KARIMNAGAR TELANGANA STPP PHASE I- ( 2 X 800 MW) SG PKG MILL REJECT SYSTEM (PNEUMATIC TYPE) TECHNICAL SPECIFICATION NO PE-TS-424-160-A001

CLAUSE NO.
FUNCTIONAL GUARANTEES AND LIQUIDATED DAMAGES

B. Following shall be demonstrated at Site

1) Vibration & Noise level of centrifugal fans & pumps of UAF units.

1.03.07 Not Used.

1.03.08 Equipment Cooling Water System

a) Parallel operation of pumps to be demonstrated at site.

b) Further pressure drop across the heat exchanger on the primary & secondary water
circuit to be demonstrated at site.

1.03.09 Not Used.

1.03.10 Compressed Air System

a) Following shall be demonstrated at shop:

i) Capacity and discharge pressure of each air compressor.

b) Following shall be demonstrated at site:

i. Parallel operation of air compressors

ii. Dew point of air at the outlet of air drying plants of instrument air
compressor.

iii. Pressure drop across the air drying plants of air compressors.

iv. Vibration and noise level of air compressors, blowers of air drying plant

1.03.11 Mill Reject System

1. Continuous effective discharge and conveying at the rated capacity of the mill rejects
without spillage or blockage in the system.

2. A) Following shall be demonstrated at shop for compressor

x Power consumption, Capacity and discharge pressure of each air

compressor

B) Following shall be demonstrated at site for compressor

x Parallel operation of air compressors, if applicable

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CLAUSE NO.
FUNCTIONAL GUARANTEES AND LIQUIDATED DAMAGES

x Vibration and noise level of air compressors

1.03.12 Ash Handling Plant

S. DESCRP PERFORMANCE GUARANTEE PARAMETERS REMARKS

No TION
A. Bottom (i) In case bidder offers intermittent type bottom Continuous
ash ash removal system employing triple V type water effective conveying
system, impounded hopper and jet pump system shall be system shall be
Economi guaranteed to meet following performance: established by no
zer stagnation of ash or
Continuous effective extraction, crushing and
ash,APH slurry at any point
conveying of bottom ash generated during various
ah (if in the complete
modes of boiler operation to the ash slurry sump
applicabl system.
and the continuous effective pumping of combined
e)
slurry from this sump to the ash slurry dump area.
The extraction of bottom ash shall be done twice in
every shift of eight (8) hours. Ash from each
individual hopper section in a unit will be removed
in parallel. Bottom ash from each unit shall be
removed sequentially. The total time for
evacuating four (4) hour collection of bottom ash
from a unit corresponding to collection rates
specified shall not exceed 75 minutes including
five (5) minutes time required for starting, stopping,
sequential change over from one unit to second
unit and water flushing of the system for the
following two conditions and with 25mm wear on
the diameter of the throat section of the jet pumps:
1) Maintained water level mode.
2) Complete draw down mode by totally emptying
the hopper of all water and ash with the make-
up valve closed.
(ii) In case the Bidder offers continuous type Continuous
bottom ash removal system employing submerged effective mixing and
scrapper chain conveyors, the system shall be sluicing shall be
guaranteed to meet the following performance. established by no
stagnation of ash or
Continuous effective discharge, crushing and
slurry at any point in
sluicing of bottom ash generated during various
the complete
modes of boiler operation to the bottom ash slurry
system.
sump and the continuous effective pumping of
slurry from this sump to the main slurry sump in
ash slurry pump house for onward effective
pumping from main sump to the ash slurry dump
area. Bottom Ash removal of the two units shall be
done in parallel and continuously.

TELANGANA SUPER THERMAL POWER TECHNICAL SPECIFICATIONS SUB-SECTION-IV

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CLAUSE NO.
FUNCTIONAL GUARANTEES AND LIQUIDATED DAMAGES

PERFORMANCE REQUIREMENTS FOR CLOSED LOOP CONTROL SYSTEM

(TABLE – 1)

[Link] Load/Rated MAXIMUM DEVIATION OF PARAMETERS FROM SET POINT

. of load
change

(% of MCR
per min.)
Throttle Flue gas Furnace S.H. R.H.
steam Steam
Pressure Oxygen Pressure Temp. Temp.
Deviation Deviation Deviation Deviation Deviat
ion
(Kg/cm²) (% O2) (mmwcl) (Deg.C) (Deg.
C)
A. Steady State Condition

1 90% to ±2.0 ± 0.4 ± 8.0 ± 5.0 ± 5.0

100%

2 60% ± 2.0 ± 0.4 ± 8.0 ± 5.0 ± 5.0

B. RAMP Test (Change For Max. Duration of Five Minutes for 3% & 5% ramp and
Three minutes for 10% ramp)

3 ± 3% ± 3.0 +0.6/-0.4 ± 12.0 ± 8.0 ± 8.0

4 ± 5% ± 3.0 +0.8/-0.4 ± 12.0 ± 10.0 ± 10.0

5 ± 10% ± 4.0 +1.0/-0.5 ± 15.0 ± 15.0 ± 15.0

C. Step Load Changes

1 From ± 5.0 +1.5/-0.5 ± 20.0 ± 15.0 ± 15.0

100% to
80% at
the rate
of 10%
per min.

Note 1 Sufficient time shall be allowed as setting period between conducting the tests.

2 Plant operating condition, i.e. main equipment status, availability of auxiliaries,

operational and equipment constraints, which can influence the test, shall also be
recorded.

TELANGANA SUPER THERMAL POWER TECHNICAL SPECIFICATIONS SUB-SECTION-IV

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CLAUSE NO.
FUNCTIONAL GUARANTEES AND LIQUIDATED DAMAGES

Annexure-I

1.00.00 Worst Case Loading Conditions for Control System (Definition)

The worst case loading conditions shall include the following tasks as a minimum:

1.01.00 All process inputs coming to Control System including SOE/annunciation inputs are being
scanned, acquired, conditioned and processed.

1.02.00 All closed loop controls are in operation during a disturbed (non-steady) state of the process.

1.03.00 All open loop controls of DDCMIS are in operation during a disturbed (non-steady) state.

1.04.00 All data being transferred between control system, system bus and HMIPIS.

1.05.00 Three (3) alarms are being generated per second from each of the functional groups of
Control System.

1.06.00 Twelve control commands from HMIPIS are being executed in one minute.

1.07.00 All processors (including hot standby) health being monitored.

1.08.00 All standby processors status being updated.

2.00.00 HMIPIS Worst Case Loading Conditions (See note below)

The worst case loading conditions shall include the following tasks as a minimum:

2.01.00 Continuous data transfer between System Bus & HMIPIS.

2.02.00 All calculations including performance calculations being performed at the specified rates.

2.03.00 Alarms being reported at the rate of three (3) alarms per second for each of the Control
System functional groups.

2.04.00 Two control operator commands for control/ information within a base period of one minute
from each OWS & each LVS.

2.05.00 Data collection for all logs/reports in progress.

2.06.00 OWS/LVS displays are in operation as follows:

LVS – 1, 4 - Sequence chain display with maximum number of dynamic data

items.

LVS - 2, 5 - Individual display with maximum number of dynamic data items.

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CLAUSE NO.
FUNCTIONAL GUARANTEES AND LIQUIDATED DAMAGES

LVS – 3, 6 - Plant mimic display with one hundred and twenty (120) numbers of
dynamic data items.

OWS - 1 - Overview display with max. no. of dynamic data items.

OWS - 2 - Group display (twenty points, current data).

OWS - 3 - Alarm display of twenty (20) points.

OWS – 4 - 4 Nos. Windows each running current trend.

Unit Incharge - Plant overview display

OWS

All PC Stations X-T plots are displayed & updated.

On Station WAN

And unit LAN

2.07.00 All printers connected to HMIPIS are in operation at rated speed.

2.08.00 HMIPIS processors and all peripherals health being monitored.

2.09.00 Data collection for trend function and historical data storage in progress.

2.10.00 Four alarm acknowledgements within a base period of one minute from each OWS & LVS.

2.11.00 Calculations for long term storage of data being performed.

2.12.00 SOE printing in progress.

2.13.00 Data transfer with other DDCMIS sub-systems, all PLCs and SG/TG C&I Systems in
progress for controls (commands) as well as for information.

3.00.00 The Worst Case Loading Conditions For System Bus

The worst case loading condition shall mean continuous data transfer between the
distributed modules (Control System/HMIPIS), at their individual worst case loading
conditions defined at 1.00.00 & 2.00.00 above respectively.

Note : This clause is generally for the unit DDCMIS. This shall be suitably modified for other
DDCMIS subsection depending or actual configuration.

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CLAUSE NO.
FUNCTIONAL GUARANTEES AND LIQUIDATED DAMAGES

APPENDIX-I

GENERAL

PREREQUISITES TO GUARANTEE TESTS TO BE ENSURED BY NTPC

1. Availability of adequate and uninterrupted supply of coal.

Specifications of coal as per N.I.T and as observed during the test shall be recorded
as per attached format (Appendix-IA).

2. Sufficiently empty bunkers to facilitate continuous tripper dumping of coal during the
test.

3. Uninterrupted power supply within specified parameters for the duration of the test.

4. Belt protection switches, local stop push buttons, hooters, brakes/rail clamps in
working order.

5. Adequate and uninterrupted water supply.

6. Plant communication system

7. Proper lubrication and oil level of all equipments.

8. Free rotation of idlers and pulleys.

9. Cleanliness of plant and removal of coal spillage at the start and during Tests.

10. Power supply voltage and frequency shall be as per technical specifications.

11. Availability of dry coal during testing of DS system

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CLAUSE NO.
FUNCTIONAL GUARANTEES AND LIQUIDATED DAMAGES

APPENDIX-IA

COAL PARAMETERS

Project :

Package :

Date :

As specified, As observed

during the test

1. Size

2. HGI

3. Moisture

4. Shale and sand-stone content

NTPC Contractor

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CLAUSE NO.
FUNCTIONAL GUARANTEES AND LIQUIDATED DAMAGES

APPENDIX-II

PREREQUISITES TO GUARANTEE TESTS TO BE ENSURED BY CONTRACTOR

1. Deputation of team to site to associate with the Guarantee tests,

2. Calibration of belt weigher scales and accuracy of same to be demonstrated to

NTPC.

3. Arrangement of wattmeters / energymeters calibrated and sealed from approved

Govt. test house or NTPC site laboratory. Arrangement of any other instrument/
accessory for the test.

4. Proper adjustment of skirt boards and belt cleaners prior to the start of tests.

5. Arrangement of calibrated equipments for measurement of vibration & noise levels.

6. Protection Relays of LT/HT switchgears and all motor feeders shall be checked.

7. Belt protection switches, local push buttons, hooters, brakes/rail clamps to be in

working order.

8. Free rotation of idlers and pulleys.

9. Protection relays of LT/HT switchgears and all motors/transformer feeders to be

checked.

10. Sufficient illumination.

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CLAUSE NO.
FUNCTIONAL GUARANTEES AND LIQUIDATED DAMAGES

ANNEXURE – IIA

FORMAT FOR SUBMISSION OF GUARANTEE TEST PROCEDURE

Clause No. as per Provision of LOA Name and NTPC comments

LOA/ Tech. Specs. / Tech. Specs. Methodology of on the tests
Test proposed by proposed by
Vendor vendor

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CLAUSE NO.
FUNCTIONAL GUARANTEES AND LIQUIDATED DAMAGES

APPENDIX-III

GUARANTEE TEST PROFORMA

FLOW PATH CAPACITY TEST

Project :

Package :

Date :

1. Composition of Stream

i) Conveyor Nos.

ii) Reversible Stacker / Reclaimer

iii) Traveling Tripper Nos.

iv) Dust suppression pumps, service water pumps, Ventilation fan drives.

v) ..........................

2. Location of Belt Weigher (s) :

3. Plant started (Time) :

4. Material started flowing over belt weigher (Time) :

5. Test period Completed (Time) :

6. Reading taken at three (3) minute intervals :

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CLAUSE NO.
FUNCTIONAL GUARANTEES AND LIQUIDATED DAMAGES

[Link] Time Flow Rate Totaliser

Total plant run time :

Average Flow Rate :

NTPC Contractor

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CLAUSE NO.
FUNCTIONAL GUARANTEES AND LIQUIDATED DAMAGES

APPENDIX-IV

GUARANTEE TEST PROFORMA

POWER MEASUREMENT

Project :

Package :

Date :

1. Equipment/Stream Composition :

2. Motor Description :

3. Sr. No. of meters used :

4. Date of Calibration of instrument and name of test house :

5. Multiplying factor (M.F.) of the wattmeter :

6. Wattmeter Readings (to be taken at 1 minute intervals) :

Sl. Measurem Time Voltag Current kw Reading Total Remarks

ent e (amps) M.F.
No. Terminal (Volts)
Location W1 W2
(W1+W2)
MF kw

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CLAUSE NO.
FUNCTIONAL GUARANTEES AND LIQUIDATED DAMAGES

APPENDIX-IV

7. Energymeter Readings

Sl. Equip- Time Energymeter Equipment Remarks*

Readings kwHr kw (R2-R1)/
Ment Duration (t2-t1)

Initial Final Initial Final

*Reason and duration for system trip/stop may be recorded in remarks column.

NTPC Contractor

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CLAUSE NO.
FUNCTIONAL GUARANTEES AND LIQUIDATED DAMAGES

APPENDIX-V

GUARANTEE TEST PROFORMA

VIBRATION LEVEL MEASUREMENTS

Project :

Package :

Date :

Time :

Details of vibration Level Meter

1. Make

2. Model & [Link].

3. Date of calibration with name of Test House

[Link]. Equipment Pick Vibration level Amplitude/Velocity

*Point

Horizontal Vertical Axial

Micron/ micron/ Micron /
mm/ sec. mm/sec. mm/sec.

* Reading shall be taken at all the bearings of motor, gear box and driven equipment.
In case of conveyor galleries, vibrations shall be measured at min. three locations, at
midpoint of stringer between two short supports.

NTPC Contractor

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CLAUSE NO.
FUNCTIONAL GUARANTEES AND LIQUIDATED DAMAGES

APPENDIX-VI

GUARANTEE TEST PROFORMA

NOISE LEVEL MEASUREMENT

Project :

Package :

Date :

Details of Sound Level Meter

1. Make

2. Model

3. Date of calibration with name of Test House

[Link]. Equipment Equipment Measurement* Sound Remarks

with location load/capacity point no. level dBA.

NTPC Contractor

* For each equipment location, a Projected Plan Diagram shall be made and the location of
measurement points shall be identified.

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SPECIFICATION No: PE-TS-424-160-A001

KARIMNAGAR TELANGANA SUPER VOLUME: II B
THERMAL POWER PROJECT PHASE I-
(2 X 800 MW) SG PACKAGE SECTION-I
MILL REJECT SYSTEM (PNEUMATIC TYPE)
SUB-SECTION-IA

SPECIFIC TECHNICAL REQUIREMENT REV 00 DATE 24.05.17


ANNEXURE VI DRAWINGS/DOCUMENTS TO BE SUBMITTED AFTER AWARD OF CONTRACT : The successful
bidder shall submit the following drawings / documents during detail engineering for customer’s approval
/information:
 
SCHEDULED REMAR
CATEGOR SUBMISSION KS
[Link]. BHELDRGNO DRGTITLE
Y (NO.OFDAYS
FROMLOA
DATE)
TECHNICALDATASHEETOF 
TEMPERATURESWITCH,
TEMPERATUREGAUGE,PRESSURE
1 PEV0424160A047 A 70
SWITCH,PRESSUREGAUGE,SOLENOID
VALVE,LEVELSWITCH,AIRFILTER
REGULATOR
EQPTANDPIPINGLAYOUTOFMILL BASIC
2 PEV0424160A013 REJECTSYSTEMANDPIPINGLAYOUT A 56 DRG.
FROMCOMPRESSORHOUSE

3 PEV0424160A002 GAOFWATERANDAIRLINEVALVES I 84
BASIC
G.AOFMRSBUNKER(Capacity
DRG.
4 PEV0424160A019 calcultionofMillRejectbunkershall A 42
besubmittedalongwithGAofBunker)
BASIC
GA&DSOFSELFMFG.ITEMS DRG.
(DENSVEYOR,HOPPER,BNKRDIS.
5 PEV0424160A008 A 42
GATE,PRV,ACIBEND,PNEU.PANEL,
AIRRECVR,TER.BOX,ETC.)

6 PEV0424160A025 GAOFKNIFEGATE/PLATEVALVE A 56 


7 PEV0424160A059 GAANDTDSOFPNEUMATICCYLINDER I 56
BASIC
8 PEV0424160A014 LAYOUTOFCOMPRESSORHOUSE A 70
DRG.
9 PEV0424160A037 GAOFCHAINPULLEYBLOCK I 56 
10 PEV0424160A035 G.A.OFRUPTUREDISC. I 56 

11 PEV0424160A034 G.AOFMETALLICEXPANSIONBELLOW I 56
12 PEV0424160A027 G.AOFBAGFILTER I 56 
BASIC
13 PEV0424160A022 TRENCHANDINSERTDETAILOFMRS A 56
DRG.
DESIGNCALCULATIONAND BASIC
14 PEV0424160A024 STRUCTURALARRANGEMENTOF A 70 DRG.
BUNKER
BASIC
15 PEV0424160A060 LOADDATAOFMILLREJECTBUNKER I 70
DRG.

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SPECIFICATION No: PE-TS-424-160-A001

KARIMNAGAR TELANGANA SUPER VOLUME: II B
THERMAL POWER PROJECT PHASE I-
(2 X 800 MW) SG PACKAGE SECTION-I
MILL REJECT SYSTEM (PNEUMATIC TYPE)
SUB-SECTION-IA

SPECIFIC TECHNICAL REQUIREMENT REV 00 DATE 24.05.17

MILLREJECTSILOFOUNDATION BASIC
PLAN DRG.
INCLUDINGLOADINGDATA,BASE
16 PEV0424160A061 I 70
PLATE/
FOUNDATIONBOLT/SHEARKEY
DETAILS

17 PEV0424160A051 CABLEINTERCONNECTIONDIAGRAM I 98
18 PEV0424160A005 INSTRUMENTSCHEDULE I 70 
19 PEV0424160A062 GA&DatasheetofSumpPumps A 98 
OPERATIONANDMAINTENANCE 
20 PEV0424160A055 I 168
MANUAL 
P&IDIAGRAMOFMILLREJECT BASIC
21 PEV0424160A006 A 28
HANDLINGSYSTEM DRG.
22 PEV0424160A053 PIPINGANDVALVESCHEDULE I 56 
23 PEV0424160A052 PAINTINGSCHEDULE I 56 
BASIC
24 PEV0424160A063 ControlWriteup A 70
DRG.
BASIC
25 PEV0424160A064 LogicforMillRejectSystem A 70
DRG.
PneumaticCircuitofConveying BASIC
26 PEV0424160A065 A 70
Vessel DRG.
DESIGNPHILOSPHYANDSYSTEM BASIC
27 PEV0424160A004 SIZINGCALCULATIONOFMILLREJECT A 28 DRG.
SYSTEM 
CABLESCHEDULESIGNALAND 
28 PEV0424160A054 I 84
CONTROL

29 PEV0424160A012 WELDINGPROCEDURESPECIFICATION A 42

TYPETESTCERTIFICATE/PROCEDURE
30 PEV0424160A066 A 70
FORMOTORS

G.A.,TECHNICALDATASHEETOF BASIC
31 PEV0424160A067 A 70
AIRCOMPRESSORMOTOR DRG.
SUBVENDORLISTWITHINSPECTION BASIC
32 PEV0424160A011 A 28
CATEGORY DRG.

33 PEV0424160A010 P&IDIAGRAMOFMRSCOMPRESSOR A 70
G.A.,TECHNICALDATASHEETAND BASIC
FOUNDATIONDETAILSOF DRG.
34 PEV0424160A043 AIRCOMPRESSOR,GAANDWIRING A 70
DIAGRAMFORLOCALPANELOF
CONVEYINGAIRCOMPRESSOR
TECHNICALDATASHEETOFCABLE 
35 PEV0424160A049 I 70
TRAY

36 PEV0424160A009 PGTESTPROCEDURE A 140


37 PEV0424160A016  CABLETRAY,EARTHINGLAYOUT A 70

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SPECIFICATION No: PE-TS-424-160-A001

KARIMNAGAR TELANGANA SUPER VOLUME: II B
THERMAL POWER PROJECT PHASE I-
(2 X 800 MW) SG PACKAGE SECTION-I
MILL REJECT SYSTEM (PNEUMATIC TYPE)
SUB-SECTION-IA

SPECIFIC TECHNICAL REQUIREMENT REV 00 DATE 24.05.17


38 PEV0424160A056 DATASHEETOFAUTODRAINTRAP I 70


39 PEV0424160A057 GAofJunctionBox I 70

BASIC
40 PEV0424160A058 Suggestedinputandoutput(I/O)list I 84 DRG.

41 PEV0424160A068 CommissioningProcedure A 140


QUALITYASSURANCEPLAN
BASIC
1 PEV0424160A801 QPforPyritehopper A 84
DRG.
BASIC
2 PEV0424160A803 QPforAirreceiver A 84
DRG.
BASIC
3 PEV0424160A804 QPforTerminalbox A 84
DRG.
BASIC
4 PEV0424160A805 QPforBunkerdischargegate A 84
DRG.
BASIC
5 PEV0424160A806 QPforPressurereliefvalve A 84
DRG.
QPforPneumaticPanelfor BASIC
6 PEV0424160A807 A 84
Denseveyor DRG.
QPforCI/CCS/CSS/Gate/Globe/ 
7 PEV0424160A811 CheckValvesFCS/CopperAlloy–Gate A 84
Valve/GlobeValve
BASIC
8 PEV0424160A814 QPACIBend A 84
DRG.

9 PEV0424160A815 MQPofSumpPump A 84

10 PEV0424160A816 MQPofTemperatureSwitch A 84

11 PEV0424160A817 QPforPressureSwitch A 84
BASIC
12 PEV0424160A802 QPforDenseveyor A 84
DRG.
QPforPneumaticActuator(Air 
13 PEV0424160A812 A 84
CylinderforDenseveyor)

14 PEV0424160A813 QPforLevelSwitch A 84

15 PEV0424160A819 QPforPipes(MSERW&GI) A 84

16 PEV0424160A823 QAPforCompressorPanel A 84
QAPforPneumaticActuator/Cylinder 
17 PEV0424160A827 A 84
(forKnifeGateValve)
QPEndorsementSheetforAir 
18 PEV0424160A820 A 84
Compressor

19 PEV0424160A825 MQPforLTMotor A 84

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SPECIFICATION No: PE-TS-424-160-A001

KARIMNAGAR TELANGANA SUPER VOLUME: II B
THERMAL POWER PROJECT PHASE I-
(2 X 800 MW) SG PACKAGE SECTION-I
MILL REJECT SYSTEM (PNEUMATIC TYPE)
SUB-SECTION-IA

SPECIFIC TECHNICAL REQUIREMENT REV 00 DATE 24.05.17


20 PEV0424160A836 QPforJunctionBox A 84

21 PEV0424160A837 QAPOFDrainSumppump A 84

22 PEV0424160A038 QPFORCABLETRAY A 84

Notes:
1. The above drawing list is tentative and shall be finalized with the successful bidder after
placementoforder.Whilesomeofthedrawingsindicatedabovemaynotbeapplicable,some
additionaldrawingsmayalsoberequiredbasedonscopeofwork.
2. Drawings shall be prepared in AutoCad latest edition. Required no. of hard and soft copies
(editable) of the drawings shall be furnished as per requirement specified elsewhere in the
specification.
3. Only manual calculation with authentic supporting literature (e.g. extracts of hand Book/
standard/codes)shallbeacceptable.AlldesigncalculationsanddrawingsshallbeinSIsystem
only.
4. All the drawings and documents including general arrangement drawing, data sheet,
calculationetc.tobefurnishedtothecustomerduringdetailedengineeringstageshallinclude
/ indicate the following details for clarity w.r.t. Inspection, construction, erection and
maintenanceetc.:
a) All drawings and documents shall indicate the list of all reference drawings including general
arrangement.
b) Alldrawingsshallinclude/showplan,elevation,sideview,crosssection,skinsection,blow
upview;allmajorselfmanufacturedandboughtoutitemsshallbelabeledandincludedinBOQ
/BOMintabularform.
c) Painting schedule shall also be made as a part of general arrangement drawing of each
equipment/itemsindicatingatleast3tradenames.
d) All the drawings required to be furnished to customer during detailed engineering stage shall
include technical parameters, details of paints and lubrication, hardness and BOQ / BOM in
tabular form indicating all major components including bought out items and their quantity,
materialofconstructionindicatingitsapplicablecode/standard,weight,makeetc.
e) Drawings/documentstobesubmittedforpurchasersreview/approvalshallbeunderRevision
A, B, C… etc. while drawings /documents to be submitted thereafter for customer’s approval
afterpurchaser’sapprovalshallbeunderR0,1,2,3….etc.
f) Drawingsanddocumentsnotcoveredabovebutrequiredtochecksafetyofmachines/system,
shallbesubmittedduringdetailedengineeringstagewithoutanycommercialimplication.
g) Alldrawingsshallinclude"B.O.M"andindicatequantity,materialofconstruction,makealong
with IS/BS No.,Technicalparameters,dimensions,hardness,machiningsymbolandtolerance,
requirementofradiographyandhydraulictests,paintingdetails,elevation,sideview,plan,skin
sectionandblowupviewforclarity.
h) AlldrawingsshallbepreparedasperBHEL'stitleblockandshallbearBHEL'sdrawingNo.
i) Scheduleofdrawingssubmissions,commentincorporations&approvalshallbeasstipulatedin
the specifications. The successful bidder shall depute his design personnel to BHEL’s/

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SPECIFICATION No: PE-TS-424-160-A001

KARIMNAGAR TELANGANA SUPER VOLUME: II B
THERMAL POWER PROJECT PHASE I-
(2 X 800 MW) SG PACKAGE SECTION-I
MILL REJECT SYSTEM (PNEUMATIC TYPE)
SUB-SECTION-IA

SPECIFIC TECHNICAL REQUIREMENT REV 00 DATE 24.05.17

Customer’s/Consultant’sofficeforacrossthetableresolutionofissuesandtogetdocuments
approvedinthestipulatedtime.
j) Biddertofollowthefollowingthedrawingsubmissionschedule:
k) 1stsubmissionofdrawingsfromdateofLOIasperthesubmissionschedule.
l) Everyrevisedsubmissionincorporatingcomments–within7days.
m) Bidder to submit revised drawings complete in all respects incorporating all comments. Any
incomplete drawing submitted shall be treated as nonsubmission with delays attributable to
bidder’saccount.Foranyclarification/discussionrequiredtocompletethedrawings,thebidder
shall himself depute his personal to BHEL for across the table discussions/ finalizations/
submissionsofdrawings.
n) NTPC drawing numbers shall be informed after award of contract and essentially to be
incorporated in drawings. The pdf files of all drawings and documents shall be named and
submittedwithNTPCdrawingnumbers.
o) Drawingsdocumentsabovehavebeenidentifiedasbasicdrawingsinremarkscolumn.During
contractengineeringstage,approvalofthesedrawingsfromBHEL/Customershallbetreatedas
clearancetomilestonepaymentforcompletionofdesign&engineering.

Uponreviewofeachdrawing,dependingonthecorrectnessandcompletenessofthedrawing,thesame
willbecategorizedandapprovalaccordedinoneofthefollowingcategories:

CATEGORYI :Approved
CATEGORYII :Approved,subjecttoincorporationofcomments/modificationasnoted.
Resubmitreviseddrawingincorporatingthecomments.
CATEGORY–III :Notapproved.Resubmitreviseddrawingsforapprovalafterincorporating
comments/modificationasnoted.
CATEGORYIV :Forinformationandrecords.

Drawingsresubmittedshallshowclearlytheportionswherethesamearerevisedmarkingtherelevant
revisionnumbersandEmployershallreviewonlysuchrevisedportionofdocuments.

B.0 [Link]DRAWINGS/DOCUMENTSFORSUBMISSION

A. DrawingforApproval No.ofprints/copies
(hardprints)
i. Forapproval 8
ii. Forfinaldistribution(afterthevendorobtains 12
finalapprovalfromthecustomer).
B. Certificate,reportsetc.(Materialtest,inspection 6
reportandallothertypeoftestsetc.)
C. O&MManual 
I. Draftforapproval 2
ii. Forfinaldistribution 12



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SPECIFICATION No: PE-TS-424-160-A001

KARIMNAGAR TELANGANA SUPER VOLUME: II B
THERMAL POWER PROJECT PHASE I-
(2 X 800 MW) SG PACKAGE SECTION-I
MILL REJECT SYSTEM (PNEUMATIC TYPE)
SUB-SECTION-IA

SPECIFIC TECHNICAL REQUIREMENT REV 00 DATE 24.05.17

AnnexureVIIInputDrawings&Documents

1) FoundationPlanofHP1103DynamicClassifier(WithPlanetarygearbox)–Drgno
 9591102102PVCV003.
2) GeneralArrangementofHP1103DynamicClassifier(WithPlanetarygearbox)–Drgno
 9591102102PVMB003.
3) BOILERAREAPAVINGMILLREJECTSYSTEM(UNIT1&2)Drgno9591102315
 PVCC0423
4) Flowdiagram















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(170&#6+10016'5Ä

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SPECIFICATIONNo:PETS424160A001
PEM-6666-0

KARIMNAGAR TELANGANA SUPER VOLUME:IIB

THERMAL POWER PROJECT PHASE I-
( 2 X 800 MW) SG PACKAGE SECTIONI
MILL REJECT SYSTEM (PNEUMATIC TYPE)
SUBSECTIONIB
SPECIFIC TECHNICAL REQUIREMENT
REV 00 DATE 24.05.17

SUB SECTION-IB

SPECIFIC TECHNICAL REQUIREMENT (ELECTRICAL)

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REV-0, DATE: 20.04.2017

ELECTRICAL SCOPE BETWEEN BHEL AND VENDOR
PACKAGES: MILL REJECT SYSTEM
SCOPE OF VENDOR: SUPPLY, ERECTION & COMMISSIONING OF VENDOR’S EQUIPMENT
PROJECT: 2X800MW KARIMNAGAR TPP (SG ISLAND)
[Link] DETAILS SCOPE SCOPE E&C REMARKS
SUPPLY

1 415V MCC BHEL BHEL 240 V AC (supply feeder)/415 V AC (3 PHASE 4 WIRE) supply shall be
provided by BHEL based on load data provided by vendor at contract
stage for all equipment supplied by vendor as part of contract. Any other
voltage level (AC/DC) required will be derived by the vendor.

2 Local Push Button Station (for motors) BHEL BHEL Located near the motor.

3 Power cables, control cables and screened control cables 1. For 3.b) & c): Sizes of cables required shall be informed by vendor at
for contract stage (based on inputs provided by BHEL) in the form of cable
a) both end equipment in BHEL’s scope BHEL BHEL listing. Finalisation of cable sizes shall be done by BHEL. Vendor shall
b) both end equipment in vendor’s scope BHEL Vendor provide lugs & glands accordingly.
c) one end equipment in vendor’s scope BHEL BHEL 2. Termination at BHEL equipment terminals by BHEL.
3. Termination at Vendor equipment terminals by Vendor.
4 Junction box for control & instrumentation cable Vendor Vendor Number of Junction Boxes shall be sufficient and positioned in the field to
minimize local cabling (max 10-12 mtrs) and trunk cable.
5 Any special type of cable like compensating, co-axial, Vendor Vendor Refer C&I portion of specification for scope of fibre Optical cables if used
prefab, MICC, optical fibre etc. between PLC/ microprocessor & DCS.
6 Cable trays, accessories & cable trays supporting system BHEL BHEL Local cabling from nearby main route cable tray (BHEL scope) to
equipment terminal (vendor’s scope) shall be through 100/ 50 mm. cable
100/ 50 mm cable trays/ Conduits/ Galvanised steel cable Vendor Vendor trays/ conduits/ Galvanised steel cable troughs, as per approved layout
troughs for local cabling drawing during contract stage.

7 Cable glands ,lugs and bimetallic strip for equipment Vendor Vendor 1. Double compression Ni-Cr plated brass cable glands
supplied by Vendor 2. Solder less crimping type heavy duty tinned copper lugs for power and
control cables.
8 Conduit and conduit accessories for cabling between Vendor Vendor Conduits shall be medium duty, hot dip galvanised cold rolled mild steel
equipment supplied by vendor rigid conduit as per IS: 9537.
9 Lighting NTPC NTPC
10 Equipment grounding (including electronic earthing) & BHEL BHEL Refer note no. 4 for electronic earthing

Page 1 of 3

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REV-0, DATE: 20.04.2017

ELECTRICAL SCOPE BETWEEN BHEL AND VENDOR
PACKAGES: MILL REJECT SYSTEM
SCOPE OF VENDOR: SUPPLY, ERECTION & COMMISSIONING OF VENDOR’S EQUIPMENT
PROJECT: 2X800MW KARIMNAGAR TPP (SG ISLAND)
[Link] DETAILS SCOPE SCOPE E&C REMARKS
SUPPLY

lightning protection
11 Below grade grounding BHEL BHEL
12 LT Motors with base plate and foundation hardware Vendor Vendor Makes shall be subject to customer/ BHEL approval at contract stage.
13 Mandatory spares Vendor - Vendor to quote as per specification.
14 Recommended O & M spares Vendor - As specified elsewhere in specification
15 Any other equipment/ material/ service required for Vendor Vendor
completeness of system based on system offered by the
vendor (to ensure trouble free and efficient operation of
the system).
16 a) Input cable schedules (Control & Screened Control Vendor - Cable listing for Control and Instrumentation Cable and electronic earthing
Cables) cable in enclosed excel format shall be submitted by vendor during
b) Cable interconnection details for above Vendor - detailed engineering stage.
c) Cable block diagram Vendor -
17 Electrical Equipment & cable tray layout drawings Vendor - For ensuring cabling requirements are met, vendor shall furnish Electrical
equipment layout & cable tray layout drawings (both in print form as well
as in AUTOCAD) of the complete plant (including electrical area) indicating
location and identification of all equipment requiring cabling, and shall
incorporate cable trays routing details marked on the drawing as per PEM
interface comments. Cabling arrangement of the same (wherever
overhead cable trays, trenches, cable ducts, conduits etc.) shall be
decided during contract stage. Electrical equipment layout & cable tray
layout drawing shall be subjected to BHEL/ customer approval without any
commercial implications to BHEL.

18 Electrical Equipment GA drawing Vendor - For necessary interface review.

NOTES:
1. Make of all electrical equipment/ items supplied shall be reputed make & shall be subject to approval of BHEL/customer after award of contract.
2. All QPs shall be subject to approval of BHEL/customer after award of contract without any commercial implication.

Page 2 of 3

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REV-0, DATE: 20.04.2017

ELECTRICAL SCOPE BETWEEN BHEL AND VENDOR
PACKAGES: MILL REJECT SYSTEM
SCOPE OF VENDOR: SUPPLY, ERECTION & COMMISSIONING OF VENDOR’S EQUIPMENT
PROJECT: 2X800MW KARIMNAGAR TPP (SG ISLAND)
3. In case the requirement of Junction Box arises on account of Power Cable size mis-match due to vendor engineering at later stage, vendor shall supply the Junction
Box for suitable termination.
4. Vendor shall indicate location of Electronic Earth pit in their Civil assignment drawing.

Page 3 of 3

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SUB – SECTION – B-01

MOTORS

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MOTORS

1.00.00 GENERAL REQUIREMENTS

1.01.00 For the purpose of design of equipment/systems, an ambient temperature of 50

deg. Centigrade and relative humidity of 95% (at 40 deg C) shall be considered.
The equipment shall operate in a highly polluted environment.

1.02.00 All equipment’s shall be suitable for rated frequency of 50 Hz with a variation of
+3% & -5%, and 10% combined variation of voltage and frequency unless
specifically brought out in the specification.

1.03.00 Contactor shall provide fully compatible electrical system, equipment’s,

accessories and services.

1.04.00 All the equipment, material and systems shall, in general, conform to the latest
edition of relevant National and international Codes & Standards, especially the
Indian Statutory Regulations.

1.05.00 The auxiliary AC voltage supply arrangement shall have 11kV, 3.3 kV and 415V
systems and DC voltage shall be 220 V. It shall be designed to limit voltage
variations as given below under worst operating condition :

(a) 11kV, 3.3 kV +/- 6%

(b) 415/240V +/- 10%

(c) 220 V DC -15% to +10%. However the nominal

continuous DC power supply shall be 240V.

1.06.00 The voltage level for motors shall be as follows :-

a) Upto 0.2KW : Single phase 240V AC / 3 phase 415V AC

b) Above 0.2KW and upto 200KW : 3 phase 415V AC

c) Above 200KW and upto 1500 KW: 3.3 kV

d) Above 1500 KW : 11 kV

1.07.00 A.C. motors shall be fed from bus at above specified voltage level and fault level
of 50 kA RMS (Max.) for 1 second. The 415V system shall be solidly grounded
and 220 VDC system shall be isolated type.

1.08.00 Paint shade shall be as per RAL 5012 (Blue) for indoor and outdoor equipment.

1.09.00 The responsibility of coordination with electrical agencies and obtaining all
necessary clearances for Contactors equipment and systems shall be under the
Contactor scope.

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1.10.00 Degree of Protection

Degree of protection for various enclosures as per IS:4691, IEC60034-05 shall be

as follows :-

i) Indoor motors - IP 54

ii) Outdoor motors - IP 55

iii) Cable box-indoor area - IP 54
iv) Cable box-Outdoor area - IP 55

2.00.00 CODES AND STANDARDS

1) Three phase induction motors : IS:325, IEC:60034

2) Single phase AC motors : IS:996, IEC:60034

3) Crane duty motors : IS:3177, IEC:60034

4) DC motors/generators : IS:4722, IEC:60034

5) Energy Efficient motors : IS 12615, IEC:60034-30

3.00.00 TYPE

3.01.00 AC Motors:

a) Squirrel cage induction motor suitable for direct-on-line starting.

b) Continuous duty LT motors upto 160 KW Output rating (at 50 deg.C ambient
temperature), shall be Premium Efficiency class-IE3, conforming to IS
12615, or IEC:60034-30.

c) Crane duty motors shall be slip ring/ squirrel cage Induction motor as per the
requirement.

3.02.00 DC Motors Shunt wound.

4.00.00 RATING

(a) Continuously rated (S1). However, crane motors shall be rated for S4 duty,
40% cyclic duration factor.

(b) Whenever the basis for motor or driven equipment ratings are not specified
in the corresponding mechanical specification sub-sections, maximum
continuous motor ratings shall be at least 10% above the maximum load
demand of the driven equipment under entire operating range including
voltage and frequency variations.

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5.00.00 TEMPERATURE RISE

Air cooled motors

70 deg. C by resistance method for both thermal class 130(B) & 155(F) insulation.

Water cooled

80 deg. C over inlet cooling water temperature mentioned elsewhere, by

resistance method for both thermal class 130(B) & 155(F) insulation.

41 deg.C over inlet cooling water maximum temperature of 39 deg.C for thermal
class Y wet wound Boiler circulation pump motor.

6.00.00 OPERATIONAL REQUIREMENTS

6.01.00 Starting Time

6.01.01 For motors with starting time upto 20 secs. at minimum permissible voltage during
starting, the locked rotor withstand time under hot condition at highest voltage limit
shall be at least 2.5 secs. more than starting time.

6.01.02 For motors with starting time more than 20 secs. and upto 45 secs. at minimum
permissible voltage during starting, the locked rotor withstand time under hot
condition at highest voltage limit shall be at least 5 secs. more than starting time.

6.01.03 For motors with starting time more than 45 secs. at minimum permissible voltage
during starting, the locked rotor withstand time under hot condition at highest
voltage limit shall be more than starting time by at least 10% of the starting time.

6.01.04 Speed switches mounted on the motor shaft shall be provided in cases where
above requirements are not met.

6.02.00 Torque Requirements

6.02.01 Accelerating torque at any speed with the lowest permissible starting voltage shall
be at least 10% motor full load torque.

6.02.02 Pull out torque at rated voltage shall not be less than 205% of full load torque. It
shall be 275% for crane duty motors.

6.03.00 Starting voltage requirement

(a) Up to 85% of rated voltage for ratings below 110 KW

(b) Up to 80% of rated voltage for ratings from 110 KW to 200 KW

(c) Up to 85% of rated voltage for ratings from 201 KW to 1000 KW

(d) Up to 80% of rated voltage for ratings from 1001 KW to 4000 KW

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(e) Up to 75 % of rated voltage for ratings above 4000KW

Except AOP & JOP motors running on D.G emergency supply, starting voltage
shall be 80%.

7.00.00 DESIGN AND CONSTRUCTIONAL FEATURES

7.01.00 Suitable single phase space heaters shall be provided on motors rated 30KW and
above to maintain windings in dry condition when motor is standstill. Separate
terminal box for space heaters & RTDs shall be provided. However for flame
proof motors , space heater terminals inside the main terminal box may be
acceptable.

7.02.00 All motors shall be either Totally enclosed fan cooled (TEFC) or totally enclosed
tube ventilated (TETV) or Closed air circuit air cooled (CACA) type. However,
motors rated 3000KW or above can be Closed air circuit water cooled (CACW).
CW motors can be screen protected drip proof (SPDP) type. Motors and EPB
located in hazardous areas shall have flame proof enclosures conforming to
IS:2148 as detailed below
(a) Fuel oil area : Group – IIB

(b) Hydrogen generation :Group - IIC or (Group-I, Div-II as per plant

area NEC) or ( Class-1, Group-B, Div-II as
per NEMA /IEC60034)
7.03.00 Winding and Insulation
(a) Type : Non-hygroscopic, oil resistant, flame resistant

(b) Starting duty : Two hot starts in succession, with motor

initially at normal running temperature.

(c) 11kV & 3.3 kV AC :

Thermal class 155 (F) insulation.
motors
The winding insulation process shall be total
Vacuum Presure Impregnated i.e resin poor
method. The lightning Impulse & interturn
insulation surge withstand level shall be as
per IEC-60034 part-15.
(d) 240VAC, 415V AC : Thermal Class ( B ) or better
& 220V DC motors

7.04.00 Motors rated above 1000KW shall have insulated bearings to prevent flow of shaft
currents.

7.05.00 Motors with heat exchangers shall have dial type thermometer with adjustable
alarm contacts to indicate inlet and outlet primary air temperature.

7.06.00 Noise level for all the motors shall be limited to 85dB(A) except for BFP motor for
which the maximum limit shall be 90dB(A). Vibration shall be limited within the
limits prescribed in IS:12075 / IEC 60034-14 . Motors shall withstand vibrations

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produced by driven equipment. HT motor bearing housings shall have flat

surfaces, in both X and Y directions, suitable for mounting 80mmX80mm vibration
pads.

7.07.00 In HT motors, at least four numbers simplex / two numbers duplex platinum
resistance type temperature detectors shall be provided in each phase stator
winding. Each bearing of HT motor shall be provided with dial type thermometer
with adjustable alarm contact and preferably 2 numbers duplex platinum
resistance type temperature detectors.

7.08.00 Motor body shall have two earthing points on opposite sides.

7.09.00 11 KV motors shall be offered with Separable Insulated Connector (SIC) as per
IEEE 386. The offered SIC terminations shall be provided with protective cover
and trifurcating sleeves. SIC termination kit shall be suitable for fault level of 25
KA for 0.17 seconds.

7.10.00 3.3 KV motors shall be offered with dust tight phase separated double walled
(metallic as well as insulated barrier) Terminal box. Employer shall provide
termination kit for the offered Terminal box. The offered Terminal Box shall be
suitable for fault level of 250 MVA for 0.12 sec. Removable gland plates of
thickness 3 mm (hot/cold rolled sheet steel) or 4 mm (non magnetic material for
single core cables) shall be provided.

7.11.00 The spacing between gland plate & centre of terminal stud shall be as per Table-I.

7.12.00 All motors shall be so designed that maximum inrush currents and locked rotor
and pullout torque developed by them at extreme voltage and frequency
variations do not endanger the motor and driven equipment.

7.13.00 The motors shall be suitable for bus transfer schemes provided on the 11kV, 3.3
kV /415V systems without any injurious effect on its life.

7.14.00 For motors rated 2000 KW & above, neutral current transformers of PS class shall
be provided on each phase in a separate neutral terminal box.

7.15.00 The size and number of cables (for HT motors) to be intimated to the successful
Contactor during detailed engineering and the Contactor shall provide terminal
box suitable for the same.

8.00.00 The ratio of locked rotor KVA at rated voltage to rated KW shall not exceed the
following (without any further tolerance) except for BFP motor.

(a) Below 110KW : 10.0

(b) From 110 KW & upto 200 KW : 9.0

(c) Above 200 KW & upto 1000KW : 10.0

(d) From 1001KW & upto 4000KW : 9.0

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(e) Above 4000KW : 6 to 6.5

10.00.00 TYPE TEST

10.01.00 HT MOTORS

10.01.01 The Contactor shall carry out the type tests as listed in this specification on the
equipment to be supplied under this contract. The Contactor shall indicate the
charges for each of these type tests separately in the relevant schedule of Section
- VII- (BPS) and the same shall be considered for the evaluation of the bids. The
type tests charges shall be paid only for the test(s) actually conducted
successfully under this contract and upon certification by the Employer’s engineer.

10.01.02 The type tests shall be carried out in presence of the Employer’s representative,
for which minimum 15 days notice shall be given by the Contactor. The Contactor
shall obtain the Employer’s approval for the type test procedure before conducting
the type test. The type test procedure shall clearly specify the test set–up,
instruments to be used, procedure, acceptance norms, recording of different
parameters, interval of recording, precautions to be taken etc. for the type test(s)
to be carried out.

10.01.03 In case the Contactor has conducted such specified type test(s) within last ten
years as on the date of bid opening, he may submit during detailed engineering
the type test reports to the Employer for waival of conductance of such test(s).
These reports should be for the tests conducted on the equipment similar to those
proposed to be supplied under this contract and test(s) should have been either
conducted at an independent laboratory or should have been witnessed by a
client. The Employer reserves the right to waive conducting of any or all the
specified type test(s) under this contract. In case type tests are waived, the type
test charges shall not be payable to the Contactor.

10.01.04 Further the Contactor shall only submit the reports of the type tests as listed in
"LIST OF TESTS FOR WHICH REPORTS HAVE TO BE SUBMITTED" and
carried out within last ten years from the date of bid opening. These reports
should be for the test conducted on the equipment similar to those proposed to be
supplied under this contract and the test(s) should have been either conducted at
an independent laboratory or should have been witnessed by a client. However if
the Contactor is not able to submit report of the type test(s) conducted within last
ten years from the date of bid opening, or in the case of type test report(s) are not
found to be meeting the specification requirements, the Contactor shall conduct all
such tests under this contract at no additional cost to the Employer either at third
party lab or in presence of client/Employers representative and submit the reports
for approval.

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10.01.05 LIST OF TYPE TESTS TO BE CONDUCTED

The following type tests shall be conducted on each type and rating of HT
motor

(a) No load saturation and loss curves upto approximately 115% of rated
voltage

(b) Measurement of noise at no load.

(c) Momentary excess torque test (subject to test bed constraint).

(d) Full load test(subject to test bed constraint)

(e) Temperature rise test at rated conditions. During heat run test, bearing
temp., winding temp.,coolant flow and its temp. shall also be measured. In
case the temperature rise test is carried at load other than rated load,

specific approval for the test method and procedure is required to be

obtained. Wherever ETD's are provided, the temperature shall be
measured by ETD's also for the record purpose.

10.01.06 LIST OF TESTS FOR WHICH REPORTS HAVE TO BE SUBMITTED

The following type test reports shall be submitted for each type and rating of HT
motor

(a) Degree of protection test for the enclosure followed by IR, HV and no load
run test.

(b) Terminal box-fault level withstand test for each type of terminal box of HT
motors only.

(c) Lightning Impulse withstand test on the sample coil shall be as per clause
no. 4.3 IEC-60034, part-15

(d) Surge-withstand test on interturn insulation shall be as per clause no. 4.2
of IEC 60034, part-15

10.02.00 LT Motors

10.02.01 LT Motors supplied shall be of type tested design. During detailed engineering,
the Contactor shall submit for Employer's approval the reports of all the type tests
as listed in this specification and carried out within last ten years from the date of
bid opening. These reports should be for the test conducted on the equipment
similar to those proposed to be supplied under this contract and the test(s) should
have been either conducted at an independent laboratory or should have been
witnessed by a client.

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10.02.02 However if the Contactor is not able to submit report of the type test(s) conducted
within last ten years from the date of bid opening, or in the case of type test
report(s) are not found to be meeting the specification requirements, the Contactor
shall conduct all such tests under this contract at no additional cost to the
Employer either at third party lab or in presence of client/Employers representative
and submit the reports for approval.

10.02.03 LIST OF TESTS FOR WHICH REPORTS HAVE TO BE SUBMITTED

The following type test reports shall be submitted for each type and rating
of LT motor of above 50 KW only

1. Measurement of resistance of windings of stator and wound rotor.

2. No load test at rated voltage to determine input current power and speed

3. Open circuit voltage ratio of wound rotor motors ( in case of Slip ring
motors)

4. Full load test to determine efficiency power factor and slip .

5. Temperature rise test .

6. Momentary excess torque test.

7. High voltage test .

8. Test for vibration severity of motor.

9. Test for noise levels of motor(Shall be limited as per clause no 7.06.00 of

this section)

10. Test for degree of protection and

11. Overspeed test.

12. Type test reports for motors located in fuel oil area having flame proof
enclosures as per IS 2148 / IEC 60079-1

10.03.00 All acceptance and routine tests as per the specification and relevant standards
shall be carried out. Charges for these shall be deemed to be included in the
equipment price.
10.04.00 The type test reports once approved for any projects shall be treated as
reference. For subsequent projects of NTPC, an endorsement sheet will be
furnished by the manufacturer confirming similarity and “No design Change”.
Minor changes if any shall be highlighted on the endorsement sheet.

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TABLE - I

DIMENSIONS OF TERMINAL BOXES FOR LV MOTORS

Motor MCR in KW Minimum distance between centre
of
stud and gland plate in mm
UP to 3 KW As per manufacturer's practice.

Above 3 KW - upto 7 KW 85

Above 7 KW - upto 13 KW 115

Above 13 KW - upto 24 KW 167

Above 24 KW - upto 37 KW 196

Above 37 KW - upto 55 KW 249

Above 55 KW - upto 90 KW 277

Above 90 KW - upto 125 KW 331

Above 125 KW-upto 200 KW 203

For HT motors the distance between gland plate and the terminal studs shall not
be less than 500 mm.

PHASE TO PHASE/ PHASE TO EARTH AIR CLEARANCE:

NOTE: Minimum inter-phase and phase-earth air clearances for LT motors with
lugs installed shall be as follows:

Motor MCR in KW Clearance

UP to 110 KW 10mm

Above 110 KW and upto 150 KW 12.5mm

Above 150 KW 19mm

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CLAUSE NO. QUALITY ASSURANCE

MOTOR

TESTS/CHECKS

Welding/Brazing(WPS/PQR)
Make/Type/Rating /General

Electrical Characteristics
Mech/Chem. Properties
Physical Inspection

NDT /DP/MPI/UT

Heat Treatment
Metallography
Dimensional
Visual
TEMS/COMPONENTS

Plates for stator frame, end shield, Y Y Y Y Y Y

spider etc.
Shaft Y Y Y Y Y Y Y
Magnetic Material Y Y Y Y Y
Rotor Copper/Aluminium Y Y Y Y Y Y
Stator copper Y Y Y Y Y Y
SC Ring Y Y Y Y Y Y Y Y
Insulating Material Y Y Y Y
Tubes, for Cooler Y Y Y Y Y Y
Sleeve Bearing Y Y Y Y Y Y
Stator/Rotor, Exciter Coils Y Y Y Y Y
Castings, stator frame, terminal box and Y Y Y Y Y Y
bearing housing etc.
Fabrication & machining of stator, rotor, Y Y Y Y Y
terminal box
Wound stator Y Y Y Y
Wound Exciter Y Y Y Y
Rotor complete Y Y Y
Exciter, Stator, Rotor, Terminal Box Y Y Y
assembly
Accessories, RTD, BTD,CT, Space Y Y Y
heater, antifriction bearing, gaskets etc.
Complete Motor Y Y Y
Note: 1. This is an indicative list of tests/checks. The manufacture is to furnish a detailed
Quality Plan indicating the practices & Procedure followed along with relevant
supporting documents during QP finalization. However, No QP for LT motor upto
50KW.
2. Additional routine tests for Flame proof motors shall be applicable as per relevant
standard
3. Makes of major bought out items for HT motors will be subject to NTPC approval.
Y1 = for HT Motor / Machines only.

TELANGANA SUPER THERMAL POWER TECHNICAL SPECIFICATION SUB-SECTION-E-21 PAGE

SECTION-VI, PART-B MOTOR 1 OF 2
PROJECT PHASE-I (2X800 MW)
BID DOC NO.:CS-9591-101-2
STEAM GENERATOR ISLAND PACKAGE

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CLAUSE NO. QUALITY ASSURANCE

MOTOR

TESTS/CHECKS

Hydraulic/Leak/Pressure Test

9283/IS 2148/IEC60034\IEC
Routine & Acceptance tests
as per IS-325/IS-4722 /IS-

Tan delta, shaft voltage &

Magnetic Characteristics

Paint shade, thickness &

Thermal Characteristics

polarization index test

Dynamic Balancing

Over speed

adhesion
Vibration
Run out

60079-I
ITEMS/COMPONENTS

Plates for stator frame, end shield,

spider etc.
Shaft
Magnetic Material Y Y
Rotor Copper/Aluminium
Stator copper Y
SC Ring
Insulating Material Y
Tubes for Cooler Y
Sleeve Bearing Y
Stator/Rotor, Exciter Coils
Castings, stator frame, terminal
box and bearing housing etc.
Fabrication & machining of stator,
rotor, terminal box
Wound stator
Wound Exciter
Rotor complete Y Y
Exciter, Stator, Rotor, Terminal
Box assembly
Accessories, RTD, BTD,CT, ,
Space heater, antifriction bearing,
gaskets etc.
Complete Motor Y Y Y Y1 Y
Note: 1. This is an indicative list of tests/checks. The manufacture is to furnish a detailed
Quality Plan indicating the practices & Procedure followed along with relevant
supporting documents during QP finalization. However, No QP for LT motor upto
50KW.
2. Additional routine tests for Flame proof motors shall be applicable as per relevant
standard
3. Makes of major bought out items for HT motors will be subject to NTPC approval.
Y1 = for HT Motor / Machines only.

TELANGANA SUPER THERMAL POWER TECHNICAL SPECIFICATION SUB-SECTION-E-21 PAGE

SECTION-VI, PART-B MOTOR 2 OF 2
PROJECT PHASE-I (2X800 MW)
BID DOC NO.:CS-9591-101-2
STEAM GENERATOR ISLAND PACKAGE

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SPECIFICATIONNo:PETS424160A001
KARIMNAGAR TELANGANA SUPER VOLUME:IIB
THERMAL POWER PROJECT PHASE I-
( 2 X 800 MW) SG PACKAGE SECTIONI
MILL REJECT SYSTEM (PNEUMATIC TYPE)
SUBSECTIONIC
SPECIFIC TECHNICAL REQUIREMENT
REV 00 DATE 24.05.17

SUB SECTION-IC

(CONTROL AND INSTRUMENTATION)

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2X800MW NTPC KARIMNAGAR STPP PHASE-1 SECTION: C

TECHNICAL REQUIREMENTS (C&I)

MILL REJECT SYSTEM

CONTROL AND INSTRUMENTATION

FOR
MILL REJECT SYSTEM

2X800MW NTPC KARIMNAGAR STPP PHASE-1 DESG AR

JOB NO: 424 CHKD MK

REV. NO. 00 DATE: 21.04.2017 APPD BS

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C&I SPECIFICATION FOR SECTION: C

SUB SECTION: C&I
MILL REJECT SYSTEM

C&I SPECIFICATION FOR

MILL REJECT SYSTEM

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C&I SPECIFICATION FOR SECTION: C

SUB SECTION: C&I
MILL REJECT SYSTEM

INDEX

S. No. DESCRIPTION

1 TITLE SHEET

2 INDEX SHEET

3 C&I SPECIFIC TECHNICAL REQUIREMENTS

4 GENERAL TECHNICAL SPECIFICATION

5 LIST OF DOCUMENTS/DELIVERABLES

6 MEASURING INSTRUMENTS (PRIMARY & SECONDARY)

7 DATA SHEETS FOR MOTORISED VALVE ACTUATOR

INSTRUMENT CABLE INTERCONNECTION AND TERMINATION

8
PHILOSOPHY

9 CABLING AND INSTRUMENT INSTALLATION DIAGRAM

10 DRIVE AND INSTRUMENT INTERFACE DIAGRAM

11 QUALITY ASSURANCE

12 TYPE TEST REQUIREMENT

13 MANDATORY SPARE LIST

14 SUB VENDOR LIST

15 KKS TAGGING PHILOSOPHY

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C&I SPECIFICATION FOR SECTION: C

SUB SECTION: C&I
MILL REJECT SYSTEM

C&I SPECIFIC TECHNICAL REQUIREMENT

FOR DCS BASED
MILL REJECT HANDLING SYSTEM

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C&I SPECIFICATION FOR SECTION: C

SUB SECTION: C&I
MILL REJECT SYSTEM

Specific Technical Requirements (C&I):

1. MRHS shall be operated from DDCMIS (in BHEL's scope) through operator work
station located in central control room.

2. Interface of MCC, Solenoid valves, etc. with DDCMIS based control system shall be
as per Drive Control Philosophy enclosed in specification.
3. Bidder to provide one number local control panel for each pyrite hoppers. This local
panel will act as interface between the DCS and the field devices for commands &
feedbacks.
4. Instrument installation shall be as per the attached "Standard Hook-up diagram of
instrument."
5. The Contractor shall provide complete Instrumentation for control, monitoring and
operation of entire MRHS. The requirements given here are to be read in
conjunction with detailed Technical specification enclosed in the specification.
Further, in case of any discrepancy in the requirement within the same section noted
by the bidder in the specification, the same will be brought to the notice of BHEL in
the form of pre- bid clarification. In absence of any pre-bid clarification, the more
stringent requirement as per interpretation of customer shall prevail without any
commercial implication.
6. The quantity of instruments for the system shall be as per tender P &ID wherever
provided of the respective system as a minimum, for bidding purpose. However,
Bidder shall also include in his proposal all the instruments and devices that are
needed for the completeness of the plant auxiliary system/ equipment supplied by
the bidder, even if the same is not specifically appearing in the P & ID. During detail
engineering if any additional instruments are required for safe & reliable operation
of plant, bidder shall supply the same without any price implication.
7. In addition to requirements specified here, all C&I systems/ sub-systems/
equipment/ devices shall also meet other requirements stipulated under other Sub-
sections/ parts/ sections of specification.

8. The make/model of various instruments/items/systems shall be as per customer

approved vendor list. No commercial and delivery implication in this regard shall be

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C&I SPECIFICATION FOR SECTION: C

SUB SECTION: C&I
MILL REJECT SYSTEM

acceptable. In case of any conflict and repetition of clauses in the specification, the
more stringent requirements among them are to be complied with.

9. Redundancy of sensors shall be provided by bidder

(i) Triple redundancy for all analog and binary inputs required for protection of
system/drives.
(ii) For all other control functions dual redundancy of the sensors shall be
provided
by the bidders.
10. All Temperature sensors shall be Duplex type and temperature transmitter shall be
provided for all temperature measurement applications. Bidder to provide
temperature transmitter along with compensating cable, JB/Rack & other erection
hardware.
11. Use of process actuated switch shall be avoided.
12. All the transmitters supplied by Bidder shall be rack mounted. The transmitter racks
shall be in Bidder's scope of supply. All transmitters shall be HART compatible
13. Instrument installation and accessories required for the same shall be in Bidder's
scope. However, any instrument/ analyzer installation not covered in the
specification, same shall be subject to customer and BHEL approval during detailed
engineering. All instruments required for the package shall be supplied, mounted on
the gauge board racks, along with accessories like impulse pipe, fittings & valve
manifolds etc.
14. All field instruments enclosure shall be [Link] panel/cabinet enclosure shall be
IP 55, unless otherwise specified.
15. All instruments and control elements shall be terminated on JB/LCP in field and
both instrument and JB/LCP are in bidder scope. Number of Junction Boxes shall be
sufficient and positioned in the field to minimize local cabling (max 12-15 mtrs) and
trunk cable.
16. Bidder to perform tests of C&I items/instruments/systems as per Quality plans/type
test attached in the specification. However, if any test not specified in the quality
plan but specified in specification Tests for I&C equipment included elsewhere in
specification will have to perform by Bidder without any cost implication. The

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C&I SPECIFICATION FOR SECTION: C

SUB SECTION: C&I
MILL REJECT SYSTEM

make/model of various instruments/items/systems shall be as per customer/BHEL

approved vendor list. No commercial and delivery implication in this regard shall be
acceptable. In case of any conflict and repetition of clauses in the specification, the
more stringent requirements among them are to be complied with.
17. Local control panel/station if any required for operation shall be in bidder scope.

18. RF Type level switches shall be provided for interlock & monitoring purpose on
transport vessels & Bunkers.

19. The solenoid operated valves/Dampers/Gate shall have a limit switch for open/close
feedback. Control voltage of Solenoid Valve shall be 24V DC only.
20. Bidder to provide mandatory spares as per mandatory spares list attached elsewhere
in the specification
21. For cable scope refer to electrical scope between BHEL and vendor defined in
electrical specification.
22. Number of pairs to be selected for Screen /Control cable (Size: 0.5 mm2)
a. F-Type: 2P/4P/24P (Size: 0.5sqmm2)
b. G-Type: 2P/4P/8P/12P (Size: 0.5sqmm2)
c. Core Cable: 3CX2.5sqmm2/ 12CX2.5sqmm2
23. Bidder’s presence is required for 3 Man days (Excluding travel time) at EDN
Bangalore during FAT of DDCMIS for certifying correctness & completeness of
implementation of Control logic. Date and other details of FAT shall be
communicated 2 days in advance. All the expenses like boarding, lodging and travel,
Air fare etc. shall be in bidder’s scope.
24. Bidder’s presence is required for 21 Man days (in three visit) at site during
commissioning of DDCMIS for assistance related to process correctness. Three visit
with total 21 Man days (Excluding travel time) in which one visit shall be of 7 Man
days each. All the expenses like boarding, lodging and travel, Air fare etc. shall be in
bidder’s scope.
25. Contractor's C&I representative shall be present at BHEL-PEM for 3 man-days, for
preparation of Control scheme of MRHS. All the expenses like boarding, lodging
and travel, Air fare etc. shall be in bidder’s scope.

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C&I SPECIFICATION FOR SECTION: C

SUB SECTION: C&I
MILL REJECT SYSTEM

26. In case of any conflict and repetition of clauses in the specification, BHEL discretion
will prevail.
27. The bidders shall specifically mention any deviation taken against any clause of the
C&I specification. In absence of any deviation, No deviation certificate is to be
furnished.
28. The specifications of instruments mentioned elsewhere in the specification is only
minimum requirement. The detailed specification shall be finalized during detail
engineering.
29. Bidder to furnish UPS load requirement during detailed engineering
30. 230 V AC UPS Power supply shall be provided by BHEL at a single point, further
distribution to various instruments/equipment of the system shall be in bidder scope.
Bidder to include necessary power distribution board/change over switch etc. in his
scope. Any power supply other than the above, if required by any
instrument/equipment has to be derived by the bidder from the above supply & all
necessary hardware for the same shall be in bidder scope. Bidder to submit the
power requirement along with the bid.
31. Contractor shall furnish Instrument Schedule, I/O list, Drive list, Cable Schedule,
Cable interconnection, JB grouping, Annunciation list, Plant schematics,
recommended control logics / write-up, SOE list, List of Instruments/devices for
HART in BHEL approved format. Also reusable database format like MS Excel, MS
Access etc. of these documents shall also be provided by Contractor in BHEL
approved format. Soft copy of the formats shall be provided to the successful bidder.
32. Guided wave radar type/ Ultrasonic Type Level transmitter shall be provided at each
MRS silo for level measurement.

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SECTION – D

GENERAL TECHNICAL
SPECIFICATION
CONTROL & INSTRUMENTATION

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BHEL-NKTPP-CPU

FORM NO. PEM-6666-0

SPECIFICATION NO.:
SPECIFICATION FOR VOLUME
CONTROL & INSTRUMENTATION FOR AUX SUB SECTION
PACKAGES
REV. NO. DATE :
SHEET OF

GENERAL REQUIREMENT

1.0 Bidder shall provide complete and independent control & instrumentation system with all
accessories, auxiliaries and associated equipments for the safe, efficient and reliable operation of
auxiliary systems.

2.0 The quantity of instruments for auxiliary system shall be as per tender P &ID wherever provided
of the respective system as a minimum, for bidding purpose. However, Bidder shall also include
in his proposal all the instruments and devices that are needed for the completeness of the plant
auxiliary system/ equipment supplied by the bidder, even if the same is not specifically appearing
in the P & ID. During detail engineering if any additional instruments are required for safe &
reliable operation of plant, bidder shall supply the same without any price implication.

3.0 Measuring instruments/equipment and subsystems offered by the bidder shall be from reputed
experienced manufacturers of specified type and range of equipment, whose guaranteed and
trouble free operation has been proven. Further all the instruments shall be of proven reliability,
accuracy, and acceptable international standards and shall be subject to employer’s approval. All
instrumentation equipment and accessories under this specification shall be furnished as per
technical specification, ranges, makes/ numbers as approved by the employer’ during detail
engineering.

4.0 The necessary root valves, impulse piping, drain cocks, gauge-zeroing cocks, valve manifold and
all the other accessories required for mounting/ erection of these local instruments shall be
furnished, even if not specifically asked for, on as required basis. The contacts of equipment
mounted instruments; sensors, switches etc for external connection including spare contacts shall
be wired out to suitably located junction boxes.

5.0 The customer specification attached as Specific Technical Requirement will supercede the Data
sheets, if there is any mismatch.

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C&I SPECIFICATION FOR SECTION: C

SUB SECTION: C&I
MILL REJECT SYSTEM

LIST OF DOCUMENTS/DELIVERABLES

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C&I SPECIFICATION FOR SECTION: C

SUB SECTION: C&I
MILL REJECT SYSTEM

LIST OF DELIVERABLES OF PEM - C&I DEPARTMENT

[Link]. DRAWING NO. DRAWING/DOCUMENT TITLE CATEGORY 

   
CONTROL & OPERATIONAL WRITE-UP FOR THE 
1
PE-V1-424-145-I901 SYSTEM A
CONTROL SCHEME/LOGIC DIAGRAM (TO BE 
2
PE-V1-424-145-I902 IMPLEMENTED IN DDCMIS) A
3 PE-V1-424-145-I903 HMI PICTURES/PLANT SCHEMATICS A
4 PE-V1-424-145-I904 INSTRUMENT SCHEDULE with set points A
5 PE-V1-424-145-I905 I/O LIST (ANALOG & BINARY) A
DRIVE LIST/SOLENOID/ACTUATOR VALVE LIST 
6
PE-V1-424-145-I906 WITH LOCATION DATA A
7 PE-V1-424-145-I907 FIELD JB/LIE/LIR,DRIVES TERMINATIONS A
8 PE-V1-424-145-I908 DATASHEETS FOR INSTRUMENTS, JBs, etc. A
9 PE-V1-424-145-I909 QUALITY PLANS (INSTRUMENTS, VMS, etc.) A
INSTRUMENT HOOK-UP DRAWING
10
PE-V1-424-145-I910 A
11 PE-V1-424-145-I911 THERMOWELL SIZING CALCULATION A
12 PE-V1-424-145-I913 CABLE SCHEDULE & INTERCONNECTION A
13 PE-V1-424-145-I914 ANNUNCIATION & SOE LIST A


NOTES:
ANY OTHER DOCUMENT DECIDED DURING DETAILED ENGINEERING SHALL BE PROVIDED BY
BIDDER WITHOUT ANY COMMERCIAL/TECHNICAL IMPLICATION.

CONTRACTOR TO SUBMIT REUSABLE DATABASE FORMATS IN BHEL/CUSTOMER APPROVED

FORMATS LIKE MS EXCEL, MS ACCESS OF DOCUMENTS LIKE INSTRUMENT SCHEDULE, I/O LIST,
DRIVE LIST, FIELD JB TERMINATIONS, CABLE SCHEDULE & INTERCONNECTION, etc.
SOFT COPY OF FORMATS SHALL BE PROVIDED TO SUCCESSFUL BIDDERS.

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SUB–SECTION – IIIC – 04
MEASURING INSTRUMENTS
(PRIMARY & SECONDARY)

TELANGANA SUPER THERMAL POWER PROJECT

TECHNICAL SPECIFICATION
PHASE-I (2X800 MW) SECTION-VI
STEAM GENERATOR ISLAND PACKAGE BID DOC. NO.: CS-9591-101-2

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TECHNICAL REQUIREMENTS

1.00.00 MEASURING INSTRUMENTS (PRIMARY AND SECONDARY)

1.01.00 Measuring instruments/equipment and subsystems offered by the Bidder shall be from
reputed experienced manufacturers of specified type and range of equipment, whose
guaranteed and trouble free operation has been proven. Refer Sub-section Basic Design
Criteria. Further, all instruments shall be of proven reliability, accuracy, and repeatability
requiring a minimum of maintenance and shall comply with the acceptable international
standards and shall be subject to Employer's approval.

1.02.00 Every panel-mounted instrument requiring power supply shall be provided with easily
replaceable glass cartridge fuses of suitable rating. Every instrument shall be provided with a
grounding terminal and shall be suitably connected to the panel grounding bus.

1.03.00 All transmitters, sensors, switches and gauges for parameters like pressure, temperature,
level, flow etc. as required for the safe and efficient operation and maintenance as well as for
operator and management information (including all computation) of equipment in the system
under the scope of specification shall be provided on as required basis with in quoted lump
sum [Link] Contractor shall furnish all Instrumentation / Control equipment & accessories
under this specification as per technical specification, ranges, makes & model as approved
by the Employer during detailed engineering.

1.04.00 The necessary root valves, impulse piping, drain cocks, gauge-zeroing cocks, valve
manifolds and all the other accessories required for mounting/erection of these local
instruments shall be furnished, even if not specifically asked for, on as required basis. The
contacts of equipment mounted instruments, sensors, switches etc. for external connection
including spare contacts shall be wired out in flexible/rigid conduits, independently to suitably
located common junction boxes. The proposal shall include the necessary cables, flexible
conduits, junction boxes and accessories for the above purpose. Double root valves shall be
provided for all pressure tapping where the pressure exceeds 40 Kg./[Link].

1.05.00 All instruments envisaged for sea water applications, shall be provided with wetted parts
made of Monel/ Hastelloy C or any other material (if provenness experience of the proposed
material for such applications is established by contractor).

1.06.00 For coastal areas, all instruments shall be provided with durable epoxy coating for
housings and all exposed surfaces of the instruments.

2.00.00 SPECIFICATION FOR ELECTRONIC TRANSMITTERS

2.01.00 SPECIFICATION FOR ELECTRONIC TRANSMITTER FOR PRESSURE, DIFF PRESS

AND DP BASED FLOW / LEVEL MEASUREMENTS

[Link]. Features Essential/Minimum Requirements

1. Type of Transmitter Microprocessor based 2 wire type, Hart protocol

compatible.

2. Accuracy ± 0.1% of calibrated span (minimum)

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TECHNICAL REQUIREMENTS

3. Output signal range 4-20 mA DC (Analog) along with superimposed digital

signal (based on HART protocol)

4. Turn down ratio 10:1 for vacuum/very low pressure applications. (i.e
.pressure <=200mmWC).
(minimum)
5:1 for very high pressure application. (i.e. pressure
>=200Kg/cm2).
30:1 for other applications.
5. Stability ± 0.1% of calibrated span for six months for Ranges up to
and including70 Kg/cm².
± 0.25% of calibrated span for six months for Ranges
more than 70 Kg/cm² .
6. Zero and span drift +/- 0.015% per deg.C at max span.
+/-0.11% per deg.C at min. Span.
7. Load impedance 500 ohm (min.)
8. Housing Weather proof as per IP-65, metallic housing with durable
corrosion resistant coating.
9. Over Pressure 150% of max. Operating pressure
10. Connection Plug and socket type
(Electrical)
11. Process connection 1/2 inch NPT (F)
12. Span and Zero Continuous, tamper proof, Remote as well as manual
adjustability from instrument with zero suppression and
elevation facility.
13. Accessories -Diaphragm seal, pulsation dampeners, syphon etc. as
required by service and operating condition.
-2 valve manifold for absolute & Gauge pressure
transmitters, 3-valve and 5 valve manifold for
DP/Level/Flow applications. The valve manifold shall be
non integral type (except Fuel Oil area).
-For hazardous area, explosions proof enclosure as
described in NEC article 500.
Mounting: 2 inch pipe mounting.
14. Diagnostics & Self-Indicating feature and digital display on transmitter
display
15. Power supply 24V DC ± 10%.
16. Adjustment/calibratio From hand held calibrator/centralized PC based system
n/maintenance (as applicable).

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TECHNICAL REQUIREMENTS

Notes
For primary air/ secondary air/flue gas applications, DP type transmitters shall be provided
for pressure measurement.
LVDT type is not acceptable.
Where the process fluids are corrosive, viscous, solid bearing or slurry type, diaphragm
seals shall be provided. Parts below the diaphragm shall be removable for cleaning. The
entire volume above the diaphragm shall be completely filled with an inert liquid suitable
for the application.

2.02.00 GUIDED WAVE RADAR TYPE LEVEL TRANSMITTER

Type Microprocessor based 2 wire type, HART

protocol compatible Guided wave radar
transmitter.

Principle TDR (Time domain reflectometry)

Probe Type & Material (i) Coaxial probe of SS316/316L. If required,

probe shall be suitable for overfill prevention.

(ii) Rod probe, cable probe of SS316/SS316L

can be used for applications wherever coaxial
probe is not suitable.

Output signal 4-20 mA DC along with superimposed digital

signal (based on HART protocol), suitable for
over fill prevention.

Accuracy +/- 0.5% of calibrated span or minimum 5mm.

Power supply 24 VDC +/- 10%.

Housing Weather proof as per IP-65, metallic housing

with durable corrosion resistance coating.

Adjustment/ calibration Using hand held HART calibrator/ centralized PC

based system (as applicable).

Zero & span adjustment Continuous, temper proof, remote as well as

manual adjustability from instrument. It should
be possible to calibrate the instrument without

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TECHNICAL REQUIREMENTS

any level in the tank/sump etc.

Display Integral digital display.

Load Impedance 500 ohms (minimum).

Electromagnetic compatibility Shall meet EN 61326-1 (1997) and AmdtA1,

class A equipment/EN 50081-2 & EN 5008 1-2 &
EN 50082-2

Mounting (i) External cage shall be provided where ever

side mounting is required. External cage and
other mounting accessories to be provided by
the contractor.

(ii) Where ever top mounting is required, all

mounting accessories, stilling well (as required)
etc., shall be provided by the contractor.

(iii) All weather canopy shall be provided for

protection from direct sunlight and direct rain for
open locations.

Note: Four wire type transmitters can also be provided for applications where 2- wire
transmitter has some technical limitations, subject to employer’s approval during detailed
engineering stage. However, in such cases isolated 4-20 mA DC (analog) output shall be
provided. Power supply required for such transmitters shall be 240V AC / 24V DC.

2.03.00 Ultrasonic Type level Transmitter

[Link]. Features Essential/Minimum requirement

1. Type of Transmitter Non-contact Microprocessor based 2 wire type,

HART protocol compatible Ultrasonic
transmitter.

2. Output signal 4-20 mA DC (Analog) along with superimposed

digital signal (based on HART protocol).

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TECHNICAL REQUIREMENTS

3. Accuracy +/- 0.5% of calibrated span or minimum 5mm.

4. Power supply 24 V DC +/- 10%.

5. Temperature compensation To be provided within transducer.

6. Housing Weather proof as per IP-65, metallic housing

with durable corrosion resistance coating.

7. Adjustment/calibration/ Using hand held HART calibrator/ centralized PC

based system (as applicable).
maintenance
.

8. Zero and Span adjustment Continuous, tamper proof, remote as well as

manual adjustability from instrument. It should
be possible to calibrate the instrument without
any level in the tank/sump etc.

9. Sensor Material Corrosion resistant material to suit individual

application requirement.

10. False signal tolerance Transmitter shall be capable of ignoring false

echoes from internal tank/sumps obstructions
such as pipes, heating coils or agitator blades.
Also transmitter shall have adjustable damping
circuitry.

11. Range Range of transmitter shall be capable of

covering the complete level span of tank taking
care of blocking distance, frequency attenuation
due to surface, obstructions, vapors etc.

12. Display Integral digital display

13. Diagnostics Loss of echo alarm etc.

14. Load Impedance 500 ohms (minimum).

15. Electrical Connection Plug and socket

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TECHNICAL REQUIREMENTS

16. Accessories x All weather canopy shall be provided for

protection from direct sunlight and direct
rain for open locations.

x All mounting accessories required for

erection and commissioning shall be
provided.

x For hazardous area, explosion proof

enclosure as described in NEC article
500

Note:

1) Contractor can also provide Radar type transmitter as per above specification in
place of ultrasonic transmitter subject to approval by Employer during detailed
Engineering. Sonic frequency based transmitters can also be provided under
“ultrasonic transmitters” category for fly ash silo level.

2) Four wire type transmitters can also be provided for applications where 2- wire
transmitter has some technical limitations, subject to employer’s approval during
detailed engineering stage. However, in such cases isolated 4-20 mA DC (analog)
output shall be provided. Power supply required for such transmitters shall be 240V
AC / 24V DC.

3) For applications where transmitter location is not accessible, the transmitter shall
have separate sensor unit and electronic unit for such applications. It shall be
possible to mount the electronic unit at accessible location.

2.04.00 HART Hand Held calibrator

Hand held calibrator shall be provided for adjustment/calibration/maintenance of the HART
compatible transmitters. The hand held calibrator shall be suitable for all types of transmitters
supplied in the package. If one type of hand held type calibrator is not suitable for
communicating with all types of transmitters then separate hand held calibrator will be
provided for that specific type of transmitter.

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TECHNICAL REQUIREMENTS

3.00.00 Temperature Elements and accessories

3.01.00 Thermocouple

Sr. Features Essential/Minimum Requirements

No.

1 Type of Thermocouple. : 16 AWG wire of Chromel-Alumel (Type K)

or 24 AWG wire Pt-Rhodium Pt (Type R)
depending on operating temperature Range
(ungrounded separate junction type).

2 No. of element : Duplex

3 Housing/Head : IP-65/Diecast Aluminium. Head of TE to be

provided with sufficient space and
arrangement to mount head mounted
temperature transmitter (as applicable).
Plug in connectors are to be provided for
external signal cable connection. TE
terminal head shall be spring loaded for
positive contacts with the thermo well.

4 Insulation and Sheathing of : Swaged type mineral (magnesium oxide)

Thermocouple insulation and SS316 sheath.

5 Calibration and accuracy : As per IEC-584/ ANSI-MC-96.1 (special

limits of errors/ class1) for T/C.

6 Accessories : Thermo well and associated fittings

7 Standard : IEC-584/ ANSI MC 96.1 for Thermocouple

and ASME PTC-19.3 for Thermo-well

3.02.00 Resistance Temperature Detector ( RTD )

Sr. Features Essential/Minimum Requirements

No.

1 Type of RTD. : Four wire, Pt-100 (100 Ohms resistance at zero

degree Centigrade).

2 No. of element : Duplex

3 Housing/Head : IP-65/Diecast Aluminium. Head of TE to be

provided with sufficient space and arrangement
to mount head mounted temperature transmitter
(as applicable). Plug in connectors are to be

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TECHNICAL REQUIREMENTS

provided for external signal cable connection.

TE terminal head shall be spring loaded for
positive contacts with the thermo well

4 Insulation and sheathing : Mineral (magnesium oxide) insulation and

of RTD SS316 sheath,

5 Calibration and accuracy : As per As per IEC-751/ DIN-43760 Class-A for

RTD

6 Characteristic : Linear with respect to temp, within ±1/2 percent

of top range value.

7 Accessories : Thermo well and associated fittings

8 Standard : IEC-751/ DIN-43760 for RTD and ASME PTC-

19.3 for Thermo-well.

NOTES :

1) The specifications for RTDs of winding/ bearings of motor/pump, can be as per their
manufacturer standards. The manufacturer shall submit the adequate supporting
documents for establishing their standard practice. However the type of RTD shall be
Pt100.
2) The specifications of temp elements for air conditioning & ventilation system /
process can be as per system manufacturer’s standards. The manufacturer shall
submit the adequate supporting documents for establishing their standard practice.

3.03.00 Metal Temperature Thermocouples

Measuring Medium Metal Temperature

Material of Chromel Alumel Type K

Thermocouple.

Type of Thermocouple Duplex with separate hot junctions, ungrounded

Insulation Mineral Insulation Magnesium Oxide.

Thermocouple wire 16 AWG

gauge

Protective sheath SS 321

Protective sheath dia 8 mm O.D

Characteristics of As per IEC-584/ANSI-MC-96.1 (special limits of error) for T/C

Thermocouple

Mounting accessories 1/2" BSP SS sliding end connector, weld pad, clamps of heat
resistant steel SS310. Adjustable gland fitting for connection at
the junction box end as per manufacturer’s standard.

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TECHNICAL REQUIREMENTS

Cold end sealing SS pot seal with colour coded PTFE Insulated flexible tails.
Sealing compound- Epoxy resin. . Length of PTFE insulated
flying leads shall be minimum 750 mm.

Minimum bending 30 mm
radius

Length of T/C On as required basis considering location of measurement

point and the JB/TTJB location

Notes :

1) The specification for thermocouples of bearings metal temp measurements can be

as per their manufacturer standards. The manufacturer shall submit the adequate
supporting documents for establishing their standard practice. However type of
thermocouples shall be K-type.
2) For boiler metal temperature applications, considering the location of installations
and response time, manufacturer’s standard and proven specification for metal
temperature measurement can also be accepted subject to employer’s approval. The
manufacturer shall submit adequate supporting documents for establishing their
standard and proven practice.

3.04.00 Thermo well (for all process temp. elements)

(a) Shall be one piece solid bored type of 316 SS of step-less tapered design. (As per
ASME PTC 19.3, 1974)

(b) For Mill classifier outlet long life solid sintered tungsten carbide material of high
abrasion resistance shall be provided.

(c) For Air & Flue gas 316 SS protecting tube with welded cap. (However contractor
shall provide better material for Flue gas service if required based on the specified
boiler design parameters).

(d) For furnace zone, impervious ceramic protecting tube of suitable material along
with Incoloy supporting tubes and adjustable flanges.

3.05.00 Not Used

3.06.0 TEMPERATURE TRANSMITTER (TT)

Following types of 2-wire temperature transmitter (directly powered from 4-20mA input
cards of DDCMIS/PLC) shall be provided. The temperature transmitter shall be fully
compatible with thermocouples and RTDs being provided by the contractor as well as
Employer. Temperature compensation of the thermocouples shall be performed in the
temperature transmitter itself.
a. Single Input Head mounted Temperature Transmitter
These shall be suitable for mounting in the head of temperature element itself.
Temperature transmitter and associated temperature element shall be factory fitted.

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b. Single Input DIN-rail mounted Temperature Transmitter

These shall be suitable for mounting on DIN-rails in JBs. The specifications of the JBs
shall be same as indicated in Subsection INST CABLE with additional DIN-rails and IP
65 Protection class. This temperature transmitter shall be the ones which are
especially designed for DIN-rail mounting with IP 20 protection class. These shall
have terminals for input/output provided on front side when mounted on DIN-rail.
Head mounted temperature transmitter with clamps to make it suitable for DIN-rail
mounting shall not be acceptable under this category.
c. Dual-input Temperature Transmitter With integral Indicator:
These shall be suitable for mounting on pipes/ support. Integral indicator shall be
provided with these transmitters. These transmitters shall have bump less change
over facility to second sensor in case first sensor fails .This change-over is to be
alarmed. Protection class shall be IP65 minimum.
d. Common requirements for each of the above type of temperature transmitters.
Output : 2-wire (power supply from input card of Control System)
with 4-20mA output with superimposed HART protocol
signal.
Input : Same transmitter shall be capable to handle Pt-100 RTD
Thermocouples –K & R types (input type to be selectable
at site through HART terminal).
Isolation : Min. 500 V AC.
EMC compatibility : As per EN 61326.
Operating ambient : 0 to 85 deg C (without indicator).
temperature
0 to 70 deg C (with indicator).
Power supply 24V DC +/- 10%.
Accessories Mounting arrangements including clamps etc.
Composite Accuracy (i) For head mounted and DIN-rail mounted types:
(Refer note 2 ) RTD =<0.4% of 0-250 deg C span
T/C-K type =<0.4% of 0-600 deg C span
T/C-R type =<0.4% of 0-1000 deg C span
CJC accuracy (for thermocouples) shall be =< 1 deg C
(ii) For dual-input type:
RTD =<0.25% of 0-250 deg C span
T/C-K type =<0.2% of 0-600 deg C span
CJC accuracy (for thermocouples) shall be =< 1 deg C
e. Field bus compatible temperature transmitters
Temperature transmitters of this category shall be field mounting type & shall be
capable of withstanding operating ambient temperature upto 85 deg C. These
modules shall be connected to DDCMIS through field bus such as Profibus,

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Foundation Field bus etc directly from the transmitter. Maximum Number of inputs
per such temperature transmitter shall be eight. These shall be mounted in
cabinets/enclosures/JBs in non-AC areas.
As an alternate, these signals from temperature transmitters can be connected to
DDCMIS through standard remote I/O modules of the DCS, in which case, the
temperature transmitter signals will be acquired through 4-20mA input modules in the
remote I/O cabinet for connecting to DDCMIS through remote I/O bus.
The no. of such modular systems/ JBs shall be provided as per Appendix-1 to Part-A.
Notes (Common for a) to d) above):-
1. In case of failure (open or burn-out) of RTD/thermocouple, temp. Transmitter shall
provide low temperature output.
2. Composite Accuracy is to be calculated as summation of all applicable accuracies of
temp transmitter, for converting sensor input to output in 4-20 mA (e.g., basic
accuracy, digital accuracy, D/A accuracy, etc.) and temperature effect on these
accuracies at ambient temperature of 50 deg C, based on the figure/ formula given in
the standard product catalogue for span as specified above for various types of
Temperature Elements specified. All such accuracy/ temp effect figures in catalogue
shall be first converted to deg C, and then percentage of this converted accuracy in
specified span shall be calculated to compare with the specified composite accuracy
figures. All temperature transmitters are to be interchangeable (i.e. can be used for
either RTD or thermocouple) and composite accuracy shall be met for each type of
input specified in (i) & (ii).

4.00.00 ELECTRICAL METERING INSTRUMENTS

Electrical metering instruments shall be furnished in accordance with the following general
specifications. However, the scope shall be governed by the Contract quantity given in
appendix-1 to part-A. Application standard for electrical metering instruments shall be as per
IS: 1248- 2003(Revised). The size of each instrument shall be as approved by Employer
during detailed engg. All metering instruments shall be flush panel mounting type.

4.01.00 (a) Frequency meters for Synchronization purposes: Accuracy: ± 1.5% of full scale.

(b) Synchroscope: Accuracy class: 0.5 or better

(c) Voltmeters: Accuracy: ± 2.0% of full scale or better.
4.02.00 Synchronizing Relays

Synchronizing check relay with necessary ancillary equipment shall be provided which shall
permit breakers to close after checking the requirements of synchronizing of incoming and
running supply. The phase angle setting shall not exceed 10 Degree and this angle shall be
adjustable and shall take the account the circuit breaker closing period. This relay shall have
a response time of less than 200 milliseconds when the two system conditions are met within
preset limits and with the timer disconnected. The relay shall have a frequency difference
setting not exceeding 0.45% at rated value and at the minimum time setting. The relay shall
have a continuously adjustable time setting range of 0.5-3 secs. Additionally, a guard relay
shall be provided to prevent the closing attempt by means of synchronizing check relay when

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functional requirements detailed above shall be met and the system shall be subject to
Employer’s approval.

8.00.00 E-P Converter

E-P converters and associated accessories shall be furnished in accordance with the
specifications given below :

Air supply: 1.5 kg/cm sq., Input signal: 4-20m A dc (as required by the design of control
system), Output signal: 0.2 to 1.0 kg/cm sq., Linearity: 0.5% of span or better, Hysteresis:
0.5% of span or better, Ambient Temperature Effect: less than 0.02% of span per deg C
between -20 to +60 deg C. Mounting: Close to actuator (but not on the actuator), output
capacity-to suit the actuator, protection class IP 55. On loss of control signal, the last set
point pressure shall be maintained so that the associated control valve remains in stay put
condition without any additional solenoid valve. The allowable drift rate will be +2% of set
point/ hour maximum.

9.00.00 NOT USED

10.00.00 NOT USED

11.00.00 NOT USED

12.00.00 SPECIFICATION FOR CORIOLIS FLOW TRANSMITTER

Type Coriolis

Material of Wetted Parts 316 SS

Material of Housing 304L SS

Accuracy ± 0.2% of Rate

Repeatability ± 0.1% of Rate

Output 4-20 mA DC, HART Compatible

Power Supply 230 VAC or 24VDC operated

Process Temperature range 0-200 degree Celsius

Others Drain / purging arrangement shall be

provided as per standard practice.

The offered Coriolis type flow transmitter shall be suitable for intended application. Contractor
shall submit flow and sizing calculation for Employer’s approval. For each type of Coriolis
type flow transmitter general arrangement and assembly drawing and cable wiring diagram
shall be submitted for Employer’s approval.

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TECHNICAL REQUIREMENTS

15.00.0 PROCESS ACTUATED SWITCHES

FEATURES ESSENTIAL / MINIMUM REQUIREMENTS

Pressure/ Draft Temperature Level switches
Switches/ DP switches
Switches
Sensing Piston actuated Vapor pressure Capacitance types, float type,
Element for high pressure sensing, liquid conductivity type, RF type,
and diaphragm or filled bellow Ultrasonic type as per suitability to
bellows for low type with SS the application. .
pr./ vacuum bulb and
capillary (5 m
minimum, to
suit application)

Material 316 SS Bulb 316 SS/ 316 SS

capillary 304 SS
End ½ inch NPT (F) ½ inch NPT (F) Manufacturer standard
connection
Over range/ 150% of - 150% of maximum operating pr.
proof pressure maximum
operating pr.
Repeatability + 0.5% of full range

No. of contacts 2 No.+2NC. SPDT snap action dry contact

Rating of 60 V DC, 6 VA (or more if required by DDCMIS)

contacts
Elect. Plug in socket.
Connection
Set point Provided over full range.
adjustment
Dead band Adjustable/ fixed as per requirement of application.
adjustment
Enclosure Weather and dust proof as per IP-55, metallic housing.

Accessories Siphon, snubber, Thermo well of All mounting accessories

chemical seal, 316 SS and
pulsation packing glands
dampeners as
required by
process
Mounting Suitable for Suitable for rack -
enclosure/ rack mounting or
mounting or direct mounting
direct mounting
Power Supply As per Contractor’s Standard practice.
(wherever
required)

TELANGANA SUPER THERMAL POWER TECHNICAL SPECIFICATIONS SUB-SECTION-IIIC-04 PAGE

PROJECT PHASE-I (2X800 MW) SECTION – VI, PART-B MEASURING INSTRUMENTS 27 OF 30
STEAM GENERATOR ISLAND PACKAGE BID DOC. NO.: CS-9591-101-2 (PRIMARY & SECONDARY)

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CLAUSE NO.
TECHNICAL REQUIREMENTS

Notes :-

1) Where the process fluids are corrosive, viscous, solid bearing or slurry type,
diaphragm seals shall be provided. Parts below the diaphragm shall be removable
for cleaning. The entire volume above the diaphragm shall be completely filled with
an inert liquid suitable for the application.

2) Pressure/ Diff pressure switches for very low press/ DP measurements can have
sensor material other than SS316 in case of any technical limitation and the offered
product is standard product of the manufacture for very low pressure applications..

3) Repeatability can be upto +/-1% of full range in case of switches with diaphragm
seals or very low pressure/DP range.

4) The specifications of switches for air conditioning & ventilation system / process can
be as per system manufacturer’s standards. The manufacturer shall submit the
adequate supporting documents for establishing their standard practice.

16.00.00 NOT USED

17.00.00 SOLENOID VALVES

Solenoid valves shall fulfil the following requirements:

a. Type 2/3/4 way SS 316/Forged Brass (depending on the application subject to

Employer’s approval during detailed Engg.)

b. Power supply 24 V DC + 10%.

c. Plug and socket electrical connection.

d. Insulation : Class ‘H’

18.00.00 REVERSE ROTATION INDICATOR (RRI)

Reverse rotation indicator comprising of proximity sensors, processing electronics with
output of 4-20mA (corresponding to speed) interconnecting cables, speed display in rpm,
normal, reverse indication and required channel alarm contact shall be provided. The contact
rating shall be 60VDC, 6VA (or more if required by Control system). The exact details of the
RRI shall be strictly as approved by Employer during detailed engineering. The power supply
of RRI is to be arranged by the Bidder

19.00.00 NOT USED

19.05.00 Electronic Flow-Meter

The electronic flow meter shall include flow sensor and flow indicator cum integrator /
totaliser and shall include all required accessories for satisfactory operation. The flow
meter shall be based on full bore ultrasonic / electromagnetic principle and shall be
electronic type of proven design, make and model acceptable to the owner.

TELANGANA SUPER THERMAL POWER TECHNICAL SPECIFICATIONS SUB-SECTION-IIIC-04 PAGE

PROJECT PHASE-I (2X800 MW) SECTION – VI, PART-B MEASURING INSTRUMENTS 28 OF 30
STEAM GENERATOR ISLAND PACKAGE BID DOC. NO.: CS-9591-101-2 (PRIMARY & SECONDARY)

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CLAUSE NO.
TECHNICAL REQUIREMENTS

Mounting : Table Top/ wall mounting.

Power : 240 V AC, 50 Hz.

supply
Output : 4-20 mA signal each for temperature.
Qty. : 15 nos. each of temperature & Humidity indicators ( combined indicators
for Humidity and temperature is also applicable).
One Set of output signal is to be connected to respective control system. Apart from
displaying the temperature/humidity values on indicator.

21.00.00 Limit switches

For offsite plant application Limit switches shall be gold plated with high conductivity and non
corrosive type. Contact rating shall be sufficient to meet the requirement of DDCMIS subject
to a minimum of 60 V, 6 VA rating. Protection class shall be IP 55.

For main plant application limit switches are to be provided as per contractor standard and
proven practice.

TELANGANA SUPER THERMAL POWER TECHNICAL SPECIFICATIONS SUB-SECTION-IIIC-04 PAGE

PROJECT PHASE-I (2X800 MW) SECTION – VI, PART-B MEASURING INSTRUMENTS 30 OF 30
STEAM GENERATOR ISLAND PACKAGE BID DOC. NO.: CS-9591-101-2 (PRIMARY & SECONDARY)

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BHEL-NKTPP-ACWT

CLAUSE NO.
MEASURING INSTRUMENTS (C-03)

16.00.00 SPECIFICATIONS FOR PR. GAUGE, D.P. GAUGE, TEMP. GAUGE AND LEVEL
GAUGE.

Sl. FEATURES ESSENTIAL/MINIMUM REQUIREMENTS

No

Pr. Gauge/ DP Temperature Level Gauge

Gauge/ Draught Gauge
gauges

1 Sensing Bourdon for high Mercury in steel Tempered *

Element and pressure, for below 450°C toughened Borosilicate
material Diaphragm/Bello and inert gas gauge glass steel
w for low pr. Of actuated for armoured reflex or
316 SS above 450°C of transparent type.
SS bulb and
capillary.

2 Body Die-cast Die-cast Forged carbon

material aluminium aluminium steel/304 SS

3 Dial size 150mm 150 mm Tubular covering entire

range

4 End 1/2 inch NPT (M) 3/4" NPT (M) Process connection as
connection per ASME PTC and
drain/vent 15 NB

5 Accuracy ±1% of span ± 1% of span ± 2%

6 Scale Linear, 270° arc Linear, 270° arc Linear vertical

graduated in graduated in °C
metric units

7 Range Cover 125% of Cover 125% of Cover 125% of max. of

selection max. of scale max. of scale scale

8 Over range Test pr. for the assembly shall be1.5 to the max. Design pr. at
test 38°C.

9 Housing Weather and Weather and CS/304 SS leak proof

dust proof as per dust proof as per
IP-55 IP-55

10 Zero/span Provided Provided --

adjustment

11 Identification Engraved with service legend or laminated phenolic name

plate

SINGARENI THERMAL POWER PROJECT TECHNICAL SPECIFICATION IIIC-03A PAGE

(2X600 MW) SECTION - VI MEASURING INSTRUMENTS 36 OF 46
BOILER TURBINE GENERATOR PACKAGE PART-B (PRIMARY & SECONDARY)

29

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BHEL-NKTPP-ACWT

CLAUSE NO.
MEASURING INSTRUMENTS (C-03)

12 Accessories Blow out disc, SS Thermowell Gasket for all KEL-F

siphon, shield for transparent
snubber, type vent and drain
pulsation valves of Steel/SS as
dampener, per CS/Alloy process
chemical seal Requirement.
(if required by
process)
gauge
isolation valve

13 Material of 316 SS / 304 316 SS / 304 SS

Bourdon/ SS
movement

Notes:-

*Bicolour type level gauges will be provided for applications involving steam and
water except for condensate and feed water services.

Length of gauge glass shall not be more than 1400 mm. If the vessel is higher,
multiple gauge glasses with 50 mm overlapping shall be provided.

Where the process fluids are corrosive, viscous, solid bearing or slurry type,
diaphragm seals shall be provided. Parts below the diaphragm shall be removable
for cleaning. The entire volume above the diaphragm shall be completely filled with
an inert liquid suitable for the application.

17.00.00 TG Related Special Measuring Instrument

17.01.00 ANALYSER INSTRUMENTS:

Common Requirements

1 Output signals Analog 4-20 mA DC

Binary 2 NO + 2 NC for high alarm

2. Zero & span Available

Adjustment

3. Ambient temp. 50°C

4. Indication Digital

5. Enclosure Weather & Dust proof (IP 55) Die cast Aluminium/SS
Type/Material

6. Type of Electronics Microprocessor based

SINGARENI THERMAL POWER PROJECT TECHNICAL SPECIFICATION IIIC-03A PAGE

(2X600 MW) SECTION - VI MEASURING INSTRUMENTS 37 OF 46
BOILER TURBINE GENERATOR PACKAGE PART-B (PRIMARY & SECONDARY)

30

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CLAUSE NO.
TECHNICAL REQUIREMENTS

1.00.00 CONTROL DESK & PANELS

1.01.00 GENERAL

1.01.01 All control desk, panels, LVS panel etc. shall be furnished fully wired with necessary
provision for convenience outlets, internal lighting, grounding, ventilation, space heating, anti-
vibration pads, internal piping & accessories as required for completeness of the system.

1.01.02 All panels, desks, cabinets shall be free standing type & have bottom / top entry for cables to
be finalised application wise during detailed engineering stage. The bottom of desk &
cabinets shall be sealed with bottom plate, compression cable glands (double for field and
single for inside rooms) and fire proof sealing material to prevent ingress of dust and
propagation of fire. Sufficient number of power receptacles with disconnect switches shall be
installed within all panels/desk.

1.01.03 Exterior steel surface shall be sand blasted, ground smooth, filled, primed, sanded and
smooth enamel painted to give a good finish subject to minimum paint thickness of 65-75
microns for sheet thickness of 3 mm and 50 microns for sheet thickness of 2mm. The exact
color shall be finalised during detailed engineering.

1.01.04 The design shall conform to the EN ISO 11064 (Ergonomical design of control room), Part-
1,2 and 3.

2.00.00 CONTROL DESK & PANEL

2.01.00 GENERAL

2.01.01 The exact dimensions, material, construction details, grounding, general arrangement etc. of
Control Desk etc. shall be as per the actual requirement and shall be finalised during detailed
engineering and subjected to Employer’s Approval. For bidding purpose, the length of the
desk/ panel and CD mounted devices are given in Appendix-I to Part-A, Section-VI.

2.01.02 For control desk mounted instruments/ devices etc., which are to be powered from UPS, all
required conversion of interface equipments / accessories to make such devices compatible
with UPS supply shall be provided. All necessary hardware like Input switches/ fuse unit for
each feeder as well as switch fuse unit for each instrument/ device on the power supply line
shall be provided. From UPS, redundant feeders shall be provided with suitably rated MCB
and provision of fast auto changeover of UPS feeders.

2.02.00 Control Desk (CD)

Control desk shall be Modular, non-welded construction free standing table top type with front & back
cover constructed of 1.6 mm thick CRCA steel plates. The tabletop of the control desk shall be arc-
shaped for mounting TFT monitors & mice for SG, TG, BOP (irrespective of scope of supply) and
synchroscope. TFT monitors and synchroscope shall be provided with adjustable mounting
arrangement. The work surface of control desk shall be 30mm thick with the top 12mm of Acrylic Solid
Surface (ASS) and the remaining 18mm of laminated medium density fiber board. Work surface shall
be made of two different colors at same level and seamlessly joined in each section. The structure
frame shall consist of extruded aluminum top and bottom horizontal beams and vertical support
tensioned together to form an integrated, finished curvilinear shaped frame. Vertical & Horizontal
supports, minimum 2.5mm and 2mm thick respectively, have to be provided for the structure frame.
Extreme side legs shall be illuminated type and should complete the overall form and aesthetics of the
desk. It shall have concealed cable & wire way management system. PA system hand sets,

TELANGANA SUPER THERMAL POWER TECHNICAL SPECIFICATIONS

SUB-SECTION-IIIC-12 PAGE
PROJECT PHASE-I (2X800 MW) SECTION – VI, PART-B
CONTROL DESK & PANELS 1 OF 4
STEAM GENERATOR ISLAND PACKAGE BID DOC. NO.: CS-9591-101-2

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FORM NO. PEM-6666-0

SPECIFICATION NO.: PE-SS-999-145-I007

SPECIFICATION VOLUME II B
FOR
SECTION D
MOTORISED VALVE ACTUATOR
REV. NO. 01 DATE: 09.02.17

SHEET 1 OF 3

Data Sheet A & B

DATA SHEET-A DATA SHEET-B
(TO BE FILLED BY PURCHASER) (TO BE FILLED-UP BY BIDDER)

* PROJECT 2 X 800 MW KARIMNAGAR TPP

OFFER REFERENCE
* TAG NO. SERVICE
* DUTY … ON / OFF … INCHING
* LINE SIZE (inlet/outlet): MATERIAL
… GLOBE … GATE … REG. GLOBE
* VALVE TYPE
… BUTTERFLY
GENERAL* * OPENING / CLOSING TIME
* WORKING PRESSURE
SHALL BE SUITABLE FOR CONTINUOUS
AMBIENT CONDITION OPERATION UNDER AN AMBIENT TEMP. OF 0-55
DEG C AND RELATIVE HUMIDITY OF 0-95%
VALVE SEAT TEST PRESS BIDDER TO SPECIFY
REQUIRED VALVE TORQUE BIDDER TO SPECIFY
ACTUATOR RATED TORQUE BIDDER TO SPECIFY
CONSTRUCTION TOTALLY ENCLOSED, WEATHER PROOF, IP:55
MECHANICAL POSITION INDICATOR TO BE PROVIDED FOR 0-100% TRAVEL
DOUBLE SHIELDED, GREASE LUBRICATED ANTI-
BEARINGS
FRICTION.
METAL (NOT FIBRE GEARS). SELF-LOCKING TO
GEAR TRAIN FOR
PREVENT DRIFT UNDER TORQUE SWITCH
LIMIT SWITCH/TORQUE SWITCH
CONSTRUCTION SPRING PRESSURE WHEN MOTOR IS DE-
OPERATION
AND SIZING ENERGIZED.
OPEN/CLOSE AT RATED SPEED AGAINST
DESIGNED DIFFERENTIAL PRESSURE AT 90% OF
RATED VOLTAGE. FOR ISOLATING SERVICE
THREE SUCCESSIVE OPEN-CLOSE OPERATIONS
SIZING
OR 15 MINS. WHICHEVER IS HIGHER. FOR
INCHING SERVICE - 150 STARTS/HR MINIMUM &
FOR REGULATING SERVICE - 3000 STARTS/HR
MINIMUM.
* REQUIRED „ YES … NO

HANDWHEEL * ORIENTATION … TOP MOUNTED … SIDE MOUNTED

*TO DISENGAGE AUTOMATICALLY DURING MOTOR OPERATION.

ACTUATOR MAKE/MODEL BIDDER TO SPECIFY
MOTOR MAKE / MODEL / TYPE / RATING
BIDDER TO SPECIFY
(KW)
SQUIRREL CAGE INDUCTION MOTOR, STARTING
@ MOTOR TYPE CURRENT LIMITED TO SIX TIMES THE RATED
CURRENT-INCLUSIVE OF I.S. TOLERANCE
„ ENCLOSED (BIDDER TO CONFIRM)
A: … DRG. NO. 3-V-MISC-24227 R00
B: … DRG. NO. 3-V-MISC-24550 R00
ACTUATOR APPLICABLE WIRING
C: „ DRG. NO. 3-V-MISC-24283 R00
DIAGRAM
ELECTRIC D: … DRG. NO. 4-V-MISC-90271 R11
ACTUATOR E: … For Thyristor based Integral starter,
Bidder/Vendor to furnish wiring diagram
COLOUR SHADE „ BLUE (RAL 5012) … …….
PAINT TYPE (## Refer Notes) „ ENAMEL … EPOXY … …….
SHAFT RPM BIDDER TO SPECIFY
OLR SET VALUE BIDDER TO SPECIFY
@ STARTING / FULL LOAD CURRENT BIDDER TO SPECIFY
NO. OF REV FOR FULL TRAVEL BIDDER TO SPECIFY
@ PWR SUPP TO MTR / STARTER 415V,+/- 10% 3PH,3 WIR 50 HZ+/-5%
TO BE DERIVED FROM THE POWER SUPPLY TO
@ CONTROL VOLTAGE REQUIREMENT
THE STARTER … 230 V „ 110 V AC /24V DC

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FORM NO. PEM-6666-0

SPECIFICATION NO.: PE-SS-999-145-I007

SPECIFICATION VOLUME II B
FOR
SECTION D
MOTORISED VALVE ACTUATOR
REV. NO. 01 DATE: 09.02.17

SHEET 2 OF 3

Data Sheet A & B

DATA SHEET-A DATA SHEET-B
(TO BE FILLED BY PURCHASER) (TO BE FILLED-UP BY BIDDER)

IP 67 FOR OUTDOOR & IP55 FOR

@ ENCLOSURE CLASS OF MOTOR
INDOOR(TOTALLY ENCLOSED SELF VENTILATED)
@ INSULATION CLASS CLASS-F TEMP. RISE LIMITED TO CLASS-B
„ THERMOSTAT (3 Nos.,1 IN EACH PHASE)
@ WINDING TEMP PROTECTION
… ---------------------------------------------------------
SINGLE PHASE / WRONG PHASE
REQUIRED
SEQUENCE PROTECTION
INTEGRAL STARTER „ REQUIRED … NOT REQUIRED
TYPE OF SWITCHING DEVICE „ CONTACTORS … THYRISTORS
TYPE „ CONVENTIONAL … SMART (NON-INTRUSIVE)
IF SMART NOT APPLICABLE
a) SERIAL LINK INTERFACE … INTEGRAL … FIELD MOUNTED

… FOUNDATION FIELD-BUS … PROFI-BUS

b) SERIAL LINK PROTOCOL
… DEVICE NET ……………

… TWISTED PAIR Cu-CBL … CO-AXIAL Cu-CBL

c) SERIAL LINK MEDIA
… OFC
d) HAND HELD PROGRAMMER … REQUIRED … NOT REQUIRED
e) TYPE OF HAND HELD
… BLUETOOTH … INFRARED …..............
PROGRAMMER
INTEGRAL
STARTER f) MASTER STATION … REQUIRED … NOT REQUIRED
g) MASTER STN INTRFACE WITH DCS … MODBUS … TCP/IP
h) DETAILS OF SPECIAL CABLE … ENCLOSED … NOT REQUIRED
STEP DOWN CONT. TRANSFORMER „ REQUIRED
OPEN / CLOSE PB „ REQUIRED … NOT REQUIRED
STOP PB „ REQUIRED … NOT REQUIRED
INDICATING LAMPS „ REQUIRED … NOT REQUIRED

LOCAL REMOTE S/S „REQUIRED … NOT REQUIRED

STATUS CONTACTS FOR MONITORING „ REQUIRED … NOT REQUIRED

REQUIRED (O/L RELAY OPERATED,
INTEGRAL STARTER DISTURBED
CONT./POWER SUPPLY FAILED, S/S IN LOCAL,
SIGNAL
TORQUE SWITCH OPTD. MID WAY)
„ INTERPOSING RELAY … OPTO COUPLER
TYPE OF ISOLATING DEVICE Also refer note no. 8
… EITHER
INTERPOSING QUANTITY „ 2 NOs. … 3 NOs.
RELAY/OPTO
COUPLER DRIVING VOLTAGE „ 20.5 – 24V DC … _____________V DC
(Applicable for DRIVING CURRENT „ 125mA MAX … _____________mA MAX
integral Starter)
„ > 192 ohms - <25 k ohms
LOAD RESISTANCE
… > _______ohms - < __________ohms

TORQUE MFR & MODEL NO. BIDDER TO SPECIFY

SWITCH OPEN / CLOSE „1 No. …2Nos. / „1 No. …2Nos
(Not Applicable
CONTACT TYPE 2 NO + 2 NC
for Smart
Actuator) RATING 5A 240V AC AND 0.5A 220V DC

($$ Refer CALIBRATED KNOBS(OPEN&CLOSE TS) REQUIRED FOR SETTING DESIRED TORQUE
Notes) ACCURACY +3% OF SET VALUE
LIMIT SWITCH MFR & MODEL NO. BIDDER TO SPECIFY
(Not Applicable OPEN : INT : CLOSE
„1 No
2 Nos. (ADJ.)
„1 No.
for Smart …2 Nos. …2Nos.
Actuator) ($$ CONTACT TYPE 2 NO + 2 NC

Refer Notes) RATING (AC / DC) 5A 240V AC AND 0.5A 220V DC

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FORM NO. PEM-6666-0

SPECIFICATION NO.: PE-SS-999-145-I007

SPECIFICATION VOLUME II B
FOR
SECTION D
MOTORISED VALVE ACTUATOR
REV. NO. 01 DATE: 09.02.17

SHEET 3 OF 3

Data Sheet A & B

DATA SHEET-A DATA SHEET-B
(TO BE FILLED BY PURCHASER) (TO BE FILLED-UP BY BIDDER)

Limit switched shall be silver plated with high conductivity and non-corrosive type. Contact rating shall be sufficient to meet the
requirement of control system subject to minimum of 60 V, 6 A rating .protection class shall be IP 55
POSITION TRANSMITTER (For inching
„ REQUIRED … NOT REQUIRED
duty & other specific applications)
MFR & MODEL NO. BIDDER TO SPECIFY

POSITION … ELECTRONIC (2 WIRE) R/I CONVERTER

TYPE
„ ELECTRONIC (2 WIRE) CONTACTLESS
TRANSMITTER
SUPPLY „ 24V DC … ………
OUTPUT „ 4-20mA
ACCURACY + 1% FS
@SPACE HEATER REQUIRED

SPACE @ POWER SUPPLY (NON INTEGRAL) 230V AC,1 PH.,50 Hz

HEATER @ POWER SUPPLY (INTEGRAL) BIDDER TO SPECIFY
@ RATING
ACTUATOR/MOTOR TERMINAL BOX REQUIRED

ENCL CLASS ACTUATOR/MOTOR T.B. @„ IP 68 @…………

TERMINAL
BOX @ EARTHING TERMINAL REQUIRED
PLUG & SOCKET(9 PIN) „ REQUIRED … NOT REQUIRED…
(FOR COMMD, LS/TS FEED BACK, PoT) „ 2 NOS. … ----------------
@ POWER CABLE GLAND SIZE:-----------------------
@ SPACE HEATER CABLE GLAND SIZE:-----------------------
CABLE GLANDS
OTHER CONTROL CABLE GLANDS-1 … 1No. for BFV of CW PUMP(Cable size 2Px1.5mm2)
OTHER CONTROL CABLE GLANDS-2 2 nos. 4 P x .5 mm2
TOTAL WEIGHT (ACTUATOR +
WEIGHT ACCESSORIES)
BIDDER TO SPECIFY _________________ Kg.

NOTES:
1. SCOPE: DESIGN, MANUFACTURE, INSPECTION, TESTING AND DELIVERY TO SITE OF ELECTRIC ACTUATOR FOR INCHING OR OPEN / CLOSE DUTY.

2. CODES & STANDARDS: DESIGN AND MATERIALS USED SHALL COMPLY WITH THE RELEVANT LATEST NATIONAL AND INTERNATION STANDARD. AS A MINIMUM,
THE FOLLOWING STANDARDS SHALL BE COMPLIED WITH:
IS-9334, IS-2147, IS-2148, IS-325, IS-2959, IS-4691 AND IS-4722
3. TEMPERATURE RISE SHALL BE RESTRICTED TO 70 DEG. C FOR AMBIENT TEMPERATURE OF 50 DEG C.

4. CABLE GLANDS OF DOUBLE COMPRESSION TYPE, BRASS MATERIAL SHALL BE PROVIDED.

5. THE TORQUE SWITCHES SHALL BE PROVIDED WITH MECHANICAL LATCHING DEVICE TO PREVENT OPERATION WHEN UNSEATING FROM THE END POSITIONS.
THE LATCHING DEVICE SHALL UNLATCH AS SOON AS THE VALVE LEAVES THE END POSITION. IF SUCH PROVISION IS NOT POSSIBLE, THE TORQUE SWITCHES
SHALL BE BYPASSED BY END-POSITION LIMIT SWITCHES WHICH OPENS ON VALVE LEAVING END [Link] LIMIT SWITCHES ARE ADDITIONAL TO THE
NUMBER OF LIMIT SWITCHES SPECIFIED ELSEWHERE.

6. THE MOTOR SHALL OPERATE SATISFACTORILY UNDER THE +/- 10% SUPPLY VOLTAGE VARIATION AT RATED FREQUENCY, -5% TO +3% VARIATION IN
FREQUENCY AT RATED SUPPLY VOLTAGE, SIMULTANEOUS VARIATION IN VOLTAGE & FREQUENCY THE SUM OF ABSOLUTE PERCENTAGE NOT EXCEEDING 10%.

7. THE MOTOR SHALL BE SUITABLE FOR DIRECT ON LINE STARTING.

$$ TORQUE SWITCH & LIMIT SWITCH SHALL ACT INDEPENDENT OF EACH OTHER. TANDEM OPERATION IS NOT ACCEPTABLE.
## EPOXY PAINT IS RECOMMENDED FOR COASTAL AREAS.
8. In case suppliers standard control voltage for open/close contactor is 110 V AC, the same is acceptable if suitable opto isolation circuit is provided with coupling
relays for 24 V DC command inputs.
9. It shall be possible to operate actuator locally. Lockable remote/local selection shall be provided on actuator.
10. Position indicator shall be provided for 0-100 % travel.
11. Wiring shall be suitable voltage grade copper wire.

PREPARED BY CHECKED BY APPROVED BY VENDOR COMPANY SEAL

NAME ANUJ WADHWA CHETAN MALIK [Link] NAME

SIGNATURE SIGNATURE

DATE 20.06.2013 20.06.2013 20.06.2013 DATE

NOTES* = TO BE FILLED BY MPL (LEAD AGENCY). @= TO BE FILLED BY ES

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OPEN FDBK
FAULT CLOSE

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INSTRUMENT CABLE INTERCONNECTION

AND TERMINATION PHILOSOPHY

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CLAUSE NO.
TECHNICAL REQUIREMENTS

Specification Type-A Type-B Type F & G Type-C cable

Requirements cable cable cable
applied to entire drum) or steel drum.

Length 1000 m + 5% for up to & including 12 pairs

500 m + 5% for above12 pairs

3.00.00 SPECIFICATION OF OPTICAL FIBER CABLES (OFC)

3.01.00 Optic Fiber cable shall be 4/8/12 core, Electrolytically chrome plated corrugated steel taped
(ECCST), fully water blocked with dielectric central member for outdoor/indoor application so
as to prevent any physical damage. The cable shall have multiple single-mode or multi mode
fibers on as required basis so as to avoid the usage of any repeaters. The outer sheath shall
have Flame Retardant, UV resistant properties and are to be identified with the
manufacturer’s name, year of manufacture, progressive automatic sequential on-line marking
of length in meters at every meter on outer sheath.

3.02.00 The cable core shall have suitable characteristics and strengthening for prevention of
damage during pulling viz. Dielectric central member, Loose buffer tube design, 4 fibers per
buffer tube (minimum), Interstices and buffer tubes duly filled with Thixotropic jelly etc. The
cable shall be suitable for a maximum tensile force of 2000 N during installation, and once
installed, a tensile force of 1000 N minimum. The compressive strength of cable shall be
3000 N minimum & crush resistance 4000 N minimum. The operating temperature shall be –
20 Deg. C to 70 Deg.C

3.03.00 All testing of the fiber optic cable being supplied shall be as per the relevant IEC, EIA and
other international standards.

3.04.00 Bidder to ensure that minimum 100% cores are kept as spares in all types of optical fiber
cables.

3.05.00 Cables shall be suitable for laying in conduits, ducts, trenches, racks and under ground
buried installation.

3.06.00 Spliced / Repaired cables are not acceptable.

3.07.00 Penetration of water resistance and impact resistance shall be as per IEC standard.

4.00.00 SPCIFICATION OF CONTROL & POWER SUPPLY CABLES

Refer Electrical sub-sections.

5.00.00 INSTRUMENTATION CABLE INTERCONNECTION AND TERMINATION PHILOSOPHY

The cable interconnection philosophy to be adopted shall be such that extensive grouping of
signals by large scale use of field mounted Group Junction Boxes (JBs) at strategic locations
(where large concentration of signals are available, e.g. valves limit & torque switches,
switchgear) is done and consequently cable with higher number of pairs are extensively
used. The details of termination to be followed are mentioned in the given Table A.

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TABLE A: CABLE TERMINATION TO BE FOLLOWED

Application Type Of Termination Type Of

Cable
FROM (A) TO (B) END A END B

Valves/dampers Marshalling / Plug in Post mount G

drives (Integral Marshalling – cum connector cage clamp
Junction box) Termination Cubicle type.
/ local group JB

Transmitters, Integral Junction box Plug in Cage clamp F,G

Process Actuated of LIE/LIR connector (Rail mount)
switches mounted in type.
LIE/LIR

RTD heads Local junction box Plug in Cage clamp F

connector (Rail mount)
type.

Thermocouple Local junction box / Plug in Cage clamp A, B, C*

CJC box (if connector (Rail mount)
applicable) type.

Other Field Local JB / Group JB Plug in Cage clamp F,G

mounted Instrument connector (Rail mount)
type.

RTD Temperature Plug in Screwed, F

transmitter connector Cage clamp
type

Thermocouple Temperature Plug in Screwed, A, B, C*

transmitter connector Cage clamp
type

Local Junction box, Group JB Cage clamp Cage clamp F,G

Temperature (Rail mount) (Rail mount)
Transmitter, Int. type. type.
Junction box of LIE/
LIR/ MCC/SWGR

Local Junction box, Marshalling / Cage clamp Cage clamp F,G

Temperature Marshalling – cum (Rail mount) (Post
Transmitter, Int. Termination Cubicle type. mounted)
Junction box of LIE/ type.
LIR/ Group JB /
MCC/SWGR

Marshalling cubicle/ Electronic system Cage clamp Plug-in Internal

Termination Cabinet cabinet (Post mounted) connector / wiring
type. other
system as
per Mfr.’s
Standard

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TECHNICAL REQUIREMENTS

Application Type Of Termination Type Of

Cable
FROM (A) TO (B) END A END B

Marshalling/ UCD mounted Cage clamp Plug in F,G

Termination System equipments (Post mounted) connector / (with
Cabinets type. Cage clamp plug-in
type (rail connect
mounted). or at
one
end)

DDCMIS/PLC PC, Printers etc. Plug in Plug in Mfr.’s

cabinets connector connector Standar
d

Notes 1 Normally 10% spare cores shall be provided when the numbers of pairs of
cables are more than four pairs, except for pre-fabricated cables which shall
be as per manufacturer’s standard.

2 For analog signals, individual pair shielding & overall shielding & for Binary
signals, only overall shielding of instrumentation cables shall be provided.

* For high temperature applications only.

3

6.00.00 TERMINAL BLOCKS

6.01.00 All terminal blocks shall be rail mounted/post mounted, cage clamp type with high quality
non-flammable insulating material of melamine suitable for working temperature of 105 deg.
C. The terminal blocks in field mounted junction boxes, temperature transmitters, instrument
enclosures/racks, etc., shall be suitable for cage clamp connections. The terminal blocks in
Control Equipment Room logic/termination/marshalling cubicles shall be suitable for post
mounted cage clamp connection at the field input end. The exact type of terminal blocks to
be provided by the Bidder and the technical details of the same including width etc. shall be
subject to Employer’s approval.

6.02.00 All the terminal blocks shall be provided complete with all required accessories including
assembly rail, locking pin and section, end brackets, partitions, small partitions, transparent
covers, support brackets, distance sleeves, warning label, marking, etc.

6.03.00 The marking on terminal strips shall correspond to the terminal numbering on wiring
diagrams. At least 20% spare unused terminals shall be provided everywhere including local
junction boxes, instrument racks/enclosures, termination/marshalling cabinets, etc. All
terminal blocks shall be numbered for identification and grouped according to the function.
Engraved labels shall be provided on the terminal blocks.

6.04.00 For terminating each process actuated switches, drive actuators, control valves,
Thermocouple, RTD, etc. in Local Junction Boxes, etc, refer Drg no. 0000-999-POI-A-065.

6.05.00 The terminal blocks shall be arranged with at least 100 mm clearance between two sets of
terminal blocks and between terminal blocks and junction box walls.

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TECHNICAL REQUIREMENTS

7.00.00 INTERNAL PANELS/ SYSTEM CABINETS WIRING

7.01.00 Internal panel/cabinet wiring shall be of multi-stranded copper conductor with FRLS PVC
insulation without shield and outer sheath meeting the requirements of VDE 0815.

7.02.00 All internal wires shall be provided with tag and identification nos. etched on tightly fitted
ferules at both ends. All wires directly connected to trip devices shall be distinguished by one
additional red colour ferrule.

7.03.00 All external connection shall be made with one wire per termination point. Wires shall not be
tapped or spliced between terminal points.

7.04.00 All floor slots of desk/panels/cabinets used for cable entrance shall be provided with
removable gasketed gland plates and sealing material. Split type grommets shall be used for
prefabricated cables.

7.05.00 All the special tools as may be required for solder less connections shall be provided by
Bidder.

7.06.00 Wire sizes to be utilised for internal wiring.

(i) Current (4-20 mA), low voltage signals (48V); 0.5 [Link].
Ammeter/Voltmeter circuit, control switches etc.
for electrical system.

(ii) Power supply and internal illumination. [Link]. minimum (shall be as

per load requirement.)

8.00.00 INSTRUMENTATION CABLE INSTALLATION AND ROUTING

8.01.00 All cables assigned to a particular duct/conduit shall be grouped and pulled in simultaneously
using cable grips and suitable lubricants. Cables removed from one duct/conduit shall not be
reused without approval of Employer.

8.02.00 Cables shall be segregated as per IEEE Std.-422. In vertically stacked trays, the higher
voltage cable shall be in higher position and instrumentation cable shall be in bottom tier of
the tray stack. The distance between instrumentation cables and those of other system shall
be as follows:

From 11 kV/6.6 kV/3.3 kV tray system - 914 mm

From 415V tray system - 610 mm

From control cable tray system - 305 mm

8.03.00 Cables shall terminate in the enclosure through cable glands. All cable glands shall be
properly gasketed. Sealing (to prevent ingress of dust entry and propagation of fire) shall be
provided for all floor slots used for cable entrance. Compression cable glands (double for
armoured and single for other cables) shall be provided.

8.04.00 Not in use

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TECHNICAL REQUIREMENTS

8.05.00 The cables emanating from redundant equipment/devices shall be routed through different
paths. The above segregation of cables & wiring for redundant equipments/devices shall be
in accordance with IEEE-Std-422.

9.00.00 CABLE LAYING AND ACCESSORIES

9.01.00 CABLE LAYING

1 Cables shall be laid strictly in line with cable schedule.

2 Identification tags for cables.

Indelible tags to be provided at all terminations, on both sides of wall or floor

crossing, on each conduit/duct/pipe entry/exit, and at every 20 m in cable
trench/tray.

3 Cable tray numbering and marking.

To be provided at every 10m and at each end of cable way & branch connection.

4 No jointing is permissible for Instrumentation cables. For other cables Jointing for
more than 250 Meters run of cable shall be permitted.

5 Buried cable protection

With concrete slabs; Route markers at every 20 Meters along the route & at every
bend.

6 Road Crossings

Cables to pass through buried high density PE pipes encased in PCC. At least 300
mm clearance shall be provided between

- HT power & LT power cables,

- LT power & LT control/instrumentation cables,

Spacing between cables of same voltage grade shall be in accordance with the
derating criteria adopted for cable sizing.

7 Segregation (physical isolation to prevent fire jumping)

a All cable associated with the unit shall be segregated from cables of other
Units.

b Interplant cables of station auxiliaries and unit critical drives shall be

segregated in such a way that not more than half of the drives are lost in case
of single incident of fire.

8 Cable clamping

All cables laid on trays shall be neatly dressed up & suitably clamped/tied to the
tray. For cables in trefoil formation, trefoil clamps shall be provided.

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TECHNICAL REQUIREMENTS

9 Optical fiber cables ( OFCs) :

Outside Building Area - to be laid necessarily inside GI conduit with support from
cable tray/Trestle structure

Inside Building Area – to be laid on separate cable sub-trays

While buried- in separate buried trench approx.1.0 meter depth, to be laid in 2”

rodent proof HDPE conduits covered with sand, brick, laid breadth-wise and soil
along the pipe line route by contractor;

While crossing roads - to be laid in GI/rodent proof HDPE conduits with sand filling
at bottom and sand, soil filling at top with cement concrete;

While crossing canals/river- to be laid in rodent proof HDPE conduits within hume
pipe.

10 Laying of Network Cable (UTP/STP) :

Out side Building Area- to be laid necessarily inside GI conduits with support from
cable tray / Tressle structure.
Inside Building Area- to be laid necessarily inside GI conduits on separate cable
sub-trays.

9.02.00 Bidder shall supply and install all cable accessories and fittings like Light Interface Units,
Surge suppressors, Opto isolators, Interface Converters, Fiber Optic Card Cage, Fiber Optic
Line Driver, Repeater / Modem (for Optical Fiber Cables), cable glands, grommets, lugs,
termination kits etc. on as required basis.
9.03.00 Bidder shall furnish two completely new sets of cable termination kits like Crimping tools,
etc., which are required for maintenance of the system as per the type of termination used.

9.04.00 Cables, which terminate in cabinets of draw out sections shall have sufficient cable coiled in
the bottom of the cabinet to permit full withdrawal of draw out sections without disconnecting
the cables. When prefabricated cables with factory connectors on both ends are longer than
required, the excess cable shall be coiled in the bottom of one or both termination cabinets.

9.05.00 No splices shall be made in conductors for instrument and control circuits except where
required at connections to devices equipped with factory installed pigtails. Such splices shall
be made only in approved splicing boxes of fitting with removable cover. The splices shall be
made with sufficient slack left in the wires to permit withdrawal of the splice from the splicing
box for ease of future disconnection of the splices. All exposed conductor or connector
surfaces shall be covered with a minimum of three half-lapped layers of all-weather vinyl
plastic electrical tape. Taping shall extend a minimum of two cable diameters over the cable
jacket and a similar distance over the other insulation or connections requiring insulation.

9.06.00 The Bidder shall be responsible for proper grounding of all equipment under this package.
Further, proper termination of cable shields shall be verified and the grounding of the same
shall be coordinated so as to achieve grounding of all instrumentation cable shields at same
potential. This shall be completed prior to system tests. All the cables etc. required for
grounding of all equipments supplied under this package are to be supplied by the Bidder.

9.07.00 The Contractor shall take full care while laying / installing cables as recommended by cable
manufacturers regarding pulling tensions and cable bends. Cables damaged in any way
during installation shall be replaced at the expense of the Contractor.

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TECHNICAL REQUIREMENTS

10.00.00 FIELD MOUNTED LOCAL JUNCTION BOXES

(i) No. of ways 12/24/36/48/64/72/96/128 with 20% spares terminals.

(ii) Material & 4mm thick Fiberglass Reinforced Polyester (FRP).

Thickness

(iii) Type Screwed at all four corners for door. Door gasket shall be of
synthetic rubber.

(iv) Mounting clamps Suitable for mounting on walls, columns, structures etc. The
and accessories brackets, bolts, nuts, screws, glands required for erection shall
be of SS, included in Bidders scope of supply.

(v) Type of terminal Rail mounted cage-clamp type suitable for conductor size upto
blocks 2.5 mm2. An M6 earthing stud shall be provided.

(vi) Protection Class IP-55 minimum for indoor & IP-65 minimum for outdoor
applications.

(vii) Grounding To be provided.

(viii) Color 7035

11.00.00 CONDUITS

11.01.00 Conduits shall be generally used for interconnecting cables from field instruments to Local
JB's. All rigid conduits, couplings and elbows shall be hot dipped galvanized rigid mild steel
in accordance with IS: 9537 Part-I (1980) and Part-II (1981). The conduit interior and exterior
surfaces shall have continuous zinc coating with an overcoat of transparent enamel lacker or
zinc chromate. Flexible conduit shall be heat resistant lead coated steel, The temperature
rating of flexible conduit shall be suitable for the following areas:

(i) Mills
(ii) Drum
(iii) Main steam, RH steam
(iv) Air Heaters
(v) Furnace, BFPDTs

For the remaining applications, water leak, fire and rust proof flexible GI conduits shall be
provided.
And for remaining applications, water leak, fire and rust proof flexible GI conduits shall be
provided. The temperature rating of flexible conduit shall be suitable for actual application.

11.02.00 The Bidder shall install conduits according to the general routing as approved by Employer
and shall coordinate conduit locations with other works.

11.03.00 All grounding bushings within all enclosures shall be wired together and connected internally
to the enclosure grounding lug or grounding bus with 8 AWG bare copper conductor. Conduit
runs to individually mounted equipment shall be grounded to the Employer's cable tray
grounding conductor with 12 AEG bare copper conductor. All grounding bushings, clamps
and connectors shall be subject to approval of the Employer.

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11.04.00 All rigid conduit fittings shall conform to the requirements of IS: 2667, 1976. Galvanized steel
fitting shall be used with steel conduit. All flexible conduit fittings shall be liquid tight,
galvanized steel. The end fittings shall be compatible with the flexible conduit supplied.

11.05.00 All individually mounted equipment and devices shall be connected to the supply conduit,
using not more than one meter of flexible conduit adjacent to the equipment or device.
Flexible conduit shall be installed in all conduit runs, which are supported by both building
steel and structures subject to vibration or thermal expansion. This shall include locations
where conduit supported by building steel enters or becomes supported by the turbine
generator foundation and where conduit supported by building steel or foundation becomes
supported by steam generator framing.

11.06.00 Special areas, such as control rooms in which external noise is to be minimized, shall have
flexible conduit in conduit runs where the runs cross from the main building framing to the
control room framing.

11.07.00 Conduit supports shall be furnished and installed in accordance with these specifications.
Support material shall comply with the following requirements.

i) Hanger rods shall be 12 mm diameter galvanized threaded steel rods.

ii) Single conduit supports shall be one-hole cast metal straps and clamp backs unless
other types are acceptable to the Employer. Multiple conduit bank supports shall be
constructed of special galvanized support channels with associated conduit clips.

11.08.00 Conduit sealing, explosion proof, dust proof and other types of special fittings shall be
provided as required by these specifications and shall be consistent with the area and
equipment with which they are installed. Fittings installed outdoors and in damp locations
shall be sealed and gasketed. Hazardous area fittings and conduits sealing shall conform to
NEC requirements for the area classification.

11.09.00 Contractor shall provide double locknuts on all conduit terminations not provided with
threaded hubs and couplings. Water tight conduit unions and rain tight conduit hubs shall be
utilized for all the application which shall be exposed to weather. Moisture pockets shall be
eliminated from conduits.

11.10.00 Conduits shall be securely fastened to all boxes and cabinets.

12.00.00 CABLE SUB-TRAY & SUPPORT

12.01.00 The cable sub-trays and the supporting system, to be generally used between Local/Group
JBs and the main cable trays and the same shall be furnished and installed by the
Contractor. It is the assembly of sections and associated fittings forming a rigid structural
system used to support the cable from the equipment or instrument enclosure upto the main
cable trays (trunk route).

12.02.00 The covers on the cable sub-trays shall be used for protection of cables in areas where
damage may occur from falling objects, welding spark, corrosive environment, etc. & shall be
electrically continuous and solidly grounded. The cable trays shall not have sharp edges,
burrs or projections injurious to the insulation or outer sheath of the cables.

12.03.00 The supporting arrangement of cable tray system shall be able to withstand the weight of the
cable and cable tray system. The supporting interval shall not be more than the
recommended span for the above loading for the type of cable tray selected. The tray shall
not overhang by more than one meter from the support at the dead end. As far as practicable

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TECHNICAL REQUIREMENTS

the cable sub-tray system shall be supported from one side only, in order to facilitate
installation and maintenance of cables.

12.04.00 The Bidder shall furnish and install the estimated quantities and sizes of sub trays/troughs
including all required fittings and adaptors on as required basis.

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5.00.00 SHOP AND SITE TESTS

5.01.00 General Requirements

5.01.01 The equipment and work performed as per this Sub-section shall be subject to shop and site
test as per requirements of Sub-section-Q (Quality Assurance & Inspection) other applicable
clauses of this Sub-section and Employer approved quality assurance plan.

5.01.02 Hydrostatic and pneumatic tests shall be performed on all pipes, tubing and systems and
shall conform to ANSI B31.1.

5.02.00 Hydrostatic Testing

5.02.01 All instrument piping/ tubing shall be hydrostatically tested upon completion of erection. The
test pressure shall be 1.5 times the maximum process pressure. The test shall be performed
either with the testing of associated process piping or without the associated process piping
(by closing the root valve). In both the cases the instrument shall be isolated by closing the
shut-off valve.

5.03.00 Air Testing

5.03.01 All air headers & branch pipes shall be air tested by pressure decay method as per ANSI
B31.1. Flexible hoses and short signal tubing shall be tested at normal pressure for leakage.
Long signal tubing shall be tested by charging each tube with air at 2 kg/ sq. cm. through a
bubbler sight glass. The boiler draft and vacuum piping shall be air tested by the same
method as long signal tubing.

6.00.00 LOCAL INSTRUMENT ENCLOSURE AND RACKS

Transmitters, switches, devices ,temperature transmitters etc. (except for all fuel oil
applications which shall be mounted close to be tapping points) mounted in the field shall
be suitably grouped together and mounted (i) local instruments enclosure in case of open
areas of the plant like boiler area, etc. and (ii) In local instrument racks in case of covered
areas. Gauges are to be mounted on a channel or a frame or a rack (Gauges shall not be
mounted directly on process pipe). These local instrument enclosures and racks shall be
furnished as per the actual requirements finalized during detailed engineering stage. The
exact grouping of instruments in a particular instrument enclosure/instrument rack shall be
as finalized during detailed engineering stage subject to Employer's approval.

For mounting of PT/DPT/LT/FT, LIEs / LIRs shall be of three types depending on the
number of transmitters located in it as elaborated in the typical GA of the LIE/LIR, drawing
no. 0000-999-POI-A-064 (Sh Nos. 1 to 3 of 5).

These dimensions and number of instruments indicated therein are only indicative and the
exact dimensions along with the number of instruments shall be as finalized during detailed
engineering stage without any price repercussions.

The internal layout shall be such that the impulse piping/ blow down lines are accessible
from back side of the enclosure / rack and the transmitters etc. are accessible from front
side for easy maintenance. Bulkheads, especially designed to provide isolation from
process line vibration shall be installed on instrument enclosures/racks to meet the process
sensing line connection requirement.

Vibration dampeners shall be installed for each enclosure / rack.

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The enclosures shall be constructed of 3 mm sheet plate and shall be of modular

construction with one or more modules and two end assemblies bolted together to form an
enclosure. Double inter locking doors shall be provided. The doors shall be the three-point
locking type constructed of not less than 1.6 mm thick steel. Doors shall have concealed
quick removal type pinned hinges and locking handles. Door locks shall accept the same
key.
Gaskets shall be used between all mating sections to achieve protection class of IP-55.

The instrument racks shall be free standing type constructed of suitable 5 mm thick channel
frame of steel and shall be provided with a canopy to protect the equipment mounted in
racks from falling objects, water etc. The canopy shall not be less than 3 mm thick steel,
and extended beyond the ends of the rack. Bulk heads, especially designed to provide
isolation from process line vibration shall be provided. Exact fabrication details shall be as
finalized during detailed engineering stage. The junction box for racks also shall conform to
IP 55 protection class.

Enclosures/racks shall be reinforced as required to ensure true surface and to provide

adequate support for instruments and equipment mounted therein. Centre posts or any
member which would reduce access shall not be provided.

Each transmitter enclosure housing instruments requiring purge air for continuous air
purging, shall be provided with common purge air header, redundant air filter regulators of
sufficient capacity, required pressure gauges, valves, fittings, SS tubing and individual
purge meters for each purge line etc. as required and indicated in Instrument Installation
drawings enclosed herewith.
A 15 mm NB service air header shall be furnished in each instrument enclosure housing air
& flue gas and coal mill instruments. The header shall be furnished complete with a
pressure regulating valve, pressure gauge, and quick disconnect connections. A hose for
connecting each header to the draft instrument line four-way valves shall be furnished. The
hose shall be self-storing nylon tubing having a burst pressure of 15 kg/sq. cm. The size of
the hose shall be 1/2" minimum. The service air header shall originate at a bulkhead
penetration or fitting located on one of the bulkhead plates.

The contractor shall prepare the piping drawings and the general arrangement layout
drawings for each of the enclosures and racks. Special attention shall be given in the piping
layout to avoid air traps in liquid filled piping or water pockets in piping intended to be dry.
Drawings shall indicate the arrangement of all equipment, piping, valves and fittings within,
the enclosure/racks and shall be subject to Employer's approval.

All liquid filled blow down lines, except those measuring vacuum shall be connected to a
two inch header which is extended through one end of the enclosure and turned downward
for directing the blow down into a drain. The material of the blow down header shall be
carbon steel as per ASTM A 106 Gr. C.

The Contractor shall submit to the Employer with his proposal a copy of his welding
procedure specification together with proof of his compliance with the latest applicable
welding ANSI code. Prior to any welding being performed, the Contractor shall submit the
qualifications of the craftsmen who will perform the work.

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CABLING & INST. INSTALLATION

DIAGRAM

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KARIMNAGAR TELANGANA STPP PHASE I- ( 2 X 800 MW) SG PKG MILL REJECT SYSTEM (PNEUMATIC TYPE) TECHNICAL SPECIFICATION NO PE-TS-424-160-A001

329 of 476
KARIMNAGAR TELANGANA STPP PHASE I- ( 2 X 800 MW) SG PKG MILL REJECT SYSTEM (PNEUMATIC TYPE) TECHNICAL SPECIFICATION NO PE-TS-424-160-A001

330 of 476
KARIMNAGAR TELANGANA STPP PHASE I- ( 2 X 800 MW) SG PKG MILL REJECT SYSTEM (PNEUMATIC TYPE) TECHNICAL SPECIFICATION NO PE-TS-424-160-A001

331 of 476
KARIMNAGAR TELANGANA STPP PHASE I- ( 2 X 800 MW) SG PKG MILL REJECT SYSTEM (PNEUMATIC TYPE) TECHNICAL SPECIFICATION NO PE-TS-424-160-A001

332 of 476