TECHNICAL SPECIFICATION

Cooling Water System for 2 x 30 MW Stage-IV Power Station Nomgkhyllem

1. Scope:
This section specifies the Technical requirements applicable to techinal specification,
materials working stress and work man-ship in design and manufacturing of the cooling
water system for Stage-IV Power Station Nongkhyllem.
2. Cooling Water Pump
The pumps shall be of high performance requisite type and of reputed make
(KSB. Kirloskar, Flowchem, Ambica, BE pumps etc) and shall be directly coupled to
their driving motors. The pump shall be of self priming type and the water seal shall
preferably be mechanical seal. The pumps shall comply with relevant national or
international standards.
The material of construction of pumps in general shall suit the service conditions
and shall be such as would be resistant to abrasive effects of silt. The pumps shall operate
quietly without undue noise and vibration in their full operating range of head and flow.
They shall be easy to maintain.
The cooling water system shall be taken from the tailrace by centrifugal pumps
and to be fed to the header and has to be provided for the purpose as per drawing
enclosed.The exact shall be finalized with the Engineer In Charge at site.
Raw water pumps draw water from tailrace through a foot valve with removable
mesh cover (of 10mm) and gate valves. Check valves and non return valve shall also be
provided to prevent flow from main to standby pump and then feed to main header. The
suction and delivery shall be through 200mm piping as per drawing enclosed.
Check valve and non return valve to be provided after pump to prevent flow from
one unit to the other.
3. Electric Motors
All motors shall comply with relevant National or International Standard for
Motors.
Supplier shall be fully responsible for determined that the motor duty cycle,
rating, performance, tests and mechanical arrangement are all entirely relevant and
suitable for compliance with the above standards for the application at the station and in
the extreme environment and site conditions type.
The preferred type of A.C motor is squirrel cage, totally enclosed, fan cooled.
The stator insulation system shall be class-B or a higher class, but in each case,
temperature rises shall be limited to Class-B where practicable on full continuous rated
load.
All A.C motors shall be capable of star/delta starting and of continuous operation
rated output under abnormal frequency conditions and shall also be capable of operation
for a period of not less than 5 minutes, with a voltage of 25 percent below nominal
voltage at normal frequency, without injurious overheating. The starting current at full
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voltage shall not exceed six times the full load current. Each of the motors shall be tested
at Manufacturers works to confirm compliance with this requirement.
The terminal box shall be weatherproof and firmly fixed to the motor frame. The
terminal studs shall be so sized as to be adequate for the current duty required and shall
be identified. All terminal boxes shall have approved cable adapter plates, sealing
chambers or conduit entries.
The arrangement of the terminal box shall be such as to facilitate installation of
cables and allow interchanging of any two phases leads without disturbing the sealing
compound, if this is used at cable terminations.
Where practicable, the motor end cover shall be removable from the driving end
and shall have a removable plug to allow the speed to be checked by means of a portable
tachometer.
All motors shall be fitted with lifting lugs.
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Starter for motor

The contractor shall also supply the starter for the above pump set along with the
cable necessary for connection to the pumps and from the LT panel of MePGCL. The
starter shall be of star/delta type of sufficient capacity complete with
overcurrent/earthfault protection and also thermal overload. Provision of current and
voltage measurement for all thee phase shall be provided
Motors starters and contractors shall be equipped with short circuit protection and
local disconnected devices. Preferably, all starters shall be from one manufacturer.
Starters and contractors shall comply with applicable IS standard or IEC 292.1 or
NEMA IC 1 and shall be suitable for star/delta starting, uninterrupted electrical duty, and
capable of 30 operations per hour. They shall be installed in ventilated enclosures for
indoor installation and weatherproof enclosures for outdoor installation, unless otherwise
approved by the purchaser. The enclosures shall be complete with the locks, cable sealing
boxes, conduit entries, cable gland plates, bus bars, internal wring, terminal boards and
other necessary items as required by the duty of the starter or contractors.
Starters and contractors shall be of minimum size compatible with motor size and
capable of satisfactory operation, without damage, for a period of 5 minutes at voltage 25
percent below nominal voltage, at nominal frequency.
Thermal type overloads and phase failure relays shall be supplied with starters.
Each starter shall have sufficient number of auxiliary contacts required for
interlocking and indication purposes plus two spare convertible contacts for purchasers.
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Cable for motor

Contractor shall provide sufficient length of three phase power cable for connection from
the motor to the starter panel and from the starter panel to the LTAC panel. The cable
shall be of sufficient capacity to meet the requirement of running the above motor
without overheating or damage. Lugs required for the termination shall be supplied by the
contractor.

6.

Materials

General Requirement: The materials should be of first class commercial quality as

normally used considering its strength, ductility, durability and best engineering for
operation of the system in normal as well as in sever operating conditions. The materials
defects and imperfections, of resent manufacture and unused and where indicated of the
classifications and grades designated therein.
The design pressure is 6.0 Bar and test pressure is 9.0 Bar
All the piping shall be ERW carbon steel as per IS 1239/3589
All connection shall be flanged as per ANSI B16.5 class 150
All flange material shall be carbon steel as per ASTM A105
All Inline valve shall be flanged connection.
Valve material:
Pump material

7.

Gate valve as per BS 1414

Casing- Cast Iron
Shaft sleeve- stainless steel
Impeller - Stainless steel.

Approval of Manufacturers and eligibility erection:-

The supplies shall furnish to purchaser for approval the names of the
manufacturer or sub-supplies of all the machinery and equipments which he intend to
incorporate in the work together with performance, capacities and other significant
information i.e performance report pertaining to the equipment or similar equipment
supplied elsewhere by him. Test report of the equipment shall also be submitted for
approval.
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Requirement of Work
8.1

Piping and Valves:

Piping and pipeline material and equipments shall be of appropriate material, size
and type to suit the function and performances and shall conform to the relevant and
applicable standards. The piping shall be complete with gate valves, foot valves etc to
provide desired functions and operations with ease and flexibility and easy maintenance.
The valves, which are to be kept normally, open or in closed position shall be provided
with suitable locking arrangement.
Pipelines may undergo expansion or contraction under service conditions and
adequate provision/allowance shall be made for the same.
All items of pipelines shall be thoroughly cleaned individually before installation
and after erection, in stages/on completion, using proper method. It shall be ensured that
they are perfectly clean inside before putting into use.
The layout shall be such that valves are conveniently located to enable easy
access for operation and reading.
Horizontal piping runs may, where necessary, be sloped to facilitate drainage.
Lagging of piping runs, where necessary, shall be provided.
The support system shall be rigid enough to prevent piping vibration when in
operation.
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The gaskets shall be requisite material, thickness to suit service condition.

(8-2) Works for piping, welding, painting, electric conduits, and cables
(a) Works for piping
The piping works and pipe support works shall be performed in accordance with the
provisions of this clause.
Unless otherwise specified in the Specifications, the piping works shall be done in
accordance with the following provision.
(a-1)

The Contractor shall perform welding works wherever necessary for installation of
pipes and pipe supports.

(a-2)

Pipes connecting with the Equipment shall be supported to so as not to convey the
weight of pipes to the Equipment. Any extra stress due to abnormal connection of
pipes shall not be put on to the Equipment.

(a-3)

For piping, a trial connection shall be performed in order not to apply an abnormal
load to the joint and so as to accurately align the flange surfaces upon which the
required packing and coating shall be filled or applied, and the joints shall be finally
fastened evenly with care to prevent any leakage of water, oil or air.

Connecting surfaces of flanges shall be furnished with match-marks considering

convenience of assembly and disassembly. The Contractor shall furnished drain cocks at
necessary positions in the piping system to be installed.
(a-4)

The pipes shall be inspected and cleaned prior to assembly. Pressure test shall be
applied to pressure pipes before assembly.

(b) Works for welding

Unless otherwise specified in the Specifications, the Contractor shall perform welding works
in accordance with the following provisions:
(b-1)

Except as specifically approved, all welding shall be executed by the electric arc
process. After welding, sludge, spatter, and/or unexpected metals shall be removed and
welded surfaces shall be confirmed to be smooth and free from clinker or pinholes. In
case any pinholes, cracks or defects are found, such portions shall be removed by a
chipping grinder and shall be re-welded.

(b-2)

Welding rods designated by the manufacturer to be used in hand welding shall be a

heavy coated type suitable for welding of all sections. The Contractor shall provide all
welding rods and the consumables.

(b-3)

The Contractor shall prepare necessary welding tools, and provide consumable
materials such as welding rods, and protecting covering staff preventing other
equipment and/or devices from receipt of sludge, spatter, and/or unexpected metals
caused during welding works.

(b-4)

The Contractor shall prepare suitable number of air exhaust fans and flexible air ducts,
which will exhaust smoke from area under welding works to the outside of the power
house.

(c) Works for painting

The Contractor shall, upon completion of installation of Equipment, perform painting
works in accordance with provisions specified in the Specifications.
(c-1) The Contractor shall provide equipment and materials necessary for cleaning of surface
and for painting. Painting shall be applied to clean surfaces free from rust, dust, oil,
moisture and other foreign materials.
(c-2) The Contractor shall apply one finish coating to the exposed surface of the Equipment
with one coat of rust preventive painting at the Contractors shop. The Contractor shall
also perform repair and finish coating of parts of shop-coated Equipment damaged
during transportation and/or installation works.
(c-3) Upon completion of piping, one coat of rust preventive paint and one coat of finishing
paint shall be applied by the Contractor to all pipes..
(c-4) The Contractor shall prepare necessary tools, and provide paints, solvent, and protecting
covering staff preventing other equipment and/or devices from painting works.
(c-5)

The Contractor shall carry out to remove drips of paint and to clear up other equipment
and/or devices, and floors and/or walls of the powerhouse. The Contractor shall carry out
special treatment for non-used remaining paint and solvent materials without disposal at
Site area.
Works for electric cable and conduits

The Contractor shall install all the starter as directed by Engineer In charge and all
electrical conduits and fittings required for completion of the exposed conduit system for
the cables and wires, which are furnished for the Installation Works. The Contractor shall
prepare and submit all design drawings covering the conduit works. The designs shall
include all plans with details and conduit schedules giving the numbering, size,
terminating points and uses.
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Schedule of Quantity As per Special condition of contract clause H3.1