tender document for fabrication, …i... · 6.5.1. testing the equipments at site ... high heat...

TENDER DOCUMENT FOR FABRICATION,

INSTALLATION, COMMISSIONING AND TESTING

OF HIGH PRESSURE HIGH TEMPERATURE

CLOSED LOOP WATER CIRCULATION SYSTEM

FOR HIGH HEAT FLUX TEST FACILITY

INSTITUTE FOR PLASMA RESEARCH

BHAT, GANDHINAGAR,

GUJARAT – 382428

Vijayan

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Vijayan

Typewritten Text

PART-A(i)

Vijayan

Typewritten Text

Vijayan

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1

CONTENTS

1. INTRODUCTION....................................................................................................... 3

2. DESCRIPTION ........................................................................................................... 3

2.1. Operating parameters at the inlet of test section ....................................................... 4

2.2. Details of proposed design........................................................................................... 4

3. TECHNICAL SPECIFICATIONS............................................................................. 4

3.1. Basis of design.............................................................................................................. 4

3.2. Site condition ............................................................................................................... 4

3.3. Design Concept ............................................................................................................ 5

3.4. System Components .................................................................................................... 5

4. OPERATING PROCEDURE ..................................................................................... 9

5. DATA ACQUISITION AND CONTROL SYSTEM ............................................... 10

6. VENDORS SCOPE OF WORK ............................................................................... 13

6.1. Validation of proposed Engineering design.............................................................. 14

6.2. Operation and control system specifications ............................................................ 14

6.3. Selection & procurement of material........................................................................ 16

6.4. Fabrication & assembly ............................................................................................ 16

6.5. Inspection & Testing ................................................................................................. 16

6.5.1. Testing the equipments at Site............................................................................ 17

6.5.2. Pre -dispatch Inspection & Testing at Vendors site........................................... 17

6.5.3. Test Certificates .................................................................................................. 19

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7. COMPLETION OF ERECTION & COMMISSIONING....................................... 20

8. ACCEPTANCE CRITERIA..................................................................................... 20

9. DELIVERABLES...................................................................................................... 20

10. QUALITY CONTROL AND ASSURANCE TEST................................................. 21

11. GUARANTEE ........................................................................................................... 21

12. SAFETY..................................................................................................................... 22

13. GENERAL TERMS AND CONDITIONS ............................................................... 22

14. EXPECTATION FROM VENDORS ....................................................................... 22

15. COMPLETION PERIOD ......................................................................................... 22

16. BAR CHART/ PROJECT SCHEDULE & PERIODICAL PREVIEW.................. 22

17. DRAWINGS .............................................................................................................. 23

ANNEXURE-1 (List of Drawings).................................................................................... 24

ANNEXURE-2 (Technical Specifications) ....................................................................... 30

ANNEXURE 3 (List of Approved make) ......................................................................... 37

ANNEXURE 4 (List of BIS & ASME Codes) ................................................................. 39

ANNEXURE 5 (Quality Assurance Plan)…………………………………………………42

ABBREVATIONS............................................................................................................. 52

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1. INTRODUCTION

Institute for Plasma Research (IPR) is working on developing various technologies based on

Tokamaks for future fusion power plants. Fusion power plants often encounter high heat

fluxes due to the high temperature plasma produced. High heat flux (HHF) testing is used to

test the integrity of various materials developed for withstanding these high heat fluxes. The

test mock –ups / components (loads) inside the HHF test facility is connected to water

circulation system which is expected to circulate water at high pressure in the range of 5 bar -

60 bar, high temperatures in the range of 25oC - 160oC and flow- rate up to 300 LPM. The

test mock – up or components to be tested will have typical internal diameters in the range of

10 mm – 20 mm and maximum length up to 1600 mm. The block diagram of HHF test

facility is shown in Annexure 1.

Institute for Plasma Research requires the fabrication, installation and subsequent

commissioning of the entire water circulation system as a part of its high heat-flux testing

facility that is being developed. For detail design concept and scope of work, refer section 3

& 4.

2. DESCRIPTION

The high pressure high temperature water circulation system has been designed to cool down

the test mock-up which is connected to the test facility. The test mock-up connected to the

water circulation loop has a maximum heat load of 210 kW. In this test loop de-mineralized

water (D.M water) is used as a working medium and system can operate in the pressure range

of 5 bar to 60 bar and the temperature range of 25oC to 160oC. Nitrogen is used as covering

gas to pressurize the D.M water in the pressure vessel. The Nitrogen source (bank of nitrogen

cylinders) connected with pressure vessel and a pneumatic pressure regulator controls flow of

Nitrogen into the pressure vessel.

Minimum pressure in the water circulation system depends upon the operating

temperature of the working medium (DM water). The system pressure of water circulation

loop is usually maintained 4 bar above saturation pressure for the safe running of the test

facility. Testing will start only after stabilizing the pressure and temperature in the water

circulation loop. The data acquisition systems (DAS) with instruments are installed along

with test facility to record and control the test parameters pressure, temperature and flow rate.

The test loop is designed as per relevant safety standards.

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2.1. Operating parameters at the inlet of test section

Operating Pressure at test section (inlet) 5 bar - 60 bar (a) with variation of ± 1 bar

Operating Temperature Range at testsection (inlet / outlet)

25oC – 160°C with variation of ± 1°C

Required volumetric flow rate at testsection

Up to 300 LPM with ± 1% accuracy

2.2. Details of proposed design

The major components of the test loop are concrete tank, reservoir tank, two positive

displacement pumps with motor, pressure vessel with accessories, bank of Nitrogen

cylinders, two booster pumps with variable frequency drive, orifice type or vortex type flow

meter, heater bank, cooling tower, different types of valves at various locations, safety

devices; pressure, temperature, level and other sensors/indicator/transmitters with controllers.

The Piping & Instrumentation diagram (P & I D) & schematic diagram of high pressure high

temperature water circulation system (HPHT-WCS) with inert gas pressurization is shown in

Annexure 1.

3. TECHNICAL SPECIFICATIONS

3.1. Basis of design

Proposed system design / engineering may be treated as indicative. The Vendor may redesign

/ modify / optimize the system or part of the system design if required. All the changes /

modifications are subject to approval by IPR. The Vendor is to give overall system

performance guarantee.

3.2. Site condition

1. Site: Institute for Plasma Research, Gandhinagar, Gujarat.

2. Outdoor design conditions:

Summer : 43.5°C DBT, 28.0°C WBT

Monsoon : 32.2°C DBT, 29.5°C WBT

Winter : 15.5°C DBT, 10.5°C WBT

3. Indoor design conditions: LABs.

Temperature: 24 ± 1°C, RH: 60 %.

4. Extreme ambient conditions:

Temperature: Max. 47°C. Min. 4.5°C.

RH Max. 86 %. Min. 17 %

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5. Rain fall: Average 823 mm.

6. Wind data: Max. Wind speed: 130 Km/hr.

Wind direction: SW to W.

Design wind pr.: 100 kg / m2

7. Site elevation: 55 m above MSL.

8. Seismic data: 0.04 g As per IS 1893 -1975.

3.3. Design Concept

The high pressure high temperature water circulation system (HPHT-WCS) is designed to

provide and maintain necessary temperature, pressure, flow to cool plasma facing

components / test mock-ups integrated with HHF test facility.

Following aspects are considered for the system design:

Integrated and modular system design.

Automatic / Self-regulating system operation with necessary safety and capacity controls.

Emergency generator power for backup whenever / wherever required like for DAC

system etc.

Provision for projected future upgrading of any system / subsystem like redundancy of

any subsystems like pumps etc.

3.4. System Components

Following components are to be interconnected to satisfy the system requirements. For

components detail specifications refer Annexure 2.

(1) Reservoir tank (R-1)

The reservoir tank (R-1) is filled with de-mineralized water (DM water), the suction of the

positive displacement pump (P.D. Pump) is taken from the reservoir. The capacity of the

reservoir is 2000 litres and it is made of SS 316 material (ref fig in Annexure 1)

(2) Positive displacement pump (P.D 1 and P.D 2)

The purpose of the PD pump is to fill and maintain the level of DM water in the pressure

vessel. The discharge of the P.D pump can be controlled by using the pump controller (by

controlling the speed of the driving motor), which receives the input signals from the level

transmitter (L.T -1), installed on the reservoir tank and also from the level transmitters (L.T-2

and L.T-3), which are connected on the pressure vessel. A bypass line is provided in the

delivery side of the pump (bypass is act as a safety feature), to bypass water to the reservoir

tank by operating the bypass valve (BPV-1). Bypass is provided for the pump start-up

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requirement and also for process safety. A non return vale (NRV-1) is connected on the

discharge line to prevent reverse flow. An accumulator (A) is fitted near the delivery side of

the P.D Pump, to get uniform flow of discharge during operation. Two PD pumps are

connected in parallel to ensure the availability of the loop.

(3) Pressure vessel (P.V)

Pressure vessel is a closed container (as per ASME boiler pressure vessel code, Section VIII,

DIV 1- 1999) designed to operate safely at 70 bar pressure and temperature up to 200°C. It is

a cylindrical shaped vessel with semi elliptical heads at both ends mounted vertically on leg

supports. The capacity of the pressure vessel is 2.3m3 where one third (1/3) of volume of

pressure vessel is filled with Nitrogen gas and two third (2/3) of volume is filled with DM

water. The required pressure in the loop is achieved with inert gas (Nitrogen) pressurization

where Nitrogen gas is used as covering gas to pressurize the DM water in the pressure vessel

and maintain required pressure. The Nitrogen source (bank of Nitrogen cylinders) is connected

to pressure vessel and a pneumatic pressure regulator controls flow of Nitrogen in to the

pressure vessel. The details of the vessel are provided in the Annexure 1.

(4) Booster pump (B.P-1 & B.P-2)

Booster pump is used to maintain the required flow of DM water in the re-circulation loop

during testing. The booster pump receives water from the pressure vessel and supplies to the

heater bank. Booster pump will create the required pressure to compensate the pressure drop

in the system as water passes through the loop. The speed of the booster pump motor is

controlled by a variable frequency drive (VFD). A by-pass line is also provided in the delivery

side of the booster pump, to bypass water to the reservoir tank by operating the bypass valve

(BPV-3). It will be used to control flow in the main loop and maintaining the required pressure

in the loop (in addition to the control valve and VFD in the loop). It can also be used as a

safety measure, provide operation flexibility and helps during pump test run, pump

maintenance etc. The capacity of booster pump is 70 bar working pressure, 10 bar boosting

pressure, 300 LPM flow rate and operating temperature up to 200°C.

(5) Flow meter (F.M-1)

For measuring the flow rate a flow meter (an orifice plate with differential pressure transmitter

or vortex type flow meter) with a flow range of 10 to 300 LPM and temperature range up to

200°C is connected in the downstream of the booster pump. The output of flow meter is

communicated to the control valve through the flow controller to ensure the required flow rate

in the loop.

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(6) Heater bank (H)

In the test circuit three separate electrical heaters (H1, H2 & H3) connected in series. These

heaters are used to rise the water temperature to the required value during start up and

maintain the same during running of the loop. Each heater is provided with bypass

arrangement with isolation valve. Of the three heaters, two heaters will be operated in the ON /

OFF control mode whereas the third heater will be provided with a PID controller. This

facilitates to use each heater independently for different load conditions. The capacity of each

heater is 200 KW. Heater controller regulates the power to the heaters based on the

temperature of DM water in the test loop.

(7) Heat exchanger

During testing, the temperature of the DM water will increase maximum by 10°C when it

passes through the test mock-up (corresponding to a maximum heat load of 210 kW). The heat

exchanger along with cooling tower is employed after the test mock –up in the water

circulation loop, to cool down the temperature of water coming from test mock-up to the

required level. It is proposed to use shell and tube type heat exchanger. The details of heat

exchanger are provided in the Annexure 2.

(8) Cooling tower

Cooling tower is operated at full load capacity of 108 TR. It is used as a heat sink for rejecting

heat from test mock –up to atmosphere. It is proposed to install induced draft FRP cooling

towers. Cooling Towers shall be selected for the most stringent Monsoon wet bulb

temperature (29.5 °C) and summer dry bulb temperature (43.5°C) with a approach of about

3.5°C and range of about 3 to 5°C for this application. The mass flow rate of the cooling

medium (DM water) is 18 kg/s.

(9) Piping, valves and accessories

All pipes, valves, fittings and other components used in the test loop are selected in according

to the recognized standard (ASME B31.3) for the designed working pressure of 70 bar and

temperature of 200oC. Pipe system contains sufficient number of valves to operate the system

properly and also for the safe running of the loop. Drain line is connected to the low point of

each pipe line for the complete draining of water for inspection and maintenance; and the

venting connections are provided to vent valve for air venting. Expansion and contraction of

pipe are need to be considered during system operating conditions. Filters are needed to be

incorporated in the design at proper locations in the system to avoid any foreign particles in

the loop. The Details of Piping & valve Specifications are attached in annexure-2.

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(10) Insulation

Insulation material for pressure vessel, pipe and other accessories shall be Perlite. The thermal

conductivity of perlite at 100°C is 0.07 W/m°C. Thickness of the insulation shall be 50 mm.

Each lot of insulation material delivered at site shall be accompanied with manufacturer test

certificate for thermal conductivity values and density. Adhesive used for setting the insulation

shall be non-flammable, vapor proof adhesive, Shalimar CPR compound, or approved equal,

cold setting compound.

(11) Water chemistry

Required properties of water temperature at 33°C

Turbidity: 50 ppm (silica scale), Max.

Chlorides: 500 ppm, Max.

Total solids: 3000 ppm, Max.

pH: 6.5 to 8.5

Specific Gravity: 1.004, Max.

Hardness: 300, Max.

(12) Instruments and control system

Necessary instruments, sensor- transmitters, Controls- transducers are used for the purpose of

process measurement, indication, control, providing required output signals for data

acquisition- monitoring and control system for the integrated operation of circulation system

with HHF test facility. Refer PID in the Annexure 1.

(13) Central data acquisition and control system

DACS (Data acquisition and Control system) includes all hardware (DDCs, system

controllers, CPU, Monitor, printer, Communicator), software, including electrical control

panel boards with all electrical components, accessories, power wiring, control wiring,

earthing and interlocking, electronic and digital components etc. The central DACS is to be

installed in the plant room control cabin with following hardware and necessary customized

software.

Necessary dial type pressure and temperature gauges are proposed to measure the

water pressure and temperature respectively at inlet and out let of each pumps, heat

exchangers, loads etc. wherever required.

Necessary water flow meters are proposed to measure the water flow mainly at inlet or

out let of the system, wherever required.

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Necessary sensors – transmitters (pressure, temperature, conductivity, pH & level) can

be installed for necessary data acquisition required for overall monitoring and control

system in the main circulation system.

Necessary capacity controls / diverting / solenoid valves, safety controls / valves /

switches, DDCs etc. are proposed to control the operating parameters.

Necessary pressure vessel accessories to indicate and control pressure, temperature and

level of DM water inside the pressure vessel

4. OPERATING PROCEDURE

The HPHT WCS has been designed to cool down the test mock-up. The test mock-up is

appropriately fastened to the test facility with arrangement for by pass DM water during

startup. Before starting the positive displacement pump make sure that the reservoir tank is

filled with sufficient quantity of DM water. Start the positive displacement pump which takes

water from the reservoir at ambient temperature and supplied to pressure vessel by

pressurizing the water to the required pressure set in the pressure controller. Remove the

entrapped air completely inside the pressure vessel with the help of Vent-Valve (VV-1)

mounted on the pressure vessel. Close the Vent-Valve and pressurize the vessel to the

required value with the help of positive displacement pump.

The pressurization of DM water in the pressure vessel is done by inert gas

pressurization system. Advantages of inert gas pressurization system are

Nitrogen gas used in the inert gas pressurization is environment friendly and

inflammable.

The pressure in the vessel can be increased to any value within the pressure limits of

Nitrogen storage tank.

The overall efficiency of the system will be employed.

The P. D Pump needn’t be operated continuously to maintain required pressure. This

will reduce the operating and maintenance cost.

In the inert gas pressurization method, the pressure vessel is initially filled with

required quantity of DM water (approximately 65% of pressure vessel volume) by operating

positive displacement pump. Sufficient quantity of nitrogen at high pressure is stored in the

bank of nitrogen cylinders and it supplied to pressure vessel through a regulator. A high

pressure pneumatic regulator is used to regulate the nitrogen pressure supplied to vessel.

Nitrogen gas is introduced in to pressure vessel until it reaches the required pressure. The

required pressure of DM water in the vessel set on the pressure controller and it controls the

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operation of the high pressure regulator. The water level in the pressure vessel is maintained

between the desired levels by operating the positive displacement pump. Two level sensors

(L.T-1 and L.T-2) are provided on the pressure vessel to indicate the water level and

communicated to the pump controller to offer the high level pump cut off and low level pump

start up. Thus the required pressure is maintained in the pressure vessel.

A booster pump is used to circulate the high pressure water in the pressure vessel through

the entire closed loop by overcoming the pressure drops in the water circuit. After attaining

required pressure in the pressure vessel, stop the positive displacement pump and switch ON

the booster pump and set the flow rate in the loop to the required value by variable frequency

drive (VFD) and also by main control valve (CV-1). The flow rate has to be measured by

vortex type flow meter / orifice type flow meter located in the discharge line of the booster

pump. The differential pressure recorded by the differential pressure transmitter (DPT-1) is

proportional to the flow rate of the DM water passing through the flow meter and it is

communicated to booster pump by a flow controller. The heater has to Switch ON (number of

heaters has to switch ON based on the heat load of external mock-up) to increase the

temperature of the DM water to the required level (150oC). When the external heat load is

210 kW (maximum value) and flow rate is 300 LPM, the temperature of DM water raised to

160oC. The temperature of the DM water passes the test mock up is reduced by cooler and

then return back to pressure vessel. The time taken to reach steady state temperature for the

entire loop depends on the different factors; namely, flow rate of DM water, external heat

load, total volume of water in the test loop and heat energy supplied by the heater. Stability of

the operating parameters (pressure, temperature, flow rate) for a time scale of 10 sec during

heat load on the test mock –up is to be ensured by the entire system.

5. DATA ACQUISITION AND CONTROL SYSTEM

The Control and monitoring of HPHT-WCS with inert gas pressurization method comprises

with number of individual controllers, they are,

1. Pump controller

2. Pressure controller

3. Flow controller

4. Temperature controllers

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(1) Pump controller for positive displacement pump

The pump controller acts as a primary controller to maintain the required water level and

pressure in the vessel. The DM water pressure inside the vessel depends on the level of water

in the vessel. The water level inside the pressure vessel can be controlled within the desired

limit by start and stop of the positive displacement pump (P.D Pump) with the help of the

pump controller. Change in water level inside the pressure vessel is monitored by level

transmitters (L.T-2 and L.T-3) and the corresponding signals are fed to the pump controller.

The water level reaches a predetermined minimum level (sensed by level transmitter L.T-2),

the pump controller generates a control signal that turns the P.D pump ON and once the water

level has reached the predetermined maximum level (sensed by level transmitter L.T-3), and

the pump controller generates another control signal that turns the P.D pump OFF. Starting of

the pump also depends on the water level in the reservoir. The height of the DM water in the

reservoir is measured by level transmitter (L.T-1); to ensure minimum water in the tank while

the P.D pump is in operation. All other protections like overload, two phase will also be

provided for the pump.

(2) Pressure controller to regulate the pressure inside pressure vessel

The pressure controller acts as a secondary controller to maintain the required pressure in the

vessel. The Nitrogen gas is used to pressurize the DM water in the pressure vessel and a

pneumatic pressure regulator (PR-1) controls flow of Nitrogen in to the vessel. Whenever, the

pressure inside the vessel decrease more quantity of Nitrogen has to be supplied in to pressure

vessel, by operating pneumatic pressure regulator. If pressure increased the excess pressure

released through pressure relief valve. For this purpose the pressure transmitter (P.T-1)

installed in the top of the pressure vessel and it generate electrical signals corresponding to

pressure inside the vessel and fed to pressure controller (P.C-1).

The control logic for water level and water pressure is provided as below.

As the water level in vessel decreased below the minimum level, the PD pump 1 will be

started to fill water. If PD pump 1 is not started for a specified time and with water level

below minimum then PD pump 2 will start. If both pumps are not started in the specified time

with water level remaining below the minimum level, a trip signal will be generated to trip

the WCS with suitable warning (alarm). The pump (either PD-1 or PD-2) will continue to

operate till the maximum water level is reached. Till that time, the pressure controller (PC-1)

will be inactive and the excess Nitrogen will be released through the pressure regulator. Once

the pump is stopped, the pressure controller (PC-1) will be made to operate and the gas

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pressure inside the vessel will be made to the required value. Pressure controller (PC-1) will

operate till the water level reaches the minimum level. Thus the pump controller will be active

during the period between minimum water level to maximum water level. Pressure controller

will be active between maximum water level to minimum water level. Time required for

filling water from minimum level (1440 l) to maximum level (1560 l) is ~ 2.4 minutes.

(3) Flow controller to control flow in the water circulation loop

The flow in the water circulation loop is controlled by two ways.

1. By controlling the control valve.

2. By controlling the booster pump using a variable frequency drive (VFD)

By controlling the control vale

A flow meter with analogue output is connected in the water circulation loop downstream of

the booster pump to monitor the flow in the loop. A control valve (C.V-1) with pneumatic

actuator, valve positioner and position transmitter is installed at the outlet of the test mock up

to control the flow. Based on the flow rate requirement of the loop, actual flow rate and valve

position, the valve opening and booster pump speed will be computed. The valve position

determines the amount of flow passing through the control valve. The valve positioner

receives signal from the flow controller and keeps the valve opening according to flow

requirements of the loop.

A temperature transmitter (TT-5) is connected in the downstream side of the cooler /

heat exchanger (C / H.E-1). The function of temperature transmitter is to monitor the

temperature of the DM water leaving the cooler / heat exchanger , it develop electrical signals

corresponding to the line temperature of DM water and communicated to control valve

through flow controller. Whenever the temperature of the DM water increase beyond the limit,

flow controller increases the flow rate and pressure in the loop by controlling the control valve

and keeps the temperature of the DM water leaving the cooler / heat exchanger to specified

level for safety.

By controlling the booster pump using variable frequency drive (VFD)

The variable frequency drive (VFD) is used to control the rotational speed of the booster pump

motor by controlling the frequency of the electrical power supplied to the motor. The VFD

receives the input signals from the pressure transmitter (PT-2) which is fitted in the delivery

line of the booster pump and the flow rate signals from the flow meter are also transferred to

VFD through flow controller. Based on load requirement the booster pump can operate at

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different speed and maintain the necessary flow rate and the pressure in the water circulation

loop.

Flow and the pressure in the loop are controlled, by combined operation of above mentioned

two controls.

(4) Temperature controller

Two temperature controllers used in the water circulation loop are.

1. Heater controller

2. Cooler controller

Heater controllerThe test loop consists of three separate electrical heater banks connected in series. One can be

controlled by PID heater controller and other two by ON/OFF controller. The rise in

temperature of the DM water flows through the heater bank can be monitored using the

temperature transmitters (TT-1 & TT-2) and the transmitter output signals are communicated

to heater controller. Power to the heater bank works in relation with the signals from the

heater controller. Whenever temperature of the DM water at the outlet of heater bank falls

below the lower set point, an appropriate power rise happen in the heater till the temperature

reaches the set value and vice versa.

Cooler controller

Cooler or heat exchanger employed in the water circulation loop to cool down the

temperature of water coming from test mock to the required level. To measure the

temperature rise due to the external heat load, two temperature transmitters (TT-3 & TT-4)

are connected on the inlet and exit line of the test mock-up. The output signals corresponding

to increase in temperature is transferred to PID type cooler controller; it control and regulate

the flow of DM water through the three way control valve (CV-2), depending upon the

temperature rise due to external heat load. The Bypass valve (BPV-10) is provided to control

the cooling water flow.

6. VENDORS SCOPE OF WORK

The Vendors scope of work for the system includes validation of the design, Manufacturing /

Fabrication, Shop testing, Supply, Installation (including, lifting, shifting, assembling etc.),

Site testing, and Commissioning of the following system components (confirming to tender

specifications, relevant BIS & ASME codes mentioned in Annexure 5 and in accordance with

the requirements of schedule of quantities and approved drawings).

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6.1. Validation of proposed Engineering design

1. Vendor shall validate the proposed Engineering design and optimize the process

parameters of the system (if required) based on the given requirement and shall obtain

IPR’s approval before proceeding further.

2. Vendor shall prepare engineering drawings based on approved design reports and

from supplied general assembly drawings. Vendor shall get it approved by IPR.

6.2. Operation and control system specifications

Mandate:

The operation and control system will be responsible for the ensuring the fail safe operation

of the HPHT system as a whole and all its subsystems. This system is expected to operate in

semi-autonomous mode. It must be provided with the manual operation interface and should

have an independent operational control system. It must be able to integrate to PXI and PLC

based High Heat Flux Test Facility (HHFTF - OCP) operation and control system. The

project must be able to provide SCADA level functionalities.

Note:

I&C for the HHFTF-OCP is indented as combination of PLC and PXI and the Electron beam

gun source is controlled by Siemens controllers. Hence, I&C controllers for the project must

be compatible in terms of software integration and hardware integration point of view. The

standard technology interface supports e.g. OPC and OPC-UA is preferred.

Functionality

The Operation and control system must be able to perform following tasks

Operational functionality

o I&C must be able to measure the process parameters at various points in the

loop and able to compensate the difference w.r.t. to set points by appropriately

modify various subsystems parameters.

o The main operational parameters must be settable by user interactively and

system must be able to maintain it.

o The system must be able to show the possible diagnostics scenarios in case of

pressure, temperature and flow loop fails.

o The operational control for regular maintenance and calibration of I&C

sensors and actuators must be provided.

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Interlocks

o The system must provide the interlocks at subsystem and system level by

implementing it at software and I&C level.

o Failure of a pump and subsystems must be detectable automatically and

appropriately alternate signal path must be chosen.

Safety

o The safety actuators and sensors must be redundant and failure scenarios must

be demonstrated on site.

SIGNALS

The signal list will be finalized after finalization of engineering design and location of

sensors/actuators. It is expected that the signal acquisition will be configurable from 200 ms –

1000 ms. The tentative list is as below as per P&ID

1. Signal for process parameter measurement (Pressure, temperature, flow at different

locations in the loop)

2. Signals for control (pressure, temperature, flow)

3. Signal for monitor (level, flow, temperature, status monitoring)

All the signal must be controlled and monitored from Operator Software interface and alarms

levels must be represented appropriately.

Deliverables

Documents

o High level architecture document for I&C and software

o I&C Engineering design documents

o Software Engineering design documents

o Signal integration schema

o I&C and Software test reports

o User manuals

Training

o Training on the different software and hardware used into the system must be

provided to the IPR personnel’s.

Hardware

o I&C Controllers

o Accessories like Cubical, Power supplies Cables and connectors

Software

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o Control loop code

o Controller and I/O module configuration code

o Code for various operational scenarios with load and without load

o Operator display and archival of the signals (The operational database system

for HHFTF-OCP is postgresSQL hence integrity is preferred.)

o Any other relevant code not mentioned above

o All the licenses of the software used for implementation

6.3. Selection & procurement of material

Vendor shall procure all the required material and equipments including sensors, transmitters,

instrumentation, cables etc. Supply of mandatory spares for two years of service of the

system is also in the scope of the Vendor. The list of spares will be finalized after finalization

of Engineering design. Vendor should prepare Quality Assurance Plan (QAP) for each

material to IPR for approval. Vendor should submit all the material test reports to IPR before

starting of the fabrication. Vendor should purchase the recommended make listed in the

Annexure 3.

6.4. Fabrication & assembly

The assembly and integration of different components will be performed after shifting the

system to IPR.

6.5. Inspection & Testing

In general following Inspection / tests are involved. Type of test, duration of test, testing

procedure / parameters, will be as per the applicable BIS codes. However the detail

Inspection and test procedure shall be worked out jointly by IPR and the Vendor along with

the approval of drawings, within 90 days from the date of contact agreement.

a. Pre-dispatch Inspection.

b. Pre-dispatch testing at manufacturers shop / factory. (Material, performance, pressure,

joints, etc.)

c. Physical Inspection – Pre-installation at site.

d. Welding joint inspection and testing at site.

e. Pressure testing at site.

f. Performance testing at site (Capacity, power consumption, pressure drop, vibration,

etc.)

g. Calibration at site.

17

6.5.1. Testing the equipments at Site

The following aspects shall be considered for performance testing.

Prevailing conditions shall be as close as to design conditions.

Type, quantity, location, frequency, duration of test parameters shall be decided and

recorded accordingly during the test.

Rated capacity, power consumption, and other operating parameters shall be checked.

Functional test for all Instruments, controls (safety and capacity) and DACS shall be

carried out to check for the expected operation / action / accuracy / response time /

repeatability parameters.

6.5.2. Pre -dispatch Inspection & Testing at Vendors site

Pre-dispatch inspection and testing (including stage wise inspection) at manufacturer’s /

fabricator’s place must be carried (in presence of IPR representative or as per approved QAP

submitted by the Vendor) for the system components. In case of larger quantity of similar

size and configuration the sampling can be done as per the applicable test code. Pre-dispatch

testing includes performance testing for the rotating / moving equipments, parts Instruments

& controls according to the approved technical specifications and drawings. The Vendor

must absorb all the charges for the pre-dispatch inspection and testing. System parts duly

inspected and tested will be stamped / marked and cleared for dispatch by IPR representative.

All the system parts shall bear the marking when received at site for the verification of IPR

representative. A copy of all the test certificates, performance data / curves, operation and

maintenance manual etc. must be submitted to IPR representative.

Site Inspection and Testing

1. All the tests shall be carried out in the presence of the representative of IPR. All

instruments, services, required for the tests shall be provided by the Vendor.

2. All the system components (Including the parts cleared after pre-dispatch inspection

and testing) will be physically inspected and tested before and after installation

according to approved specifications and drawings.

3. Capacity ratings and power consumption with operating points clearly indicated shall

be submitted and verified at the time of testing and commissioning of the installation.

Manufacturer’s tests certificates shall be furnished for all equipments / materials.

4. The Vendor shall demonstrate the capacity and the power consumed by the

equipments.

18

5. The Vendor shall also demonstrate the proper operation of all controls, Instruments

and other equipments.

6. Integrity test for rubber lining for equipment and piping by spark testing shall be

carried out.

7. Alignment of drives, checking of abnormal vibration, noise, running tests for pumps,

etc. shall be carried out.

8. Water piping, fittings shall be tested to hydraulic test pressure of at-least one and half

(1.5) times the maximum operating pressure as per the QAP, at least 2 hrs. Any

leaks, defects shall be rectified and re-tested in same manner. After completion of the

installation, all water system shall be adjusted and balanced to deliver the water as

specified. (All piping shall be measured in units of length along the centerline

including of all joints, bends, fittings, flanges and other accessories).

Welding: Inspection &Acceptance Standards:

Following Inspection and testing shall be carried out.

Root and final run for Butt-welds, Nozzle welds, Structural attachment weld, Hanger,

Support welds, socket welds etc. shall be checked with –

-100 % Visual examination + 10 % DP (Dye Penetration) examination + sample

Radiography (SS piping- 100 NB and above)

-100 % Visual examination +100 % DP examination + sample Radiography (Pr. Vessels

and tanks & for socket welds)

-100 % Visual examination + 10 % DP examination for Structural welds.

Visual Checkup Includes : Base metal identification, Base metal defects rectification,

Edge preparation, Joint - Fit-up checking for both longitudinal and circumferential

welding, Check of pipe –dia., Cleanliness, Tacking, Root pass & subsequent pass

appearance, Cleaning between the passes, Completed weld appearance, Condition of the

base metal in the area adjoining the welds, Excessive distortion if any due to welding.

DP examination: Procedure shall be as per Pr. Vessel code. However it includes: Check

for any crack or linear indication, porosity, or slag inclusion.

Tolerances for Fabrication of pipes and fittings:

Pipes:

Dia: Tolerance: ± 0.5 % of OD.( Check by measurement of circumference), Length : < 5 mm

for 3 m length., Roundness : 1 % of Pipe Dia.

19

Fittings:

Angular Dimension: ± 1/8” degree.

OD at Bevel: Nominal + 6.25 mm - 4.5 mm.

ID at Bevel: Nominal ± 2.25 mm

Reinforcement Pads for Structural attachment: with gap < 1.5 mm.

Radiography: For pipe 100 mm and above and pressure vessels, selection of the location

and dia. of the pipe and sample size shall be at the discretion of quality supervisor from

Purchaser. If a joint or weld length is acceptable, the remaining length by same welder or

group length shall be acceptable. In case of rejection two more length from the same lot /

group shall be examined at the discretion of quality supervisor from Purchaser. If weld

joints found defective after second radiography examination, all the remaining group

joints shall be rejected. However the contractor shall have option of 100 % radiography.

Welds with the crack, slag inclusions, cavity and incomplete fusion shall be rejected.

Repair of Welds: Welds shall be repaired by additional welding in case of dimensional

problem, but new weld joint to be done for deficient quality. Cracks can be removed by

grinding, chipping, arc or flame gouging with DP test.

Valves:

Physical, material, machining check shall be carried out stage-wise as required.

Hydro-pneumatic leakage test for Body, seat shall be carried out for the time duration as per

BIS code, including shop torque test for gear operated and motorised valves. All technical

performance parameters shall be checked within the allowable tolerance.

6.5.3. Test Certificates

Vendor shall furnish following Test certificates.

Material testing of various components of the equipments/ system parts.

Fabrication inspection / test certificates– Radiography and others

Welder’s qualification certificate.

Performance test certificates carried out by manufacturer before Pre- dispatch inspection

& testing.

Performance test certificates carried out by manufacturer.

Performance guarantee certificate./ calibration certificate/ balancing certificate.

Performance curves of all equipment, along with operation and maintenance manual.

20

7. COMPLETION OF ERECTION & COMMISSIONING

All the equipments shall be installed for the lowest operating noise level. All equipments

shall be mounted on concrete foundation, through cushy foot mountings or as per

manufacturer’s recommendations. All equipments shall be installed so as to have ease of

operation and maintenance.

Electrical work:

Electrical installation shall be carried out in accordance with the specifications, local rules,

Indian Electricity Act 1910 as amended up to date and rules issued thereunder, regulations of

the Fire Insurance Company and relevant BIS code of practice. Sizing of panel board, general

arrangement and all wiring system shall be approved by IPR, before fabrication, wiring etc.

Painting:

All equipments shall be supplied with approved finish, shop coat of paint that have become

marred during transportation or erection, shall be cleaned off with mineral, spirits, wire

brushed and spot primed over the affected areas, then coated with enamel paint to match the

adjoining areas or as directed by IPR.

8. ACCEPTANCE CRITERIA

1. System components or system as a whole shall be tested for performance as per the

various operating conditions like (1) 60 bar, 150°C, 300 LPM for 1 hour (2) 10 bar,

100°C, 100 LPM for 1 hour (3) 5 bar, 50°C, 50 LPM for 1 hour as suggested by IPR

to check the stability of the entire system at different conditions. System can be

accepted and taken-over by IPR for regular operation only after satisfactory

performance testing in all respect. All the system components shall meet the

guaranteed performance & safety requirements to the satisfaction of IPR.

2. Necessary replacement / modification / rectification shall be carried out with the

approval of IPR. The installation shall be tested again after removal of defects and

shall be commissioned only after approval by the IPR.

3. No visible leaks and permanent deformations in the total system after the tests.

9. DELIVERABLES

The following are the documents to be submitted to IPR

1. System description, design calculations and selection criteria or details.

2. Detailed Engineering drawings in soft copy as well as hard copy.

3. Detailed PFD and P&ID of the optimized flow loop system.

21

4. Equipment technical data, Operation and maintenance manuals.

5. Photographs taken during various stages of fabrication, X-radiography reports.

6. Details of the procedure and material test reports carried out during various stages of

development along with rating charts, performance curves etc.

7. Inspection and performance test reports (Including pre-dispatch, site test reports).

8. Details of additional utilities prior to the installation such as space taken by the entire

system, power requirements for the individual components and the entire system,

amount of nitrogen gas required to run the system after commissioning, safety

requirements.

9. Detailed operation manual of the entire system which contains operational limits of

the system including the control systems, individual components, various operating

procedures, safety, troubleshooting etc.

10. Complete installation and testing of the entire system, including the individual

components under all conditions as per design criteria.

11. List of recommended spares and cost, Rate for maintenance contract valid for five

years (for Chillers and DACS system) from the date of handing over.

10. QUALITY CONTROL AND ASSURANCE TEST

The Vendor shall submit Quality Assurance plan (QAP) to IPR for the approval with detailed

time schedule for entire scope of work as per the QAP given in Annexure 6. The quality

assurance plan shall include all the stages starting from specification and covering material

procurement, identification of raw material, fabrication of equipments and up to final

acceptance. Design & engineering, fabrication, testing, inspection, erection etc shall be

covered in Quality Assurance plan (QAP) which will be submitted to IPR for final approval.

IPR reserves the right to appoint a third party for inspection/testing of work done. Vendor

shall have no objection for third party inspection and testing. The cost for third party

inspection will be borne by IPR. Sub-Vendors (if any) are required to be appraised and

approved by IPR before placement of contract job to the sub-Vendor.

11. GUARANTEE

Vendor shall give guarantee / warranty for the performance of the entire system for twelve

months (12 Months) or more from the date of final acceptance. During this period if any fault

occurs, Vendor shall rectify at IPR site without extra cost. If the components have to be sent

22

to the Vendor site, the total expense for to and fro transportation including insurance shall be

beard by Vendor.

12. SAFETY

Vendor shall submit the details of Safety norms/precautions followed for site activities in

routine work. Since the design pressure is fairly high, safety valves at appropriate location of

adequate capacity shall be worked out in accordance with ASME codes, during the

finalization of the P&ID drawings like safety relief valves, over temperature sensors, etc.

Vendor is advised to make a visit at IPR site to understand the IPR site constraints before

quoting if necessary. Safety approval of different components like pressure vessel from

CCOE Nagpur and total system from concerned safety department is under the scope of

Vendor.

13. GENERAL TERMS AND CONDITIONS

1. In case the Vendor is involving any outside party for any purpose, he shall give the details

of the concerned party and get the approval of IPR before doing so.

2. Understanding and knowledge of all the technical areas covered in the scope of work.

3. Experience /arrangement (provide the details of agencies planned for outsourced /

subcontract activities) with, pressure test.

4. The qualification of the people to be employed for the job with organization structure and

how he will execute the work if awarded

14. COMPLETION PERIOD

The total completion period estimated is about 9 months from the date of LOI, however the

Vendor shall clearly indicate the deviation if any. This period includes the approval of

drawings also. The work in totality must be completed within the completion time period as

per approved Bar chart / Project schedule. The entire project is to be completed at the earliest;

hence the Vendor’s labour may have to work on 24 hours basis / round the clock if required,

with necessary prior permission. Necessary penalty shall be applied as per the Penalty / L.D

clauses in case of delay on part of Vendor.

15. BAR CHART/ PROJECT SCHEDULE & PERIODICAL PREVIEW

The Vendor shall provide preliminary Bar chart along with the offer to justify the specified

completion period. The successful Vendor has to prepare Bar Chart / project schedule in

detail, covering activities for all the parts / components and entire system. The Bar chart,

23

PERT chart must be approved by IPR. Periodical / regular progress review of the entire

project work will be carried out at site at least once in a month and same shall be submitted as

site progress report by the Vendor to IPR. However detail of review meeting schedule can be

worked out mutually. Vendor must take corrective measures; follow up action agreed /

suggested during such review meetings.

16. DRAWINGS

Drawings enclosed with Tenders given in Annexure 1 are schematic only and indicate the

extent of work covered in the contract. The drawings broadly suggest the concept and routes

to be followed. The actual site details shall be examined for exact location of equipments and

other system parts.

The Vendor shall follow the tender drawings in preparation of shop floor drawings after

detail engineering. All the shop floor drawings (including electrical) must be approved before

manufacture / supply / installation. Any modifications / changes required to coordinate

installation work as per site conditions, shall be made in consultation with and approval of

IPR. Within 8 weeks after the award of the contract, the Vendor shall furnish three sets of

detailed shop floor drawings, including overall system flow diagram (P & I diagram), Plant

room layout, Piping & Equipment layout, foundation/ support details, Electrical - panel

boards G.A. diagram, power and control wiring diagram etc. with necessary sectional views

as required for the approval of IPR. 3 D & / or Isometric views shall be prepared as per the

instruction of the IPR.

All drawings shall be submitted for approval in hard as well as soft copy in the size as desired

by the Engineer In-charge.

24

ANNEXURE-1 (LIST OF DRAWINGS)

1. Block diagram of HHF test facility

2. Schematic diagram of HPHT-WCS system

3. Isometric view of HPHT-WCS

4. Control loop diagram of HPHT-WCS system

5. Pressure vessel

6. Reservoir tank

Block diagram of HHF test facility

30

ANNEXURE-2 (TECHNICAL SPECIFICATIONS)

(1) Reservoir tank

Capacity 2000 litersDiameter 1.5 mHeight 1.2 mThickness 5 mmMaterial SS 316

(2) Positive displacement pump

Flow rate 50 LPMMaximum pressure 70 barTemperature 25oC to 80oCFluid medium DM waterPower 16 kWSuction size 50 mmDelivery size 50 mmPump input power 18 hpMotor power for pump 16 kWPower supply 415±10 % volts, 3 phase, 50 cycles, ACMaterial for construction SS 316 for wetted parts and carbon steel for

other parts Installation: The pump shall be installed on a concrete foundation

Performance: All the pumps must perform according to selected duty point and

respective performance curve. Pre-dispatch performance test and site performance test

shall confirm the design / required performance.

(3) Pressure vessel

Design pressure (P) 70 barDesign temperature (T) 200oCMaterial SS 316Dimensions Attached in annexure1Shell height 2.44 mShell diameter 1.1 mThickness of cylindrical shell 40 mmThickness of top and bottom head 36 mmSupport Leg support (4 nos)Support leg I section thickness 12 mmTotal volume 2.3 m3

Water volume in the pressure vessel 1.5 m3

Nitrogen gas volume in the pressure vessel 0.8 m3

31

(4) Booster pump

Flow rate 300 LPMOperating pressure 70 barBoosting pressure 10 barTemperature 25oC to 180oCFluid medium DM waterPower 10.5 kWSuction size 50 mmDelivery size 50 mmMaterial for construction SS 316 for wetted parts and carbon steel for

other parts

(5) Heater bank

Capacity (each) 200 kWMedium DM waterPressure rating 80 barTemperature range 25oC to 200oCEnd connection 2ʺ NPS threadHeating element INCOLOYBody SS 316Heater controller / driverType PID (1 no), ON/OFF (2 no)Drive Thyristor basedAccuracy ± 1oCInput Temperature signalsOutput 4-20 mA / 4- 20 mV

(6) Heat exchanger

Configuration Shell and tube with counter flowMedium in shell side and tube side DM waterShell diameter (Ds) 0.34 mShell length (Ls) 1.3 mTube length (L) 1 mNumber of tubes (Nt) 58Tube diameter do = 27 mm, di =19 mmHeat exchanger cooling load 210 kWHeat exchanger type One shell and two pass (F type)Baffle type Longitudinal with sub bafflesNo. of main baffle 1No. of sub baffles 10Sub baffle spacing ~ 0.25 mTube layout Triangular layout

32

(7) Cooling tower

Capacity 108 TRType Induced draftMaterial Fiber reinforced plasticPower supply 415±10 % volts, 3 phase, 50 cycles, AC

Piping & Valve specifications

Pipe (P) Schedule 80MOC : SS 316 ASTM A-312 / A-213Velocity of flow in loop: 2.55 m/sDiameter : 60 mm (NB) & ~ 10 m lengthDiameter : 50 mm (NB) & ~ 25 m lengthDiameter : 40 mm (NB) & ~ 2 m length

Pressure Relief valve (PRV-1 & PRV-2) Set Pressure: 60barTemperature range: up to 200 °CTemperature range: up to 200 °CSize : 2.5"End connection: Threaded (NPT)MOC: SS 316 for wetted parts & Carbonsteel for other parts

Safety valve (SV-1) Set pressure : 65 barTemperature range: up to 200 °CSize : 2.5" x 2.5"End connection : Threaded (NPT)MOC: SS 316 for wetted parts & Carbonsteel for other parts

Rupture Disc (R.D-1) Set Pressure: 70 barTemperature range: up to 200 °CSize : 2.5"End connection : Threaded (NPT)Membrane : SS 316

Control Valve (C.V-1) Size : 50 mm (NB)Cv = 50Operating pressure : 80 barOperating Temperature: 200 °CEnd connector: FlangedRating : ANSI 600 RFActuation : Pneumatic with valveOutput: 4-20 mAPositioner and position transmitter MOC :SS 304 (wetted parts) & Carbon Steel(Body)

Isolation valve Type : Full boreOperating pressure : 80 barOperating Temperature: 200 °CRating : 600Size

33

1"( V - 17)1.5 " ( VV-1to VV-3), DV-1to DV-8)2"( V-1 to V-12, V-15, V-16, V-18 to V-21,BPV-1, BPV-4 to BPV-9),2.5"(BPV-2, BPV – 3)3"(BPV-10, V13, V14 )

Non return valve (NRV-1 & NRV-2) Type : Spring loadedSize : 50 mmMOC : SS 316Operating pressure : 80 barTemperature : 200 °CEnd fittings : Threaded

Three way control valve (CV-2) Size : 50 mm (NB)Cv = 50Operating pressure : 80 barOperating Temperature: 200 °CEnd connector: Flanged raised face perASME B16.5Actuation : Pneumatic with valveOutput: 4-20 mAMOC : SS 304 (wetted parts) & CarbonSteel (Body)

Float Valve Size: 2"MOC : SS 316/SS 304Max Temp: 60⁰COperating pressure: 3 barWorking medium : waterEnd connection: 2" NPT/BSP

34

Analog instrumentation specifications

Level transmitter with indicator (L.T-1) Water level: 2mAccuracy: 0.2%Temperature range: 20 to 200oCWorking medium: waterOperating pressure: 2 barOutput signal: 4 -20 mAIndicator: 3 ½ digits LED displayPower supply: 230 V AC/ 50 HzEnd connector: Threaded (1/2ʺ BSP)MOC: SS 316 for wetted parts

Level transmitter with indicator (L.T-2 &L.T-3)

Water level: 2mAccuracy: 0.2%Temperature range: 20 to 200oCWorking medium: waterOperating pressure: 80 barOutput signal: 4 -20 mAIndicator: 3 ½ digits LED displayPower supply: 230 V AC/ 50 HzEnd connector: Threaded (1/2ʺ BSP)MOC: SS 316 for wetted parts

Vortex flow meter / orifice flow meter Line size: 50 mm (2ʺ)Flow rate: 300 LPM (18 m3/hr)Maximum pressure: 70 barTemperature: up to 180oCFluid medium: DM waterAccuracy: 5% of readingOutput: 4-20mAEnd fittings: FlangedANSI B16.5 Class 300 flangeMOC: SS 316 for wetted parts

Temperature Indicator (T.I-1 to T.I-6) Temperature range: 0-200oCType: RTDAccuracy: ± 0.3 °CFluid medium: DM waterIndicator: 3 1/2 digit LED displayPower Supply: 230 V AC / 50 HzPt-100 sensorProbe: 3 mm dia. x 100 mm lengthMOC: SS 316 for wetted partsEnd connector: Threaded( 3/4 " BSP)

Temperature transmitter (T.T-1 to T.T-5) Temperature Range: 0 -200°CAccuracy: ± 0.2 % of readingFluid medium: DM waterOutput: 4-20mVMounting: Bracket mountingPressure rating: 80 barMOC: SS 316 for wetted partsEnd connector: Threaded( 3/4 " BSP)

35

DP Transmitter (D.P.T-1) Maximum pressure = 70 barDP measuring Range = 1 barAccuracy: 0.2 % of readingTemperature : 20 to 200 °CFluid medium: DM waterOutput : 4-20 mVMounting: Bracket mountingMOC: SS 316 for wetted parts(For orifice flow meter)

Pressure Transmitter (P.T-1) Maximum pressure = 70 barAccuracy: 0.2 %Temperature : 20 to 200 °CFluid medium: NitrogenOutput: 4-20mVMounting: Bracket mountingMOC: SS 316 for wetted partsEnd connector: Threaded( 3/4 " BSP)

Pressure Transmitter (P.T-2) Maximum pressure = 70 barAccuracy: 0.2 %Temperature : 20 to 200 °CFluid medium: DM waterOutput: 4-20mVMounting: Bracket mounting MOC: SS316 for wetted partsEnd connector: Threaded( 3/4 " BSP)

Heater controller / Driver Type : PID (I no), ON/OFF(2 no)Drive : Thyrister basedAccuracy : ±1°CInput : Temperature signalsOutput : 4-20 mA /4-20 mV

Controllers (TC1,TC2,FC,PC) Type : PID Accuracy : ±1%Output : 4-20 mA /4-20 mV

Pressure gauge with isolator PI-1 and PI-3 Type : Bourdon TubeDial size : 200 mm;Range – 0 -100 barFluid : waterEnd connection: Threaded (1" BSP)MOC : SS for wetted parts

Pressure gauge with isolator (PI-2 ) Type : Bourdon TubeMOC : SS ; Dial size : 200 mm;Range – 0 -100 barFluid : NitrogenEnd connection: Threaded (1" BSP)MOC : SS 316 for wetted parts

Pressure regulator with relief option (PR-1) Supply pressure : Upto 140 barOutlet pressure : 10 - 70 barAccuracy : 1 %Size : 1"

36

Flow rate : 200 lpmMedium : Nitrogen/ AirEnd connection: Threaded (1" BSP)MOC : SS 316

Calibration and Testing: All automatic controls and instruments shall be factory calibrated

and provided with necessary instructions for site calibration and testing. Various items of the

same type shall be completely interchangeable and their accuracy shall be guaranteed by the

manufacturer. All automatic controls and instruments shall be tested at site for accuracy and

reliability before commissioning the installation.

.

37

ANNEXURE 3 (LIST OF APPROVED MAKE)

Note: For any system components:

• If make is not specified, only reputed make must be used with prior approval from

IPR.

• In case of delivery or any other serious problem which may affect the progress of the

work the alternative Make other than mentioned above may be approved by the purchaser on

written request. However the final decision by purchaser will be binding on the Vendor in this

regard.

S.NO Details of material

/Equipment

Approved manufacturers name

1 Pressure vessel Oriental fabricators / Fedo Engg. Works /Thermax

2 Positive displacement pump CAT Pumps / Goma engineering/ Hironisha

pumps/

Varicon pumps

3 Booster pump Sulzer Pumps Ltd /Mather & Platt /KBL /KSB

4 Level transmitter with indicator OMEGA Engg. /Rosemount /Yokogawa

5 Vortex / orifice flowmeter Khrone marshell /ABB.Ltd /Honeywell /Yokogawa

6 Temperature indicator OMEGA Engg, /Rosemount /Yokogawa

7 Temperature transmitter ABB.Ltd /Honeywell /Yokogawa

8 DP transmitter Rosemount /ABB.Ltd /Honeywell /Yokogawa

9 Pressure transmitter Rosemount /ABB.Ltd /Honeywell /Yokogawa

10 Heater bank Bharath heater /Heat con /Thermax /OMEGA Engg

11 Pressure relief valve Generant /Tyco /KSB valves /Darling Musecco

12 Safety valve Flowtek Valves and controls /Instrumentation Ltd.

/KSB valves

13 Rupture disc Fike India Pvt. Limited. /B & B Engineering

14 Piping Shipro Steel Industries /Viratra metal industries

/Maulik Enterprises /Tata steel

15 Control valve Instrumentation Ltd./MIL controls /Koso Fluid

Power /Fisher valves

16 Isolation valve KSB valves /Fisher Valves / Oswal Industries

Limited

38

17 Non return valve Flosteer Engineers Pvt. Lt /Unimac valves

18 Heater controller / driver OMEGA Engg /Heatcon / OMRON/ FUJI

19 Controllers (Pressure, flow,temperature)

OMEGA Engg /Heatcon

20 Cooling tower Classik cooling towers /Universal /Thermax

21 Heat exchanger Abacus heat transfer Ltd /Thermax /Universal

22 Three way control valve Fisher valves /KSB

23 Float valve Honeywell

24 Pressure gauge with isolator WIKA Instrument Corporation /Budenberg GaugeCo. Ltd.

25 Pressure regulator with reliefoption

Pressure Tech Ltd / Swagelok

26 Tubing and tube fittings for N2supply

Swagelok / Parker

27 Pipe fittings Oswal industries

28 Electrical control panel Keltron /Siemens /Yokogawa

39

ANNEXURE 4 (List of BIS & ASME Codes)

Relevant of the following IS specifications and codes with all amendments will beapplicable for the work.

IS : 732 III - 1982 Inspection and testing of installation.

IS : 2379 - 1963 Color code for identification of pipelines.

IS : 6272 - 1987 Industrial Cooling Fans

IS : 4894 -1987 Test code for Centrifugal fan.

IS : 3103 -1975 Code of practice for Industrial Ventilation.

IS :778 , 780 - 1980, 210,318, 5312

Gun metal gate, globe and check valves for generalpurpose.

IS : 8092 : 1992 Inspection of Steel Castings.

IS : 12992 : 1993 Safety relief Valves

IS : 5659 : 1970 Pumps for process water

IS : 10596 : 1983 Installation , operation and maintenance of pumps

IS : 1520 Horizontal Centrifugal pumps for clear, cold and freshwater.

IS : 1239 I & II - 1982 MS / GI tube, pipes, tubular and other wrought steelfittings. Hot-dip zinc coatings on steel tubes.

IS : 10773 : 1995 Wrought copper tubes for Ref. & AC purposes.

IS : 4736 - 1968 Code of procedure for manual metal arc welding of MS.

IS : 3589 Electrically welded steel pipe for water, gas and sewage.Above: 200 NB, ANSI B 16.9 for pipe fittings.

IS : 3656 Welds testing by DP

IS : 1536 – 1976 Flanges configuration. (ANSI B 16.5 for SS flanges).

IS : 6392 - 1971 Steel pipe flanges.

IS : 226 Structural Steel.

IS : 638 Gaskets

IS : 628 Rubber gasket, Teflon gasket for SS piping.

IS : 554 – 1975 Dimensions for pipe threads for pressure tight joints

40

IS : 3016 - 1982 Code of practice for fire precautions in welding andcutting operations.

IS : 655 – 1963 Metal air Ductwork.

IS : 277 - 1977 Galvanized steel wire sheets.

IS : 3069 Glossary of Items symbols and units relating to thermalmaterials.

IS : 7240 - 19817413 - 1981

Code for practice for application and finishing ofthermal insulation material at temp. From -80°C to40°C. & 40°C to 700°C.

IS : 10556 : 1993 Storage and handling of insulation material

IS : 3624 Bourdon tube pressure and vacuum gauges.

IS : 1367 Bolts, nuts, and studs./ threaded fasteners.

IS : 2825 - 1969 Code for unfired pressure vessels.

IS : 7403 Cooling tower structure.

IS : 875, 1893 V belts and pulleys for Industrial purpose.

IS : 5141 Code for shell and tube type heat exchanger.

IS : 325- 1970 Specification for three phases Induction motor.

IS : 4029 Testing of three phase Induction motor.

IS : 900 Code of practice for installation of Induction motor.

IS : 996 Single phase small AC and universal motors.

IS : 4064 1978 –II Switches for domestic & similar purpose.

IS : 2959 : 1975 Contractors for AC up to 1100 V.

IS : 2516- I &II ACB

IS : 3854 – 1969 Accessories for electrical wiring

IS : 3837 – 1976 Code of practice for electrical wiring and fitting forbuilding.

IS : 732 –1963 , 1973 Code for practice for installation and Testing ofelectrical wiring.

IS : 694 - 1977

IS : 1554 : 1981

PVC insulated electric cable for working up to andincluding 1100 volts.

PVC insulated (HD) electric cable for working up to 1.1kV and 11kV volts.

41

IS : 1248 Direct acting electrical indicating instruments.

IS : 1822 Starters.

IS : 8544 - I to IV 1979 Motor starters for voltage not exceeding 1000 Volts.

IS : 2208 - 1979 HRC fuse and links, up to 650 Volts.

IS : 2147 – 1962 Degree of protection provided by enclosures for lowvoltage switch gear and control gears.

IS : 10118: 1982 Code of practice for installation and maintenance of

Switchgear.

IS : 3043 : 1966 Earthing.

ISO R281 Rolling Bearings - Dynamic Load Ratings and RatingLife.

IS : 4758 : 1968 Methods of measurement of noise emitted by machines.IS : 14280 : 1995 Mechanical vibration – balancing.

IS : 12065 : 1987 Permissible limits of noise level for rotating electricalmachines

Other / Equivalent Applicable Codes :ASME Code All applicable / equivalent American Society of

Mechanical Engineers’ANSI - B89.1 American National Standards Institute Safety Code for

Unfired Pressure Vessels - Section VIII (Design,construction, testing and certification of pressurevessels).

ANSI - B31.1 American National Standards Institute- Code forPressure Piping. Code for Refrigerant Piping.

ANSI - B36.19 Stainless Steel pipe.

TEMA Code Tubular Exchanger Manufacturer’s Association.

ANNEXURE 5QUALITY ASSURANCE PLAN

Legend: P : test performed by W :test witnessed by R :Reviewed by TP – Third party

,

42

Item 1 : Pressure VesselSl.No. Description of Item Characteristics Type of check Quantum

of checkInspection Acceptance

NormFormat of

record RemarksSupplier TP IPR

01 Raw material ChemicalComposition

Chemical Sample P W R As per Applicablespec. &procedure

Testcertificate

02

FabricationFabrication of dishends and nozzlesRolling of plates

Dimension Measurement 100 % P W R

As per Applicablespec. & approveddrawing &procedure

Inspectionreport

03

WeldingWelding of shellWelding of dish endsWelding of nozzles andspools

Weldingparameters &weld soundness

VisualLPE, X ray 100 % P W R

As per Applicablestandards. &approveddrawing &procedure

Test report

04AssemblyAssembly of pressurevessel

Dimensional Measurement 100% P W W


Inspectionreport

05 Hydrostatic testAfter assembly Over pressure 1.5times

pressure 100% P W W


Test report

Item 2 : ReservoirSl.No. Description of Item Characteristics Type of check Quantum


NormFormat ofrecord Remarks

Supplier TP IPR

01 Raw material ChemicalComposition Chemical Sample P W R As per Applicable

spec. &procedure

Testcertificate

02FabricationFabrication of nozzlesRolling of plates

Dimension Measurement 100 % P W R


Inspectionreport



,

43

03

WeldingWelding of shellWelding of nozzles andspools

Weldingparameters &weld soundness

VisualLPE 100 % P W R

As per Applicablestandard &approveddrawing &procedure

Test report

04 AssemblyAssembly of Reservoir Dimensional Measurement 100% P W W


Inspectionreport


pressure 100% P W W


Test report

Item 3 : Booster pumps & PD pumpsSl.No. Description of Item Characteristics Type of check Quantum



Supplier TP IPR

01 Raw material ChemicalComposition Chemical Sample P R R

As per Applicablespec. &procedure

Testcertificate


pressure 100% P R R


Test report

03 Performance test H - Q curve Flow test 100% P R R


Test report

Item 4 : Flow meter (Orifice / Vortex type)Sl.No. Description of Item Characteristics Type of check Quantum



Supplier TP IPR



Testcertificate



,

44

02FabricationFabrication of Orificeplate

Dimension Measurement 100 % P R R


Inspectionreport

03 Hydrostatic test(Vortex ) After assembly Over pressure 1.5times

pressure 100% P R R


Test report

04 InstrumentationPerformance test Characteristics Measurement 100 % P R R


Test report

05 Performance testFinal assembly

Flowcharacteristics Flow test 100% P R R


Inspectionreport

Item 5 : Heater bankSl.No. Description of Item Characteristics Type of check Quantum



Supplier TP IPR

01 Raw material ChemicalComposition Chemical Sample P W R


Testcertificate

02FabricationFabrication of heaterbank

Dimensional Measurement 100% P W R


Inspectionreport

03 WeldingWeldingparameters &weld soundness

VisualLPE 100% P W W


Test report

04 Assembly Dimensional Measurement 100% P W W


Inspectionreport



,

45

05

Heating coilsBefore assembly:Coil resistivity checksInsulation checks

Electrical Using megger 100% P W R


Test report

After assembly:Insulation & earthingchecksTerminations & housingsafety checks

Electrical

Using megger

Visual check 100 % P W W/R


Test report


pressure 100% P W W


Test report

Item 6 : Isolation ValvesSl.No. Description of Item Characteristics Type of check Quantum



Supplier TP IPR



Testcertificate

02 Hydrostatic test Over pressure Measurement 100% P R RAs per Applicablespec. &procedure

Test report

03 Seat leakage test Seat leakage Measurement 100% P R RAs per Applicablespec. &procedure

Test report

Item 7 : Heat exchangerSl.No. Description of Item Characteristics Type of check Quantum



Supplier TP IPR

01Raw materialTubes, Plates andfittings

ChemicalComposition

Chemical Sample P W R As per Applicablespec. &procedure

Testcertificate



,

46

02 Fabrication Dimension Measurement 100 % P W R


Inspectionreport

03 Welding Weldingparameters &weld soundness



Test report

04AssemblyAssembly of Heatexchanger



Inspectionreport


pressure 100% P W W


Test report

06PID controllersBeforeassembly/installation:Controllability

Functionalitycheck 100 % P W W/R


Inspectionreport

07After assembly:Tuning & responsechecks

Functionalitycheck 100 % P W W/R


Inspectionreport

08 Performance test Heat capacity Measurement 100% P W W


Inspectionreport

Item 8 : Cooling TowerSl.No. Description of Item Characteristics Type of check Quantum

of checkInspection Accepted

standardFormat ofrecord Remarks

Supplier TP IPR

01Raw materialTubes, Plates andfittings

ChemicalComposition

Chemical Sample P W RAs per Applicablespec. & approveddrawing &procedure

Testcertificate



,

47

02 Fabrication Dimension Measurement 100 % P W R


Inspectionreport

03 Welding Weldingparameters &weld soundness



Test report

04AssemblyAssembly of coolingtower



Inspectionreport

05 Performance test Heat capacity Measurement 100% P W W


Test report

Item 9 : Static / Differential Pressure TransmittersSl.No. Description of Item Characteristics Type of check Quantum



Supplier TP IPR



Testcertificate

02 Hydrostatic test Over pressure Measurement 100% P R RAs per Applicablespec. & approvedprocedure

Test report

03 Performance Functionalitycheck 100 % P W/R


Inspectionreport

Item 10: Pressure Relief / Safety / Control / Non return ValvesSl.No. Description of Item Characteristics Type of check Quantum



Supplier TP IPR



,

48



Testcertificate

02 Hydrostatic test Over pressure Measurement 100% P R RAs per Applicablespec. & approvedprocedure

Test report

03 Seat leakage test Seat leakage Measurement 100% P R R


Inspectionreport

04 Performance test Performance Measurement 100% P R R


Inspectionreport

Item 11: Rupture disc

Sl.No. Description of Item Characteristics Type of check Quantum



Supplier TP IPR


As per Applicablespec. & approvedprocedure

Test report

02 Performance test Performance Measurement Sample P W/R R


Inspectionreport

Item 12: Temperature Transmitter / Indicator and level sensor



standardFormat ofrecord

Supplier TP IPR



,

49



Test report



Inspectionreport

Item 13: Pressure gauge with isolator




Supplier TP IPR



Test report



Inspectionreport

Item 14: Controllers




Supplier TP IPR



Inspectionreport



,

50

Item 15: Pressure Regulator




Supplier TP IPR



Testreport

02 Hydrostatic test Over pressure Measurement 100% P R R


Inspectionreport



Inspectionreport

Item 16: Pipe and fitting



standardFormat ofrecord

Remarks

Supplier TP IPR



Testreport

02 Hydrostatic test Over pressure Measurement 100% P R R


Inspectionreport



,

51

Item 17: Final assembly




Supplier TP IPR

01 Hydrostatic test Over pressure Measurement 100% P W WAs per Applicablespec. & approvedprocedure

Testreport

02 Level control test Level sensitivity P W W


Inspectionreport

03 Heat Capacity test Heat load P W WAs per Applicablespec. & approvedprocedure

Testreport

04 Flow capacity test Max and min flow P W W


Inspectionreport

05 Temperature rise test Temperature riseand rise rate P W W


Inspectionreport

06 Pressure rise test Pressure rise andrise rate P W W


Inspectionreport

07 Performance test Functionalitycheck 100 % P W W


Inspectionreport

52

ABBREVATIONS

HPHT High Pressure High Temperature

WCS Water Circulation System

IPR Institute for Plasma Research

D.M Water De-Mineralized water

DAS Data Acquisition Systems

P & I D Piping & Instrumentation Diagram

T.I Temperature Indicator

T.T Temperature Transmitter

P.I Pressure Indicator

P.T Pressure Transmitter

L.I Level Indicator

L.T Level Transmitters

D.P.T Differential Pressure Transmitter

P.C Pressure Controller

T.C Temperature Controller

F.C Flow Controller

V.F.D Variable Frequency Drive

P.D Pump Positive Displacement Pump

R Reservoir Tank

CT Concrete Tank

P.V Pressure Vessel

B.P Booster Pump

F.M Flow Meter

C.V Control Valve

V Isolation Valve

V.V Vent Valve

D.V Drain Valve

B.P.V By-Pass Valve

N.R.V Non Return Valve

B.V Breather Valve

P.R.V Pressure Relief Valve

S.V Safety Valve

53

R.D Rupture Disc

H.E Heat Exchanger

C Cooler

C.T Cooling Tower

H Heater

SS Stainless Steel

PID Controller Proportional Integral Derivative Controller

ANSI American National Standards Institute

ASME American Society of Mechanical Engineers

TEMA Tubular Exchanger Manufacturers Association

C.A Corrosion Allowance

HL Higher Level

ML Middle Level

LL Lower Level

N2 Nitrogen

LMTD Log. Mean Temperature Difference

CL Tube Layout Constant

CTP Tube Count Calculation Constant

PR Tube pitch ratio

FRP Fiber Reinforced polymer

Fig Figure