPC
contractor shall rectify the same in a period not exceeding 30 days and if he is not able
to rectify, then the contractor should substitute the entire system with a new system.

The system should be designed strictly as per the specification approved by

HWB and as per good engineering practices. Whatever changes/modifications,
carried out during the technical discussions and subsequent changes in
engineering, by the EPC contractor , same need to conform to the Technical
specifications. All subsequent changes in the previously approved
drawing/approved discussions held between EPC contractor and Heavy Water
Board; need to be vetted through HWB, prior to their implementation. The
following guarantee needs to be given by the EPC contractor –

2.0. BATTERY LIMIT UNDER THE SCOPE OF CONTRACT

Main plant of SPP consists of main plant equipment, machineries, vacuum system,
package utility & auxiliary units, scrubber unit, underground effluent pit, Effluent
treatment unit (ETP), POCl3/PCl3 storage unit, Bulk storage unit, Butanol purification
unit, Cooling water unit, Chilled water unit, Steam generation unit etc. as shown
hatched in the site lay out drawing No: HWB/SPP(T)/CIVI 0001/ REV 00/A3/INST.

All the above equipment and systems are to be connected as per P&ID drawings,
along with the respective headers, Instruments and sensors, Power supply etc. Distant
units like Bulk storage tank and cooling water unit are also to be connected with the
main building of SPP as per the scope of this tender work.

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All the parameters of the package units mentioned above to be integrated with DCS
for monitoring/controlling.
Instrument air system and all classes of power supplies shall be supplied by HWB at
Approx. 10 m distance from main SPP plant building. The contractor has to start his
Cabling / Tubing /piping work from this point onwards for respective utility piping for
the SPP main plant.

3.0. CONFIRMATION BY THE CONTRACTOR AT THE TIME OF SUBMISSION

OF TENDER.
Quotations should, in general, be in conformity with the specifications. Each
Contractor is required to specifically confirm that the followings are considered /
included in the offer.
Note: 1. Contractors are to mention Yes /No for each of the below Statements.
2. Tender evaluation shall be made as per the response of the above.
3. Making deviation to the technical specification and other tender conditions is
likely to result in rejection of tender; hence EPC contractor has to submit duly
signed “no deviation certificate” along with the offer. However any deviation
from our tendered technical specification (if exist) shall be clearly mentioned.

S. No Statement Yes/No

1. The details given in “Point wise clarification/Deviation” given in Sl. No.-

19 of tender along with total scope of work, technical specifications of
instrumentation and automation system mentioned with standard general
specific conditions of contract guide given in Technical document is fully
understood.

2. The battery limit of the work is accepted.

3 Specification of general basic design of DCS and complete field

instrumentation is accepted and data sheet enclosed including make, model
physical dimension and installation details etc.

4 Plant operation, Control philosophy, Instrumentation philosophy with

control system architecture is accepted.

5 Procurement and Supply will be from the list of recommended EPC

contractor list.

6 The total scope of supply is understood.

7 The Detailed specifications for the work, design and procurement of the
items are considered in the offer.

8 All the technical documents/certificate as per tender submission Guide are

downloaded, signed, scanned and submitted online (uploaded while
submission of the bids).

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9 The total offered price for the respective items are inclusive of all testing at
supplier’s work as per QAP of the tender, packaging & forwarding,
transportation & safe delivery and cost of spares as listed in the tender.

10 The QA with Factory Acceptance Test (FAT) and Site Acceptance Test
(SAT) plan for the respective items is to be submitted for approval and
same shall be confirmed and is considered in the offer.

11 The network components lay out and Site Plot plan is tentative which may
require minor change as per detailed engineering of the work which is the
contractor’s scope. This minor change shall be considered during execution
of the job without any financial impact of the work.

12 Any components damaged/consumed during testing (before mechanical

completion and final acceptance) shall be borne by the contractor

4.0. TENTATIVE SCHEDULE OF QUANTITY OF INSTRUMENTS AND

ASSOCIATED ITEMS WITH SPARES

S. No Type/Description Total Qty.

Configuration, Supply & Installation of DCS system of 1000 I/O’s
including total system Integration, testing and Commissioning as per
specifications mentioned in S. No. 8 to 9. Including Colour laser
1 1 system
printer for printing document up to A3 size laser (A4 size black &
white), Hardwire Alarm system, Printer table & Chairs for operator

Supply and Installation of Operator console with cut out and fixing
2 as per dimension given in Annexure-II of the Inst. & control 3 Nos.
Specification.

25 KVA UPS System as per detailed specification given in electrical

3 1 system
technical specification.

Control Valve
As per specification mentioned in Sl. No. 10 to 11 as list of
instruments mentioned in Sl. No. 1 to 7.
4
PTFE lined Control valve with accessories 4

SS Control valve with accessories 16

Level Transmitter
As per specification mentioned in Sl. No. 10 to 11 as list of
instruments mentioned in Sl. No. 1 to 7.
5
Radar type 9

Ultrasonic type 1

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Remote seal type 3

Non contact type RADAR 6
RTD PT 100(Temp transmitter)
As per specification mentioned in Sl. No. 10 to 11 as list of
instruments mentioned in Sl. No. 1 to 7.
6
RTD with SS thermo well( With transmitter) 31

RTD with Hastelloy-C thermo well ( With transmitter) 19

Temperature gauge
7 As per specification mentioned in Sl. No. 10 to 11 as list of 14
instruments mentioned in Sl. No. 1 to 7.
Pressure Transmitter
As per specification mentioned in Sl. No. 10 to 11 as list of
instruments mentioned in Sl. No. 1 to 7.
8
Normal Pressure Transmitter 4

Pressure Transmitter with diaphragm seal 12

DPT
9 As per specification mentioned in Sl. No. 10 to 11 as list of 2
instruments mentioned in Sl. No. 1 to 7.
Solenoid valve SS
10 As per specification mentioned in Sl. No. 10 to 11 as list of 6
instruments mentioned in Sl. No. 1 to 7.
Speed transmitter
11 As per specification mentioned in Sl. No. 10 to 11 as list of 7
instruments mentioned in Sl. No. 1 to 7.
Flow transmitters
As per specification mentioned in Sl. No. 10 to 11 as list of 36
instruments mentioned in Sl. No. 1 to 7.
Hastelloy C Mass flow meter coriolisis 5
12 SS Mass flow meter coriolisis 3
Rotameter with transmitter 14
Rotameter with local indication only 9
Steam mass flow transmitter(Vortex/Orifice) 5
Level switch
As per specification mentioned in Sl. No. 10 to 11 as list of
13 instruments mentioned in Sl. No. 1 to 7.
Level switch LG mounted 48

14 Pressure switch 8

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 Chapter-9 Technical specification

Level gauge
As per specification mentioned in Sl. No. 10 to 11 as list of
instruments mentioned in Sl. No. 1 to 7.
15
SS 316 21
PTFE lining 16
Pressure gauges
As per specification mentioned in Sl. No. 10 to 11 as list of
instruments mentioned in Sl. No. 1 to 7.
16
SS PG 57

PTFE Lining PG 25
Vacuum gauge
As per specification mentioned in Sl. No. 10 to 11 as list of
instruments mentioned in Sl. No. 1 to 7.
17
Mcleod 6

Pirani with Transmitter 6

‘pH' Transmitter
18 As per specification mentioned in Sl. No. 10 to 11 as list of 3
instruments mentioned in Sl. No. 1 to 7.
Weight transmitter (Load cell)
19 As per specification mentioned in Sl. No. 10 to 11 as list of 5
instruments mentioned in Sl. No. 1 to 7.
Weighing machine
20 3
As per specifications
POCl3 detector
21 As per specification mentioned in Sl. No. 10 to 11 as list of 6
instruments mentioned in Sl. No. 1 to 7.
Online HCL monitor
22 As per specification mentioned in Sl. No. 10 to 11 as list of 6
instruments mentioned in Sl. No. 1 to 7.
Online Hydrocarbon monitor
23 As per specification mentioned in Sl. No. 10 to 11 as list of 4
instruments mentioned in Sl. No. 1 to 7.
Online Hydrogen monitor
24 As per specification mentioned in Sl. No. 10 to 11 as list of 3
instruments mentioned in Sl. No. 1 to 7.
UV + IR Flame sensors
25 As per specification mentioned in Sl. No. 10 to 11 as list of 3
instruments mentioned in Sl. No. 1 to 7.
1/4" SS Tube meters
26 As per specification mentioned in Sl. No. 12 to 13 as list of lot
instruments mentioned in Sl. No. 1 to 7.

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1/2" SS Tube meters

27 As per specification mentioned in Sl. No. 12 to 13 as list of lot
instruments mentioned in Sl. No. 1 to 7.
Fittings, connectors, cable glands, tags and all other required
accessories for tubing
28 lot
As per specification mentioned in Sl. No. 12 to 13 as list of
instruments mentioned in Sl. No. 1 to 7.
Multi core Cable(various sizes)
29 As per specification mentioned in Sl. No. 12 to 13 as list of 4000 meters
instruments mentioned in Sl. No. 1 to 7.
RTD cable
30 As per specification mentioned in Sl. No. 12 to 13 as list of 3000 meters
instruments mentioned in Sl. No. 1 to 7.
Control cable from DCS to MCC Panel
31 As per specification mentioned in Sl. No. 12 to 13 as list of lot
instruments mentioned in Sl. No. 1 to 7.
Signal Cable (various sizes)
32 As per specification mentioned in Sl. No. 12 to 13 as list of lot
instruments mentioned in Sl. No. 1 to 7.
Cable trays
As per specification mentioned in Sl. No. 12 to 13 as list of
instruments mentioned in Sl. No. 1 to 7.
33
100mm/50mm 1000 meters
300mm 500 meters
Junction boxes
34 As per specification mentioned in Sl. No. 12 to 13 as list of 18 nos.
instruments mentioned in Sl. No. 1 to 7.
Misc. Items like hard wares , components required for interfacing
35 1 lot
and total system integration.

36 Structural material required for different type supports 1 lot

37 Auxiliary Panels (If required) lot

TOTAL AMOUNT (A)

Spares Required

1
Diaphragm seal type PG 5

2 Without diaphragm PG 5
3 Pressure transmitter 1
4 Pressure Transmitter with diaphragm seal 1
6 PTFE Control valve with accessories 1

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7 SS Control valve with accessories 1

8 Electro pneumatic positioner 2
9 Air filter regulator 10
10 LG mounted switch 3
11 Control Valve spares 1 lot 1
12 RADAR LT 1

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SYSTEM OVERVIEW

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5.0. SYSTEM DESCRIPTION

5.1 SPP Control Room

5.1.1 There shall be a Control Room for the Plant Operation and for installation of
DCS system. Control Room is located in the SPP Main plant building.
5.1.2 The Operator / Engineering console, Printers (one colour laser printer for
printing document up to A3 size and one laser (A4 size black & white) for
alarm, log printing), and hardwire Alarm system shall be located in the SPP
control room. The system cabinets and all other type marshalling panels will be
housed in SPP control room with partition from operating area.
5.1.3 Ample space will be provided around the instrument panel/desk, about a
minimum of 1.25 m to 1.5 m.
5.1.4 Double door air curtain facilities will be provided at the entry to the SPP control
room and SPP control room will have minimum two entries.
5.1.5 The SPP control room will be air-conditioned having raised floor and false
ceiling.
5.1.6 The clear height of the SPP control room between raised floor and false ceiling
will be minimum 3000 mm.
5.1.7 The floor will be provided with antistatic matting. (Leakage resistance shall be
< 108 ohm to avoid static charges). The SPP Control Room shall achieve a high
environmental standard. Noise level shall not exceed 55 dB(A) at any position
within the SPP Control Room. Lighting shall be confirming to minimum lux
level at operating place and anti-shadow & glare environment is envisaged at
any operating panel.
5.1.8 The SPP control room door will be made of glass fixed in aluminum frames.
The glass panels will be long preferably one sheet of each frame. The layout
shall permit an easy operation and supervision of the unit.
5.1.9 The walls and panels shall provide good acoustic insulation, shall prevent the
ingress of dust and shall ensure the efficient operation of the air-conditioning
system in SPP control room.
5.1.10 Chairs provided shall be ergonomically designed to suit Operators comfort. The
SPP control room shall also provided with sufficient number printer tables
which shall be matching in appearance and dimension with the other hardware
located in the room.

5.2 Design Objective

5.2.1 The Primary Objective of C&I system design are as follows:

 To ensure maximum availability of the plant.

 To effectively monitor and control the plant to ensure desired output.

 To ensure plant and personnel safety and reduce down time.

5.2.2 Instrumentation Design/ Engineering will be done such a way that no single

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equipment/ instrument failure will lead to a Plant Shut down.

5.2.3 The design and selection of process control and instrumentation systems shall
include consideration of the following:

 Application suitability

 Reliability

 Quality

 Accuracy

 Repeatability

 Life cycle cost

 Flexibility of use

 Compatibility with the environment (climatic).

5.2.4 Environmental Conditions: All instruments and Instrument items shall be

tropicallized and suitable for outdoor installation in climatic conditions. In
summary, all Instruments, Instrument accessories and enclosures shall be
suitable for location outdoors for the following worst case conditions:
 Max. Design Temperature: 60 °C

 Min. Design Temperature: 22 °C

 Design relative humidity for Instrument and Instrument items: 85 % to 100%.

6.0 PLANT OPERATION AND CONTROL PHILOSOPHY.

6.1 The SPP operations shall take place from SPP control room. It is planned to have
common control room for different solvent production facility at HWPT in future.
6.2 The Distributed Control System (DCS) of SPP shall form the central control system
to provide a plant-wide integrated system for control and monitoring. The control
systems are designed on a top down principle with plant control, monitoring and
operations under normal operating conditions being performed from the DCS
workstations located in the SPP unit control room. This integrated approach permits a
single control point for plant process operation through the DCS as opposed to
controlling by a number of different systems.
6.3 Local start / stop push button stations shall be provided for all main plant pumps,
agitators, compressors, heater etc and shall be terminated in DCS panel so that all the
trip logics will be applicable in the status of Local start.
6.4 Package unit control system such as Chilled water unit, Thermic fluid heating system,
HCL scrubber unit, Steam generation unit, vacuum system, POCl3/PCl3 storage unit,
Bulk storage unit, Butanol purification unit, underground effluent pit, and Effluent
treatment unit ETP etc. Above package unit shall have its own control panel which
shall be housed locally near the unit. All the operations of unit will be performed from

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unit’s control panel locally. The parameters required for monitoring the status of the
unit shall be communicated to the SPP DCS system through hardwire connectivity.
6.5 Instrument/ Electrical Interface
6.5.1 The interface between instrument and electrical systems shall generally be
achieved by use of interposing relays located within the instrument/electrical
interface section of each MCC cabinet.
6.5.2 All signal /cable interfaces between C&I and Electrical Groups, shall take place
at an Instrument/Electrical Interface Cabinet.
6.5.3 All field start/Stop for Electrical equipments like pump, compressor, heater etc.
shall be terminated in Instrument cabinet and configuration of control
philosophy is in the scope of contractor.
6.6 The Operator Workstation will facilitate operator performance for the following
activities:

 Monitor and Control process variables.

 Monitor process and equipment alarms.

 Adjust manual set points and automatic control.

 Initiate plant shut down, start-up by-passes, maintenance over-rides etc..

 Monitor plant safety system.

 Start up and shut down of major equipment.

 Monitor system diagnostics for all Control systems.

6.7 The functional availability required at SPP Control Room will be as follows:

 Monitor, Supervise, and Record all parameters of all the Units.

 Monitor usage of utilities, and chemicals.

 Periodic reports of product output details.

 Periodic reports of production rates against utility.

 Monitor major equipment status (e.g. running and stopped)

7.0 INSTRUMENTATION SYSTEM PHILOSOPHY

7.1 Generally the method for representing instruments & controls in piping & instrument
diagrams will be in accordance with ISA S 5.1, S 5.2 & S 5.3 except when modified
for the process units by the P& ID legend sheet.
7.2 Instrument selection shall be as per Design Basis for Field Instruments.
7.3 Field instruments connected to the DCS, and to the package equipment control panel
shall be compatible to Highway Addressable Remote transducer (HART) protocol on
4 to 20 mA.

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7.4 Instrument scales/ranges shall be selected so, that the normal operating point will be
at approximately 50% of the full scale/range for pressure, temperature and density,
and at 70% for flow rate and level.
7.5 All Field instruments shall be 24VDC Loop powered from DCS.
7.6 Upstream and Downstream pipe lengths shall be based on ISO 5167.
7.7 All RTDs shall be calibrated as per IEC 60751. Temperature Transmitters shall be
utilized with the RTDs and shall be head mounted type. Thermo wells for the RTD’s
shall be used with immersion length as 70% internal dia. of pipeline and full length
for Vessels.
7.8 Transmitters and manifolds shall be supported in a way to allow safe de pressurization
of transmitter and removal for maintenance.
7.9 Sun shields shall be provided for all electronic instrumentation under direct solar
exposure.
7.10 The accuracy shall be as mentioned below:

 pH meters: 0.5% of Value

 Pressure, DP Transmitter: 0.075 % of span

 Pressure Gauges: 1 % of span for Burdon type, 1.5 % of span for Diaphragm
type.

 Level transmitter: ± 6 mm

 Temperature Gauge bimetallic: ± 1 %

 Temperature Transmitter for Thermocouple, RTD: ± 0.12°C

 Orifice Plate: ± 2 % of flow rate

 Vortex Meter: ± 0.7 % of flow rate

 Mass Flow Meter: ± 0.25 % of rate

 Pirani gauge: ± 20% of reading

7.11. Control Valves and Actuators: Control valve sizing shall conform to ISA
S75.01.Valve sizing shall be done to pass the design flow rate of normal operation
condition with the valve opening of 60% to 80%. But at the same time, valve shall be
capable of handling 10% more flow rate than the maximum flow rate expected. It
shall be ensured those maximum and minimum flow rate are within the limits of 90%
and 5% of Cvs value or not. If the process requires a Cv value of more than 90%
and/or less than 5% of the Cvs value, two valves shall be considered in parallel. The
standard design criteria shall be chosen Cv will be 1.3 of Calculated Cv unless it is
specified.
The maximum sound pressure level (SPL) at 1 m downstream of the valve, and at 1 m
from the piping surface shall not exceed 85 dBA.

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IEC 60534 control valve leakage standard shall be generally followed in specification
of control valves. Leakage Class IV/V will be used as per process requirement.
Actuators shall be normally single action (spring opposed) pneumatic diaphragm
operated type. Actuators are to be designed to withstand maximum shutoff differential
pressure existing across the valve during operation, as well as to overcome frictional
forces.
Valves in control service will be equipped with electro-pneumatic positioners
wherever applicable. Positioner shall be suitable for the climatic conditions, and shall
have mechanical protection class of minimum IP54. It shall have metallic enclosure.
All control valves and actuators shall be provided with individual filter-regulator as
required.
7.12 Switches: Switches shall be of snap acting DPDT contacts rated at 1A at 24V DC,
adjustable set points and adjustable dead bands.
Position activated switches, e.g. status switches etc.., shall be used for logic function.
Proximity type Limit Switches shall be used for shutdown valves and control valves
(as applicable).
Hand actuated switches e.g. push buttons, selector switches etc.. shall be used for
logic function.
Contacts from position feedback switch (limit switches of valves, etc..) will be closed
when position is reached.
Switch modules shall be hermetically sealed and vibration resistant.
7.13 Fail Safe requirements
The failure of any power supply, instrument air supply, signal or instrument shall
cause the final control element to move to a safe operating position. The system shall
have redundancy as per the criticality of application.
Control Valve actuator design shall take care of failsafe condition i.e. bringing valve
to full open/full close or stay put mode, on signal (pneumatic/electric) failure. In order
to avoid undesired position of control valve with interlock on return of interlock to
healthy condition, controller shall go to “Manual” and output of controller shall go to
a value corresponding to interlock position of the valve when interlock occurs.
Digital input and output for interlocking and annunciation system shall be used in fail-
safe manner i.e., in normal operating conditions contact shall be closed and solenoid
valve and relays shall be energized to operate.
7.14 Instrumentation Pneumatic Supply requirements. For pneumatic on-off and control
applications, the actuating signal shall be derived from 5-7Kg/cm2 (g) header through
Air filter regulator for each instrument.
7.15 Instrumentation Power Supply requirements: Power supplies for all transmitters,
controllers, signal converters, electric system and components in shutdown system
shall be supplied from uninterruptible power supplies. Instrument power supply
voltage shall be as follows:

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Coriolis mass flow meter 24 V DC

All types of field Gas detector /monitors 24VDCUPS
Solenoid Valve 24 V DC (UPS)
Panel/Cabinet illumination lamps 110 V AC (Non UPS).
Interposing relay for MCC 24 V DC. (UPS)
Transmitters, I/O modules, Intrinsic Safety
barriers, auxiliary Console, Lamp switch, Push
Buttons 24V DC. (UPS)

7.16 Instruments earthing system

To ensure good protection to both personnel and instrumentation, three earthing
systems shall be provided. Instrumentation Earthing requirement.
The earthing systems shall be defined as follows:

 PE : Protective Earth

 IPE : Instrument Protective Earth

 I.E. : Instrument Earth System

7.16.1 Protective Earth : The PE shall be used to protect power systems, and
instrumentation equipment and personnel against electrical shock.
7.16.2 Instrument Protective Earth (IPE) : The IPE shall be a protective earth used only
for instrumentation equipment. All instrument enclosures, equipment and
instrument cables shall be connected to the IPE.
The termination of incoming instrument cables shall be connected via the IPE
bus bar to a crossing terminal located on the side of the junction box. The
outgoing multipair cables shall not be connected to the IPE bus bar inside the
junction box. It shall be earthed in Central control room.
Every marshaling, termination cabinet located in local or main technical room
shall be fitted with an IPE bus bar. The incoming and outgoing cables shall be
connected to this bus bar
7.16.3 Instrument Earth System (IE) : The IE shall be the reference point for all digital
and analog signals. All individual screens and overall screens shall be connected
to this point. Data highway co-axial cable shall also be connected to this point.
For instruments the screen shall be insulated from local earth.
For junction boxes all screens of analog and digital signals incoming cables
shall be connected to specific non-disconnecting terminal type. They shall be
isolated from junction boxes’ IPE bus bar. All screen terminals shall be looped
together. The overall screen of the outgoing multi pair cable shall also be
connected to the last screen terminal.

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Termination cabinets / Marshaling / DCS stations located in local or main

technical room shall be fitted with IE bus bar mounted on insulation blocks. All
overall screens of analog and digital signal multi pair cables shall be connected
on this IE bus bar.
However there will be three nos. earth pit required to be provided for the
following
1. Earth pit for Instrument
2. Earth pit for Panels
3. Earth pit for DCS system
7.17 Instrumentation Equipment Protection requirements
7.17.1 Environmental protection: All instruments / equipment and installation material
shall be suitable for the overall climatic conditions, the position within the
installation and the local environment, with particular attention to site ambient
conditions.
All field instruments shall be provided with necessary weathering and
anticorrosion protection.
7.17.2 Ingress protection: All field instruments shall have ingress protection to IP 65 or
better.
Pneumatic field instruments used for control applications shall have ingress
protection to IP 54 or better.
All instruments installed inside pressurized equipment / control rooms shall
have ingress protection to IP 32 as a minimum.
7.17.3 RFI Interference and Electromagnetic Compatibility: All equipment shall
remain unaffected by radio transmissions (Levels of permissible RFI shall be as
per IEC 801). Band-pass and / or band stop filters shall be fitted, as necessary.
The design of electronic instruments should be in compliance with the
electromagnetic compatibility (EMC) requirements as per IEC 801.
7.18 Instrument Material Selection Philosophy
7.18.1 Environmental protection Suitability for the specified process conditions, with
SS 304 as the minimum.
7.18.2 The selection of materials for all in-line mounted instruments, including all their
components connected to the line, e.g. instrument valves, flow meters etc.., shall
be in accordance with the associated piping material specification as a
minimum.
7.18.3 The selection of materials for all on vessel mounted instruments, including all
their components connected to the vessel, e.g. level transmitter chambers, level
gauges etc.., shall be in accordance with the associated vessel trim material
specification as a minimum.
7.18.4 Material for all junction boxes, and instrument electronics and termination
housings shall be SS 316/304/die cast aluminum.

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7.18.5 All proposed standard plastic components if any shall be non-toxic and fire
resistant, UV stabilized and compatible with the environmental conditions.
7.18.6 All spindles, bushings, bolting, screws, brackets, etc.., shall be manufactured
from a suitable grade of stainless steel as a minimum.
7.18.7 Stand pipes, supports for instruments and any other item directly welded to the
structure shall be CS galvanized.
7.19 Instrumentation Connection requirements
7.19.1 All threads shall be to “NPT” (ASME B 1.20.1 taper). Where the instrument
item is not available with NPT connections, suitable adapter to NPT shall be
provided irrespective of the scope of installation.
7.19.2 Electric connections shall be “ISO metric”.
7.19.3 Flanges shall be per ASME B16.5.
7.19.4 Piping Vent and Drain Valves associated with Instruments on vessels or
standpipes shall be 3/4” or ½”.
7.19.5 Gasket types and flange face finishes shall match the requirements of the piping
specification.
7.19.6 In-line instruments shall match the associated piping or vessel or mechanical
equipment mating connection.
7.19.7 Where multiple connections for power input, signal input and signal output on a
single instrument or accessory, separate electrical connections shall be provided
for each of them.
7.20. Instrument Installation requirements
7.20.1 Installation shall be carried out in accordance with Hook up and Installation
detailed drawings.
7.20.2 Visibility and accessibility shall be maintained for both maintenance and
operations purpose.
7.20.3 All instruments and valves shall be free from vibration or within the acceptable
limit of the instrument or valve.
7.20.4 Where process fluid or moisture can accidentally leak into electrical circuits,
instruments and controls shall be installed with necessary seals, drains and
isolating valves.
7.20.5 Removal of instruments and controls must be possible without stopping the
process, the necessary isolating valves and by-pass valves shall be installed.
7.20.6 Instrument orientation shall suit the operator’s use of the associated data, for
example: pump discharge pressure indicator shall be readable at the starter
controls; level indicator/level gauge shall be visible from the platform (or level
control valve if possible), etc..

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7.20.7 Instruments and controls shall be located for direct accessibility and easy
removal to provide safe, convenient access for operators and maintenance
personnel. As a rule, they shall be located in such a way that their axis is at 1.4
meter from the floor or the platform. Careful consideration shall be given to
such requirements as equipment isolation, maintenance disassembly, in-place
connection of test equipment and calibration, line slopes, seals, vents, drains,
etc.. Maintenance work must be made as convenient and comfortable as
practicable. Maintainability shall be considered just as important as operability.
7.20.8 Impulse lines for remote mounted instruments shall be 15mm OD, 1.65mm wall
thickness, seamless, annealed 316 SS/compatible with fluid handled, with SS
316/compatible with fluid handled compression fittings. Pneumatic signal and
air supply tubing shall be 6mm (minimum), seamless, annealed 316/304 SS,
with 316/304 SS fittings, unless otherwise specified.
7.20.9 Instruments and impulse tubing shall not be supported from process lines.
7.20.10 Individual instruments that are not line mounted shall be located on pedestals,
50mm diameter Instrument Pipe Stands or equal, on structural steel or set in
concrete.
7.21 Instrument Spares requirement
7.21.1 List of recommended spares to be submitted for fifteen year’s trouble free
operation.
7.21.2 All spare parts shall comply with the same standards and specifications as the
original equipment and shall be fully interchangeable with original parts.
7.21.3 All spare parts shall be marked with the manufacturer’s part number, name and /
or reference number.

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DISTRIBUTED
CONTROL SYSTEM (DCS)

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8.0 DCS DESIGN BASIS:

8.1 The DCS, by employing distributed intelligence and database techniques, shall
provide highly secure, safe, reliable, maintainable, effective process / safety
monitoring and control of the production/ancillary facilities, from a permanently
manned Central Control Room (CCR). DCS shall not be a PLC/SCADA based
system. PLC Hardware like CPU, I/O modules etc. in any form are not acceptable in
DCS.

8.2 The system shall enable process monitoring, control, safety detection & protection to
be achieved, at several equipment nodes, with serial high-speed communications to
the operator's console employing VDU's, keyboards, print server & printer, data
storage devices, etc. All VDU shall be standard 21” square model or 24” wide screen
LED type colour monitor.

8.3 The DCS shall employ Dual redundant (single fault tolerant) communications links.
The system supplier shall prove that the system hardware redundancy, will achieve an
availability better than 99.99% using this chosen hardware configuration.

8.4 Process and sequential control shall be achieved using plant wide multi-loop
microprocessor based digital controllers, with full functional interfaces being
provided by the operator's consoles.

8.5 Minimum one set of controllers are envisaged for DCS. Controllers should not be
loaded more than 60%. If more number of controllers are required to meet 60%
controller loading criteria, the same should be included.

8.6 The operator's VDU shall provide MS windows HMI. All VDU shall be 21” square
model or 24” wide screen LED type colour monitor as a minimum.

8.7 The system shall be fully configurable without specialized programming knowledge,
using proven, fully de-bugged and tested Supplier's standard software packages.
Sufficient online storage shall be included to accommodate the database and alarm,
event, Trends, Reports and historic data logs. To achieve the reliability/availability
targets required, redundancy requirements shall be calculated and employed.
Operational control of the plant will normally be from the CCR. Facilities shall be
provided such that in the event of failure of operator workstations, the controllers
shall continue to provide control operation at the last known set point.

8.8 The system shall be built on the latest state-of- the-art hardware and software platform
and hardware/software/firmware revisions of complete system will be latest at the
time of supply. The system architecture shall have Microsoft Windows (latest version)
operating systems and compatible RISC hardware. All the operator station and
engineering station shall equipped with 21” square model or 24” wide screen LED
type colour monitor. Conventional CRTs are not acceptable. Number of consoles
envisaged is indicated elsewhere in this document. Client Server Architecture is not
acceptable. All Workstations should be directly sitting on Plant Communication Loop

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as INDEPENDENT NODES. No operating Station should be connected to Plant

communication loop through a server. All workstation should be directly connected to
main Plant communication loop as independent nodes with full functionality.
However, “remote monitoring stations" which are meant for remote operation/
monitoring can be connected to plant communication loop through server in case
distance is a limitation for Server-Server configuration.

8.9 The system shall be 100% fault tolerant and dual redundant for control processor,
system bus, data highway, I/O for closed loops, power supply and communication.
This means, all central control processors, all communication processors and all other
rack and individual node’s common cards, all the communication cards, networks and
cables, etc. shall be 100% fault tolerant. All the hardware including
control/communication processors, networks, cables, all type of system cards, all type
of I/O cards shall be hot replaceable.

8.10 All the I/O cards shall have individual channel to channel as well channel to field
isolation. Analog input/output cards shall be galvanically isolated and digital
input/output cards shall be optically isolated. Group isolated type or bulk I/O cards
shall NOT be accepted in the whole system architecture. All I/O cards shall be
intelligent type with microprocessor/microcontroller based hardware and capable of
all type of signal conditioning, self diagnostic, fail safe value configurable
(programmable) and time stamping at I/O card level.

8.11 I/O cards’ Channel density shall not exceed the following limits Analog Input – 16
Channels Analog Output – 8 Channels Digital Input -16 Channels Digital Output -16
Channels All I/O cards in individual category shall be of same type/model/revision
only. No different bulk I/O cards or I/O cards with degraded features shall be accepted
in any of the category in a mix mode supply.

8.12 The scan time of all type of analog/digital inputs cards & DCS algorithm (Scan time
means the sum of total time required for reading an input, running control algorithm
and writing the output values) shall be less than 250 milli-seconds for any type of
channel.

8.13 There shall be one engineering station in overall DCS architecture, from where the
complete DCS project can be developed and deployed on any other operator/control
station, independently. Non-availability of engineering station shall not affect the
plant normal operation and shall neither cause any historical/trend data loss. All
operator station shall be independent of engineering stations, self bootable and do not
require engineering station for putting them into normal operation or restoring them
after rebooting, once the developed project is deployed. System should allow on-line
modification, addition / deletion or change in any control loop or part thereof.

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8.14 All operator stations and engineering stations shall be OPC compliant without any
upper limit on number of tags. However, if there is any specific limit applicable on the
proposed system, it is to be specified.

8.15 Complete system hardware/software and communication load shall not exceed 50%
system load even after the complete implementation of project and running at peak
load. This includes redundant control processor load also.

8.16 System shall have 50% spare margin in software memory/load for future spare
addition without replacing/upgrading any existing system hardware/software at all the
levels. System shall be capable of loading up to 100% without any
overrun/degradation of performance, etc. System shall report all type of load limit
alarms, diagnostic alarms up to channel level, communication alarms, system
hardware failure alarm and other global information with alarm facility on
engineering/operator station in real time with 1 second resolution.

8.17 The system shall support all various type of control/interlock/sequence algorithm and
shall also support various high level programming language like VB, C/C++ in real
time control application, in addition to standard control algorithms available in the
DCS.

8.18 System shall support various Hourly/Shift/Daily/Monthly Reports/Logs, Totalizers

reports, etc. in Microsoft excel format only. The layout and type of reports/data, nos.
of tags per report, etc. shall be as per owner’s requirement. All the operator station,
engineering stations shall be equipped with MS Office licensed copy. System shall
support history for min. 5000 tags, out of which 2000 points shall be configurable for
1 second resolution, 1000 points shall be configurable for 2 seconds interval and
remaining shall be configurable from 5 to 10 seconds. There shall be no limit on
history data retention time, except the hard disk size. All the stations, wherever
engineering database of complete project and historical/run time data is stored, shall
be equipped with redundant hard disk with RAID1 configuration, to prevent any data
loss. This will include not only the engineering station but all the operator station also,
wherever applicable.

8.19 System shall support 1 second time resolution real time trend for all the system
tag/parameters, without any time limit. Also, all PID loop face plate display shall have
real time/historical trend window by default for min. three parameters, i.e. measured
or process variable, operator entered or remote/calculated set-point and output value
or manipulated value for that particular loop.

8.20 DCS system shall have latest; windows based alarm manager with 1 second or better
time resolution with time stamping. In addition to various process alarms, the system
shall also store operator action journal, system error messages, any other event, etc.
Alarm manager shall also have historian facilities and there shall not be any storage
limit except hard disk size for retention period of various alarms/events.

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8.21 Complete system hardware shall be certified for ISA G3 class corrosion level
protection and shall be compatible with various RFI/EMI immunity as per IEC. The
complete system shall be supplied with either 1200 mm (W) x 800 mm (D) x 2200
mm (H) or standard RITTAL make panels with RAL7032 colour shade. Marshalling
philosophy and panel segregation for various type of I/O shall be as per HWB’s
requirement, which is described in tender.

8.22 Floating power supply 110 V AC +/- 10% at 50 Hz -3/+1 Hz, UPS grade, for
complete DCS system will be available at one location in cabinet room up to PDB
panels. All digital input shall have 24 V DC interrogation voltage level. All Analog
cards shall be capable of accepting 2 wire and 4 wire analog inputs and shall supply
24 V DC to field transmitters. All Digital output cards shall drive 24 V DC, Omron/
Phonix make, 4 NO/NC, socket mounted, interposing relays with 230 VAC/5 Amp
contact ratings. All field loads from Digital Output cards, including Solenoid valves,
MCC switch gear signals, etc. shall be interfaced via these interposing relays only.
The digital output cards driving the MCC related output relays (which are to be wired
to MCC/Sub station) shall be accommodated in Digital Interface panel, separately to
avoid any interference problems in low voltage instrument signal cables. There shall
be intrinsically safe active barriers of MTL3000 series / P&F make for analog inputs
& outputs, and all NAMUR sensors (proximity switches).

8.23 For various categories of I/O cards, 20% (minimum one set where 20% works out to
be less than one) of each type of spare I/O modules as ware house spares shall be
considered. These spare modules shall also include related termination assembly,
isolating barriers and all system pre-fab cables. For modules, (controllers,
communication modules, power supplies etc.) which are specified as redundant, 20%
ware house spares shall be considered or 1 pair of each type if 20% works out to be
less than one. However spare I/O cards required is elaborated at point no 9.5 and the
detailed requirement of number of AI,AO,DI,DO will be intimated during the
approval of DCS system.

8.24 The offered system shall be supported by the DCS EPC contractor for min. 15 years
for all type of hardware and software spares and service supports.

8.25 While preparing DCS database, all configuration like graphic symbols, colour codes,
control/logic schematics, etc. shall be based on ISA standards.

8.26 The DCS based system shall consist of dual redundant power supply cards for each
I/O rack as well as controller rack, dual redundant hot standby controller, dual
redundant hot standby communication at all level. The no. of all type cards required
shall be rounded off to next higher number. All communications like between
redundant CPUs, controller unit and I/O cards shall be through redundant high-speed
(not less than 12 mbps) highly deterministic communication protocol so as to achieve
scan times mentioned in this document. All stations namely Controller Stations,
Operator Stations, Engineering station, shall be connected through fiber optic based

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dual redundant (high-speed not less than 100 mbps) Industrial Ethernet protocol
communication. All field input / output signals will be hardwired to control stations
(via its I/O card). The human interface with the system shall be via Operator station,
engineering station and hardwired alarm. The function of Operator station shall be to
provide supervisory and control functions under password protection. The function of
engineering station shall be to enable Instrument Engineer to modify the existing or
add new control capability to suit the day-to-day operational requirements of the
complex.

8.26.1 The DCS shall provide process control and monitoring for the SPP. At the
process control level the DCS shall perform basic regulatory and sequential
control, process monitoring, alarm management, data archiving, reporting, etc..
8.26.2 The DCS shall function as a central information centre, controlling and
monitoring devices and equipment throughout the facility. The DCS shall
integrate and facilitate information gathering for package units.
8.26.3 The DCS shall be provided with redundant communication and processor
architecture to provide uninterrupted automatic control and increased reliability.
Communication between processors can be non-redundant.
8.26.4 There shall be sufficient spare capacity incorporated into the DCS such that
reasonable future expansion can take place without the need for additional
hardware.
8.26.5 DCS components shall be linked together via redundant separate data highways.
8.26.6 All electronic module/equipments should meet the environmental classification
class G3 as per ISA-S71.4.
8.26.7 Functionality: The DCS shall provide the primary operating window to the plant
and monitoring window in case of package unit control systems. Plant
monitoring and control for start-up, normal operation, and shutdown operations.
Functions as required for instrument set-up, diagnostics and testing for the DCS
and Alarm Systems.
Alarm Management, Logging and Trending in both real-time and historical.
The DCS shall provide reports to support operational, maintenance, and
management needs. These shall be available on demand or printed automatically
at specific intervals, all reports shall be logged and archived within the system
for future reference.
The DCS shall provide Historisation for the selected variables.
The DCS shall have ability to communicate with SMART field devices on 4-20
mA line.
One of operating workstation shall provide engineer level access to
configuration and programming functions of the DCS system with password
protection.

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8.26.8 Operator HMI and Engineering Interface

HMI’s displays shall include process graphics as well as standard displays such
as faceplates, groups, trends, loop details, and alarm summaries. Process
Graphics shall be so designed as to provide a unified view of the plant
irrespective of location or origin of signals.
DCS HMI’s shall consist of LED screens, keyboard, and cursor control device
(e.g. mouse/ trackball etc..).
HMI shall have access to printers for reporting and for printing screen
hardcopies.
One of the HMI (Operator console) shall have capability to act as workstations
for DCS under password protection. HMI in engineering mode shall provide for
diagnostics, configuration and software maintenance, addition/deletion of new
controls etc..
HMI shall have at least 3 levels of security access, typically Operator,
Supervisor and Engineer for example.
HMI system shall allow for the log-in of personnel to specific process units at
their appropriate access level, each level shall permit specific operations to be
carried out.
The operator will be able to interact with the process through several graphic
interfaces (detail displays, faceplates, group displays and custom displays). Data
entered by the operator will be subject to checks and only valid data will be
passed into the system to modify the process. Bad data entry will be indicated to
the operator.
The DCS shall allow on-line configuration changes, i.e. control processors stay
on-line during a download.
8.26.9 Process Alarms

 In general all alarm conditions, from DCS, other package shall annunciate
through the DCS.

 Provision of a separate hard wired alarm(16X3 window) and annunciator

system in operator console shall be provided. The function of this panel shall
be to provide facility of annunciation of few critical alarms including reset and
bypass facility. Similarly few critical pumps and valves shall also be started
and stopped from this auxiliary panel with help of self illuminated pushbuttons
any command from the panel will override in case both s/w as well as h/w
actuation is done simultaneously.

 There shall be a minimum of three levels of priority for alarms, e.g. Low,
High, and Emergency.
8.26.10 Control System interfaces: Communication interfaces from the DCS to other
control systems shall be through signal duplication and hardwire connectivity.

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8.26.11 Panel and housing

A. Local control panel ( if required to be supplied)
The panel shall be designed to withstand following environmental conditions
Ambient Temperature 5- 55 °
Relative humidity up to 95%
Internal wiring shall be solder less type i.e Wrap technology for cable
termination . It shall be either screwed terminals or maxitermi connection.
B. Enclosure/housing
Generally wall /Pedestal/ Colum mounted panels shall be provided if the panel
height does not exceed 1.2 mtr, If greater height is necessary , they shall be
designed for free standing floor mounting ,unless other wise specified in data
sheet.
C. Panel dimensions.
Panel height shall generally not exceed 2.2 mtr.
Panel shall be sheet steel enclosed and shall be dust, weather and vermin proof
providing a °ree of protection better than IP 52 for indoor use and IP 54 for
outdoor use. Sheet steel used shall be cold rolled and properly braced to
prevent wobbling. The sheet thickness shall be 3 mm for main body and 1,6
mm for doors.
The panels shall be provided with hinged doors wall / column mounted panels
shall have front doors and floor mounted shall have front and or rear doors.
All doors removable covers and plates shall be gasketed all around with
neoprene gaskets. All accessible live connections shall be shrouded and it
shall be possible to change individual fuses, switches MCBs, without danger
of contact with live metal.
Floor mounted panels shall be supplied with suitable base channels (ISMC)
with adequate number and sizes of holes for anchoring to the floor so as to
meet the seismic qualification. The necessary foundation bolts shall be also be
supplied. Wall / Column mounted panels, on the other hand shall also be
supplied with brackets / Channels for mounting on the wall / column.
D. The operator / engineering console
3 nos. of The Operator console & 1 no. of Engineering station shall be
provided as per the tentative dimension given in Annexure-II
The sheet thickness shall be 3 mm for main body and 1,6 mm for doors
fabricated out of CR sheet. The panels shall be provided with hinged doors
and floor mounted shall have front doors.
All doors removable covers and plates shall be gasketed all around with
neoprene gaskets. All accessible live connections shall be shrouded and it
shall be possible to change individual fuses, switches MCBs, without danger
of contact with live metal.

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Printers(one colour laser printer for printing document up to A3 size and one
laser (A4 size black & white) for alarm, log printing), and hardwire Alarm
system shall be located in the SPP control room. Provision shall be made in
the control system, so that in future SPP can be operated and controlled from
common control room which is located away from SPP control room.

8.26.12 Control and Automation System Architecture

The Control System Architecture contains the following three layers:

 Field Instrumentation System layer.

 Central Control Equipment (DCS) layer.

 Operating layer.
8.27 SPP plant shall be controlled by a dedicated Control system. The essential
components for safe operation of the plant shall be redundant.
8.28 The normal mode of operation shall be from the operator workstation in the SPP
Control Room.

9.0 DCS Specifications

9.1 DCS System Overview: Independent DCS shall be the Central Control system for
Control and Monitoring of SPP.Design, Engineering (including making logics and
control schemes as per owner’s drawings and incorporating the same in DCS),
Supply, Installation and commissioning of DCS System including operator consoles,
remote consoles, engineering workstation, printers as per details specifications.
Design, engineering, and incorporation of control schemes in DCS, Field instruments
as per List of Field Instruments and associated hardware.
Cables, Cable Trays, structural material for cable laying as per annexure. Respective
EPC contractors should visit site to assess material requirement. It is envisaged that
the cables will be laid on over ground.

9.2 DCS hardware

9.2.1 General
The DCS shall consist of following hardware as a minimum:

 Control and data acquisition modules.

 Process Input / Output modules (for all types of signals listed under I/O
counts).

 Communication interface modules between the DCS and HMI modules.

 Operator stations.

 Communication network.

 System cabinets.

 Marshalling/ Relay Cabinets.

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 Interconnecting cabling between various DCS equipment in the SPP Control

Room.

 Applicable Network Devices and Cables.

 Historian & Storage Devices.

 All peripherals of Workstations & PC.

 All panel internal hardware like terminal strips, fuses etc..

 Network laser Printer (one number) with colour and black & white print
facility. (for printing in pages upto A3 sizes).

 Network laser black & white printer (A4 size one number).

 Network Switches.
9.2.2 System Cabinet
DCS system cabinets shall be Rittal make, free standing type of dimension
( Approx) 800mm wide x 800mm deep x 2100mm high including 100mm plinth
with cable entries from the bottom. Lifting lugs shall be provided at the top of
the cabinets.
All free standing cabinets shall have only front and rear access with single leaf
hinged lift off door.
The system cabinets shall have an ingress protection of IP32 as a minimum.
The cabinet layout shall be such as to provide clear access to the internals for
maintenance.
Ventilation fans and louvers backed by dust filters shall be provided in each
cabinet.
Panel temperature monitoring shall be provided.
Each cabinet shall be provided with internal illumination activated by door
switch.
All electronic cards shall have unique serial number and node number (where
applicable) which shall be indicated on the hardware test report.
All unused card locations shall be fitted with cover plates.
20% wired spare I/O space on each I/O rack shall be provided in all DCS
system cabinets.
Cables entering the DCS system cabinets shall be properly clamped with armour
grounding.
Each DCS system cabinet shall have its own independent protection against
Radio Frequency Interference (RFI) with door open in accordance with IEC
61000-4.
The following shall be applicable to both System cabinets as well as
Marshalling cabinets:

 Equipment cabinets, consoles and termination cabinets will be installed within

Control Room.

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 Cable entry to cabinets will be from below via standard Rittal fixing/sealing
arrangement. All openings remaining after entry of all cables shall be sealed.
The seals shall be easily removable to enable entry of cables for future use.

 All cabinet colors shall be RAL 7035.

 The 110-VAC power distribution to I/O panels shall include a main circuit
breaker. Individual breakers shall be provided for the following circuits: 24-
VDC-power supply, rack power supply, output modules. Each output shall be
individually fused.

 Panel lighting and receptacles for maintenance shall be provided with 230
VAC, 50 Hz which shall be derived from UPS supply. Each panel shall be
provided with separate incoming breaker for 230VAC & 110VAC incoming
power isolation.

 Equipment and enclosures shall be constructed to withstand normal vibration

encountered in plant environments. The equipment shall not come loose or be
damaged in any way due to vibration. Anti-Vibration pad shall be provided.

 Cooling fans shall be provided wherever required. Cooling fan noise level
shall not be higher than 65 dBA measured at a distance of 1 meter from source
with cabinet doors closed. Filters associated with cooling mechanisms should
be readily and easily accessible and replaceable.

 Each DCS Controller and I/O panel with a power supply shall provide a high
temperature alarm, ventilation fan failure alarm.

 A common key shall be provided for all locks. No equipment / components

shall be mounted on doors of side panels.
9.2.3 Marshaling Cabinet
The marshaling cabinets shall be Rittal, free standing cabinets of dimension
1200mm wide x 800mm deep and 2100 mm high including a plinth of 100 mm.
The marshaling cabinets shall be a single cabinet construction divided into front
and rear sections. Separation shall be by means of two off gear plates. Front and
rear sections shall be referred to as discrete cabinet equipment numbers.
The marshaling cabinets shall be provided with front and rear access with
double leaf hinged lift off doors.
Cable entry to the marshaling cabinet shall be from the bottom. All cables shall
be clamped.
The field cables shall be terminated at knife edge terminals Klippon SAKR 2.5
or equal.
Terminals within cabinet shall be standard beige colour.
The system cables shall be plug in type and shall be terminated at sockets.
Conductor size of internal signal wiring shall be 1.0 sq. mm. minimum.

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Conductor shall be stranded type terminated with crimped wire lugs.

Earth bus bars (safety earth and instrument earth) shall be provided in the
marshalling cabinet.
Marshaling cabinet shall be provided with internal illumination activated by a
door switch.
9.2.4 Wiring
The colour coding of the cabinet signal and power supply wiring shall be as per
the following:
Power Distribution
110V AC (Live): Brown
110V AC (Neutral): Blue
24V DC (Positive): Red
24V DC (Negative) : Black

Signal : 24V DC (Analogue & Digital): Light Grey

Earthing : Instrument Earth: Green

Safety or Dirty Earth: Yellow with green strips

9.2.5 Power supply

Dual 110V, ±10%, 50 ± 3 Hz, single phase uninterrupted power supply (UPS)
feed point at SPP control room shall be provided. Feed to all DCS equipment via
Power Distribution Cabinet (PDC).
All power supply modules provided in the system equipment shall be fully
redundant.
The maximum static transfer time of UPS, which the DCS system should
tolerate is 40 to 50 ms.
Redundant 24 V DC power supplies for each DCS controller shall be supplied
and mounted with both continuously active. It shall be possible to remove one
power supply for maintenance without affecting the overall load requirements of
the system. The power supplies shall have separate circuit breaker protection
and isolation. For easy access and maintenance, DIN rail mounting provision for
Bulk Power Supply is preferred.
There shall be provision to power all field transmitters, analogue outputs, digital
inputs and digital outputs from the 24 VDC systems.
Appropriate alarms shall occur on any power supply failure.
The operator shall, by means of a system alarm, be informed of the failure and
switch-over of either power supply. No loop shall be lost by the failure of a
single power supply.

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Power supplies shall be equipped with internal short circuit protection and shall
have thermal overload self-resetting protection unit. Every power failure shall
generate a system alarm and have LED status indication integral with the unit.
Power supplies shall be mounted at the top of the racks.
9.2.6 Spare Philosophy and Spare Parts
Spare philosophy shall be as follows:
I/O level (Wired): 20% or rounded off to the next higher integer
Spare in rack space – I/O racks: 20% or rounded off to the next higher integer.
Marshaling rack: 20% or rounded off to the next higher integer
Mandatory spares: 10 % or rounded off to the next higher integer of each type of
non I/O module DCS card. 20 % or rounded off to the next higher integer of
each type of I/O module. Spare cores of all field cables minimum 10 % shall be
terminated in the marshaling cabinets. Commissioning spare parts shall not be
counted within spare philosophy and special tools (if any) shall be provided.
Availability of spares shall be guaranteed for at least 15 years from the date of
completion of the SAT.

9.3 Functional Requirement of DCS

General: The DCS system can be divided into following major sub-systems based
on functional distribution.

 Input / Output sub-system;

 Controller sub-system;

 Operator Workstation cum engineering station sub-system;

 Communication sub-system;
The functional requirements of these sub-systems are described in the following
sections.
A. Input/ Output Sub-system
The input/output sub-system shall consist of I/O modules located inside the
DCS system cabinets located in the SPP Control Room.
The input/output sub-system shall be microprocessor based and shall consist of
different modules for different types of input and output signals like analogue,
digital, contacts, etc. mixed type I/O module (i.e. input and output
functionality in single card or analogue type and digital type input output in
single card) is not considered.
The I/O modules shall be on-line replaceable with the system energized
without causing spurious effects on other modules in the system.

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The I/O modules shall be capable of accepting the following types of inputs
and outputs:

 Analogue inputs (4-20 mA DC);

 Digital inputs, potential free contacts;

 Analogue outputs (4-20 mA DC) ;

 Digital outputs;
The digital outputs activating relays shall have 24V DC power supply with
minimum contact rating of 1.0 amperes at 24V DC. The digital inputs shall
sense potential free contacts of field switches with 24V DC power supplied
from the DCS system.
Each input shall be provided with appropriate filters.
The analogue input cards shall provide 24 VDC power supply to field
transmitters. Each transmitter power supply shall be protected against short
circuit.
Isolators-barriers as per area classification shall be provided for Analog inputs/
outputs & Digital inputs whereas interposing relays shall be provided for
Digital outputs in addition to the built in isolation in cards.
Digital I/O shall be configured with dead band filters to prevent chattering.
The process input / output modules shall be capable of supporting process
signals from all types of process sensors and contact closure devices without
external or auxiliary signal conditioning devices.
Analogue to Digital conversion shall have:

 Resolution - 12 bits minimum

 Linearity - Least significant bit

 Repeatability - ½ least significant bit

 Accuracy - 0.1% of full scale

 CMRR - 120 dB from DC TO 60Hz

 NMRR - 60 dB at 50Hz

The system shall be able to detect erroneous measurements on both open

circuit, short circuit, and off limit values of input.
Digital to analogue conversion shall have:

 Resolution - 12 bits minimum

 Linearity - Least significant bit

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 Repeatability - ½ least significant bit

 Accuracy - 0.25 % of full scale

For inputs and outputs, which cannot be provided by means of standard input /
output cards, option shall be quoted (relay converters).
9.4 Input and Out put cards
9.4.1 Input card
Input card shall be intelligent one.
a. Digital Input cards shall be solid state input circuits rated for 24 V DC
operation.
b. Digital input card shall provide interrogation voltage to the input.
c. Types of Inputs: Digital and Analog inputs.
d. Separate card shall be provided for analog and digital inputs.
e. Filtering against contact bounces shall be minimum 10msec.
f. Galvanic isolation between DCS system and any other system shall be
provided.
g. Provision for online diagnostic testing of all input channels, but not be
limited to, namely Low and High current for analog inputs, rate of change
of analog signal etc. shall be provided.
h. On each input card LED indication for status of contact input channel,
status of analog channel and module fault annunciation shall be provided.
1) Input signal validation: The state of all inputs shall be specified under
various conditions, but not be limited to, such as when any hardware or
software failure occurs, any of the inputs are not valid or not available ,
input is not within specified limits, power failure occurs etc..
2) The input card shall perform all types of linearization viz. square root, as
per channel basis.
3) Channel to channel isolation shall be provided.
Digital Input cards shall have following features
a. These cards shall have channel LED for status indication.
b. All the digital inputs shall be potential free contacts.

i. Resolution & Accuracy: For Analog input cards A/D conversion resolution
and accuracy shall be as given below:
Type of input card A/D conversion Accuracy
Resolution

4-20 mA dc input card 16 bits or better 0.1% of full range or better

9.4.2 Output cards
Output card shall be intelligent

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a. Types of Outputs: Digital and Analog outputs.

b. Separate card shall be provided for analog and digital outputs.
c. Output relays shall preferably have minimum two changes over contacts
with RC arc quenching/diode contact protection.
d. Insulation resistance: 100 MΩ at 500 V DC between contacts to coil.
e. Dielectric strength of relay: 500 V AC RMS for 60 secs between contacts
to coil/body.
f. Provision for online diagnostic testing of all output channels. Low and High
current for analog outputs etc. shall be provided.
g. On each output card LED indication for each channel for output status
indication, module fault annunciation shall be provided.
h. The output fuse shall be with fuse failure indication.
i. All the output cards shall be able to give the output values from -5% to
+105% i.e. from 3.2 mA to 20.8 mA.
j. The output card shall perform output scaling, direct / reverse output. Output
signal validation:
k. The state of all outputs shall be specified under various conditions , but not
be limited to, such as when any hardware or software failure occurs, any of
the related inputs are not valid or not available, output is not within
specified limits, power failure occurs, AO’s shall be monitored for open
loop condition etc..
l. Digital Output cards shall have following features These cards shall have
channel LED for status indication. All digital outputs shall be potential free
contacts with contact rating 24V DC, 2A.
m.The output circuits shall be fitted with overload protection against inductive
loads, over currents and reverse polarity and short circuit.

9.5 Details of I/O requirement of DCS to be supplied

Control system I/O tentative count – below counts are only tentative, suppliers shall
provided required I/O count for completeness of the project as per specifications
mentioned earlier. This tentative I/O count does not include spare I/Os as per spare

I/O TYPE UNIT 43 UNIT 44 UNIT 45 UNIT 46 UNIT 49 TOTAL

AI 54 56 22 2 10 144
AO 09 13 10 0 0 32
DI 81 59 20 06 24 190
DO 50 41 14 06 26 137
RTD 28 16 6 50
TOTAL I/O CALCULATED 553
ADDITONAL 30% 166
TOTAL 719
TOTAL SYSTEM WITH CONFIGURABLE I/O REQUIRED 1000
( Total spare I/O’s with details AI,AO,DI,DO will be given latter)
philosophy

Wired spare rack capacity and loose spare shall be provided as mentioned earlier in this
document.

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9.6 Controller Sub-system

The Controller sub-systems shall consist of microprocessor based multi-loop
controllers, which will receive data from process through input / output subsystem,
execute control functions and send output signals to process via input / output sub-
system.
The controller sub-systems shall provide pre-programmed algorithms to achieve
various regulating control functions.
Controllers shall be able to operate in manual, auto, cascade or remote mode. Mode
changeover shall be bump less in either direction.
It shall be possible to change controller set points, tuning constants, operating mode
and controller configuration from the operator station through operator’s keyboard
and engineer’s keyboard.
The controller shall have facility for fast and slow ramping of set point and output.
The PID algorithm shall have integral wind up protection and initialization.
It shall be possible to reconfigure any particular control loop on line and without
disrupting any other control loop in the system. Remainder of the controllers,
including those executed in the same module, shall not be decommissioned by this
procedure.
The control module shall have logic functions based on logics, alarm states and
sequence control functions, which shall be used for inputting and outputting discrete
variables to and from the control modules. All these logic and sequence control
functions shall be configurable on line without disturbing the rest of the system.
The execution period for the control functions shall be within the limits specified. It
shall be possible to assign different execution periods to different control loops.
In cascade loops, the primary controller shall be able to track the set point of the
secondary controller when secondary controller is not operating in cascade mode.
The system shall be capable of implementing automatic sequence logic involving
control and monitoring functions during start-up and shutdown situations.
9.7 Controller Redundancy:
To ensure control strategy integrity, a reliable means of controller redundancy shall be
provided. Any active-controller failure shall cause the failed controller to switch over
to the redundant controller without upsetting the process or causing interruption or
loss of control, within minimum possible time viz., maximum twice the cycle. The
power supplies to controllers shall also be redundant. The controller redundancy shall
be 1 to 1. Redundant controller shall be in hot stand-by condition all the time.
Transfer to redundant controller shall be bumpless and shall not affect the prevailing
process condition.

9.8 Controller Security

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Security of control shall be ensured by providing internal, failure protection circuitry,

such that continuous uninterrupted control is ensured in the event of any controller or
communication failure.
Failure of any controller module shall cause an alarm to be generated on the
associated operators console and the failure shall be logged.
Loss of the active controller or, in case of application of redundant controllers, both
the active and redundant controller, shall cause system outputs to drive to pre defined
fail-safe condition. In addition, all alarms shall be generated on the associated
operator’s console and each alarm shall be logged.

9.9 Controller Configuration:

Configuration of the process controller shall be accomplished at the Engineer’s
console, using a “fill-in-the –blanks’, graphical, or conversational technique.
Configuration shall be in an on-line fashion and shall not require more than one
screen display for the configuration process.
It shall also be possible to update an individual loop configuration in the multiple loop
controllers, including the addition of functional elements, without disrupting the
normal operation of other loops resident in that controller.

9.10 System Security

System shall be protected from viruses, hackers and should not have any effect on
controllers and network loading.

9.11 Operator Workstation

The HMI shall be provided by Operator Work Stations (OWS) and operator cum
Engineering Work Station (EWS), which shall permit the operator to control and
monitor the plant normal operation as well as during start-up, shutdown and process
upset conditions.
The function of the Operation Workstation sub-system is to provide the following
information to the plant operator / engineer in a centralized manner:

 Display of all information related to open and closed loops of analogue and digital
process variables.

 Manipulation of control loops, e.g. changing set point, mode, configuration, output,
and tuning (with password protection).

 Display of alarms;

 Display of plant dynamic graphics;

 Logging and report generation;

 Trend recording;

 Providing self diagnostic messages.

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The DCS system Operator Workstations (OWS) and Operator cum engineering
Workstations (OWSs) shall be located in an air-conditioned SPP Control Room. For
switching to engineering mode from operator mode engineer password shall be
required.
It is envisaged that there will be two (02) DCS OWSs located in the SPP Control
Room. Each OWS shall be equipped complete with one (01) twenty-one inch (21”)
Flat screen LED Monitors each, to monitor and control the complete Plant facilities.
Out of two OWSs, one OWS can switch to engineering mode for programming in
HMI application package and logic application package.

9.12 Access Levels:

There shall be various access levels provided at the operator consoles with password
protection to ensure security of operation. Broadly each operator console shall have
three main categories of access level as described below:
a. OPERATOR: Lowest level, access to view and browse through all, able to
acknowledge alarms, set point of PID, but will not have the authority to tune loops
and change alarms limits.
b. PROCESS ENGINEER: As OPERATOR level but with additional rights to change
set point of alarm and by-pass of alarm.
c. INSTRUMENT ENGINEER: Apart from all the rights of process engineer, shall
have rights to do logic and HMI programming.
Each DCS OWS shall have the capability of printing the information displayed on the
screen.
9.13 Workstation Hardware: Each of the DCS OWS and OWS cum engineering station
shall consist of the following hardware:
a. Industrial grade PCs with Core i5 or latest processor and Windows XP Professional
operating system or any suitable windows series OS.
b. Two high resolution 21” Flat screen LED Monitors.
c. Operators’ keyboard & mouse .
d. One hard disc drive of 250 GB minimum.
e. DVD R/W / CD R/W drive 52X.
f. Dual power supply.
g. Dual redundant network interface card.
9.14 Workstation Software: The DCS EWS shall incorporate configuration softwares,
which shall be Windows based supporting drag and drop configuration. Standard user
definable templates shall be supported to allow for rapid application development.
The engineering configuration software shall support on-line monitoring of control
loops. On-line changes of control parameters, as well as creation, loading, activation,
deactivation and deletion of control strategies shall be possible. Existing control loops

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and I/O modules shall continue to operate while configuration changes are being
made. Access to the DCS EWS shall be controlled by password protection. The
control strategies built in the DCS EWS shall be capable of being directly loaded into
the system. Also following software shall be loaded as required:
9.15 Electronic documentation facility shall be available in EWS. Electronic
documentation shall be provided for the following:

 System documents e.g. Functional Design Specification, Software Design

Specification, Loop schematics, drawings etc..

 System hardware & software Manuals for operations and maintenance.

 Input data like P&IDs, Cause & Effect diagram, I/O schedules and descriptions,
process functional descriptions, sequence and logic diagrams, etc..

 Useful technical data for operation & maintenance.

All Operator and Engineering Work Stations shall have the same database and
displays.
All real time clocks of the system shall be synchronized with only one clock in the
network.
Colour capability of LED shall be 256 colour / True colours.
Each point in the system shall be designated by a tag number consisting of minimum
twelve alpha-numeric characters.

9.16 Operator Keyboards and optical mouse

The operator and process engineering shall be able to take following actions and any
other actions as per access rights through the keyboard and mouse:

 Calling up of all displays

 Acknowledgement of alarms

 Changing parameters

 Control of cursor

 Initiating printouts of logs, alarm history, event history

 Changing of controller mode

Alarms shall be defined according to three levels of priority.

 First Level - High Priority

 Second Level - Normal Priority

 Third Level - Low Priority

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The DCS shall have an audible alarm. High Priority and equipment protection related
alarms shall be configured for first out and subsequent alarm sequencing.
The DCS EWS keyboard and optical mouse shall enable the Instrument engineer to
take the followings actions and programming of the system through the keyboard and
mouse:

 Changing data base configuration.

 Inhibiting alarms during plant maintenance.

 Changing of alarm settings.

 Changing of tuning constants.

 Changing of displays.

 Changing of clock settings.

9.17 Screen Displays: The following displays shall be provided as a minimum on the DCS
Operator Work Stations.
The following capabilities shall be available as a minimum:

 The user shall be capable of building a library of shapes for use in configuring
displays. All shapes shall be capable of being rotated and scaled.

 An operator control function will require at least two (2) steps (i.e., no single
operator action shall initiate a control change). Access to specify displays and pick
points is restricted by password.

 Key-lock or password protection shall be provided to allow features such as loop

tuning to be performed by only authorized personnel.

 The capability shall exist at the Engineer’s Console to configure, upload and
download (to a hard disk, floppy/CD/DVD or other removable storage media)
configurations of database, control and graphic displays.

 Graphic displays shall be stored in each Operator Console in hard disk. Each
Operator Console shall have its own dedicated memory, as opposed to a central
storage area for graphic displays.

 Display data (including alarms) shall be updated at least at one second intervals. The
DCS EPC contractor shall guarantee that no value or status on any display shall be
more than one second old regardless of its origin in the DCS.

 A display hierarchy can be built by allowing the user to target points, page up, down,
left, and right as well as recall the last display.

 Each Operator Console shall be able to access all historical trend data for all tags in
the system.
The following cursor control devices shall be available; keyboard and mouse .

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The status of the process shall be presented on the following displays:

a. Overview Display
The overview display shall enable operator to have overall information of the
process and shall consist of a single page display which will be divided into a
number of groups.
Each group shall consist of a number of instrument tags. Information related to
analogue inputs shall be represented by deviation bars with alarm limits.
Information related to discrete inputs shall be shown with tag numbers.
Any tag number on the overview display, which is alarm shall be identified by
flashing or any colour change. The operator shall be capable of directly calling up
the group display, corresponding to a tag number, which is in alarm, from the
overview display by a single click of mouse.
Overview display shall incorporate a minimum of 128 analogue or discrete inputs
which can be monitored simultaneously on the screen (referred as page).
All analog points in overview display shall be represented as variable lengths
indicating deviation above or below the normal operating value or set point.
It shall not be possible to acknowledge alarms directly from the overview display.

b. Group (Faceplate) Display

Each Group Display shall show a limited number of points, i.e. analogue or
digital inputs or outputs. The groups shall be the same as displayed in the
overview display. The number of points in a group shall be at least 6 and up to 8
loops of analogue control, digital control or indicator loops. The loops will be
grouped by related operation. For example, in a cascade control loop, the primary
and secondary controllers will both appear on the same group display. Any
system point can be configured in any group and displayed in as many groups as
desired. There shall be no limit on the number of group displays available at a
particular Operator Console.
Each point in the group shall be displayed as an instrument face plate with bar
graph display. The number of bar graphs per point shall be based on the function
of the point i.e. control or data acquisition. Instrument tag number, description,
alarm status controller mode, engineering units and digital values of process
variable and set points in engineering units shall be displayed. The control valve
failure position shall be incorporated in the bar graph display. The bar graph
display of output signal shall always move upwards when the valve opens. The
discrete input/output shall be represented by on/off software lamps and
alphanumeric description of status. It shall be possible to assign a particular point
to more than one group with control being possible from only one group.
Group displays will be called up from the associated Process Graphic displays.
The group display catalogue will also permit call up of individual group displays.
At the Group Display, the Operator shall be able to perform the following:

 View a bar indication of controller process variable, set point and output.

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 Select a control loop or device for control action.

 Change the mode of the control loop selected (manual/auto mode, remote/local
selection).

 Change the set point of a loop while in automatic.

 Alarm acknowledges, toggle value, ramp value, direct entry of value.

 Change the output of a controller while in manual.

 Issue commands to Start/Stop Motors increment/decrement VFD speed and

heater power or Open/Close valves.

c. Point Display
The point display shall provide a separate detailed display for each of the points
in the system. The display shall depict the face plate and all other information
displayed for that point in the group display including the associated trend of that
single point. These displays shall be automatically available for all points/tags
without the requirement for configuration. The display shall allow the user to
view on-line a control strategy in the same format in which it has been
configured.
Additionally, the following shall also be included in the point display:

 Tuning constants for controller.

 All configuration parameters of the point e.g. process variable zero and span
values, alarm limits, rate of change of parameter alarm, set point limits,
controller action, computational constants, etc.. The engineer actions shall be
under a password to prevent unauthorized changes to these vital parameters.

 Alarm settings displayed on the edge of the trend grid.

 Loop Scan rates and phase.

 All operator adjustment modes such as set point, manual/auto mode,

remote/local selection.

 A high resolution (1 second) trend display with a time base of 60 seconds which
will be used for tuning of control loop.

 A fast trend (5-10 minutes) consisting of a minimum of 300 data samples for the
loops measured variable, set point and output. Loop trends shall have dynamic
range scaling.
d. Trend Display: The trend display shall present the data in the format of a strip
chart on the screen. The Trend Display shall allow the user to interact with up to
8 control loops or devices via a multi-line display. This display shall include all
the capabilities of the Group Display with the exception of bar indication of
variables.
The trend display shall consist of two types:

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 Real time trend

 Historical trend
The real time trend package shall be capable of storing and displaying real time
data for at least 100 variables with a time base of 30 minutes and sampling rates
of 2 to 10 seconds.
It shall be possible to assign any tag number including package unit tags numbers
to real time trend.
The historical trend package shall be capable of collecting 200 to 100,000 trend
points at selectable sample rates of 2, 5, 10, 20, 30, seconds, 1, 2, 5 and 10
minutes. It shall be possible to assign any variable like process variable, set point,
output, etc.., to real time or historical trending. It shall be possible to trend either
instantaneous or average date for a particular variable. It shall be possible to store
all analogue parameters including those received from package units.
All trend data shall be stored on non-volatile memory (hard disk) of the system so
that the trend data can be archived and subsequently recalled. The selection of
trend tag number and time base shall be possible from the operator’s keyboard.
The detail trend display shall contain the information on tag number, engineering
unit, span, present value of the point being trended, alarm status, etc..
Capability shall exist to save and play back historical trends by means of
removable storage media.
By selection with the cursor or numeric entry of time and date, the operator shall
have the capability of retrieving a “snapshot” of the process variable or status in
direct digital value. Scrolling of the trend shall be possible.
A minimum of 90 days limited to 50% of the hard disk capacity whichever is less,
shall be available and there shall be provision to back-up it on High density media
device.

e. Graphic Display
The trend display shall present the data in the format of a strip chart on the screen.
The Trend Display shall allow the user to interact with up to 8 control loops or
devices via a multi-line display. This display shall include all the capabilities of
the Group Display with the exception of bar indication of variables.
The graphic display shall be multi-page display with each page providing a flow
diagram of a certain section of the plant in a dynamic fashion. It shall show the tag
numbers of important analogue / digital variables at their respective locations on
the process and shall display their dynamic behavior through instantaneous values,
alarm status, control modes, etc.. Position of control valves and pump running
status shall also be shown. Operator shall be able to control the process from
graphics display in a similar fashion as the group or point displays.
Full Custom Graphic Display capability shall exist such that the user can combine
shapes, text, and process variables to mimic the actual process based upon the
P&ID’s. The graphic display shall support dynamic display symbols, dynamic

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values, control targets, page link targets and dynamic bars. The display symbols
shall be capable of changing to reflect process data status as follows:

 Colour change (colour of the display element changes)

 Display blinking (displayed image blinks) or any other kind of highlighting

 Reverse video (character string data appears in reverse video)

 Text character string change (e.g., NORMAL message is substituted by

WARNING message)

 Dynamic display functions shall be used for depicting level changes in vessels
etc..
The graphic displays shall be capable of being configured from engineer’s
keyboard by using standard graphic symbols of process equipment and valves to
be available in graphic symbols library, which will be part of graphic building
software. It shall also be possible to develop user defined symbols in the graphics.
The graphic building software shall be user friendly and interactive. It shall allow
building graphic displays at a central location and download files to individual
operator consoles.
The graphic building software shall have the ability to setup a graphic display
hierarchy for navigating efficiently through the process.
The graphic display shall have a minimum of 256 colours / True colour
capability.
The console subsystem shall have a facility of viewing multiple windows on one
screen enabling the operator to conveniently access and control all the necessary
factors at the same time.
The plant graphics shall consist of the following types and overall content;

 Loop display;

 Plant profile;

 System alarm / status displays;

 Tabular listing (data matrix) displays;

 Plant sequence displays (operator guidance).

f. Alarm Display
All alarms generated shall be displayed on operator’s console by a flashing
symbols and/or distinctive colours to attract Operator’s attention to colour change
and audio signal. The audible alarm signal shall have multiple different tones to
distinguish between alarms of different priorities. Irrespective of the current
display, this initial advice of an alarm shall be displayed on the screen, with a

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screen display banner to indicate the group or area in which the alarm has
occurred.
All alarms shall latch until acknowledged individually by the operator, after
which they will change to “steady mode" until the alarm condition no longer
exists. It shall be ensured that any keystroke to acknowledge or clear an alarm is
only associated with a single alarm (e.g. do not have a repeat key facility on
alarm acknowledgement.
Each type of alarm, whether acknowledged or unacknowledged, shall be listed in
the alarm summary. Removal of the alarm from the system shall take place
automatically after it has been acknowledged and has returned to normal status.
However the operator shall be able to access history of cleared alarms.
The system must alert the operator to each alarm regardless of the current display
on the screen. The operator shall be able to call up the relevant display with
maximum two key strokes.
An area on the screen shall allow for display of alarms when the alarm is not
displayed.
It shall be possible to assign different priorities e.g. high, normal, low etc.., to
individual alarm points. Alarms shall be prioritized to allow the operator to make
judgments about relative importance of alarms. The operator shall have the
capability to segregate alarms by process area at each operator workstation.
Separate priorities shall be available for each value’s high-high, high, low, low-
low and rate of change of process parameter alarm. A minimum of three alarm
priorities shall be available. Alarm priority display shall be colour segregated,
with a separate colour for each alarm level.
The system shall provide a current alarm summary and a historical alarm
summary, which may be displayed and printed by the operator.
The current alarm summary shall contain a minimum of 500 most recent alarms
in order of appearance. Alarms shall be acknowledged on a page at which the
alarm appears.
The resolution of alarms shall be at least 2 second.
The historical alarm summary shall contain minimum 5000 alarms. This
summary shall be updated on FIFO basis.
It shall be possible to suppress alarms on a group basis or on an individual basis.
The system shall allow alarms to be suppressed and unsuppressed automatically
by applying specific rules.
The system diagnostic alarms shall be displayed to the operator irrespective of the
display on the screen and will help pinpoint fault in any sub-system to the I/O
level.
The alarm displays shall list the following for each alarm as a minimum:
1. The date and time of occurrence.

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2. Point identification (i.e. tag number).

3. Point description.
4. Type of Alarm.
5. Serial number of alarm in the sequence of its occurrence.
6. Time of acknowledgement of alarm
7. Time of alarm going to normal.
Alarm checks shall be made at each scan by the system.
It shall be possible to suppress alarms on a point-to-point basis from selected
operator stations at the appropriate location.

9.18 DCS Communication Sub-System

The DCS communication sub-systems shall consist of two separate networks, namely,
DCS control network, communications at the controller level and the TCP / IP
network or equivalent at Operating System level.
9.18.1 DCS Control Network
The control network shall be dedicated to the DCS. The control network shall be
high performance type with the following characteristics:
a) Redundant.
b) Speed shall be suitable to the cycle time defined elsewhere in the system.
c) Network shall be deterministic type.
d) Network traffic shall not affect controller performance.
9.18.2 System Communication Network:
The communication system shall be based on a dual redundant network. Each
device on the network shall be supplied with a redundant communication
interface.
The redundancy in communication network shall be active in nature, i.e. both
the buses shall be active
n case of failure of one of the buses, the other bus shall take over automatically
without any interruption to the process with a diagnostic alarm informing the
operator of the failed bus. Network failures shall never result in any disturbance
to process control.
The communication protocol shall be such as to ensure that the communication
is not disrupted in case a particular device on the bus fails to respond.

9.19 Serial Interface Sub-system

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The system model offered shall have range of modules to interface third party system
via Modbus/ Profibus etc. for bi-direction communication. In present scope of work
these modules shall not be offered in the bid.

9.20 Control Software Requirement

The software control languages shall demonstrate a high level of integration by
providing the ability to perform data reads and writes to each other.
It shall be possible to execute programs in high level languages, from any of the
workstations.

9.21 Configurable Block Structured Language

The primary means of process control and monitoring shall be accomplished via a
predefined set of block-structured algorithms which can be chained together to form
various configurations of control, calculation, and loops.
The configurable block structured software shall support a full range of functions
including but not limited to:
a) Input (analogue, digital, pulsed input, pulse input time derivative, etc.)
b) Output (analogue, digital, pulse train, pulse duration, etc.)
c) Calculation (linearization, compensation, filtering, square root, logic, rate of
change etc.)
d) Controller (P, PI, PID, Discrete Devices, etc..)
e) Extended processing (standard deviation, periodic total, max, min, avg., etc.)
f) User defined algorithms.
g) The standard controller algorithm shall include provision for bumpless mode
transfers, anti-reset windup, and tracking functions.
h) The configurable block structured software shall provide a means of establishing a
unique I/O name and descriptor for a collection of algorithms which form a
control, indicating, or calculation loop. Once defined, the I/O name shall be
available for use system wide by all system application software packages without
the requirement for knowing its physical address or location.
i) The configurable block structured software shall include provisions for setting the
execution rate (scan) and phase individually for each loop to allow processor load
distribution. It shall be possible to execute loops of different scan rates within the
same Controller CPU.
j) The configurable block structured software shall be configurable by means of fill
in the blank menus or other user friendly approach that allows the user to easily
create and modify control strategies by merely software linking the predefined
algorithm blocks.

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k) Provision shall be included for adding user defined ‘custom’ algorithms to the
standard predefined set of algorithms for cases where standard algorithms do not
meet the project requirements.
l) Algorithms for device control shall be provided to handle a wide variety of devices
requiring multiple input/output channels and states.

9.22 Programming Language

A high level programming language directed to process control shall be provided to
perform control, calculating and supervisory functions. The programming language
shall support a protective environment to provide safety from disturbing crucial
parameters or system code. The programming language shall have the ability to be
executed in the Controller.
The programming language shall have free format capability so the user need not be
concerned with text position or line numbering. The programming language shall use
high level commands (keywords) and easy to read English-like code. The
programming language shall have provision for performing read/write functions
directly to any configurable block structured software loop by I/O name and
descriptor without regard to the physical address. Program variables shall consist of
user defined English syntax words.
The programming language shall have a hierarchical structure and full provision for
scheduling, parallel task execution, emergency handling, event detection, and
program execution priority setting. The programming language shall also have
intrinsic math functions and logical and relational operators.
The generation and editing of the programming language program source code shall
be performed on the DCS EWS.
9.22.1 Boolean (Function Block) Logic Language
Boolean logic programming language shall be provided with the system.
Boolean logic shall be executable in the Controller CPU.
Boolean logic element data shall be accessible from the other control languages.
System utilities shall be provided to allow Boolean logic program source code
print out, I/O cross-reference printout, and program back up.

9.23 Historical Data, Reports and Logs

A report generator shall be supplied to build and change reports. Reporting function
shall be initiated by a control program, by operator demand or on schedule.
All points in the system shall be capable of being logged.
The standard logs shall mainly consist of alarm summary and event summary reports
to be printed out at the end of each shift.
Alarm summary report shall be printed out of the historical alarm summary at the end
of each shift.

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The event summary report shall consist of the operator actions like auto / manual
changeover manual overrides, resets, etc..
A daily report shall be provided to log the important process parameters. The report
shall be printed at 12 hourly intervals.
It shall be possible for the operator to modify / update certain fields in a report prior to
printing.
It should be possible to retrieve this data and be able to manipulate it to produce
displays and reports.
Alarm and return to normal shall be printed as they occur. Alarm message shall
contain time, tag number, service description, process data and the type of alarm.
Operator actions i.e. set point change, auto/manual changeover etc.., shall be logged
as they occur.
Alarms associated with DCS equipment shall be logged as they occur.
Alarm Time stamping shall be carried out at Server level with one second resolution.
All alarms and operator actions printed in the log report shall have date and time
printed alongside the action.

9.24 Diagnostics
The DCS shall have extensive off-line and on-line diagnostics. The self-diagnostics
shall detect the following minimum faults.
a) Data highways and communication lines.
b) Power supplies.
c) All cards (I/O, controllers, CPU, etc.).
d) Other peripheral cards.
Wherever fault tolerant/redundant paired equipment is provided, the equipment shall
continue functioning in case of failure of one of the pair.
The diagnostic alarm message for any failure shall appear on the operator’s work
station.
It shall be possible to get accurate and detailed diagnostic information through system
status displays which can be called from operator’s keyboard.
The self-diagnostic software shall be capable of detecting and reporting fault up to
card level.
The operator stations shall have the same capability in respect of displaying
diagnostic messages.
In addition to the above, all modules shall be provided with diagnostic LEDs to
indicate their status at a local level.

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The off-line diagnostic programs shall consist of a library of programs used to verify
operation of a device or to aid in the troubleshooting of a device.
Off-line diagnostics shall be provided for every device in the system.

9.25 Self-diagnostics features and display page

All types of required self-diagnostic features, (that include but not be limited
to I/O Diagnostics, CPU Diagnostics, Power distribution Diagnostics,
Communication Diagnostics, Processor Diagnostics, DCS cabinet Air
Conditioning failure alarm by sensing cabinet temperature etc.), to detect all
possible faults ( such as but not be limited to hardware/software faults,
diagnostic on system start up, diagnostic during run time and identification of
failed system components etc.) shall be available in system.
The system diagnostic shall perform automatically. When the DCS/ detects a
system error (for example, a watchdog being exceeded, an input/output error,
division by zero, etc..), information will be sent to the diagnostic viewer. The
diagnostic viewer will display a system error message As with the project
diagnostic, the information viewed on the Viewer comes from the DCS/'s
diagnostic buffer, consequently the events shall be dated at the source and give
the precise status of the process monitored.
The system must be able to perform self-diagnostic and report any problems to
the operator console. In addition to that display page shall be available
connecting to system bits generated for fault such as Self-diagnostics, Auto
Scan, and Monitoring system. The display page shall contain following
minimum display.
1. Display of different scan time taken by the system.
2. Arithmetic overflow.
3. Network diagnostics with network loading display and network break.
4. I/O module error display page error.
5. External fault or counting input fault:
6. Line break or short circuit
7. Incorrect constant
8. Bit combination not associated with any configuration
9. Error in the components
10. System fault used in debugging
11. Invalid command ID
12. Command not implemented yet
13. Drive has detected communications fault
14. Hardware end of travel fault
15. Input/output error
16. Watchdog overflow
17. Watchdog duration
18. Character string fault
19. Task period overrun
20. Index overflow
21. Saturation in event processing
22. Time loss in real time clock
23. State of the PCMCIA application memory card battery
24. State of processor battery
25. Diagnostic buffer full

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26. General Fipio I/O fault

27. General in-rack I/O fault
28. Diagnostic function: save
29. Diagnostic function: de-registration
30. Diagnostic function: number of errors
31. Fipio bus arbiter function display
32. List of Fipio channel manager faults
9.26 Controller Tuning display
Each loop controller shall have a trending display for tuning. This tuning display shall
show the loop controller tuning values and include the capability to change the loop
controller tuning values while trending. Different colours shall be used for each
parameter trended. The minimum controller parameters trended shall be:
 Set point
 Process variable
 Controller output signal
Trending intervals shall be user selectable between 0.25 second to 5 seconds. The
overall trend display must show as a minimum between 1 minute and 20 minutes of
trending per the following table:

Sample Interval Maximum Duration of Screen Trend

0.25 seconds (4 times per second) 1 minute
0.5 seconds (2 times per second) 2 minute
1 second (1 time per second) 4 minute
2 seconds (0.5 times per second) 8 minute
5 seconds (0.2 times per second) 20 minute
The DCS shall have a historical data base which can be accessed for trending, report
generation, alarm history retrieval and event history retrieval to both printer and
screen. All alarms, trends and events shall be historised.
It shall be possible to configure the database through the EWS.
The history data base shall also store hourly, shift, daily, weekly, and monthly
averages for logging purposes.
The DCS shall have a history database to satisfy reports and trending requirements,
preferably RDBMS.
Trends shall be available on OWSs.
The DCS shall have the capability of archiving to removable storage media and shall
be capable of retrieving back the stored data in the same formats e.g. trends, reports
etc.
History stations shall be sized on the basis of 5% analogue inputs being trended at one
(1) second, 15% of the analogue inputs being trended at six (6) seconds and remainder
(80%) is being trended at one (1) minute intervals for 30 days without any backups as
a minimum. The sizing shall include 20% extra capacity at 70% loading of Historians
which shall be dual redundant (mirror image).

9.27 System Performance

Redundancy: The following parts of the system shall be redundant:

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a) Controller subsystem 1:1

b) Communication Subsystem 1:1(communication between controllers may non
redundant)
c) Power supply 1:1
d) Interfaces 1:1
Externally Engineered I/O Redundancy not Acceptable. Field devices should have
single termination point up to the Dual I/O modules wherever redundancy is required.

9.28 System Loading

The loading refers to the use of memory, CPU time and communication capacity. The
loading shall consider worst case system activity.
The maximum loading allowed are as follows:
a) Control processor : 60%
b) History data base : 50%
c) Network Loading : 50%
9.29 System Response Time
9.29.1. Controller Scan Time / Controller Response Time
The Control system shall be able to read inputs, perform control algorithm,
calculation function etc. and update controller output for each loop within the
scan time as defined below:

Process Category Maximum Control Response time

Flow, Pressure, Differential pressure 500 millisecond
Temperature, Level 500 millisecond
All other (Analysis, Density, pH, etc..) 500 millisecond
Digital inputs and outputs for interlock 300 millisecond

9.29.2. Alarm Response: Within 1 or 2 seconds after a new alarm has occurred, the
system shall annunciate the alarm and have the alarm ready for display.
9.29.3 Command Action Response: Command from the operator shall result in an
output to the control device within 2 seconds following the command to
execute.
9.29.4 Display Call-up time: This is time that elapses between operator’s command
and appearance of the display on the screen. This time shall not exceed 2 to 3
seconds including graphic display.
The LED update time requirements are as follows:
New screen call-up time - 2 secs.
Screen updates time – 1 to 2 secs. (Refreshment of process data on a display
screen)
9.29.5 Display Refresh Rate: This is the rate at which the value of a particular input to
the system gets updated on the display of the screen. This rate shall not exceed 2
seconds.

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FIELD
INSTRUMENTS

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 Chapter-9 Technical specification

10.0 Design basis for field instruments

10.1 Scope
This specification gives directives for the basic design criteria for instrumentation in
general. The specific design requirements for each type of instrument or instrument
system are covered by the individual specification of that particular item/category.
Any conflict between the requirements of this specification and related codes,
standards, data sheets, drawings, requisition, etc.., shall be referred to the HWB for
clarification. HWB’s approved EPC contractor list shall be followed strictly for
procurement of various instruments.
The contractor shall supply the field instrument and spare instrument as per Section 4.

10.2 Units of Measurement

The following practical units of measurement shall be applied:

Acceleration m/s2
Analysis % or ppm or ppb
Conductivity µS/cm
Current mA, A
Density Kg/m3, gm/cc
Displacement M
Flow, Liquid (by Volume) m3/hr
Flow, Liquid (by weight) Kg/hr
Frequency Hz
Gas and vapors (by volume) Nm3/hr
Gas and vapors (by weight) Kg/hr
Heat Kcal
Length m or mm
Level (relative) %
Mass Flow Kg/hr, t/hr
Mass Kg, t
Molecular Weight MW
Power kW
Pressure (vacuum) mm Hg
Pressure mmWC, Kg/cm2 g, Kg/cm2 a
Speed (Linear) m/s,
Speed (Rotation) °ree/s, radian/s, rpm
Steam Kg/hr, t/hr
0
Temperature C
Time sec, hr
Vibration µm
Viscosity Cp
Volume Flow m3/hr, Nm3/hr
Volume m3
Voltage V

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10.3 Basic Design Criteria

10.3.1 Measurement and Control:
a. All field transmitter shall be intrinsically safe EExia IICT4, 2 wire, 24 V DC,
SMART with HART protocol and with local LCD type display.
b. All Switch function shall be snap acting, Dual-pole Double Throw (DPDT),
hermetically sealed and potential-free contacts.
Minimum contact rating for disconnecting inductive loads shall be:
1.0A for 24-48 V DC
0.4A for 110-125 V DC
5.0A for 60-260 V AC
c. In general Transmitters shall be utilized for trip functions.
d. Instrument ranges for trip functions and control functions in the same service
shall be equal.
e. All field instruments, junction boxes, cabinets, panels etc.. shall be provided
screwed SS tag plate with tag no. engraved or embossed on it.
f. All intermediate fittings shall be double compression, SS316 MOC, Swagelok
make only.
g. Standardization features shall be taken care of during design and packages
for junction boxes, instrument air headers, instrument fittings, and other
erection hardware like cable duct, cable trays, etc.. like cable duct, cable
trays, etc..

10.3.2 Signal Types & Transmission

a. Electric Signals: Electric signal transmission shall be applied in conjunction
electronic/digital control systems. In general the loop power will be supplied
by the systems.
b. Analog Signals with standard 4 – 20 mA DC signals (24 V DC, two wire
system) shall be applied as measuring inputs and controller outputs.
c. Proximity signals shall be 2 wire NAMUR sensors as per EN
60947(NAMUR).
d. Digital signals may be applied as potential-free inputs: The standard signals
for transmitting measuring and control shall be a current of 4 to 20 mA. DC,
superimposed with digital communication protocol (HART). All interlock
shall also be realized from 4-20 ma analog input transmitters and digital
inputs through switch contacts in the ESD.
10.3.3 Field instrumentation
a. Field instrument connections shall be as follows.
b. Flanged instrument connections shall be in accordance with ASME B16.5.
Flange surface finish shall be as per relevant piping specification and in
accordance with ASME B46.1.
c. Cable gland connections to be M20 x 1.5mm as a minimum in accordance
with EN 60423.

d. Standard instrument connection shall be ½” NPT female.

e. Pressure/compound Gauges/ Pressure Transmitter/ Pirani gauge
The selection criteria for Pressure/compound gauge shall be the following:

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 Pressure element type shall be bourdon.

 Pressure element material shall be SS 316.

 Socket material shall be SS 316.

 The pressure gauge shall be diaphragm seal type with wetted material lined
with PTFE when SS316 is not compatible with process fluid being handled.

 Dial size of gauge shall be 150 mm.

 In application where vibrations are anticipated gauges shall have flexible

connections to mount remotely.

 Gauges shall be provide over range limit of 130%.

 The seal protects the gauge by placing a diaphragm between the process and
the gauge. The cavity between the gauge and the diaphragm is filled with a
stable, low thermal expansion, low viscosity and non-corrosive fluid.
The selection criteria for Pressure transmitter shall be the following:-

 All pressure transmitter shall be provided with local indication and wetted
MOC compatible with process fluid. Turn ration shall be 100:1. Instrument
shall be 2-wire system.

 Pirani gauge shall be used for vacuum measurement. The transmitter shall be
capable of measuring vacuum up to 0.001 torr. Transmitter shall be provided
with local indication in engineering unit apart from 4-20 mA transmission to
control system.
f. Flow/Mass transmitter with totalizer : Following are the considerations
for Flow measurement.
All Flow/Mass transmitter shall be provided with local indication and 4-20
mA o/p for control room indication for instantaneous indication as well as
totalizer wherever applicable.

 Orifice type flow transmitter/vortex type mass flow meter shall be used for
steam application. It shall also be ensured that at maximum flow with beta
ratio between 0.3 to 0.7 delta P is 2500 mm WC, and this pressure drop
does not affect process. This type of instrument shall be only used where
density of fluid remains constant.

 Variable area type flow meter with totalizer (local display of flow rate and
totalized flow, reset facility for totalizer reset shall be locally available) shall
be used where rangebility requirement is in the ratio of 10:1. Wetted MOC
of SS316/PTFE lined SS 316/304 shall be used as per compatibility of the
process fluid. This type of instrument shall be only used where density of
fluid remains constant.

 Coriolis mass flow transmitter shall be used in the application where

accurate accounting of process fluid is to done for ensure exact quantity of

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reactant in the reactor. MOC of the instrument shall be Hastelloy-C or

suitable to the process fluid. Instrument shall be provided with totalizer
facility with local display of mass flow and totalized mass flow, reset facility
for totalizer shall be locally available. Provision shall be provided for using
single instrument for measurement of different fluids with different specific
gravity, and temperature.

g. Level transmitter/gauge/switch
For continuous level measurement in reactor vessel Guided Wave radar with
stilling well shall be used. MOC of the guided rod shall be SS316 with
PTFE coated.
For continuous level measurement in other vessel where there is no boiling
of process fluid is taking place unguided radar type or ultrasonic type can be
used.
Level gauges shall be magnetic coupled float type with rotocyl/bicolour
flapper indicator. MOC of the wetted part shall be compatible with
process/utility fluid being handled. All the level gauges shall be provided
with two numbers of level switches adjustable throughout the range.
All the level transmitter shall be provided with local indication also apart
from remote transmission.

h. Temperature transmitter/temperature gauge

 Temperature element shall be 3 wires duplex RTD (Pt-100 type), MgO

insulated, SS 304 sheathed. Element shall be vibration proof for 1 g. RTD
shall be of tolerance class A. Temperature Transmitter shall head mounted
on RTD for giving 4-20 mA. RTDs for temperature measurement of flush
bottom shall be of flexible type of appropriate length. Temperature
transmitter shall be 2 wire system.

 The thermo well (up to 4” insertion length) shall be drilled from bar stock,
tapered type with thermo well material as SS316 or Hastelloy C as per
process compatibility. Above 4” size thermo well can be fabricated from
pipe of appropriate schedule of SS 316 or Hastelloy C as per process
compatibility.

i. Control Valve
Electro-pneumatic globe valve shall be used for flow control application.
Valve shall be provided with electro-pneumatic positioner, AFR(15 micron
min.), SOV in air supply line and two limit switch with two potential free
contact for each position for showing 100% open and close position. All
valve actuator shall be spring loaded with diaphragm type actuator. All valve
shall be air actuated. Wetted MOC shall be SS 316 in case of utilities and
Metal jacketed PTFE or equivalent in case for process fluid wherever SS
316 is not compatible. Valve shall be provided with hand wheel for manual
operation. End connection shall be flange type and 1 set of companion
flanges shall be provided. Packing material shall PTFE and grafoil in case of
steam.

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j. On/ Off Valve

Electro-pneumatic full bore ball vale shall be used for ON/OFF application.
Valve shall be provided with AFR (15 micron min.), SOV in air supply line
and two limit switch with two potential free contact for each position for
showing 100% open and close position. All valve actuator shall be spring
loaded piston type actuator. All valve shall be air actuated. Wetted MOC
shall be SS 316 in case of utilities and Metal jacketed PTFE or equivalent in
case for process fluid where SS 316 is not compatible. Valve shall be
provided with hand wheel. End connection shall be flanges type. Packing
material shall PTFE and grafoil in case of steam.

h. pH Measurement:-
The pH sensor and transmitter with local and remote indication suitable for
services in agitated vessels shall be used. The sensor body material shall be
compatible with fluid being handled. pH measurement range shall be 2-12.
The system shall consist of temperature compensation circuits with suitable
RTD to take care of effects of temperature variation on emf generation.
i. Load Cell:-
Electronic portable load cell for drum weighing of suitable range shall be
provided. Portable load cell shall provide 4-20 mA DC signal transmission
and local display. Fixed load cell based on strain gauge principle on all the
support leg shall be used for measuring the weight for vessels with fluid
which are fixed in position. Provision for transmitting 4-20 mA Dc signal
shall be provided.
10.3.4.Environmental Conditions: All instruments and Instrument items shall be
tropicallized and suitable for outdoor installation in climatic conditions. All
electronic instrument shall be intrinsically safe for gas group IIC. In summary,
all Instruments, Instrument accessories and enclosures shall be suitable for
location outdoors for the following worst case conditions:

 Max. Design Temperature: 60 °C

 Min. Design Temperature: 9 °C

 Design relative humidity for Instrument and Instrument items: 85 % to 100%.

11.0. Specifications of Field Instrument

11.1. Electronic Transmitters
General: All electronic transmitters shall be of microprocessor based 2 wire, Smart
type with an output signal range of 4-20 mA DC and with superimposed digital output
signal, transmission of which shall employ HART protocol. Transmitters shall be
suitable for 24 VDC power supply and shall be able to drive an output impedance of
600 Ohms minimum at 24 V DC. All Transmitters shall be intrinsic safe type for gas
group IIC. Transmitter enclosures shall be of IP 65 protection class.

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Hand held communicating devices with facility for digital communication with
transmitter for functions such as remote range change; span & zero adjustment,
diagnostics etc. are to be provided.
11.1.1. Pressure Transmitters, Differential Pressure Transmitters and Remote
seal type DP Transmitter.
Differential pressure transmitters shall be used for measurements of differential
pressures, fluid flow rates and liquid levels (except for vacuum and low pressure
application). The range of the Differential pressure transmitters offered for flow
measurement shall match with the design parameters of the primary flow
element.
Pressure transmitters and differential pressure transmitters shall be of the
following specification.

Measuring element Diaphragm

Static Pressure 130% of maximum span
Range approx. 1.5 times normal value
Accuracy  0.075% of calibrated span or better
Turn Down Ratio 100:1 for vacuum and very low pressure applications,
30:1 for other applications
Temperature effect The combined zero & span drift shall not be more than
0.015 % per ° C at maximum span and not more than
0.01 % per ° C. at minimum span.
Stability  0.1% of calibrated span for six months up to range
69 bar and  0.25% for ranges more than 69 bar
Zero and span drift +/- 0.015% per ° C at maximum span and +/- 0.01 %
per ° C at minimum span
Span & Zero Tamper Proof, continuously adjustable from remote as
adjustment well as manually from instrument externally with zero
suppression and elevation facility
Suppression & 200% of maximum up to medium pressure i.e. up to
elevation 59 bar, 150% of max. for high pressure services (>59
bar)
Diagnostic features Required
Housing Weather & Dust proof as per IP – 65 with corrosion
resistant material.
Process connection ½” NPT (F)
Electrical connection Plug in socket connection with matching plug
Mounting Suitable for enclosure/ rack/ field mounting, as
applicable
Accessories to be
provided
Pressure Transmitter 2 Valve Manifold
Differential pressure 5 Valve Manifold
transmitter as pressure
transmitter for vacuum
pressure measurement
Differential pressure 5 Valve Manifold
transmitter (for flow,

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differential pressure,
level)
For corrosive liquids Diaphragm seals with minimum 3 meter capillary
unless specified for bigger length and DIP ring

The technical features and materials for manifolds shall be suitable for intended
service conditions.
Pulsation dampeners, syphon etc.. shall be provided as required by service and
operating conditions.

11.1.2. Level Transmitters

A. RADAR Level Transmitter
Type Radar type
Transmitter Integral (smart type)
Signal output 4-20mA
Accuracy +/- 6mm
Protection Class Weather & dust proof as per IP-65
Process Connection Manufacturer’s standard
Electrical connection Plug in socket connection with matching plug
Automatic Required
temperature
compensation
Accessories As required for the installation of the instrument.

B. Ultrasonic level Transmitter

Measuring range 0.45-11 m

Enclosure IP66 Glass filled nylon
Transducer Material PVDF
Display 4 Digit LCD
Power supply 12-30V DC, Loop powered.
Output 4-20 mA
Impendence 750 ohms

Relays 2
Hart protocol Yes
Integral LCD display 4 digit LCD
Process connection 2” BSPT
Cable Entry 2 x M20 x 1.5mm entries

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Accuracy 0.25% of measured value

Resolution 1 mm
Operating Temperature -20 to +90 deg C
Max. pressure 3 bar max

11.1.3 Flow Transmitter

The flow meter shall be of smart type and shall provide suitable 4-20mA DC
output signal with superimposed digital output signal, transmission of which
shall employ HART protocol. The flow meter shall be provided with indication
of LCD display of measured value in engineering units. Temperature
compensation shall be considered while selection of flow meter.
a. Variable area flow meters
1. Metal tube transmitting type ROTAMETER
Rotameter having smart transmitter with two wire type (4-20mA loop powered)
shall be utilized. Transmitter shall support HART communication protocol.
Ranges as mentioned in the data sheets shall be selected such that normal flow
will at 50 – 60% of span.
Materials:
a. Wetted parts: SS304L/SS316L
b. Non wetted parts: Die cast Al with polyurethane paint
c. Gasket, O ring: PTFE.
Pressure drop : 100 mm bar (maximum).
Accuracy : Accuracy calss 1.6 as per VDI/VDE code
Max. Temperature :As per tag list
Max pressure : As per Tag list
Ambient : 5-50 °C, up to 100 % RH at 40 ° C.
Inlet/outlet : Bottom/Top (Down/Up).
Mounting : Pipe.
Coupling : Preferably Magnetic
Float guiding : Using Float extension & retainer
Local indicator : required side mounted
TRANSMITTER DETAILS
Type : electronic type
Output : 4-20mA DC, 2 wire system
Rangeability : 10:1
Repeatability : <0.1%
Power supply : 12 to 36 VDC
Power influence : Preferably <0.1% for the above power supply range
Load resistance dependence : Preferably < 0.1% for the above power supply
range
Wiring system : 2wire type ( 4-20 mA) loop powered
Allowable load resistance : 600 ohms at 24 VDC
Electrical connection: ½” NPT(F) with double compression SS cable gland
Protection category : IP 65

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Indicator housing material: Cast Aluminium alloy with epoxy polyurethane

paint double
coating and with toughened glass window
Flange to flange distance: Constant irrespective of meter size.

2. Glass tube ROTAMETERS

Apart from transmitting type at many places local indicative glass tube type
rotameter
for purge and flush shall be used. List of these instruments is given in INST tag
list’.
1) Accuracy : ± 2 % of full scale or better
2) Repeatability : ± 0.5 % of full scale or better
3) Rangebility : 10 to 1
4) Scale graduation : in SLPM
5) Material of construction :
a) metering tube : Heavy walled borosilicate glass
b) Float : Contractor to specify
c) Gland packing for tube: PTFE
d) Float stop : PTFE / SS 304
e) End fittings, bolts, screws, scale side plate, gland ring : SS
f) Safety shield : Laminated safety glass, SS frame.
6) Pressure rating : Rated for max. line pressure (As per Table)
7) End connections:
a) For ¼” OD tube : Back entry, compression fitting with double ferrule.
b) Orientation: Outlet – Up; Inlet – Down
8) Mounting: Flush panel bezel is required . All necessary accessories required
for mounting shall be provided.

g. Coriolis Mass flow meter

General specifications
Applicable fluid : liquid and gas
Density range : 0 to 2 g/ml
Temp. range : -200 ° C to 200 ° C
Tube withstand at 20 ° C : Liquid : 15 MPa
: Gas : .98 MPa
Flow direction : Bidirectional
Ingress protection : IP66/67

h. Orifice type flow meter

General specifications

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Sizing calculations According to ISO 5167 (Latest edition)

Meter pipe AISI 304

Orifice assemblies As per ASME B 16.36 (Latest edition)

Assemblies shall consists of two butt weld

flanges, orifice plate, gasket, studs, nuts,
jack bolts and nuts and spacer ring of mild
steel.

Type of orifice Flange type

Type of tapping Flange tapping

Studs/Nut MOC ASTM A 193 grade B7/B16 acc. To

temperature/A1942H

Orifice plate AISI SS 316

11.1.4 Temperature Elements

Type of RTD 3 wire Pt – RTD, 100 0.1 0hm at 0 ° C, 18 AWG wire for
temperature 0-400 ° C
Number of elements Duplex
Application Standard ANSI MC 96.1 for Thermocouple, IEC-751 for RTD
Sheathing 8mm OD, 316 SS seamless tube, using Magnesium Oxide
Packing for insulation and minimum insulation resistance of 5
Mega Ohms at 5400C.
Calibration and RTD – as per DIN IEC 751 (class – A)
accuracy
Characteristics Linear with respect to temperature within 0.5% of top range
value
Head Beveled type – IP-65/Die Cast Aluminum

RTDs provided for motor winding temperature measurement and thermocouples

/ RTDs provided for the equipment and motor bearing metal temperature
measurement shall withstand, without damage, vibrations of frequencies from
10 to 2000 Hz.
For Temperature elements of the bearing metal temperature measurement
applications, the protecting sleeve shall be of the type fitted with springs that
press the sleeve to the hot surface in order to maintain a good thermal contact.

11.1.5 Thermo well

Material 316 SS/Hastelloy-C in

Type One piece tapered, Drilled from bar stock for up to 4”
insertion length and pipe for above 4”.
Applicable ASME PTC 19.3 (latest)

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Standard
Element ½ “ NPT (M) to suit the element
connection
Insertion length Based on maximum pressure, temperature, velocity and
piping dimensions, as per ASME PTC 19.3.

Meter enclosure housing the electrical parts shall be of IP- 65 protection class.

11.1.6 .Local gauges

a. Pressure/ Differential gauge

Sensing element 316 stainless steel bourdon tubes for high

pressure, 316 SS bellows or diaphragms for
normal and low pressure applications.
Dial size 150mm diameter
Case Type & material Die cast Aluminum with threaded bezel rings
or 316 SS stoved enameled, anti corrosive
painting of black colour, Non glare glass front
Movement 316SS
Mounting Bottom stem shall be provided with union,
shut-off valves etc..
Process connection 1/2" NPT
Over-range Pressure 130% of max scale
Pointer Micrometer with zero adjustment facility on
front
Accuracy +/- 1.0 % of Span
Scale Linear, 270 ° arc, graduated in metric unit
Housing Weather and dust proof as per IP-65
Accessories Safety blow out discs, Syphons, snubbers,
pulsation dampers as required for process
conditions. Valve manifolds are to be provided.
Chemical seal diaphragm shall be provided
wherever required.
b. Level Gauges
Level gauges shall be magnetic coupled float type with rotocyl/bicolour flapper
indicator. MOC of the wetted part shall be compatible with process/utility fluid
being handled. All the level gauges shall be provided with two numbers of level
switches adjustable throughout the range.
General Specifications
Material: All wetted parts and external metal parts are stainless steel.
Indicator tube is glass or, optionally, polycarbonate. Many other optional
materials are available.
Float Chamber: 2-1/2 inch pipe with RF slip-on/blind drain flange.

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Scale: Feet and inches are standard with 1/2 inch scale divisions; resolution
is approximately 1/4 inch. Custom scales for elevation, volumetric and other
calibrations are available.
Indicator: 7/8 inch diameter by 1-1/4 inch long. Brightly colored for long-
distance viewing. Optional Flipper/Roller is available.
Pressure: Up to 4000 psig.
Temperature: From -200 to 1100 ° F continuous.

11.1.7 .Online monitors

a. Explosion proof detector of hydrogen chloride gas :

Principle of measurement Electrochemical Type Sensor

Sensor life 2 years typical
Range 0-50 PPM
Accuracy ±1% of full scale or 2 PPM
Drift Zero drift : <5%/year, Span drift : <10%/year
Wiring requirements 3-wire ( with “Quick-glance” LEDs, and Relay)
Signal output 4-20 mA + HART, 3 Wire Current Source
Intrinsically Safe Port Connecting HART Hand Held Communicator In
Hazardous Area
Type of protection UL Approval for intrinsically safe apparatus
Display Field Display 3 and a ½ Digit
Humidity 15 – 95% RH, Non Condensing

Power 7-30 VDC

Conduit ¾ NPT
Protection NEMA 4X (IP 66)
Enclosure 316 Stainless steel housing

b. Explosion proof detector of hydrogen gas

Continuous online monitors as per process parameter sheet shall be
provided and installed in the plant are for continuous monitoring with 4-20
mA o/p for control room indication.

Principle of measurement Catalytic Type Sensor

Sensor life 2 years typical
Range 0-100% (for LEL of 4% of Hydrogen in air)
Accuracy ±5% of full scale
Drift Zero drift : <5%/year, Span drift : <10%/year
Wiring requirements 3 – wire ( with “Quick-glance” LEDs and Relay)
Signal output 4-20 Ma, + HART , 3 Wire Current Source
Type of protection FM approval for intrinsically safe apparatus
Intrinsically Safe Port Connecting HART Hand Held Communicator in
Hazardous Area
Display Field Display 3 and a ½ Digit
Humidity 15 – 95% RH, Non Condensing

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Power 7-30 VDC

Conduit entries ¼ NPT
Protection NEMA 4X (IP 66)
Enclosure 316 Stainless steel housing

c. Explosion proof detector for Hexane vapour (Hydrocarbon)

Principle of Catalytic Type Sensor

measurement
Sensor life 2 years typical
Range 0-100% (for LEL of 0-1.2% in air)
Accuracy ±5% of full scale
Drift Zero drift : <5%/year, Span drift : <10%/year
Wiring requirements 3 – wire ( “Quick-glance” LEDs and Relay)
Signal output 4-20 mA + HART , 3 Wire Current Source
Type of protection FM approval for intrinsically safe apparatus
Intrinsically Safe Connecting HART Hand Held Communicator in Hazardous
Port Area
Display Field Display 3 and a ½ Digit
Humidity 15 – 95% RH, Non Condensing
Power 7-30 VDC
Conduit entries ¼ NPT
Protection NEMA 4X (IP 66)
Enclosure 316 Stainless steel housing

d. Explosion proof detector of Xylene vapour ( Hydrocarbon ) :

Principle of Catalytic Type Sensor

measurement
Sensor life 2 years typical
Range 0-100% (for LEL of 0-1% in air)
Accuracy ±5% of full scale
Drift Zero drift : <5%/year, Span drift : <10%/year
Wiring requirements 3 – wire ( “Quick-glance” LEDs and Relay)
Signal output 4-20 mA + HART , 3 Wire Current Source
Type of protection FM approval for intrinsically safe apparatus
Intrinsically Safe Connecting HART Hand Held Communicator in Hazardous
Port Area
Display Field Display 3 and a ½ Digit
Humidity 15 – 95% RH, Non Condensing
Power 7-30 VDC
Conduit entries ¼ NPT
Protection NEMA 4X (IP 66)
Enclosure 316 Stainless steel housing

e. Intrinsically safe hand-held controller for above detector:

Intrinsically safe approved hand-held controller for `one-person’
calibration and access to all features through its full-function keypad. The
controller is housed in a leather case as standard and is used to

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- Set the real-time clock

- Set alarm levels
- Change span-gas values
- Display – date of last calibration
- Display – minimum , maximum and average gas values
- Change address
- Set future calibration time / date
In addition to providing calibration functions.
The controller is completely password protected and is UL/CE approved as
intrinsically safe and can be used to communicate with all above Series
detectors/monitors; therefore only one is needed per site.

f. UV+IR Flame monitor

Operating Voltage Range: 10 to 32 VDC

Power Consumption: Nominal 35 mA / 0.84 W | Maximum 65 mA / 1.6W
(at 24 VDC) Nominal 78 mA / 1.88 W | Maximum 112 mA / 2.7W (with
heater)
Temperature Range Certified: -40°C to +75°C (-40°F to +167°F)
Operational: -50°C to +75°C (-58°F to +167°F)
Field of View: 120° horizontal / 95° vertical @ 50% of maximum on axis
distance
Spectral Range: UV Radiation 185 to 260 nano meters (1850 to 2600
angstroms) | IR Radiation in the 4.4 micron range
Time Delay: DIP switch selectable to 0, 3, 5, 7 seconds
Sensitivity Settings: DIP switch selectable to 8, 16, 24 or 32 counts per
second
Typical Response Time: <6 seconds depending on fuel source, fire size and
distance
Enclosure Material: Anodized, copper-free aluminum (optional stainless
steel) factory sealed housing
Humidity Range: 0 to 95% RH, non-condensing
Outputs: 0 to 20 mA - Into a maximum loop impedance of 800 Ohms at 32
V dc or 150 Ohms at 11.0 VDC Non-isolated loop supply
Certifications: CSA and NRTL/C certified for hazardous locations. Class I,
Division 1, Groups B, C and D. Temperature code T5 Enclosure type
NEMA 4X, IP67. Ex d II B+H2 T5 (Class I, Zone 1, Grp II B+H2 T5)
Factory Mutual (FM) flame detector performance certification FM3260
g. POCl3 Detector

Gases Detected Phosphorous Oxychloride (POCl3)

Detection Principle Electrochemical
Range 0 – 15 ppm
Electrolyte EL-3468
Membrane M-3400M

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T90 < 30 s
Operating Temperature -10 to +35 ºC
Humidity 0 – 100 %
Lower Detection Limit 0.5 ppm
Installation Angle Maximum 45 º
Height 3 1/2″
Dimensions
Depth 1 3/8″
Housing Material PVC / PTFE

11.1.8 Field controller for above

Electrical data
Supply voltage 110 VAC ± 15% 50/60 Hz
Power consumption :
12 VA transformer 10.5 VA
17 VA
6W
10-200 mV as measuring range
spread 4-20 mA
System response time < 0.5 seconds for 100% measuring range (without
sensor)
Zero and sensitivity drift < ± 0.5% of measuring range ± 1 digit /month
(without sensor)
Repeatability < ± 1% for 100% measuring range (excluding
sensor)
Analog output signals ( repeater 4-20 mA (linear), to connect to
output)
Analog error signals 0, 2 , 4 , 20 mA or frozen (selectable)
Sensor connection 2, 3 or 4 wire connection
Permitted wire cross section 0.75 – 2.5 sq.mm
Switched outputs
Relay outputs SPDT Warning “W” Alarm “A” Failure “F” and Horn
Relay outputs DPDT Failure “F”
Maximum contact load 5A/24 VDC and 250 VAC - resistive load (relay
outputs are common to both channels)
Opto-isolated outputs Caution “C”
Warning “W”, Alarm “A” Failure “F”, Horn
(optional)
Maximum load 30 mA / 24 VDC – open collector

Mechanical Data

Dimensions of PCB (W x L) 100 x 220 mm for panel mounting

Front plate W x H 40 x 128.5 mm 3Ux8U
Weight 720 g (with 25 VA Transformer)
Conditions for use
Temperature 15ºC to +50ºC
Storage Temperature 15 ºC to +40 ºC

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Humidity 5% - 90% relative humidity (non-condensing)

Vibration 10-55 Hz / 0-15 mm amplitude
Protection IP 31 for plug-in –control system module in 19”
rack
Mounting Panel mounting

Notes:

1. Calibration test certificate to be submitted for the instrument during PDI

2. It should be certified by M/s. BASEEFA, GENLEC or CMRS , Dhanbad for
Group II C (Hydrogen area) , Intrinsically safe,
(Ex ib, IIC, T4) as the equipment is to be used in Hydrogen atmosphere
.Certificates to be submitted during PDI.
3. Detailed technical manual with circuit diagram is to be supplied along with
the instrument (2 copies)
4. One year trouble free guarantee to be ensured
5. Copy of above certificates to be supplied along with the instrument.
6. Detailed Technical catalogue should accompany the quotation for verification
of the suitability
1. Accessories to be supplied with the respective instruments :
i. Calibration kit - 1 Set for each type
ii. Calibration gas/sample – 1 for each type of gas
iii. Installation hardware - 1 for each sensor
iv. Set up assistance for commissioning/calibration
11.1.9 Speed transmitter
Input : Proximity switch
Range : 0.06 to 9999 rpm
Accuracy : +/- 0.01 % of reading , +/- 2 counts
Resolution : 0.01/0.1/1 rpm, auto-ranging
Display : 4 digit, 0.39”, 7 segment red for rpm.
No. of set point : 2 (user programmable)
Analog Output : 4- 20 mA
Supply voltage : 24V DC
Type of sensor : 3 wire DC inductive proximity sensor
Nominal sensing distance : 5 mm
Load current : 400 mA

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CABLING & TUBING

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12.0. Basis of cable & cable trays selection

12.1. All signal exchange between field and central cabinet room shall be via individual
hardwire pair of cable as specified in detailed cable specifications. From the field, all
field transmitters shall be routed to field mounted junction boxes, from where these
shall be taken to central cabinet room via multi pair cables. Use of 6 pair or 12 core
cable is not allowed.
12.2. All analog multi pair cable shall be 12 pair only. All Digital input/output multi pair
cables shall be either 24 core or 12 pair only. Multi-pair power cable shall also be 12
pair only.
12.3.To the extent possible, direct run cable from field instrument to central cabinet room
shall not be employed. All the signals to the central cabinet room shall be routed
through multi pair cables via field mounted junction boxes only.
12.4. All the power/control and signal cables in a single or multi pair cables between field
instruments to field junction boxes and between field junction boxes/local panels to
the central cabinet room shall be thru’ overhead cable trays/cable duct on the pipe
racks.
12.5. On the main cable route, cable duct shall be used with clear separation of various low
voltage signal cables (AI/AO/DI/DO with 24 V DC and lower voltage) and high
voltage power cables (e.g. 110 / 220 V AC / DC for Solenoid valves, 110 V A.C.
power supply cables to field instruments, etc..). On the trunk and branch route from
main cable duct to field junction boxes and local panels, 300 mm(w) x 60mm
(H)x3mm thick Aluminium perforated cable trays will be used. For other branch
cables various sizes of perforated Aluminium cable trays shall be used with the
following general specifications.
300 mm (W) x 60 mm(H) x 3 mm thick perforated Aluminium cable trays
100 mm (W) x 50 mm (H) x 3 mm thick perforated Aluminium cable trays
50 mm (W) x 40 mm (H) x 3 mm thick perforated Aluminium cable trays
All the fiber optic cables / system cables, special cables shall be armoured type laid
preferably in overhead trays/duct only. All system cables outside control room should
be armoured. No GI conduits to be used.
12.6. All type of single and multi pair power, control and signal cables in the field shall be
with GI armoured only for mechanical protection.
12.7. Fiber optic cables, if any, shall also be with armoured only
12.8. All the cable exchange between the central cabinet room and field instrumentations
shall be from one side of the cabinet room through MCT blocks.
12.9. All the above mentioned philosophy shall be followed for various type of cable
exchange between electrical and instruments signals. Signal and power/high voltage
cables shall be laid in separate cable duct between cabinet room and MCC.

13.0. Specification of cables, cable trays, air tubes to be used for instrumentation and
automation system
13.1. Cables: The cables covered under this enquiry specification shall be used in
hazardous plants instrumentation jobs. The most of cables shall be laid on open cable
trays and shall be exposed to direct sunlight, heat, rain, and seasonal changes. The
area is wet tropical coastal climate.
Applicable standards:

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1.IS standard as indicated.

2.IS-10810 for testing of cables.
Single pair/ triad cables shall be twisted with minimum 13 twist per meter. Shielded
cables shall have aluminum maylar tape wounds with at least 25º over lap and 100%
coverage. Drain wire shall be helically laid either below or above but continuous
contact with aluminum shield.
PVC sheathing shall be used below armour and above armour. The armour shall be
annealed galvanized steel wire. In case of multipair/triads of 12 pair / triads, flat
armour also applicable. Armour shall conform to IS 3975. Armouring shall cover 80%
of circumference (min).
Field mounted electrical instruments should be wired and connected to the identified
junction boxes. Instrument wiring between the Control building and field junction
boxes should be by means of multi core / multi pair cable.
After final installation of the plant, 20% spare shall remain in each of the multicore /
multi pair cables for future use.
The number of types of cable should be restricted to a minimum. Field analog and
digital signal shall be 1P/2P 1.0/0.75 Sq. mm, 6P/12P 0.75 Sq. mm stranded annealed
copper conductor.
RTD, mV, vibration, and gas detector shall be 1T/2T/8T cable 1.0/1.5 Sq. mm
stranded annealed copper conductor.
For solenoid valve cable shall be 2C/12C/24C 1.5 Sq. mm stranded annealed copper
conductor.
Basic selection criteria of some instrument cables given below:-
SL.NO SPECIFICATION STANDARDS

1 Signal cable 1 pair

Twisted pairs 13 twist per meter (Min)

Conductor matl/ type Tinned copper / stranded

Conductor standard IS8130

Conductor Insulation/standard LDPE/IS6474

Inner sheath FRLS PVC

Insulation resistance (Ohm per km) >5000 M Ohm

Flame retardance IEC332 Part 3 Type A

Mutual Capacitance

A. Between core to core 0.06 micro farad/Km

B. Between core to screen 0.40 micro farad/Km

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Inductance at 1 KHz mH/Km 0.9 mH/Km

L/R ratio Max 40

Dielectric test voltage

a. Core to core 1500 VAC for 10 minutes

b. Core to shield 1000 VAC for 1 min

c. Armor to shield 500 VAC for 1 min

Multi pair Signal cable

Signal cable 12 pair

Twisted pairs 13 twist per meter ?( Min)

Conductor matl/ type Tinned copper / stranded

Conductor standard IS8130

Conductor Insulation/standard LDPE/IS6474

Inner sheath FRLS PVC

Insulation resistance (Ohm per km) >5000 M Ohm

Flame retardance IEC332 Part 3 Type A

Mutual Capacitance

A . Between core to core 0.06 micro farad/Km

B. Between core to screen 0.40 micro farad/Km

Inductance at 1 KHz mH/Km 0.9 mH/Km

L/R ratio Max 40

Dielectric test voltage

a. Core to core 1500 VAC for 10 minutes

b. Core to shield 1000 VAC for 1 min

c. Armor to shield 500 VAC for 1 min

Power Cable (Control cable)

Conductor cross section 2.5 sq. mm

Conductor matl/ type Tinned copper / stranded

Conductor standard IS8130

Conductor Insulation/standard Extended PVC Type C and

IS 5831

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Inner sheath FRLS PVC

Insulation resistance (Ohm per km) >100 M Ohm

Flame retardance IEC332 Part 3 Type A

Voltage grade 400/750 V

Dielectric test voltage core to core 4000 VAC for 10 min

13.2. Specification of cable trays

Supply and installation of perforated Aluminum alloy trays, sections, riser, bends, tray
cover complete with coupler plates, nuts and bolts etc. The quantities in this tender
document is tentative and may change after the detailed engineering. Any
addition/deletion of items, reduction/increase in quantities should not affect the total
price quoted.
MOC : Aluminum alloy as per IS 737:1974 grade 19000, H2, 52000 #2
Thickness shall be: 3mm for 300 wide tray
: 2mm for 100 mm/150mm / 50 mm wide tray
Collar height : 75 mm for 300 mm and 200 mm wide tray
: 35 mm for 100 mm and 50mm wide tray
Length of each section : 2500 mm
13.3. Specification of SS tubes
SS tubes for instrument installations shall in general be in accordance with this
specification.
The tube shall be made by seamless process, cold finished, according to ASTM-A
269.
Tubes shall be in finished free from scale, annealed condition suitable for bending and
flaring.
The finished tubes shall be reasonably straight and free from bents, injurious defects
and shall have good finished and smooth ends.
13.4. Specification of Instrument valves
Instrument valve : Nominal rating :150 # Class
Light weight, globe type valves used for isolating and zeroing of PG/PT.
Body material: AISI SS 304
All other wetted parts: AISI SS 316
Port size- 6mm
Sealing and packing : Grafoil /PTFE
13.5. Instrument air tubing.
Most of the Pressure Transmitter and Differential pressure transmitter are back
pressure type measurement Air is used to pressurize the LP & HP side and back
pressure is used to measure the differential pressure( in case of DP) and pressure in
case of PTs). Accordingly a large quantity of 6 mm/8 mm SS tubing will be required
.This tubing will have to be laid from Air header up to the process points in field and
then back to the transmitter bay. Transmitter bay is the location where all the local
transmitter indications can be seen on the panel.( Refer general layout drawing of the
plant). The Air header & DP & P transmitter bay is installed at first floor. Whereas all
the DP & P transmitters points are located in the plant . Accordingly huge amount of
tubing will be required.

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Qty. of SS 316 tubing: As per requirement + 20 % spare.

All tubing and fittings shall be imperial sizes, expressed in nominal outside diameter
(OD) and all threads shall be NPT.
Tubing and fittings shall be of 316 SS to ASTM A269 unless otherwise specified. The
minimum size shall be ¼” OD. Tubing runs shall be supported and protected. Tube
fittings shall be of double ferrule, pressure seat, no torque type for use on heavy or
thin wall tubing, and shall be of reputable makes (such as Swagelok / Parker/wintech).
Ferrule and nut shall be of the same material as the fittings.
Tubing shall be supported and protected by stainless steel angle / channel or ladder /
tray along the complete length of each run and shall be fastened with stainless steel
saddles at a maximum of 1 m intervals on straight runs. Channel or tray support for
tubing runs shall be sized for a minimum capacity of 30% greater than that required.

13.6. Instrument Air Headers

Instrument air/gas mains shall be in accordance with the piping specification of
appropriate service and operation rating.
The size of instrument air/gas mains shall be established in accordance with the table
below unless otherwise specified.
Nom. Pipe Size Max. Members of Users
½” 3
¾” 14
1” 23
1½” 50
2” 100
All take-off for branch lines shall be of SS 316/304 & shall be from the top of the
main header with SS 316/304 block valves equal in size to the branch line. All low
points shall have a ½” valve installed as a drain and blow down point.
The branches to individual pneumatic instruments shall be as per the Hook-up
drawing.
13.7. Instrument Junction Box
Junction boxes shall be IP65, corrosion resistant, explosion proof type and provided
with drain fittings. Terminals shall be sized for the specified number of wires plus
20% spares and suitable for environmental conditions and electrical classification. For
individual shielded multi pair cables, a separate terminal shall be provided for each
shield drain wire.
The junction boxes will be installed at a maximum height of 1.4 meter (measured at
top portion of Junction Box) relative to the floor elevation.
Isolated outputs shall be used to drive the motor contactor or the contactor relay for
starters.

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INSPECTION AND TESTING

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14.0 Inspection and Testing of Field Instruments.

The manufacturer shall conduct all tests required to ensure that the field instruments
furnished shall conform to the requirements of this specification and in compliance
with the requirement of the applicable codes. Owner has the right to witness the type
tests which shall be as finalized by the HWB during detail engineering.
Test certificates shall be provided for all the items included under this Section of the
specification for the Owner’s approval.
The following tests shall be conducted for the field instruments:
Field transmitters shall undergo Calibration test, Hydro test, over range test,
Accuracy test and Repeatability test.
Pressure Gauges/ Differential Pressure Gauges shall undergo Calibration test,
Hydrostatic test (1.5 times max. pressure.), Over range test, Accuracy test and
Repeatability test.
Differential Pressure Indicators shall undergo Calibration test, Hydro test, Leak test,
over range test, Accuracy test and Repeatability test.
Temperature Gauges shall undergo Calibration test, Material test, Accuracy test, Bore
concentricity test, Hydrostatic test for TW (1.5 times max. pr.).
Resistance temperature detector assembly shall undergo Calibration test, Material test,
Bore concentricity test, Insulation test ( 500 M at 500V DC) as per ISA,
Hydrostatic test for TW, Bore concentricity test, Accuracy test and repeatability test.
Thermo wells shall undergo material test, Bore concentricity test, Hydrostatic test.
Level Gauges shall undergo Hydrostatics test, Material test, Seat leakage test and Ball
check test etc..
Flow element shall undergo Hydro test and Calibration test for flow element shall be
witnessed by Owner.
Electro Pneumatic Converters shall undergo Calibration test/ and Accuracy test.
Mass flow meter shall undergo Performance test, Calibration test and Hydrostatics
test.
Radar LT shall undergo Performance test, Calibration test and Hydrostatics test.
Control valve shall undergo function test, hydro test for seat leakage, Cv, body and
flange leakage and calibration.
pH transmitter shall Performance test, Calibration test and Hydrostatics test.
The type test certificate, MOC certificate shall be verified during the inspection of all
the above materials. Wherever required these type tests shall be incorporated in the
detail engineering stage. All the functional test and calibration test and routine test
shall be witnessed by the purchaser representative.

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15.0. Inspection and Testing of DCS

15.1. Functional Testing

Testing shall be carried out by SUPPLIER against SUPPLIER standard procedures
and the project specific test specifications which shall be developed during the
detailed design phase of the projects.
15.1.1. Test Order
Functional testing shall be performed by SUPPLIER in a number of ‘Test
Stages’, these being:

 Test Stage 1: Factory Acceptance Test(s).

 Test Stage 2: Site Acceptance Test (SAT).

15.1.2. Test Guidelines
Each stage of testing shall be performed in accordance with the following
guidelines governing how the different items of hardware, application software
or system software (firmware), which constitutes the system designs, are tested.
SUPPLIER standard product hardware inspection and test are covered by
SUPPLIER's standard procedures/work practices for the manufacture, inspection
& test of the SUPPLIER products. Standard inspection and test record sheets
shall be used to perform and record the results which were approved by Client.
Verification (i.e. internal/customer review) of the overall system’s design, and
individual module’s design, shall be performed in accordance with SUPPLIER’s
standard procedures/work practices for verification of standard (reuse library)
designs, new/adapted designs, and final overall system design. Notes or minutes
of the review shall be used to record the results.
New or adapted module’s design, implementation and prototype testing shall be
verified and tested against the test specifications/procedures produced for each
particular module.
All application software testing shall be performed in accordance with project
specific test specifications/ procedures, produced as required. Test record/result
sheets included within each test specification shall be used to perform and
record the individual test results. Test copies of related customer
design/configuration requirement documentation would also be used for
validation purposes.
15.1.3. Test Stage 1: Functional Block Testing
The objectives of the FAT are to verify the DCS system (as configured for
delivery) meets or exceeds specified design and functional requirements. Tests
shall be conducted at the DCS staging site and shall be done according to
Factory Acceptance Test procedures for the project. Functional testing shall
include all system hardware including network interfaces and all software
including operating system, console software, network software, complete
application software etc..

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Before the system is delivered to the site, satisfactory performance of the entire
system shall be demonstrated. The system shall simulate the final onsite
configuration as closely as possible. The technician and test equipment shall be
made available full time during testing.
The tests undertaken shall demonstrate each of the following responsibilities has
been fulfilled.

 The system has been tested as an integrated system

 The hardware and software responsibilities have been fulfilled

 All tests have been documented in a checklist fashion

 The system is fully proven and ready for service

 The system satisfies the requirements of this specification and the particular
project application.
The test procedures shall be developed as system engineering proceeds and shall
be submitted for approval at least one month before commencement of the first
factory test.
No material or equipment shall be transported until all required tests are
successfully completed and certified "Ready for Shipment".
During acceptance tests of integrated systems, formal testing of all operating
and application software shall be conducted. Tests shall be based on established
software reliability test procedures. As a minimum, test procedures shall be
based on recognized industry standards for development and testing of the
system and application software.
A log of all failed components/modules in a sub-system shall be maintained
which shall give description of the failed component/module, effect of failure on
the sub-system cause of failure and number of hours of operation before if
failed.
Supplier shall perform tests at his works to ensure that all components function
in accordance with their respective specifications for each type of test. A test
report shall be submitted to the owner for review within two weeks of
completion of each type of test giving details.
All the Test Reports shall be reproduced to the Owner for verification two
weeks prior to the Test witness.
The test log book shall contain the following information about the tests:

 Date/Time

 Assembly designation/loop tag number

 Test input

 Test results and sign off with personnel name

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 Action required (if deficiency is detected)

 Action taken, date of completion and sign off

 Special test methods (including special equipment requirement, bypasses used

etc..)
Quality control tests shall be carried out to assure quality of all components and
modules in accordance with Supplier’s quality control and assurance
procedures. The sampling procedures for all purchased components or
components manufactured by the Supplier, for quality assurance tests shall be in
accordance with relevant international standards. All assemblies shall be aligned
and adjusted and all test observations shall be recorded as manufactures
published set ups and testing methods.
EPC contractor as a minimum shall check the functions of all the systems
hardware and software including diagnostic software at sub-system level by
simulating the inputs.
Visual and mechanical testing Visual and mechanical testing shall be carried out
in principle to assure correct, proper, good and neat workmanship.
Functional testing shall include the simulation of each input and output to verify
proper system response for both analog and discrete signals.
Demonstration of all controller functions e.g. changing of tuning constants, loop
tuning, checking of algorithm functions changing algorithms, changing
controller mode, changing controller action etc.. Checking of the scan time
values shall be carried out for controllers and data acquisition sub-system.
Checking of loop configuration as required for correctness with respect to
ranges, limits, alarm points, engineering, units etc.. Checking shall be required
for LED displays including process and system displays on operator and
Engineering console.
Correct changeover of the back-up units shall be checked in case of main unit’s
failure.
System diagnostics shall be thoroughly checked for all sub-systems on local
level as well as on operator/Engineering console. These shall include failure of a
sub-system, module, power supply, interface unit, failure of transfer to
redundant module on main module failure etc.. and other detailed diagnostic
displays. Diagnostic alarms for any ventilation fan failure shall also be checked.
Loop check shall be carried out for checking the interconnection, configuration
and overall system functioning.
15.1.4. Test Stage 2: Site Acceptance Test
The objective of the SAT is to verify the “as installed” DCS meets or exceeds
specified structural and functional requirements. The SAT shall be conducted in
two phases. The first phase shall consist of post installation inspection and
software module testing. The second phase shall be an abbreviated version of
the FAT. Tests shall verify that all equipment, interconnecting cables, external

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power connections and grounding connections have been installed correctly.

Data communication cables installed by others shall be tested.
Field Testing shall be carried out as follows:

 All the equipment shall be checked thoroughly after its receipt at site. The
tests, as a minimum, shall include:

 Visual and mechanical testing.

 Complete system configuration loading.

 Demonstration of all system functions.

 Checking of loop configuration.

 Checking of all LED MONITOR displays.

 Checking of correct functioning of all keyboards.

 Demonstration of all system diagnostics.

 Checking of correct changeover of redundant devices.

 Checking of bus degradation.

 Checking of proper functioning of all printers and hard copy units, sample
printing of all types of log reports.

 Checking of all disc drives, historical trending points, alarm summary and
alarm history.

 Complete checking of shutdown system

 Complete checking of hard-wired instruments.

 Demonstration of proper operation of system at specified power supply

specifications.

 Loading of user's program and check out of results.

The SAT shall essentially be a repeat of the FAT with the following additions:

 The connecting wiring between distributed components shall be the actual

field installed wiring and cable

 The field inputs and shutdown devices shall be connected and exercised to
confirm the correct connection and compatibility of the field components.

 The system will be interfaced and tested with other systems (Package unit.)

 Electrical Installation Test as described below:

o Electrical systems shall be tested for insulation resistance, correct polarity
and continuity. To prevent damage to electronic and extra-low voltage

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equipment all such equipment shall be disconnected at both ends of the cable
prior to the cable test and reconnected prior to the functional test of the
system.
o Grounding shall be tested for faults, continuity and conformity with the
Contractor’s requirements.
o Terminations, glands, junction boxes and equipment enclosures shall be
inspected for correct application, installation assembly and closure.
o Power supply tests over the required range.
o Series and common mode noise rejection on input signals to required
specifications.

16.0 RECOMMENDED QUALITY ASSURANCE PLAN

RECOMMENDED QUALITY ASSURANCE PLAN

The EPC contractor shall produce its own detailed Test procedure, which may include the
following recommended quality test plan but not be limited to, with Check lists along with
the quotation itself. However QAP shall be approved duly by the client.

Sr. Item Test to be Extent of Reference Acceptance norms

No Conducted check standards or its
equivalent

STAGE: I Inward Inspection

1 Control Overall 100% Approved Proper dimensional

cubicles, Dimensional General details, smooth finish,
desks and details, finish and Assembly proper welding quality &
other workmanship & Drawing smooth finish color shade
fabricated painting Quality matching etc..
items

2 Bought out Verification Test 100% Product Conformance to

items like of performance specifications specifications
isolators,
computers,
printers etc.

STAGE: II MANUFACTURING

3 Fully Visual Inspection 100% Manufacture’s Correctness & proper

assembled test report quality of assembly and
modules finishing

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RECOMMENDED QUALITY ASSURANCE PLAN

The EPC contractor shall produce its own detailed Test procedure, which may include the
following recommended quality test plan but not be limited to, with Check lists along with
the quotation itself. However QAP shall be approved duly by the client.

Sr. Item Test to be Extent of Reference Acceptance norms

No Conducted check standards or its
equivalent

Burn-in test: At 100% 1. No malfunctioning. No

ambient for 100 drifts beyond
hrs in fully permissible limits.
powered up
condition. 2.Test report to be filled
and submitted for
vetting to purchaser.

4 Panel Visual inspection 100% Approved All panel components are

manufacturin General properly located as per
g Assembly the approved drawing.
Drawing

5 Panel Crimping quality, 100% Approved wiring Correctness of wiring

Wiring color coding and drawings
grounding
schemes

6 Software Software & Logic 100% Approved Complete Simulation of

developmen Simulation test Document Software & Logic
t containing I/O Package to be tested to
allocation confirm that the system
drawing,. meets purchaser.
Termination requirements
details, Logic
details with
functional
description and
software facilities

STAGE: III Pre-FAT

7 Complete Dimensional 100% Approved GA Dimension within

system checks for - drawings specified tolerance limits
SCADA cubicles
& marshalling
cabinets
8 Complete General 100% Approved GA Conformance to
system arrangement for - drawings approved GA drawings
SCADA cubicles/
marshalling
cabinets
9 Complete Overall system 100% Approved system Conformance to
system architecture architecture approved drawings

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 Chapter-9 Technical specification

RECOMMENDED QUALITY ASSURANCE PLAN

The EPC contractor shall produce its own detailed Test procedure, which may include the
following recommended quality test plan but not be limited to, with Check lists along with
the quotation itself. However QAP shall be approved duly by the client.

Sr. Item Test to be Extent of Reference Acceptance norms

No Conducted check standards or its
equivalent

drawing

10 Panel wiring Visual Inspection 100% Approved wiring Correctness of wiring,

drawing ferruling, proper quality
of dressing, segregation
of power & control
cables

Crimping quality, 100% Approved wiring Correctness of wiring

color coding and drawings
grounding
schemes

11 Complete Power-up/power- Complete Approved test Satisfactory starting of

system down test for system to be procedure system after system is
system switched off & switched on.
rechecked for
100%
automatic
proper start-up
after resuming
of power

12 Complete Communication All Overall system All system buses should

system tests for integrated communication architecture be healthy & hot
system buses to be redundancy is operational
checked for wherever provided. All
healthiness diagnostic messages
&redundancy appear appropriately

13 Complete Individual I/O 100% I/O allocation I/O operation is proper

system simulation drawing and from termination
termination modules to its
details approved corresponding display on
document operator station & vice
versa

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 Chapter-9 Technical specification

RECOMMENDED QUALITY ASSURANCE PLAN

The EPC contractor shall produce its own detailed Test procedure, which may include the
following recommended quality test plan but not be limited to, with Check lists along with
the quotation itself. However QAP shall be approved duly by the client.

Sr. Item Test to be Extent of Reference Acceptance norms

No Conducted check standards or its
equivalent

14 Complete Detail Software & Complete Approved Complete Simulation of

system Logic simulation Software & Document Software & Logic
logic should be containing I/O Package to be tested to
tested by allocation confirm that the system
simulating I/O drawing,. meets purchaser.
conditions Termination requirements
using switches details, Logic
& analog signal details with
sources functional
description and
software facilities

15 Complete MMI All OWS pages Approved screen- Correctness of OWS

system configuration to be checked dumps/soft pages as per Purchase’s
checks for static and copies requirements
dynamic
displays

16 Complete System I/O module As per All diagnostics displays

system diagnostics diagnostics specification for as Purchase’s
hardware & requirements
CPU diagno- software
stics

Power supply
diagnostics

OS diagnostics

17 Complete Redundancy a)I/O module As per All hot standby

System checks redundancy specification for redundancies perform as
hardware & per specifications
software

b) CPU redunda- As per All hot standby

ncy specification for redundancies perform as
hardware & per specifications
software

c) As per All hot standby

Communication specification for redundancies perform as
buses redunda- hardware & per specifications
ncy software

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 Chapter-9 Technical specification

RECOMMENDED QUALITY ASSURANCE PLAN

The EPC contractor shall produce its own detailed Test procedure, which may include the
following recommended quality test plan but not be limited to, with Check lists along with
the quotation itself. However QAP shall be approved duly by the client.

Sr. Item Test to be Extent of Reference Acceptance norms

No Conducted check standards or its
equivalent

d) Power supply As per All hot standby

redundancy specification for redundancies perform as
hardware & per specifications
software

18 Complete System response time checking

system

19 a) Scan time As per As per specification As per specification for

specification for hardware & hardware & software
for hardware & software
software

20 b) Overall system As per As per specification As per specification for

response time specification for hardware & hardware & software
for hardware & software
software

c) Accuracy of As per As per specification As per specification for

timers specification for hardware & hardware & software
for hardware & software
software

21 Complete Continuous Run 100% Full system be kept No single failure should
system test running for 100 be reported
hours on
continuous basis

STAGE: IV FAT

22 Complete All the test 100% As per specification As per specification for
system mentioned in the for hardware & hardware & software
PRE FAT should software
be conducted
during FAT
including the
following tests and
the tests as
mentioned in
specification under
FAT

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 Chapter-9 Technical specification

RECOMMENDED QUALITY ASSURANCE PLAN

The EPC contractor shall produce its own detailed Test procedure, which may include the
following recommended quality test plan but not be limited to, with Check lists along with
the quotation itself. However QAP shall be approved duly by the client.

Sr. Item Test to be Extent of Reference Acceptance norms

No Conducted check standards or its
equivalent

Panel wiring Megger & High 1. Insulation IS:4237 Insulation resistance

Voltage test resistance to be should be greater than
checked at 500 100 mega ohms & no
V DC insulation breakdown
2. H V occurs at 1.5kV AC
breakdown to
be tested at
1.5kV AC

Insulation As per relevant Between either As per relevant

Resistance standards signal terminal and standards
the chassis ground
better than 100 MΩ
at 500 V DC when
temp is at 25º and
RH is 60%

STAGE: V OSAT

23 Complete The OSAT will be 100% As per specification As per specification for
system conducted after for hardware & hardware & software
system installation software
on site and is
intended to assure
that no damage
occurred to the
system during
shipment, that the
system is correctly
installed and that
the system
requirements are
satisfied when
connected to
“live” field
inputs/outputs.

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DOCUMENTATION

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 Chapter-9 Technical specification

17.0. Submission of documents for approval

EPC contractor shall submit the detailed time schedule of the activities starting from
placement of order showing the schedules
All the documents listed bellows are to be submitted by the EPC contractors for
our approval and certifications. After necessary approval only EPC contractors
shall place the orders for field instruments, DCS, panels and all other
components.

a. Detailed Specifications sheet of DCS & all the field instruments before freezing
and placing the work order.
b. QAP for DCS and all other field instruments.
c. Intimations for Pre dispatch inspection of all the items should be communicated.
Inspection of all the items (100%) shall not be waived off without clients
approval.
d. Inspection should be done as per the details mentioned in Section 20 and
approved QAP.
e. Application development.
f. FAT, DELIVERY and SAT details of DCS.
g. Cable schedule of
- Interconnection diagram between field instruments and control room
- Interconnection cables with MCC.
JB details
h. Installation details with isometric drawings of field instruments.
i. Power distribution schemes in single line diagram.
j. Proposed architects of the total systems.
k. Specification of UPS.
18.0. Technical documents to be supplied for the system
a. Terminal strip wiring diagram showing the termination details of field cables to
the input/output interfaces, intrinsic safe barriers , control cable and operator
consoles.
b. Final loop diagram with complete wiring and terminal identification, power
supply, and distribution drawings.
c. Operator consoles, Marshalling cabinet, isolator panel, CPU cabinet, Power
supply cabinet etc. dimensional drawing and mounting details in control room.
d. Internal GA drawing for all the cabinets and panels as mentioned above.
e. Signal wiring diagram
f. Earthing drawings with termination references.
g. Total power requirement for complete instrumentation job has been envisaged
well within 25 KVA. However party shall calculate the total power requirement
for the instrumentation system to be supplied for SPP and submit for approval by
HWB.
h. Input / Output list data bases.
i. \Tag data bases for HMI and DCS.
j. Control programme for each loop.
k. Description of the function of each programme. This shall include the logic
configuration requirement and constraints and sub programmes used up to
component level.
l. List of softwares and detail manuals.

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 Chapter-9 Technical specification

m. Documentation of all applications software such s process management, Graphics,

Utilities, real time operating system, Process management software, Languages
etc..
n. Final FAT and SAT to be carried out.
o. QAP for all field instruments

19.0.Point wise Clarification / Deviation

All the points mentioned below shall be filled up by the EPC contractor and to be
submitted along with the quotation.

S. No. DESCRIPTION EPC

CONTRACTOR
TO SPECIFY

19.1 GENERAL REQUIREMENT

a) EPC CONTRACTOR DISCLOSURE
i. EPC contractor name
ii. Location
iii. Model No.
iv. Year of introduction of the offered system for
commercial
v. Any system introduced in the market After this
model.
vi. Nos. of trained personnel available with EPC
contractor, experienced in installation,
commissioning & operation of the system.
vii. Nos. of identical system supplied in India Or
abroad.
viii. Address of users & their phone, fax nos.
ix. Sales support
x. Engineering support
xi. Service support
xii. Other Details
19.2 MANUFACTURER ( Original Source agency
of hardware items) DISCLOSURE
i. Name
ii. Location
iii. No. of Years in DCS field
iv. Sales support
v. Engineering support
vi. Service support
vii. Number of similar systems sold
viii. User list
ix. Company history
x. Company financial
19.3 EPC CONTRACTOR'S COMMITMENT
i. No additional cost implication for any hardware &
software additions by EPC contractor of their own
to the functional requirement with any Change of

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 Chapter-9 Technical specification

scope by client
ii. Supply of spares for 15 years from the date of
commissioning of system
iii. System shall not become obsolete for at least15
years.
iv. Period for which technical support shall be
available after 15 years .
19.4 System Overview
a) Analog input
b) Digital input
c) Digital output
d) Serial ports
e) Parallel ports
f) Tag names
g) Power requirements
h) Dimensions
i) Environmental requirements
j) Noise immunity
k) Grounding
l) Performance data
m) MTTR
n) MTBF
o) Availability
p) Intrinsic safety
q) Standards
r) Diagnostic features of system
s) Programming languages
t) Accuracy
u) Redundancy
v) Expansion
w) Speed
x) Storage devices
y) Printers
z) Algorithms
aa) Security
bb) Interface
cc) Central computer
dd) Man-machine interface
ee) Communication
ff) Data highway type
gg) Data highway speed
hh) Data highway concept
ii) Alarming
jj) Interlocks
19.5 Expansion Requirements
a) Maximum size
b) Tags
c) Analog inputs

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d) Digital inputs
e) Digital outputs
f) Serial ports
g) Parallel ports
h) Slots
i) Nests
j) Displays
19.6 SYSTEM ARCHITECTURE
a) Architecture conforming to spec EPC contractor to
indicate deviation & submit their architecture
19.7 SYSTEM SECURITY
a) Automatic switch over from primary to secondary
bus
b) Errors Checks on all parallel data transfer.
c) Priority Check on all serial data transfer.
d) Automatic retries in the event of errors.
e) Dual power for communication processor
f) Built in cable fault detection.
g) System level fault diagnosis.
h) Status indication of all devices with history of
errors.
19.8 CONTROLLER SECURITY
Status & error detection of
a) Input over or under range.
b) Computational Check & error
c) CPU bus time out.
d) Watch dog timer error
e) Power supply status & error detection.
f) Automatic Change over from primary to
secondary controller detection
19.9 SECURITY AT CONSOLE LEVEL
Status & error detection of
a) Console electronics failure/error detection.
b) Error detection & identification of each type of
modules
c) Security at operator/Engineer level.
19.10 PRINTER AND KEY BOARD
a) EVENT LOG & ALARMS PRINTER with
COVER
i. Make :
ii. Model:
iii. Type
iv. Printing speed
v. Noise level(<50 dBa)
vi. Number of Printer
19.11 SOFTWARE
i. Programming language
ii. Configuring language

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iii. Custom programs

iv. Multitasking
v. Operating system
vi. Display builder
vii. Alarm management
viii. Report Management
ix. System Diagnostics
x. Engineering station functionality
xi. Self-documentation
xii. Other software offered by EPC contractor
xiii. Application software including
complex loop software
19.12 Peripherals
a) Bulk storage devices
i. Hard disk
ii. DVD’S
iii. Other
b) Storage locations
i. Control Parameters
ii. Algorithms
iii. Diagnostic routines
iv. Operating system
v. Calculations
vi. Reports
vii. Other
19.13 Redundancy
i. Data highway
ii. Controllers
iii. Operators' station
iv. I/0 racks
v. Interfaces
vi. Processor module
vii. I/O Module
viii. Power Supply Module
ix. Communication links
x. Backplane failure
19.14 ENGINEERING WORKSTATION:
a) WORKSTATION
i. Make
ii. Offered CPU
iii. CPU Memory
iv. Math Co-Processor
v. Model
vi. Min 32 BIT
vii. CLOCK SPEED
viii. No. of stations
ix. Single/Redundant
x. Make

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b) MONITOR
i. No. of monitor
ii. Screen size
iii. Furniture
iv. Antiglare screen
v. Key board
c) LED
i. Resolution in Pixels
ii. Colour 256/more
iii. Touch Screen /light pen
iv. Type of touch screen
v. Display access time
d) MAIN CPU MEMORY: Capacity in MB(RAM)
e) AUX. MEMORY
i. Hard disc capacity
ii. DVD’S/ any other latest storage device.
iii. Tape drive/digital audio tape
f) SOFTWARE FACILITY
i. Loop built up facility
ii. On-line addition deletion
iii. History report of maintenance
iv. Logging report of load/save facility
v. Historical documentation o/p
vi. Software revision management
vii. Detailed diagnosis of fault cause.
viii. System start up support
ix. Database backup/recovery facility
x. Hard disk back up to & from
xi. Facility Electronic documentation
xii. Reports
xiii. Display generation
xiv. Level of expertise required
xv. Alarm acknowledgment
xvi. Report writing program
xvii. Logic/sequence program
xviii. Changing algorithms
xix. Changing alarm parameters
19.15 AUXILIARY CONSOLE
i. Size, Thickness of sheet
ii. Self-illuminating push buttons for pump start/stop
19.16 CONTROLLER SUBSYSTEM
a) CONTROL PROCESSOR & I/O
PROCESSOR
i. Make, Model
ii. Min 32 bit
iii. Clock speed
iv. Single/redundant
b) I/O SUB SYSTEM
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i. Nos. of analog 4-20 mA dc input card.

ii. Nos. of digital inputs
iii. Nos. of digital outputs
iv. Nos. of RS 232 input
v. Redundancy at I/O level
c) POWER SUPPLY
i. Redundancy/single
ii. Field transmitter power supply
d) CONTROL SYSTEM SPEED
i. Closed loop
ii. Open loop
iii. Digital I/Os
e) MAIN MEMORY Capacity in MB(RAM)
i. CONTROLLER CAPABILITIES
ii. Nos. I/Os handling capacity
iii. Algorithms, Complex loops
iv. Nos. of closed loop processing
v. Nos. of open loop processing
vi. CPU loading should not exceed 50%
f) CONTROLLER SOFTWARE FACILITY
i. Logic
ii. Alarm & analysis
iii. Sequential control
19.17 CABINET
a) GENERAL SPECIFICATION
i. Size
ii. Painting
iii. Fabricated from good quality of steel sheet
iv. Cabinet drawing to be attached with offer
v. Nos. of cabinets
vi. Front & rear opening
vii. Ventilation fan
viii. Panel illumination
ix. Terminals MAKE
x. Type of cabinet
b) NOS. OF CABINET OFFERED
i. System cabinet
ii. Marshalling cabinet
iii. Power distribution cabinet
iv. Relay cabinet
v. Electrical instrument interconnection cabinet
vi. Cabinet for free issue items
vii. Any other
19.18 Electrical power
i. Voltage
ii. Phase
iii. Amps
iv. Noise

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v. Grounding
vi. Isolation
vii. UPS requirements
viii. Redundancy
ix. Frequency
x. Feeder rating
xi. Earthing system required
xii. System earth in ohms.
19.19 Alarm Requirements
a) Number of alarms per unit
b) Total number of alarms
c) Types of alarm
i. Process variable absolute
ii. Deviation
iii. Calculated
iv. Digital input
v. Electrical signal limit
vi. Self diagnostic
vii. Highway
d) Alarm priority
e) Key to acknowledge
f) Hardcopy required
g) Printer information
19.20 Storage Requirements
a) DVD storage
b) Hard disk storage
c) Tape storage
d) Memory storage
e) Historical trending
f) Recovering old data
19.21 CALCULATED & SIZING DETAILS WITH
OFFER.
a) Controller CPU loading
b) Power consumption
c) Bus loading
d) Heat dissipation rate by system (for A/C system
sizing).
19.22 ON-LINE HELP
a) system configuration details
b) Maintenance manuals /procedures
c) Software and it’s features
d) Process manual including P & I Diagram
19.23 Grounding
a) Specification
b) Ground loop avoidance
c) Other
19.24 Power failure
a) Failsafe mode
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b) Power up
c) Power supply failure
d) Restore memory
e) Restore clock
f) Restore configuration
g) Restore graphics
h) Restore trending
i) Restore interlock logic
19.25 Documentation
a) Operation
b) Programming
c) Installation
d) Dimensions
e) Description
f) Software
19.26 Maintenance
a) Special tools
b) Special training
c) Parts availability
d) Card replacement procedures
e) Documentation
f) Service contracts
g) On Line card testing
h) Response time
19.27 Training
a) Locations
b) Courses
c) Schedules
19.28 FUNCTIONAL CAPABILITIES
a) Logic function
b) Timing/counter function
c) Delay function
19.29 INTERFACING CAPABILITIES OFFERED:
a) With supplied DCS
b) Type of interface with Engineering PC/SOE PC( if
any)
19.30 SYSTEM REQUIREMENT
a) TUV certified.
b) All communication shall be dual redundant.
c) free from obsolescence for at least another 15
years.
d) No single failure within the system component or
field I/O s shall lead to a shutdown of the plant.
e) The system design shall have dual redundant
architecture with 1002D voting according to
Safety Integrity Level SIL-2 as per ANSI/ISA
84.01 standards.
f) The system design and architecture shall follow

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IEC 61508 SIL level 2 compliant & certified by

TUV
g) Scan time
h) diagnostic features for both hardware and software
functions
i) On line replacement of faulty modules
j) System is designed to operate in the high electrical
noise environment of an industrial plant.
19.31 CPU
a) Full redundancies of entire system is required at
CPU, I/O LEVEL (except few which are used for
alarm purposes), COMMUNICATION BUS,
POWER SUPPLY ETC.
b) The total system loading for CPU and other
subsystem shall not exceed 50%.
c) All modules shall be distributed on a single
motherboard or backplane.
d) internal diagnostic checking and "green" indicator
when no fault is detected and a "red" indicator
when a fault is detected
19.32 INPUT / OUTPUT SYSTEM
a) Input with signal conditioning circuitry , galvanic
/ optical isolation.
b) I/Os for hazardous area with suitable barriers of
M/s P & F.
c) I/O protected against polarity reversal of I/O
power voltage
d) I/O short circuit proof and protected by visual
indicating fuses / MCB’s
e) On line replacement of I/O modules
f) I/O card with LED indication for card healthiness
status
g) Current distribution point protected by fuse. with
LED indicator.
h) Number of channel per I/O cards
i) I/O cards shall have Channel LED for status
indication
j) Digital inputs shall be potential free contacts.
k) Digital outputs shall be potential free contacts with
contact rating 30 V DC, 500mA with short circuit
protection with help of external fuse
19.33 POWER SUPPLY SYSTEM
a) Load requirement of various sub-systems.
b) Two independent dual redundant power supplies
for CPU system
c) Two independent dual redundant power supplies
for each I/O rack
19.34 Auxiliary panel
a) Auxiliary panel for trips pushbutton in CCR and
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CH.
b) Emergency pushbutton provided to trip the entire
process safely as per the logic.
19.35 EVENT RECORDING SYSTEM
a) System with inbuilt sequence of events (SOE)
capability
b) Logging of analog trip value change
c) Time stamping resolution of 100 msec
d) Synchronization between and DCS timings
e) No duplicate wiring needed for configuring any
particular channel for event recording
19.36 ALARMS
a) First up trip alarm shall be flashing. Succeeding
alarms shall be indicated by steady display
b) Manual forcing On / Off of any input from
keyboard.
c) Forced I/Os indication on the LED screen
d) Audible alarm different from the trip alarm for
system alarms
e) Alarms gets printed with time stamping up to a
resolution of 100 msec in the order of its
appearance with first up indication on each
Interlock Group
19.37 Maintenance support features
a) Live viewing of Ladder execution
b) Forcing of input & output
c) Concept of existing Programme Matrix is be
maintained in software form
d) System shall have simulation facility.
19.38 CODES AND STANDARDS:
a) Latest copies of all relevant standards as per
specification , e.g. IEC 61508, TUV
certification test etc. including applicable
Company standards, ISA standards , Factory
manuals, and Underwriters Laboratories test
procedures is supplied by EPC contractor along
with the quotation.
b) List of codes and standards for which system has
compliance
19.39 Circuit details of all PCBs: 3 copies of Circuit
details of all PCBs of the system with various test
point voltages details & their maintenance
procedures.
19.40 Tests: List of various tests, with their procedures
details and relevant code reference along with
the copy of that code/standard, which were
carried out on components, PCBs and on system.
19.41 MTBF: (Mean Time Between Failure) of their

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system Components, PCBs and Units.

19.42 MTTR: (Mean Time To Repair) of their system
Components, PCBs and Units.
19.43 I/O CARDS OFFERED:
Required / offered
19.44 System Environmental Requirements
a) Air conditioning
b) Temperature limits
c) Humidity limits

20.0 LIST OF RECOMMENDED EPC CONTRACTORS

Sl. No Type of instrument Recommended EPC

contractors
1 Diaphragm seal PG/CPG General instruments, Waree,
2 PG without Diaphragm seal Wika, Manometer India, Forbes
Marshall
3 Mcleod gauge ABB, Rosemount, Teledyne,
Honeywell, Foxboro
4 Pirani gauge ABB, Rosemount, Teledyne,
Honeywell, Foxboro
5 Pressure Transmitter ABB, Rosemount, Honeywell,
Fuji, E&H, Yokogawa
6 SS LG Pune techtrol, RK Dutt,
Chemtrol engineering, Levcon
7 PTFE lined LG Pune techtrol,Levcon,M/s
V.Automat
8 Guided wave Radar LT ABB, Forbes Marshall,
Honeywell, E&H, Yokogawa
9 Ultrasonic LT ABB, Forbes Marshall,
Honeywell, E&H, Yokogawa
10 RTD without thermo well Pyroelectric, General
11 RTD with SS thermo well Instrument, Altop, Electrical
12 RTD with Hastelloy C thermo well and electronics corporation
13 Temperature transmitter with TT Honeywell, E&H, Yokogawa,
ABB
14 Weighing machine Purnima, contech, Mino
15 Load cell weight, jay instrument pvt ltd,
Novo weight
16 PTFE control valve with accessories M/s MIL, Fisher, Forbes
17 SS control valve with accessories Marshall, Inst Ltd,
18 SS ON/OFF valve with accessories
19 Online H2 monitor Steam equipment for Teledyne,
ABB, Honeywell, Dagger,
Prism Gas detection Pvt ltd.
20 Online Hydrocarbon monitor Steam equipment for Teledyne,
ABB, Honeywell, Dagger,
Foxboro, Prism Gas detection
Pvt ltd.

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21 Online HCl monitor ABB, Foxboro, Prism Gas

detection Pvt ltd.
22 Hastelloy C Mass flow meter coriolisis Honeywell, E&H, Yokogawa,
Forbes Marshall, ABB
23 SS Mass flow meter coriolisis Honeywell, E&H, Yokogawa,
Forbes Marshall, ABB
24 Steam mass flow transmitter (vortex) Forbes Marshall, Honey well,
ABB, Foxboro, E&H,
Yokogawa
25 pH transmitter Forbes Marshall, Honey well,
ABB, Foxboro, steam
equipment for teledyne
26 DCS Eurotherm, ABB, Honeywell,
Yokogawa, Allen bradly,
Siemens, GE
27 Cable glands, Instrument fittings Wintech, Swagelog, Parker

28 SS tube Wintech, Swagelock, Praker,

Sandvic
29 Cable Universal, polycab, finolex,
Associated cables, Delton
cables
30 Alarm window with Annunciator Minilec, procon, industrial
instruments and control
31 Industrial PC Chino Laxson, Advantech,
ABB, Phoenix
32 Cable tray & accessories Globe electrical industries,
Indian engg works Pvt ltd,
sadhna engg. corporation
33 Junction box Baliga lighting equipments ltd,
Ceag flame proof control gears
ltd
34 Terminals Connectwell, phoenix, elmex,
weidmuller
35 Control panels Rittal, Bell controls, ECIL,
Industrial controls & appliances
(ICA)
36 Isolator cum barrier P&F, MTL, Stahl, phoenix,
weidmuller
37 Relay Omron, Phoenix, weidmuller

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 Chapter-9 Technical specification

STANDARDS AND DRAWINGS

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 Chapter-9 Technical specification

21.0. Recommended Standards

Codes and Standards

American National Standards Institute (ANSI)

 ANSI B 2.1 - Pipe Threads

 ANSI B 16.5 - Steel Pipe Flanges, Flanged Valves and Fittings

 ANSI B 16.34 - Hydrostatic body and leak testing of isolation valves

 ANSI B 16.37 - Hydrostatic Testing of Control Valves

 ANSI MC 96.1 - Temperature Measurement Thermocouples

American society of Mechanical Engineers (ASME)

 ASME B1.20.1 - Pipe Threads, General Purpose

 ASME B16.5 - Pipe Flanges and Flange Fittings

 ASME B16.10 - Face-to-Face and End–to-End Dimensions of Valves

 ANSI/ASME B16.36 - Orifice Flanges

 ASME PTC 19.3 - Performance Test Code Temperature Measurement

American Society for Testing and Materials (ASTM)

 ASTM A269 - Stainless Steel Tube

 ASTM A276.316L - Stainless Steel Fittings

International Electro technical Commission (IEC)

 IEC STD 801 Part 3 – EMI and RFI Immunity

 IEC 60534 – Industrial Process Control valves

 IEC 60529 - degrees of Protection provided by enclosures

 IEC 332 Part III Cat. A – Test on bunched wire or cables

 IEC-61000-4-3 – Instrument EMC

 IEC 60751 – RTD

Instrumentation Systems and Automation Society (ISA)

 ISA 5.1 - Instrumentation Symbols and Identification

 ISA 5.2 - Binary Logic Diagrams for Process Operations

 ISA 18.1 - Annunciator sequences and Specifications

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 Chapter-9 Technical specification

 ISA 7.0.01 - Quality Standard for Instrument Air

 ISA S 75 - control valves

International Organization for Standardization (ISO)

 ISO 5167 - Measurement of Fluid Flow by means of Orifice Plates

National Electrical Manufacturers Association (NEMA)

 NEMA Std. ICS-6 - Enclosure for Industrial Control and Systems

Indian Standards (IS)

IS: 2848 - Industrial Platinum resistance thermometer

 IS 7358 – Specifications for Thermocouples

 IS: 3624 - Bourdon tube pressure and vacuum gauges

 IS 1554 Part 1 – PVC insulated RTD cables-working voltage up to and including

1100 V
 IS 5831 (1984) – PVC insulation and sheath of RTD cables.

 Signal cable (1.0 sq. mm) - Fire Retardant as per IEC 332 Part III CAT –A Voltage
grade 600 Volts.
 Control cable (1.5 sq. mm)-as per IEC 332 Part III CAT–A Voltage grade 600
Volts.
 Instrument power cable (2.5 sq. mm) -)-as per IEC 332 Part III CAT –A Voltage
grade 1100 Volts.

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 Chapter-9 Technical specification

22.0.DRAWINGS
Annexure-I
Control System Architecture

OWS EWS/OW
S

SW1 SW2

CONTROLLER-1 CONTROLLER-2
P P U U C D D P P P P U U C D D P P
C C P C C C C C C P C C C C
S S O O U O O O O S S O O U O O O O
M M M M M M M M M M M M

D D I I P P
C C
O O O O S S
M M

EWS-engineering work station OWS-operator work station

SW-switch PS-power supply card/module
CPU-processor card IO-input output card
UCOM-upward comm. Card DCOM-downward comm. Card
PCOM-parallel comm. card (this can be non-redundant)

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 Chapter-9 Technical specification

ANNEXURE-II
PROPOSED TENTATIVE OPERATOR CONSOLE AND SYSTEM PANELS FOR
SPP AT HEAVY WATER PLANT ( TUTICORIN)

MARSHALLING AND SYSTEM CABINET

Total 6000 mm
800 1200
mm mm

2200
mm

100 mm with 15 mm
Anti-vibration pad

3 NOS OPERATOR CONSOLE IN CONTROL ROOM

Total
1500 mm

2200 mm
MTR

400 mm

600 mm
200 mm
PREPARED BY : P.D.ROY ( SO/F) TDP, Mumbai

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 Chapter-9 Technical specification

ANNEXURE III
PLOT, PLAN LAYOUT OF SPP

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 Chapter-9 Technical specification

23.0. LIST OF INSTRUMENTS WITH PROCESS PARAMETERS

LIST OF INSTRUMENTS WITH PROCESS PARAMETERS

S. No. Contents Page No.

1 LIST OF FLOW TRANSMITTERS UNIT -43 IC-116

LIST OF INSTRUMENTS WITH OVERALL SPECIFICATION
2 IC-118
UNIT -43
3 LIST OF FLOW TRANSMITTERS UNIT- 44 IC-135
LIST OF INSTRUMENTS WITH OVERALL SPECIFICATION
4 IC-137
UNIT -44
5 LIST OF FLOW TRANSMITTERS UNIT -45 IC-149
LIST OF INSTRUMENTS WITH OVERALL SPECIFICATION
6 IC-151
UNIT -45
LIST OF INSTRUMENTS WITH OVERALL SPECIFICATION
7 IC-160-164
UNIT -49

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 Chapter-9 Technical specification

1. LIST OF FLOW TRANSMITTERS UNIT-43

MASS Flow transmitter with totalizer

Type of
Normal op. Operating/ Indication Operating Wetted
S. no. Tag no. Description / Location Type Range Line size
range. Design temp local/control /Design press MOC
room
to indicate flow / quantity from 500 to 1500 kg/hr
1 43 FT 01 43V01 to 43RV01 & 43RV02 / on Coriolisis 50/80 ° C 100 to 2000 kg/hr Local & CR 2/6 Kg/cm2(g) 25 SS
line no. 25-ROH-1003-SS-UI 500 to 1100 Kg/hr

to indicate flow / quantity from 50 to 100 kg/hr

2 43 FT 02 43V02 to 43RV01 / on line no. Coriolisis 50 to 175 kg/hr 80 ° C 25 to 500 kg/hr CR 2/6 Kg/cm2(g) 25 Hastelloy-C
25-POC-1009_GL-UI 50 to 250 kg/hr
to indicate flow / quantity from 50 to 100 kg/hr
3 43 FT 03 43V03 to 43RV02 / on line no. Coriolisis 50 to 250 kg/hr 100 ° C 25 to 500 kg/hr CR 2/6 Kg/cm2(g) 25 Hastelloy-C
25-POC-1010-GL-UI 50 to 300 kg/hr
to indicate flow / quantity from
4 43 FT 04 43V04 to 43RV01 / on line no. Coriolisis 100 to 300 kg/hr 100 ° C 25 to 500 kg/hr CR 25
25-OCl-1011-GL-UI
2/6 Kg/cm2(g) Hastelloy-C
to indicate flow / quantity from
5 43 FT 05 43V05 to 43RV01 / on line no. Coriolisis 100 to 300 kg/hr 100 ° C 25 to 500 kg/hr CR 25
25-HEX-1022-GL-UI
to indicate flow / quantity from
6 43 FT 06 43V06 to 43RV02 / on line no. Coriolisis 50 to 150 kg/hr 100 ° C 25 to 500 kg/hr CR 2/6 Kg/cm2(g) 25 Hastelloy-C
25-PRL-1146-SS-UI

to indicate flow / quantity from 100 to 500 kg/hr

7 43 FT 07 43V07 to 43RV01 / on line no. Coriolisis 100 ° C 100 to 2000 kg/hr CR 2/6 Kg/cm2(g) 25 SS
25-ALK-1015-SS-UI 200 to 500 kg/hr

100 to 500 kg/hr

to indicate flow / quantity from
8 43 FT 08 43V08 to 43RV02 / on line no. Coriolisis 100 to 500 kg/hr 100 ° C 100 to 2000 kg/hr CR 2/6 Kg/cm2(g) 25 SS
25-ALK-1016-SS-UI
100 to 300 kg/hr

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 Chapter-9 Technical specification

Volumetric Flow transmitter without totalizer

To indicate flow of cooling water / 32 ° C

chilled water to the jacket of
9 43 FT 10 Rotameter 1500 to 6000 lit/hr 1000 to 10000 lit/hr CR 2/6 Kg/cm2(g) 50 SS
43RV01 for cooling / on line no.
50-CHS-0142-CS-IC 2°C

To indicate flow of cooling water

to the jacket of 43RV01 for
10 43FI11 Rotameter 40 to 200 lit/hr 32 °C 30 to 300 lit/hr Field 4/6 Kg/cm2(g) 15 SS
cooling / on line no. 15-CWS-
0184-CS-UI
To indicate flow of cooling water / 32 ° C
chilled water to the jacket of
11 43 FT 13 Rotameter 1500 to 6000 lit/hr 1000 to 10000 lit/hr CR 4/6 Kg/cm2(g) 50 SS
43RV02 for cooling / on line no.
50-CHS-0142-CS-IC 2°C

To indicate flow of cooling water

to the jacket of 43RV02 for
12 43FI14 Rotameter 40 to 200 lit/hr 32 °C 30 to 300 lit/hr Field 15 SS
cooling / on line no. 15-CWS-
0184-CS-UI
4/6 Kg/cm2(g)
To indicate flow of thermic fluid
to the jacket of 43RV03 for
13 43FT15 Rotameter 1500 to 6000 lit/hr 240 °C 1000 to 10000 lit/hr CR 50 SS
heating / on line no. 50-THF-
0135-SS-IH

Mass Flow transmitter/local flow indicator

Type of
Normal op. Operating/ Indication Operating Wetted
S. no. Tag no. Description / Location Type Range Line size
range. Design temp local/control /Design press MOC
room

To indicate flow of steam to the

vortex/orif 7/10 Kg/cm2
1 43FT09 jacket of 43RV01 for heating / on 20 to 40 kg/hr 165 / 250 °C 10 to 100 kg/hr 50 SS
ice FT (g)
line no. 50-ST-0173-CS-IH
CR ( indication
& totaliser)
To indicate flow of steam to the
vortex/orif 7/10 Kg/cm2
2 43FT12 jacket of 43RV02 for heating / on 20 to 50 kg/hr 165 / 250 °C 10 to 100 kg/hr 50 SS
ice FT (g)
line no. 50-ST-00-CS-IH

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 Chapter-9 Technical specification

2. LIST OF INSTRUMENTS WITH OVERALL SPECIFICATIONS UNIT-43

PRESSURE GAUGE and mcleod gauge

Normal op. Normal op. WettedMO

S. no. Tag no. Description / Location Type Range Indication Design press Design temp Line size
press. temp C

To measure the pressure in

0 to 2
1 43-PG-01 ROH day tank (43V01) / PG Ambient 0 to 6 Kg/cm2(g) Field 6 Kg/cm2(g) 80 ° C 25 SS
Kg/cm2(g)
on ROH day tank (43V01)

To measure the pressure in

(-)1 to 4 PTFE lined
2 43-CPG-02 charging vessel 43V02 / on PG 350 torr Ambient Field 6 Kg/cm2(g) 80 ° C 25
Kg/cm2(g) SS
vessel (43V02)

To measure the pressure in

0.5 to 2 (-)1 to 4 PTFE lined
3 43-CPG-03 charging vessel 43V03 / on PG Ambient Field 6 Kg/cm2(g) 80 ° C 25
Kg/cm2(g) Kg/cm2(g) SS
vessel (43V03)

To measure the pressure in

(-)1 to 4 PTFE lined
4 43-CPG-04 charging vessel 43V04 / on PG 350 torr Ambient Field 6 Kg/cm2(g) 80 ° C 25
Kg/cm2(g) SS
vessel (43V04)

To measure the pressure in

0 to 2 PTFE lined
5 43-PG-05 hexane vessel 43V05 / on PG Ambient 0 to 6 Kg/cm2(g) Field 6 Kg/cm2(g) 80 ° C 25
Kg/cm2(g) SS
vessel (43V05)

To measure the pressure in

0 to 2 PTFE lined
6 43-PG-06 RCl + ROH vessel 43V06 / PG Ambient 0 to 6 Kg/cm2(g) Field 6 Kg/cm2(g) 80 ° C 25
Kg/cm2(g) SS
on vessel (43V06)

To measure the pressure in

0 to 2
7 43-PG-07 vessel 43V07 / on vessel PG Ambient 0 to 6 Kg/cm2(g) Field 6 Kg/cm2(g) 80 ° C 25 SS
Kg/cm2(g)
(43V07)

To measure the pressure in

0 to 2
8 43-PG-08 vessel 43V08 / on vessel PG Ambient 0 to 6 Kg/cm2(g) Field 6 Kg/cm2(g) 80 ° C 25 SS
Kg/cm2(g)
(43V08)

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 Chapter-9 Technical specification
To measure discharge
pressure of pump 43P01A / 0 to 2
9 43-PG-22 PG Ambient 0 to 6 Kg/cm2(g) Field 6 Kg/cm2(g) 80 ° C 25 SS
on discharge line of Kg/cm2(g)
43P01A
To measure discharge
pressure of pump 43P01B / 0 to 2
10 43-PG-23 PG Ambient 0 to 6 Kg/cm2(g) Field 6 Kg/cm2(g) 80 ° C 25 SS
on discharge line of Kg/cm2(g)
43P01B
To measure discharge
pressure of pump 43P07A / 0 to 2
11 43-PG-24 PG Ambient 0 to 6 Kg/cm2(g) Field 6 Kg/cm2(g) 80 ° C 25 SS
on discharge line of Kg/cm2(g)
43P07A
To measure discharge
pressure of pump 43P07B / 0 to 2
12 43-PG-25 PG Ambient 0 to 6 Kg/cm2(g) Field 6 Kg/cm2(g) 80 ° C 25 SS
on discharge line of Kg/cm2(g)
43P07B
To measure discharge
pressure of pump 43P08A / 0 to 2
13 43-PG-26 PG Ambient 0 to 6 Kg/cm2(g) Field 6 Kg/cm2(g) 80 ° C 25 SS
on discharge line of Kg/cm2(g)
43P08A
To measure discharge
pressure of pump 43P05A / 0 to 2 PTFE lined
14 43-PG-27 PG Ambient 0 to 6 Kg/cm2(g) Field 6 Kg/cm2(g) 80 ° C 25
on discharge line of Kg/cm2(g) SS
43P05A
To measure discharge
pressure of pump 43P05B / 0 to 2 PTFE lined
15 43-PG-28 PG Ambient 0 to 6 Kg/cm2(g) Field 6 Kg/cm2(g) 80 ° C 25
on discharge line of Kg/cm2(g) SS
43P05B
To measure discharge
pressure of pump 43P06A / 0 to 2 PTFE lined
16 43-PG-29 PG Ambient 0 to 6 Kg/cm2(g) Field 6 Kg/cm2(g) 80 ° C 25
on discharge line of Kg/cm2(g) SS
43P06A
To measure discharge
pressure of pump 43P06B / 0 to 2 PTFE lined
17 43-PG-30 PG Ambient 0 to 6 Kg/cm2(g) Field 6 Kg/cm2(g) 80 ° C 25
on discharge line of Kg/cm2(g) SS
43P06B
To measure the pressure in
(-)1 to 4 PTFE lined
18 43-CPG-12 Receiver 43V12 / on PG 100 torr 20 ° C Field 6 Kg/cm2(g) 80 ° C 25
Kg/cm2(g) SS
Receiver (43V12)

To measure the pressure in

(-)1 to 4 PTFE lined
19 43-CPG-13 Receiver 43V13 / on PG 0.1 torr 20 ° C Field 6 Kg/cm2(g) 80 ° C 25
Kg/cm2(g) SS
Receiver (43V13)

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 Chapter-9 Technical specification

To measure the pressure in

(-)1 to 4 PTFE lined
20 43-CPG-14 Receiver 43V14 / on PG 10 torr 20 ° C Field 6 Kg/cm2(g) 80 ° C 25
Kg/cm2(g) SS
Receiver (43V14)

To measure the pressure in

(-)1 to 4 PTFE lined
21 43-CPG-15 Receiver 43V15 / on PG 0.1 torr 20 ° C Field 6 Kg/cm2(g) 80 ° C 25
Kg/cm2(g) SS
Receiver (43V15)

To measure the pressure in

(-)1 to 4 PTFE lined
22 43-CPG-16 Receiver 43V16 / on PG 0.1 torr 20 ° C Field 6 Kg/cm2(g) 80 ° C 25
Kg/cm2(g) SS
Receiver (43V16)

To measure the pressure in

0.1 torr to 2 (-)1 to 4 PTFE lined
23 43-CPG-18 Reactor 43RV01 / on PG 90/145 ° C Field 6 Kg/cm2(g) 150 ° C 80
Kg/cm2(g) Kg/cm2(g) SS
Reactor (43RV01)

To measure the pressure in

0.1 torr to 2 (-)1 to 4 PTFE lined
24 43-CPG-19 Reactor 43RV02 / on PG 90/190 ° C Field 6 Kg/cm2(g) 150 ° C 80
Kg/cm2(g) Kg/cm2(g) SS
Reactor (43RV02)

To measure the pressure in

0.1 torr to 2 (-)1 to 4 PTFE lined
25 43-CPG-20 Reactor 43RV03 / on PG 220 ° C Field 6 Kg/cm2(g) 200 ° C 80
Kg/cm2(g) Kg/cm2(g) SS
Reactor (43RV03)
To measure discharge
pressure of pump 43P09A / 0 to 2 PTFE lined
26 43-PG-31 PG Ambient 0 to 6 Kg/cm2(g) Field 6 Kg/cm2(g) 80 ° C 25
on discharge line of Kg/cm2(g) SS
43P09A
To measure discharge
pressure of pump 43P09B / 0 to 2 PTFE lined
27 43-PG-32 PG Ambient 0 to 6 Kg/cm2(g) Field 6 Kg/cm2(g) 80 ° C 25
on discharge line of Kg/cm2(g) SS
43P09B
To measure discharge
pressure of pump 43P10A / 0 to 2
28 43-PG-33 PG Ambient 0 to 6 Kg/cm2(g) Field 6 Kg/cm2(g) 80 ° C 25 SS
on discharge line of Kg/cm2(g)
43P10A
To measure discharge
pressure of pump 43P10B / 0 to 2
29 43-PG-34 PG Ambient 0 to 6 Kg/cm2(g) Field 6 Kg/cm2(g) 80 ° C 25 SS
on discharge line of Kg/cm2(g)
43P10B
To measure the pressure in
0 to 2 PTFE lined
30 43-PG-09 vessel 43V09 / on vessel PG Ambient 0 to 6 Kg/cm2(g) Field 6 Kg/cm2(g) 60 ° C 25
Kg/cm2(g) SS
(43V09)

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 Chapter-9 Technical specification

To measure the pressure in

0 to 2 PTFE lined
31 43-PG-10 vessel 43V10 / on vessel PG Ambient 0 to 6 Kg/cm2(g) Field 6 Kg/cm2(g) 80 ° C 25
Kg/cm2(g) SS
(43V10)

To measure the pressure in

0 to 2 PTFE lined
32 43-PG-11 vessel 43V11 / on vessel PG Ambient 0 to 6 Kg/cm2(g) Field 6 Kg/cm2(g) 80 ° C 25
Kg/cm2(g) SS
(43V11)

To measure steam pressure 0 to 6

33 43-PG-35 PG 165 °C 0 to 8 Kg/cm2(g) Field 10 Kg/cm2(g) 200 ° C 100 SS
/ on steam header Kg/cm2(g)

To measure cooling water

supply pressure / on 0 to 4
34 43-PG-36 PG 38 °C 0 to 6 Kg/cm2(g) Field 6 Kg/cm2(g) 80 ° C 150 SS
cooling water supply Kg/cm2(g)
header
To measure nitrogen
0 to 2
35 43-PG-38 supply pressure / on PG Ambient 0 to 6 Kg/cm2(g) Field 6 Kg/cm2(g) 80 ° C 25 SS
Kg/cm2(g)
nitrogen header

VACUUM gauge

Normal op. Normal op. wetted

Sr. no. Tag no. Description / Location Type Range Indication Design press Design temp Line size
press. temp MOC

To measure the pressure in

Reactor 43RV01 / on 0.01 torr to 760 PTFE lined
1 43VPG01 Mcleod 0-2 kg/cm2 35 to 170 oC Field 5 kg/cm2 200 ° C 15
Reactor (43RV01) Mcleod torr SS
gauge
To measure the pressure in
Reactor 43RV02 / on 0.01 torr to 760 PTFE lined
2 43VPG02 Mcleod 0-2 kg/cm2 35 to 170 oC Field 5 kg/cm2 200 ° C 15
Reactor (43RV02) Mcleod torr SS
gauge
To measure the pressure in
Reactor 43RV03 / on 0.01 torr to 760 PTFE lined
3 43VPG03 Mcleod 0-2 kg/cm2 35 to 170 oC Field 5 kg/cm2 200 ° C 15
Reactor (43RV03) Mcleod torr SS
gauge

PRESSURE TRANSMITTER including pirani gauge

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 Chapter-9 Technical specification

Normal op. Normal op. Wetted

Sr. no. Tag no. Description / Location Type Range Indication Design press Design temp Line size
press. temp MOC

To measure the pressure in

Reactor 43RV01 / on 0.005 torr to 0.005 torr to 760 PTFE lined
1 43PT01 pirani 90/145 ° C CR 6 Kg/cm2(g) 150 ° C 80
Reactor (43RV01) pirani 760 torr torr SS
gauge
diaphrag
To measure the pressure in
m seal 0 to 4 kg/cm2 PTFE lined
2 43PT01 A Reactor 43RV01 / on 90/145 ° C 0 to 6 kg/cm2 (g) CR 6 Kg/cm2(g) 150 ° C 80
Press (g) SS
Reactor (43RV01)
trans
To measure the pressure in
Reactor 43RV02 / on 0.005 torr to 0.005 torr to 760 PTFE lined
3 43PT02 pirani 90/190 ° C CR 6 Kg/cm2(g) 200 ° C 80
Reactor (43RV02) pirani 760 torr torr SS
gauge
diaphrag
To measure the pressure in
m seal 0 to 4 kg/cm2 PTFE lined
4 43PT02 A Reactor 43RV02 / on 90/190 ° C 0 to 6 kg/cm2 (g) CR 6 Kg/cm2(g) 200 ° C 80
Press (g) SS
Reactor (43RV02)
trans
To measure the pressure in
Reactor 43RV03 / on 0.005 torr to 0.005 torr to 760 PTFE lined
5 43PT03 pirani 220 ° C CR 6 Kg/cm2(g) 200 ° C 80
Reactor (43RV03) pirani 760 torr torr SS
gauge
diaphrag
To measure the pressure in
m seal 0 to 4 kg/cm2 PTFE lined
6 43PT03 A Reactor 43RV03 / on 220 ° C 0 to 6 kg/cm2 (g) CR 6 Kg/cm2(g) 200 ° C 80
Press (g) SS
Reactor (43RV03)
trans
To measure cooling water
supply pressure / on Press 0 to 4
43PT05 38 °C 0 to 6 Kg/cm2(g) CR 6 Kg/cm2(g) 100 ° C 150 SS
9 cooling water supply trans Kg/cm2(g)
header
To measure chilled water
Press 0 to 4
43PT06 supply pressure / on chilled 2 °C 0 to 6 Kg/cm2(g) CR 6 Kg/cm2(g) 100 ° C 80 SS
11 trans Kg/cm2(g)
water supply header

To measure Nitrogen
Press 0 to 4
43PT07 pressure / on Nitrogen Ambient 0 to 6 Kg/cm2(g) CR 6 Kg/cm2(g) 100 ° C 80 SS
12 trans Kg/cm2(g)
header

To measure 2EHA pressure Press 0 to 4

13 49PT01 Ambient 0 to 6 Kg/cm2(g) CR 6 Kg/cm2(g) 100 ° C 80 SS
from bulk tank to 43V01 trans Kg/cm2(g)

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 Chapter-9 Technical specification

LEVEL GAUGE / LEVEL switch

Normal op. Normal op. C-C, Wetted

Sr. no. Tag no. Description / Location Type Range Indication Design press Design temp
press. temp mm MOC

43 LG 01
level 0 to 2
1 with 2 To indicate level in 43V01 Ambient 0 to 100% Field /CR 6 Kg/cm2(g) 80 ° C SS
gauge Kg/cm2(g)
switches

43 LG 02
level 0 to 2 PTFE lined
2 with 2 to indicate level in 43V02 Ambient 0 to 100% Field /CR 6 Kg/cm2(g) 80 ° C
gauge Kg/cm2(g) SS
switches

43 LG 03
level 0 to 2 PTFE lined
3 with 2 to indicate level in 43V03 Ambient 0 to 100% Field /CR 6 Kg/cm2(g) 80 ° C
gauge Kg/cm2(g) SS
switches

43 LG 04
level 0 to 2 PTFE lined
4 with 2 to indicate level in 43V04 Ambient 0 to 100% Field /CR 6 Kg/cm2(g) 80 ° C
gauge Kg/cm2(g) SS
switches

43 LG 05
level 0 to 2 PTFE lined
5 with 2 To indicate level in 43V05 Ambient 0 to 100% Field /CR 6 Kg/cm2(g) 80 ° C
gauge Kg/cm2(g) SS
switches

43 LG 06
level 0 to 2 PTFE lined
6 with 2 To indicate level in 43V06 Ambient 0 to 100% Field /CR 6 Kg/cm2(g) 80 ° C
gauge Kg/cm2(g) SS
switches

43 LG 07
level 0 to 2 PTFE lined
7 with 2 To indicate level in 43V07 Ambient 0 to 100% Field /CR 6 Kg/cm2(g) 80 ° C
gauge Kg/cm2(g) SS
switches

43 LG 08
level 0 to 2 PTFE lined
8 with 2 To indicate level in 43V08 Ambient 0 to 100% Field /CR 6 Kg/cm2(g) 80 ° C
gauge Kg/cm2(g) SS
switches

43 LG 09
level 0 to 2 PTFE lined
9 with 2 To indicate level in 43V09 Ambient 0 to 100% Field /CR 6 Kg/cm2(g) 80 ° C
gauge Kg/cm2(g) SS
switches

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 Chapter-9 Technical specification

43 LG 10
level 0 to 2 PTFE lined
10 with 2 To indicate level in 43V10 Ambient 0 to 100% Field /CR 6 Kg/cm2(g) 80 ° C
gauge Kg/cm2(g) SS
switches

43 LG 11
level 0 to 2 PTFE lined
11 with 2 To indicate level in 43V11 Ambient 0 to 100% Field /CR 6 Kg/cm2(g) 80 ° C
gauge Kg/cm2(g) SS
switches

43 LG 12
To indicate level in level PTFE lined
12 with 2 100 torr 20 ° C 0 to 100% Field /CR 6 Kg/cm2(g) 80 ° C
Receiver 43V12 gauge SS
switches

43 LG 13
To indicate level in level PTFE lined
13 with 2 0.1 torr 20 ° C 0 to 100% Field /CR 6 Kg/cm2(g) 80 ° C
Receiver 43V13 gauge SS
switches

43 LG 14
To indicate level in level PTFE lined
14 with 2 10 torr 20 ° C 0 to 100% Field /CR 6 Kg/cm2(g) 80 ° C
Receiver 43V14 gauge SS
switches

43 LG 15
To indicate level in level PTFE lined
15 with 2 0.1 torr 20 ° C 0 to 100% Field /CR 6 Kg/cm2(g) 80 ° C
Receiver 43V15 gauge SS
switches

43 LG 16
To indicate level in level
16 with 2 10 torr 20 ° C 0 to 100% Field /CR 6 Kg/cm2(g) 80 ° C SS
Receiver 43V16 gauge
switches

LEVEL transmitter (guided radar/ultrasonic)

Type of
Normal op. Normal op. Indication Wetted
Sr. no. Tag no. Description / Location Type Range Design press Design temp C-C, mm
press. temp local/control MOC
room
ultrasoni
0 to 2
1 43 LT 01 to indicate level in 43V01 c/unguid Ambient 0 to 100% CR 6 Kg/cm2(g) 100 ° C SS/PTFE/PP
Kg/cm2(g)
ed radar

0 to 2
2 43 LT 18 to indicate level in 43RV01 G radar Ambient 0 to 100% CR 6 Kg/cm2(g) 200 ° C Hastelloy-C
Kg/cm2(g)

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 Chapter-9 Technical specification

0 to 2
3 43 LT 19 to indicate level in 43RV02 G radar Ambient 0 to 100% CR 6 Kg/cm2(g) 200 ° C Hastelloy-C
Kg/cm2(g)

0 to 2
4 43 LT 20 to indicate level in 43RV03 G radar Ambient 0 to 100% CR 6 Kg/cm2(g) 200 ° C Hastelloy-C
Kg/cm2(g)

0 to 2
5 43LT02 to indicate level in 43V02 G radar Ambient 0 to 100% CR 6 Kg/cm2(g) 200 ° C Hastelloy-C
Kg/cm2(g)

Temperature Indicator RTD/temp gauge (Temperature element with thermo well and transmitter)

Type of
Indication Design Wetted
Sr. no. Tag no. Description / Location Type Normal op. pt. Range Design press Line size
local/control temp MOC
room
to measure temperature in
64-67 / 90-145
1 43TI01 43RV01 / on top of RTD 0 to 200 °C CR 6 Kg/cm2(g) 200 °C 80 Hastelloy-C
°C
43RV01

to measure temperature in
64-67 / 90-145
2 43TI02 43RV01 / on bottom of RTD 0 to 200 °C CR 6 Kg/cm2(g) 250 °C 80 Hastelloy-C
°C
43RV01
to measure utility
temperature from/to jacket
3 43TI03 RTD 38 / 8 / 165 °C 0 to 200 °C CR 6 Kg/cm2(g) 250 °C 50 SS
of 43RV01 / on utility line
of 43RV01

to measure process side

inlet temperature to
4 43TI04 RTD 90 / 145 °C 0 to 200 °C CR 6 Kg/cm2(g) 250 °C 150 Hastelloy-C
condenser 43R01 / on line
150-PRG-0188-GL-IH

to measure cooling water

return temperature of
5 43TI05 RTD 38 °C 0 to 100 °C CR 6 Kg/cm2(g) 100 °C 80 SS
condenser 43R01 / on line
80-CWR-0173-CS-UI

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 Chapter-9 Technical specification

to measure temperature of
condensed process liquid in
6 43TI06 RTD 45 °C 0 to 100 °C CR 6 Kg/cm2(g) 100 °C 50 Hastelloy-C
condenser 43R01 / on line
50-PRL-0191-GL-UI

to measure temperature of
condensed process liquid in
7 43TI07 RTD 20 °C 0 to 100 °C CR 6 Kg/cm2(g) 100 °C 50 Hastelloy-C
condenser 43R02 / on line
50-PRL-0191-GL-UI

to measure chilled water

return temperature of
8 43TI08 RTD 2 to 8 °C 0 to 100 °C CR 6 Kg/cm2(g) 100 °C 50 SS
condenser 43R02 / on line
50-CHR-0194-CS-UI

to measure temperature in
9 43TI09 43RV02 / on top of RTD 80-140 °C 0 to 200 °C CR 6 Kg/cm2(g) 250 °C 80 Hastelloy-C
43RV02

to measure temperature in
10 43TI10 43RV02 / on bottom of RTD 80-140 °C 0 to 200 °C CR 6 Kg/cm2(g) 250 °C 80 Hastelloy-C
43RV02

to measure utility
temperature from/to jacket
11 43TI11 RTD 38 / 8 / 165 °C 0 to 200 °C CR 6 Kg/cm2(g) 250 °C 50 SS
of 43RV02 / on utility line
of 43RV02

to measure process side

inlet temperature to
12 43TI12 RTD 90 / 190 °C 0 to 250 °C CR 6 Kg/cm2(g) 300 °C 150 Hastelloy-C
condenser 43R03 / on line
150-PRG-0191-GL-IH

to measure cooling water

return temperature of
13 43TI13 RTD 38 °C 0 to 100 °C CR 6 Kg/cm2(g) 100 °C 80 SS
condenser 43R03 / on line
80-CWR-0173-CS-UI

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 Chapter-9 Technical specification

to measure temperature of
condensed process liquid in
14 43TI14 RTD 45 °C 0 to 100 °C CR 6 Kg/cm2(g) 100 °C 50 Hastelloy-C
condenser 43R03 / on line
50-PRL-0191-GL-UI

to measure temperature of
condensed process liquid in
15 43TI15 RTD 20 °C 0 to 100 °C CR 6 Kg/cm2(g) 100 °C 50 Hastelloy-C
condenser 43R04 / on line
50-PRL-0191-GL-UI

to measure chilled water

return temperature of
16 43TI16 RTD 8 °C 0 to 100 °C CR 6 Kg/cm2(g) 100 °C 50 SS
condenser 43R04 / on line
50-CHR-0194-CS-UI

to measure temperature in
17 43TI17 43RV03 / on top of RTD 220 °C 0 to 300 °C CR 6 Kg/cm2(g) 350 °C 80 Hastelloy-C
43RV03

to measure temperature in
18 43TI18 43RV03 / on bottom of RTD 220 °C 0 to 300 °C CR 6 Kg/cm2(g) 350 °C 80 Hastelloy-C
43RV03

to measure utility
temperature from/to jacket
19 43TI19 RTD 225 °C 0 to 300 °C CR 6 Kg/cm2(g) 350 °C 50 SS
of 43RV03 / on utility line
of 43RV03

to measure process side

inlet temperature to
20 43TI20 RTD 220 °C 0 to 300 °C CR 6 Kg/cm2(g) 350 °C 150 SS
condenser 43R05 / on line
150-PRG-0188-SS-IH

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 Chapter-9 Technical specification

to measure cooling water

return temperature of
21 43TI21 RTD 38 °C 0 to 100 °C CR 6 Kg/cm2(g) 100 °C 50 SS
condenser 43R05 / on line
50-CWR-0173-CS-UI

to measure temperature of
condensed process liquid in
22 43TI22 RTD 45 °C 0 to 100 °C CR 6 Kg/cm2(g) 100 °C 50 SS
condenser 43R05 / on line
50-PRL-0191-SS-UI

to measure temperature of
condensed process liquid in
23 43TI23 RTD 20 °C 0 to 100 °C CR 6 Kg/cm2(g) 100 °C 50 SS
condenser 43R06 / on line
50-PRL-0191-SS-UI

to measure chilled water

return temperature of
24 43TI24 RTD 8 °C 0 to 100 °C CR 6 Kg/cm2(g) 100 °C 50 SS
condenser 43R06 / on line
50-CHR-0194-CS-UI

to measure process gas

temperature from
25 43TI33 RTD 20 °C 0 to 100 °C CR 6 Kg/cm2(g) 100 °C 50 Hastelloy-C
condenser 43R02 / on line
150-PRG-1122-PP/FRP-UI

to measure process gas

temperature from
26 43TI34 RTD 20 °C 0 to 100 °C CR 6 Kg/cm2(g) 100 °C 50 Hastelloy-C
condenser 43R04 / on line
150-PRG-1122-PP/FRP-UI

to measure process gas

temperature from
27 43TI35 RTD 20 °C 0 to 100 °C CR 6 Kg/cm2(g) 100 °C 50 SS
condenser 43R06 / on line
150-PRG-1122-PP/FRP-UI

to measure cooling water

28 43TI36 temperature to 43H01 / on RTD 32 °C 0 to 100 °C CR 6 Kg/cm2(g) 100 °C 50 SS
line 50-CWR-0173-CS-UI

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 Chapter-9 Technical specification

Electronic weighing machine

Type of
Indication Design Wetted
Sr. no. Tag no. Description / Location Service fluid Normal op. point. Range
local/control temp MOC
room

To measure the quantity in

1 43-WM-01 POCl3 / PCl3 / TEA 100 to 300 Kg 0 to 500 kg Field 100 ° C
POCl3 / PCl3 / TEA drums

To measure the quantity in

2 43-WM-02 POCl3 / PCl3 / TEA 100 to 300 Kg 0 to 500 kg Field 100 ° C
POCl3 / PCl3 / TEA drums

Load cell four legged type

Type of
Indication Design
Sr. no. Tag no. Description / Location Service fluid Normal op. point. Range
local/control temp
room

To measure the quantity in

1 43-WT-01 POCl3 / PCl3 / TEA 800 to 1000 Kg 0 to 1500 Kg CR 100 ° C
43V02

To measure the quantity in

2 43-WT-02 POCl3 / DHA / DOP 800 to 1000 Kg 0 to 1500 Kg CR 100 ° C
43V03

To measure the quantity in

3 43-WT-03 OCl 800 to 1000 Kg 0 to 1500 Kg CR 100 ° C
43V04

CONTROL / ON-OFF VALVE

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 Chapter-9 Technical specification
type of
Description / Allowable Range (min / Indication Design Design Wetted
Sr. no. Tag no. Service fluid Normal op. point. Line size
Location DP Nor / Max) local/control press temp MOC
room
Tin = Ambient °C
Tout = Ambient °C
Flow = 10.26 / 102.6 0.05 to 0.1 Flow = 10 to
POCl3
/ 128.25 Kg/hr Kg/cm² 130 kg/hr
(min / Nor / Max)
Press=1.5 kg/cm2 (g)
Tin = Ambient °C
Tout = Ambient °C
Flow = 17.65 / 176.5 0.05 to 0.1 Flow = 15 to
PCl3
/ 220.6 Kg/hr Kg/cm² 225 kg/hr
(min / Nor / Max)
43RV01 Reaction Press=1.5 kg/cm2 (g) metal
43TCV01/FC temperature control
1 Tin = Ambient °C CR 6 Kg/cm².g. 70 °C 25 jackete
V valve on feed line
Tout = Ambient °C d PTFE
(Also to act as FCV)
Flow = 24.16 / 241.6 0.05 to 0.1 Flow = 20 to
TEA
/ 302 Kg/hr Kg/cm² 305 kg/hr
(min / Nor / Max)
Press=1.5 kg/cm2 (g)

Tin = Ambient °C
Tout = Ambient °C
Flow = 24.75 / 247.5 0.05 to 0.1 Flow = 20 to
OCL
/ 309.4 Kg/hr Kg/cm² 310 kg/hr
(min / Nor / Max)
Press=1.5 kg/cm2 (g)

Tin = Ambient °C
sodium carbonate Tout = Ambient °C
43TCV02/43 from 43 V07 inlet Flow = 56.45 / 564.5 0.05 to 0.1 Flow = 50 to
2 Sodium carbonate CR 6 Kg/cm².g. 70 °C 25 SS
FCV07 temperature control / 705.63 Kg/hr Kg/cm² 800 kg/hr
valve to 43RV01 (min / Nor / Max)
Press=1.5 kg/cm2 (g)

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 Chapter-9 Technical specification

Tin = Ambient °C
Tout = Ambient °C
Flow = 10.26 / 102.6 / 128.25 0.05 to 0.1 Flow = 10 to
POCl3
Kg/hr Kg/cm² 130 kg/hr
(min / Nor / Max)
Press=1.5 kg/cm2 (g)

POCl3 / DOP / DHA Tin = Ambient °C metal

43TCV03/FC Tout = Ambient °C
3 inlet temperature CR 6 Kg/cm².g. 70 °C 25 jackete
V Flow = 30.6 / 306 / 0.05 to 0.1 Flow = 20 to
control valve DOP d PTFE
382.5 Kg/hr Kg/cm² 400 kg/hr
(min / Nor / Max)
Press=1.5 kg/cm2 (g)

Tin = Ambient °C
Tout = Ambient °C
Flow = 24.49 / 244.9 0.05 to 0.1 Flow = 20 to
DHA
/ 306.13 Kg/hr Kg/cm² 350 kg/hr
(min / Nor / Max)
Press=1.5 kg/cm2 (g)
Tin = Ambient °C
sodium carbonate Tout = Ambient °C
43TCV04/43 from 43 V07 inlet Flow = 56.45 / 564.5 / 705.63 0.05 to 0.1 Flow = 50 to
4 Sodium carbonate CR 6 Kg/cm².g. 70 °C 25 SS
FCV08 temperature control Kg/hr Kg/cm² 800 kg/hr
valve to 43RV02 (min / Nor / Max)
Press=1.5 kg/cm2 (g)

To control flow rate

of steam to the Flow = 12 / 36.19 /
jacket of 43RV01 45.25 Kg/hr 0.05 to 0.1 Flow = 10 to 10 Kg/cm2
43FCV09 Steam CR 180 °C 50 SS
5 for heating / on line (min / Nor / Max) Kg/cm² 100 kg/hr (g)
no. 50-ST-0173-CS- Press=7 kg/cm2 (g)
IH

To control flow rate

of cooling water / Flow = 1500 / 3840 /
chilled water to the 6000 Kg/hr 0.05 to 0.1 Flow = 1000 to
43FCV10 Cooling water CR 6 Kg/cm².g. 70 °C 50 SS
6 jacket of 43RV01 (min / Nor / Max) Kg/cm² 8000 kg/hr
for cooling / on line Press=3.5 kg/cm2 (g)
no. 50-CHS-0142-

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 Chapter-9 Technical specification
CS-IC Flow = 1500/
2000/3000 Kg/hr 0.05 to 0.1
chilled water
(min / Nor / Max) Kg/cm²
Press=3.5 kg/cm2 (g)

To control flow rate

Flow = 12 / 48.02 /
of steam to the
60.03 Kg/hr 0.05 to 0.1 Flow = 10 to 10 Kg/cm2
43FCV12 jacket of 43RV02 Steam CR 70 °C 50 SS
7 (min / Nor / Max) Kg/cm² 100 kg/hr (g)
for heating / on line
Press=7kg/cm2 (g)
no. 50-ST-00-CS-IH

Flow = 1500 / 3840 /

To control flow rate 6000 Kg/hr 0.05 to 0.1
Cooling water
of cooling water / (min / Nor / Max) Kg/cm²
chilled water to the Press=3.5 kg/cm2 (g)
Flow = 1000 to
43FCV13 jacket of 43RV02 CR 6 Kg/cm².g. 70 °C 50 SS
8 8000 kg/hr
for cooling / on line
Flow = 1500/
no. 50-CHS-0142-
2000/3000 Kg/hr 0.05 to 0.1
CS-IC Chilled water
(min / Nor / Max) Kg/cm²
Press=3.5 kg/cm2 (g)

To control flow rate

of Cooling
Flow =1500 / 9814.1
water/Chilled water
/ 10000 Kg/hr 0.05 to 0.1 Flow = 1000 to
43FCV15 to the jacket of Thermic fluid CR 6 Kg/cm².g. 200 °C 50 SS
9 (min / Nor / Max) Kg/cm² 12000 kg/hr
43RV03 for heating
Press=4.5 kg/cm2 (g)
/ on line no. 50-
THF-0135-SS-IH
To control flow rate Flow = 12 / 48.02 /
of steam to the 60.03 Kg/hr 0.05 to 0.1 Flow = 10 to 10 Kg/cm2
43FCV12 Steam CR 70 °C 50 SS
10 jacket of 43RV03 (min / Nor / Max) Kg/cm² 100 kg/hr (g)
for heating Press=7kg/cm2 (g)

for closing the feed full bore

Press=1.5 kg/cm2
11 43SOV 01 valve on LAH/ feed 2EHA/IAA on/off ball CR 6 Kg/cm².g. 70 °C 25 SS
(g)
to 43 V01 valve

pH Transmitter

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 Chapter-9 Technical specification

Description / Design
Sr. no. Tag no. Service fluid Normal op. point. Range Indication Design press Line size
Location temp

to measure pH of
effluent discharged
from reactors
1 43PH01 Aqueous with salts 2 to 10 pH 0 to 14 pH CR 6 Kg/cm2(g) 100 ° C 50
43RV01 / 43RV02
during draining
operation
to measure pH of
effluent discharged
from reactors
2 43PH02 Aqueous with salts 2 to 10 pH 0 to 14 pH CR 6 Kg/cm2(g) 100 ° C 50
43RV03 / 43RV04
during draining
operation

Monitors

Sr. no. Tag no. Description Location Service fluid Range Design temp Indication

Online Hydrogen
1 43AI01 At scrubber vent Hydrogen 0 to 0.5% 80 ° C CR & Field
monitor

online hydrocarbon Xylene / hexane /

2 43AI02 Inside the SPP building 0 to 1 80 ° C CR & Field
monitor ROH

online hydrocarbon Xylene / hexane /

3 43AI03 Inside the SPP building 0 to 1 80 ° C CR & Field
monitor ROH

4 43AI04 online HCl monitor Inside the SPP building HCl 1 to 5 ppm 80 ° C CR & Field

5 43AI05 online HCl monitor At scrubber vent HCl 1 to 5 ppm 80 ° C CR & Field

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 Chapter-9 Technical specification

6 43AI06 online HCl monitor PCl3 storage area HCl 1 to 5 ppm 80 ° C CR & Field

7 43AI07 POCl3 detector POCl3 80 ° C CR & Field

8 43AI08 POCl3 detector POCl3 80 ° C CR & Field

9 43AI09 UV+IR Flame 80 ° C CR & Field

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 Chapter-9 Technical specification

3. LIST OF FLOW TRANSMITTERS UNIT-44

Volumetric Flow transmitter without totalizer

Type of
Normal op. operating/design Indication operating/design Wetted
Sr. no. Tag no. Description / Location Type Range Line size
range. temp local/control pressure MOC
room

to indicate flow / quantity from

Pure Butanol tank to 44RV01 & 2 kg/cm2 /5
1 44 FT 01 Rotameter 0.16 to 1.6 m3/hr 100 ° C 0 to 3 m3/hr CR 40 SS
44RV02 / on line no. 40-BUP- kg/cm2
0114-SS-IC

to indicate flow / quantity from

2 kg/cm2 /5
2 44FT02 44V02 & 44V03 to 44RV01 / on Rotameter 0.27 to 2.7 m3/hr 100 ° C 0 to 4m3/hr CR 40 SS
kg/cm2
line no. 40-BUP-0109-SS-IC

to indicate flow / quantity from

0.038 to 0.38 2 kg/cm2 /5
3 44 FT 03 44V02 & 44V03 to 44RV01 / on Rotameter 100 ° C 0 to 1 m3/hr CR 25 PTFE lined SS
m3/hr kg/cm2
line no. 25-POC-1104-GL-UI

to indicate flow / quantity from

0.038 to 0.38 2 kg/cm2 /5
4 44FT04 44V02 & 44V03 to 44RV02/ on Rotameter 100 ° C 0 to 1 m3/hr CR 25 PTFE lined SS
m3/hr kg/cm2
line no. 25-POC-1101-GL-UI

to indicate flow / quantity from

2 kg/cm2 /5
5 44FT05 44V04 to 44RV01/ on line no. 40- Rotameter 0.55 to 5.5 m3/hr 100 ° C 0 to 6 m3/hr CR 40 SS
kg/cm2
PRL-1105-SS-UI

to indicate flow / quantity from

2 kg/cm2 /5
6 44FT06 44V05 to 44RV02/ on line no. 40- Rotameter 0.55 to 5.5 m3/hr 100 ° C 0 to 6 m3/hr CR 40 SS
kg/cm2
PRL-1100-SS-UI

to indicate flow / quantity from

0.082 to 0.82 2 kg/cm2 /5
7 44FT07 44V07 to 44RV03/ on line no. 40- Rotameter 100 ° C 0 to 1 m3/hr CR 40 SS
m3/hr kg/cm2
PRL-0194-SS-UI

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 Chapter-9 Technical specification

To indicate flow of cooling water

/ chilled water to the jacket of 2 kg/cm2 /5
8 44FT08 Rotameter 0.76 to 7.6 m3/hr 2°C 0 to 9 m3/hr CR 80 SS
44RV01 for cooling / on line no. kg/cm2
80-CHS-0140-CS-UI

To indicate flow of cooling water

/ chilled water to the jacket of 2 kg/cm2 /5
9 44FT09 Rotameter 0.76 to 7.6 m3/hr 2°C 0 to 9 m3/hr CR 50 SS
44RV02 for cooling / on line no. kg/cm2
50-CHS-0142-CS-IC

Mass Flow transmitter/local flow indicator

Type of
Normal op. operating/design Indication operating/design
Sr. no. Tag no. Description / Location Type Range Line size Wetted MOC
range. temp local/control pressure
room

To indicate flow of steam to the

vortex/ori
10 44FT10 jacket of 44RV03 for heating / on 20 to 40 kg/hr 165 / 250 °C 10 to 100 kg/hr CR 7/10 Kg/cm2 (g) 50 SS
fice FT
line no. 50-SLS-0187--CS-IH

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 Chapter-9 Technical specification

4. LIST OF INSTRUMENTS WITH OVERALL SPECIFICATIONS UNIT-44

PRESSURE GAUGE and mcleod gauge

Sr. Normal op. Normal op. Design Wetted

Tag no. Description / Location Type Range Indication Design press Line size
no. press. temp temp MOC

To measure the pressure in

Intermediate storage tank 0 to 6
1 44-PG-01 PG 0-2 kg/cm2 Ambient Field 5 kg/cm2 100 ° C 25 SS
(44V01) / on Intermediate Kg/cm2(g)
storage tank (44V01)

To measure discharge pressure

0 to 6
2 44-PG-02 of pump 44P01A/ on discharge PG 0-2 kg/cm2 Ambient Field 5 kg/cm2 100 ° C 40 SS
Kg/cm2(g)
line of 44P01A

To measure the pressure in Final

neutralisation washing and 0.5 to 2 (-)1 to 4 PTFE lined
3 44-CPG-03 PG 35 to 170 oC Field 5 kg/cm2 200 ° C 15
recovery reactor vessel 44RV03 Kg/cm2(g) Kg/cm2(g) SS
/ on vessel (44RV03)

To measure the pressure in

0.5 to 2 (-)1 to 4
4 44-CPG-04 charging vessel 44V02 / on PG Ambient Field 5 kg/cm2 100 ° C 25 SS
Kg/cm2(g) Kg/cm2(g)
vessel (44V02)
To measure the pressure in
Esterification and Neutralisation 0.5 to 2 (-)1 to 4 PTFE lined
5 44-CPG-06 PG 35 to 170 oC Field 5 kg/cm2 200 ° C 15
reactor vessel 44RV01 / on Kg/cm2(g) Kg/cm2(g) SS
vessel (44RV01)
To measure the pressure in
0.5 to 2 (-)1 to 4
6 44-CPG-07 vessel 44V03 / on vessel PG Ambient Field 5 kg/cm2 100 ° C 25 SS
Kg/cm2(g) Kg/cm2(g)
(44V03)

To measure the pressure in

0.5 to 2 (-)1 to 4
7 44-CPG-09 vessel 44V04 / on vessel PG Ambient Field 5 kg/cm2 100 ° C 25 SS
Kg/cm2(g) Kg/cm2(g)
(44V04)

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 Chapter-9 Technical specification

To measure the pressure in

0 to 6
8 44-PG-10 vessel 44V05 / on vessel PG 0-2 kg/cm2 Ambient Field 5 kg/cm2 100 ° C 25 SS
Kg/cm2(g)
(44V05)

To measure discharge pressure

0 to 6
9 44-PG-11 of pump 44P02A / on discharge PG 0-2 kg/cm2 Ambient Field 5 kg/cm2 100 ° C 25 SS
Kg/cm2(g)
line of 44P02A

To measure discharge pressure

0 to 6
10 44-PG-12 of pump 44P02B / on discharge PG 0-2 kg/cm2 Ambient Field 5 kg/cm2 100 ° C 25 SS
Kg/cm2(g)
line of 44P02B

To measure the pressure in

0.5 to 2 (-)1 to 4
11 44-CPG-13 vessel 44V06 / on vessel PG Ambient Field 5 kg/cm2 100 ° C 25 SS
Kg/cm2(g) Kg/cm2(g)
(44V06)

To measure discharge pressure

0 to 6
44-PG-14 of pump 44P06A / on discharge PG 0-2 kg/cm2 Ambient Field 5 kg/cm2 100 ° C 25 SS
12 Kg/cm2(g)
line of 44P06A

To measure discharge pressure

0 to 6
44-PG-15 of pump 44P06B / on discharge PG 0-2 kg/cm2 Ambient Field 5 kg/cm2 100 ° C 25 SS
13 Kg/cm2(g)
line of 44P06B

To measure discharge pressure

0 to 6
44-PG-16 of pump 44P03A / on discharge PG 0-2 kg/cm2 Ambient Field 5 kg/cm2 100 ° C 25 SS
14 Kg/cm2(g)
line of 44P03A

To measure discharge pressure

0 to 6
44-PG-17 of pump 44P03B / on discharge PG 0-2 kg/cm2 Ambient Field 5 kg/cm2 100 ° C 25 SS
15 Kg/cm2(g)
line of 44P03B

To measure discharge pressure

0 to 6
44-PG-18 of pump 44P08A / on discharge PG 0-2 kg/cm2 Ambient Field 5 kg/cm2 100 ° C 25 SS
16 Kg/cm2(g)
line of 44P08A

To measure discharge pressure

0 to 6
44-PG-19 of pump 44P08B/ on discharge PG 0-2 kg/cm2 Ambient Field 5 kg/cm2 100 ° C 25 SS
17 Kg/cm2(g)
line of 44P08B

To measure the pressure in 0.5 to 2 (-)1 to 4

44-CPG-21 PG Ambient Field 5 kg/cm2 100 ° C 25 SS
18 vessel 44V08/ on vessel (44V08) Kg/cm2(g) Kg/cm2(g)

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 Chapter-9 Technical specification

To measure the pressure in 0 to 6

44-PG-20 PG 0-2 kg/cm2 Ambient Field 5 kg/cm2 100 ° C 25 SS
19 vessel 44V07/ on vessel (44V07) Kg/cm2(g)

To measure the pressure in 0 to 6

44-PG-22 PG 0-2 kg/cm2 Ambient Field 5 kg/cm2 100 ° C 25 SS
20 vessel 44V09/ on vessel (44V09) Kg/cm2(g)

To measure Instrument air

0 to 6
44-PG-26 supply pressure / on Inst. air PG 0-2 kg/cm2 Ambient Field 5 kg/cm2 100 ° C 25 SS
21 Kg/cm2(g)
header

To measure the pressure in

0.5 to 2 (-)1 to 4 PTFE lined
44-CPG-12 reactor vessel 44RV02 / on PG 35 to 170 oC Field 5 kg/cm2 200 ° C 15
22 Kg/cm2(g) Kg/cm2(g) SS
vessel (44RV02)

To measure discharge pressure

0 to 6
44-PG-03 of pump 44P01B/ on discharge PG 0-2 kg/cm2 Ambient Field 5 kg/cm2 100 ° C 40 SS
23 Kg/cm2(g)
line of 44P01B

VACUUM gauge

Sr. Normal op. Normal op. Design Wetted

Tag no. Description / Location Type Range Indication Design press Line size
no. press. temp temp MOC

To measure the pressure in

0.01 torr to PTFE lined
1 44VPG01 Reactor 44RV01 / on Reactor Mcleod 0-2 kg/cm2 35 to 170 oC Field 5 kg/cm2 200 ° C 15
760 torr SS
(44RV01) Mcleod gauge

To measure the pressure in

0.01 torr to PTFE lined
2 44VPG02 Reactor 44RV02 / on Reactor Mcleod 0-2 kg/cm2 35 to 170 oC Field 5 kg/cm2 200 ° C 15
760 torr SS
(44RV02) Mcleod gauge

To measure the pressure in

0.01 torr to PTFE lined
3 44VPG03 Reactor 44RV03 / on Reactor Mcleod 0-2 kg/cm2 35 to 170 oC Field 5 kg/cm2 200 ° C 15
760 torr SS
(44RV03) Mcleod gauge

PRESSURE TRANSMITTER including pirani gauge

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 Chapter-9 Technical specification

Sr. Normal op. Normal op. Design Wetted

Tag no. Description / Location Type Range Indication Design press Line size
no. press. temp temp MOC

To measure the pressure in

Diaphragm seal 0.5 to 2 (-)1 to 4 PTFE lined
1 44PT01 Reactor 44RV01 / on Reactor 35 to 170 oC CR 5 kg/cm2 200 ° C 15
type PT Kg/cm2(g) Kg/cm2(g) SS
(44RV01)

To measure the pressure in

Diaphragm seal 0.5 to 2 (-)1 to 4 PTFE lined
2 44PT02 Reactor 44RV02 / on Reactor 35 to 170 oC CR 5 kg/cm2 200 ° C 15
type PT Kg/cm2(g) Kg/cm2(g) SS
(44RV02)

To measure the pressure in

Diaphragm seal 0.5 to 2 (-)1 to 4 PTFE lined
3 44PT03 Reactor 44RV03 / on Reactor 35 to 170 oC CR 5 kg/cm2 200 ° C 15
type PT Kg/cm2(g) Kg/cm2(g) SS
(44RV03)

To measure the pressure in

0.5 to 2 (-)1 to 4 PTFE lined
1 44PT01A Reactor 44RV01 / on Reactor Pirani 35 to 170 oC CR 5 kg/cm2 200 ° C 15
Kg/cm2(g) Kg/cm2(g) SS
(44RV01) pirani gauge

To measure the pressure in

0.5 to 2 (-)1 to 4 PTFE lined
2 44PT02A Reactor 44RV02 / on Reactor Pirani 35 to 170 oC CR 5 kg/cm2 200 ° C 15
Kg/cm2(g) Kg/cm2(g) SS
(44RV02) pirani gauge

To measure the pressure in

0.5 to 2 (-)1 to 4 PTFE lined
3 44PT03A Reactor 44RV03 / on Reactor Pirani 35 to 170 oC CR 5 kg/cm2 200 ° C 15
Kg/cm2(g) Kg/cm2(g) SS
(44RV03) pirani gauge

LEVEL GAUGE /LEVEL switch

Sr. Normal op. Normal op. Design Wetted

Tag no. Description / Location Type Range Indication Design press C-C, mm
no. press. temp temp MOC

1 44 LG 01 To indicate level in 44V01 level gauge 0-2 kg/cm2 Ambient 0 to 100% Field 5 kg/cm2 100 ° C 2950 SS

44 LG 04
2 with 2 to indicate level in 44V04 level gauge 0-2 kg/cm2 Ambient 0 to 100% Field /CR 5 kg/cm2 100 ° C 2150 SS
switches

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 Chapter-9 Technical specification

44 LG 05
3 with 2 To indicate level in 44V05 level gauge 0-2 kg/cm2 Ambient 0 to 100% Field /CR 5 kg/cm2 100 ° C 2150 SS
switches

44 LG 06
PTFE lined
4 with 2 To indicate level in 44V06 level gauge 0-2 kg/cm2 Ambient 0 to 100% Field /CR 5 kg/cm2 100 ° C 1000
SS
switches

44 LG 07
5 with 2 To indicate level in 44V07 level gauge 0-2 kg/cm2 Ambient 0 to 100% Field /CR 5 kg/cm2 100 ° C 2150 SS
switches

44 LG 08
6 with 2 To indicate level in 44V08 level gauge 0-2 kg/cm2 Ambient 0 to 100% Field /CR 5 kg/cm2 100 ° C 2950 SS
switches

44 LG 09
PTFE lined
7 with 2 To indicate level in 44V09 level gauge 0-2 kg/cm2 Ambient 0 to 100% Field /CR 5 kg/cm2 100 ° C 2150
SS
switches

LEVEL transmitter (guided radar/ultrasonic)

Type of
Sr. Normal op. Normal op. Indication Design Wetted
Tag no. Description / Location Type Range Design press C-C, mm
no. press. temp local/control temp MOC
room

Remote seal
1 44 LT 01 to indicate level in 44V01 0-2 kg/cm2 Ambient 0 to 100% CR 5 kg/cm2 100 ° C SS
DPT

Non contact
2 44 LT 02 to indicate level in 44V02 0-2 kg/cm2 Ambient 0 to 100% CR 5 kg/cm2 100 ° C PTFE
RADAR type

Non contact
3 44 LT 03 to indicate level in 44V03 0-2 kg/cm2 Ambient 0 to 100% CR 5 kg/cm2 100 ° C PTFE
RADAR type

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Non contact 0.5 to 2

4 44 LT 11 to indicate level in 44RV01 35 to 170 oC 0 to 100% CR 5 kg/cm2 200 ° C PTFE
RADAR type Kg/cm2(g)

Non contact 0.5 to 2

5 44 LT 12 to indicate level in 44RV02 35 to 170 oC 0 to 100% CR 5 kg/cm2 200 ° C PTFE
RADAR type Kg/cm2(g)

Non contact 0.5 to 2

6 44LT 13 to indicate level in 44RV03 35 to 170 oC 0 to 100% CR 5 kg/cm2 200 ° C PTFE
RADAR type Kg/cm2(g)

Temperature Indicator RTD/temp gauge (Temperature element with thermo well and transmitter)

Type of
Sr. Normal op. Normal op. Indication Design Wetted
Tag no. Description / Location Type Range Design press Line size
no. pt. temp local/control temp MOC
room

to measure temperature in 0.5 to 2 Hastelloy-

1 44TI01 RTD 35 to 170 oC 0 to 200 °C CR 5 kg/cm2 200 ° C 50 mm
44RV01 / on top of 44RV01 Kg/cm2(g) C

to measure temperature in 0.5 to 2 Hastelloy-

2 44TI02 RTD 35 to 170 oC 0 to 200 °C CR 5 kg/cm2 200 ° C 50 mm
44RV02 / on top of 44RV02 Kg/cm2(g) C

to measure utility temperature

0.5 to 2 Hastelloy-
3 44TI03 from/to jacket of 44RV03 / on RTD 35 to 170 oC 0 to 200 °C CR 5 kg/cm2 200 ° C 50 mm
Kg/cm2(g) C
top of 44RV03

Vessel
to measure temperature in 0.5 to 2 Hastelloy-
4 44TI04 RTD 35 to 170 oC 0 to 200 °C CR 5 kg/cm2 200 ° C manufacturer
44RV01/ on bottom of 44RV01 Kg/cm2(g) C
scope

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 Chapter-9 Technical specification

Vessel
to measure temperature in 0.5 to 2 Hastelloy-
5 44TI05 RTD 35 to 170 oC 0 to 200 °C CR 5 kg/cm2 200 ° C manufacturer
44RV02 / on bottom of 44RV02 Kg/cm2(g) C
scope

to measure utility temperature Vessel

0.5 to 2
6 44TI06 from/to jacket of 44RV03 / on RTD 35 to 170 oC 0 to 200 °C CR 5 kg/cm2 200 ° C manufacturer SS
Kg/cm2(g)
bottom of 44RV03 scope

to measure temperature line

7 44TI07 between 44E02 & 44V01/ on RTD 0-2 kg/cm2 Ambient 0 to 200 °C CR 5 kg/cm2 100 ° C 40 SS
Line 40-BUP-0114A-SS-IC

to measure temperature in
8 44TI08 RTD 0-2 kg/cm2 Ambient 0 to 200 °C CR 5 kg/cm2 100 ° C 50 SS
44V01/ on bottom of 44V01

to measure temperature at the

9 44TI09 inlet of Condenser 44E1-A/On RTD 0-2 kg/cm2 Ambient 0 to 200 °C CR 5 kg/cm2 100 ° C 250 SS
line 250-PRG-0188-SS-IH

to measure temperature at the

10 44TI10 outlet of Condenser 44E1-A/On RTD 0-2 kg/cm2 Ambient 0 to 200 °C CR 5 kg/cm2 100 ° C 50 SS
line 50-PRL-0188A-SS-IH

to measure temperature at the

11 44TI11 outlet of Condenser 44E1-B/On RTD 0-2 kg/cm2 Ambient 0 to 200 °C CR 5 kg/cm2 100 ° C 50 SS
line 50-PRL-0188B-SS-IH

to measure cooling water return

12 44TI12 temperature of condenser RTD 0-2 kg/cm2 Ambient 0 to 200 °C CR 5 kg/cm2 100 ° C 50 SS
44RV03

to measure cooling water return

13 44TI13 temperature of condenser RTD 0-2 kg/cm2 Ambient 0 to 200 °C CR 5 kg/cm2 100 ° C 50 SS
44RV01

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 Chapter-9 Technical specification

to measure cooling water return

14 44TI14 temperature of condenser RTD 0-2 kg/cm2 Ambient 0 to 200 °C CR 5 kg/cm2 100 ° C 50 SS
44RV02
to measure temperature at the
cooling water outlet of
15 44TI15 RTD 0-2 kg/cm2 Ambient 0 to 200 °C CR 5 kg/cm2 100 ° C 80 SS
Condenser 44E1-A/On line 80-
CWR-0173-CS-UI

to measure temperature at the

chilled water outlet of
16 44TI16 RTD 0-2 kg/cm2 Ambient 0 to 200 °C CR 5 kg/cm2 100 ° C 50 SS
Condenser 44E1-B/On line 50-
CHR-0194-CS-UI

CONTROL/ON-OFF VALVE

Type of
Sr. Normal op. Range (min / Indication Design Wetted
Tag no. Description / Location Service fluid Allowable DP Design press Line size
no. point. Nor / Max) local/control temp MOC
room

Flow = 100/
150/302
To control temperature of
Kg/hr metal
44RV01 by controlled addition 0.05 to 0.1 Flow = 50 to
1 44TCV01 POCL3 (min / Nor / CR 5 kg/cm2 100 ° C 25 jacketed
of POCL3 /On the line 25-POC- Kg/cm² 350 kg/hr
Max) PTFE
1104-GL-UI
Press=3.5
kg/cm2 (g)

Flow = 2500/
3500/4326
To control temperature of Kg/hr
0.05 to 0.1 Flow = 2000
2 44TCV02 44RV02 by controlled addition Na2CO3 (min / Nor / CR 5 kg/cm2 100 ° C 25 SS
Kg/cm² to 5000 kg/hr
of Na2CO3 Max)
Press=3.5
kg/cm2 (g)

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 Chapter-9 Technical specification

Flow = 2500/
3500/4326
To control temperature of Kg/hr
0.05 to 0.1 Flow = 2000
3 44TCV03 44RV01 by controlled addition Na2CO3 (min / Nor / CR 5 kg/cm2 100 ° C 25 SS
Kg/cm² to 5000 kg/hr
of Na2CO3 Max)
Press=3.5
kg/cm2 (g)

Flow = 100/
150/302
To control temperature of Kg/hr metal
0.05 to 0.1 Flow = 50 to
4 44TCV04 44RV02 by controlled addition POCL3 (min / Nor / CR 5 kg/cm2 100 ° C 25 jacketed
Kg/cm² 350 kg/hr
of POCL3 Max) PTFE
Press=3.5
kg/cm2 (g)

Flow = 1000/
2000/4500
Kg/hr
0.05 to 0.1
chilled water (min / Nor /
Kg/cm²
Max)
Press=3.5
To control flow rate of chilled kg/cm2 (g)
water/cooling water to the jacket Flow = 1000
44FCV08 CR 5 kg/cm2 100 ° C 80 SS
5 of 44RV01 for cooling /On the to 8000 kg/hr
line 80-CHS--0140-CS-UI Flow = 1500
/ 3840 / 6000
Kg/hr
0.05 to 0.1
cooling water (min / Nor /
Kg/cm²
Max)
Press=3.5
kg/cm2 (g)

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 Chapter-9 Technical specification

Flow = 1500/
2000/3000
Kg/hr
0.05 to 0.1
chilled water (min / Nor /
Kg/cm²
Max)
To control flow rate of chilled Press=3.5
water/cooling water to the jacket kg/cm2 (g) Flow = 1000
44FCV09 CR 5 kg/cm2 100 ° C 50 SS
6 of 44RV02 for cooling /On the to 8000 kg/hr
line 50-CHS--0142-CS-UI
Flow = 1500
/ 3840 / 6000
Kg/hr
0.05 to 0.1
cooling water (min / Nor /
Kg/cm²
Max)
Press=3.5
kg/cm2 (g)

Flow = 49/
To control flow rate of steam to 80/104 Kg/hr
the jacket of 44RV03 for heating (min / Nor / 0.05 to 0.1 Flow = 20 to
44FCV10 steam CR 5 kg/cm2 100 ° C 50 SS
7 / on line no. 50-SLS-0187-CS- Max) Kg/cm² 150 kg/hr
IH Press=3.5
kg/cm2 (g)

Solenoid valve

Type of
Sr. Normal op. Indication
Tag no. Description / Location Service fluid
no. temp local/control
room

Control Valve
1 44EV01 44TCV01 Ambient CR
Accessories

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 Chapter-9 Technical specification

Control Valve
2 44EV02 44TCV02 Ambient CR
Accessories

Control Valve
3 44EV03 44TCV03 Ambient CR
Accessories

Control Valve
4 44EV04 44TCV04 Ambient CR
Accessories

electronic weighing machine

Type of
Sr. Normal op. Indication Design Wetted
Tag no. Description / Location Service fluid Range
no. point. local/control temp MOC
room

To measure the quantity in POCl3 / PCl3 /

1 44-WM-01 Field
POCl3 / PCl3 / TEA drums TEA

Load cell four legged type

Type of
Sr. Indication
Tag no. Description / Location Service fluid Range
no. local/control
room

To measure the quantity in POCl3 / PCl3 /

1 44-WT-02 Field/CR
44V02 TEA

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 Chapter-9 Technical specification

To measure the quantity in POCl3 / DHA /

2 44-WT-03 Field/CR
44V03 DOP

pH Transmitter

Sr. Normal op. Design

Tag no. Description / Location Service fluid Range Indication Design press Line size
no. point. temp

to measure pH of effluent
discharged from reactors Aqueous with
1 44PH01 2 to 10 pH 0 to 14 pH CR 6 Kg/cm2(g) 100 ° C 50
44RV01 / 44RV02 during salts
draining operation

Monitors

Type of
Sr. Indication Design
Tag no. Description Location Service fluid Range
no. local/control temp
room

1 44AI01 Online Hydrogen monitor Hydrogen 0 to 0.5% CR & Field 80 ° C

Xylene /
2 44AI02 online hydrocarbon monitor hexane / 0 to 1 CR & Field 80 ° C
ROH

Xylene /
3 44AI03 online hydrocarbon monitor hexane / 0 to 1 CR & Field 80 ° C
ROH

4 44AI04 online HCl monitor HCl 1 to 5 ppm CR & Field 80 ° C

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 Chapter-9 Technical specification

5 44AI05 online HCl monitor HCl 1 to 5 ppm CR & Field 80 ° C

6 44AI06 online HCl monitor HCl 1 to 5 ppm CR & Field 80 ° C

7 44AI07 POCl3 detector POCl3 CR & Field 80 ° C

8 44AI08 POCl3 detector POCl3 CR & Field 80 ° C

9 44AI09 POCl3 detector POCl3 CR & Field 80 ° C 7

5. LIST OF FLOW TRANSMITTERS UNIT-45

Volumetric Flow meter with local indication & Transmitter

Type of
Sr. Normal op. operating/design Indication operating/design Wetted
Tag no. Description / Location Type Range Line size
no. range. temp local/control pressure MOC
room

to indicate flow / quantity from

Pure Butanol tank 45V02 to
1 45 FI 01 Rotameter 0-5 m3/hr 100 ° C 0-10 m3/hr CR 2 kg/cm2 /5 kg/cm2 40 SS
Butanol pre-cooler 45E2 / on
line no. 25-BUX-0340-SS-UI

to indicate flow / quantity of

2 45FT02 steam to 45R1 45C2 / on line Rotameter 100 ° C CR 2 kg/cm2 /5 kg/cm2 40 SS
no. 50-SLS-0325-CS-HI

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 Chapter-9 Technical specification

to indicate steam flow rate to

3 45FT03 the inlet of 45R1 / on line no. Rotameter 100 ° C CR 2 kg/cm2 /5 kg/cm2 25 SS
50-SLS-0325-SS-HI

to indicate flow / quantity from

4 45FI04 45D1 & 45C1/ on line no. 25- Rotameter 100 ° C Field 2 kg/cm2 /5 kg/cm2 25 SS
BUX-0332-SS-IH

to indicate flow / quantity from

5 45FI05 45D1 to 45E1/ on line no. 50- Rotameter 100 ° C Field 2 kg/cm2 /5 kg/cm2 40 SS
BUX-0335-CS-HI

to indicate flow / quantity of

10 to 15 0 to 20
6 45FI06 CW supply to 45 E1/ on line no. Rotameter 32 ° C Field 2 kg/cm2 /5 kg/cm2 40 SS
m3/hr m3/hr
50-CWS-0314-SS-UI

to indicate flow / quantity from

7 45FI07 45E3 to 45C2/ on line no.25- Rotameter 100 ° C Field 2 kg/cm2 /5 kg/cm2 40 SS
BUX-0322-SS-HI

To indicate flow of steam to the

0 to 250 0 to 400
8 45FT08 heat exchanger/on line 25-SLS- Rotameter 100 ° C CR 2 kg/cm2 /5 kg/cm2 50 SS
kg/hr kg/hr
0347-CS-IH

Mass Flow transmitter/local flow indicator

Type of
Sr. Normal op. operating/design Indication operating/design Line
Tag no. Description / Location Type Range Wetted MOC
no. range. temp local/control pressure size
room

To indicate flow of steam

20 to 40 10 to 100 CR ( indication
9 45FT08 water to condenser / on line no. Vortex/Orifice FT 165 / 250 °C 7/10 Kg/cm2 (g) 80 SS
kg/hr kg/hr & totaliser)
25-SLS-0347-CS-IH

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 Chapter-9 Technical specification

6. LIST OF INSTRUMENTS WITH OVERALL SPECIFICATIONS UNIT-45

PRESSURE GAUGE and Mcleod gauge

Sr. Normal op. Design Line Wetted

Tag no. Description / Location Type Normal op. temp Range Indication Design press
no. press. temp size MOC

To measure the pressure in

0 to 6
1 45PG01 vessel 45R1 / on vessel PG 0-2 kg /cm2 Ambient Field 6 Kg/cm2(g) 80 ° C 25 SS
Kg/cm2(g)
(45R1)

0 to 6
2 45PG02A To measure discharge PG 0-2 kg /cm2 Ambient Field 6 Kg/cm2(g) 80 ° C 25 SS
Kg/cm2(g)
pressure of pump 45P02A/ on
discharge line of 45P02A

0 to 6
3 45PG02B To measure discharge PG 0-2 kg /cm2 Ambient Field 6 Kg/cm2(g) 80 ° C 25 SS
Kg/cm2(g)
pressure of pump 45P02B/ on
discharge line of 45P02B

0 to 6
4 45PG04 To measure discharge PG 0-2 kg /cm2 Ambient Field 6 Kg/cm2(g) 80 ° C 25 SS
Kg/cm2(g)
pressure of pump 45P03A/ on
discharge line of 45P03A

0 to 6
5 45PG05 To measure discharge PG 0-2 kg /cm2 Ambient Field 6 Kg/cm2(g) 80 ° C 25 SS
Kg/cm2(g)
pressure of pump 45P03B/ on
discharge line of 45P03B

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0 to 6
6 45PG06A To measure discharge PG 0-2 kg /cm2 Ambient Field 6 Kg/cm2(g) 80 ° C 25 SS
Kg/cm2(g)
pressure of pump 45P02A/ on
discharge line of 45P02A

To measure discharge
0 to 6
7 45PG06B pressure of pump 45P02B/ on PG 0-2 kg /cm2 Ambient Field 6 Kg/cm2(g) 80 ° C 25 SS
Kg/cm2(g)
discharge line of 45P02B

To measure the pressure in 0 to 6

8 45PG08 PG 0-2 kg /cm2 Ambient Field 6 Kg/cm2(g) 80 ° C 25 SS
steam header Kg/cm2(g)

0 to 6
9 45PG09 To measure discharge PG 0-2 kg /cm2 Ambient Field 6 Kg/cm2(g) 80 ° C 25 SS
Kg/cm2(g)
pressure of pump 45P01/ on
discharge line of 45P01

To measure the pressure in

0 to 6
10 45PG10 vessel 45V01 / on vessel PG 0-2 kg /cm2 Ambient Field 6 Kg/cm2(g) 80 ° C 25 SS
Kg/cm2(g)
(45V01)

To measure the pressure in

0 to 6
11 45PG11 vessel 45V02 / on vessel PG 0-2 kg /cm2 Ambient Field 6 Kg/cm2(g) 80 ° C 25 SS
Kg/cm2(g)
(45V02)

0 to 6
12 45PG12 To measure discharge PG 0-2 kg /cm2 Ambient Field 6 Kg/cm2(g) 80 ° C 25 SS
Kg/cm2(g)
pressure of pump 45P5 / on
discharge line of 45P5

To measure the steam 0 to 6

13 45PG13 PG 0-2 kg /cm2 Ambient Field 6 Kg/cm2(g) 80 ° C 25 SS
pressure to condenser Kg/cm2(g)

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 Chapter-9 Technical specification

To measure the pressure in

0 to 6
14 45PG14 Distillation column 45C2 / on PG 0-2 kg /cm2 Ambient Field 6 Kg/cm2(g) 80 ° C 25 SS
Kg/cm2(g)
vessel (45C2)

To measure the pressure in

0 to 6
15 45PG15 Distillation column 45C2 / on PG 0-2 kg /cm2 Ambient Field 6 Kg/cm2(g) 80 ° C 25 SS
Kg/cm2(g)
vessel (45C2)

PRESSURE TRANSMITTER including Pirani gauge

Sr. Normal op. Design Line Wetted

Tag no. Description / Location Type Normal op. temp Range Indication Design press
no. press. temp size MOC

0-2 kg /cm2/
1 45PT02 To measure the pressure in Diaphragm seal PT 70-93 ° C/30-40 ° C 0-6 kg/cm2 CR 6 Kg/cm2(g) 200 ° C 25 SS
0-3 kg/cm2
Head condenser 45E1 / on
Head condenser 45E1

2 45DPT02 To measure the pressure Remote seal DPT 0-2 kg /cm2 0-100 ° C 0-6 kg/cm2 CR 6 Kg/cm2(g) 200 ° C 50 SS
difference across the
distillation column 45C2

3 45DPT01 To measure the pressure Remote seal DPT 0-2 kg /cm2 0-100 ° C 0-6 kg/cm2 CR 6 Kg/cm2(g) 200 ° C 50 SS
difference acr4oss the
distillation column 45C1

LEVEL GAUGE /LEVEL switch

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 Chapter-9 Technical specification

Sr. Normal op. Design C-C, Wetted

Tag no. Description / Location Type Normal op. temp Range Indication Design press
no. press. temp mm MOC

45 LG 01
1 with 2 To indicate level in 45V01 level gauge 0-2 kg /cm2 Ambient 0 to 100% Field 6 Kg/cm2(g) 150 ° C 2950 SS
switches

2 45 LG 02 To indicate level in 45C2 level gauge 0-2 kg /cm2 0-100 ° C 0 to 100% Field 6 Kg/cm2(g) 200 ° C SS

3 45 LG 03 To indicate level in 45C1 level gauge 0-2 kg /cm2 0-100 ° C 0 to 100% Field 6 Kg/cm2(g) 200 ° C SS

45 LG 04
4 with 2 To indicate level in 45V02 level gauge 0-2 kg /cm2 Ambient 0 to 100% Field /CR 6 Kg/cm2(g) 150 ° C 2950 SS
switches

LEVEL Transmitter

Sr. Normal op. Design C-C, Wetted

Tag no. Description / Location Type Normal op. temp Range Indication Design press
no. press. temp mm MOC

1 45 LT 01 to indicate level in 45C1 Remote seal DPT 0-2 kg /cm2 0-100 ° C 0 to 100% CR 6 Kg/cm2(g) 200 ° C SS

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 Chapter-9 Technical specification

2 45 LT 04 to indicate level in 45C2 Remote seal DPT 0-2 kg /cm2 0-100 ° C 0 to 100% CR 6 Kg/cm2(g) 200 ° C SS

Temperature Indicator RTD (Temperature element with thermo well and transmitter)

Type of
Sr. Normal op. Indication Design Line Wetted
Tag no. Description / Location Type Normal op. temp Range Design press
no. pt. local/control temp size MOC
room

RTD,PT-100,3
to measure temperature in the
1 45TI01 wired sensor 0-2 kg /cm2 0-100 ° C 0-200 ° C CR 6 Kg/cm2(g) 200 ° C 100 SS
line from 45R1 to 45C1
system

RTD,PT-100,3
to measure temperature in
2 45TI03 wired sensor 0-2 kg /cm2 0-100 ° C 0-200 ° C CR 6 Kg/cm2(g) 200 ° C 100 SS
outlet line of 45C1
system

RTD,PT-100,3
to measure temperature at the
3 45TI04 wired sensor 0-2 kg /cm2 Ambient 0-200 ° C CR 6 Kg/cm2(g) 100 ° C 100 SS
bottom of 45D1
system

RTD,PT-100,3
to measure temperature in
4 45TI05 wired sensor 0-2 kg /cm2 0-100 ° C 0-200 ° C CR 6 Kg/cm2(g) 200 ° C 100 SS
outlet line of 45C2
system

RTD,PT-100,3
to measure temperature at the
5 45TI06 wired sensor 0-2 kg /cm2 0-100 ° C 0-200 ° C CR 6 Kg/cm2(g) 200 ° C 100 SS
bottom of 45C1
system

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 Chapter-9 Technical specification

RTD,PT-100,3
to measure temperature at the
6 45TI08 wired sensor 0-2 kg /cm2 0-100 ° C 0-200 ° C CR 6 Kg/cm2(g) 200 ° C 100 SS
bottom of 45C2
system

Temp gauge (Temperature element with thermo well )

Type of
Sr. Normal op. Indication Design Line Wetted
Tag no. Description / Location Type Normal op. temp Range Design press
no. pt. local/control temp size MOC
room

to measure temperature bimetallic/Capillar

1 45TG02 0-2 kg /cm2 0-100 ° C 0-200 ° C Field 6 Kg/cm2(g) 200 ° C 100 SS
between mid of 45C1 y type

to measure temperature bimetallic/Capillar

2 45TG03 0-2 kg /cm2 0-100 ° C 0-200 ° C Field 6 Kg/cm2(g) 200 ° C 25 SS
between mid and top of 45C1 y type

to measure temperature at the bimetallic/Capillar

3 45TG04 0-2 kg /cm2 Ambient 0-200 ° C Field 6 Kg/cm2(g) 100 ° C 25 SS
top of 45C1 y type

to measure temperature at the

bimetallic/Capillar
4 45TG05 outlet of 45E2 / on line no- 0-2 kg /cm2 0-100 ° C 0-200 ° C Field 6 Kg/cm2(g) 200 ° C 25 SS
y type
25-BUX-0341-SS-IH

to measure temperature of
bimetallic/Capillar
5 45TG06 outlet of 45E2 / on line no- 0-2 kg /cm2 0-100 ° C 0-200 ° C Field 6 Kg/cm2(g) 200 ° C 25 SS
y type
25-BUP-0352-SS-IH

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 Chapter-9 Technical specification

to measure temperature at the bimetallic/Capillar

6 45TG07 0-2 kg /cm2 0-100 ° C 0-200 ° C Field 6 Kg/cm2(g) 200 ° C 25 SS
top of 45C2 y type

to measure temperature at the bimetallic/Capillar

7 45TG09 0-2 kg /cm2 0-100 ° C 0-200 ° C Field 6 Kg/cm2(g) 200 ° C 25 SS
mid of 45C2 y type

to measure temperature at the

CW outlet of Head Condenser bimetallic/Capillar
8 45TG10 0-2 kg /cm2 0-100 ° C 0-200 ° C Field 6 Kg/cm2(g) 200 ° C 50 SS
45E1/On line 50-CWR-0336- y type
CS-UI

to measure temperature at the

outlet of Head Condenser bimetallic/Capillar
9 45TG11 0-2 kg /cm2 0-100 ° C 0-200 ° C Field 6 Kg/cm2(g) 200 ° C 50 SS
45E1/On line 50-BUX-0335- y type
SS-HI

Pressure Switch

Type of
Sr. Normal op. Indication Design Line Wetted
Tag no. Description / Location Type Normal op. temp Range Design press
no. pt. local/control temp size MOC
room

To trip the pump 45 P2 A/B

0-10 kg
1 45PS2A/B when cooling water pressure is Pressure switch 0-4 kg /cm2 0-100 ° C CR 10 Kg/cm2(g) 200 ° C 25 SS
/cm2
low

To trip the pump 45 P5 when 0-10 kg

2 45PS5 Pressure switch 0-4 kg /cm2 0-100 ° C CR 10 Kg/cm2(g) 200 ° C 25 SS
cooling water pressure is low /cm2

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 Chapter-9 Technical specification

To trip the pump 45 P1 when 0-10 kg

3 45PS1 Pressure switch 0-4 kg /cm2 0-100 ° C CR 10 Kg/cm2(g) 200 ° C 25 SS
cooling water pressure is low /cm2

To trip the pump 45 P3 A/B

0-10 kg
4 45PS3A/B when cooling water pressure is Pressure switch 0-4 kg /cm2 0-100 ° C CR 10 Kg/cm2(g) 200 ° C 25 SS
/cm2
low

To trip the pump 45 P4 A/B

0-10 kg
5 45PS4A/B when cooling water pressure is Pressure switch 0-4 kg /cm2 0-100 ° C CR 10 Kg/cm2(g) 200 ° C 25 SS
/cm2
low

Speed Indicator and controller

Type of
Sr. Normal op. Indication Design Line Wetted
Tag no. Description / Location Type Normal op. temp Range Design press
no. pt. local/control temp size MOC
room

to measure and control the

1 SIC(45P1) 0-2 kg /cm2 0-100 ° C CR 6 Kg/cm2(g) 200 ° C SS
speed of pump 45P1 A/B
Speed indicator
controller

SIC(45P4 to measure and control the

2 0-2 kg /cm2 0-100 ° C CR 6 Kg/cm2(g) 200 ° C SS
A/B) speed of pump 45P4 A/B
Speed indicator
controller

SIC(45P2 to measure and control the

3 0-2 kg /cm2 0-100 ° C CR 6 Kg/cm2(g) 200 ° C SS
A/B) speed of pump 45P2 A/B
Speed indicator
controller

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 Chapter-9 Technical specification

SIC(45P3 to measure and control the

4 0-2 kg /cm2 0-100 ° C CR 6 Kg/cm2(g) 200 ° C SS
A/B) speed of pump 45P3 A/B
Speed indicator
controller

CONTROL/ON-OFF VALVE

Type of
Range
Sr. Normal op. Indication Design Line Wetted
Tag no. Description / Location Service fluid Allowable DP (min / Nor Design press
no. point. local/control temp size MOC
/ Max)
room

To control temperature of
1 45TCV01 Steam 0-2 kg /cm2 0.05 to 0.1 Kg/cm² Flow = 10 CR 6 Kg/cm2(g) 200 ° C 50 SS
Reboiler 45E1
to 100
kg/hr

To control Level of aqueous

2 45LCV04 column./on line 25-PRW- Aqueous Effluent 0-2 kg /cm2 0.05 to 0.1 Kg/cm² Flow = 10 CR 6 Kg/cm2(g) 200 ° C 25 SS
0323-SS-IH to 100
kg/hr

To control flow of steam to

3 45FCV08 aqueous column/on line 25- Steam 0-2 kg /cm2 0.05 to 0.1 Kg/cm² Flow = 10 CR 6 Kg/cm2(g) 200 ° C 25 SS
SLS-0347-CS-IH to 100
kg/hr

Solenoid valve

Type of
Sr. Indication
Tag no. Description / Location Service fluid Range
no. local/control
room
Control Valve
1 45EV04 45LCV04 CR
Accessories

Monitors

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 Chapter-9 Technical specification
Type of
Sr. Indication Design Line Wetted
Tag no. Description Location Service fluid Range Design press
no. local/control temp size MOC
room

1 45AI01 Online Hydrogen monitor Hydrogen 0 to 0.5% CR & Field 80 ° C

2 45AI02 UV+IR Flame sensor Flame CR & Field 80 ° C

3 45 AI03 POCl3 detector POCl3 CR & Field 80 ° C

7. LIST OF INSTRUMENTS WITH OVERALL SPECIFICATIONS UNIT-49

PRESSURE GAUGE and mcleod gauge

Sr. Normal op. Design Line Wetted

Tag no. Description / Location Type Normal op. temp Range Indication Design press
no. press. temp size MOC

To measure the pressure in

0 to 6
1 49PG01 vessel 49V01 / on vessel PG 0-2 kg /cm2 Ambient Field 6 Kg/cm2(g) 100 ° C 25 SS
Kg/cm2(g)
(49V01)

To measure the pressure in

0 to 6
2 49PG02 vessel 49V02 / on vessel PG 0-2 kg /cm2 Ambient Field 6 Kg/cm2(g) 100 ° C 25 SS
Kg/cm2(g)
(49V02)

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 Chapter-9 Technical specification

To measure the pressure in

0 to 6
49PG03 vessel 49V03 / on vessel PG 0-2 kg /cm2 Ambient Field 6 Kg/cm2(g) 100 ° C 25 SS
3 Kg/cm2(g)
(49V03)

To measure the pressure in

0 to 6
49PG04 vessel 49V04 / on vessel PG 0-2 kg /cm2 Ambient Field 6 Kg/cm2(g) 100 ° C 25 SS
4 Kg/cm2(g)
(49V04)

To measure the pressure in

0 to 6
49PG05 vessel 49V05/ on vessel PG 0-2 kg /cm2 Ambient Field 6 Kg/cm2(g) 100 ° C 25 SS
5 Kg/cm2(g)
(49V05)

0 to 6
49PG01A To measure discharge PG 0-2 kg /cm2 Ambient Field 6 Kg/cm2(g) 100 ° C 40 SS
6 Kg/cm2(g)
pressure of pump 49P01A /
on discharge line of 49P01A

0 to 6
49PG02A To measure discharge PG 0-2 kg /cm2 Ambient Field 6 Kg/cm2(g) 100 ° C 40 SS
7 Kg/cm2(g)
pressure of pump 49P02A/
on discharge line of 49P02A

0 to 6
49PG03A To measure discharge PG 0-2 kg /cm2 Ambient Field 6 Kg/cm2(g) 100 ° C 40 SS
8 Kg/cm2(g)
pressure of pump 49P03A /
on discharge line of 49P03A

0 to 6
49PG04A PG 0-2 kg /cm2 Ambient Field 6 Kg/cm2(g) 100 ° C 40 SS
9 Kg/cm2(g)
To measure discharge
pressure of pump 49P04A /
on discharge line of 49P04A

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 Chapter-9 Technical specification

PRESSURE TRANSMITTER including pirani gauge

Sr. Normal op. Design Line Wetted

Tag no. Description / Location Type Normal op. temp Range Indication Design press
no. press. temp size MOC

To measure the pressure in 0 to 6

1 49PT01 Vessel 49V01/ on Vessel Diaphragm seal PT 0-2 kg /cm2 Ambient Field 6 Kg/cm2(g) 100 ° C 25 SS
Kg/cm2(g)
49V01
To measure the pressure in
0 to 6
2 49PT02 Vessel 49V02/ on Vessel Diaphragm seal PT 0-2 kg /cm2 Ambient Field 6 Kg/cm2(g) 100 ° C 25 SS
Kg/cm2(g)
49V02

To measure the pressure in 0 to 6

3 49PT03 Vessel 49V03/ on Vessel Diaphragm seal PT 0-2 kg /cm2 Ambient Field 6 Kg/cm2(g) 100 ° C 25 SS
Kg/cm2(g)
49V03
To measure the pressure in 0 to 6
4 49PT04 Vessel 49V04/ on Vessel Diaphragm seal PT 0-2 kg /cm2 Ambient Field 6 Kg/cm2(g) 100 ° C 25 SS
Kg/cm2(g)
49V4
To measure the pressure in 0 to 6
5 49PT05 Vessel 49V05/ on Vessel Diaphragm seal PT 0-2 kg /cm2 Ambient Field 6 Kg/cm2(g) 100 ° C 25 SS
Kg/cm2(g)
49V05
LEVEL GAUGE /LEVEL switch

Sr. Normal op. Design C-C, Wetted

Tag no. Description / Location Type Normal op. temp Range Indication Design press
no. press. temp mm MOC
To indicate level in
1 49LG01A/B level gauge 0-2 kg /cm2 Ambient 0-100 % Field 6 Kg/cm2(g) 100 ° C 25 SS
49V01
To indicate level in
2 49LG02A/B level gauge 0-2 kg /cm2 Ambient 0-100 % Field 6 Kg/cm2(g) 100 ° C 25 SS
49V02
To indicate level in
3 49LG03A/B level gauge 0-2 kg /cm2 Ambient 0-100 % Field 6 Kg/cm2(g) 100 ° C 25 SS
49V03
To indicate level in
4 49LG04A/B level gauge 0-2 kg /cm2 Ambient 0-100 % Field 6 Kg/cm2(g) 100 ° C 25 SS
49V04

To indicate level in
5 49LG05A/B level gauge 0-2 kg /cm2 Ambient 0-100 % Field 6 Kg/cm2(g) 100 ° C 25 SS
49V05

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 Chapter-9 Technical specification

LEVEL TRANSMITTER

Sr. Normal op. Design C-C, Wetted

Tag no. Description / Location Type Normal op. temp Range Indication Design press
no. press. temp mm MOC

1 49LT01 to indicate level in 49V01 Remote seal DPT 0-2 kg /cm2 Ambient 0-100 % Field 6 Kg/cm2(g) 100 ° C 25 SS

2 49LT02 to indicate level in 49V02 Remote seal DPT 0-2 kg /cm2 Ambient 0-100 % Field 6 Kg/cm2(g) 100 ° C 25 SS

3 49LT03 to indicate level in 49V03 Remote seal DPT 0-2 kg /cm2 Ambient 0-100 % Field 6 Kg/cm2(g) 100 ° C 25 SS

4 49LT04 to indicate level in 49V04 Remote seal DPT 0-2 kg /cm2 Ambient 0-100 % Field 6 Kg/cm2(g) 100 ° C 25 SS

5 49LT05 to indicate level in 49V05 Remote seal DPT 0-2 kg /cm2 Ambient 0-100 % Field 6 Kg/cm2(g) 100 ° C 25 SS

Temp gauge (Temperature element with thermo well )

Type of
Sr. Normal op. Indication Design Line Wetted
Tag no. Description / Location Type Normal op. temp Range Design press
no. pt. local/control temp size MOC
room

to measure temperature in bimetallic/Capillar

1 49TG01 0-2 kg /cm2 Ambient 0-100 % Field 6 Kg/cm2(g) 100 ° C 25 SS
Vessel 49V01 y type

to measure temperature in bimetallic/Capillar

2 49TG02 0-2 kg /cm2 Ambient 0-100 % Field 6 Kg/cm2(g) 100 ° C 25 SS
Vessel 49V02 y type

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 Chapter-9 Technical specification

to measure temperature in bimetallic/Capillar

3 49TG03 0-2 kg /cm2 Ambient 0-100 % Field 6 Kg/cm2(g) 100 ° C 25 SS
Vessel 49V03 y type

to measure temperature in bimetallic/Capillar

4 49TG04 0-2 kg /cm2 Ambient 0-100 % Field 6 Kg/cm2(g) 100 ° C 25 SS
Vessel 49V04 y type

to measure temperature in bimetallic/Capillar

5 49TG05 0-2 kg /cm2 Ambient 0-100 % Field 6 Kg/cm2(g) 100 ° C 25 SS
Vessel 49V05 y type

Monitors

Type of
Sr. Indication Design Line Wetted
Tag no. Description Location Service fluid Range Design press
no. local/control temp size MOC
room

1 49AI02 UV+IR Flame sensor Flame CR & Field 80 ° C

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 Chapter-9 Technical specification

DRAWINGS FOR PROCESS

(16 Sheets)

Tender No.: HWB/SPP/e-Tender/2016/01

 ANNEXURE P1

VACUUM SYSTEM /
N2

DM WATER

CHWS

STEAM
SCRUBBER

CWS

COND.
CHWR
CWR
~ ~

VENT HEADER

FROM BUTANOL/IAA
STORAGE TANK
(44-V-1)

FROM BUTANOL
PFN.UNIT

ALKALI SOLN.

43-R-2 43-R-1 43-R-4 43-R-3 43-R-6 43-R-5

(SS) (SS)
DM WATER

44-R-3A 44-R-3B

43-V-15 43-V-14 44-R-1

44-R-2
RCl+ROH XYLENE
43-V-12 43-V-13 RECEIVER RECEIVER 44-V-1 44-V-7
43-V-16
~ ~

~ ~
HEXANE RCl+ROH MSGL MSGL EXCESS ALKALI /
BUTANOL/
RECEIVER RECEIVER (1KL) (1KL) RCl+ROH WATER
+DOP
IAA
MSGL MSGL RECEIVER DAY TANK
(1KL) (1KL) SS(5KL) VESSEL
DRUM DRUM SS(1KL) SS(2KL)

DRUM
44-P-1A/B

M M 44-P-7 A/B
M
M M
44-V-4 44-V-8
ALKALI / IMPURE
44-V-2 WATER BUTANOL
43-RV-1 43-RV-2 43-RV-3 TANK
POCl 3
VESSEL SS(3KL)
MSGL MSGL
CSNL 44-RV-1 44-RV-3
SS(2KL)
MSGL TO BUTANOL
(2KL) (2KL) (2KL) 44-P-4 MSGL
(1KL) MSGL PURIFICATION UNIT
(5 KL)
(5 KL)
OCL
FROM DRUM

44-P-8A/B

POCl3 FROM DRUM

POCl3/PCl3
FROM DRUM/TEA

M
44-V-5
2EHA FROM
BULK STORAGE TANK 44-V-3 ALKALI /
POCl 3 WATER 44-V-6 44-V-9
DUMP TANK
VESSEL 44-RV-2 MSGL(4KL) PRODUCT
MSGL SS(2KL) TANK
43-V-1 43-V-2 43-V-3 43-V-7 43-V-8 43-V-9 43-V-10 (1KL)
POCl3/ 43-V-4 43-V-5 43-V-6 DM
MSGL
POCl3/
ALKALI ALKALI HCl 43-V-11 (5 KL) SS(2KL)
2EHA PCl3/TEA DHA/DOP OCl HEXANE RCl WATER
FEED FEED PROD.
DAY TANK FEED FEED
FEED DAY VESSEL VESSEL VESSEL TANK 44-P-5
TANK TANK TANK VESSEL TANK
TANK
SS(2KL) MSGL MSGL MSGL MSGL SS SS(1KL) HDPE MSGL TO PRODUCT
(0.5KL) (0.5KL) (1KL) (1KL) SS(1KL) (1KL) (1KL) DRUMS
(1KL)

RECYCLE AS PER
DRUM REQUIREMENT
43-P-5A/B 43-P-6A/B 43-P-7A/B 43-V-17
43-P-1A/B DUMP TANK 43-P-8A/B 43-P-9A/B 43-P-10A/B 44-P-6
MSGL(2KL)

RECYCLE AS PER FROM POCl 3

REQUIREMENT DRUM

43-P-17

U/G EFF. TANK

GOVERNMENT OF INDIA
HWB/SPP(T)/PROC/0002

HEAVY WATER BOARD

DEPARTMENT OF ATOMIC ENERGY
TITLE: DRN. GEORGE DES'D.
DATE:
DATE: 13.04.2015 S.PARASURAMAN

SCHEMATIC DIAGRAM FOR SPP CHK'D.

DATE:
APP,D.
DATE:
D.MAJUMDAR S. K. NAYAK

JAMES PROJECT: SPP SCALE : NTS

01 - SUBMISSION TO CWC PROJECTION
17/11/2015 TUTICORIN SHEET NO. 1 OF 1
No. LOC. DESCRIPTIONS REVD. REVD. REVD. REVD. REVD. REV.NO.
A1

DR'N. DRG. FILE NAME :

REFERENCE DRAWINGS DRAWING NO. REVISIONS DATE CHKD. PROC. INST. ELE. CIVIL. MECH.
APP'D. DRG. NO : HWB/SPP(T)/PROC/0002 1 A1 SPP(T)-PROC-0002
 N
ANNEXURE PII

AUTO GARAGE
72M X 8M
(EXISTING)
NORTH
GATE

3.5 11.10

20
WORK SHOP
46M X 20M
(EXISTING)
SPIC FENCING

RAMP
TRASFORMER
FOR SPP 14.5
12.5M x 5M

440-S

6,5
6,5

36
1755-E

5M R O A D

U/G CABLE ROUTE

UTILITY
6

U/G CW PIPE
36M X 6M
451-S

OTHER CHEMICALS STORAGE

2

MCC
PANEL

20M X 5M
6X6

MAIN BLDG FOR SPP

CONTROL
18

UNIT-43 & 44 ROOM COOLING

TOWER
104.2

30M X 18M 6X6 FOR SPP

(EXISTING
HOT WELL)

MCC SHED
PANEL
STORES
(EXISTING)
6X6
2
SPIC

RECOVERY
1812-E

FUTURE
FENCING

ETP
10

EXPANSION
M/S

11M X 10M
7.75M R O A D

8M X 10M 15M X 12M

FUTURE
YC SX PLANT
12

EXPANSION
(EXISTING)
36M X 10M
SX
MCC
6,5

5M R O A D

503-S
R O A D
1755-E

PCl3/POCl3
1770-E

STORAGE
WARE HOUSE
511-S (EXISTING)
6M
6

STEEL YARD
58M X 79M
(EXISTING)
SPIC FENCING

FENCING

77.7

MAIN
GATE

SCOPE OF WORK FOR PROCESS,

MECH., ELECT, INSTR & CONTROL
EPC CONTRACT AS MARKED
DRAWING ISSUED FOR TENDERING
EXISTING
GOVERNMENT OF INDIA

HEAVY WATER BOARD

NOTE: DEPARTMENT OF ATOMIC ENERGY
ALL DIMENSIONS ARE IN M
SCALE: NTS TITLE: DRN. P.J.JAMES DES'D.
SITE PLOT PLAN DATE:
DATE: 14-10-2015 S.PARASURAMAN
FOR SOLVENT PRODUCTION PLANT APP,D.
CHK'D.
AT HWP - TUTICORIN DATE:
D.MAJUMDAR
DATE:
S. K. NAYAK

PROJECT: SCALE : NTS

PROJECTION SPP - TUTICORIN SHEET NO. 1 OF 1

REV.NO. FILE NAME :

DRG. NO : HWB/SPP(T)/CIVIL/0001 00 A3 SPP(T)-CIVIL-0001
A1

HWB/SPP(T)/MECH/0003
MS PLATFORM
ANNEXURE P III
REACTION REACTION REACTION
VESSEL VESSEL VESSEL
REACTION REACTION REACTION
VESSEL VESSEL VESSEL
43RV03 43RV02 43RV01
44RV01 44RV02 44RV03
FFL

44P1A
44 V 01

44RV01
44P1B
44V 06

44V 02
UNIT-44
TBP / TiAP

44RV02
44P8B
44V 08

44P06 A/B

44V 03
44P8A

44V 04
44V 09

44RV03

44P4A/B
RCC RCC

44P5

44V 05
RAFT RAFT
44R1/R2

44P7A

44V 07
SYSTEM - 2
VACUUM

44P7B
43R06
43V16

43R05
SYSTEM - 1

43V08
43P08
VACUUM

43P07A/B
43RV03
43V15

43V07
43P10B
D2EHPA-II / DHOA / TOPO

43P17A/B
43R04
43P10A

43V10
43V11

43V17

43V06
43P06A/B
UNIT-43

43R03

43V04
43V14

43RV02

43P09A 43P09B

43V09

43V03
43V13

43R02

43P05B

43V02
43V05
43P05A
43R01

43P01B

43V12
43V01
43RV01

43P01A

OPERATOR
ROOM
MCC ROOM

MCC ROOM
ENTRANCE
LOBBY

PLAN

SECTIONAL ELEVATION

DRAWING ISSUED FOR REVIEW BY HWP TUTICORIN

GOVERNMENT OF INDIA

HEAVY WATER BOARD

DEPARTMENT OF ATOMIC ENERGY
TITLE: DRN. GEORGE DES'D.
DATE:
EQUIPMENT LAYOUT DATE: 14.10.2015 S.PARASURAMAN

UNIT 43 & UNIT 44 CHK'D. APP,D.

DATE: DATE:
D.MAJUMDAR S. K. NAYAK

PROJECT: SPP SCALE : NTS

00 - - PROJECTION
TUTICORIN SHEET NO. 1 OF 1
No. LOC. DESCRIPTIONS DR'N. DRG. REVD. REVD. REVD. REVD. REVD. REV.NO. FILE NAME :
REFERENCE DRAWINGS DRAWING NO. REVISIONS DATE CHKD. PROC. INST. ELE. CIVIL. MECH.
APP'D. DRG. NO : HWB/SPP(T)/MECH/0003 00 A1 SPP(T)-MECH-0003
 12 11 10 9 8 7 6 5 4 3 2 1

ANNEXURE P IV

H H

TO 43RV01
G G

F F

E E

P N 01 P N 02

43PSV06
43PSV05

43SOV01

43PSV02 43PSV03 43PSV03

43PSV01
43V08
43V07 43V05 43V06
ALKALI RCl + ROH
ALKALI HEXANE
CHARGING VESSEL
43V0I CHARGING FEED TANK
VESSEL (MSGL.1KL)
2EHA (SS. 1KL) VESSEL (MSGL.1KL)
FEED TANK 43V03 (SS. 1KL)
D (SS 2.K.L) 43V02 POCL3/DHA/ 43V04 D
DOP/BO OCl/THF
FEED TANK FEED TANK FEED TANK
MSGL 0.5KL (MSGL. 1KL) (MSGL.0.5KL)

43P05 A/B 43P06 A/B

C
43P07A 43P07B 43P08A

43P01A

C
43P01B

B B

DRAWING ISSUED FOR TENDERING

GOVERNMENT OF INDIA
HWB/SPP(T)/PROC/0010

LEGEND NOMENCLATURE FOR VALVE NO. PIPING NOMENCLATURE

- VESSEL X X X X X XX ABC X X XX
V
RV - REACTOR VESSEL
P - PUMP G-GLASSLINED PROCESS SYSTEM RUNNING NO. PIPE SIZE PROCESS PROCESS RUNNING NO.
DEPARTMENT OF ATOMIC ENERGY
UNIT NO.
PN - PNEUMATIC PUMP S-SS BALL VALVE (NB) FLUID SYSTEM
3 0F 40
R - CONDENSER C-CS 1&2- PROCESS FLUID TITLE: DRN. DES'D. S.PARASURAMAN
SERIES GEORGE
H - HEAT EXCHANGER / WATER COOLER P-PPVALVE 3-DRAIN 1&2- PROCESS FLUID
DATE: 10.09.2015 DATE:
CP-CPVC VALVE 4-VENT
5-COOLING WATER
3-DRAIN P & ID OF UNIT 43 (MAIN PLANT)
H-HDPE 4-VENT APP,D.
NOTE:- CHK'D. D.MAJUMDAR S.K. NAYAK
6-CHILLED WATER 5-COOLING WATER
A 1. ALL DRAIN & VENT VALVES ARE REGULATING/GLOBE VALVES. 7-STEAM&CONDENSATE DATE: DATE: A
6-CHILLED WATER
2. ALL VALVES ON GLASS LINE ARE MSGL.DIAPHRAGM TYPE VALVES 8-EFFLUENT/VENT 7-STEAM&CONDENSATE
3. MOC OF VALVES ON RESPECTIVE PIPE LINES ARE SAME AS THAT OF PIPE LINES
9-IMBUST AIR/N2/ PROJECT: SCALE : NTS
8-EFFLUENT/VENT
4. ALL VALVES ON SS LINE ARE SS BALL VALVES. THERMIC FLUID 9-IMBUST AIR/N2/
PROJECTION SPP-TUTICORIN
THERMIC FLUID SHEET NO. 1 OF 3

REV.NO. FILE NAME :

A1

DRG. NO : HWB/SPP(T)/PROC/0010 00 SPP-PROC-0010

12 11 10 9 8 7 6 5 4 3 2 1
 12 11 10 9 8 7 6 5 4 3 2 1

ANNEXURE P IV

H H
TO 43RV01

G G
TO 43RV02

43TCV01 43FCV03
43FCV02 43TCV03

43TCV04
43TCV02 43FCV08
43FCV07
F F

43FCV09 43FCV12

43 RV 01 43 RV 02
( MSGL 2KL ) ( MSGL 2KL )

43AG01 43AG02
E E

D D
43-PN-03

43PSV15
43PSV13
FRESH
XYLENENE
43PSV14 DRUM
43PSV12
(CPVC)

43 V 14 43 V 15
C 43 V 12 43 V 13 RECEIVER RECEIVER
(MSGL 1 K.L) (MSGL 1.0KL)
RECEIVER RECEIVER
(MSGL 1 K.L) (MSGL 1 K.L)
43PH01
PH MEASUREMENT C
UNIT

1000LTR.

INTERMEDIATE AQUEOUS
COLLECTION TANK

B B

DRAWING ISSUED FOR TENDERING

GOVERNMENT OF INDIA
HWB/SPP(T)/PROC/0010

LEGEND NOMENCLATURE FOR VALVE NO. PIPING NOMENCLATURE

- VESSEL X X X X X XX ABC X X XX
V
RV - REACTOR VESSEL
P - PUMP G-GLASSLINED PROCESS SYSTEM RUNNING NO. PIPE SIZE PROCESS PROCESS RUNNING NO.
DEPARTMENT OF ATOMIC ENERGY
UNIT NO.
PN - PNEUMATIC PUMP S-SS BALL VALVE (NB) FLUID SYSTEM
3 0F 40
R - CONDENSER C-CS
SERIES
1&2- PROCESS FLUID TITLE: DRN. GEORGE DES'D. S.PARASURAMAN
H P-PPVALVE 3-DRAIN
- HEAT EXCHANGER / WATER COOLER 1&2- PROCESS FLUID
P & ID OF UNIT 43 (MAIN PLANT) DATE: 10.09.2015 DATE:
CP-CPVC VALVE 4-VENT 3-DRAIN
5-COOLING WATER 4-VENT
NOTE:- H-HDPE CHK'D. D.MAJUMDAR APP,D. S.K. NAYAK
6-CHILLED WATER 5-COOLING WATER
A 1. ALL DRAIN & VENT VALVES ARE REGULATING/GLOBE VALVES. 7-STEAM&CONDENSATE
DATE: DATE: A
6-CHILLED WATER
2. ALL VALVES ON GLASS LINE ARE MSGL.DIAPHRAGM TYPE VALVES 8-EFFLUENT/VENT 7-STEAM&CONDENSATE
3. MOC OF VALVES ON RESPECTIVE PIPE LINES ARE SAME AS THAT OF PIPE LINES
9-IMBUST AIR/N2/
PROJECT: SCALE : NTS
8-EFFLUENT/VENT
4. ALL VALVES ON SS LINE ARE SS BALL VALVES. THERMIC FLUID PROJECTION
9-IMBUST AIR/N2/
THERMIC FLUID
SPP-TUTICORIN SHEET NO. 2 OF 3

REV.NO. FILE NAME :

A1

DRG. NO : HWB/SPP(T)/PROC/0010 00 SPP-PROC-0010

12 11 10 9 8 7 6 5 4 3 2 1
 12 11 10 9 8 7 6 5 4 3 2 1

ANNEXURE P IV

H H

G G

43FCV12

F F

43 RV 03
( 2KL )
CSNL

43AG03
E E

PN 04

43V09
D AQ. HCl 43V10 D
FEED TANK DM
(PPFRVE. 1KL) WATER TANK
43V17 (SS. 1KL)
DUMP TANK
43PSV16 (MSGL. 2KL)

CON.
HCl.
DRUM

43V11
PRODUCT
TANK
(MSGL. 1KL)

43P17A
C HEXANE/ 43 V 16
WATER
RECOVERY TANK
CIRCULATION 43P17B
DRUM (SS 1.K.L)

43PH02
PH MEASUREMENT C
UNIT 43P10 A/B
43P09 A/B

500LTR.

INTERMEDIATE AQUEOUS
COLLECTION TANK

B B

DRAWING ISSUED FOR TENDERING

GOVERNMENT OF INDIA
HWB/SPP(T)/PROC/0010

LEGEND NOMENCLATURE FOR VALVE NO. PIPING NOMENCLATURE

- VESSEL X X X X X XX ABC X X XX
V
RV - REACTOR VESSEL
P - PUMP G-GLASSLINED PROCESS SYSTEM RUNNING NO. PIPE SIZE PROCESS PROCESS RUNNING NO.
DEPARTMENT OF ATOMIC ENERGY
UNIT NO.
PN - PNEUMATIC PUMP S-SS BALL VALVE (NB) FLUID SYSTEM
3 0F 40
R - CONDENSER C-CS 1&2- PROCESS FLUID TITLE: DRN. DES'D.
SERIES GEORGE S.PARASURAMAN
H - HEAT EXCHANGER / WATER COOLER P-PPVALVE 3-DRAIN 1&2- PROCESS FLUID
4-VENT DATE: 10.09.2015 DATE:
CP-CPVC VALVE
5-COOLING WATER
3-DRAIN P & ID OF UNIT 43 (MAIN PLANT)
H-HDPE 4-VENT APP,D.
NOTE:- CHK'D. D.MAJUMDAR S.K. NAYAK
6-CHILLED WATER 5-COOLING WATER
A 1. ALL DRAIN & VENT VALVES ARE REGULATING/GLOBE VALVES. 7-STEAM&CONDENSATE DATE: DATE: A
6-CHILLED WATER
2. ALL VALVES ON GLASS LINE ARE MSGL.DIAPHRAGM TYPE VALVES 8-EFFLUENT/VENT 7-STEAM&CONDENSATE
3. MOC OF VALVES ON RESPECTIVE PIPE LINES ARE SAME AS THAT OF PIPE LINES
9-IMBUST AIR/N2/ PROJECT: SCALE : NTS
8-EFFLUENT/VENT
4. ALL VALVES ON SS LINE ARE SS BALL VALVES. THERMIC FLUID PROJECTION
9-IMBUST AIR/N2/
THERMIC FLUID
SPP-TUTICORIN SHEET NO. 3 OF 3

REV.NO. FILE NAME :

A1

DRG. NO :
HWB/SPP(T)/PROC/0010 00 SPP-PROC-0010

12 11 10 9 8 7 6 5 4 3 2 1
 ANNEXURE P V

FC
44SDV01

44PSV01
N1 N9 N7
N4 N8
N5A
44V01
INTERMEDIATE
STORAGE TANK

N2
N5B
N3

44PSV02 44PSV03

N8 N3 N7 N1 N8 N3 N7 N1 N8 N2 N1
N5A N5A
44V04 44V05 44 V07 N5A
CONC.SODIUM CONC.SODIUM DILUTE
CARBONATE CARBONATE SODIUM
CHARGING CHARGING CARBONATE
N3 N2 N3 N2 CHARGING
VESSEL VESSEL
N6 N10 N9 N6 N10 N9 (SS 2KL) (SS 2KL) VESSEL
(SS 3KL)
44V02 44V03 N2 N6 N5B N2 N5B N5B
N6 N6
44WT02 POCL3 44WT03 POCL3
CHARGING CHARGING
VESSEL VESSEL
44WI (GL 1KL) 44WI (GL 1KL)
02 03
L L
44WI 44WI
02 03

44P7 A/B

44P4A/B 44P5

DRAWING ISSUED FOR TENDERING

GOVERNMENT OF INDIA
HWB/SPP(T)/PROC/0011

HEAVY WATER BOARD

DEPARTMENT OF ATOMIC ENERGY
TITLE: DRN. GEORGE DES'D.
DATE:
DATE: 10.09.2015 S.PARASURAMAN

P & ID OF UNIT 44 (MAIN PLANT) CHK'D. APP,D.

DATE: DATE:
D.MAJUMDAR S. K. NAYAK

PROJECT: SPP SCALE : NTS

00 - - PROJECTION
TUTICORIN SHEET NO. 1 OF 2
No. LOC. DESCRIPTIONS REVD. REVD. REVD. REVD. REVD. REV.NO.
A1

DR'N. DRG. FILE NAME :

REFERENCE DRAWINGS DRAWING NO. REVISIONS DATE CHKD. PROC. INST. ELE. CIVIL. MECH.
APP'D. DRG. NO : HWB/SPP(T)/PROC/0011 00 A1 SPP(T)-PROC-0011 SH. 1
 ANNEXURE P V

MAIN TBP PLANT

CONDENSERS

44E3 44E4

44TCV01 44TCV02

44TCV03 44TCV04

44 44
RV01 SG RV02 SG 44
44TSV01 RV02 SG
44TSV02

44TSV03

44 RV 02
44 RV 01 44FCV10
ESTERIFICATION
ESTERIFICATION 44 RV 03
& NEUTRALIZATION
& NEUTRALIZATION FINAL NEUTRALIZATION
REACTOR
REACTOR WASHING & RECOVERY
( GL 5KL )
( GL 5KL ) REACTOR
( GL 5KL )

44AG1 44AG2 44AG3

ST01
44 FBV 03

44PSV08

44PSV09
VENT

44PSV06

N9 N7 N2 N5 N3

44 V 06 44 V 08 44 V 09
DUMP TANK IMPURE BUTANOL PRODUCT
( GL 4KL) TANK
RECEIVER TANK
N10 N6
(SS 3.K.L) (SS 2.K.L)

44P6 A/B
DUMP LIQUID
44 V10 RECYCLE PUMP
44 V11
2KL(PP) 2KL(PP)

44P8 A/B
INTERMEDIATE EFFLUENT INTERMEDIATE EFFLUENT
COLLECTION TANK COLLECTION TANK

44WM04
SP SAMPLE POINT

DRAWING ISSUED FOR TENDERING

GOVERNMENT OF INDIA
HWB/SPP(T)/PROC/0011

HEAVY WATER BOARD

DEPARTMENT OF ATOMIC ENERGY
TITLE: DRN. GEORGE DES'D.
DATE:
DATE: 24.08.2015 S.PARASURAMAN

P & ID OF UNIT 44 (MAIN PLANT) CHK'D. APP,D.

DATE: DATE:
D.MAJUMDAR S. K. NAYAK

PROJECT: SPP SCALE : NTS

00 - - PROJECTION
TUTICORIN SHEET NO. 2 OF 2
No. LOC. DESCRIPTIONS REVD. REVD. REVD. REVD. REVD. REV.NO.
A1

DR'N. DRG. FILE NAME :

REFERENCE DRAWINGS DRAWING NO. REVISIONS DATE CHKD. PROC. INST. ELE. CIVIL. MECH.
APP'D. DRG. NO : HWB/SPP(T)/PROC/0011 00 A1 SPP(T)-PROC-0011 SH. 2
 ANNEXURE P VI

45PSV01

45PSV03

HEAD
CONDENSER
45E1
ORGANIC COLUMN
FEED TANK
5 KL, SS

45V01
ORGANIC
COLUMN
FEED PUMPS
45P1A/1B

ORGANIC
PHASE
DISTILLATION
I COLUMN
ORGANIC
PHASE
DISTILLATION 45C1
COLUMN
REBOILER

I 45R1

DECANTER FROM 45E3

45TCV01
45D1

BUTANOL 45E2
PURIFIED PRE-COOLER
BUTANOL
TANK
5 KL, SS
PURE
BUTANOL(44V1) 45V02

PURIFIED
BUTANOL
T/F PUMP
AQUEOUS
45P2 PHASE T/F
I PUMP I
45P4 A/B

PURIFIED BUTANOL PUMP

45P3 A/B

ORGANIC
PHASE
T/F PUMP
45P5 A/B

TO CONDENSER
COLLECTION TANK

DRAWING ISSUED FOR TENDERING

GOVERNMENT OF INDIA
HWB/SPP(T)/PROC/0012

HEAVY WATER BOARD

DEPARTMENT OF ATOMIC ENERGY
TITLE: DRN. GEORGE DES'D.
P & ID OF UNIT 45 DATE: 24.08.2015
DATE:
S.PARASURAMAN

(BUTANOL RECOVERY) CHK'D. APP,D.

DATE: DATE:
D.MAJUMDAR S. K. NAYAK

PROJECT: SPP SCALE : NTS

00 - - PROJECTION
TUTICORIN SHEET NO. 1 OF 2
No. LOC. DESCRIPTIONS REVD. REVD. REVD. REVD. REVD. REV.NO.
A1

DR'N. DRG. FILE NAME :

REFERENCE DRAWINGS DRAWING NO. REVISIONS DATE CHKD. PROC. INST. ELE. CIVIL. MECH.
APP'D. DRG. NO : HWB/SPP(T)/PROC/0012 00 A1 SPP(T)-PROC-0012
 ANNEXURE P VI

45E4

AQUEOUS
PHASE
DISTILLATION
COLUMN

45C2

45E3
AQUESOUS
EFFLUENT
H.E.

DRAWING ISSUED FOR TENDERING

GOVERNMENT OF INDIA
HWB/SPP(T)/PROC/0012

HEAVY WATER BOARD

DEPARTMENT OF ATOMIC ENERGY
TITLE: DRN. GEORGE DES'D.
P & ID OF UNIT 45 DATE: 24.08.2015
DATE:
S.PARASURAMAN

(BUTANOL RECOVERY) CHK'D. APP,D.

DATE: DATE:
D.MAJUMDAR S. K. NAYAK

PROJECT: SPP SCALE : NTS

00 - - PROJECTION
TUTICORIN SHEET NO. 2 OF 2
No. LOC. DESCRIPTIONS REVD. REVD. REVD. REVD. REVD. REV.NO.
A1

DR'N. DRG. FILE NAME :

REFERENCE DRAWINGS DRAWING NO. REVISIONS DATE CHKD. PROC. INST. ELE. CIVIL. MECH.
APP'D. DRG. NO : HWB/SPP(T)/PROC/0012 00 A1 SPP(T)-PROC-0012
 ANNEXURE P VII

49 49 49
PG03 PG03 PG03

2EHA STORAGE TANK (49V01) IAA STORAGE TANK (49V02) DUMP TANK (49V03)
(A516 Gr. 70, 20KL) (A516 Gr. 70, 20KL) (A516 Gr. 70, 30KL)

49 P 01A 49 P 01B 49 P 02A 49 P 02B 49 P 03

2EHA UNLOADING / TRANSFER PUMPS IAA UNLOADING / TRANSFER PUMPS DUMP TANK TRANSFER PUMP

49 49
PG03 PG03

BUTANOL STORAGE TANK (49V04) BUTANOL STORAGE TANK (49V05)

(A516 Gr. 70, 30KL) (A516 Gr. 70, 30KL)

49 P 04A 49 P 04B

BUTANOL UNLOADING / TRANSFER PUMPS

DRAWING ISSUED FOR TENDERING

GOVERNMENT OF INDIA

HEAVY WATER BOARD

DEPARTMENT OF ATOMIC ENERGY
TITLE: DRN. GEORGE DES'D.
DATE:
P&I DIAGRAM OF UNIT 49 DATE: 17.07.2015 S.PARASURAMAN

(STORAGE TANKS) CHK'D.

DATE:
APP,D.
DATE:
D.MAJUMDAR S. K. NAYAK

PROJECT: SPP SCALE : NTS

00 - - PROJECTION
TUTICORIN SHEET NO. 1 OF 1
No. LOC. DESCRIPTIONS REVD. REVD. REVD. REVD. REVD. REV.NO.
A1

DR'N. DRG. FILE NAME :

REVISIONS DATE CHKD. PROC. INST. ELE. CIVIL. MECH.
APP'D. DRG. NO : HWB/SPP(T)/PROC/0016 0 A1 SPP(T)-PROC-0016
 ANNEXURE P VIII

DRAWING ISSUED FOR REVIEW BY HWP TUTICORIN

GOVERNMENT OF INDIA
HWB/SPP(T)/PROC/000

HEAVY WATER BOARD

DEPARTMENT OF ATOMIC ENERGY
TITLE: DRN. GEORGE DES'D.
DATE:
SCHEMATIC OF UNIT 46 DATE: 19.01.2016 S.PARASURAMAN

(ALKALI DISSOLUTION) CHK'D.

DATE:
APP,D.
DATE:
D.MAJUMDAR S. K. NAYAK

PROJECT: SPP SCALE : NTS

00 - - PROJECTION
TUTICORIN SHEET NO. 1 OF 1
No. LOC. DESCRIPTIONS REVD. REVD. REVD. REVD. REVD. REV.NO.
A1

DR'N. DRG. FILE NAME :

REFERENCE DRAWINGS DRAWING NO. REVISIONS DATE CHKD. PROC. INST. ELE. CIVIL. MECH.
APP'D. DRG. NO : HWB/SPP(T)/PROC/0013 00 A1 SPP(T)-PROC-0013
 ANNEXURE P IX
TO VENT
AT 12M HT.

47V1A 47K1
1M3 BLOWER HCL MONITOR TO TRIP TCV OF
THERMIC HWB
FLUID SYSTEM
I
H2 MONITOR
N2 HEADER

VENDOR

VACUUM 6" 2"

CHW OUTLET
SWITCH

CHW INLET
VS FROM VACUUM UNIT B
PG SS304L
TI

CPVC
HWB FROM MAIN PLANT
MG MCLEOD VENT HEADER
GAUGE
CPVC
VENDOR

TI
AIR CPVC
PT PIRANI ADMITTENCE
VACUUM VALVE
TRANSMITTER 47C1
M
VENT SCRUBBER
M

CW

47P2A
BOOSTER 47P3A LG
47E2
VACUUM PUMPS GRAPHITE
TS TEMP. (OSRV)
WATER COOLER
SWITCH AIR
ADMITTENCE
VALVE PG
M

CPVC

HWB
47P4A 47P1A PG
DRAIN
VACUUM PUMPS TO ETP
(OSRV)
LG
CONDENSATE
COLLECTION TANK
47E1A/B VENDOR
CATCH POT VACUUM
47P1B
CONDENSERS

NOTE: SCHEMATIC IS FOR ONE UNIT

DRAIN
A SIMILAR UNIT SHALL ALSO BE PROVIDED BY VENDOR
AND SHALL BE SUITABLY INTERCONNECTED

DRAWING ISSUED FOR REVIEW

GOVERNMENT OF INDIA
HWB/SPP(T)/PROC/0014

HEAVY WATER BOARD

DEPARTMENT OF ATOMIC ENERGY
TITLE: DRN. JAMES DES'D.
SCHEMATIC FOR UNIT 47 DATE:
DATE: 20.01.2016 S.PARASURAMAN

(VACUUM &VENT SCRUBBER) CHK'D. APP,D.

DATE: DATE:
D.MAJUMDAR
S. K. NAYAK

PROJECT: SCALE : NTS

SPP
00 - - PROJECTION
TUTICORIN SHEET NO. 1 OF 1
No. LOC. DESCRIPTIONS DRG. REVD. REVD. REVD. REVD. REVD. REV.NO.
A3

DR'N. FILE NAME :

APP'D. DRG. NO : HWB/SPP(T)/PROC/0014
REFERENCE DRAWINGS DRAWING NO. REVISIONS DATE CHKD. PROC. INST. ELE. CIVIL. MECH. 00 SPP(T)-PROC-0014
 ANNEXURE P X

PI

PT

ATM
PCV
VENT

SV SV

SOFTNER
1 2
PG PS
2 1
HEATING
COIL

VENDOR
48V01 SCOPE
FEED WATER LG HWP(T)
TANK 1A SCOPE

LG
1

HWP(T) VENDOR
SCOPE SCOPE LG LG
PG 1C 1B
FEED WATER

48B1
M BOILER
AMP.
AMP.
CONTROLLER
CONTROLLER
48P2A/B
FEED WATER
PUMP

Ev

NOTE: SCHEMATIC IS FOR ONE UNIT BLOW DOWN

A SIMILAR UNIT SHALL ALSO BE PROVIDED BY VENDOR TO DRAIN
AND SHALL BE SUITABLY INTERCONNECTED

DRAWING ISSUED FOR TENDERING

LEGEND:
LG - LEVEL GAUGE
PG - PRESSURE GAUGE
PS - PRESSURE SWITCH
SV - SAFETY VALVE
S.PARASURAMAN

SCHEMATIC DIAGRAM OF UNIT 48

JAMES S. K. NAYAK
(ELECTRODE BOILER PACKAGE UNIT)
25-10-2012
A3

D.MAJUMDAR
HWB/SPP(T)/PROC/0015
 TI HWP ANNEXURE P XI
CS
CHILLED WATER FROM PLANT

CS
PG
LI LI
PG

PG

STR 2"

COLD WELL
PG

HOT WELL
STR
PG TI CHILLED WATER TO PLANT
CS
STR FI
2" PG

STR

STR
50P1A/B/C 2"

CS
CHILLED WATER
RECIRCULATION PUMPS
CS

STR
SUCT.Pr. DISCH.Pr.
50P2A/B/C
50V01 CHILLED WATER
CHILLED WATER SUPPLY PUMPS
T
TANK
M

50K1A/B LEGENDS:
COMPRESSOR FS - FLOW SWITCH
TS AFT PV PG - PRESSURE GAUGE
SV TI - TEMPRATURE INDICATOR
FI - FLOW INDICATOR
TI
C.S LI - LEVEL INDICATOR
C.W OUTLET STR - Y TYPE STRAINER
C.S PV - PURGE VALVE
50E2A/B FS
TO TRIP C.W INLET SV - SAFETY VALVE
CHILLER THE COMPR. 50E1A/B AFT - ANTI FREEZE THERMOSTAT
CONDENSER FS TO TRIP
TS - THERMOSTAT
THE COMPR.

50V02 T - TRANSMITTER
ACCUMULATOR
SOLENOID VENDOR
VALVE
DRAWING ISSUED FOR TENDERING

THERMO STATIC SIGHT DRIER

GLASS
EXPANSION VALVE

S.PARASURAMAN

JAMES
SCHEMATIC OF UNIT 50 S. K. NAYAK

25-10-2012 (CHILLER PACKAGE UNIT)

A3

D.MAJUMDAR
HWB/SPP(T)/PROC/0017
 ANNEXURE P XII
CT-51
MAIN COOLING TOWER
Fluid handled : Cooling Water
Capacity : 200.0 m^3/hr

HWB

RV
RV
51K01A 51K01B

VENDOR

PG

CT51

51P01C

PG

51P01B

PG

51P01A

DRAWING ISSUED FOR REVIEW

GOVERNMENT OF INDIA

HEAVY WATER BOARD

HWB/SPP(T)/PROC/0018

DEPARTMENT OF ATOMIC ENERGY

TITLE: DRN. GEORGE DES'D.
SCHEMATIC FOR UNIT 51 DATE:
DATE: 18.02.2016 S.PARASURAMAN

(COOLING TOWER) CHK'D. APP,D.

DATE: DATE:
D.MAJUMDAR
S. K. NAYAK

PROJECT: SCALE : NTS

PROJECTION SPP
00 - -
TUTICORIN SHEET NO. 1 OF 1
No. LOC. DESCRIPTIONS DR'N. DRG. REVD. REVD. REVD. REVD. REVD. REV.NO. FILE NAME :
A3

APP'D. DRG. NO : HWB/SPP(T)/PROC/0018

REFERENCE DRAWINGS DRAWING NO. REVISIONS DATE CHKD. PROC. INST. ELE. CIVIL. MECH. 00 SPP(T)-PROC-0018
 Chapter-9 Technical specification

DRAWINGS FOR ELECTRICAL

(13 Sheets)

Tender No.: HWB/SPP/e-Tender/2016/01

 1. OVERVIEW OF ELECTRICAL SYSTEM OF SPP - TUTICORIN (SINGLE LINE DIAGRAM - SLD)

3 Ø 415V , 3200A
BC (ACB-III)
3 Ø 415V , PMCC T2 BUS
3 Ø 415V , T1 PMCC
415 V , 800A
BUS
ACB-IV
35 Feeders

G 250 KVA
415 V AC

ETP MCC PDB-I LIGHTING LOADS T-1 PDB-II LDB-II (N)

26 Feeders 17 Feeders LDB- I(N) 20 Feeders 21 Feeders 18 Feeders
415 V , 800A
ACB-VII

EMCC PANEL BUS

415V , 400A
ACB-VIII

PH Panel VFD Panel LDB CLASS-III

7 Feeders 13 Feeders 13 Feeders
 2.2KW 49P02A IAA

2.2KW 49P03A N-Butanol

FeedPump

300KW ELEC. BOILER-I

80KW VACU.SYSTEM-I

99KW CHIL. SYSTEM-I

Total Load = 835 KW

2. T1 SECTION - SLD

15KW LIGHTING LOAD - T!

135KW ETP MCC

10 KW CRANE
3 Ø 415V , T1 BUS
3.7KW AIR BLOWER

3.7KW AIR BLOWER

5KVA CONTROL TRANSFORMER

12 KW SPARE

40 KW PDB-I UTILITY BUILD.

2.2KW 43 P01 A 2EHA Pump

0.75KW 43 P 05 A Hexane Pump

FRLS

0.75KW 43 P06A RCL Feed Pump

3C x 400 Sq.mm
CABLE - 2 Run
3C x 300 Sq.mm

ALU. CABLE - 8 Run

FRLS, XLPE UE ALU.

0.75KW 43 P07A Alkali

Char.Pump

0.75KW 43 P09A HCL Charg.Pump

3.3KV HT Pannel

0.75 KW 43 P10A DM Water Feed

Pump
3.3KV supply from Panel No 8 of

0.75KW 43 P17A Dump Liquid

3.3 KV , 630A,

R.C Pump
250 MVA VCB-I

3.3KV/415V △ /

415V , 3200A ACB-I

45 KW SPARE
2MVA TRANSFORMER

0.75KW 44P04A conc. Na2CO3

Charg.Pump

0.75KW 44P05A conc. Na2CO3

Charg.Pump

2.2KW 44P06A Dump

Liq.Rec.Pump

1.5KW 44P07A Dil.Na2CO3

Charg.Pump

2.2KW 44P08A Imp.But.Transfer

Pump.

0.75KW 45P01A Organ.Col. Feed

Pump.

60 KW Tank Form area Temp. DB

0.75KW 45P03A Purified

But.Pump

0.75KW 45P04A Aq. Transfer

Pump
BC (ACB-III)

0.75KW 45P05A Purified But.

3 Ø 415V , 3200A

Transfer Pump

1.5KW 46P01A Na2CO3(aq)

Dos.Pump

1.5KW 46P01C Na2CO3(aq) Dos.

Pump
SUPPLY TO T-2 SEC.

2.2KW 49P01A EHA

 2.2KW 49P02B IAA

2.2KW 49P03B N-Butanol

FeedPump

300KW ELEC. BOILER-II

COUPLER
80KW VACU.SYSTEM-II

3Ø 415V FROM BUS

Total Load = 1000 KW

99KW CHIL. SYSTEM-II
3. T2 SECTION - SLD

7 KW LIGHTING LOADS

2.2KW 49 P03 Dump Tank Pump

3.7KW AIR BLOWER

3.7KW AIR BLOWER

3 Ø 415V , T2 BUS

5KVA Control Transformer

10 KW SPARE

13 KW POWER LOADS

2.2KW 43 P01 B 2EHA Pump

0.75KW 43 P 05 B Hexane Pump

0.75KW 43 P06B RCL Feed Pump

0.75KW 43 P07B Alkali

Char.Pump
CABLE - 2 Run
3C x 300 Sq.mm

ALU. CABLE - 8 Run

3C x 400 Sq.mm FRLS
FRLS, XLPE UE ALU.

0.75KW 43 P09B HCL Charg.Pump

0.75 KW 43 P10B DM Water Feed

Pump
3.3KV HT Pannel

0.75KW 43 P17B Dump Liquid R.C

Pump
ACB-II

0.75KW 44P04B conc. Na2CO3

3.3KV supply from Panel No 20 of

415V , 3200A

Charg.Pump
3.3 KV , 630A,
250 MVA VCB-II

3.3KV/415V △ /

0.75KW 43P08A Alkali Char.Pump

2MVA TRANSFORMER

2.2KW 44P06B Dump

Liq.Rec.Pump

1.5KW 44P07B Dil.Na2CO3

Charg.Pump

2.2KW 44P08B Imp.But.Transfer

Pump

0.75KW 45P01B Organ.Col. Feed

Pump

0.75KW 45P02 Purified But.

Transfer Pump

0.75KW 45P03B Purified

But.Pump

0.75KW 45P04B Aq. Transfer

Pump

0.75KW 45P05B Purified But.

Transfer Pump

1.5KW 46P01B Na2CO3(aq)

Dos.Pump

2.2KW 49P01B EHA

365 KW EMCC

80 KW SPARE

50 KW SPARE
 4. EMCC - SLD

Total Load = 335KW

25KVA UPS

0.75 KW 47901 A NaOH

Recirculation
3 Ø 415V , EMCC PANEL BUS

0.75 KW 47901 B NaOH

Recirculation

48 KW CHILLER C.W.
MOTOR
FRLS ALU.

3 1/2 x 240 Sq.mm

CABLE - 2 Run

ACB-VII
3 1/2 x 400 Sq.mm

Cable
415 V , 800A

155KW Pump House Panel

75KW VFD PANEL

2KW INST. Power Supply

415V Supply from T2 MCC

ACB-IV

G
415 V , 800A

9KW CLASS III L.D.B

250 KVA
415 V AC

ACB-VIII
415 V , 800A

3KVA Control Transformer

FRLS ALU.
CABLE - 2 Run
3 1/2 x 400 Sq.mm

16.5KW SPARE
 5. VFD PANEL - SLD

Total Load = 75KW

5.5 KW 43 AG 01
Agitator of RV01

5.5 KW 43 AG 02
Agitator of RV02

5.5 KW43 AG 03
Agitator of RV03

7.5 KW 44 AG 01
Agitator of RV01

7.5 KW 44 AG 02
Agitator of RV02

7.5 KW 44 AG 03
3 Ø 415V, VFD PANEL BUS

Agitator of RV03

1.1 KW 46 AG 01
Dissolution Tank agita.
5 KW 53-AG- 1-V2
Agitator of 53V02
FeCl3
5KW 53-AG-5-R-11
EMCC BUS

Agitator of 53 R 11
SDFU

5KW 53-AG-6-R12
SDFU

Agitator of 53 R 12

5KW 53-AG-7-R21
Agitator of 53 R 21

5KW 53-AG-8-R-22
Agitator of 53 R22

10KW VFD SPARE

 2.2KW 53P31 NaOH
Transfer Pump.

2.2KW 53P32 NaOH

6. ETP MCC - SLD

Transfer Pump.

2.2KW 53P21 HCL

Transfer Pump.

2.2KW 53P22 HCL

Transfer Pump.

Total Load = 135 KW

1.10KW 53P 41 FeCl3
Dosing Pump

1.10KW 53P 42 FeCl3

Dosing Pump

2.2KW 53P11 Effluent

Transfer Pump

2.2KW 53P12 Effluent

Transfer Pump.

3.5KW 53P51 Slurry

Acidic Pump
3 Ø 415V , ETP PANEL BUS

3.5KW 53P52 Slurry

Acidic Pump

3.5KW 53P61 Slurry

Alkaline Pump

3.5KW 53P62 Slurry

Alkaline Pump

3.5KW 53P91 Acidic

Filtrate Pump

3.5KW 53P92 Acidic

MCC

Filtrate Pump

3.5KW 53P93 Alkaline

SDFU
SDFU

Filtrate Pump.
415V Supply from T1

3.5KW 53P94 Alkaline

Filtrate Pump

15KW 53VP11 Vacuum

Pump For RVDF

15KW 53VP12 Vacuum

Pump For RVDF

15KW 53VP13
Vacuum Pump For
RVDF

15KW 53VP14 Vacuum

Pump For RVDF

5KW 53RVF 11 Rotary

Vacuum Filter.

1.5KW 53RVF/AG11
RVF- Vat Agitator.

5KW 53RVF 12 Rotary

Vacuum Filter.

1.5KW 53RVF/AG12
RVF- Vat Agitator

3KVA Control
Transformer

15KW SPARE
7. PUMP HOUSE PANEL - SLD
FROM EMCC
PANEL

415V , 400A
ACB-VIII
3 1/2 x 240 Sq.mm
FRLS ALU.
CABLE - 1 Run
SDFU

3 Ø 415V , P.H PANEL BUS

40KW Cooling Water

40KW Coolin Water

15KW ID FAN-II
15KW ID FAN-I

15KW SPARE
15KW SPARE

15KW SPARE
Pump-II
Pump -I

Total Load = 155KW

Total Load = 5.4 KW
8. LIGHTING DB-II - SLD

MCB
ENTRANCE (S.B)

MMCC ROOM (SB)

OPERATOR ROOM (SB)

VFD ROOM (SB)

CONTROL ROOM (SB)

LDB-II (N) 3Ø 415V BUS

CONFERENCE ROOM
(SB)

UPS ROOM (SB)

ENGINEERS ROOM (SB)

TOILET ROOM (SB)

T-2 MCC
3Ø 415V FROM

Main Plant Lighting

Main Plant Lighting

Main Plant Lighting

SPARE

SPARE

SPARE

SPARE

SPARE

SPARE
Total Load = 13KW
TANK FORM AREA
9. POWER DB-II - SLD

RECOVERY UNIT

ETP UNIT

MAIN PLANT

MAIN PLANT

MAIN PLANT

MAIN PLANT
PDB-II 3Ø 415V BUS

TRANSFORMER I

TRANSFORMER II

CONTROL ROOM A/C

T-2 MCC

UPS ROOM AC
3Ø 415V FROM

VFD ROOM A/C

CONF. ROOM A/C

ENGINEERS ROOM S.B

(SPARE)

ENTRANCE (S.B)

SPARE

SPARE

SPARE

SPARE

SPARE

.SPARE
 MCB

Total Load = 40 KW
SPARE

INDUSTRIAL SOCKET

INDUSTRIAL SOCKET
10. POWER DB-I - SLD

3Ø ISOLATOR

3Ø ISOLATOR

EXHAUST FAN
PDB-I 415V BUS (UTILITY BUILDING)

EXHAUST FAN

EXHAUST FAN

TUBE LIGHT
MCC
3Ø 415V FROM

TUBE LIGHT
T-I

TUBE LIGHT

TUBELIGHT

SPARE

SPARE

SPARE

SPARE

SPARE
 MCB
SPARE

Plant Outer Tube lights

Total Load = 13.6KW

Plant outer Tube Lights

ETP/ Recovery Unit Lights

Recovery Unit Lights

ETP Unit Lights

11. LIGHTING DB-I - SLD

Street Lights
LIGHTING LOADS -T1

Chemical Storage Shed

PCL3/POCL3 Storage Unit

Main Plant Lighting

T-1 MCC

Main Plant Lighting

3Ø 415V FROM

Main Plant Lighting

Main Plant Ligting

Main Plant Lighting

Main Plant Lighting

SPARE

SPARE

SPARE

SPARE

SPARE
MCB
 DCDB

CONTROL ROOM (SB)

CONFERENCE ROOM.

CHEMICAL STORAGE
ROOM

TRANSFORMER YARD

TANK FORM AREA

CONFERENCE ROOM (SB)

12. LIGHTING DB-CLASS III - SLD

3Ø 415V LOADS (CLASS-III SUPPLY)

MAIN PLANT LIGHTING

MAIN PLANT LIGHTING

UTILITY UNIT S.B

3Ø 415V EMCC BUS

RECOVERY UNIT LIGHT

ETP UNIT LIGHT

ENTRANCE LOBY (S.B)

ENGINEERS ROOM LIGHT

UPS ROOM TUBE LIGHTS

VFD ROOM LIGHTS (S.B)

MMCC ROOM LIGHTS

(S.B)
Total Load = 9KW
SPARE
13. DC DB-CLASS- I - SLD

SPARE
110V DCDB LOADS

SPARE

TRANSFORMER-II

TRANSFORMER-I

MMCC ROOM DB
DG SET ROOM

VFD ROOM DB
110V-DCDB LOCATED AT 400KVA

UTILITY BUILDING

MAIN PLANT LIGHTING

MAIN PLANT, REC.UNIT,

ETP LIGHTING

MAIN BUILDING
LIGHTING
  e‐Tender checklist for PQ and Technical bid

 
 
 
 
CHECKLIST FOR E-TENDER
PQ AND TECHNICAL BIDS
(3 Sheets)
To be uploaded in Excel sheets
 

Tender No.: HWB/SPP/e‐Tender/2016/01

 GOVERNMENT OF INDIA
DEPARTMENT OF ATOMIC ENERGY
HEAVY WATER BOARD
5th floor, Vikram Sarabhai Bhavan, Anushaktinagar, Mumbai – 400 094
E-TENDER PRE QUALIFICATION DATA SHEET
NIT No.: HWB/SPP/2016/01
NAME OF THE WORK: Engineering, Procurement, Construction (EPC) of Solvent Production Plant (SPP) consisting of Glass-
Lined reactors, Nickel cladded reactor, CS bulk storage tanks, SS & Graphite heat exchangers, SS & CS columns, SS & GL process
vessels;Package utility systems like cooling water system, vacuum system, vent scrubber system, chilled water system, alkali dissolution
system and electrode boiler; Centrifugal & diaphragm pumps along with the associated piping, supports, fitting & valves in metallic,
glass-lined and non-metallic material; Electrical system,Instrumentation & Control system;Complete project management & execution;
Supply & erection; QA testing; Pre-commissioning, Commissioning and Performance testing at Heavy Water Plant, Tuticorin, Tamil
Nadu.
S.NO GENERAL PARTICULARS DETAILS
I Name of the Agency
II Postal address
III Contact with STD code
IV Fax with STD code
V Name of Contact person
VI Mobile No.
VII e-mail ID

BELOW GIVEN DOCUMENTS TO BE SCANNED AND UPLOADED IN THE

SCAN COPY ATTACHED
WEBSITE www.tenderwizard.com/DAE WITHIN THE PERIOD OF Rs. in lakh "YES" OR "NO"
SUBMISSION
1 Gross Annual Turn Over Certified by CA (refer FORM-A) amount to
be entered in Rs. Lakh
2011 - 12
2012 - 13
2013 - 14
2014 - 15
2015 - 16
2 Profit & Loss Statement Certified by CA (refer FORM-A) Profit /
loss amount (+ / -)to be entrered in Rs. Lakh
2011 - 12
2012 - 13
2013 - 14
2014 - 15
2015 - 16
3 Latest Bank Solvency Certificate (refer FORM-B)Solvency amount to
be entered in Rs. Lakh
4 List of Similar Works carried out in last seven years (refer FORM-C) ATTACH SIGNED SCAN
COPY SEPARATELY

5 Performance report of works carried-out (refer FORM-D) ATTACH SIGNED SCAN

COPY SEPARATELY

6 Structure and Organisation (refer FORM-E) ATTACH SIGNED SCAN

COPY SEPARATELY

7 Letter of transmittal as per Chapter- 3 ATTACH SIGNED SCAN

COPY SEPARATELY

8 Certificates:
i) Registration Certificate, if Any. ATTACH SCAN COPY
SEPARATELY
ii) Certificates of Work Experience / Performance certificates ATTACH SCAN COPY
SEPARATELY
iii) Certificates of Registration for Sales Tax / VAT / WCT and Service ATTACH SCAN COPY
Tax SEPARATELY
iv) TIN Registration Certificates ATTACH SCAN COPY
SEPARATELY
v) PAN (Permanent Account Number) Registration ATTACH SCAN COPY
SEPARATELY
vi) Other License(s) ATTACH SCAN COPY
SEPARATELY
9 Whether the eligible similar work(s) were done on back to back
basis.(Yes/No)

10 Net Banking/Credit card/Debit reference number of transaction towards

Cost of Tender Processing Fee (enter the amount in Rs.)

11 Demand Draft / Pay Order or Banker's Cheque / Deposit at Call Receipt

/ FDR of any scheduled Bank Against EMD (enter the amount in Rs.
Lakh. )

12 Bank Guarantee of any Scheduled Bank against EMD, if any

13 I/We have downloaded and gone through the prebid clarifications issued
by the Department after close of sale of tenders and submitting tender
accordingly. (Yes / No)
 GOVERNMENT OF INDIA
DEPARTMENT OF ATOMIC ENERGY
HEAVY WATER BOARD
5th floor, Vikram Sarabhai Bhavan, Anushaktinagar, Mumbai – 400 094
E-TENDER CONFIRMATION & DOCUMENTS FOR TECHNICAL BID
NIT No.: HWB/SPP/2016/01
NAME OF THE WORK: Engineering, Procurement, Construction (EPC) of Solvent Production Plant (SPP) consisting of
Glass-Lined reactors, Nickel cladded reactor, CS bulk storage tanks, SS & Graphite heat exchangers, SS & CS columns, SS &
GL process vessels;Package utility systems like cooling water system, vacuum system, vent scrubber system, chilled water
system, alkali dissolution system and electrode boiler; Centrifugal & diaphragm pumps along with the associated piping,
supports, fitting & valves in metallic, glass-lined and non-metallic material; Electrical system,Instrumentation & Control
system;Complete project management & execution; Supply & erection; QA testing; Pre-commissioning, Commissioning and
Performance testing at Heavy Water Plant, Tuticorin, Tamil Nadu.

Bidder is required to specifically confirm the following by uploading signed scan copy in the offer:-

NAME OF THE BIDDER

S.NO GENERAL PARTICULARS

Confirmation of Combined scope of work along with equipment and item list ( Chapter 9 -
1
Technical specification - Combined scope of EPC work for SPP )

2 Exclusion from the scope of work, if any.

3 Deviations from the tender document, if any.

4 Contradictions in the Technical specifications, if any.

5 List of Vendor/Subvendor for the bought out items.

Acceptance of Design basis, data sheets, drawings & technical specifications as given in the
6
tender document.

7 Confirmation of List of Spare parts as per Tender requirement.

8 Acceptance of all Quality Assurance plan as indicated in the tender.

9 Confirmation of completion of entire work in scheduled time.

10 Confirmation that HAZOP study has been considered in the scope of work.

11 Acceptance of Performance Guarantee requirement as per the Tender Document.

12 Memorandum of work as per Chapter-4 (Part-II, Vol.1)

Confirmation for detailed plan about project execution with respect to Engineering,
13 Procurement & Construction, including agreement, consortium, undertaking made
with outsourced agencies.
Confirmation of placement of purchase order for long delivery item (as listed in CS-
14 23 of Combined scope of work) within three months from the date of issue of work
order by HWB
Note: 1. Please write "Yes" or "No" as applicable.
2. Please upload all the relevant documents as above.
3. Technical evaluation of the bids shall be made based on above documents.
 Part-III Financial/Commerical bid

PART –III FINANCIAL BID

Tender No.: HWB/SPP/e-Tender/2016/01

 Part-III Financial/Commerical bid

COMMERCIAL CONDITIONS

1.0 GENERAL CONDITIONS

This part of tender is for filling the rates against Schedule of Quantities enclosed. Some of
the Clauses of tender document have been reproduced in this part also, so that, bidders do not
quote the rates without accounting the facilities to be provided by the department and they
make themselves aware of the site conditions. All technical aspect including technical
deviation shall be recorded/submitted in technical part of tender i.e. Part-II. All Commercial
aspects shall be brought out in this commercial part (Part-III) of tender. This part of the
tender shall be opened after finalization of technical part of the tender i.e. Part-II of the
tender.

2.0 ACCOMODATION AND TRANSPORT

The contractor shall make his own arrangement for providing all facilities like
accommodation and transport for his employees at his own cost. However, accommodation
and transport facilities can be provided on chargeable basis subject to its availability.
Department shall not be responsible for any risk faced by the contractor while transporting
the personnel to and fro from site.

3.0 MEDICAL FACILITIES

No medical facilities will be provided to the employees of the contractor by the department.

4.0 INSURANCE

While carrying out the above work, necessary insurance coverage for contractor workmen
and material should be done by the contractor. If any accident/injury occurs to the working
personnel, the contractor only has to bear all the expenses for any sort of the compensation
payable to the injured person. The department will not be responsible in any manner in this
regard.

5.0 FOOD FOR CONTRACTOR EMPLOYEES:

Contract employees can avail food from the departmental canteen at the specified rates for
the contract employees subject to availability of food at the canteen.

6.0 STORAGE

The Contractor shall arrange his own storage facility for all his belongings at his cost at plant
site in the place allotted to him by the department.

Tender No.: HWB/SPP/e-Tender/2016/01

 Part-III Financial/Commerical bid

7.0 STORES & EQUIPMENT

The Contractor shall be responsible for all the materials, which he is storing in the storage
room and the department will not bear any responsibility for the loss/damage to the
contractors material by any reasons whatsoever it may be.

8.0 WORKING HOURS

The General Shift working hours of the plant is from 09.00 hours to 17.00 hours. The
Contractor should follow these working hours. If a particular job can not be completed
within the stipulated period, contractor can continue beyond the above mentioned hours with
the permission of the competent authority. All workers of the contractor working inside
plant premises have to follow safety and security instructions issued from time to time. All
workers have to acquire entry-pass from designated authority as per requirement/rules.

9.0 ELECTRICITY

Temporary single phase 230 Volt or 3 phase 415 volt will be provided to the contractor
depending upon the requirement at the Applicable tariff prevailing from time to time.
Contractor should also see that all his electrical equipment are maintained in excellent
condition and no sparking/burning etc. should occur as the plant is having ignitable materials
such as n-hexane and other inflammable organic chemicals. Contractor should obtain
necessary certificate by the Electrical Engineer before starting work.

10.0 WATER

Drinking water will be provided by the department free of cost.

11.0 VALIDITY OF OFFER

The tenderer/tenderers should keep his/their quotation opened for a minimum period of 240
days from the date of opening of the tender. If the tenderer/tenderers withdraw or modify
his/their tenders with in the period of 240 days, his/their EMD shall be liable to forfeiture.

12.0 SUBMISSION OF TENDER

The tender should be submitted in three parts along with EMD. The three parts are
Prequalification bid (Part-I), technical bid (Part-II) and commercial bid (Part-III).The
Prequalification bid should contain the necessary forms/document for the eligibility criteria
as per PQ document. The technical bid should contain all the technical details required and
also all the relevant details which are all related to the tender, while the commercial bid will
include only the rate details. First the Prequalification bid will be opened and the suitability

Tender No.: HWB/SPP/e-Tender/2016/01

 Part-III Financial/Commerical bid

of the bid will be assessed. The prequalified bidders will be further evaluated for Technical
bid. After the assessment of the technical part (Part-II) only, commercial bid will be opened.

13.0 PRICE SHEDULE

13.1 The bidder shall quote their price under the price schedule on Lump sum basis as
well as price break up schedule as per the items break up given in the price section.
13.2 It is a Lump Sum Turn-Key (LSTK) contract on EPC mode. Hence the offer shall
be evaluated based on Lump sum offered price and break up price shall be considered
only for progressive payment and addition/deletion of any items if required for the
process.
13.3 The price offered for the respective items shall be inclusive of (along with basic
cost) all applicable taxes & duties but not limited to service, central, VAT, entry,
works contract insurance, inspection/testing charges, packing, transportation (safe
delivery), transit insurance, supervision & operation charges for erection &
mechanical testing, cleaning, functional & performance test run, spares as listed.
13.4 The rates shall be firm throughout the period of contract. Before quoting, the
tenderer is requested to understand the complete work and department will not be
responsible for any under quoting due to wrong understanding.
13.5 All the work of piping & pipe fittings shall be a lot as per P&ID indicated in the
tender. The final equipment lay out & isometric are to be prepared by the contractor
(based on tentative equipment lay out and site plot plan given in the tender) and
approved by the department. Detailed engineering, electrical work, erection, testing,
pre-commissioning work for cleaning, leak test run, calibration and functional, water
& performance test run shall be as per the scope & quantum of job indicated in the
tender. Other items will be as per schedule of quantity of the tender. It is the
responsibility of the bidder to estimate the quantum of job of the above lot items and
offer accordingly. A BOQ is to be made by the contractor for all the above items
during execution of the job and get it reviewed and approved by the department. The
same quantity will be the binding for supply of all these items under the scope of
EPC contract within the offered price.
13.6 The bidder shall include the cost of the spares (as indicated in Excel sheet)
13.7 The spare parts as may be consumed during functional test and performance
guarantee test run of all equipment, machineries etc, shall be borne by the contractor,
without any cost implication of the department.
13.8 The contractor shall have valid commercial/tax registration in the state of Tamil
Nadu, or furnish an undertaking to register themselves before issue of work order, for
carrying out the works contract job.

Tender No.: HWB/SPP/e-Tender/2016/01

 Part-III Financial/Commerical bid

14.0 INSURANCE COVERAGE

The tenderer shall insure the plant & machinery for which mobilization advance sought &
given at his own cost for all the materials during transit as well as during storage at site.
Department shall not reimburse any insurance charges.

15.0 Any part of the tender document shall not be detached. The entire document shall be
submitted signed on each page, filling the rates and other details. Deviations and other
conditions shall be spelled out along with the tender in the enclosed format mentioned
elsewhere of this document.
16.0 No compensation shall be paid to the bidder on account of stoppage of work due to
unsafe and non-compliance to the statutory rules and regulations.
17.0 Liquidated damages for delay in completing the job for the reasons not attributable to the
department shall be as indicated elsewhere in the tender.
18.0 If at any time after commencement of the work, the department for any reason or
whatsoever not requires the whole or part thereof as specified in the tender the bidder shall
not claim any payment or compensation.
19.0 After the completion of work, site clearance is the responsibility of the bidder and shall
hand over the area allotted to him in a neat and hygienic manner.
20.0 The bidder, while execution of the job shall take necessary precautions not to cause any
loss or damage to the departmental property and such loss/damage if any, shall be recovered
from the bidder’s bill estimated as per the prevailing rate/standard accounting method
depending upon the criticality and value of the item as will be decided by the department
case to case.
21.0 Complete offer but not in line with the format given by us would be summarily rejected.
The bidder shall quote separately for each of the items as indicated under break up price
schedule. Clubbing of price for more than one item would be considered as incomplete offer
and is liable for rejection.
22.0 The bidder should adhere to all labour laws such as minimum wages Act, 1948, Payment
of Wages Act, 1956, Contract Labour Regulation and Abolition Act 1970, Workmen’s
Compensation Act 1923, EPF and Miscellaneous Provision Act 1962 and such other Acts.
In the case of non-fulfillment of any of the above Act or any notification issued by the
Labour Department therein, Department has the full right to with held any type of payment
or recover such sum of as may be required for liquidating the bidder’s above availability.

23.0 TERMS OF PAYMENT

Following terms of payment are offered to the contractors as per Clause 2.0 of Terms of
payment indicated in VI. Special requirement of Chapter-6:

Tender No.: HWB/SPP/e-Tender/2016/01

 Part-III Financial/Commerical bid

2.1. 10% of contract value as mobilization advance as per clause 10-B (ii) of GCC
against Bank Guarantee of 110% of advance.
2.2. 80% of quoted value of engineering work against the completion of engineering
work and placement of Purchase Orders for long delivery item as listed in page
CS-23. Service tax on engineering work will be reimbursed on production of
documentary evidence.
2.3. 80% of the quoted value (Supply value) along with 100% taxes & duties against
the supply of items upon receipt at site and its acceptance.
2.4. 80% of the quoted value (Erection value) along with 100% taxes & duties against
the erection work of the items covered under above point 2.3. However, Service
Tax on erection will be reimbursed on production of documentary evidence.
2.5. 10% of the quoted value (supply + erection) against mechanical completion
2.6. Balance of the contract value after completion of commissioning activities.
2.7. Total no. of payments would be restricted to maximum 15.
2.8. The recovery of advance would commence after 10% payment is made and the
entire amount together with interest shall be recovered by the time 80 % payment
is made.

24.0 Stage payment as above shall be made on pro-rata basis on submission of certified
documents & bills.
25.0 Paying authority shall be Pay & Accounts Officer, Heavy Water Plant, Tuticorin under
the approval f competent authority as per DAE guidelines.
26.0 Shri S.K.Nayak, AD(SET) shall be Nodal Officer of the work from HWB Central Office
and GM, HWP, Tuticorin or his authorized person shall be Engineer-in-Charge (EIC) of the
work.
27.0 Income tax, Surcharge on IT, EC on IT & SC and Sales Tax shall be deducted from
running bills and final bills as per the prevailing rates. The service tax shall be reimbursed
on production of proof that the same has been paid by the party. TDS will be effected as per
rules.

Note: No Foreign Exchange payment shall be made by us and also no extra payment due to
variation in F.E. shall be permitted on imported components.

Tender No.: HWB/SPP/e-Tender/2016/01

 Part-III Financial/Commerical bid

28.0 Defect Liability Period/Performance Guarantee period:

Responsibility of entire work of the SPP facility under scope of work i.e. design of all
equipment, machineries & piping, electrical system, instrument & control system, thermal
design of heat Exchangers, procurement & erection and functional & performance guarantee
test run of all the items under schedule of quantity lies on the contractor. The contractor
shall stand Guarantee for functioning of all the items supplied for a minimum period of 12
months from the date of acceptance of the system or 18 months after the mechanical
completion & acceptance of the same by the department whichever is later.

29.0 Liquidated Damages:

If contractor fails to maintain the required progress on or before the time schedule or
extended date of completion, he shall without prejudice to any other right or remedy
available under the law to the government on account of such breach, pay as agreed
compensation the amount calculated at the rates stipulated in CPWD 2014.

30.0 Compliance of Terms & Conditions:

The bidder shall comply with all the technical as well as General Terms & Conditions of this
Work without any reservation, except those which have been specified/agreed to and
mentioned herein.

31.0 Performance Guarantee

The contractor shall deposit an amount equal to 5% of the tendered and accepted value of the
work as performance guarantee under performance security bank guarantee bond within a
period of ranging 4 to 15 days of issue of Letter of Acceptance. For further details General
Conditions of Contract shall be referred.

32.0 Security Deposit

The security deposit of the work is 2.5% of the tendered and accepted value of the work.
The same amount will be recovered from the running bill & final bill (stage payment) at the
rate of 2.5% of each bill amount till complete deduction of security deposit is made. The
security deposit will be returned after guarantee period of 12 months after commissioning of
the plant or 18 months from mechanical completion (erection, testing & performance test
run).

Tender No.: HWB/SPP/e-Tender/2016/01

 Part-III Financial/Commerical bid

FINANCIAL/ PRICE BID

To be uploaded in Excel sheets

Tender No.: HWB/SPP/e-Tender/2016/01

 GOVERNMENT OF INDIA
Department of Atomic Energy
Heavy Water Board
V S Bhavan
Mumbai – 400 094
PRICE BID
NAME OF WORK : Engineering, Procurement, Construction (EPC) of Solvent Production Plant (SPP) consisting of Glass-
Lined reactors, Nickel cladded reactor, CS bulk storage tanks, SS & Graphite heat exchangers, SS & CS columns, SS & GL
process vessels; Package utility systems like cooling water system, vacuum system, vent scrubber system, chilled water system,
alkali dissolution system and electrode boiler; Centrifugal & diaphragm pumps along with the associated piping, supports, fitting
& valves in metallic, glass-lined and non-metallic material; Electrical system, Instrumentation & Control system; Complete
project management & execution; Supply & erection; QA testing; Pre-commissioning, Commissioning and Performance testing
at Heavy Water Plant, Tuticorin, Tamil Nadu.
NIT No. : HWB/SPP/2016/01
NAME OF THE BIDDER
LUMP SUM PRICE OF THE WORK :
Fig. in Rs.
In words : Rupees
Total lump sum price is inclusive of all applicable taxes & duties for total scope of work inclusive of spares as listed in the tender
for the respective items
( The Price bid shall be evaluated on this total lump sum price only. Price shall remain firm )

BREAK UP OF PRICES :
( This is for making progressive payment )

(All cost figure in Rs. )

Sl. No Item description Qty. Broad Specification Unit Cost # Total cost #
Refer technical
Residual Engineering for Process,
specifications and
Mechanical, Instrument & Control,
combined scope of work
1 Electrical and Package systems ( as per lot
under technical tender
scope of work mentioned under Technical
document under Part II,
bid document)
Vol.2
Total of 1

Refer technical
Manufacture / Procurement and specification and
2 supply of following (A detailed scope of work
to E) under technical tender
document
A. PRICE BREAK UP FOR MAIN PLANT EQUIPMENT & MACHINERIES
Sl.
Item description Qty.* Broad Specification Unit Cost # Total cost #
No
Jacketed MSGL Reactors with Agitator & Motor
1 and Flush Bottom valves, 43 RV1, 43 RV2 (2 2
KL each)
Jacketed CS-Ni cladded Reactor with Agitator
2 & Motor (43 RV 03 ) (2 KL) 1

Jacketed MSGL Reactors with Agitator & Motor

3 and Flush Bottom valves , 44 RV1,2,3 (5 KL) 3
4 MSGL Feed Tanks, 0.5 to 4 KL 14 *Refer Mechanical/
5 SS Feed tanks, 1 to 5 KL 14 Process specification
6 CS storage tanks, (20 to 30 KL) 5 under tender document
7 SS columns (Butanol purification unit) 1
PTFE lined CS columns (Butanol purification
8 unit) 1
9 Graphite Heat exchangers, (9 to 20 m 2 ) 7
10 SS Heat exchangers, (2.8 to 15m 2 ) 9
11 Centrifugal pumps, ( 1 to 6 m 3/hr) 18
12 Diaphragm pumps, ( 0.15 to 3 m 3/hr) 22
13 PP-FRP vessels 5
Total of 2A
 B. PRICE BREAK UP FOR INSTRUMENT & CONTROL SYSTEM
Sl no. Type of instrument Qty * Specification Unit Cost # Total cost #
DCS system of 1000 I/O’s and 3 nos. of
1 operator console with cutout and total system 1
integration
2 25 KVA UPS System 1
3 Control Valve & accessories lot
4 Level / DP ( remote seal) Transmitters lot
5 RTD & Temperature guages lot * Refer Instrument
6 Flow transmitters lot specification in tender
7 Level & Pressure switches lot document
8 Level & Pressure guages lot
9 Monitors & sensors lot
10 Tubings & fittings lot
11 Multicore/signal/RTD cable etc lot
12 Cable trays & junction boxes lot
13 Miscellaneous item lot
Total of 2B
C. PRICE BREAK UP FOR PIPE, PIPE FITTINGS, VALVES & ACCESSORIES

Sl. No Item description Qty.* Broad Specification Unit Cost # Total cost #
1 MSGL pipe, pipe fitting & valves lot
*Refer mechanical
2 SS pipe, pipe fitting & valves lot
specification in tender
3 CS pipe, pipe fitting & valves lot
document
4 Non metallic pipe, pipe fitting & valves lot
Total of 2C
D. PRICE BREAK UP FOR ELECTRICAL SYSTEM

Sl. No Item description Qty.* Broad Specification Unit Cost # Total cost #
2000 KVA 3.3 KV/415 Volt. DY11, 3 Phase,
1 2
50 c/s, Power Transformer
2 3.3 KV, 25 KVA VCB panel 2
3 250KVA DG set 1
415V Power & Motor Control Centers(with 2
4 1
No. Bus section & Bus coupler)
5 415V ETP MCC 1
6 415V Pump House Panel 1
7 CLASS-III power panel EMCC 1
8 VFD Panel for agitator motors 1
9 Class-I load center 110VDCDB 1
10 Light Fittings lot
11 Supply of cables lot
(a) 3.3KV 3Cx300sq.mm armoured FRLS ,
XLPE UE aluminum power cable (~ lot
4Runsx375mt) *Refer Electrical
(b) 415V 2MVA Power Transformer sec. cable specification in tender
3Cx400sq.mm armoured FRLS aluminum lot document
power cable (16runsx85mt)
(c) Other 415 V cables meant for motors, light
lot
fitting and all other electrical loads.
(d) Control cable lot

(e) 1.1KV 3.5 Cx300sq.mm armoured FRLS ,

lot
aluminum power cable (1Runsx275mt)

(f) 1.1KV 3.5 Cx400sq.mm armoured FRLS,

aluminum power cable (6Runsx350mt) for E.B, lot
Chiller.
12 Cable trays lot
13 Cable trench including hume pipe lot
14 Grounding & lightning protection lot
15 Building electrification & Push buttons lot
10 Nos. of 1.5 TR split AC for Air
16 lot
conditioning of main plant building

Total of 2D
 E. PRICE BREAK UP FOR UTILITIES & PACKAGE SYSTEM

Sl. No Item description Qty.* Broad Specification Unit Cost # Total cost #

Complete package of vacuum system including

1 2
suction buffer vessel

2 Complete package of Vent scrubber 1

3 Complete package of Alkali dissolution system 1 *Refer technical

specification and detailed
4 Complete package of chilled water system 2 scope of work under tech.
document
5 Complete package of steam generation system 2

6 Complete package of cooling water sytem 1

7 Complete package of 10 T EOT crane 1

Total of 2E

Sub Total of 2 ( 2A to 2 E)

3 Field erection/ Installation/testing

etc. for achieving mechanical completion
and functional & performance test run
for all Equipment, Machinery, Piping,
Instrumention system , Electrical system &
Package units & battery limit interconnections. Refer technical
This also includes supply and fabriction of specification and detailed
lot
structural material, pipe rack, Hot & Cold scope of work under
Insulation, cable rack, cable laying , cable technical tender document
termination, cable trenching, minor civil work
for grouting , dressing, alignment etc., as per
technical specifications.

Total of 3
4 Spares for Mechanical, Electrical, Refer technical
Instrumentation & control and package lot specification for list of
system spares

Total of 4

Grand Total of 1 to 4
Note: # Unit cost and total cost shall be inclusive of all applicable taxes and duties.