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Technical Specification For Water Treatment Plant
Technical Specification For Water Treatment Plant
TABLE OF CONTENTS
1. INTRODUCTION 4
2. WATER REQUIREMENT 4
8. BATTERY 9
9.1. MECHANICAL 10
10. MATERIAL OF CONSTRUCTION 16
10.1. GENERAL 17
11. ELECTRICAL 18
12. INSTRUMENTATION AND CONTROL 18
ANNEXURES
1. INTRODUCTION
The main sources of water are from the River Water. From the bore well, the water is transferred to
main reservoir located in the power plant premises. The analysis of this raw water is as given in
Annexure.
One no. of raw water reservoir is envisaged for storing raw water. The water treatment system draws
raw water from this reservoir and supplies DM water and drinking water as needed to the power plant
and also treating the effluent.
If clarifier is used, the water from the River is directly feed in to clarifier. The clarified water will be stored
in the raw water tank.
2. WATER REQUIREMENT
Water is used as a cooling medium in the heat exchanger equipment in power plant such as oil coolers,
generator air coolers etc. of turbo-generator, make up water for the boiler to compensate the blow down
and other losses, dust suppression system in fuel storage area, dust conditioning in dry ash handling
system and fire fighting system. A small quantity of water will be required for drinking and sanitation for
plant personnel.
The following facilities are envisaged to meet the power plant water requirements as
One (1) stream of DM plant of 12 m³/h capacity (net output from mixed bed outlet)
The design of water treatment facilities needs to be done based on given raw water quality as per
Annexure. Consider 20% margin for designing the system and design value shall be furnished.
The Pretreatment of raw water shall consist of one Clarifier to remove the turbidity along with the dosing
system such as chlorine, polymer & coagulant. The clarified water is stored in the raw water tank. The
raw water from River will be pumped to clarifier by 2 x150 m³/hr (1W+1S) RWP. The sludge from
clarifier is dried in sludge drying beds.
The DM plant consist of one Multi grade filter (MGF), one Activated filter (ACF),one UF, One RO, one
degasser unit (DG), One strong acid cation (SAC) unit, One strong base anion (SBA) and One mixed
bed unit (MB). The raw water will be pumped from the raw water storage tank to a Multi grade filter by
18 ³/hr (1W+1S) Raw water transfer pumps. The outlet of the MGF via ACF is feed in to the UF which
has 90% recovery. The outlet of UF will be transferred to UF permeate tank. From this, the water is fed
in to RO which has 75% recovery (max80% recovery) and then to degasser unit where the CO2 is
removed using air blower. The degassed water is stored and fed to SAC & SBA. The water from the
SBA is polished in a mixed bed filter. The water from the mixed bed is stored in a DM storage tank. Raw
water shall be used for the back wash of MGF, UF permeate for UF back wash, Degassed water shall
be used for the back wash of RO and DM water shall be used for the regeneration of SAC, SBA and
MB.
Sodium hypo chlorite dosing systems shall be provided in the raw water tank. Auto pH correction dosing
shall be provided in the MB outlet line. The pressure of the water at the outlet of MB shall not be less
than 2 Kg/cm² (g).
4.1.3. Proposed scheme for the treatment for boiler water treatment
Option 1 :RO ---- Degasser ---SAC ---SBA --- Mixed Bed The throughput of RO shall be 12
m³/hr. The throughput of each stream of DM shall be 12 m³/hr.
Option 2 :RO ---- Degasser --- Mixed Bed(1W+1S) The throughput of RO shall be 12 m³/hr. The
throughput of each stream of DM shall be 12 m³/hr.
Sodium leakage through cation exchanger shall not exceed 1 mg/l as CaCO3.
Bidder shall also guarantee the total power consumption of the equipment indicated by him.
5. SCOPE OF SUPPLY
Design, engineering, manufacture, supply, transport, unloading, storage, erection & commissioning and
performance testing of complete pretreatment plant consisting of pretreatment, Reverse Osmosis/ion exchange
system as per the scope of work given below:
5.1. THE DETAILED SCOPE OF EQUIPMENT FOR CLARIFIER & DM PLANT STREAM IS AS FOLLOWS:
One (1) no. of Clarifier (High rate solid contact or Lamella or tube settler)
One (1) no. of chlorine, polymer & coagulant dosing system
One (1) no. of Sodium Hypochlorite dosing tank with 2 nos. of pumps in raw water tank. (if it is dosed in
clarifier, then separate dosing system is not required)
Two (2) Nos. micron cartridges filter feed pump with complete electric motors and accessories
One (1) nos. of multi grade Filters complete with filter media & accessories for the DM stream.
One (1) nos. of Activated Carbon Filters.
One (1) no. of Ultra filtration unit
One (1) of UF permeate tank of capacity 30 min storage.
One (1) No. Antiscalant dosing system with dosing tank, agitator, two (1W+1S) metering pumps,
necessary valves piping and accessories.
One (1) No. Acid dosing system with dosing tank, necessary valves piping and accessories.
One (1) No. micron cartridge filter housing with required number of cartridges of 5µ size.
Two (2) Nos. high pressure pump with complete electric motors and accessories.
One (1) No. module of R.O complete set, mounted on R.O skid with necessary number of pressure
vessels and elements, with adequate piping & valves to withstand the necessary pressure developed by
high pressure pump with all necessary accessories & instruments with necessary control / power wiring
for the instruments and other motors / electrics to the control panel mounted on the skid.
One (1) No. module of chemical cleaning in process (CIP) circuit with necessary chemical CIP tank,
cleaning pump, cartridge filter, Heating Element & agitator with necessary piping and accessories for
both UF and RO separately
One (1) nos. of of Degasser Tower
One (1) nos. of Degassed Water Storage Tank of 30 min storage
Two (2) nos. of (1W+1S) Degasser Blower
Two (2) nos. of (1W+1S) Degassed Water Pump
Two (2) nos. of Strong acid cation exchangers
Two (2) nos. of Strong base anion exchangers
Two (2) nos. of Mixed bed exchangers
Two (2) nos. of (1W+1S) Air scouring blowers. The same blower shall be used for Neutralization pit air
agitation.
Two (2) nos. of Acid measuring tank for cation bed & MB
Two (2) nos of Caustic dilution tank for anion bed & MB
One (1) no. of Caustic dilution tank for neutralization pit
One (1) no. of Morpholine solution tank
Two (2) nos. of (1W+1S) Morpholine dosing pumps with necessary valves, piping and accessories
One (1) no of bulk acid storage tank of capacity 50KL (if req)
One (1) no of bulk alkali storage tank of capacity 50KL (if req)
Two (2) nos of unloading pump for HCl/Alakali of each capacity 10m3/hr
Associated pipes, valves, gaskets, fasteners, etc
Air grid for the neutralization pit.
2x100% effluent transfer pumps (if req)
Piping between the tank/pump and the acid measuring tanks.
Agitators for all dosing tanks.
Interconnecting pipe work complete with valves fittings, supports and accessories including air agitation
grid in neutralization pit.
Piping required for the back wash and regeneration of the vessels
Instrumentation as per requirement
Proprietary treatment chemicals for 3 months to be provided.
Common base frame for each pump and motor, foundation bolts and nuts required for grouting all
equipment within terminal points shall be included in the scope of supply.
MCC, power and control cables.
Cable trays and other hardwares as required.
Signal cables
Local push button stations
A portable water analysis kit including SDI testing kit and Jar testing kit.
Special tools and tackles and Commissioning spares.
2 years operational spares
Complete instrumentation consisting of local instruments, flow measuring instruments, PLC based
control panel for UF & RO skid, level and pressure switches as specified in the technical specification.
Final painting.
O & M manuals for the complete system with necessary drawings, catalogues and other information
pamphlets for all the equipment covered in the scope.
Furnishing load data for all equipment foundations.
Furnishing civil drawings for all RCC structures.
First fill of lubricants with operating chemicals and lubrication chart showing the lubricants required for
each equipment, interval of topping up, quantity required per annum with the name of the Indian
suppliers.
Earthing above the ground to be included in the scope.
All consumable chemicals, spares, and lubricants sufficient for 3 months operation.
Layout comprises Clarifier, UF/RO, DM plant, softener plant, control room & Lab.
All pumps/blower etc. shall be supplied with base plate, coupling, coupling guard, anchor bolts and nuts,
canopy’s etc. for the equipment.
All frontal piping / all interconnecting piping / recirculation piping / priming piping / valves/ fittings /
fasteners / ejectors / pipe racks / pipe supports and accessories integral to the plant. All piping shall be
pre-fabricated as per the layout so that they shall be erected directly. All puddle pipes with flanges for all
RCC tanks & pits shall also be supplied.
All the ion exchangers / filters shall be with the resin/filtering material, all internals, water distribution
drain system and V Notch boards.
All terminal points shall be provided with suitable dummy flanges.
Earthing from the equipment to the nearest riser.
MCC, cables, cable trays, LPBS shall be supplied and erected.
One(1) lot of necessary field instruments , cables, installation materials, erection, calibration, testing and
commissioning.
Control panel with annunciation.
Foundation bolts, base plates, grouting with grouting materials.
Commissioning spares
2 year operational spares
Special maintenance tools and tackles.
7.0. EXCLUSIONS
Multi Grade Filter of shall be designed for an operating pressure of 5 kg/cm² (g). Multi Grade Filter
will be used to reduce the turbidity and hardness of the raw water to the required level. Free board
of at least 50% shall be left over the filtering media to facilitate backwash. The filter shall be
provided with the necessary nozzles including water inlet, water outlet, back wash, air scour and air
release nozzles. The filter shall be complete with necessary filtering medium. Scope of supply
shall include automatic backwash system. Raw water shall be used for back washing of MGF.
The RO system shall be skid mounted consisting of micron filter, high pressure pumps,
pressure tubes, dosing system, PLC, Wet panel etc. along with required interconnecting piping
and instruments and assembled at shop.
The RO permeate water tank / degassed water tank shall have an effective capacity of 9 KL.
The permeate water tank shall be provided with suitable level gauges and three level switches,
one for high level, one for medium level and one for low level for interlocking with RO feed
pump and MB feed pump. The permeate water tank shall also be provided with vent & drain
facilities.
9.1.7. Degasser
Degasser shall be designed for a maximum operating pressure of 5 kg/cm² (g). One (1)
degasser of design capacity with counter current flow of water and air shall be supplied. The
degasser tower shall have adequate cross –sectional area for efficient removal of carbon
dioxide. The carbon dioxide content in the degassed water shall not be more than 5 ppm as
CO2. The degasser tank shall be filled up with polypropylene packings and shall be provided
with internal distributors. The degasser tower shall store maximum effluent from one cation
exchanger unit for 30 minutes. Degasser sump shall be provided with level gauge glass,
overflow and drain lines, staircase, handrails, platforms etc., as required for each access. The
plant shall be designed such that level in degasser sump shall remain constant during
regeneration of exchanger units. The equipment shall have adequate built in capacity to cater
to the high flow rate during regeneration. The degasser sump shall be of MSRL construction.
Technical Data:
Type : Forced draft
No. of units : One
Capacity of each tower : *
Design Pressure :
Atmospheric Temperature : 50°C
Material of construction : Carbon steel rubber lined or FRP
Rubber lining : 4.5 mm thk (1.5 x 3 layers as per IS
4682 Part-I)
Packing : Polypropylene rasching rings or Pall
rings
Minimum air requirement : * Guaranteed
effluent quality : *
Minimum shell thickness : 8 mm
Mounting / foundation : Requirement preferably mounted on top
of permeate water tank
* Bidder to specify
Material of construction of blower : Carbon steel, preferably FRP lined Intake filters,
dampers, doors
Etc. : Carbon steel, preferably FRP lined The blower and
motor shall be mounted on a common base frame.
Two (w) DM feed pumps, each of 100% (unit production plus the regeneration water required
during regeneration time) capacity shall be supplied complete with flexible coupling, common
base plate, valves, discharge pressure gauges and all other accessories, including drive
motors. The pumps shall supply degassed water through the anion exchanger followed by
mixed bed to water tank. Two (2) pumps shall run during service run and a third pump will
meet the water requirement during the time of regeneration also. Necessary recirculation line
from pump discharge to sump shall be supplied.
Type : Centrifugal, motor driven
Capacity of each pump : Vendor to specify.
Head : After pH correction shall be 3.5 kg/cm² (g)
Material of construction :
Casing : SS 316
Impeller : SS 316
Shaft : SS 316
Shaft sleeve : SS 316
Base frame : IS 2062
9.1.10. Strongly Acidic Cation Exchanger:
One (1) strongly acid cation exchanger of 100% capacity (12 m³/h unit production) and shall be
designed for a maximum operating pressure of 5 kg/cm² (g) and filled up with adequate
quantity of strongly acidic resin. The flow velocity through the exchanger shall not exceed 40
m/h. Exchanger shall run continuously for 20 hours after which counter current shall be carried
out. At least 100% free space shall be kept over resin bed for expansion during regeneration
and back washing. Water shall be supplied to the unit from a common header and the effluent
shall be discharged to a common header and the effluent shall be discharged to a common
header. Two resin traps shall be provided, one on the main water outlet and the other on the
backwash regeneration distribution water outlet for each unit. The unit shall be vertical shell
type with dished ends having internal collection pipe works and provided with manholes of
proper size and sight glasses. Decationised water shall be used for regeneration purposes.
One (1) Mixed bed exchangers of each 12 m³/hr capacity shall be designed for an operating
pressure of 5 kg/cm² (g) shall be supplied. The exchanger shall be filled up with adequate
quantity of strongly acidic and strongly basic resins. The design specific loading shall not be
more than 9 m³/hr/m². 100% free space shall be left over the resin bed to allow expansion of
resin during air scouring/mixing and back washing. The influent water shall be fed from a
common header and treated water discharged to a common header. Two resin traps shall be
provided, one in the main water outlet line and the other in the backwash/regeneration shall be
supplied. The unit shall have sight glasses and manholes of proper size. Flow measuring
orifice board of PVC shall be supplied in the sump of the exchanger. DM water from the mixed
bed exchanger shall be stored in a storage tank. DM water shall be used for regeneration
purposes.
One (1) 20 m³ capacity acid storage tank in MS construction with epoxy coated shall be
supplied for storing the acid received by road tankers. Two (2) unloading and transfer pumps of
required capacity, one (1) running and one (1) standby shall be included as part of the scope of
supply.
The storage tank shall be provided with vent, drain, overflow, gauge glass platforms, handrails,
ladder, fume absorber etc. as required. All the valves and fittings shall be rubber lined.
9.1.16. Resin
The resins shall be of proven quality and guaranteed to offer stable and trouble-free operation
for minimum five (5) years. The resins offered must have previous satisfactory record for
similar applications in large industrial plants for not less than five(5) years. Resins shall have
good stability and attrition resistance against specified operating conditions.
High capacity type-I strongly basic iso-pours anion exchanger resin shall be used for anion
exchanger and anion part of mixed bed units.
For cation exchanger and cation part of mixed bed, styrene base resins with di-vinyl benzene
cross-linking shall be used. All resins shall be supplied in manufacturer’s original sealed
containers.
All resins shall be suitably sieved for uniform size so that jamming of the collection/distribution
system inside the exchanger vessels due to fines are eliminated. Attrition losses of resins shall
not exceed 3% per year.
9.1.17. Dosing System
All dosing tanks shall be of FRP/ HDPE construction and shall have a capacity of 125% of 24
hours requirement or 240 litres, whichever is higher. All the dosing tanks shall be provided with
low level switches to give alarm. In the case of antiscalent dosing and de-chlorination dosing,
in addition to alarm, tripping of RO High Pressure Pump shall also be envisaged.
All dosing tanks shall be provided with motorized agitator, wherever vigorous agitation is
required and where solids / flakes are dissolved.
All dosing tanks shall be provided with suitable tubular level gauges.
Each dosing system shall have two dosing pumps (one working and one standby). The stroke
length of all dosing pump shall be adjustable when the pump is in operation.
All internal pipes and header shall conform to IS : 1239 Part 1 upto 150 mm NB and IS:
3589 Class 3 above 150 mm NB. All pipe and fittings above 50 mm NB shall be 3 mm
rubber lined. Pipes and fittings before activated carbon filter shall be unlined.
For Blowers
Impeller and casing shall be of carbon steel conforming to IS : 2062. Shaft shall be of IS
: 2073 Gr. C45/EN8 and sleeve ASTM A 276 TP 316.
For Pumps
For pumps in SS pump casing and sleeve shall be of ASTM A 276 TP 316. Impeller shall
be of ASTM A 743 Gr GF 8 TP 316 and shaft shall be EN8. The pump shall be provided
with impregnated teflon packing.
For Flanges
Flanges upto 20 mm thick shall conform to IS : 6392 and above 20 mm thick shall conform
to IS: 2062.
For Gaskets
Gaskets shall be compressed asbestos fibre with nitrlle rubber binder conforming to IS:
2712.
Fasteners
Fasteners shall be of ASTM A 307 Gr. B carbon steel.
Rubber lining
Shore hardness of natural rubber for lining shall be 65 ± 5° in all cases
Two coats of internal painting and two coats of external painting wherever required shall
be done. For unlined vessels, the internal painting shall be with two coats of primer and
two coats of epoxy. For lined vessel, internal painting shall be with two coats of primer.
External painting shall be with two coats of primer and two coats of enamel.
Note: No asbestos based material and cadmium based material shall be used in the RO
system.
10.1. GENERAL
The design of vessels and tanks shall be as per IS 2825.
All tanks shall be provided with vent & drain facility.
For the pumps 10% margin shall be added on the maximum flow and 5% margin
shall be added on the maximum dynamic head.
All flanges at the terminal point and within the battery limit shall be only as per
ASME B 16.5.
The maximum noise level of all equipment within the battery limit shall be 85 dba.
All pipes within the battery limit including that required for backwash and
regeneration shall be included in the scope.
All pipe supports and auxiliary steel structure required for supporting pipe shall be
included in the scope.
Any platform, ladder required for operational convenience shall be included in the
scope.
Minor chipping of concrete and grouting of equipment shall be included in the
scope.
The commissioning spares shall be included in the basic lump sum price and the
list of commissioning spares shall be indicated
If after performance test, the treated water quality does not meet the stipulated
quality requirement, BIDDER shall take necessary action to rectify or replace the
system without any extra cost.
All pressure tapings shall be provided with one root valve.
All pumps shall be provided with suction strainers with perforated plates and
strainer element made of stainless steel.
All valve material shall be compatible to the pipe material, wherever they are
used.
Note : * Bidder to specify the relevant data
11. ELECTRICAL
Refer Annexure, for the requirement of LT motor, MCC, Cables and Local push button stations.
The Water Treatment Plant (WTP) shall be provided with adequate number of instruments and controls for
ensuring safe, smooth and efficient operation of the plant. The instrumentation and control systems
provided shall be sufficient to control and monitor all significant process parameters continuously and
provide necessary safety controls and interlocks including alarms for abnormal conditions to ensure
adequate safety to man, machine and environment.
The instrumentation and Control system envisages local control of Water Treatment Plant. Critical
signals to be made available in central control room. All the safety interlocks, sequencing, logic solving
and digital signal handling shall be through a Programmable Logic Controllers (PLC) based system
supplied by the Bidder. Necessary information from these shall be hooked-up to the DCS.
The Bidder shall supply control panels for the Water Treatment Plant, complete with necessary relays,
switches, lamps and other accessories. The panels shall be completely wired and tubed and with
necessary provision for interfacing with DCS systems (supplied by others).
All necessary cabling and accessories including junction boxes, cable trays, structural supports, cable
glands, lugs, ferrules, cable ties, etc. up to the control panels shall be supplied by the bidder and from
control panel to marshalling cabinets shall be supplied by others.
All instruments supplied under the contract shall be erected, calibrated, tested and commissioned by the
Bidder. All necessary erection hardware as required shall be supplied by the Bidder. This includes items
like cable glands, junction boxes, instrument valves, stanchions, mounting accessories. Impulse tubing /
piping, tube / pipe fittings, pneumatic signal tubes, cable trays, pipe / tube trays, conduits, name plates,
structural steel requirement, instrument / instrument tray supports, etc. and any other erection.
hardware / accessory required for successful erection, calibration, testing and commissioning of
instruments supplied under this package.
This general specification together with enclosures if any cover the design of Control and
Instrumentation system, complete with all accessories and materials along with special test equipment
where the supply of such instruments is a part of a larger plant.
The detailed scope of work, specific requirements, exclusions, deviations, additions etc. if any, will be
indicated else wherein this specification.
Bidder shall be fully responsible for design, materials selection, sizing and selection of the proper
instruments for their system.
All equipments supplied shall be of proven quality both with respect to design and materials. No
prototype instrument or instrument of an experimental nature shall be offered or supplied.
Bidder shall prepare and submit a P&I diagram for the system within the scope of his supply, showing
all the instruments and interlock / trip operations. Each instrument shall be given individual tag numbers
from blocks of numbers allotted by the Purchase / Consultant. Symbols shall be as per ISA S5.1.
Bidder shall supply complete process data to the Purchase / Consultant to specify those instruments not
appearing in the Bidder’s scope of supply but are an integral part for the control of this package.
Bidder shall clearly define the operational philosophy suggested by him, which should be in line with
requirements specified in the main package / equipment specification. Bidder shall also clearly specify
the provision of control panel requirements for their package in their offer.
General
The basic concept for Control & Instrumentation system is the use of electronic instruments throughout
for measurement, transmission and control with 4-20mA DC signal level.
Pneumatic instrumentation may be used for local control loops. Pneumatic signal pressure shall be 0.2
– 1.0 Kg/cm²(g).
Electrical Power
The power source for Control & Instrumentation shall be 240 V AC + 2%, 50 Hz + 3%. Analysers,
conventional panel instruments like indicators shall operate at this voltage level or 24V DC voltage
derived from this.
Solenoid valves and other instruments shall be suitable for 24 V DC / 240 V AC and the same shall be
derived internally by the manufacturer from 240 V AC 50 Hz.
2 wire transmitters powering and field instruments interrogation voltage level shall be 24 V DC.
Any repeat relays used for alarm / interlock purpose shall be working on 24 V DC.
Normal power supply of 240 V AC, 50 Hz shall be used for illumination of panels / cabinets.
Instrument Air
Instrument air at pressure of 5 Kg/cm² (g), temperature 20-40ºC and dew point - 40ºC or below shall be
the source of power for al pneumatic instruments. All pneumatic instruments shall be selected such that
even if air supply pressure selected such that even if air supply pressure falls to 3 Kg/cm²(g),
instruments operate satisfactorily.
Panel
Multiplying factors for flow scales shall be specified on manufacturer’s name plate.
Annunciators, in general, shall be solid state type with plug in module, in a cabinet with back lighted
engraved windows and integral power supply.
Field mounted annunciator circuit shall be intrinsically safe with power supply unit in a safe area.
Annunciator alarm sequence shall be as per ISA sequence.
A minimum of 20% spare windows with cards shall be providing as spares.
Control Panels
Control panels shall be free standing type and fabricated preferably from 3 mm thick cold rolled steel
sheet or 5 mm thick hot rolled steel sheet. Angle iron framework shall use a minimum section of 50 x 50
x 4 mm angle. The finish shall include sand blasting, grinding, chemical cleaning, surface finishing by
suitable filter and two coats of high grade lacquer with wet sanding between coats. Two coats of paint in
panel colour shall be given for non-glossy high stain finish. Panel face final colour can be any of the
following to IS:5.
Panel rear surface, frame work and bulk head plates shall have a finish of pale cream IS:353 or beige
IS:388. A final coat of paint shall be given at site.
Control panel inside the control room shall be totally enclosed cubical type with 2100 mm high, 1200
mm wide and minimum 80 mm deep if mounted locally. The panel width to be increased if necessary.
Control panels shall have removable hinged doors, generally at the back for easy maintenance and
accessibility of the instruments. Doors shall be double leaved type with handle and shall be provided
inside the panel. All light fittings shall be suitable for 230C, 50 Hz AC.
No process fluid, except air shall be piped to the control panel.
Mounting heights
a. Annunciators (top row)
b. Miniature and subminiature instruments (next 3 rows)
c. Electric push buttons (last row)
Panel Wiring
Open terminals shall generally be avoided. Terminal strips shall be of “Klippon” or equivalent type and
shall be mounted in an enclosure.
1.5 sq.mm multi stranded PVC insulated copper conductor shall be used in general. These shall be laid
in PVC troughs as far as possible.
Wire carrying measurement signals associated with pH instruments and other low level signals shall be
routed in separate wire ways and not along with power cables.
All intrinsically safe wires shall be routed in separate wire ways from non-intrinsically safe and power
wiring.
Intrinsically safe terminals shall be separated from non-intrinsically safe terminals atleast by 50 mm.
Instrument Connection
Pneumatic connection for signal and air supply shall be ¼” NPTF. Electrical connection shall be ½”
NPTF.
Threaded and connection shall be to NPTF as per ANSI B2.1. Flanged end connections shall be as per
ANSI B16.5
Pressure Measurement
Pressure gauges
All local pressure gauges shall be bourdon / diaphragm type of material SS 316. Pulsation dampener
shall be used wherever pulsating pressure occurs in process. Diaphragm seat type shall be considered
for corrosive services.
Dial size for local gauges shall be 150 mm.
For temperature greater than 70ºC, necessary precautions shall be taken like use of syphon in steam
services.
All pressure gauges shall be considered with safety vent consisting of rubber grommet at the back of
housing.
Switches
Pressure switches shall have micro switch with auto reset and fixed differential.
Level Measurement
Level Transmitters
Level transmitters shall generally be differential pressure type with local indication.
Capacitance type level measurements can also be used as an alternative method wherever
required for highly viscous fluids or bulk materials. PTFE sheathed SS tubes shall be used as
measuring probe.
Gauge Glasses
Gauge glasses shall be considered generally as per process requirements. Maximum length of
each gauge glass shall be limited to about 1000 mm. If greater distance is to be covered, several
such gauge glasses shall be considered with minimum overlapping of about 50 mm.
Each gauge glass shall be considered with excess flow ball check valve. Chamber end connected
check value shall be of offset type of facilitate cleaning of chambers.
For clear / clean colourless liquid services, reflex type shall be preferred. For other services like
liquids containing sediments and coloured liquids, steam services, two phase measurement,
transparent type level gauges shall be considered.
Level indication with magnetic coupling of follower magnet, shall be considered for corrosive,
dangerous / hazardous fluids.
Level Switches
For interlock services separate level switches shall be provided. Generally external float type level
switches shall be provided.
Flow Measurement
Orifice Meters
In general, orifice plates with DP transmitter or DP gauge (where only local indication is required)
shall be used. Orifice bore calculation shall be based on ISO-5167 or BS 1042.
Flange taps shall be used in general.
Rotameters
Rotameters shall be used for line sizes upto 3”.
Metal tube Rotameters shall be used wherever application warrants and glass tube Rotameters
shall be used for non-critical services like cooling water, purge applications, flushing applications
etc.
The Bidder shall ensure and supply all erection hardware required for installation of all instrumentation
which form a part of the package unit. This includes items like cables, cable glands, junction boxes,
instrument values, mounting accessories, impulse piping / tubing, pipe / tube fittings, pneumatic signal
tubes, air line pipes, filter regulators, steam / electrical tracing, insulation materials, cable trays,
conduits, identification tags, structural material required for instrument supports and trays etc.
The above broadly covers the items required for any typical plant, however the Bidder shall supply all
necessary items to make the erection and commissioning work complete in all respects, irrespective of
whether erection and commissioning is included in this scope or not.
The following are the minimum acceptable salient features of some of the erection materials :
Pneumatic Tubing
For pneumatic signal transmission, PVC sheathed, ¼” OD, copper tubes shall be used. All fittings shall
be of brass, double compression type.
Seamless galvanized inside and outside carbon steel pipes shall be used for instrument air distribution,
and shall be as per IS:1239 class heavy.
Isolation valves on instrument air service shall be packless gland type full bore ball / globe valves.
Bidder shall supply instrument values (miniature type) and valve manifolds wherever required.
Body material and rating shall be as per piping class or SS whichever is better and shall be forged
type.
Valve trim material shall be 315 SST as minimum or superior as required by process conditions.
Bidder shall supply a minimum of 10% of such instrument value and manifolds as spare.
Instrumentation Cables
For 4-20 mA current signal, twisted pair stranded screened cables (1.5 sq.mm) shall be used.
Multipair cables (0.75 sq.mm) stranded shall be considered from DM Plant control room upto
junction boxes. Multipair cable shall have overall screening & Individual pair screening. Required
parameters for intrinsic safe signal handling shall be considered according to Indian Standards or
British Standards, when applicable.
For control cables, 1.5 sq.mm, 7 stranded, 2 core cables shall be considered between instruments
and junction boxes, and 0.75 sq.mm, 7 stranded, multicore cables shall be considered between
junction boxes and control panels.
For power supply to solenoid valves, 2.5mm².2 core cable shall be considered.
All field instrumentation cables shall be armoured type and shall be with electrolytic grade copper
conductor.
The insulation grade shall be as a minimum 600 V.
Cable Glands
Bidder shall supply all cable glands required for glanding the above mentioned cables both at field
instrument and at control room (local & main) / control room devices / junction boxes/battery limits.
All cable glands shall be of anodized aluminium alloy or of nickel-plated brass and they shall be double
compression type suitable for armoured cables. Panel end cable glands shall be with locknut.
Explosion proof glands wherever required shall be supplied. Bidder shall supply a maximum of 20% of
cable glands as spare.
Junction Boxes
Bidder shall supply junction boxes wherever required. These shall be of die cast aluminium alloy body
and shall be weather proof.
These boxes shall have terminals suitable for min 2.5 mm² cable termination (klip on) mounted on rails.
20% spare terminals shall be supplied in each junction box.
Each junction box shall have a minimum of 10% or 2 nos. whichever is more, spare entry duly provided
with plugs (weather proof / explosion proof, as applicable).
Cable Trays
Bidder shall supply instrument stands (stanchions) and other structural steel material required for
supporting the cable trays, impulse lines and instruments.
12.9. INSTALLATION
Bidder shall be completely responsible for installation of all instruments within his battery limit, as per
the installation sketches (typical) furnished along with this specification.
All direct mounted instruments like pressure gauges, pressure switches etc. shall be installed in such a
way that they have better readability and accessibility.
All pressure, differential pressure instruments shall be provided with block and bleed, by-pass, drain /
vent valves etc. as per the installation sketches, and shall have accessibility.
All primary piping / tubing (impulse lines) shall have a slope of 10% on the horizontal run.
All threaded joints shall be joined by Teflon tapes only. All impulse lines shall be supported at regular
intervals.
Instrument drain / vent connections shall be piped to safe area like OWS or above pipe racks to avoid
accumulation of hazardous fluid in the plant atmosphere.
All tubes / cables shall be properly laid on cable trays which shall be supported at regular intervals.
Separate routing or physical separation shall be maintained between signal cables and shut down /
power cables.
The cases of instruments shall be earthed by earthing wire to the nearest earth bus bar provided by
others, for safety reasons.
In case the cables are to be buried or laid in concrete trench the same shall be carried out by Bidder
with prior intimation to client.
Painting of cable trays / ducts, M.S. cable ways, angle trays, instrument supports, all structural supports
shall be as under :
The surface to be painted shall be thoroughly cleaned with brush sand paper to remove all scales. After
cleaning, one coat of red oxide zinc chromate primer shall be given conforming to IS-2074 and allowed
to dry. One coat of final paint shall be applied.
Second and final coats of paint of final colour shall be given before handling over the plant /
commissioning.
All impulse lines shall be properly flushed after isolating both the instrument and the vessel / piping.
All impulse lines shall be tested hydraulically at 1.5 times the maximum operating pressure. Ensure that
instrument and vessel / piping is isolated during this test.
In case of special conditions where hydrotesting is not permitted due o service conditions, the impulse
lines testing shall be carried out by using air or nitrogen.
After pressure testing all these impulse lines shall be drained and dried with dry air to remove any
moisture.
Instrument air lines will be service tested only for any leak after pressurizing and isolating the main root
valve, by soap solution.
Pneumatic signal tubes shall be flushed and tested with instrument air for any leak at a pressure of 1.5
kg/cm²(g). After pressurizing the line, the source of pressure is cut off and rate of fall in pressure shall
be less than 1 psi for each 100 feet for a period of 3 minutes.
All instrument cables shall be tested for continuity and insulation. While megger is used for insulation
testing, ensure that all instruments and zener barrier are isolated at both ends. All instruments supplied
by the Bidder shall be calibrated using proper test equipment.
All instruments shall be calibrated for 0%, 25%, 50%, 75%, 100% and vice versa. All transmitters shall
be calibrated as per instrument ranges.
All alarm and trip switches shall be calibrated over the entire range and finally set and checked for alarm
/ trip points and reset points as per the alarm / trip set point schedule. After setting these shall be
sealed.
All special instruments like analyzer shall be checked and calibrated as per manufacturer’s instruction.
Prior to testing, all analyzer sample lines shall be thoroughly cleaned by carbon tetra chloride or any
other cleaning liquid. After cleaning, these lines shall be thoroughly purged with dry nitrogen.
The accuracy of overall loop shall be within + 1% for electronic and + 1.5% for pneumatic loops.
After performing the calibration of all instruments, the entire loop shall be checked for proper operation.
The entire shutdown scheme shall be simulated from the process trip switches and the scheme shall be
tested for its proper operation, prior to start up of the unit.
12.11. COMMISSIONING
This activity shall be carried out in a systematic manner so as to avoid any accident to plant and
operating personnel.
During the plant start up all the instruments calibration, trip point settings shall be trimmed so as to meet
the operation requirement.
Prior to guarantee run of any package unit the vital instruments as required by Bidder have to be
recalibrated and the results recorded.
Spare instruments :
10% spare instrument with a minimum of one in each type for instruments like field switches, temp
gauges, pressure gauges etc.
Commissioning spares : This shall be as per vendor standards
Operational spares : The operational spares for all instruments shall be based on
vendor recommendation.
12.14. CONTROL & INSTRUMENTATION AND CONTROL FOR RO/DM PLANT
The pump on off Status and water quality parameters are monitored by PLC. The PLC shall have RS 485 serial
port for communication with plant DCS.
All the instruments specified in the specification shall be of reputed make and no local make will be entertained.
P & I diagram within the battery limit indicating the line sizes, controls, interlocks etc.
Process calculation including Rosa projection
All chemical dosage levels in milligram / litre and per day requirement
Process calculation for mixed bed
Process flow diagram within the battery limit
Overall layout with the space requirement, clearly indicating the covered space.
Motor data sheet and characteristic curves
Instrument schedule and instrument data sheet
Weight of single heaviest item
Quantity of water required for regeneration and water quality
Schedule of Utilities requirement
Individual and Total power consumption for water treatment package
BIDDER shall indicate quality and quantity of effluent at various outlet points, suggested neutralization,
effluent pit size etc.
BIDDER shall indicate the quality and quantity of backwash / regeneration water required for mixed bed.
List of bought out items with vendor list
Completely filled up data sheets (Format enclosed)
14.0. DRAWINGS & DOCUMENTS TO BE SUBMITTED AFTER AWARD OF CONTRACT (ALL IN FIVE SETS)
Note:-
Non Deviation will be accepted.
Bidder will quote In Bifurcate manner and only after Technical Freezing.
For any Deviation in Vendor/Sub-vender list, approval from Real Ispat & Power Ltd. must before
quote.