Section VI D

J P MUKHERJI & ASSOCIATES PVT LTD
Tendaho Sugar Project
TECHNICAL SPECIFICATIONS
Section-VI-D
Page - 1 / 88
BID DOCUMENT FOR

POWER GENERATION PLANT
TABLE OF CLAUSES
2400
1.1
1.2
1.3
1.4
1.5
1.6
2401-1
1.1
1.2
1.3
1.4
1.4.1
1.4.2
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.11.1
1.11.2
1.11.3
1.12
1.12.1
1.12.2
1.12.3
1.12.4
1.12.5
1.12.6
1.13
1.14
1.15
2401-2
2.1
2401-3
3.1
3.2
3.2.1
3.2.2
3.2.3
3.2.4
3.2.5
3.2.6
3.2.7
3.2.8
POWER GENERATION PLANT ..................................................................... 2

General........................................................................................................... 2
Codes and Standards...................................................................................... 2
Performance test ............................................................................................. 2
Work schedule................................................................................................. 2
Conditions of service ....................................................................................... 2
Design basis .................................................................................................... 2
STEAM TURBINE ........................................................................................... 2
Turbine Casing ................................................................................................ 2
Turbine Rotor .................................................................................................. 2
Combined stop and emergency valve (CSEV) and Control Valves................. 2
Safety Valves and Quick Acting Non Return Valves ....................................... 2
Quick Acting Non Return Valves ..................................................................... 2
Safety Valves .................................................................................................. 2
Gland Sealing System ..................................................................................... 2
Bearing ........................................................................................................... 2
Barring Gear ................................................................................................... 2
Base Plate ....................................................................................................... 2
Governing System ........................................................................................... 2
Set Lubrication Oil System and Turbine Control Oil System ........................... 2
Condensing Plant ............................................................................................ 2
Turbine condenser .......................................................................................... 2
Vacuum package............................................................................................ 2
Condensate Extraction Pump.......................................................................... 2
Instrumentation............................................................................................... 2
Lot Turbine Control and Indicating Instrumentation........................................ 2
Lot Turbine safety and protection system....................................................... 2
Lot Local Instrumentation Panel with display in Control Room ...................... 2
Lot Recording and Integration ......................................................................... 2
Lot Dedicated Independent Micro Processor Based System .......................... 2
System Integration between Turbine Control Systems and plant DCS .......... 2
Lot Thermal Insulation and Lagging ................................................................ 2
Motor List......................................................................................................... 2
Pump List ........................................................................................................ 2
SPEED REDUCING GEAR BOX .................................................................... 2
General............................................................................................................ 2
ALTERNATOR AND EXCITER ....................................................................... 2
General............................................................................................................ 2
Alternator Parameters ..................................................................................... 2
Earth Terminals ............................................................................................... 2
Exciter ............................................................................................................ 2
Neutral Earthing .............................................................................................. 2
Limits of Vibration Severity .............................................................................. 2
Over speed ...................................................................................................... 2
Power Factor ................................................................................................... 2
Rating Plate Details ......................................................................................... 2
Base Plate ....................................................................................................... 2

Section-VI-D
Page - 2 / 88
BID DOCUMENT FOR

TABLE OF CLAUSES
3.2.9
3.2.10
3.2.11
3.3
3.3.1
3.3.2
3.3.3
3.3.4
3.3.5
3.3.6
3.3.7
3.3.8
3.3.9
3.3.10
3.4
3.4.1
3.4.2
3.4.3
3.4.4
3.4.5
3.5
3.5.1
3.5.2
3.5.3
3.5.4
3.5.5
3.5.6
3.5.7
3.5.8
3.5.9
3.6
3.6.1
3.6.2
3.6.3
3.6.4
3.6.5
3.6.6
3.6.7
3.6.8
3.6.9
3.6.10
3.7
3.7.1
3.7.2
3.7.3
3.7.4
3.7.5
Bearing ............................................................................................................ 2
Enclosure and Ventilation................................................................................ 2
Routine Tests .................................................................................................. 2
Auxiliary Panels ............................................................................................... 2
Scope .............................................................................................................. 2
Codes & Standards ......................................................................................... 2
Sheet Metal Work ............................................................................................ 2
Painting ........................................................................................................... 2
Constructional Features .................................................................................. 2
Control, Annunciation & Metering panel .......................................................... 2
Relay and Protection Panel ............................................................................. 2
Excitation- AVR Panel ..................................................................................... 2
Neutral Grounding Resistance Panel .............................................................. 2
Synchronising Panel........................................................................................ 2
Alternator Breaker Panel ................................................................................. 2
Constructional Features .................................................................................. 2
Painting ........................................................................................................... 2
Safety Interlocks .............................................................................................. 2
Main Busbars .................................................................................................. 2
Circuit Breakers ............................................................................................... 2
General............................................................................................................ 2
Operating Mechanism ..................................................................................... 2
Spring Operated Mechanism........................................................................... 2
Operating Mechanism Control......................................................................... 2
Earthing ........................................................................................................... 2
Cubicle Module Accessories and Wiring ......................................................... 2
Cable Termination Compartment .................................................................... 2
Instrument Transformers ................................................................................. 2
Miscellaneous Accessories ............................................................................. 2
One 110 V Battery Charger and DC DB ....................................................... 2
Scope .............................................................................................................. 2
Code & Standards ........................................................................................... 2
Type ................................................................................................................ 2
Rating .............................................................................................................. 2
Charger Cubicle & Wiring ................................................................................ 2
Accessories ..................................................................................................... 2
Indication & Protection .................................................................................... 2
Following Protections shall be provided .......................................................... 2
Performance.................................................................................................... 2
Tests................................................................................................................ 2
Set 110 V, 200 AH Battery .............................................................................. 2
Scope .............................................................................................................. 2
Construction .................................................................................................... 2
Battery Racks .................................................................................................. 2
Ventilation........................................................................................................ 2

Section-VI-D
Page - 3 / 88
BID DOCUMENT FOR

TABLE OF CLAUSES
3.7.6
3.7.7
3.7.8
3.7.9
3.7.10
3.8
3.8.1
3.8.2
3.8.3
3.9
3.9.1
3.9.2
3.9.3
3.10
3.11
3.12
3.13
3.14
2104
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.12
1.13
1.14
1.15
1.16
1.17
1.18
1.19
1300
1301
1302
2421
1.1
1.2
1828
Capacity .......................................................................................................... 2
Charging.......................................................................................................... 2
Life................................................................................................................... 2
Identification .................................................................................................... 2
Tests................................................................................................................ 2
Lot Electrical Motors and Panels for TA, EOT Crane, Cooling Tower and
Compressor Comprising of Motors, Motor Control Centre (MCC), HT/LT
Cables, Earthing, Drives, PB Station etc. ........................................................ 2
General............................................................................................................ 2
Induction Motors .............................................................................................. 2
Low Voltage (LV) Panels ................................................................................. 2
Technical Specifications For LV Cables .......................................................... 2
Scope .............................................................................................................. 2
Construction .................................................................................................... 2
Tests................................................................................................................ 2
Technical Specifications for Earthing Equipment ............................................ 2
Illumination ...................................................................................................... 2
Commissioning Spares.................................................................................... 2
Spares ............................................................................................................. 2
Special tools and tackles ................................................................................. 2
H.P/L.P STEAM PIPING ................................................................................. 2
66 bar (a) Pressure Steam .............................................................................. 2
8 bar (a) Pressure Steam ................................................................................ 2
2.6 bar (a) Pressure Steam ............................................................................. 2
0.14 bar (a) Pressure Steam ........................................................................... 2
Piping, valves and fittings ................................................................................ 2
Materials ......................................................................................................... 2
Hangers and supports ..................................................................................... 2
Valves............................................................................................................. 2
Construction .................................................................................................... 2
Preparation for site assembly .......................................................................... 2
Flanges and Fasteners.................................................................................... 2
Steam Traps .................................................................................................... 2
Gaskets ........................................................................................................... 2
Pipe testing...................................................................................................... 2
Pipe Quantities ................................................................................................ 2
Material of Construction .................................................................................. 2
Condensate Piping ......................................................................................... 2
Lot Thermal Insulation and Lagging ................................................................ 2
Drain Water ..................................................................................................... 2
STEAM DISTRIBUTION PLANT .................................................................... 2
De-superheater for 8 bar (a) steam 3 Nos.................................................... 2
De-superheater for 2.6 bar (a) steam 3 Nos................................................. 2
EOT CRANE FOR CO-GENERATION POWER HOUSE ............................... 2
Specifications .................................................................................................. 2
Spares ............................................................................................................. 2
COOLING TOWERS AND AUXILIARIES....................................................... 2

Section-VI-D
Page - 4 / 88
BID DOCUMENT FOR

TABLE OF CLAUSES
1.1
1.2
1.3
1.4
1.5
1.5.1
1.5.2.
1.5.3.
1.5.4.
1.5.5.
1.5.6.
1.6
1.7
1.8
1.9
1.9.1
1.9.2
1.9.3
1.9.4
1.9.5
1.10
1.11
1.12
1.13
1829
1.0
1.1
1.2
1.3
1.4
1.5
2423
1.1
1.2
1.3
1.4.1
1.4.1
1.4.2
1.4.3
1.4.4
1.4.5
1.4.6
1.4.7
1.4.8
1.4.9
1.4.10
1.4.11
Design requirement ......................................................................................... 2

Maintenance requirement................................................................................ 2
Electrical scope of work requirements............................................................. 2
Features of construction .................................................................................. 2
Mechanical equipment .................................................................................... 2
Fans ................................................................................................................ 2
Fan Drives ....................................................................................................... 2
Prime Mover .................................................................................................... 2
Accessories ..................................................................................................... 2
Ladder ............................................................................................................. 2
Distribution Basin Cover .................................................................................. 2
RCC support structure and basin .................................................................... 2
Piping, valves and specialties ......................................................................... 2
Materials of construction.................................................................................. 2
Tests and Inspection ....................................................................................... 2
Performance Test............................................................................................ 2
Visual Inspection ............................................................................................. 2
Material Test Certificates................................................................................. 2
Welding Test ................................................................................................... 2
Painting and Protections ................................................................................. 2
Motor List......................................................................................................... 2
Pump List ........................................................................................................ 2
Electrical works ............................................................................................... 2
Scope of erection and commissioning............................................................. 2
COOLING WATER PUMPS ............................................................................ 2
Scope of supply ............................................................................................... 2
Circulating water pumps .................................................................................. 2
Auxiliary cooling water pumps ......................................................................... 2
Make up water pumps ..................................................................................... 2
Cooling Water Piping....................................................................................... 2
Design criteria for piping.................................................................................. 2
COMPRESSED AIR SYSTEM FOR TURBO ALTERNATOR UNITS ............. 2
Scope of supply ............................................................................................... 2
Codes & Standards ......................................................................................... 2
Design Requirements ...................................................................................... 2
Specifications .................................................................................................. 2
Air Compressors.............................................................................................. 2
Crosshead ....................................................................................................... 2
Valve assemblies ............................................................................................ 2
Bearings .......................................................................................................... 2
Intercooler ....................................................................................................... 2
Suction Filter ................................................................................................... 2
Controls ........................................................................................................... 2
After cooler/Moisture Separator....................................................................... 2
Electrical.......................................................................................................... 2
Air Receiver ..................................................................................................... 2
Mountings ........................................................................................................ 2

Section-VI-D
Page - 5 / 88
BID DOCUMENT FOR

TABLE OF CLAUSES
1.4.12
1.4.13
1.4.14
Inspection and Tests ....................................................................................... 2

Compressed air piping / tubing........................................................................ 2
Spares ............................................................................................................. 2

Section - VI-D
Page - 6 / 88
BID DOCUMENT FOR

2400
1.1
General
This specification is intended to cover the design, manufacture, supply, erection,
testing and commissioning of three (3) Nos. of turbo alternator units with gear box,
surface steam condenser and all other auxiliaries, with a nominal power output of 40
MW (or best at given steam flow parameters) at the alternator terminals at the site
conditions with 45 0C ambient (maximum temperature) and at 0.8 PF, 11 kV and 50
Hz. The units will be operated in parallel with the National Electricity Grid. The steam
turbine shall be a double extraction cum condensing type with uncontrolled extraction
at 8 bar (a) and controlled extraction at 2.6 bar (a).
This specification is also intended to cover the design, manufacture, delivery,
erection, testing and commissioning of H.P/M.P/L.P steam piping, Compressors,
60/20 ton EOT crane, Cooling tower with pumps.
Supplies and services shall be rendered in conformity with proven engineering
principles, taking into account the current state of the art technology. The
requirements of the bid must be fulfilled in its entirety.
The supplies and services within the scope shall be rendered inclusive of all
appliances and interconnecting arrangements with other supplies necessary for
installation of all accessories for satisfactory operation and maintenance.
The scope of supply and services shall include all necessary work and supply of
equipment and material whether mentioned in these specifications or not, but which
are necessary for the satisfactory, reliable and safe operation and maintenance and
required for achieving guaranteed performance of the plant.
Any equipment, device or material even if not included in the original bid but found
necessary for the safe and satisfactory functioning of the units under the bid shall be
supplied, erected and commissioned by the Bidder at no extra cost to the Employer
as if such equipment, material or work were originally specified and formed part of
the scope of work.
Schedule of equipment included in the scope of supply are listed hereunder. Each
equipment bears identification Equipment code number, which must be used by the
Bidder in his entire document.
Equipment
Number
Quantity
Description
2401-1
Three
Three
Lot
Three
Steam turbine
Governing system
Lubrication oil system and turbine control oil system
Emergency supply DC system

Section - VI-D
Page - 7 / 88
BID DOCUMENT FOR

Equipment
Number
Quantity
Description
Three
Lot
Lot
Condensing system
Instrumentation and controls for turbine
Thermal insulation and lagging
2401-2
Three
Speed Reduction Gear box
2401-3
Three
Alternator and auxiliaries

AVR Panel.
NGR panel.
LAPT and SURGE Capacitor panel
Relay protection and metering panel
Battery , battery charger and DCDB
Synchronization panel.
11 KV TA Breaker Panel.
HV cable and termination kits
LV cable and termination kits
Power Cum Motor Centre (PMCC)
Motor Control Centre (MCC)
APFC panels
AC Distribution boards
MS Structural works
2104
1300
Lot
Six
Piping- HP/MP/ LP
De-Superheaters.
2421
One
Power house crane with Auxiliaries.
1828 &
1829
2423
Cooling Tower, Pumps and Auxiliaries.

Seven
Four
Four
Two
Cooling tower cells

Main water pumps.
Auxiliary water pumps.
Make up water pumps.
Two
Lot
Air Compressors with Dryers and Receiver.

Miscellaneous.
Price of spares for 2 years normal operation shall be quoted separately along with list
of spares and unit rate for spare parts included.
For location of the Power Generation Plant, following drawings are enclosed :
(a)
General layout of Plant and Machinery for Milling Option, Drawing No. 4LO1926

Section - VI-D
Page - 8 / 88
BID DOCUMENT FOR

(b)
(c)
General layout of Plant and Machinery for Diffuser Option, Drawing No. 4LO1927
General layout of Power House, Drawing No. 2LO-2006.
List of all the drawings along with above three is enclosed under Section-VI-J.
1.2
Codes and Standards

The design, manufacture, testing and performance of the Turbo alternator sets and
accessories, H.P/L.P steam piping, Compressors, 60/20 ton EOT crane, and Cooling
tower with pumps shall comply with the requirements of applicable
Indian/British/American/German/French Standards, and those standards specified
there in, so far as they apply. The Bidder should specifically mention relevant codes.
All equipment, systems, hardware and services covered under this specification shall
comply with all currently applicable statutes, regulations and safety codes in the
locality where the equipment will be installed.
The following specific standards are applicable for the major equipment and system
in the package.
Turbine:
IEC Recommendation Publication No. 45 API Standard 611 or Equivalent
Condenser :
H.E.I. Standards for steam surface condensers or Equivalent
TEMA or Equivalent
ASME Section III or Equivalent
Lube and Control Oil System:
API Standard 614 or Equivalent
Piping:
ANSI B 31.1 or Equivalent
Any other established national and international standards equal to or superior to the
above may also be used.
The Bidder shall furnish English translation of all standards for which his equipment
and systems offered are conforming to.

Section - VI-D
Page - 9 / 88
BID DOCUMENT FOR

In the event of any conflict between the codes and standards referred to and the
requirements to these specifications the more stringent of the two shall govern.
1.3
Performance test
After completion of erection, the plant shall be trial operated and performance tested
as detailed in the relevant sections of the specifications. The Bidder may note that
the performance parameters guaranteed shall be considered in the bid evaluation.
The Bidder shall furnish these and other parameters as required in the performance
data sheets.
1.4
Work schedule
The earliest feasible schedule to be given by the bidder, along with the bar chart
indicating major activities for supply, erection and commissioning. The quality
assurance plan for the major equipment shall be furnished.
1.5
1.6
Conditions of service
a.
All the three steam turbine sets will be installed in a same power house.
b.
The turbine control shall be located in the control room whereas important
indicating instruments shall be provided near by the turbine in the local gauge
board and local panel, in addition to the control room instruments. Emergency
stop arrangements shall be provided in the local panel.
Design basis
The turbo alternator and the auxiliary equipment covered under this specification
shall be designed to achieve maximum power generation as per normal steam flow
rates from the double extraction cum condensing set.
It is proposed that the plant will generate a nominal power output of 40 MWe at the
alternator terminals at 11 kV.
Note: All power generation figures in this bid document are indicative. Bidder can
give his best steam rates, higher than those indicated.
Part of this generated power will be fed to the sugar plant, irrigation pump house and
the rest will be exported to the National Electricity Grid, after stepping up the voltage
to 230 kV and transporting the power through transmission lines to the nearby
Ethiopian Electricity and Power Corporation (EEPCO) grid. The extractions from the
turbine provides the sources for the medium and low pressure steam for the use in
the sugar plant and de-aerator.

Section - VI-D
Page - 10 / 88
BID DOCUMENT FOR

The steam will be available at the turbines isolation valve at 64 bar (a) and 500 + 0, 5 0C. The project viability depends on the continuous, uninterrupted running of the
plant, it is essential that the equipment are designed for the maximum availability.
The turbo alternator sets shall be designed taking into consideration all possible
electrical parameters affecting the choice of the machine, assuring stable and reliable
operation in a rural network. The selection, if necessary, shall be based on the
complete study of the electricity system, including transient stability study, short
circuit study, load flow and reactive power short fall study etc. For this bid, the Bidder
shall offer his standard micro processor based controls and instrumentation system
with panels etc for the start up, shut down and operation with all standard features.
Operating conditions for boiler, which shall supply steam to the turbo-alternator, shall
be generating steam at 66 bar (a) pressure and 5100C temperature with 150 t/h MCR
capacity each. After allowing for piping losses, the steam conditions at turbine stop
valves shall be 64 bar (a) pressure, 500 + 0, -5 0C temperature.
The sugar plant shall be requiring steam for process at 8 bar (a) and 2.6 bar (a). For
this purpose, the turbo-alternators shall be double extraction condensing type. The
condenser pressure selected is 0.14 bar (a). Extraction at 8 bar (a) shall be
uncontrolled whereas the same at 2.6 bar (a) shall be controlled.
The turbo-alternators should be suitable to meet demands imposed during different
operating modes of the Co-generation Power Plant (CPP). The modes are classified
in 3 different categories as listed below.
Mode A:
During season sugar factory will be in operation and co-generation

plant and grid are running in parallel. This is the mode for normal
operation. Factory shall be operating in this mode for about 5397.8 hrs
in a year.
Mode B:
When sugar factory is under breakdown, but turbo-alternator is

running to export power to grid. Factory shall be operating in this
mode for about 952.6 hrs in a year.
Mode C:
When sugar factory is operating but grid is off due to some reason.
Turbo-alternator shall be running at reduced load during this mode.
Factory shall be operating in this mode for about 110.2 hrs in a year.
For the power generation plant two options are considered for operating inline with
two options of Sugar factory requirement I.e. One for Milling and other for Diffuser.
The installed capacity of TA sets for both the options are same, but steam inlet and
extraction and power generation figures are varying for both the cases.
Steam supply to each turbo-alternators and amount of extraction steam required by
sugar factory for both options during above modes is presented in enclosed flow
diagram.

Section - VI-D
Page - 11 / 88
BID DOCUMENT FOR

Note: All power generation figures in below table are indicative. Bidder can
give his best steam rates, higher than those indicated.
Option -1
Sr.
No.
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
- For Milling,
Option -2
Option -1
Description
Unit
- For Diffuser
Mode A
Mode B
64
500 + 0,
-5
205
64
64
500 + 0, 500 + 0,
-5
-5
75
159
t/h
Process-sugar factory
t/h
Steam jet ejector
0
Steam temperature
C
Second extraction steam @
2.6 bar (a) pressure
26..5
*
*
15
*
*
0.00
*
*
Steam temperature
Power available at alternator
terminal
Condenser
operating
pressure
Condensing cooling water
inlet temperature
Condenser sizing
Condenser
outlet
water
temperature
Alternator
- Generation voltage
- Power factor,
- Parallel operation
with grid
- Grid voltage
- System frequency
Ambient conditions
Atmospheric
conditions
prevalent in the plant
Duty requirements
t/h
0
C
MW
157.5
*
*
94
*
*
53.5
*
*
bar (a)
0.14
0.14
0.14
32.0
32.0
32.0
kV
11.0
0.8 lagging
Required with grid
kV
230
50 5 %
As specified in bid document
Dusty
Altitude 350 m
Continuous 8000 hrs in a year
Inlet live steam - For Each

Steam Turbine
bar (a)
- pressure
0
- temperature
C
- flow
t/h
First uncontrolled extraction
steam @ 8.0 bar (a)
pressure
C
C
Mode C

Section - VI-D
Page - 12 / 88
BID DOCUMENT FOR

Sr.
No.
9.0
10.0
11.0
12.0
Description
Unit
Mode A
The economical steam rate

required at percentage load
at 80 % and 100 %
Vibrations
The maximum noise level at
1.0 m distance for any
equipment
from
the
equipment shall be equal to
or less than
The minimum continuous
load at which the turboalternator is expected to
operate as a percentage of
the MCR load
mm/sec
[db(A)]
Below 2.8
85
15
Mode B
Mode C
* - Information to be submitted by the Bidder

Design criteria for steam flows are indicated below :
Bidder can give his best steam rates, higher than those indicated below.
-
Turbo-alternators shall be designed for maximum inlet steam flow of 205 t/h
at 65 bar (a) and 510 + 5 0C temperatures.
Uncontrolled extraction at 8 bar (a) steam at extraction conditions of

temperature and pressure to be designed for maximum steam flow of 26.5 t/h.
Controlled extraction at 2.6 bar (a) steam at extraction conditions of

temperature and pressure to be designed for maximum steam flow of 158 t/h.
Condenser shall be designed for maximum steam flow of 55 t/h and pressure
of 0.14 bar (a)
Guaranteed performance shall be for conditions during MODE A

Section - VI-D
Page - 13 / 88
BID DOCUMENT FOR

Option - 2
Sr.
No.
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
Description
Unit
Inlet live steam - For Each Steam

Turbine
bar (a)
- pressure
0
- temperature
C
- flow
t/h
First uncontrolled extraction steam
@ 8.0 bar (a) pressure
Mode A
Mode B
64
64
500 + 0, 500 + 0,
-5
-5
166.87
214
Mode C
64
500 + 0,
-5
69.69
t/h
t/h
Steam jet ejector
0
Steam temperature
C
Second extraction steam @ 2.6 bar
(a) pressure
27.8
*
*
15.75
*
*
0.00
*
*
t/h
0
Steam temperature
C
Power available at alternator MW
terminal
Condenser operating pressure
bar (a)
Condensing cooling water inlet 0C
temperature
Condenser sizing
Condenser outlet water temperature 0C
163.45
*
*
103.16
*
*
47.16
*
*
0.14
32.0
0.14
32.0
0.14
32.0
Alternator
- Generation voltage
- Power factor,
- Parallel operation with grid
- Grid voltage
- System frequency
Ambient conditions
Atmospheric conditions prevalent in
the plant
Duty requirements
The economical steam rate required
at percentage load at 80 % and 100
%
Vibrations
kV
11.0
0.8 lagging
Required with grid
230
50 5 %
As specified in bid document
Dusty
Altitude 350 m
Continuous 8000 hrs in a year
*
mm/sec
Below 2.8
kV

Section - VI-D
Page - 14 / 88
BID DOCUMENT FOR

Sr.
No.
11.0
12.0
Description
Unit
The maximum noise level at 1.0 m [db(A)]

distance for any equipment from the
equipment shall be equal to or less
than
The minimum continuous load at %
which
the
turbo-alternator
is
expected
to
operate
as
a
percentage of the MCR load
Mode A
Mode B
Mode C
85
15
* - Information to be submitted by the Bidder

Design criteria for steam flows are indicated below :
Bidder can give his best steam rates, higher than those indicated below.
-
Turbo-alternators shall be designed for maximum inlet steam flow of 214 t/h
at 64 bar (a) and 500 + 0, -5 0C temperatures.
Uncontrolled extraction at 8 bar (a) steam at extraction conditions of

Controlled extraction at 2.6 bar (a) steam at extraction conditions of

Condenser shall be designed for maximum steam flow of 55 t/h and pressure
of 0.14 bar (a)
Guaranteed performance shall be for conditions during MODE A
For both option-1 and option -2, 40 MWe is nominal rating of the each turboalternator set. Bidder shall inform and guarantee Maximum Continuous Rating (MCR)
at alternator terminals based on above conditions.
The turbo-alternator sets shall be part of a bagasse based co-generation plant in
sugar factory where surplus power generated shall be exported to national Grid,
hence maximum power generation shall be one of the main criteria for selection.
The turbo-alternator shall be suitable for synchronizing with grid, diesel engine and
another turbo-alternator in future.
The turbine shall be double extraction machine. The design shall also ensure highest
possible efficiency, reliability and availability. Inlet steam flow to turbine shall be
through a main stop valve and control valve and three or more control valve.

Section - VI-D
Page - 15 / 88
BID DOCUMENT FOR

Governing system shall be of high accuracy electronic Woodward 505 E or
equivalent. The governors shall control speed, load, and steam pressure. The
governor shall be provided with DSLC so that all three sets will run in parallel load
sharing mode during islanding.
Condensate from turbine condenser shall be used as boiler feed water. Hence this
water shall be used as cooling water for gland steam condenser. Also steam
emanating from condenser steam jet ejector shall be used to further raise the
temperature of condensate from turbine. The condensate from gland steam
condenser and ejector steam shall be piped back to hot well of turbine condenser.
The increase in the temperature of the condensate shall be advantageous for boiler
operation. The condensate line shall be up to hot well of boiler.
The Bidder shall submit the performance curve and correction curves for variation in
inlet steam pressure and temperature.
Quality assurance and control plan shall be submitted, listing various stages and
steps of quality control.
The turbo-alternator is to be operated through fully automatic and remote controls.
These controls shall be through Instrumentation provided by the Bidder, hooked up
with Distributed Control System (DCS), which shall be provided by the Employer.
Automatic and remote controlled operations shall be performed by the
instrumentation supplied by the Bidder as well as through Employers Distributed
Control System. All valves and dampers coming under the instrumentation control,
shall be motorised. Wherever standby pumps are provided, they shall be with
automatic cut in/cut out arrangement.
2401-1 STEAM TURBINE
Quantity:
3 Nos.
Capacity
40 MWe MCR, each
Type
Double extraction condensing type
1st extraction
Uncontrolled to meet sugar factory demand at 8 bar (a).
2nd extraction
Controlled for sugar factory process requirement at 2.6

bar (a).
Condenser Pressure
0.14 bar (a).
Material of construction for different parts shall be appropriate to the pressure,

temperature, speed, load, and to which the parts are subjected and shall ensure long
trouble free operation. Quality of material shall be specified.
Heavy parts such as casing, steam chest, rotor, bearing and gland housings shall be
stress relieved before machining. And parts shall be rough machined, than subjected

Section - VI-D
Page - 16 / 88
BID DOCUMENT FOR

to secondary stress relieving. After secondary stress relieving only the parts shall be
final machined. Wherever matching of top and bottom parts is required, final
machining shall be done only after blue matching of the parts.
All casting shall be thoroughly cleaned from inside and outside and no sand either
loose or fused should be allowed to remain in the casting.
The Bidder must offer reliable and efficient systems with state of the art proven
design with good performance over a long period. The bid shall offer the system
including (but not limited to) the following design and engineering features.
-
Highest possible thermal and energy efficiency.

State of the art technology and well proven in actual operation over a long
period.
Rugged conservatively designed proven components and system.
Minimum outage for field maintenance and routine inspection (period to be
indicated).
Better operability at various load conditions.
Advance instrumentation, control systems, shut down and protection system,
very reliable online supervisory and surveillance system, with diagnostics.
Minimum requirement of operating and maintenance manpower and
amenability to unattended automatic operation.
Standardization of components.
Suitability for harsh tropical ambient conditions prevailing at site.
Simple design.
Short installation and commissioning period.
Maximum shop assembly and testing of modules and systems at the works to
eliminate potential start up delays at site.
Availability and reliability approaching 100%.
Good after sales service.
The turbine shall be complete in all respects, including but not limited to turbine
casing, fully bladed rotor, combined stop and emergency valve (CSEV), control
valves, quick acting non-return valve (QCNRV) for both extractions, gland box with
sealing system, barring gear, bearings with housing, Electronic Governing System,
PRDs if any.
The Bidder may incorporate additional features and improvements to enhance the
efficiency and reliability of the system.
1.1
Turbine Casing
The turbine casing shall be of symmetrical design, with an internal and external
envelope, to reduce the thermal stress to a minimum during load variations or
temperature fluctuations.
The turbine shall be supported directly by the casing in order to allow free internal
expansion and to absorb a maximum of steam temperature variation. The casing

Section - VI-D
Page - 17 / 88
BID DOCUMENT FOR

shall ensure freedom from distortions or expansions caused by sudden rise/fall in
extraction steam flow.
Orientation of turbine steam inlet, extraction outlets and condenser cooling water inlet
and outlet nozzles shall match with locations of respective source/end users.
1.2
Turbine Rotor
Rotor, balance piston and disks shall be made from a single forging. Steam wetted
areas of rotor, blades shall be ground and have mirror like finish. Complete rotor
assembly shall be preferably dynamically balanced at operating speed under
vacuum. After balancing, fully bladed rotor shall be subjected to an over speed test at
120 % of normal speed under vacuum. Critical speeds of the rotor shall not fall within
20 % range of operating speed.
The turbo alternator controls with unit responsibility shall analyse the complete
couple train for both lateral and torsion vibrations, and ensure proper separation
margins. The rotor design shall provide for protection from accidental contact with
labyrinths by sleeves of other similar device.
Adequate shock loading values shall be taken for the design of the gearbox and the
alternator rotor. The Bidder shall clearly describe in his offer the construction of the
rotor, the heat treatment proposed and the procedure for inspecting the shaft to
ensure soundness and homogeneity of the material. The material of construction
shall be consistent with proven practices and standards.
The blading shall be designed to withstand all vibrations, thermal shocks and other
loading that may be experienced during service and system disturbances. The
blades shall be machined from forge bars or die forged and the materials shall be
chromium steels consistent with proven reliability and standards. Any blade coating
used to improve performance or resistance to erosion shall be described.
The Bidder shall clearly indicate the type of fastening of the blades on to the wheels
and also give the specific advantages of the particular fastening method. The rotating
blades are either shrouded or tied with lacing wires depending on the stresses and
the excitation frequencies and the offer shall indicate the arrangement. The details of
the seal strips used to control the steam leakages shall also be indicated.
1.3
Combined stop and emergency valve (CSEV) and Control Valves

The main stop valve shall serve to isolate the turbine during emergency trips and
also during normal shutdown. Directly connected to the steam chest, it shall be an
independent system and of rapid closing design.
The control valves are to be operated by a single servomotor directly attached to the
valve to minimize backlash. In order to minimize the losses during part load
operation, minimum three control valves shall be provided. The control valves shall

Section - VI-D
Page - 18 / 88
BID DOCUMENT FOR

be decoupled from each other i.e. H.P. (High pressure), M.P. (Medium pressure) and
L.P. (Low pressure) valves should control independently.
Steam strainer shall be installed in the main steam stop valve.
1.4
Safety Valves and Quick Acting Non Return Valves
1.4.1
Quick Acting Non Return Valves

For both 8 and 2.6 bar (a) extractions, quick acting non-return valves (QCNRV) shall
be provided to avoid reverse flow of steam to turbine.
These valves shall be fitted on the extraction steam piping between the turbine outlet
and de-superheaters of respective lines of 8 bar (a) and 2.6 bar (a) pressure
extraction steam.
1.4.2
Safety Valves
Three safety valves shall be provided, one for 8 bar (a) extraction steam and two for
2.6 bar (a) extraction steam. These valves shall be fitted on the extraction steam
piping between the turbine outlet and de-superheaters of respective lines of 8 bar (a)
and 2.6 bar (a) pressure extraction steam. The outlet of safety valves shall be taken
outside the powerhouse to safe elevation.
1.5
Gland Sealing System

The glands shall preferably of labyrinth type and sealed with steam. The gland
packing shall be of 13 % chromium stainless steel or material suitable for the
application. The labyrinths shall be of multi-section spring back type, which would
allow for any temporary deformation of the rotor shaft without overheating the rotor
due to friction. The gland sealing system design shall permit the examination of and
replacement if necessary, of the glands without lifting the upper half of the turbine
casing. The complete piping, valves, pressure gauges, regulator etc. required for the
end seals shall be provided. During the normal operation of the turbine the source of
sealing steam will be from the turbine. During start up of the machine, steam shall be
supplied externally, at the suitable pressure for effecting the sealing.
A vacuum system if required by the design or required gland steam condenser with 2
x 100 % capacity AC motor driven exhausters shall be provided. Suction fans
wherever provided shall have one operating fan and one standby fan. All piping and
components of shaft seal system shall be sized for 300 % of the calculated new
clearance leakages. It shall be possible to inspect and replace the end seals without
opening the casing and without damaging the thermal insulation.
1.6
Bearing
The turbine shall be provided with liberally rated hydrodynamic radial and thrust
bearings. The radial bearings shall be spilt for ease of assembly, and of the sleeve of

Section - VI-D
Page - 19 / 88
BID DOCUMENT FOR

pad type, with steel shell backed, babitted replaceable pads. These bearings shall be
equipped with anti-rotation pins and shall be positively secured in the axial direction,
the thrust bearings shall be of the steel backed babitted multiple segment designed
type, designed for equal thrust capacity in both directions.
A liberal flow of lube oil under pressure shall be supplied to all the bearings for
lubrication and cooling. The Bidder shall provide the complete details regarding the
radial and the thrust bearings.
1.7
Barring Gear
1.8
The turbine shall be provided with a barring gear of mechanical type driven by an
A.C. motor, to rotate the turbine and alternator after shutdown to prevent thermal
distortion of the rotor. The barring gear shall be capable of starting the rotor from rest
and run it continuously at low speeds. The barring gear shall be interlocked with the
lubrication system to prevent its operation without lubrication.
Base Plate
Suitable base plate either individual or combined with gearbox shall be provided for
mounting the turbine. The base plate should be rigid in construction and suitable for
the application. The base plate shall be complete with mounting pad/ grouting pads,
sole plates, foundation and holding down bolts with nuts, adjusting shims etc.
Suitable openings shall be provided to pour the grout.
1.9
Governing System
The turbine governing system shall be electro-hydraulic designed for high accuracy,
speed and sensitivity of response. All components used shall be well proven to
assure overall system reliability and shall be designed for easy and quick
replacement when necessary. The governor shall be configurable in the field. The
turbines shall be equipped with a digital microprocessor based programmable
governing system. The system shall operate with very high governing accuracy with
response to parametric changes better than NEMA D. Signal provided by the digital
control system will act on electro hydraulic actuators, which operate the control
valves for extraction steam at 2.6 bar (a) and inlet steam valve in MODES B and
C
The speed governor shall permit the turbine to start from rest and run up to the
selected nominal speed (max. possible being the trip speed) under the control of the
speed-adjusting device and shall be within the limits as specified in IEC
Recommendations Publication 45. The governor shall have a derivative action in
order to limit the frequency increase during partial or total load rejection. The
governor shall be suitable to synchronize with grid and other TA set / DG set (for
start-up). The governor shall have drooping speed v/s kW load characteristics and
facility to adjust the same from remote location. The governor shall be capable of
changing the operating modes operation automatically without causing disturbance in
the controlled parameters.

Section - VI-D
Page - 20 / 88
BID DOCUMENT FOR

Self-diagnostics shall be integral part of the governor operation with clear indication
of the defective portions on the front LCD screen.
Vibration measuring and monitoring systems of reputed make shall be provided at
each bearings and the shaft. This system shall include the alternator, gearbox
bearings also. Temperature scanner shall be provided indicating temperature at
different locations.
The critical speed for the combined turbine and alternator shall be sufficiently above
from the rated speed to avoid any adverse effect on the operation of the unit over the
range of operating speeds.
General Control Philosophy
The turbines shall be designed to operate under following modes.
MODE A: Factory ON and Grid ON
Normal operation in season.
1.
Inlet Steam Pressure Control: The control will function as a supervisory

control for maintaining steam pressure at turbine stop valve. The control will
sense pressure in steam line upstream of turbine stop valve and will act to
increase steam flow into the turbine with increase in upstream pressure and
vice-versa with decrease in upstream pressure
2.
Process Control: In process control there are two operating parameters as

given below.
a.
Medium Pressure (M.P) steam at 8 bar (a): Extraction at 8 bar (a)

pressure shall be uncontrolled extraction/bleeding, which means the
flow shall vary as per demand irrespective of pressure from MP
control valve. The uncontrolled extraction shall not affect the inlet
steam flow through turbine. Extraction steam flow limiting controls
shall be provided to control extraction flow.
b.
Low-pressure (L.P) steam at 2.6 bar (a): Extraction at 2.6 bar (a)
pressure shall be controlled extraction. Extraction pressure controller
shall operate only on LP control valve by sensing downstream
pressure and inlet control valve opening shall not be affected.
Extraction steam flow limiting control with adjustable set point shall be
provided.
MODE B: Factory OFF and Grid ON

(Factory under downtime and turbine is in parallel with grid during the
season.)
MODE C: Factory ON and Grid OFF
(Factory operating and grid tripped during the season.)

Section - VI-D
Page - 21 / 88
BID DOCUMENT FOR

In modes B, C, the turbine shall operate on load control with L.P extraction process
control.
a.
Load control: Load controller shall control speed during start-up, isolated
operation and during load throw off condition as per the load demand. In this
mode of operation the speed governor will regulate inlet steam flow through
turbine.
b.
Extraction pressure controller (L.P) at 2.6 bar (a): Extraction at 2.6 bar (a)
shall be controlled extraction. Extraction pressure controller shall operate only
on LP control valve by sensing downstream pressure and inlet control valve
opening shall be adjusted to maintain load demand.
c.
Over speed trips: The trip mechanism shall function independently of

governing valve. Interlocks shall be provided so that trip resetting cannot be
effective unless steam admission is as per normal starting procedure.
The governor shall include as minimum, but not limited to following additional
features:
-
Bump less transfer of control from extraction pressure control mode to load
control during Mode C on grid failure.
Acceleration control
Extraction steam flow limiting controls
KW limiter
The governor shall include as minimum, but not limited to following remote set point
adjustments for
-
Speed
Inlet pressure steam
Load
Emergency and control valve lift
Control fluid pressure
Journal bearing metal temperature
Thrust pad metal temperature
Axial position of thrust collar relative to its own housing
Differential expansion between shaft and casing at any critical point
Trip and start
Axial expansion of casing from anchor point
Shaft eccentricity
Bearing pedestal or shaft vibration
Extraction steam maximum flow set points for both extractions.
kW limiter
Contacts for annunciators and alarms, as required
On sudden load throw off from rated load to no load, the speed shall remain below
tripping speed as per NEMA Class D Standard.

Section - VI-D
Page - 22 / 88
BID DOCUMENT FOR

The local gauge board shall contain as a minimum the following
-
Inlet steam pressure and temperature

Uncontrolled extraction steam pressure and temperature
Controlled extraction steam pressure and temperature
Exhaust steam pressure and temperature
Lube oil header pressure
Control oil header pressure
Steam turbine/alternator speed indicator
Steam turbine/alternator stop push button
Run light
Emergency shutdown push button
Safety trips of the turbo-alternator shall include, but not limited to following:
1.10
Steam inlet pressure lower than the pre-set pressure

Steam inlet temperature lower than pre-set temperature
Condenser vacuum below pre-set value
Lubricating oil pressure falling below pre-set pressure
Excessive axial thrust wear trip.
Excessive vibration trip
Set
Lubrication Oil System and Turbine Control Oil System
A pressure lubrication and control oil system shall be furnished for the turbo
alternator units to supply oil at the required pressure to the steam turbine, gearbox,
alternator and governing system. The lubrication oil system shall supply oil to the
turbine alternator under all the load conditions, including the turning gear operation.
The oil system of the turbo alternator shall be designed with adequate redundancy
and emergency provisions such that a failure of a single active component will not
prevent the safe operation or a safe shutdown of the turbo alternator. Oil in the
reservoir shall be maintained at an appropriate temperature when the TA set is idle
by providing suitable electric heaters and temperature controls if required.
For the hottest ambient conditions to be encountered at the site the oil outlet
temperature at any bearing shall neither exceed the maximum permissible
temperature for the bearing metal nor the maximum safe operational temperature of
the oil.
The system shall be complete with following parts and all necessary interconnecting
pipes and fittings for the oil supply system:
-
Oil tank, complete with all fittings like oil level indicator, filter (in the
discharge pipe) and lube oil vapour extractor. Inside of the tank shall
be de-salted and rust proof with permanent coating. Reservoirs with
top mounted equipment shall have sufficient rigidity. All openings in
the tank shall be dust and waterproof. The oil reservoir shall be so

Section - VI-D
Page - 23 / 88
BID DOCUMENT FOR

located to permit draining of the contents by gravity and shall be
equipped with fine and coarse mesh strainers.
The reservoir made of carbon steel conforming to IS 2062 or
equivalent, and shall be of adequate capacity. The reservoir shall be
provided with oil vapour extractor for proper ventilation. All necessary
piping connections, valves and fittings, level switches and level
gauges shall be provided.
-
Main lube oil pump, (positive displacement pump) centrifugal/gear

type for 100% oil flow with suction filters driven by main shaft/low
speed gear shaft.
Auxiliary lube oil pump, (positive displacement pump)

centrifugal/gear type for 100% oil flow with AC motor drive and
automatic cut-in, when the lube oil pressure falls below a preset
value. This pump shall also meet the requirements during the start
up and shutdown.
Emergency lube oil pump, (centrifugal pump) for operation of

lubricating and control oil flow with DC motor drive in the event of a
failure of the AC motor driven pump.
This pump also shall cut in automatically at a pre set value of the oil
pressure.
Manually operated oil pump for supplying oil to bearings in case of

failure of AC and DC power operated pumps
Oil vapour extractor with AC motor drive.
Oil coolers, each of 100% capacity, with in-situ changeover valve

while turbine is running. The oil coolers shall be water cooled with a
duplex arrangement and change over valves. The coolers shall be of
shell and tube type with removable tube bundle. The coolers shall be
constructed in accordance with TEMA Class C. The provided surface
area shall be adequate to cool the oil with 32 0C inlet cooling water
temperatures even with 20 % of the tubes plugged.
The sizing of the coolers shall consider a tube side (water side) fouling
factor of 0.0002 h.m2.0C/ kcal. The water velocity shall be not less
than 1.5 m/sec.
The material of the cooler shall conform to the requirements of API
614 or equivalent. The coolers shall be available for easy inspection
and maintenance and cleaning of one cooler while the other one is in
service should be possible.

Section - VI-D
Page - 24 / 88
BID DOCUMENT FOR

The cooler tubes shall be of copper, and the body and the tube sheets
shall be of carbon steel conforming to IS 2062 or equivalent
standards. The cooler on both the tube and the shell side shall be
designed for a pressure of 5 kg/cm2 (g).
-
Oil filters, each for 100% capacity, with in-situ changeover valve
while turbine is running. The filters and the coolers shall be arranged
with continuous flow transfer valves. Filter size shall be 10 microns
nominal for the lube oil. Filter cartridges shall have a minimum
collapsing differential pressure of 3.5 kg/cm2 (g). The minimum design
pressure for the filters shall be the maximum discharge pressure of
the oil pumps. Differential pressure gauge with alarm shall be
provided across the filters.
The filters shall be either common or separate for the lube and control
oil. The filter grade for the control oil shall be 10 microns nominal. If a
common filter is used for lube and control oil, the filter grade shall be
10 microns nominal.
Lot
Flow and temperature indication for oil from every bearing
Oil centrifuge
Common to three T/A sets
Provided for the removal of water, sediments and other oxidation
products. The centrifuge shall be a separate complete package,
mounted on a skid, complete by itself with drive motor, piping valves
and fittings. The capacity of the centrifuge shall be at least two percent
of the rate of normal flow through the reservoir. Feed to the centrifuge
shall be from the drain end of the reservoir and its operation shall be
independent of the oil system.
Overhead oil tank Common to three T/A sets

Capacity of oil tank shall be suitable to hold 30 minutes oil
requirement of all the three turbines. The tank shall be complete with
piping, valves, fittings, supports etc and shall be fitted on powerhouse
building columns at maximum possible height above ground level.
Inlet piping for oil supply to tank shall be from auxiliary oil pump.
Outlet piping shall be from tank outlet at its bottom to all the bearings
of turbine, gearbox and alternator and gears of gearbox. Tank shall be
fitted with necessary vent and drain connection.
The overhead tank shall be lined with stainless steel sheet and all the
piping and fitting also shall be out of stainless steel.
Reverse flow protection device installed in the bleed pipe.

Section - VI-D
Page - 25 / 88
BID DOCUMENT FOR

-
Speed control system with locally and remotely operated set value
adjustment, speed adjustable between 0 and over speed trip
speed variable proportional band.
Pressurized accumulator to allow oil injection during fast governing

actions.
Voltage supply for safe operation of turbine control system
Turbine safety and protection system
Steam strainer installed in the main stop valve
Emergency Supply DC System

For operation of lubricating and control oil pump, emergency DC
power supply system shall be provided. The system shall be a
dedicated system only for operation of the lubricating and control oil
pump.
The system shall be complete in all respects and all necessary items
such as DC Motor, Starter, Battery and Battery Charger along with
Cables, Cable termination, supports etc shall be provided.
The auxiliary oil pumps and the emergency oil pumps shall be arranged to have
flooded suction.
All necessary piping, valves and fittings for the complete oil system shall be provided.
The piping from the outlet of the filters and up to the user point shall be of stainless
steel. The piping from the reservoir to the filters and the return oil piping shall be of
carbon steel. The complete piping shall meet the requirements of API 614 or
equivalent. Supply of the flushing oil and the first fill up of lube oil for the turbine and
accessories shall be preferably from the local market. Bidder shall draw all his
cooling water requirements from cooling water pumps (installed at cooling tower
pump house) piping, fitting, valves, strainer shall be all in the Bidders scope of
supply. The complete cooling water circulation system for the turbo alternator is
included in the Bidders scope.
1.11
Condensing Plant
Condensing plant shall consist of shell and tube type water-cooled condenser, air
ejector vacuum system, condensate extraction pump with condensate control system
to maintain hot well level. The condenser shall be of divided water box type complete
with following
-
1
1
2
Shell and tube type condenser

expansion bellow between turbine and condenser
condensate extraction pump 120 % of capacity

Section - VI-D
Page - 26 / 88
BID DOCUMENT FOR

-
2
1
1
1
1
steam ejectors 120 % of capacity.

ejector for initial building of vacuum (Hogging ejector)
level control equipment
relief valve
vacuum breaker arrangement and rupture disc
1.11.1 Turbine condenser

The condenser shall be of non-contact surface type condenser designed as per the
requirements of Heat Exchange Institute Standards for Steam Surface Condensers
and ASME Section VIII Division-1. The condenser shall be sized to condense 55 t/h
of exhaust steam quantity with the inlet cooling water temperature at 32 0C. Suitably
designed condenser air evacuation system shall be provided. The design shall be of
divided water box construction.
The Bidder shall draw his entire cooling water requirement from cooling tower basin
through circulating water pumps (installed at cooling water pump house).
The complete cooling water system as per enclosed drawing no 2FD -934,
The water velocity through the tubes shall not be less that one (1) meter per second
and the fouling resistance on the tube side shall be 0.0002 h.m2.0C/kcal. The total
waterside pressure drop in the condenser shall not exceed 8 MLC. The condenser
neck shall be suitably designed to reduce the inlet steam velocity to ensure lowpressure drop and to protect the tubes from impingement of steam. The condenser
shell shall be adequately designed for the external pressure of full vacuum and
stiffeners and bracings wherever required be provided. The tubes shall be provided
with supports to eliminate any serious tube vibration problems and sagging. The
tubes shall be expanded into the tube sheets at both the ends and flared at the
cooling water inlet side. The condenser neck shall be connected to the turbine
exhaust hood. The thermal expansion of the condenser shall be suitably taken care
off with a properly designed stainless steel expansion bellow in the neck, or with
properly designed spring supports for the condenser or by both.
The hot well at the condenser bottom shall have a minimum capacity of 2 minutes
storage while handling maximum quantity of exhaust steam. The hot well shall be
provided with level gauges and connections for condensate extraction and drain. A
suitably designed level control system shall be provided. No makeup will be added in
the condenser hot well. Water-cooled steam turbine condenser shall be of horizontal
shell and tube type. The steam inlet connection shall be solid and rectangular section
and welded to condenser shell.
Heat transfer section shall be in the form of high efficiency tube bundle designed and
located to optimise peripheral distribution of steam. The air removal section shall be
achieved by shrouding sections of the tube and shall be located centrally in the
condenser at the cold end of the cooling water inlet pass.

Section - VI-D
Page - 27 / 88
BID DOCUMENT FOR

The condenser shall be provided with an atmosphere relief valve sized as per
recommendations of HEI standards with water seal around the valve disc to ensure
proper sealing.
Condenser shell shall be of carbon steel construction and shall withstand all
mechanical stresses without deformation. The condenser shall be provided with inlet
and outlet water boxes with flanged cooling water connection.
1.11.2 Vacuum package
The air extraction system shall consist of twin element two-stage steam ejector.
Each ejector shall be fitted with isolating valve on the motive steam inlet and air
suction inlet and discharge system shall be complete with necessary pipe work,
valves drain traps etc.
The motive steam required for ejector shall be 8 bar (a) pressure steam. 8 bar (a)
pressure steam shall be taken from the extraction steam piping or from suitable
location by the Bidder. The Bidder shall submit quantity requirement and this quantity
shall be added to the steam quantities furnished in flow diagrams i.e. these quantities
shall be considered as steam consumption of turbo-alternator.
The Bidder shall inform the arrangement provided for starting the hogging ejector for
creating vacuum in the condenser, before the turbo-alternator is started. Pressure
reducing valve with control valve and bypass system and line connecting to hogging
condenser is included in the scope of supply.
Condensate extraction pumps with condensate control system to maintain hot well
level is to be provided by the Bidder.
1.11.3 Condensate Extraction Pump
Two numbers (1 working + 1 standby) each of 120% capacity, electrical motor driven
condensate extraction pumps shall be installed. The pumps shall be preferably
vertical multi stage turbine type.
The pumps shall be designed to extract condensate from turbine condenser. Pump
shall draw feed water from the hot well of condenser and deliver to the Employers
boiler hot well. The necessary piping with valves is in the scope of Bidder.
Condensate extraction pump shall have sufficient head to pump the turbine
condenser condensate through gland cooling and ejector condensers to boiler hot
well flange, which shall be about 15 m above ground level and the hot well shall be
under 2.6 bar (a) pressure thus the pump shall have additional 35 m head over and
above that required by the Bidders system.
The unit shall be supplied with the following:
-
Base plate

Section - VI-D
Page - 28 / 88
BID DOCUMENT FOR

-
Flexible coupling and guard

Holding down bolts
Foundation bolts
Casing vent with cock.
Casing drain with plug
Capacity
m3/h
* Bidder to specify
Head
* Bidder to specify
Suitable to pump feed water condenser
outlet to Employers boiler hot well
Liquid to be pumped
- Specific gravity
- Temperature
- Viscosity
1.12
water
0
0.95 - 1
Bidder to decide
As water
Suction
Casings, end covers,
Wear plate
*
Cast iron
Impeller
Stainless steel
Shaft
Carbon steel
Shaft sleeve
Stainless steel
Gland
Suitable for operating temperature of

condensate
Suction, delivery connections
Flanged
Instrumentation
The Bidder shall provide electronic instrumentation controls for automatic and remote
control of the turbo-alternator. A master control console for the control of the turboalternator from the control room shall be provided. The indicators and controls shall
be displayed on computer screen and the controls shall be actuated by the
microprocessor.
The control room operator should be able to observe and control various parameters
either through Bidders PC or DCS system.
Sensing elements like transmitters shall be electronic type with 4 to 20 mA output.
All controls, except actuators, shall be solid-state electronic type. Actuators shall be
pneumatic. All controls and actuators shall interface with the control system through
I/P converters. The master controller shall be a microprocessor interfacing with the

Section - VI-D
Page - 29 / 88
BID DOCUMENT FOR

sensors, the valves and the actuators. The output signals from the microprocessor
shall first interface with the I/P converters and then with the pneumatic automatic/
remote/manual stations which in turn shall be connected to the valves and actuators.
The Bidder shall mount the manual stations near the turbo-alternator for use. In
manual mode the operator should be able to operate the valves and actuators. Local
control shall over ride automatic / remote control.
Range of pressure, vacuum and temperature gauges shall be at least 1.5 times the
maximum values attained. Bidder shall draw all his electrical requirements of 440 and
230 Volts from the electrical panels supplied by him. All necessary cabling, wiring,
fitting etc shall be provided. If any other voltage is required for any instrument, step
down/step up transformers shall have to be provided by Bidder.
Complete turbine start up and supervisory panel with all operating, indicating and
monitoring devices necessary for start up and continuous operation of the turbine
with alarm annunciation shall be provided. All necessary wiring, cabling, tubing,
terminal blocks, pressure switches with frames supports shall be provided.
Arrangement for recording and integration of parameters shall be provided.
1.12.1 Lot
Turbine Control and Indicating Instrumentation

Instrumentation and control panels shall be with complete turbine start up and
supervisory functions including, but not limited to following. This should also
include the temperature scanner for all bearings, steam, condensate etc.
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
m)
n)
speed
load
emergency and control valve lift
control oil pressure
journal bearing metal temperature
thrust pad metal temperature
axial position of thrust collar relative to its own housing
differential expansion between shaft and casing at any critical point
axial expansion of casing from anchor point
shaft eccentricity
bearing pedestal or shaft vibration
appropriate steam and metal temperatures and their differentials,
especially with a view to ensure safety during starting operations and
under transient conditions
annunciators and alarms, wherever required
turbine accessories Interlock and Protections
All these shall be installed in the control room.

Section - VI-D
Page - 30 / 88
BID DOCUMENT FOR

1.12.2 Lot
Turbine safety and protection system

The turbo-alternator shall be equipped with, but not limited to following safety
devices, with indication, trips and alarms as applicable.
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
low lubricating oil pressure

over speed
excessive axial displacement
excessive thrust bearing wear
excessive vibration
excessive bearing temperature
low condenser vacuum
emergency push button located in the centralised control room and on
or near turbo-alternator
high alternator winding temperature
high alternator bearing temperature
high oil temperature
All these shall be installed in the control room.

1.12.3 Lot
Local Instrumentation Panel with display in Control Room

Following indicating instruments shall be installed on turbo-alternator or a
local panel near the turbo-alternator and also displayed on the PC in control
room.
This shall consist of, but not limited to the following instruments.
a)
b)
c)
d)
d)
e)
f)
g)
h)
i)
j)
k)
l)
m)
n)
o)
p)
live steam pressure gauge

extraction steam 8 bar (a) pressure gauge
extraction steam 2.6 bar (a) pressure gauge
exhaust steam 0.14 bar (a) pressure gauge
gland steam pressure gauge
live steam temperature indicator
extraction steam 8 bar (a) pressure temperature indicator
extraction steam 2.6 bar (a) pressure temperature indicator
exhaust steam 0.14 bar (a) pressure temperature indicator
gland steam temperature gauge
lubricating oil pressure gauge
governing oil pressure gauge
dial type tachometer
lubricating oil temperature indicator
turbine bearing temperature indicators
gear box bearing temperature indicators
turbine speed indicator

Section - VI-D
Page - 31 / 88
BID DOCUMENT FOR

1.12.4 Lot
Recording and Integration

Facility should be available in the PC to record and integrate various
parameters.
Parameters, which require Recording and Integration, are listed below.
Item
Turbine
Live steam:
- Temperature
- Pressure
- Flow
8 bar (a) steam pressure
8 bar (a) steam temperature
8 bar (a) steam flow
2.6 bar (a) steam pressure
2.6 bar (a) steam temperature
2.6 bar (a) steam flow
Exhaust steam at 0.14 bar (a)
- Pressure
- Temperature
Steam to ejectors
- Pressure & temperature
- Flow
Condensate from turbine condenser
- Condensate temperature
- Condensate flow
Running hours
Power generated
1.12.5 Lot
Control room
Recording
Recording
Recording-Integrating
Recording
Recording
Recording
Recording
Recording
Recording
Recording
Recording
Integrating
Dedicated Independent Micro Processor Based System

Following functions of the turbine shall be realised by dedicated independent
micro processor based system and shall be interfaced for
monitoring/interlocking purpose:
a)
Turbine vibration monitoring system of make Bentley Nevada, USA or

equivalent
b)
Turbine governing system of make Woodward 505 E or equivalent
1.12.6 System Integration between Turbine Control Systems and plant DCS
The turbine Bidder shall include the turbine control systems as listed in the para
1.12.1 and 1.12.2 along with the vibration monitoring system (Bentley Nevada or
equivalent) in his scope.

Section - VI-D
Page - 32 / 88
BID DOCUMENT FOR

The turbine control system shall be microprocessor PLC based with its own local
control panel. As far as the compatibility is concerned the PLC shall provide 4-20 mA
outputs for all analog signals listed under 1.12.3. In addition the PLC will accept 4-20
mA from the DCS for control. As far as the signal for digital inputs and outputs are
concerned these shall be potential free contacts rated for 230 V AC.
Regarding digital communication using the bus technology the turbine control
systems shall be compatible with Fieldbus / Profibus.
The system shall therefore provide for full local control from the PLC and
retransmission of critical signals to the DCS and alternatively supervisory control
from the DCS.
1.13
Lot
Thermal Insulation and Lagging

High grade insulating materials for the exposed portion of the turbo-alternator
and accessories, including but not limited to steam turbine casing and control
valve should be insulated.
Insulation material of appropriate quality including but not limited to ceramic
wool, mineral wool, insulation bricks/mats, hard settling compounds, holding
lugs/studs, stainless steel wire mesh for forming mattress-covering, Hessian
cloth, paint, cladding etc. shall be provided.
In addition to insulation, the turbo-alternator and accessories, steam, hot
water piping, etc shall be provided with suitable casing or minimum 1 mm
thick Aluminium cladding.
At steady state operation the difference in temperature between the ambient
and the outside surface of insulation shall not be more than 20 0C.
1.14
Motor List
Description
Auxiliary lubrication oil pump
Emergency lubrication oil pump
Condensate Extraction pump
Oil vapour extractor
Oil centrifuge
Barring gear
1.15
Quantity
1 Nos.
1 Nos.
2 Nos.
1 Nos.
1 Nos.
1 Nos.
Type
AC Motor
DC Motor
AC motor
AC motor
AC motor
AC Motor
RPM
*
*
*
*
*
*
Rating
*
*
*
*
*
*
Pump List
Description
Auxiliary lubrication oil pump
Emergency
lubrication
oil
pump
Condensate Extraction pump
Quantity
1 Nos.
1 Nos.
Type
Centrifugal
Centrifugal
Discharge Head
*
*
*
*
2 Nos.
Vertical

Section - VI-D
Page - 33 / 88
BID DOCUMENT FOR

* - Bidder to Specify
2401-2 SPEED REDUCING GEAR BOX
Quantity 3 Nos.
2.1
General
A speed reduction gear box shall be provided to reduce the turbine speed to drive the
alternator at 1500 rpm.
The reduction gearbox between the turbine and the alternator shall be of proven
design preferably of double helical arrangement with an acceptable service factor of
minimum 1.3. It shall be capable of transmitting the maximum rating of the set and be
able to withstand 20% over speed over a period of minimum five minutes. The
gearbox shall also be designed for the short circuit condition of the alternator. All
bearings of the gearbox shall be readily renewable and shall be possible to inspect
the bearings and the gears readily without disturbing the shaft alignment. Illuminated
sight glasses shall be provided to inspect lube oil drain from each individual bearing.
The gearbox shall be as per the requirements of AGMA. Gearbox shall be complete
with following:
-
Reduction gear
Coupling between turbine and gear and between gear and alternator
Shaft vibration monitoring
Bearing temperature monitoring
The gear box shall be of double helical design mounted on Common base plate with
turbine.
The coupling between turbine and gear shall be flexible and membrane type to allow
free expansion and misalignment.
The coupling between gear and alternator shall be rigidly bolted.
The coupling shall be designed to withstand torque developed during wrong
synchronisation with other machines or the grid
Suitable base plate either individual or combined with gearbox shall be provided for
mounting the turbine. The base plate should be rigid in construction and suitable for
the application. The base plate shall be complete with mounting pad/ grouting pads,
sole plates, foundation and holding down bolts with nuts, adjusting shims etc.
Suitable openings shall be provided to pour the grout.

Section - VI-D
Page - 34 / 88
BID DOCUMENT FOR

2401-3 ALTERNATOR AND EXCITER
Quantity 3 Nos.
Each Alternator and Exciter shall comprise of following.
3.1
General
The alternator and Exciter shall comply with IS 4691 / 4722 / 5422, IEC-34, and
designed to operate within the specified temperature rises and to withstand all
normal operating conditions including suddenly applied loads, switching surges and
short circuits external to the alternator.
The alternator shall be totally enclosed, revolving field, brush less type provided with
fully interconnected damper winding in the rotor faces. Excitation shall comprise of
directly coupled overhung exciter armature with shaft mounted rotating rectifier
assembly, Permanent Magnetic Generator with surge suppressors. The alternators
shall be fitted with suitable surge capacitor for protection from switching and other
surges.
Alternator of 50000 KVA / 40000 kW at 0.8 Power Factor with class F insulation and
temperature rise to restricted to class B, suitable for 45 C ambient temperature and
32C cooling water. IP-54, 4 pole synchronous alternator complete with
-
3.2
Stator winding temperature detectors

Bearing temperature detectors
Anti-condensation heaters
Alternator Parameters
Sr.
No.
1.0
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.12
1.13
1.14
Description
Rating & Performance
Applicable code
Nominal Output
Duty
Rated Voltage
Voltage variation
Rated Power Factor
Rated Current
Rated Frequency
Frequency variation
Rated Speed
Rotation viewed from NDE
No. of phases
Type of connection
No. of line connections
Unit
KVA
V
%
Lag
Amps
Hz
%
rpm
Details
IS 4722/IEC 34
50000
Continuous
11000
10
0.8
*
50
5
1500
*
Three
Star
Three

Section - VI-D
Page - 35 / 88
BID DOCUMENT FOR

Sr.
No.
1.15
1.16
1.17
1.18
1.19
1.20
1.21
1.22
1.23
1.24
1.25
1.26
1.27
1.28
1.29
1.30
1.31
1.32
1.33
1.34
1.35
1.36
1.37
1.38
1.39
1.40
1.41
1.42
1.43
1.43a
1.43b
1.44
1.45
1.46
1.47
1.48
Description
No. of Neutral connections
Enclosure Alternator
Enclosure Exciter
Cooling System-Alternator
Excitation System
Short circuit ratio
Design Ambient Temperature
Max. Permissible capacitive Loading
Unit
C
KVAR
P.F. Lead
Max. Permissible inductive Loading
KVAR
P.F. Lag
Steady state 3 phase S.C. Current
kA
Max. Initial S.C. current (peak)
kA
3 Phase S.C. withstand time
Sec
Max. Continuous negative sequence %
current withstand
Max. Deviation from sine wave
Synchronous Impedance
Ohms
Max. Noise level at 1 M from equipment Db
within IS limits
Max. Permissible impact load
MW
Mode of earthing
Ohm
Insulation class
Stator
Rotor
Main Exciter armature
Main exciter field
Temperature rise limited to class
Stator
Rotor
Type of winding treatment
Stator
Rotor
Max. Vibration
Max. Harmonic content in output
%
Overload capacity- 50 %
Sec
Overload capacity- 10% in every 12 hour Hour
interval
Efficiency at rated Power Factor
100% load
75% load
50% load
25% load
Critical speed of Alternator
rpm
Details
Three
IP 54
IP 23
CACW
Brush less
*
45
*
*
*
*
*
*
3
Min. 10 %
*
*
*
*
*/ NGR
F
F
F
F
B
B
VPI
Roll impregnation
*
Less than 5
30
1
*
*
*
*
*

Section - VI-D
Page - 36 / 88
BID DOCUMENT FOR

Sr.
No.
2.0
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
3.0
3.1
4.0
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
4.13
4.14
4.15
4.16
4.17
4.18
4.19
4.20
4.21
4.22
4.23
4.24
4.25
4.26
4.27
Description
Reactances
Base MVA
X d (Sat)
X d (UnSat)
X d (Sat)
X d (UnSat)
X d (Sat)
X d (UnSat)
X 2 (Sat)
X 2 (UnSat)
X 0 (Sat)
X 0 (UnSat)
Inertia Constant
Moment of Inertia (GD2)
Alternator
Excitation System
Excitation system type
Excitation supply
Initial flash excitation equipment
Short circuit excitation equipment
Field Breaker
Discharge resistance rating
Redundant Thyrister circuits
Parallel Diodes
Diode Failure compensation
Quadrature Droop compensation
Exciter rating
Exciter nominal response
PMG rating
PMG Voltage
PMG frequency
AVR make
AVR type, sensitivity, burden
AVR steady state voltage accuracy
AVR response time
Voltage change for 100% load change
Alternator voltage regulation
AVR make
AVR type, sensitivity, burden
AVR steady state voltage accuracy
AVR response time
Voltage change for 100% load change
Alternator voltage regulation
Unit
Details
MVA
%
%
%
%
%
%
%
%
%
%
*
*
*
*
*
*
*
*
*
*
*
Kg M2
*
KW
KVA
V
HZ
%
ms
%
%
%
ms
%
%
Brushless
*
*
*
*
*
Required
Required
*Required
*Required
*
>1
15
230
50
*
*
0.5
<100
<15
Less than 0.5
*
*
*
*
*
Less than 0.5

Section - VI-D
Page - 37 / 88
BID DOCUMENT FOR

Sr.
No.
5.0
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
6.0
6.1
6.2
6.3
6.4
6.5
7.0
7.1
7.2
7.3
7.4
7.5
7.6
8.0
8.1
8.2
9.0
10.0
10.14
10.2
10.3
10.4
Description
Cooling system
Type of cooler
Mounting
No. of coolers/ Sections
Capacity of cooler/ section
Cooling water requirement
Redundancy in cooling system
Arrangement of cooler tubes
Material of cooling tubes
Cooler tube side design pressure
Bearing
Type of Bearing for DE, NDE
Mounting
Lubrication
Type of lubrication
Quantity of oil required
RTDs
Per Phase
Each Bearing
Cooling system
Inlet
Outlet
Microprocessor
based
Multipoint
Temperature scanner with Min. 2 spare
channels and separate output contacts for
Alarm and Trip for each channel
Space Heater
Alternator
Exciter
Terminal Box
Total weight of alternator
Total weight of Stator
Total weight of Rotor
Total weight of Exciter
Heaviest lift
Unit
Details
kg/ cm2
CACW
*
*
*
*
Required
*
Admiralty Brass
*
LPM
*
*
*
*
*
No.
No.
2
1
%
LPM
As required
As required
Reputed make
Kg
Kg
Kg
Kg
Kg
As Required
As Required
Suitable for Cu 11
kV, UE, XLPE
cable termination
*
*
*
*
*
Tolerance to be applied for characteristics of synchronous alternator shall be in

accordance with IS 4722, IS 5422.
Irregularities of the Waveform
When tested on open circuit and rated speed and voltage the telephone harmonic
factor (THF) of the line-to-line terminal voltage shall not exceed 1.5%.

Section - VI-D
Page - 38 / 88
BID DOCUMENT FOR

3.2.1
Earth Terminals
Machine shall be provided with means for connecting a protective conductor or an
earth conductor, such means being identified by the appropriate symbol or legend.
3.2.2
Exciter
The static accuracy of the alternator voltage shall be better than 0.5 % at all
symmetrical loads from no-load to rated load. The voltage level shall be set
steplessly with 10 % of the rated voltage. The alternator shall have drooping speed
v/s kVAR load characteristics and facility to adjust the same from remote location.
3.2.3
Neutral Earthing
The Alternator shall be suitable for continuous operation with the Neutral at or near
Earth potential. It shall also be suitable for operation on Unearthed systems with one
line at earth potential for infrequent periods of short duration for e.g. as required for
normal fault clearance.
The insulation for Neutral and Line shall be uniform.
3.2.4
Limits of Vibration Severity

Limits shall be as per IS 12075:1987 or equivalent.
3.2.5
Over speed
The Alternator shall withstand an over speed not less than 1.2 times the Max. rated
speed for min. 2 minute.
3.2.6
Power Factor
Unless and otherwise specified the alternator design Power factor is 0.8 Lag. The
alternator must be capable of delivering rated load at designed power factor. The
same power factor shall be considered for overload conditions.
3.2.7
Rating Plate Details

The Alternator name plate shall have following of details:
i)
ii)
iii)
iv)
v)
vi)
vii)
Reference Standard/Code
The Manufacturers name
The manufacturers serial number and identification mark and year of
manufacturer
Frame reference as per IS 1231 or equivalent
Type of machine
The class of rating or the duty type as per IS 12842 or equivalent
Rated Voltage

Section - VI-D
Page - 39 / 88
BID DOCUMENT FOR

viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
xix)
xx)
xxi)
xxii)
3.2.8
Rated current
Rated frequency
Rated power factor
No. of phases
Winding connection with symbol
Rated excitation current and voltage at rated output
Rated output in kW, kVA
Rate speed
Permissible over speed
Class of insulation
Temperature rise permitted
Max. ambient temperature (Considered) 45 0C
Max. water temperature (Considered) 32 0C
Designed Altitude considered if exceeding 1000 m
Total Mass of machine in kg.
Base Plate
The alternator shall be built on a fabricated rectangular steel base plate, which forms
the main constructional member and provides locations for all the other components.
3.2.9
Bearing
There shall be two sleeve bearings, each mounted in a short pedestal on a stool,
bolted to the base plate.
Each bearing liner may be made from steel lined with white metal and split on the
centre line.
A low-pressure oil supply shall be taken from the turbine oil system. Each bearing
shall have a sump and an oil ring for lubrication during run-down.
Both bearing pedestals shall be insulated from the base plate. A removable link shall
be provided to earth the drive and bearing and to facilitate testing of the bearing
insulation.
3.2.10 Enclosure and Ventilation

The radial ducts provided in the stator core and the design of the end-winding
ventilation shall ensure optimum uniformity of temperature.
3.2.11 Routine Tests
The manufacturer shall conduct all the routine tests as per IS or equivalent and listed
below without any extra charge. Following Routine tests shall be conducted in the
presence of Employers /Consultants representative at no additional cost.

Section - VI-D
Page - 40 / 88
BID DOCUMENT FOR

Following routine tests shall be conducted:
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
Measurement of winding resistance (Stator, Rotor, Exciter)

Insulation resistance test
Phase sequence test
Regulation test
Measurement of open circuit characteristics
Measurement of short circuit characteristics
High voltage test
Measurement of bearing current
Pressure test on coolers
Dielectric tests
Insulation Resistance Test:
The alternators above 3.3 kV, 1000 kVA will be tested for polarization index
(PI) of insulated winding. The method for measurement of polarization index
shall be in as per IS 7816 or equivalent.
3.3
Auxiliary Panels
3.3.1
Scope
This specification covers the design, material, construction features, manufacture,
inspection and testing, delivery to site and performance testing of metal enclosed Low
Voltage Switchgear of voltage not exceeding 1000 V AC.
Set of panels consisting of
-
3.3.2
Control, Annunciation & metering panel

Relay and protection panel
Excitation AVR Panel
Synchronising Panel
110 V DC Battery & battery Charger, DC DB
Codes & Standards

The design, construction, manufacture and performance of equipment shall conform to
latest applicable standards and comply with all currently applicable statutory,
regulations and safety codes in the locality where the equipment will be installed.
Equipment shall conform to the latest applicable contractual standards as mentioned.
In case of conflict between the Standards and this specification, this specification shall
govern.
3.3.3
Sheet Metal Work

The switchgear frame shall be fabricated using suitable mild steel structural sections or
pressed and shaped cold rolled sheet steel of thickness not less than 2.5 mm.

Section - VI-D
Page - 41 / 88
BID DOCUMENT FOR

Frames shall be enclosed by sheet steel of thickness not less than 2 mm cold rolled,
smoothly finished, levelled, and free from flaws. Doors and covers shall be made of
sheet steel of thickness not less than 1.6 mm cold rolled. Stiffeners shall be provided
wherever necessary.
The complete structure shall be rigid, self-supporting, and free from vibration, twists
and bends.
3.3.4
Painting
All the panels shall have suitable 7 tank process treatment. Powder coated paint shade
shall be light gray exterior & bright white interior.
3.3.5
Constructional Features
Switchgear shall be
i)
Metal enclosed, compartmentalised, indoor, floor mounted modular type
ii)
Made up of the requisite vertical sections
iii)
Dust and vermin proof construction
iv)
Provided with degree of protection IP 5X
v)
Easily extendable on both sides by the addition of vertical sections after

removing the end covers.
vi)
Provided with a metal steel frame made of structural steel channel section
properly drilled for mounting the switchgear along with necessary mounting
hardware. Hardware shall be zinc plated and passivated.
vii)
Provided with labels on the front and rear indicating the switchgear designation.
viii)
Provided with cable entry facilities at bottom with 3 mm thick removable

undrilled gland plates and necessary cable glands. For single core cables these
plates shall be non-magnetic.
xi)
Uniform height of not more than 2300 mm.
x)
Single front execution.
xi)
Provided with gaskets all round the perimeter of adjacent panels, panel and
base frame, removable covers and doors.
xii)
The maximum mounting height of operating handle / switch Indicating

instruments shall not exceed 1800 mm from FFL and the minimum height not
below 400 mm.

Section - VI-D
Page - 42 / 88
BID DOCUMENT FOR

Operating devices shall be incorporated only in the front of the switchgear.
Rear of single front switchgear shall be provided with removable panels/hinged doors.
It shall be possible for one person to remove and fix the removable panel.
All doors shall be provided with concealed type hinges and captive screws.
3.3.6
Control, Annunciation & Metering panel

This shall accommodate the following. All the meters shall be electronic type having
accuracy CL-0.5 or better. For details refer the single line diagram. All the necessary
controls shall be provided on this panel. The panel may be suitably divided in to sub
sections like Control-Metering Panel, Annunciation Panel.
Meters:
-
Ammeter (individual)
Voltmeter with selector switch
Integrating type kWh meter with reverse lock
KW meter
KVAR meter
KVA meter
Power factor meter
Frequency meter
Running hour meter
Microprocessor based Multipoint Temperature scanner for Alternator with Min. 2

spare channels and separate output contacts for Alarm and Trip for each channel
Energy monitor and recording meter shall monitor all the electrical parameters and
shall have accuracy CL 0.5 or better.
Indicating Lamps
Indicating lamps shall be LED type and as required but not limited to following:
-
For breaker ON, OFF, Tripped position

Neutral Isolator ON
Neutral Isolator OFF
Auxiliary DC Supply on
Auxiliary DC Supply Failure
Audio-visual alarm annunciation with different tone and having Amber Indication for
Alarm and Red Indication for Trip faults for the following:
-
DC failure trip
Winding temperature high Alarm
Winding temperature Very high Alarm

Section - VI-D
Page - 43 / 88
BID DOCUMENT FOR

3.3.7
Bearing temperature high Alarm

Bearing temperature Very high Alarm
Inlet Air temperature high Alarm
Outlet Air Temperature high Alarm
CB trip when turbine trips
All the electrical faults Alarm & Trip.
Relay and Protection Panel

This shall accommodate mainly but not limited to following protection relays.
-
Voltage restrained over current relay

Earth fault relay
Restricted earth fault relay
Differential relay
High-speed master trip relay
Over voltage relay (2 Elements)
Under voltage relay (2 Elements)
Reverse power relay,
Reverse reactive power relay
Under frequency (Min. 2 Stages)
Over frequency relay (Min 2 stages)
df/dt (Min. 2 stages)
Field failure relay
Rotor earth fault relay (2 Stages)
Trip circuit supervision relay
Negative phase sequence over current relay
All the relays shall have suitable contact multiplication and Trip arrangement. Except
those relays, which are not being, manufactured all the relays shall be digital,
Microprocessor based. All relays shall be suitable for communicating with Distributed
Control System (DCS). The relays shall be provided with windows based software.
The Contractor shall submit Electrical Fault Action- Alarm- CB and/or Turbine trip
Logic diagram for all the protections provided.
3.3.8
Excitation- AVR Panel

Excitation panel consisting of electronic type, one operating and one hot standby
(with automatic changeover switch) Automatic Voltage Regulator complete with other
accessories. The AVR shall be suitable for parallel operation with turbo alternator,
Black start DG Set and Grid. Excitation system complete with DC Ampere and
Voltmeters, circuit breaker, field discharge resistance, ON, OFF indicating lamps.
The AVR shall have Set PF/ Set kVAR mode. The AVR shall be suitable for remote
operation from Synchronising panel.

Section - VI-D
Page - 44 / 88
BID DOCUMENT FOR

The regulator shall be provided with a remote control facility, including but not limited
to the following:
3.3.9
Hand-auto changeover switch

Rheostat or variable transformer for manual voltage control
Excitation support system
Under frequency protection
Set PF mode/ Set kVAR mode
Neutral Grounding Resistance Panel

The neutral isolator and neutral grounding resistor shall be housed in this panel. It
should be possible to operate the neutral isolator from remote and facility to
Close/Open the Isolator manually also, in case of Power/Motor failure. Neutral
grounding panel shall be provided with necessary interlocks, Motorised isolating
switch and the requisite grounding resistance, earth fault CT, differential CT,
Restricted Earth Fault CT, Indicating lamps etc. The resistance shall be of punched
steel grid type. For details refer SLD. The NGR isolator Open/Closed position shall
be indicated using semaphore indicators. Allowable Temperature rise (Maxi.) is 375
Deg C for 10 Sec.
3.3.10 Synchronising Panel

The synchronizing panel shall be complete with push button operation, Rotary
Control Switches, Indicating lamps, Digital Meters, Semaphore indicators, Necessary
Interlocks, Inter panel wiring, Mimic diagram of complete Cogeneration scheme,
Discrepancy switches with Audio visual alarm, Dead Bus Relays and shall consist of
following:
-
Automatic synchronizer with auto voltage and frequency matching, CB

closing with CB closing time compensation
Synchroscope with check synchronizing facility (LED type)
Double frequency meter (Digital)
Double voltmeter (Digital)
Indicating lamps (LED type)
Control switch and fuses
Potential transformers
Dead bus relays
It should be possible from the synchronising panel to synchronise the turbo-alternator

set across following CBs
-
Turbo-alternator Incomers CBs. (52 G1, 52 G2, 52 G3), Bus Couplers and DG.
set circuit breakers as shown in SLD.
The required PT. signals, Governor, AVR remote set point shall be brought and
controlled from this panel. The panel shall be provided with required CB. Selection
switches, Local/Remote switches and Discrepancy switches for each CB.

Section - VI-D
Page - 45 / 88
BID DOCUMENT FOR

Raise/Lower Luminous Push Buttons. The Dead Bus closing scheme shall be
provided with the help of relays for all the CBs.
3.4
Alternator Breaker Panel
3.4.1
Codes and Standards

The design, material, construction, manufacture, inspection, testing and performance
of metal-clad switchgear shall comply with all currently applicable statutes, regulations
and safety codes in the locality where the Equipment will be installed. The Equipment
shall also conform to the latest applicable standards.
3.4.2
Metal-clad switchgear and control gear shall comprise metal-enclosed switchgear and
control gear in which components are arranged in separate compartments with
metal-enclosures intended to be earthed.
The metal-clad switchgear and control gear shall have separate compartments for the
following components:
i)
ii)
Each set of busbars

Current transformers
iii)
Voltage transformers on incomer side
iv)
Each main switching device
v)
Cable chamber suitable for heat shrinkable or push on type cable termination of
cables as indicated in single line diagram.
vi)
Metering and relaying devices.
The partitions of fore listed compartments shall have the following degrees of
protection:
Complete protection against approach to live parts or contact with internal moving
parts i.e. IP 54 class for all the above compartments except for item (a) i.e. each set
of bus bars. Compartments of each set of bus bars shall be provided with protection
against approach to live parts or contact with internal parts, by tools, wires or similar
objects of thickness greater than 2.5 mm.
Switchgear shall comprise 11 kV indoor, metal-clad, Draw out type circuit breakers.
Switchgear shall be dust, moisture and vermin-proof.
All doors, panels, removable covers shall be gasketted all around with neoprene
gaskets. All louvers shall have screens and filters. Vent openings shall be covered

Section - VI-D
Page - 46 / 88
BID DOCUMENT FOR

by fine mesh on the vertical face. The screens and grills shall be made of either
brass or galvanised iron wire mesh.
Metal-clad unit shall comprise rigid welded structural frame enclosed completely by
metal sheets, minimum 2.0 mm thick (cold rolled), smooth finished, levelled and free
from flaws.
Switchgear design shall comprise fully compartmental execution having separate
vertical sections for each compartment. Compartments with doors for access to
operating mechanism shall be so arranged as not to expose high voltage circuits.
Switchgear cubicles shall be provided with hinged doors on the front with facility for
padlocking door handles.
Instruments, relays and control devices shall be mounted flush on hinged door of the
metering compartment located in the front portion of cubicle. Panel door shall be
supported by strong hinges and braced in such a manner as to ensure freedom from
sagging, bending and general distortion of panel or hinged parts. All auxiliary relays not
requiring manual resetting will be mounted inside the LT compartment.
Switchgear cubicles shall be provided with bottom sheet metal plates 2 mm thick
(minimum). Removable gland plate shall be 3 mm thick.
Mounting in the form of mild steel channels properly drilled shall be supplied along with
anchor bolts for mounting the switchgear cubicles. These shall be despatched in
advance so that they may be installed and levelled when concrete foundations are
poured.
Each switchgear cubicle shall be fitted with a label on the front and rear of the cubicle.
Also shall be fitted with label indicating the switchgear designation, rating and duty.
Each relay, instrument, switch, fuse and other devices shall be provided with separate
label.
3.4.3
Painting
All sheet steel work shall be phosphated in accordance with relevant standards for
phosphating iron and steel.
3.4.4
Safety Interlocks
Switchgear shall be provided with following interlocks:
Breaker shall not be drawn out unless the associated circuit breaker is in the open
position.
Compartment door of a breaker shall not open unless the breaker is in open position.

Section - VI-D
Page - 47 / 88
BID DOCUMENT FOR

3.4.5
Main Busbars
Main busbars shall be of Copper and non-segregated type.
Busbars shall be located in air insulated enclosures and segregated from all other
compartments of the cubicle. Direct access or accidental contact with busbars and
primary connections shall not be possible. To provide a seal between adjacent
cubicles, busbars shall be taken through seal-off bushings or insulating pads.
Busbars shall be rated in accordance with the service conditions and the rated
continuous and short time current ratings specified
in Data Sheet enclosed.
Maximum temperature of the busbars and bus bar connections, under operating
conditions, when carrying rated normal current at rated frequency shall not exceed 85
0
C
Busbars shall not be painted and all performance characteristics specified shall be
obtained with unpainted busbars.
3.5
Circuit Breakers
3.5.1
General
Circuit breakers shall be of 11 kV SF6 / VCB type. These shall conform to relevant
standards specified and shall be of draw out type. Circuit breakers shall comprise
three separate identical single pole units operated through a common shaft by the
operating mechanism.
SF-6 circuit breaker shall have completely sealed interrupting units for interruption of
arc inside the SF6 gas chamber. It shall be possible to isolate easily the SF6
interrupter unit from the breaker operating mechanism for mechanical testing of the
interrupter to check loss of SF6 gas.
The SF6/VCB breaker shall be complete with surge arrestors to provide protection to
the equipment controlled by the breaker, against switching surges.
3.5.2
Operating Mechanism
Circuit breaker shall be power operated, by a motor charged spring operated
mechanism. Main poles of the breakers shall be such that unless otherwise specified,
the maximum difference between instants of contacts touching during closing shall not
exceed half cycle of rated frequency.
Operating mechanism shall be provided with non-pumping feature, electrically and
mechanically. Electrical anti pumping feature shall be obtained by means of an
auxiliary relay.

Section - VI-D
Page - 48 / 88
BID DOCUMENT FOR

Main poles of the breaker shall operate simultaneously. There shall be no
objectionable rebound and the mechanism shall not require any critical adjustment. It
shall be strong, rigid, positive and fast in operation.
A mechanical indicator shall be provided to show open and closed positions of breaker.
It shall be located in a position where it will be visible to the operator standing on the
front of the switchgear with cubicle door closed.
The closing coil shall operate correctly at all values of voltage between 80 % and 110
% of the rated voltage. A shunt trip shall operate correctly under all operating
conditions of the circuit breaker up to the rated breaking capacity of the circuit breaker
and all values of supply voltage between 50 % and 110 % of rated voltage.
Mechanical trip and close devices shall be provided for manual operation of the
breaker. Access to mechanical closing device shall be only after opening the cubicle
door. However, the mechanical trip device shall be brought out to the front of the
cubicle door.
Working parts of the mechanism shall be of corrosion resisting material. Bearings,
which require grease, shall be equipped with pressure type grease fittings. Bearing
pin, bolts, nuts and other parts shall be adequately pinned and locked to prevent
loosening or changing adjustment with repeated operation of the breaker.
Auxiliary switches mounted on the fixed portion of the cubicles and directly operated
from the breaker operating mechanism on each breaker having 8 'NO' and 8 'NC'
potential-free contacts rated for 10 amps, 230V AC and 2 amp (inductive breaking) 110
V DC shall be provided. The contacts shall be in addition to those utilised in the control
circuit of each breaker and shall be exclusively meant for the Employers use in
external interlocks and controls.
3.5.3
Spring Operated Mechanism

i)
Spring operated mechanism, shall be complete with motor, opening spring,

closing spring with limit switch for automatic charging and all necessary
accessories to make the mechanism a complete operating unit.
ii)
As long as power is available to the motor, a continuous sequence of closing

and opening operations shall be possible. After failure of power supply to the
motor, at least one open- close-open operation of the circuit breaker shall be
possible.
iii)
Breaker operation shall be independent of the motor, which shall be used solely
for compressing the closing spring.
iv)
Closing action of the circuit breaker shall compress the opening spring ready
for tripping.

Section - VI-D
Page - 49 / 88
BID DOCUMENT FOR

3.5.4
3.5.5
v)
When closing springs are discharged, after closing a breaker, closing springs
shall automatically be charged for the next operation.
vi)
Motor shall be such that it requires only about 30 sec. for fully charging the
closing spring. Motors shall be rated for or 230V AC and shall operate
satisfactorily at all values of voltage from 80% to 110% of rated voltage.
vii)
Mechanical indicators to indicate charged and discharged condition of spring

shall be provided.
Operating Mechanism Control

i)
The closing and tripping control shall be by a control switch mounted on the
cubicle door.
ii)
The mechanical trip and close devices shall be provided on the breakers in
addition to above.
Earthing
An earthing bus shall be provided and extended throughout the length of the
switchgear. It shall be bolted/brazed to the framework of each unit and each breaker
earthing contact bar.
The earth bus shall have sufficient cross section to carry the momentary short circuit
and short time fault current for 3 second.
All non-current carrying metal work of the switch-board shall be effectively bonded to
the earth bus.
Hinged doors shall be earthed through flexible earthing lead.
3.5.6
Cubicle Module Accessories and Wiring

Cubicle accessories and wiring shall include following accessories:
The Bidder shall carry out Inter-cubicle wiring between cubicles of same switchgear.
The Bidder shall furnish separate schematics, internal and inter-cubicle wiring
diagrams and external cable connection diagrams for each cubicle. The external
connection drawings shall indicate all external connections to be made by the
Employer to the respective cubicles from the Employers remote equipment.
The Employer will furnish necessary data for remote connections to the Vendor.
Terminal blocks with 10 % spare shall be complete in all respect i.e. internal wiring and
inter-cubicle wiring as required.

Section - VI-D
Page - 50 / 88
BID DOCUMENT FOR

3.5.7
Cable Termination Compartment

Supply of Cable glands and termination kits is included in the scope of switchgear
Bidder. Adequate space shall be provided in the switchgear to install and terminate the
cables.
Gland plate for control and power cables shall be of removable type and shall be of 3
mm thick.
3.5.8
Instrument Transformers
The current transformers (CT) and voltage transformers (VT) shall conform to the
requirements stipulated in relevant standards specified.
The CTs and VTs shall be of cast resin type (insulation Class 'F') and shall be able to
withstand the thermal and mechanical stress resulting from the maximum short circuit
and momentary current ratings of the switchgear. These shall be completely
encapsulated.
CTs shall have polarity marks indelibly marked on each transformer and at the
associated terminal block. Facility shall be provided for short circuiting and earthing the
CT secondary at the terminal blocks.
VTs shall be protected on their primary sides by current limiting HRC fuses with
interrupting ratings corresponding to breaker rating and on secondary side with MCBs.
Provision shall be made such that the primary fuses can be handled only in the deenergised position.
3.5.9
Miscellaneous Accessories
3.5.9.1 Heater & Light Point

Each switchgear cubicle shall be equipped with heater to prevent moisture
condensation within the enclosure and shall be complete with switch fuse unit for
power supply. Heaters and switch fuse units shall be suitable for continuous operation
on 230 V, 1 phase, 50 Hz, AC supply, 20 W, FT L with door switch shall be provided in
control cubical.
3.5.9.2 Plug Point
A 230 V, 1 phase, 50 Hz, AC plug point shall be provided in the interior of each cubicle
with an ON-OFF switch for connection of hand lamps.
3.5.9.3 Tests and Test Reports
The Vendor shall completely assemble, with all the associated equipment including
bought out items mounted and wired and test each cubicle as per relevant standard.
All routine tests shall be carried out as per this standard.

Section - VI-D
Page - 51 / 88
BID DOCUMENT FOR

Type test certificate shall be furnished along with routine tests reports.
Copies of the test certificates shall be submitted for the Employers approval before
despatch of the switchgear. Bound copies of complete test results as specified in the
distribution schedule shall be furnished with the switchgear. These shall include
complete reports and results of the routine tests as also certified copies of type tests
carried out on equipment of identical design.
Oscillographic test records for closing and tripping timings of the breakers shall also be
furnished.
3.6 One 110 V Battery Charger and DC DB
3.6.1
Scope
This specification covers requirement of 110 V DC Float and Float cum Boost
(FCBC) Battery charger equipment comprising of SCRs, SCR transformer, DC
Distribution Board and auxiliary equipment.
3.6.2
Code & Standards
3.6.3
The design, manufacture and performance of equipment shall comply with all
currently applicable statues, regulations and safety codes. Nothing in the
specification shall be construed to relieve the Bidder of his responsibilities. Unless
otherwise mentioned specified, equipment shall conform to latest applicable
standards.
Type
The battery charger shall be static type with SCR connected in three-phase full wave
bridge circuit. The SCR transformer shall be indoor dry type double wound with
adequate no. of primary and secondary taps.
The charger shall be Float and Float Cum Boost Charge type.
3.6.4
Rating
The charger shall be suitable for charging 200 Ah substation batteries continuously.
The Float Cum Boost Charger shall be designed for supplying the boost charging
current requirement of the batteries. It shall be responsibility of the Bidder to
coordinate with the battery manufacturer and ascertain the float and boost charging
currents and voltages required by the battery.
3.6.5
Charger Cubicle & Wiring

Cubicle accessories and wiring shall conform to low voltage switchgear specification
below 1000 V.

Section - VI-D
Page - 52 / 88
BID DOCUMENT FOR

3.6.6
Accessories
Each charger shall include the following:
One Set
One Set
One Set
One Set
Two Set
Two set
One Set
Set
One set
Set
3.6.7
SCR rectifiers connected in three phase full wave bridge circuit with
ripple filtering device.
Double wound dry type main transformer of suitable rating with
adequate primary and secondary taps for the charger output voltage
control.
Transformer for Float Cum Boost charger (FCBC)
Transformer or Float charger
Automatic voltage regulator unit
Coarse and fine control knobs for Manual control.
Selector switch for Mode selection.
Separate DC Voltmeters and Ammeters for Float and FCBC mode
Incoming TPN MCB of required rating.
output two pole MCBs and Distribution Board for DC Loads. Min. 15
outgoing MCBs shall be provided.
Indication & Protection

Following Indication shall be provided:
-Three LED Indicating lamps for Incoming supply.
-Over current Float
-Float charger fail
-Rectifier fuse failure
-Over current Boost
-Rectifier fuse failure Boost
-DC Earth leakage
3.6.8
Following Protections shall be provided

-DC Earth leakage
-AC Thermal over current relay
3.6.9
Performance
The automatic voltage regulator shall regulate the DC Voltage within 1 % of the set
value from No load to Full load under the supply voltage and frequency variation of
10 % and 5 % respectively. The charger shall have built-in current limiting feature
to drop the output voltage on currents more than 110% of rated current. Suitable
ripple filtering circuits shall be provided to give smooth DC output. The ripple content
shall be limited to less than 5%.

Section - VI-D
Page - 53 / 88
BID DOCUMENT FOR

3.6.10 Tests
All the routine tests as listed in applicable standards free of cost shall be carried out
at Manufacturers works in presence of Employer/Consultants representatives.
3.7
Set 110 V, 200 AH Battery
3.7.1
Scope
This specification covers requirement of stationary lead acid storage batteries
complete with battery racks, intercell and inter tier connectors and all other
accessories.
3.7.2
Codes and Standards

The design manufacture and performance of the equipment shall comply with all
currently applicable statues, regulations and safety codes.
Unless otherwise specified, the equipment shall conform to latest applicable IS
standards.
3.7.3
Construction
The batteries offered should be lead acid sealed in type. The battery shall be suitable
for indoor type installation.
The battery shall be complete with accessories and devices including but not limited
to following:
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
Battery racks
Porcelain insulators, rubber pads etc.
Set of inter-cell, inter-row and inter-bank connectors, cables up to battery
charger as required for the complete installation.
Electrolyte for first filling and 10% extra
Stand insulators PVC sheets
Spanner
Accessories for testing and maintenance
-One
-One
-One
-Three
-Two
-Two
-Four
-Two
(-3.0 to + 3.0) Volts DC Voltmeter with suitable leads for

measuring cell voltage.
Hydrometer for measuring specific gravity of electrolyte.
Filler hole thermometer fitted with plug cap and having specific
gravity correction scale.
Pocket thermometers acid resisting funnels.
Acid resisting jugs of adequate capacity
Rubber aprons
Rubber gloves
Cell lifting straps

Section - VI-D
Page - 54 / 88
BID DOCUMENT FOR

-Two -Spare -
3.7.4
Rubber siphon
Terminals & cable boxes with glands for connecting cables as
required. Spare connectors, Spare Vent plugs, Spare Nuts and
bolts, Suitable set of spanners and PVC spill trays under the
battery cells.
Battery Racks
Battery racks shall be constructed from good quality teak wood and painted with two
coats of approved acid resisting paint. The construction of the racks shall be suitable
for fixing to a flat concrete floor. The racks shall be rigid, freestanding type and free
from warp and twists. The completed racks shall be suitable for being bolted and to
form a continuous row.
3.7.5
Ventilation
The shall indicate in the tender the requirement of ventilation in the battery room.
The battery shall operate satisfactorily over the entire range of temperature indicated
without affecting the its normal life. If any special ventilation is required the same
shall be included in the scope of supply.
3.7.6
Capacity
The standard ampere hour capacity at ten hour rate of discharge of the battery has
been based on the requirement of the loads. shall guarantee that the capacity of the
battery offered is adequate for the duty specified It may be assumed that the battery
is fully charged at the start of the cycle and is discharged to a voltage of 1.85 V /cell
at the end of the cycle.
3.7.7
Charging
The battery shall be suitable for Float and Float Cum Boost Charge type of charging.
3.7.8
Life
The Contractor shall quote in the offer the guaranteed life of the battery.
3.7.9
Identification
Each cell shall be marked in a permanent manner to indicate the following
information:
(i)
(ii)
(iii)
(iv)
(v)
(vi)
Cell Number
Type of positive plate
Ah capacity at 10 Hour rate
Type of container
Manufacturers name
Month & year of manufacture

Section - VI-D
Page - 55 / 88
BID DOCUMENT FOR

3.7.10 Tests
All the routine tests shall be performed free of cost at Manufacturers works and shall
be witnessed by Employers/Consultants representative.
The tests shall comprise of:
i)
ii)
iii)
iv)
Visual Inspection
Dimensional check
Capacity check
Retention of charge test
3.8
Lot
Electrical Motors and Panels for TA, EOT Crane, Cooling Tower and
Compressor Comprising of Motors, Motor Control Centre (MCC), HT/LT
Cables, Earthing, Drives, PB Station etc.
3.8.1
General
All electrical equipment included in the scope of these specifications shall be suitable
for Rated voltage 10 %, 50 Hz 5 %, and 3-phase power supply to be feed from
MCC`s. For control, instrumentation, plant lighting and any single-phase equipment,
the single phase 230 V shall be made available In MCC. Design, manufacture and
testing should comply with latest edition of relevant IS or equivalent international
standard.
3.8.2
Induction Motors
i)
Motors shall be capable of giving rated output without reduction in the

expected life span when operated continuously under following conditions.
1.
2.
3.
Variation of supply voltage from the rated voltage

Variation in supply frequency from the rated frequency
Combined Voltage and frequency variation
ii)
Motors shall be suitable for the method of starting as specified.
iii)
Insulation
10%
5%
10%
The insulation shall be as specified and Vacuum and pressure impregnated,

shall be given tropical and fungicidal treatment.
iv)
Construction
Bearing shall permit running of motor in either direction.
If oil lubricated type bearings are provided, a drain plug and oil level sight
glass shall be provided.

Section - VI-D
Page - 56 / 88
BID DOCUMENT FOR

Terminal box shall be weatherproof construction suitable for outdoor
application. It shall be suitable for top and bottom entry of cables. Terminal
box shall be suitable for termination of Copper cables. Further, it shall be
capable of being turned through 360 deg. in steps of 90 deg.
v)
Painting
External parts shall be finished and painted to produce neat and durable to
prevent rusting and corrosion.
vi)
Tests
The shall conduct all the routine and type tests as per IS or other equivalent
international standards
vii)
Documents
After the award of contract, G A drawings, Schematic drawings, Bill of
material shall be furnished for clients approval.
3.8.3
Low Voltage (LV) Panels

The contractors scope covers design, construction features, material, manufacture,
inspection and testing, delivery to site and performance testing of metal enclosed Low
Voltage Switchgear (MCC) of voltage not exceeding 1000 V AC to feed power supply
to individual electrical equipment of juice extraction plant. The supply, installation,
testing and commissioning of all equipment / materials / accessories, etc. shall comply
with the latest applicable standards and codes of practices.
Maximum current rating of LV Switchgear shall be limited to 8000 Amps.
i)
Sheet metal work

The switchgear frame shall be fabricated using Cold Rolled Sheet Steel or
Cold Rolled Cold Annealed of suitable thickness.
ii)
Painting
Painting shall be of Synthetic Enamel / Powder coated. For painting seven
tanks method shall be followed. Shade shall be 631 of IS 5. (Light grey & Bright
white as exterior and interior respectively)
iii)
IP-5X construction shall be provided with power connections to the equipment
mounted on withdraw able mounting plate of the bolted type.

Section - VI-D
Page - 57 / 88
BID DOCUMENT FOR

All identical equipment and corresponding parts including chassis of draw-out
modules of the same size shall be fully interchangeable.
iv)
Bus Bars
Switchgear shall be provided with E-91 grade, 50 kA for 1 Second three phase
or three phase and neutral bus bars with temperature range of 0 Deg. C to 90
Deg. C. for Main and Auxiliary bus bars.
v)
Circuit Breakers
Circuit breakers shall be air break draw-out type (EDO), 400 Volt, 50 kA,
Motorised in operation. Closing and tripping shall be possible with 85 % to 110
% of rated voltage and 50 % to 110 % of rated voltage respectively.
Microprocessor based release shall be used.
vi)
Fuses For Control Circuit

HRC cartridge having rupturing capacity at 400/230 V, 80 kA at 400/230 V and
16 kA at 220 V DC Shall be provided.
vii)
Motor Starters
Motor Protection Circuit Breakers or direct on-line starters of suitable size for
Class AC 3 shall be provided. Automatic star-Delta starters shall comprise
three sets of contactors of AC 3 duty. Reversing starters shall be suitable for
Class AC 4 duty.
viii)
Moulded Case Circuit Breakers

Moulded case circuit breakers (MCCBs) shall be provided for the motor
controls. The MCCBs shall conform to the latest applicable standards.
Under-voltage, Earth Fault release shall be provided.
ix)
Miniature Circuit Breakers

Miniature circuit breakers for use on motor, space heater and control circuits
shall comply with of applicable standards.
x)
Current And Voltage Transformers

Shall be of the dry resin cast type, 15 VA, accuracy class 1.0 with instrument
safety factor of 5. Protective accuracy class 5P with accuracy limit factor of 10.
Measuring VTs - 50 VA per phase with accuracy class 1.0. Protective VTs - 50
VA per phase with accuracy class 3. Dual purpose VTs - 100 VA and dual
accuracy class 1.0 / 3.0 for metering and protection respectively.

Section - VI-D
Page - 58 / 88
BID DOCUMENT FOR

xi)
Relays
The relays shall be static / microprocessor type. Electromagnetic relays may be
considered for those type of relays which are not being manufactured as static
/ microprocessor type.
xii)
Transformers For Control, Space Heater AND Annunciator

Suitable size single phase, two winding, dry type transformers shall be
provided.
xiii)
Indicating Instruments And Meters

Electrical indicating instruments shall be of 144 Sq. mm sizes for incomer and
96 mm sq. mm. size for outgoing feeder, suitable for flush mounting.
xiv
Indicating Lamps
Indicating lamps shall be LED type and of low watt consumption and easily
replaceable from the front.
xv)
Control And Selector Switches

Control and selector switches shall be of the rotary type adequately rated.
xvi)
Push Buttons
Push buttons shall be of momentary contact, push to actuate type rated to
carry 10 A at 230 V AC, 1A (inductive breaking) at 110 V DC. Emergency
Stop' push buttons shall be Mushroom head type.
xvii)
Space Heaters And Panel Indication Lamps

Anti condensation heaters of suitable rating and numbers shall be provided.
Filament type 230 V, 40 W lamps shall be provided in Cable Alleys and
wherever necessary.
xviii)
Window Type Alarm Annunciators

The alarm annunciation scheme in control wiring drawings shall incorporate
visual indication of audible alarm on the occurrence of the fault.
xix)
Capacitors And APFC relay

The capacitors of suitable type and rating shall be supplied to achieve pf of 0.9.
It shall be indoor type, delta connected suitable for use of 3 phase, 400 volts,
50 Hz.

Section - VI-D
Page - 59 / 88
BID DOCUMENT FOR

xx)
Internal Wiring
Switchgear internal wiring shall be carried out with 1100 V grade, PVC, flexible,
stranded, insulated copper conductor wires. For power circuits is 4 Sq. mm.
and for control circuits 2.5 sq. mm. shall be used.
xxi)
Terminal Blocks
Terminal blocks for CT and VT circuits shall be of finely threaded pairs of brass
studs. Minimum rating of the terminal block is 10 A.
xxii)
Labels
All labels shall comprise black letters of Min. 10 mm height on a white
background and shall be properly fixed.
xxiii)
Earthing
Suitable size earth busbar running along the entire length of the board shall be
provided.
xxiv)
Inspection
Stage and Final Inspection of L V Switchgear Assembly will be carried out at
the s Works as per need to be assessed from time to time.
xxv)
Tests
The shall conduct all the routine tests as per IS or equivalent and listed below
without any extra charge. The shall furnish valid Type test certificate for
equipment at no extra cost.
xxvi)
I)
Type Tests
II)
Routine Tests
Documents
After the award of contract, G A drawings, Schematic drawings, Bill of material
shall be furnished for clients approval.
3.9
Technical Specifications For LV Cables
3.9.1
Scope
This specification covers requirement of Design, Manufacturing, Supply and Delivery
of 1100 V grade cables and accessories like termination etc.

Section - VI-D
Page - 60 / 88
BID DOCUMENT FOR

3.9.2
Construction
The cables shall be of XLPE copper conductor with maximum conductor
temperature of 90 deg. C. For selection of cable 20 % deration factor shall be
considered.
For Three and Half core cables the current carrying capacity if the neutral conductor
shall be 50% of that of the main phase conductors.
3.9.3
Tests
Following tests shall be conducted on cable length of each rating in the presence of
Employers representative free of cost:
i)
ii)
iii)
iv)
v)
3.10
Conductor resistance test

High Voltage test
Insulation Resistance test
Continuity check
Check for standard mark and embossed rating.
Technical Specifications for Earthing Equipment

Scope
This specification covers the requirement of earthing of all equipment in the juice
extraction plant including Motors, Distribution Boards, Push Buttons and MCC etc.
Maximum Fault level
:
50 kA at 400 V.
3.11
Duration of fault
For 400 V 1s.
Earth conductor
2 Nos. separate
50 x 10 mm G I strip,
25 x 10 mm G I strip
2.64 sq. mm Bare Copper wire
Illumination
Scope
Has to design and give required illumination at different locations in Mill house,
Control room, walkways, platforms, basement etc.
3.12
Commissioning Spares
Bidder shall supply the commissioning spares. List of commissioning spares to be
supplied shall be submitted.

Section - VI-D
Page - 61 / 88
BID DOCUMENT FOR

3.13
Spares
Bidder shall supply the spares parts List and unit rates for spare parts shall be
submitted.
The spares for two years normal operation for each turbine shall include, but not
limited to following:
a)
Turbine
1)
1 set of front journal bearings and Rear journal bearing

1 set of front journal bearing pads and Rear journal bearing pads
2)
1 set of thrust bearing

1 set of thrust bearing pads
3)
1 set of gasket and fasteners

-
b)
Gasket for governor valve

Gasket for emergency stop valve
Packing for lubricating oil filters
Packing for control oil filters
Packing for ring gasket ( EMV + Casing)
Ring for ring gasket ( EMV + Casing)
4)
1 set of pressure switches
5)
1 gland condenser fan
6)
1 set of speed pickups
7)
1 set Labyrinth fins for casing and rotor.

1 set Labyrinth fins for glands
8)
1 set Oil scrapper ring
9)
Spring for overspeed trip device
Gear box
1)
1 set of bearing
c)
Alternator
1)
2)
3)
1 set of front journal and rear journal bearings

1 set RTDs for bearing
1 set of seals

Section - VI-D
Page - 62 / 88
BID DOCUMENT FOR

3.14
Special tools and tackles

Bidder shall supply two sets of special tools and tackles for maintenance, inspection
and repairs for turbo-alternator. List of such tools and tackles shall be furnished by
the Bidder.
2104
H.P/L.P STEAM PIPING

All piping connecting between the equipment supplied by the Bidder, and between
the Bidders equipment and Employers equipment outlined under terminal points,
shall be provided by the Bidder.
The arrangement is shown schematically in drawing Flow Diagram for Steam
Distribution # 2FD - 932.
H.P. and Exhaust piping rooting with terminal points for boiler and power house are
shown in the drawing - 5BH-846.
1.1
66 bar (a) Pressure Steam

66 bar (a) pressure steam piping from outlet nozzles of steam distribution header to
turbines inlet including flow transmitter and blow off arrangement shall be in the
scope of Bidder.
a.
Piping, valves shall be made of steel of a grade and thickness appropriate to

working steam pressure 66 bar (a) and temperature 510 0C, and generally in
accordance with BS 806 or equivalent.
b.
For H.P. steam piping, loads due to expansion are to be compensated by

utilizing loops or bends. Where this is not possible then bellows may be
used. Piping design, expansion and stresses should be calculated and get
approved by the Employer / consultant.
All pipe work shall be tested hydraulically to 2 times the working pressure
after installation before commissioning.
Gland seal steam piping form turbine gland sealing to gland condenser shall
be supplied by the bidder,
1.2
8 bar (a) Pressure Steam

8 bar (a) pressure steam piping from outlet of all three turbines to 8 bar (a) header or
M.P steam header after de-superheater in power house shall be provided by the
Bidder. De-superheater shall be included in the scope of bidder.
The 8 bar (a) pressure steam piping from outlet of header from power house is
extended 50 m outside the power house, this is the terminal point for bidder.

Section - VI-D
Page - 63 / 88
BID DOCUMENT FOR

8 bar (a) pressure piping for steam requirement of ejector shall be completely in the
scope of bidder.
1.3
2.6 bar (a) Pressure Steam

2.6 bar (a) pressure steam piping from outlet of all three turbines to 2.6 bar (a)
header or L.P steam header after desuperheater in power house shall be provided
by the Bidder. De-superheater shall be included in the scope of Bidder.
The 2.6 bar (a) pressure steam piping from outlet of header from power house is
extended 50 m outside the power house, this is the terminal point for bidder.
1.4
0.14 bar (a) Pressure Steam

Complete pipeline from outlet of turbine to the condenser including expansion bellow
shall be in the Bidders scope of supply.
1.5
Piping, valves and fittings

All piping required for effectively connecting the turbine with the sub system within
battery limit shall be provided.
The piping provided shall be complete in all respects including valves, fittings,
supports, etc as required and include the following:
a.
The design of the piping system shall be based on the ANSI B 31.1 or
equivalent code. In addition the statutory requirements of the Boiler
Regulation shall also be taken care of wherever required.
Flexibility and stress analysis shall be made for all piping systems with
operating temperatures above 100 0C.
The correct locations of hangers and supports, with as applicable spring
stiffness, shall be considered for the flexibility analysis.
Suitable expansion loops restraints and anchors shall be provided so as to
ensure compliance with the applicable codes and to limit the stress and
reactions to within the allowable values.
b.
The flow velocities in pipes shall be limited to the following values:

Super heated steam
Saturated steam
Cooling water
c.
:
:
:
35 to 40 m/sec
20 to 35 m/sec
Upto 3 m/sec
Drains at all low points and vents at all high point shall be provided. All the
drains shall be connected to common drain line.

Section - VI-D
Page - 64 / 88
BID DOCUMENT FOR

d.
1.6
All local instruments shall be located on pipelines so as to render them

observable from the nearest available platform.
Materials
Pipe materials for various services and materials for fittings, flanges, fasteners shall
not be inferior to the specifications given below.
All piping except for cooling water, raw water and air services shall be of seam less
steel. For cooling water and raw water and air applications the piping could be ERW.
1.7
a.
Steam services at temperatures to 500 + 10 0C piping shall be of Alloy steel

piping as per ASTM A-335 or equivalent.
b.
Other services Carbon steel piping as per ASTM A -106 Grade B or ASTM A
-53 or equivalent
c.
Fittings and flanges: As per applicable codes conforming to pipe material

specifications.
d.
For cooling water and raw water applications the piping material shall be IS:
1239 Black Medium Class or equivalent.
e.
For services air applications the piping shall be IS:1239 Black Medium
Class or equivalent.
f.
For instrument air applications IS:1239 GI pipes or equivalent
g.
The fittings for ERW applications shall be as per IS:1239 Part II or equivalent.
Hangers and supports

Piping shall be provided with suitable supports to ensure that no undue stresses are
placed on adjoining pipe work and equipment.
Piping connected to equipment shall be so supported that included equipment,
valves etc., can be readily removed without additional supports and with a minimum
or dismantling.
Anchor supports shall be supplied for those pipe runs demanding this form of fixing
and shall be fabricated in accordance with the pipe.
All supports, hangers, anchors, etc., for aligning and controlling the piping shall
conform to BS 3974 Pt 1-3 or equivalent.
Proper expansion facilities shall be provided for pipes meant for hot fluids

Section - VI-D
Page - 65 / 88
BID DOCUMENT FOR

a.
The Bidder shall design, fabrication and furnish fabrication drawings for all
hangers, anchors, guides, clamps, stops and supports, auxiliary structures,
etc required for the proper installation and support of the piping.
b.
It is desirable that supports should as far as practicable, be arranged

adjacent to the pipe joint.
c.
Constant load hangers/spring hangers shall be provided wherever necessary

for critical piping systems.
The variation between hot and cold loads, if variable spring hangers are
used, shall not exceed 25 % of the rated load.
d.
1.8
Lugs and additional structural members should be suitably welded to the

pipes wherever necessary for hangers and restraints.
Valves
a.
All valves shall be suitable for the service conditions i.e. flow, temperature
and pressure under which they are required to operate and those performing
similar duties shall be interchangeable with one another unless otherwise
approved.
b.
All gate valves shall be of the full wage type and unless otherwise approved
and when in the full open position the bore of the valve shall not be
obstructed by any part of the gate.
c.
Globe valves shall have curved or spherical seating and the discs shall be
free to revolve on the spindle.
d.
All non-return valves shall have an arrow cast or embossed on the side of the
valve body to indicate the direction of the flow.
For severe service conditions cushioned check valves are preferred to
prevent valve chatter. In case of swing check valves the body seat shall be
inclined at such an angle to the vertical as will facilitate closing and prevent
chatter.
e.
The internal diameter of all valve ends to be connected to pipes shall be the
same as the internal diameter of the pipe to which they are joined so as to
minimise use of reducers/expanders.
f.
Where applicable valves shall be of the outside screw and yoke type.
g.
All the important valves shall be fitted with indicators so that percentage of
valve opening can be readily determined locally and in the control room.

Section - VI-D
Page - 66 / 88
BID DOCUMENT FOR

h.
Steam valves shall not be fitted in an inverted position. Eye bolts shall be
provided where necessary to facilitate handling heavy valve or part of valves.
i.
Special attention shall be given to operating mechanism for large size valves
with a view to obtaining quick and easy operation and to ensure that
minimum of maintenance is required.
For valves of size 250 mm and above either bevel or spur gearing shall be
provided to facilitate manual operation.
j.
The materials, design and construction of all types of valves shall be subject
to the approval of the Employer.
k.
All sampling and root valves furnished shall be of integral body bonnet type.
l.
All valves shall be rising spindle outside screw type.
Valves shall be installed so that any plant item may be isolated from the service and
process lines and to allow tanks and vessels to be drained and vented.
The piping shall be complete including, but not limited to valves, traps/collecting tank
with automatic level control wherever applicable, fittings, drains, vents, bends, Tees,
etc.
1.9
Construction
Where steel pipe work is to be welded it shall be carried at by the electric arc
process and shall conform to relevant BS or equivalent standards. Welding shall only
be carried at by suitably qualified welders who shall hold a current welding certificate
in accordance with the appropriate British Standards or equivalent.
All the shop welds or site welds for steam piping shall be subjected to x-ray
examination as per latest BS standards or equivalents.
The Bidder shall be responsible for determining the locations of site butt welds to
break the piping runs into separate sections for the purpose of shipment to site, and
for properly and clearly designating each section for correct site assembly.
All welding elbows shall have a mean radius of 1.5 times the diameter of pipe where
possible short radius elbows may be used only where space requirements dictate.
All welded fittings shall be as strong as the pipe to which they are welded.
Welded branch connections and special welded fabricated fittings shall be fitted and
reinforced as required by the latest relevant piping code.
A change in the line size on horizontal runs is to be made only through eccentric
reducers with the flat at the bottom.

Section - VI-D
Page - 67 / 88
BID DOCUMENT FOR

All horizontal lengths of pipes should have 1mm in 1200 mm slope towards flow.
1.10
Preparation for site assembly

All pipe work supplied for site butt welding shall have ends machined and protected.
Prefabricated piping sections shall be capable of being fitted into place without
springing or forcing except where cold pull is required.
The outside surface of the piping shall be painted with one coat of red oxide.
All flanges and nozzles shall be protected with wood or suitable covers and thread
end greased and protected.
1.11
Flanges and Fasteners

All flanges and orifice plate flanges standard to schedule unless otherwise stated an
arrangement drawings.
Loose flanges or cutting lengths shall be supplied to allow for minor alignment errors
of plant locations.
All bolts, nuts, gaskets, and washers plus 10% spare shall be supplied.
1.12
Steam Traps
For all steam piping, steam distribution header, suitable steam traps with by-pass
arrangement shall be provided as required. Drain pockets shall be provided at each
trap point.
1.13
Gaskets
The Bidder shall include for supply of gaskets required for jointing of pipe flanges.
For H.P. steam piping of 66 bar (a) pressure and 5100C temperature. Spiral wound
metallic type gaskets with smooth finish (63-125 micron AARH) shall be used.
For L.P. steam piping Non-metallic Compressed Non Asbestos Fibre (CNAF) type
gaskets with serrated finish gasket (125-250 micron AARH) shall be used.
1.14
Pipe testing
Prior to application of any insulation each section of completed piping system shall
be subjected to hydraulic test.
The required test pressure will be held for minimum 8 hrs during which time an
inspection will be made of all joints and connections.

Section - VI-D
Page - 68 / 88
BID DOCUMENT FOR

All testing equipment shall be supplied by the Bidder. This includes pump, pressure
gauges, etc.
The test pressure will be 2 times the working pressure unless otherwise specified in
applicable standards or instructed by the Employer.
1.15
Pipe Quantities
Bidder to provide unit prices of each item. This is to arrive at exact cost after detail
engineering.
Bidder has to give unit rate / meter for all the pipe line sizes. This is required so as to
compensate the supplies for any additional length of work carried out by him.
Sr.
No
a
b
c
d
e
f
g
h
g
h
i
j
k
1.16
Description
Pipe line from steam header to turbine inlet
Pipe line from turbine uncontrolled extraction
to inlet of desuperheater
Pipe line from M.P. desuperheater outlet
nozzle to header
M.P Header
Pipe line from turbine controlled extraction to
inlet of desuperheater
Pipe line from L.P. desuperheater outlet
nozzle to header
L.P. Header
One isolating valve, at steam distribution
header for line supplying to co-generation
turbo-alternator. Size and class to be specified
by Bidder.
Expansion loops or bellows for steam piping,
as required included in scope of supply
Support structure as required for steam piping
included in scope of supply
Hydraulic testing equipment one unit, included
in scope
Insulation, cladding etc. as required, included
in scope
All steam piping supply, erection and testing
within battery limits is in battery limits is
included in supply.
Size in
Inch NB
300
150
Unit Price/
meter (US$)
*
*
350
350
1400
*
*
1400
2500
Lot
*
*
lot
lot
One set
lot
*
*
Material of Construction
Steam header
BS 3602 HFS grade 23 or fabricated from boiler quality

plates BS 1501 151 or equivalent

Section - VI-D
Page - 69 / 88
BID DOCUMENT FOR

Flanges as per BS10 -
BS-1501 151 boiler quality plates or ASME

SA 105 or equivalent
H.P. Steam Pipe
BS 3602 HFS grade, 23 or ASME

SA 335 Gr B or equivalent
L.P. and M.P Steam

Pipes
-
1.17
BS 3602 HFS grade, 23 or ASME

SA 106 Gr B or equivalent
Insulation
Mineral wool, all cladding outside casing, temperature

Shall not exceed 700C, Class 600.
Valves
Yoke, rising steam, parallel slide valve flanged.
Condensate Piping
a.
Condensate from turbine condenser

All condensate piping from turbine outlet to ejector/gland cooling outlet,
whichever is later, including, but not limited to following shall be in the
Bidders scope
Suction line from the hot well of turbine condenser to condensate
extraction pumps
b.
Delivery line from outlet of condensate extraction pumps to ejectors
Piping from ejectors to gland steam condenser outlet
Piping from gland steam condenser outlet to hot well of boiler
Condensate from gland steam condenser and ejector
Condensate from gland steam condenser and ejector shall be piped back to turbine
condenser hot well. The complete piping along with pumps, valves, fittings etc, is in
the Bidders scope of supply.
The arrangement is shown schematically in drawing 2 FD - 934
1.18
Lot
Thermal Insulation and Lagging

Pipe lines shall not be insulated before the system in hydraulically tested and
approved by the Employer.
Insulation shall be by mineral wool and secured to the pipe, valves, and
fittings by binding wire or mesh.

Section - VI-D
Page - 70 / 88
BID DOCUMENT FOR

High grade insulating materials for H.P piping from outlet flanges of main
header to turbines inlet and M.P and L.P piping from exhaust nozzles up to
headers and all condensate piping should be insulated.
All headers and steam piping insulation and cladding is included in the scope
of supply
Insulation material of appropriate quality including but not limited to ceramic
wool, mineral wool, insulation bricks/mats, hard settling compounds, holding
lugs/studs, stainless steel wire mesh for forming mattress-covering, Hessian
cloth, paint, cladding etc. shall be provided.
In addition to insulation, piping system shall be clad with 1 mm thick
Aluminium sheets and fastened by sheet metal screws on horizontal runs, the
joints of the cladding shall be at the bottom of the piping.
At steady state operation the difference in temperature between the ambient
and the outside surface of insulation shall not be more than 20 0C.
NOTE :
1.19
1)
All the piping with valves, fitting, steam traps, drains are in the
Bidders scope.
2)
The piping supports, hangers are in the scope of Bidder.
3)
The piping calculations for stress analysis shall be prepared by the

Bidder and the same to be approved by Consultant/Employer prior to
supply.
4)
All steam piping shall be as per ASME B31.1 Standard and Bidder to
get the piping drawings authenticated by concerned authorities in
Ethiopia.
5)
The flow diagrams are indicative for the system envisaged. However,
Bidder to provide all the necessary piping, valves, instrumentation for
efficient operation of the system
Drain Water
Bidder shall divide drain water in two streams, one stream for the re-circulation water
for bearing cooling, second stream for once through usage such as for washing,
gland cooling, etc.
Bidder shall provide piping, fittings etc to the re-circulation water system. Drain water
shall be connected to nearest drain water system outside the power house building.

Section - VI-D
Page - 71 / 88
BID DOCUMENT FOR

Required piping supports, gaskets, fasteners, various nozzles, flanges and valves
shall be supplied to match the total requirement of water.
1300
STEAM DISTRIBUTION PLANT
1301
De-superheater for 8 bar (a) steam 3 Nos.

De-superheater shall be provided to reduce temperature of extracted 8 bar (a) steam
to its saturation temp of 170 0C. The de-superheating water used shall be from the
outlet of boiler de-aerator at temperature of 105 0C. However, de-superheater shall
be suitable for 95 0C temperature of de-superheating water.
1302
De-superheater for 2.6 bar (a) steam 3 Nos.

De-superheater shall be provided to reduce temperature of extracted 2.6 bar (a)
steam to its saturation temp of 128 0C. The de-superheating water used shall be
from the outlet of boiler de-aerator at temperature of 105 0C. However, desuperheater shall be suitable for 95 0C temperature of de-superheating water.
De-superheater Water piping and Pumps
Both 8 bar and 2.6 bar de-super heaters, piping of de-superheating water and desuperheating water pumps shall be included in the scope of Bidder. Bidder shall
consider suitable quantity of de-superheating water required for each desuperheater.
The piping shall be provided from feed pump suction header located at the height of
8 m above from ground level to respective de-supers heaters.
Bidder shall install suitable de-superheating water pumps for 2.6 bar (a) and 8 bar
de-super heaters with one working and one stand by for pumping the water.
Maintenance platform
Bidders to include in his scope structural work required for erection of maintenance
and operating platform, with approaching ladder, handrail etc.
2421
EOT CRANE FOR CO-GENERATION POWER HOUSE
1.1
Specifications
One number three motion electrically operated overhead travelling (EOT) crane
indoor duty conforming to BS 466 :1984 specifications OR equivalent Class II as per
IS 3177 (1977) and IS 807 having one crab of 60 t SWL capacity and one crab of 20
t SWL capacity with independent trolley mounted on same gantry bridge. Crane
Gantry Bridge shall be double girder box type construction.

Section - VI-D
Page - 72 / 88
BID DOCUMENT FOR

The crane span shall be to suit the Power house building span of 84 m. The gantry
length shall be suitable for one end to the other end of the Power house i.e. approx.
84 m.
The crane shall be complete in all respects including but not limited to current
collectors, power input wires/cables etc
Major details are furnished below.
Columns centre to centre distance of building
Length of building
84
Height of column upto Eaves level
Height of crane hook above ground level
Operation
Indoor
The crane travel shall cover the entire length of the Powerhouse building.
The crane shall be electrically operated, bridge type fabricated construction and shall
be complete with all accessories including main girder, rails, cables, panels, gearbox
rope, drum with wire etc. Access walkways with hand railing shall be provided along
the full span length on either side of the bridge girders. Suitable buffers shall be
provided on the trolley and bridge structural frames at suitable places to absorb the
shock of impact without transferring to the structural frame. Bridge and trolley track
wheels shall be of forged steel and shall be double flanged with cylindrical straight
tread and shall have hardness not less than 250 BHN.
Hooks shall be swivelling type and solid forged heat-treated alloy or carbon steel
suitable for the duty. The swivels shall operate on ball or roller thrust bearings with
hardened races. Locks to prevent hooks from swivelling shall be furnished. The lifting
hooks shall comply with the requirements of BS: 2093 or BS: 3017 or equivalent and
if required, shall have a safety latch to prevent rope coming off the hook.
Hoist ropes shall be of extra flexible, and out of plough steel rope with well lubricated
hemp core and having minimum six strands of 37 wires per strand with an ultimate
tensile strength of 160/180 kg/mm2.
Hand operated grease lubrication shall be provided for all bearings.
All the drive motors shall be of crane duty. Totally enclosed, suitable for operation
on a 400 V, 3 phase, 50 Hz AC. Motor winding insulation shall be Class F with the
temperature rise restricted to Class B.
For hoisting, long and cross travels of the crane as well as auxiliary hoist, motors
shall be of high starting torque Class D characteristics.

Section - VI-D
Page - 73 / 88
BID DOCUMENT FOR

Pendant type push button shall be supported independently of the electrical cable,
and the arrangement shall facilitate the operator to operate the crane standing away
from the load. All control equipment for the crane shall be housed in dust tight, sheet
steel cabinets.
Illumination lamps shall be provided on the crane.
Indicative speeds are furnished below
a
For main hook of 60t lifting capacity

-
Vertical lift
Longitudinal travel
Cross travel
meters/minute
meters/minute
meters/minute
0.75
8.00
8.00
For auxiliary hook of 20 t lifting capacity

-
Vertical lift
Other speeds
meters/minute
meters/minute
4.00
same as above
Main hoist motor should be squirrel cage TEFC and long travel and cross travel
motors should be slip ring TEFC. All motors should be of crane duty.
Drive
Type of motor
kW
Rating
Hoisting drum
TEFC sq. cage
1 hour
Long travel
TEFC slip ring
1/2 hour
Cross travel
TEFC slip ring
1/2 hour
Auxiliary hoist
TEFC sq. cage
1/2 hour
All gear boxes shall be totally enclosed, dust proof, helical type conforming to BS
436 and with designed service factor of 2. All couplings shall be of flexible gear type
/ centrifugal type. All brakes shall be of Electro-hydraulic thruster operated type.
Crane should be provided with a creep speed facility while hoisting at maximum
capacity to allow the heavier loads to be slowly and carefully handled. The crane
operation shall be from ground floor through pendent push button station moving
along with the crab.
The Bidder shall provide the loading data, span details, head room requirement, etc.,
to enable the Employer to arrange suitable design columns for the crane.

Section - VI-D
Page - 74 / 88
BID DOCUMENT FOR

1.2
Spares
List of spares for two year operation and maintenance, with unit price shall be
furnished for the EOT crane.
1828
1.1
COOLING TOWERS AND AUXILIARIES

a.
Seven cells, each cell of 1800 m3/hr cooling tower of 10800 m3/hr total
capacity.
b.
Water distribution system, with fills and support.
c.
Fans with motor.
d.
All support steel structure
e.
All associated mechanical, electrical and instrumentation jobs within battery

limits
f.
All piping, valves and fittings within scope of work
g.
All civil works such as RCC basin, cooling tower RCC structure, staircase
with handrails, access doors, foundations, pump house etc are excluded from
scope of Bidder. However Bidder shall provide all relevant data, designs, and
drawings to the Employer for civil and structural construction.
Design requirement
The equipment offered shall be capable of cooling the rated capacity of water
through the specified range at the design wet bulb temperature.
The range of cooling tower shall be 12 deg C from 42 to 30 deg C. The approach of
cooling tower shall be 5 deg C maximum.
Each cell shall be identical with the other cells of the tower in all respects. The total
heat load and flow shall be equally shared amongst the number of operating cells.
The structure shall be designed for wind and other loads as per IS: 1893 or
equivalent.
The equipment shall be designed for the continuous operation throughout the year.
The specified design wet bulb temperature of 25 0C includes the necessary recirculation allowance. Hence Bidder shall design his cooling towers based on this
design wet bulb temperature without considering further re-circulation allowance.

Section - VI-D
Page - 75 / 88
BID DOCUMENT FOR

Bidder shall offer a fan diameter which has already been supplied and installed by
him in other cooling towers and has been in satisfactory operation for at least two
years. List of similar installations should be furnished by Bidder.
While arriving at the air flow through the tower, due consideration shall be given to
heat carried away by evaporation and enthalpy correction of altitudes. Bidder shall
furnish detailed heat balance calculation in support of the air flow through the tower.
Bidder shall also furnish the basis of the enthalpy values indicated.
Bidder shall take into account the effect of heat recovery, because of provision of
recovery stack, while arriving at the fan power consumption. Bidder shall furnish
along with the bid, detailed calculations for the guaranteed power input to fan and
this should clearly be indicated as how the effect of recovery stack is considered. No
credit will be given during bid evaluation if a Bidder indicates higher power
consumption and claims that the heat recovery is not considered.
For the fans Bidder shall furnish his or his sub Bidders experience list clearly
indicating fan diameter, kW rating, material of construction, year of commissioning
and users satisfactory report.
The motor rating of the cooling tower fans shall be at least 125 % of the fan power
requirement at the motor output shaft to take care of any changes in tower loading or
fan performance at a later date, Bidder shall furnish calculations for arriving at the
motor rating.
1.2
Maintenance requirement
Suitable access shall be provided for maintenance of drift eliminators.
Suitable access door shall be provided on each side for approach to the inside of the
tower. Fan stack shall also be provided with inspection door.
All isolation valve shall be easily accessible.
Suitable handling facility shall be provided for handling mechanical equipment (i.e.
fan and other accessories). The handling equipment shall be a part of the cooling
tower and shall be self contained including all necessary hoist, chains etc., to
erect/dismantle mechanical/electrical equipment and transport them from fan stack to
ground and vice versa. Bidder shall demonstrate use of this handling facility
immediately after completion of tower erection.
1.3
Electrical scope of work requirements

Bidder will need to distribute power to all drive of controls in his battery limits and
provide for all required switch gear, fuses, relays, main isolator, etc.
All motors shall be squirrel cage induction motors suitable for direct on line/star delta
starting as required. Motors shall conform to the enclosed specification.

Section - VI-D
Page - 76 / 88
BID DOCUMENT FOR

Bidders scope shall include routine tests on all the motors and furnishing type test
certificates conducted on similar motors.
1.4
Features of construction
The cooling tower shall be complete with tower, basin foundation and mechanical
equipment as described below, the tower shall be of double inlet flow type of
construction. The tower shall be of induced draft type with the fans located on top of
the tower. Bidder should give all relevant data, drawings, design to Employer for civil
construction. If Bidder, is bidding for any other type of cooling tower, he should
furnish full details of the same along with drawings, literature, etc.
a.
Casing
Casing of field erected towers shall be of RCC. External casing as well as
partition walls in between cells shall be provided with air tight access doors.
b.
Inlet Louvers
The water loss in the louver openings shall be prevented with proper slope,
width, spacing and tightness of louvers. RCC louvers must be properly
designed to give uniform distribution of air with minimum pressure drop and
must be able to withstand corrosive atmosphere. Slip fit type louvers may be
provided for access to interior of tower.
c.
Fill and Fill Supports

Fill shall be of V shaped bars made of extruded PVC supported on SS: 304.
Splash bars shall be adequately supported to prevent staging and damaging.
The tower shall be levelled so that water will be uniformly distributed over the
splash bars and does not cause channelling.
d.
Supporting Structure
RCC supporting structure shall be designed to withstand the wind or
earthquake loads, dead load such as weight of the tower and circulating
water and line load and live load.
e.
Drift Eliminators
The drift eliminators shall be designed to keep the drift loss to a maximum of
0.14 % of the circulation rate. The air pressure drop across the eliminators
shall be kept to a minimum by providing a proper number of air flow direction
change across the eliminators, the water collected in the eliminators shall be
returned to the tower basin and shall not mix with the discharge air stream,
eliminators shall be multi-pass herringbone type or angular honey comb
arrangement.

Section - VI-D
Page - 77 / 88
BID DOCUMENT FOR

f.
Water Distribution System

The hot water shall be distributed to the fill through distribution basins through
distribution nozzles. Hot water shall be distributed to the basin by steel pipes.
The water shall be equally distributed among the working cells by having
control valves in the supply pipes. These shall also serve as isolating valves
for the cells. The control valves shall be easily accessible for any
maintenance work.
g.
Recovery Stack
h.
Recovery stack shall be of proper shape to improve the fan performance. The
height of the stack shall be sufficient to recover the velocity and discharge the
humid air at a sufficiently high level to minimise re-circulation. The minimum
clearance between the stack and fan blades shall be maintained along with
entire periphery of the stack to prevent the rubbing of fan blades while
rotating.
Fan Deck
The fan deck should be sturdy in construction to transmit the live loads to the
frame to support a stack and act as an access platform for the mechanical
equipment and distribution system.
i.
Internal Walkways
Walkways with platform and suitable hand rails shall be provided inside the
towers. The draft eliminators shall be easily accessible from these walkways.
j.
Hardware
The hardware used shall be a combination of hot dip galvanised steel, naval
brass, phosphor bronze, silicon bronze and stainless steel. Generally all
hardware material above fan deck level shall be hot dip galvanised steel and
rails shall be SS 304 and nails shall be screw shank type. All hardware item
to be SS: 304.
1.5
Mechanical equipment
1.5.1
Fans
Fans shall be of open type, multi blade construction with the blades of aerofoil
section. Fan blade shall be of cast or moulded construction. These shall be of easily
removable and adjustable pitch type. Blade shanks and hubs shall be suitably
insulated to prevent electrolyte corrosion.

Section - VI-D
Page - 78 / 88
BID DOCUMENT FOR

1.5.2. Fan Drives
a)
Fan drives shall be as follows:

Reduction gear drive
The gears shall be of spiral bevel, helical or worm type. The gear reduction
may be of single stage or multi stage. All gear drives shall be of enclosed
type and shall operate in oil bath. Remote oil level indicators, fill and drain
lines shall be provided. The service factor of the gear drive with electric motor
as the prime movers shall be as follows: 2 for spiral bevel and helical for
intermittent services. For worm gear drive the service factor shall be not less
than 1.7.
b)
The drive shafts shall have flexible coupling at both driving and non driving
ends. This shall be of hollow hot dip galvanised carbon steel. The flexible
coupling bushing shall be rubber. Drive shafts shall be dynamically balanced.
c)
All exposed moving parts of the drive shall have metallic safety guards.
1.5.3. Prime Mover

The fan driver shall be an AC electric motor of squirrel cage induction type.
1.5.4. Accessories
The following accessories shall be provided
1.5.4.1 Hand Rail
Double hand rail of hot dip galvanised steel pipe (32 mm nominal dia) shall be
provided on all open sides of the fan deck and distribution basin cover.
1.5.4.2 Fan Guards
Each fan guard shall have a suitable wire mesh safety guard.
Locally mounted instruments
The following instruments shall be supplying by Bidder:
-
Temperature gauge on cold water outlet pipe near basin

Temperature gauges on the hot water inlet to each cell
Float switches to indicate high/low levels in the basin
All necessary instruments required for testing the cooling tower shall be
provided by Bidder
Vibration limit switch to stop the fan on excessive vibrations
Foundation bolts

Section - VI-D
Page - 79 / 88
BID DOCUMENT FOR

1.5.5. Ladder
Bidder shall provide all relevant data, designs, and drawings to the Employer for
RCC ladder. Ladder shall be provided on one side of cooling tower for access to the
fan deck.
1.5.6. Distribution Basin Cover
The hot water distribution basin shall be provided with a suitable cover to avoid direct
sunrays falling on the distribution through or basin, to minimise algae growth and to
prevent choking of distribution nozzles from external falling objects.
1.6
RCC support structure and basin

Bidder shall provide all relevant data, designs, and drawings to the Employer for Civil
and structural construction. The complete construction is by the Employer.
The Bidder shall consider in his design concrete support structure and basin for
cooling tower with a common outlet channel. The structure shall be designed as per
IS: 3370 or equivalent. Cooling tower basin shall be provided with partition for
isolation purposes. Basin shall be water tight without the use of any fillers, paints or
sealing compounds.
1.7
Piping, valves and specialties

Piping up to 150 mm shall be as per IS: 1239 or equivalent. From 150 mm to 600
mm it shall be of IS: 1972 or equivalent. Above 600 mm piping shall be fabricated
from plates of IS: 226 or equivalent in accordance with IS: 3539 or equivalent. Joints
up to 65 mm shall be screwed. Joints 80 mm and above shall be butt welded or
flanged.
Valves up to 65 mm shall be of bronze, to IS: 778 or equivalent with the ends
screwed to IS: 554 or equivalent Valves of 80 mm and above shall be of cast iron
with ends flanged. Scope will include supply & installation of supply & return headers
at cooling tower. Piping & Instrumentation with valves to pumps; supply & return
cooling water lines with required supports, ground protection, bends, gauges etc
supply & return headers near turbine condenser.
1.8
Materials of construction
All materials of construction shall be of tested quality. These shall be free from any
defects and imperfections, and shall be of latest manufacture having certified quality
for physical and chemical properties. Materials shall be of IS, ASTM, BS or any
equivalent standard. Liberal factor of safety shall be used in selecting the materials.

Section - VI-D
Page - 80 / 88
BID DOCUMENT FOR

1.9
Tests and Inspection
1.9.1
Performance Test
Field erected units after complete erection and commissioning shall be field tested
for performance. The test shall be conducted at a time when the atmosphere
conditions correspond to as soon as possible the design conditions. The test shall be
conducted in accordance with the standard procedure for acceptance test of Cooling
Tower Institute, USA.
1.9.2
Visual Inspection
After completion of work, equipment shall be offered for visual inspection to
Employer and/or his representatives. Any work or component not in accordance with
the specification and approved drawings shall be redone or replaced to the
satisfaction of the inspector. Stage inspection if specified shall be offered to improve
the quality of the final product.
1.9.3
Material Test Certificates

Test certificates of the materials of the various components for the cooling tower
shall be furnished.
1.9.4
Welding Test
All welding procedure and welders test certificates shall be offered for Employers
approval if specified. All welding shall be performed by shielded electric arc, gas or
other approved methods. All welding shall conform to IS: 816 or equivalent and the
qualification of the welding operators shall be at least equal to the requirement of IS:
827 or equivalent.
1.9.5
Painting and Protections

All parts which are subjected to wetting and drying alternatively shall be painted with
three water proof coats as per relevant standards.
All exposed steel and cast iron surface shall be given three coats of rust and
corrosion resisting paint.
1.10
Motor List
Description
Drive for Make up water pumps
Drive for Circulating water pumps
Drive for Auxiliary water pumps
Drive for Fans
Quantity
2 Nos.
4 Nos.
4 Nos.
7 Nos.
Type
*
*
*
*
RPM
*
*
*
*
Rating
*
*
*
*

Section - VI-D
Page - 81 / 88
BID DOCUMENT FOR

1.11
Pump List
Description
Make up water pumps
Circulating water pumps
Auxiliary water pumps
Quantity
2 Nos.
4 Nos.
4 Nos.
Type
*
*
*
Discharge
*
*
*
Head
*
*
*
* - Bidder to Specify
1.12
Electrical works
Motor Control Centre (MCC)
For supplying power to various motors the motor control centre (MCC) shall be used.
1.13
Scope of erection and commissioning

a.
Mechanical/Electrical/Instrumentation and controls

All items covered under scope of supply including base plates, foundation
bolts, anchor boxes, etc.
b.
Consumables
Specifications including brand names and quantities of all consumable
materials such as lubricants, flushing oil, hydraulic fluids etc required for start
-up, initial filling, commissioning and performance tests and yearly
requirements of the same for normal operation are to be submitted by the
Bidder.
However, supply of all consumables required for start-up, commissioning,
initial filling and performance tests is included in the scope and shall be
supplied by the Bidder at appropriate time.
c.
Spare parts
A minimum requirement of spare parts sufficient for the two years of normal
trouble free operation shall be listed and priced by the Bidder in the spare
parts schedule.
In addition to the above spares the Bidder shall also supply commissioning
spares along with this main equipment as per his experience, for replacement
of damaged or unserviceable ones during the execution of the project at site,
to avoid delay in the project schedule.

Section - VI-D
Page - 82 / 88
BID DOCUMENT FOR

d.
Special maintenance tools and tackles

Two sets of special tools and tackles required for operation maintenance,
inspection and repair neatly packed in steel boxes complete with instructions
for the cooling tower, pumps and all other equipment covered in this scope of
work shall be supplied by the Bidder.
1829
COOLING WATER PUMPS
1.0
Scope of supply
1.1
a.
Circulation water pumps (condenser water)
b.
Auxiliary cooling water pumps (cooling water for turbo-alternator and their
auxiliaries)
c.
Make up water pumps
d.
All piping, valves and fittings within battery limits
e.
All support steel structure for piping, railing, etc within battery limits
f.
Cooling tower and auxiliaries
g.
h.
All associated mechanical, electrical and instrumentation within battery limits.

All civil works such as foundations, building to house the pumps, etc are
included in the scope of Employer. However Bidder shall provide all relevant
data, designs, and drawings to the Employer for civil construction.
Circulating water pumps

Quantity:
4 Nos.
These circulating water pumps shall circulate water from cooling tower basin to
condenser of double extraction condensing type turbo-alternator and back from
condenser to top of the cooling tower water distribution system.
Horizontal centrifugal pumps, each of 3500 m3/hr capacity to develop a head of 40
mwc maximum at condenser inlet flange. Out of the four pumps, three will be in
operation and one will be a standby unit. All pump units shall be complete with
electric motor, coupling guards, base frame, starter, etc.
Scope of supply shall be upto inlet flange/header of condenser and from outlet flange
of condenser to the cooling tower. Required isolation valves, non-return valves, local
pressure and temperature gauge, etc shall be provided.

Section - VI-D
Page - 83 / 88
BID DOCUMENT FOR

1.2
Auxiliary cooling water pumps

Quantity:
4 Nos.
These pumps shall be installed in the pump house near cooling tower to supply
cooling water from cooling tower basin to oil coolers of turbine and air coolers of
alternator of co-generation power plant. The return line from respective coolers or
common header from power house shall be connected back to cooling tower.
Horizontal centrifugal pumps, each of 600 m3/hr and develop a head of 40 mwc
maximum. at power house turbo-alternator coolers. Out of four pumps, three will be
in operation and one will be a standby unit.
All pumps units shall be complete with electric motor, coupling guards, base frame,
starters, etc.
Scope of supply of valves, piping, fittings, etc include upto inlet flange/header of
respective consumers of power house turbo-alternator and return line upto cooling
tower. Required isolation valves, non-return valves, local pressure and temperature
gauges, foundation bolts, etc shall be included in the scope of supply.
1.3
Make up water pumps

Quantity:
2 Nos.
These pumps shall be installed in the existing service water pump house of the sugar
factory. These pumps will supply water from overflow collection tank of clarifier to
cooling tower basin for initial fill up as well as to meet make-up requirements.
Horizontal centrifugal pumps, each of 300 m3/hr capacity at 30 mwc head. These
pump units shall be complete with electric motor, coupling guards, base frame,
starter, etc.
Necessary valves, piping both suction connections from the clarifier overflow tank
and discharge pipe up to cooling tower basin is included in the scope of supply.
1.4
Cooling Water Piping

All piping shall be in Bidders scope of supply. This shall include cooling water for the
turbine condenser, turbine auxiliaries, instrument compressor and other bearings.
Piping supports, gaskets, fasteners, various nozzles, flanges and valves shall be
supplied to match the total requirement of water.
1.5
Design criteria for piping

All suction pipes shall be designed for velocity not exceeding 1 m/sec and
delivery/discharge piping for velocity not exceeding 2 m/sec.

Section - VI-D
Page - 84 / 88
BID DOCUMENT FOR

All piping shall be designed to withstand at least double the working pressure in the
system.
2423
COMPRESSED AIR SYSTEM FOR TURBO ALTERNATOR UNITS
1.1
Scope of supply
Includes
1.2
1.3
Two (2) air compressors (1 working + 1 standby) reciprocating air

compressors of required capacity.
One air receiver
One heat less air drier with twin absorption tower
Necessary instrumentation and local control panel
Compressor air piping, valves, piping, fittings, supports etc
Codes & Standards

After cooler
IS:4503/TEMA C/R or equivalent
Air compressors & exhausters

positive displacement type
IS:5456-1969 or equivalent
Air compressor plants with

operating pressure up to 10
bars
IS:6206-1971 or equivalent
Pipes
IS:1239 Part I duty medium/heavy or equivalent
Fittings
ASTM B16.9-Butt Welded or equivalent

ASTM B16.11-Srewed & Socket or equivalent
Flanges
DIN/ANSI 16.5/IS:6392 or equivalent

BOLTS/NUTS IS:1363 or equivalent
Design Requirements
The air compressor will be installed on permanent/stationary foundation or shall be
skid mounted in the plant room. The compressor, motor, pulley, V-belt guard, after
cooler, moisture separator, air receiver, etc may be mounted on a skid which shall be
anchored to the floor. If the compressor is to be installed on stationary foundation,
the structural design of the foundation, anchor bolts, first and final grouting shall be in
the scope of the Contractor.

Section - VI-D
Page - 85 / 88
BID DOCUMENT FOR

1.4.1
Specifications
1.4.1
Air Compressors
Reciprocating non lubricating type two compressors, complete with moisture
separator, air receiver, pressure switch, drive motor, safety valve, etc for supplying
oil and moisture free air for instrumentation and control. The compressor shall be
with automatic unloading arrangement and pressure switch to maintain requisite
pressure.
Out of two, one compressor shall be operating and one standby. Automatic start
arrangement shall be provided to automatically switchover the standby compressor
in the event the running compressor suddenly stops.
Capacity and pressure of each compressor shall be suitable to operate the
instrumentation and control system.
Compressor shall be fitted with automatic mechanical air governors which enable
them to load and unload at pre-adjusted cut-in and cut-out pressures.
1.4.2
Crosshead
Preferably be provided with replaceable white metal/Aluminium lined shoes to save
Crosshead guide wear.
1.4.3
Valve assemblies
Low clearance, low lift, automatic double dampened valves, two cushion plates with
spring plates to reduce shocks of valve plate impact on valve body and give longer
life.
1.4.4
Bearings
Two main bearings, white metal lined thin walled main and big end bearing,
preferably extra main bearing on belt wheel side for taking belt pull load, extending
bearing life.
1.4.5
Intercooler
Conforming to IS: 4503/TEMA heat exchanger or equivalent standard, with shell &
tube type, floating head tube bundle for easy removal, with efficient moisture
separator. Drain valve for removing moisture. Flanged connections for water inlet
and outlet. Additional ports for de-scaling chemical circulation shall be provided.

Section - VI-D
Page - 86 / 88
BID DOCUMENT FOR

1.4.6
Suction Filter
In closed metallic box with replaceable/cleanable filter element. Preferably to be
provided with suction filter choking indication by vacuum valve. Filter is of dry type
with silencing arrangement.
Foundation bolts of suitable size and according to structural strength requirement
shall be provided along with compressor.
1.4.7
Controls
Following control switches should be provided:
1.
2.
3.
High discharge pressure/temperature cut-out switch.

Oil low pressure cut-out switch.
Capacity control
Capacity control should be on pneumatic circuit of copper/PVC tubing rigidly secured

upto suction valves on both the sides. Pneumatic circuit opened and closed on the
logic pressure switches set with minimum differential pressure of 0.2 kg/cm2 (g)
through solenoid valves-three port, two way. The air required for unloading shall be
taken from the air receiver.
1.4.8
After cooler/Moisture Separator

Horizontal, water/air cooled shell and tube type, removable tube bundle types after
cooler for cooling discharge air 5 0 above outlet cooling water temperature. If to be
mounted separately on case foundation, necessary foundation bolts are to be
supplied complete with moisture separator, manual/auto drain trap.
The heat exchanger should conform to the IS: 4503 or TEMA R/C design standards
and shell with IS: 2825 or equivalent standard for unfired pressure vessels. The after
cooler heat exchanger shall preferably of water through tubes for easy cleaning and
maintenance.
1.4.9
Electrical
The compressor MCC shall be in the plant control room.
1.4.10 Air Receiver

Air receiver shall provide a fly wheel effect, that is, it shall meet the varying demands
without compressor regulation functioning incessantly. The air holding capacity of
receiver shall be 30 minutes.
The Air Receiver shall also condense and trap as much as possible the moisture in
the compressed air and also to let oil and other impurities settle down.

Section - VI-D
Page - 87 / 88
BID DOCUMENT FOR

Manufacture should submit his design and drawings for approval clearly indicating
corrosion allowance.
Air receiver shall be manufactured according to IS:2825-1969 or equivalent but the
design pressure shall be assumed as maximum working pressure plus 10 %.
Receivers shall be regarded as Class II vessels.
1.4.11 Mountings
Each air receiver shall be provided with a safety valve preferably of the direct spring
loaded type and shall be so constructed and adjusted so as to permit the air to
escape from the air receiver without increasing the pressure beyond 10 % above the
working pressure
A drain valve or cock shall be provided either for manual or automatic operation, at a
point for enabling the draining of the condensate.
Pressure gauge shall be fitted to each receiver. The bourdon type of gauge
conforming to IS: 3624-1966 or equivalent is recommended. The dial shall be
graduated in bar and graduation shall be from zero to not less than one-and-half
times, and not more than twice the design pressure of the receiver.
Fusible plugs may be fitted to safeguard the installation in case of excessive rise in
temperature due to fire. The position of fusible plug where fitted shall be such that
discharge of the plug will not do injury to any person.
1.4.12 Inspection and Tests
Inspection
The requirements of inspection shall be as given in IS: 2825-1969 or equivalent.
Hydraulic Test
Every receiver shall be tested at the manufacturers works by hydraulic pressure to
1.5 times the design pressure. While under pressure the air receiver shall be struck
with a hammer on both sides and close to welded seams and a thorough
examination shall be made. The pressure shall be maintained for 10 minutes.
Installation
Proper foundation details for the receiver and the support shall be provided by the
manufacturer.
Surface Treatment
An appropriate surface protection shall be given inside and outside of air receiver to
prevent corrosion.

Section - VI-D
Page - 88 / 88
BID DOCUMENT FOR

1.4.13 Compressed air piping / tubing
Complete air supply piping for instrumentation and controls for turbo alternator
system, shall be in the scope of Bidder.
Complete air supply piping, including but not limited to valves, fittings, moisture
separator, supports, vents, drains etc, from the compressor to the end users shall be
in the scope of Bidder.
1.4.14 Spares
List of spares for two year operation and maintenance, with unit price for each spare
shall be furnished for the compressors.

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J P MUKHERJI & ASSOCIATES PVT LTD

Tendaho Sugar Project

BID DOCUMENT FOR

POWER GENERATION PLANT ..................................................................... 2

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Design requirement ......................................................................................... 2

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Inspection and Tests ....................................................................................... 2

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BID DOCUMENT FOR

POWER GENERATION PLANT

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BID DOCUMENT FOR

Speed Reduction Gear box

Alternator and auxiliaries

Power house crane with Auxiliaries.

Cooling Tower, Pumps and Auxiliaries.

Cooling tower cells

Air Compressors with Dryers and Receiver.

J P MUKHERJI & ASSOCIATES PVT LTD

BID DOCUMENT FOR

Codes and Standards

J P MUKHERJI & ASSOCIATES PVT LTD

BID DOCUMENT FOR

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BID DOCUMENT FOR

During season sugar factory will be in operation and co-generation

When sugar factory is under breakdown, but turbo-alternator is

J P MUKHERJI & ASSOCIATES PVT LTD

BID DOCUMENT FOR

Inlet live steam - For Each

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BID DOCUMENT FOR

The economical steam rate

* - Information to be submitted by the Bidder

Uncontrolled extraction at 8 bar (a) steam at extraction conditions of

Controlled extraction at 2.6 bar (a) steam at extraction conditions of

Guaranteed performance shall be for conditions during MODE A

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BID DOCUMENT FOR

Inlet live steam - For Each Steam

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BID DOCUMENT FOR

The maximum noise level at 1.0 m [db(A)]

* - Information to be submitted by the Bidder

Uncontrolled extraction at 8 bar (a) steam at extraction conditions of

Controlled extraction at 2.6 bar (a) steam at extraction conditions of

Guaranteed performance shall be for conditions during MODE A

J P MUKHERJI & ASSOCIATES PVT LTD

BID DOCUMENT FOR

40 MWe MCR, each

Double extraction condensing type

Uncontrolled to meet sugar factory demand at 8 bar (a).

Controlled for sugar factory process requirement at 2.6

0.14 bar (a).

Material of construction for different parts shall be appropriate to the pressure,

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BID DOCUMENT FOR