VOL.IIA

CHENNAI METROPOLITAN WATER SUPPLY AND SEWERAGE BOARD

MECON LIMITED(A Govt. of India Enterprise)

BANGALORE

FEBRUARY 2010

CONSTRUCTION AND OPERATION & MAINTENANCE FOR 7 YEARS OF 100 MLD SEAWATER REVERSE OSMOSIS

DESALINATION PLANT AT NEMMELI, TAMILNADU

CONTRACT AGREEMENT WITH

M/s. VA TECH WABAG LIMITED, CHENNAI & M/s. IDE TECHNOLOGIES LTD., ISRAEL

CONSORTIUM

VOLUME II A

CONSULTANT M/s. MECON LIMITED, BANGALORE

CHENNAI METROPOLITAN WATER SUPPLY & SEWERAGE BOARD

ADECO TECHNOLOGIES MECON LIMITED

List of volumes

Volume number Description Volume I Commercial Volume II A Technical specification Volume II B (1 of 2 & 2 of 2) Technical specification Volume III Drawing Folders ( 1 to 6) Volume IV Bill of Quantities


ADECO TECHNOLOGIES ( i ) MECON LIMITED

VOLUME II A & II B TECHNICAL SPECIFICATION

Sl. No. Description Location

VOLUME II A 1. Intent of specification, plant & process

description and scope of work & guarantees Chapter-1 of volume II A

2. Technical specification for mechanical systems /equipment

Chapter-2 of volume II A

3. Site details Chapter-3 of volume II A 4. Technical Specification for sea water intake

& outfall system Chapter-4 of volume II A

5. Technical Specification for Pipes, fittings & Valves


6. Technical Specification for Erection & testing Chapter-6 of volume II A 7. Technical Specification for shop & field

Painting Chapter-7 of volume II A

8. Technical Specification for internal lining of pipes, tanks , vessels


9. Preferred makes Chapter-9 of volume II A VOLUME II B

10. Technical Specification for Civil works Chapter-1 of volume II B (1of 2)

11. Technical Specification for Steel & Structural works

Chapter-2 of volume II B (1of 2)

12. Technical Specification for Power Distribution

Chapter-3 A of volume II B (1of 2)

13. Technical Specification for HT motors Chapter-3 B of volume II B (1of 2)

14. Technical Specification for Shop Electrics Chapter-4 of volume II B (1of 2)

15. Technical specification for Illumination Chapter-5 of volume II B (2of 2)

16. Technical Specification for Instrumentation & Automation


17. Technical Specification for Air Conditioning & Ventilation


18. Technical Specification for Repair shop Chapter-8 of volume II B (2of 2)

19. Technical Specification for Laboratory Chapter-9 of volume II B ( 2of 2)


ADECO TECHNOLOGIES ( ii ) MECON LIMITED

Sl. No. Description Location 20. Technical Specification for Material

handling equipment Chapter-10 of volume II B (2of 2)

21. Technical Specification for Fire fighting Chapter-11 of volume II B (2of 2)

22. Technical Specification for air compressor


23. Technical Specification for Sewerage treatment plant


24. Technical Specification for Safety Equipment


25. Technical Specification Portable Fire Extinguishers

Chapter-15 of volume II B (2 of 2)



INTENT OF SPECIFICATION,

PLANT & PROCESS DESCRIPTION,

AND

SCOPE OF WORK & GUARANTEES


ADECO TECHNOLOGIES (i) MECON LIMITED

CONTENT

SL.NO. DESCRIPTION PAGE NO. 1.0 Preamble 1 2.0 Intent of Specification 1-3 3.0 Special instructions to the contractor 3-4 4.0 Technical description 4 5.0 Tender drawing & data sheet 4-5 6.0 Design basis 5-27 7.0 Plant description 27-46 8.0 Process description 46-55 9.0 Scope of work 55-56

10.0 Detail scope of work 56-67 11.0 Performance guarantee 67-74

12.0 Drawings, documents etc to be submitted by the contractor

75-76

13.0 Drawings, documents etc to be submitted by the contractor

76-84

Annexure-IA 85 Annexure-IB 86 Annexure-II 87 Annexure-III 88-89

Annexure-IV 90-91 ATTACHMENTS

RO & UF PROJECTIONS, CORRECTION/NORMALISATIONCURVES, PERFORMANCE GUARANTEE, SP.CHEMICAL CONSUMPTION, SP. POWER CONSUMPTION


ADECO TECHNOLOGIES Page 1 of 91 MECON LIMITED

1.0 PREAMBLE

Chennai Metropolitan Water Supply and Sewerage Board (CMWSSB) intends to install a 100 MLD capacity Sea Water Reverse Osmosis (SWRO) desalination plant at Nemmeli, Kancheepuram district, Chengalpattu taluk, Chennai, Tamilnadu, India to augment the drinking water supply to the city of Chennai.

MECON Ltd., Bangalore in association with ADECO Technologies, Lugano, Switzerland was awarded the work of preparation of a detailed project report and contract document including detail engineering for this project. For fulfilling the assignment, MECON carried out site surveys (topographical & geotechnical), oceanographic and marine studies (hydrographic survey, onshore geophysical and hydro geological studies), pumping tests to study the feasibility of beach wells and EIA/EMP studies. Basic engineering was furnished by ADECO Technologies and detailed engineering was carried out by MECCON.

2.0 INTENT OF SPECIFICATION 2.1 The intent of this technical specification (Volume –II A & B) is to define

the requirements for residual engineering, manufacture, assembly, inspection, shop testing, supply, packing, forwarding to site, unloading, storage and preservation, handling at site, insurance, erection and complete installation, supervision, painting, pre-commissioning, testing & commissioning, completion of facilities, conducting performance guarantee tests, initial fill of lubricants, spares, consumables, special tools & tackles and handing over including operation and maintenance for seven years for 100 MLD sea water reverse osmosis desalination plant along with its associated infrastructure facilities and to enable the contractor to submit a detailed and comprehensive offer matching the requirements specified in this document and other conditions of contract.

2.2 The contractor’s proposal for execution of the complete scope of works covered in the technical specification for the Desalination Plant and associated facilities shall be a single point responsibility, completely covering the following facilities in respect of the equipment & works specified under this contract document.

• Offshore sea water open intake pipeline facilities and onshore pumping station,

• Onshore water conditioning system, settling basin/sedimentation tank and degritted storage tank

• Pre-treatment system by means of automatic back washable disc filters followed by in to out, out to in highly hydrophilic Ultra filtration membranes system.



• Desalting by reverse osmosis (RO membrane process), high pressure pumping and energy recovery system.

• Chemical cleaning system for RO and UF skids • Intermediate storage and pumping system • Interplant pipelines • Bulk chemical storage facilities and & centralized chemical

dosing systems, • Re-carbonation & Re-mineralisation systems including

limestone storage and re-charging system • Final Product storage excluding potable water transfer pumps

& potable water transfer pump house, • Reject storage, pumping & outfall system • Fire fighting facilities including fire water storage tank & fire

water pump house including fire hydrant network system, potable fire extinguishers and safety equipment

• Electrical power distribution, shop electrics & illumination • Instrumentation & controls including DCS • Material handling facilities • Repair shop • Laboratory • Other non plant buildings facilities like gate complex, security

cum time office, security cabin vehicle parking shed, amenity & canteen building, administrative building, view gallery cum guest house

• Boundary wall including land development for the entire plant area, plant inside roads & green belt

• Sewage treatment plant 2.3 These units are required for safe, trouble free, continuous and efficient

operation with adequate maintenance facilities within the defined battery limits as per the latest engineering practices. The intent of this specification also covers all facilities and features, which may not have been explicitly specified but required to complete the desalination plant.

2.4 This technical specification (volume IIA & B) forms technical part of

the contract document and shall be read in conjunction with other parts of the contract document i.e volume 1, III & IV. All these documents are complementary to each other and anything called by one and not by others shall be considered as binding as though called for by one and all.

2.5 This specification pertains to the setting of a complete integrated sea

water reverse osmosis desalination plant along with associated facilities and includes the description of the plant and unit, operating conditions, throughput and product capacity, feed and product specifications, scope of work, battery limits and exclusions, technical specifications, equipment & instrument datasheets and specification drawings, structural design drawings with marking plan, civil design &



detail drawings, equipment and plant layout drawings, process flow sheets & material balance, piping &instrumentation drgs, pipeline detail drawings, single line electrical loop drawings and performance guarantee parameters, penalty clauses and operation and maintenance requirements.

2.6 The data/documents/drawings/technical requirements furnished in this

specification are based on site data obtained from the studies conducted at the plant location and well established technical know-how. Basic & detail engineering have been carried out based on information related to analogous equipment and site data. Any change in these, if necessary, shall be intimated to the contractor and shall be binding on the contractor for complying of the same.

3.0 Special instructions to the contractor 3.1 The instructions to the contractor shall be read in

conjunction with the Invitation to Tender, General Conditions of Contract, Technical Specification, scope of work, drawings and other supplementary documents detailing the complete work under the contract specification.

3.2 All parts of contract documents shall be considered mutually

supplementary and complementary to one another. However, in case of any conflict/contradiction, the documents will prevail over one other in following order.

i) For all commercial contractual and general conditions,

Volume-I and commercial terms shall prevail. ii) For any technical aspect/ details, the technical specification (

Vol. II ) & drawings ( Vol. III ) shall prevail. Any contradiction either between various parts or volumes of document or in the contents of same document shall be a matter for clarification to be obtained by the contractor from the Purchaser and only after obtaining the same should proceed with the manufacture/erection of the items in question. The Purchaser’s decision shall be final. However, as a general guideline the order of preference in case of conflict between various parts of the document shall be as follows: a) Drawings b) Datasheets c) Technical specification d) Standard specifications e) Standard and codes

3.3 The standard specification requirement, if superior to the technical

specifications will prevail over the technical specification. If the standard specification requirement is inferior to the standards & codes requirement, then the ’Standards and codes will prevail. But in any



case, the contractor shall proceed after obtaining the necessary clarifications from the purchaser/consultant.

3.4 All the equipment and accessories shall be supplied from the “List of

Preferred Makes” given separately or the makes and model mentioned in the technical specification, datasheet and equipment schedule.

3.5 The contractor shall be fully responsible for any residual

engineering required due to variation from the pre-engineered drawings and documents enclosed with the tender, supply, erection, testing, commissioning operation and maintenance of the system in his scope of work for guaranteed performance.

3.6 The contractor shall carefully check the enclosed Technical

Specifications and drawings and shall satisfy himself to the suitability of the equipment, facilities and layout in totality as given in the technical Specification, drawings & datasheets and shall take full responsibility for the efficient operation and guarantee of the specified output of the plant and equipment offered.

3.7 All norms pertaining to statutory authorities including electrical/

environment/pollution control shall be adhered in strict compliance with the National/ State/ Workplace Health and Safety regulations and guidelines for the complete plant and equipment under the contractor’s scope during the contract execution period.

4.0 Technical Deviations 4.1 No deviations are acceptable in the contractors offer. Clarifications if

any, with suitable justifications, have to be furnished to CMWSSB within stipulated date for consideration and reply by CMWSSB. Further, contractors shall note that the contract document as published by CMWSSB and all subsequent correspondences between CMWSSB & contractors till contract submission will form a part of the contract document.

4.2 Changes if any which may arise at the execution stage shall be

allowed only if prior approval is obtained from Purchaser/ Consultant in writing..

5.0 TENDER DRAWINGS & DATASHEETS 5.1 The tender is deemed to be an engineered package wherein the

technical specifications covering site data, datasheets, design and detail drawings, standard specification for plant and equipment along with process flow sheets & material balance diagram, P & IDs, equipment datasheets, general layout plan, civil and architectural design & detail drawings for plant & non plant buildings including equipment foundations and supports, structural design drawings,



underground submarine pipeline intake & outfall details and alignment drawings, above ground detail piping drawings, electrical & instrumentation details, material handling including limestone storage and charging system, firefighting, air conditioning and ventilation, laboratory, repair shop, work shop, warehouse details & drawings have been included and the same forms the part of the tender document.

5.2 The datasheets, design and detail drawings enclosed with this

specification shall form the basis for procurement and construction of the plant & equipment. The technical & standard specification shall supplement the design and detail drawings. These drawings are for erection & construction purposes and are subject to minor changes only that may be necessary for adjustments due to variations in the equipment footprint from the preferred vendor list. These changes shall be carried out by the successful contractor under residual engineering with prior approval from the purchaser/consultant keeping intact the basic footprint & engineering details of the building and associated piping as applicable. Various details for building, equipment, valves, electrical & instrumentation, piping etc. specified in the tender drawings are the bare minimum requirement and any increase in these parameters if required to meet the system requirement shall be made by the contractor without any additional cost implication to Purchaser.

6.0 DESIGN BASIS

The envisaged seawater desalination system is based on the best available, proven reverse osmosis technology reflecting the latest innovation in the design, operation and maintenance of water treatment plants and is conceived with the contribution of multidisciplinary experiences acquired in seawater desalination. The plant is designed and engineered to produce 100 MLD of drinking water as per IS -10500 for 365 days a year on uninterrupted basis for onward pumping to CMWSSB city distribution storage tank from sea water through open pipeline intake.

6.1 PROCESS & PLANT DESIGN

Marine & oceanographic studies, historical data detailed in chapter 3 of volume II A (Site details) and current technological trends for large SWRO plants has been the basis for process & plant design and equipment selection. Utmost emphasis has been laid in the selection and design of sea water intake and site selection. It is proposed to adopt integrated membrane system design approach i.e. ultra filtration membrane as pre-treatment followed by single pass Reverse Osmosis membrane system. Chemical and power consumption were the other two thrust areas which formed the basis for process and equipment selection for the pretreatment and energy recovery system. Advanced



membrane pretreatment system comprising of automatic back washable disc filters followed by ultrafiltration membrane system has been preferred over the convention pre-treatment system of coagulation, flocculation, clarifiers/tube settlers, gravity sand filters, pressure filters/dual media filters and pressure eliminating to a great extent the usage of chemicals normally used in pre-treatment section. Pressure exchangers have been preferred over pelton wheel turbines, energy recover turbines, DWEER type work exchanger as energy recovery device.

The disc filtration and ultra filtration section is designed for a minimum recovery of 90% and the RO section is designed for 45.38% recovery. Recovery is designed as the % ratio of output flow to the input flow. Considering the losses at the intake section, backwashing requirement at various stages of the process and other in-plant consumption, the plant will operate at an overall recovery of 37.7%. This means that more than twice the flow of product water must be pumped from the ocean and slightly more than the product water quantity must be returned as reject into the sea. Hence, special considerations has been made based on the experience of other similar operating plants in the design & selection of equipment, piping and material of construction for the intake system, reject pumping and outfall system to ensure reliable operation of the desalination plant. The pitting resistance equivalent for the wetted metallic component in the system has been taken as 40.

The design considerations are detailed below for the contractor to understand the design aspects of the process and plant design.

6.1.1 SITE SELECTION 1. The site selected is free from industrial activities in the vicinity

and no influents/effluent/external steam joins at this location. 2. The site is free from any port or harbor activities 3. Plant is located close to the sea i.e on the shore to minimize

piping cost.

6.1.2 DESIGN CONSIDERATIONS FOR INTAKE SYSTEM, PRETREATMENT

SYSTEM, RO SYSTEM & POST TREATMENT SYSTEM 6.1.2.1 INTAKE SYSTEM 6.1.2.1.1 The intake is one of the key components of every membrane seawater

desalination plant, its purpose being twofold:

i) Adequate and consistent flow



ii) Quality of water over entire useful life of the desalination plant.

The two key types of intakes used for seawater reverse osmosis (RO) desalination plants are beach well (subsurface intakes) and open surface intakes. Beach wells are located on the seashore, in close proximity to the sea. They are relatively simple to build and the seawater collected is already pretreated via slow filtration through the subsurface seabed formations in the area of source water extraction. Therefore, source seawater collected using beach well intakes is usually of better quality in terms of solids, silt, oil and grease, natural organic contamination and aquatic micro-organisms as compared to open seawater intake. Sometimes, beach well intakes may also yield source water of lower salinity. However, it is seen that the beach wells are generally suited for relatively small capacity SWRO desalination plants. At present, worldwide there are only four operational SWRO facilities with capacities larger than 20 MLD where water intake is through beachwells. The largest SWRO facility with beach wells is the 54 MLD Pembroke plant in Malta. The 42 MLD Bay of Palma plant in Mallorca, Spain has 16 vertical wells each with a capacity of 5.6 MLD. The third largest plant is the 24 MLD Ghar Lapsi SWRO plant in Malta.

There are a number of key factors that have to be taken into consideration when assessing the viability of beach well intake for large desalination plants as given below:

a) Transmissivity/productivity of the seashore’s geological

formation b) Thickness of the beach deposits and the existence of nearby

fresh water source aquifiers which could be negatively impacted by the beach well operations for large desalination plants.

c) Beaches of shallow bays as the one near the proposed

desalination plant contain significant amount of mud/alluvial deposits and has a limited natural flushing ability of the beach wells.

High content of fine solids in bay seawater in combination with low frequency of bay flushing and low transmissivity of the beach deposits make shallow bay beaches less desirable or unsuitable for construction of beach well intakes for large SWRO plants. If beach well intake is feasible then the pretreatment unit of desalination plant becomes simpler and the chemical consumption is reduced to a large extent since seawater feed derived from a well-designed subsurface intake well requires minimum pretreatment. The feed obtained from these wells tends to be of high quality feed with an SDI as low as 1 or less.



In view of the above, onshore studies and pumping tests were conducted to study the feasibility of a beach well and but it has been established that the required input water quantity of about 11000m3/h cannot be obtained through beach wells due to the terrain and hydrogeology of the area. Hence the design of the plant is based on open sea intake.

6.1.2.1.2 The plant has been designed to minimize the effect of variations in

feed water quality on plant operations. The seawater open pipeline intake system has been located at a sufficient depth to avoid sediment from bottom being entrained by wind and waves. The depth of the intake and disposal provided is sufficient to provide clearance for navigation, minimize entrainment & impingement of marine organisms that takes place during water drawl. Hence, it has been ensured that the effect on the aquatic ecosystem will be minimal.

6.1.2.1.3 Intake point has been located at a sufficient distance from the reject

disposal point to prevent short-circuiting. The same has been decided based on the current and tidal studies being conducted at site and dispersion studies accompanied with computer modeling.

6.1.2.1.4 Drawing water from the sea from an area at a distance from the shore

so that it is unaffected by inflows from the land leads to more consistent salinity. Lower suspended solid, entrainment and impingement of marine organisms has been important consideration in the intake design. The efficient and adequate selection in the intake design has helped in the reduction in the extent of pretreatment equipment and has thus reduced the plant capital & operating costs and operational risks.

6.1.2.1.5 Based on the field studies for onshore and offshore water intake

(details of studies are in chapter 3 of volume II B), sea water open pipeline intake at a distance of 1000m from the shore line where the availability of clear water depth has been found to be 10m has been selected for receiving raw feed water to the plant. The clear head available at the in take head will be 5m. (refer drg no. MEC/10EP/01/01/WOR/0168 for sea water intake facilities)

6.1.2.1.6 Intake pipeline of high density polyethylene pipelines (1600 mm dia,

PE-100, PN-10, IS 4984) has been designed for non-turbulent in-flow rates so that it will require low maintenance, have a lower tendency for bio-growth and will be simpler to clean and have no hazardous … materials for the membrane elements. The intake pipeline is envisaged to be laid below the sea bed with minimum top cover of 1.5 m and special expansion flexible joints have been envisaged for intake filter system and HDPE pipeline connection to take care of settlement and unbalanced forces (Refer drawing no.MEC/10EP/01/01/WOR/0166). The specification for intake, datasheet no. MEC/10EP/01/01/DS/0115 and outfall datasheet no.



MEC/10EP/01/01/DS/0116 expansion joints is given in Attachment no-15A & 15B respectively.

6.1.2.2 PRETREATMENT SYSTEM 6.1.2.2.1 The plant requires a reliable source of water of consistent quality. The

feed water salinity, suspended solid loads and organics are the determining factors in the selection of pretreatment systems and RO recovery and for consistent working of the plant. The intake head location depth having clear sea water depth of 5m has been selected which will ensure reliable and consistent quality of feed water supply considering the low tide level. At this depth a fluctuation in the feed water quality parameters and impact on flora and fauna will be minimum. However, enough cushion in the pretreatment section design has been kept considering the worst possible fluctuation that can ever happen, the pre-treatment section has been selected for average suspended solid loads 50 ppm and peak suspended solid load of 200 ppm.

6.1.2.2.2 The desalination plant process design is based on the site-specific

seawater quality parameters. The water samples were collected at locations in the sea 1 km to 3 km from shore and analyzed for various parameters given in table 6.1. These results obtained from the water samples collected has been considered as the basis for design of pretreatment & RO systems. However, the results obtained on the samples have been compared with full one year data available for the nearby sea area within 10 km radius. The plant has been designed for normal 50ppm total suspended solid load and can take care of 200 ppm peak total suspended solid load. The plant has been envisaged for 40100 ppm TDS inlet at the intake filter inlet. However, the plant is designed to take care for a TDS load of 41900 ppm considering addition of water conditioning chemicals in the feed water.

6.1.2.2.3 The raw water quality & the permeate water quality which shall form

the basis of design for pretreatment & RO section detailed in section 4.3.2.

6.1.2.2.4 The following temperatures shall form the basis of design.

Maximum temperature o C = 32 Minimum temperature o C = 24 6.1.2.2.5 Low chemical and energy consumption has been considered as

another key factor in the design and selection of equipment for pre-treatment section and RO section so as to minimize the operational cost.

6.1.2.2.6 The design envisages two parallel lines of 50% capacity

interconnecting between the intake pumping station and the pre-



treatment section of the plant. This approach increases plant availability and reliability (ensuring at least 50% availability).

6.1.2.2.7 Underground up flow rapid sand media filter with adequate retention

time has been sized and envisaged as the first line of defence in the pretreatment section for arresting large size suspended particles and jelly fish that might escape from the intake suction filter. The water is pumped from the intake chamber so as to enter the from the bottom of the up flow filter by means partition wall envisaged for this purpose and the clarified water from the top is led to degitted water storage tank.

6.1.2.2.8 Advanced pretreatment system comprising of 30 sets of disc filters

with high filtration efficiency and UF skid has been envisaged with automatic backwash system. Dedicated auto disc filter has been provided for each UF stream. The filtration cut off selected for disc filters is 100 micron. The highlight of the system is provision of automatic back washing without interrupting plant operation and to achieve an SDI less than 3 for RO feed thereby increasing the RO membrane life and decreased chemical cleaning frequency. The membrane life assumed is 5 years and it has been assumed that progressive membrane replacement for each RO skid shall be completed in minimum 5 years without affecting the guaranteed quality and quantity.

6.1.2.2.9 30 nos. of Ultra filtration skids with dedicated disc filter system at the

upstream of RO skids have been envisaged. Each skid capacity sizing has been kept optimal considering the UF product storage capacity, downtime for membrane replacements and availability so as to ensure that 100 MLD of product water as per specifications is achieved throughout. Each disc filter skid has four disc filters and each UF skid has 4 trains with suitable piping, valve, instrumentation and automation arrangement for sequential operation and to ensure maximum flexibility in operation & maintenance and achieve guaranteed production.

6.1.2.2.10 Vertical, in to out /out to in, pressurized, cross flow, hydrophilic, hollow

fiber ultra filtration (UF) membrane system having MWCO as 1,00,000 Daltons has been envisaged to take care of the total suspended solids, colloidal particles and microorganisms. The UF system is equipped with backwashing, fast flushing chemical cleaning features. The UF membrane system is designed for constant feed flow and each skid flow is controlled by a flow transmitter and flow control valve, pressure transmitter and pressure control valve on each skid ensures that the feed pressure does not go beyond the specified limit, no negative pressure or surges or water hammer is developed in the system. The backwashing pumps are variable frequency drive controlled.



6.1.2.2.11 100% standby is envisaged for pumps & motors in the pretreatment system

6.1.2.3 REVERSE OSMOSIS (RO) SECTION 6.1.2.3.1 In RO section, 20% standby high pressure (HP) pump with energy

recovery (ERD) device is envisaged (12 RO trains, each RO train having a HP pump + ERD & 1 no standby HP pump +ERD for four RO trains). The high-pressure and energy recovery components can be operated independently thus increasing the number of alternative operation modes of the system.

6.1.2.3.2 In the RO section, a design approach favouring economies of scale,

better flexibility, high reliability & availability of the plant has been adopted. 12 nos. RO trains have been envisaged wherein each RO train includes a VFD controlled high pressure pump, pressure exchanger as energy recovery device, VFD controlled booster pump and membranes. High-pressure pumps shall be coupled with pressure exchangers. The criteria for selection of these devices had been high efficiencies, lower capital and operating expenditures, high flexibility in the operational mode, allowing for quick and easy activation (or de-activation) and long term successful experience with this type of equipment in SWRO plants. ERI, USA make pressure exchangers (model PX-220) has been chosen after due consideration for the energy saving devices like energy recovery turbine, Pelton wheel turbine, Double Work Exchanger Energy Recovery (manufacturer -DWEER) and Pressure Exchangers in terms of efficiency, market share, reliability & performance. It has been found that ERI pressure exchanges are the most reliable, efficient (95% efficiency) and has 90% market share in SWRO desalination plants. Other small manufactures of pressure exchanges have not yet proved their performance in large sized plants.

6.1.2.3.3 Each RO membrane skid capacity sizing has been kept optimal

considering the RO product storage capacity, downtime for membrane replacements and availability so as to ensure that 100 MLD of product water is achieved throughout. Each RO membrane skid has dedicated high pressure pumping and energy recovery system and a group of four RO trains has one high pressure pumping and energy recovery system as common standby with suitable piping, valve, instrumentation and automation arrangement to ensure maximum flexibility in operation & maintenance and achieve guaranteed production. The permeate pumping system from suck back tanks to permeate storage tanks has configuration similar to the high pressure pumping system.

6.1.2.3.4 Variable frequency drives have been adopted selectively for high

pressure & booster pumps & motors so as to keep the energy consumption minimum and to take care of the total dissolved solids variations as well as feed temperature variation.



6.1.2.3.4 The “auxiliaries” systems and equipment in RO section comprises of

the chemical cleaning system. In addition, one suck back tank of capacity 13 m3 has been provided for to avoid any suck back and automatic flushing of the RO membranes by gravity in the event of power failure.

6.1.2.4 POST TREATMENT SYSTEM 6.1.2.4 The post treatment section comprises of equipment for re-carbonation

and re-mineralisation of the permeate obtained in the RO section. The recarbonation and remineralisation plant processes the permeate so as to get the desired potable water alkalinity & hardness (as CaCO3) and positive Langlier Saturation Index suitable for long distance transportation & distribution. The water after post treatment becomes non aggressive & non corrosive. 93% purity limestone (reactive) of particle size 2-5mm and carbon dioxide is the main chemical required for re-carbonation and re-mineralisation. The important consideration in selecting these equipment is that lime requires stoichio-metrically almost double the quantity of CO2 than limestone and secondly limestone is much cheaper than lime. In addition, lime based system requires more complicated lime handling systems because in such large installations the lime consumption is high and complete lime milk and limewater preparation systems are required. The use of limestone filters is more convenient as handling of chemicals and as carbon dioxide consumption. The online direct chemical injection system has been ruled out as it is suitable only for small desalination plants.

6.1.2.4.2 Carbon dioxide absorption has been envisaged for optimal limestone

dissolution filter sizing and to reduce the plant cost. The major portion of the permeate stream flow has been designed for bypassing the limestone filters and only a fraction of the permeate stream is treated in the re-carbonation plant followed by blending of the bypassed water and carbonated water passed through carbon dioxide absorber and limestone dissolution filters. Degasser is also envisaged to ensure the removal of any excess carbon dioxide. Sodium hypochlorite and sodium hydroxide dosing has been envisaged for maintaining the required levels of residual chlorine in potable water and pH adjustment.

6.1.2.5 REJECT SYSTEM 6.1.2.5.1 The reject outfall pumping and pipeline system having 1200mm dia,

(PN 10, PE 100, HDPE, IS 4984) has been designed and sized with suitable diffusers and it is proposed to be located at suitable depth and distance (620m) for efficient and effective dispersion drg no. (Refer drg no. MEC/10EP/01/01/WOR/0167 for Outfall diffuser)

6.1.2.6 GENERAL



6.1.2.6.1 Vertical and horizontal centrifugal pumps with high efficiencies (pumps & motors- minimum efficiency indicated in the datasheet of respective equipment) and wetted component material of construction being super duplex steel (S32750 or equivalent) having pitting resistance equivalent no. greater than 40 are envisaged for intake pumping system.

6.1.2.6.2 Piping materials of construction have been selected considering the

duty conditions and with a view to optimize capital and maintenance costs. The following materials of construction will in general be used for pipelines:

Sea water intake: HDPE, PN 10, PE-100, IS 4984

Low pressure sea water in pretreatment and RO sections: HDPE, PN 10, PE-100, IS 4984

High pressure water in RO section: Duplex SS 2205, PREN > 35 Permeate water from RO & Post treatment section: SS 316L Product water: SS316L Low pressure RO reject water: HDPE, PN 10, PE-100, IS 4984

Chemicals storage and handling: HDPE/carbon steel/SS 316 as per piping specification

6.1.2.6.3 Materials for wetted parts of valves for sea water lines shall be Super

Duplex Steel (S32750 or equivalent) having pitting resistance equivalent no. greater than 40.

6.1.2.6.4 Full redundancy is provided for each dosing station. Each pump will

be provided with auto & manual flow adjusting mechanism. 6.1.2.6.5 The storage capacity of intake chamber, degritted water storage

tanks, UF permeate and backwash tanks, , RO permeate storage tanks, product water storage tanks, reject water storage tanks, bulk chemical storage tanks, chemical preparation and dosing tanks has been kept optimum considering the plant performance requirements and guaranteed off take of 100 MLD of product water.

6.1.2.6.6 EOT cranes for maintenance has been envisaged in the RO building

and additionally moving platforms mounted on scissor cranes has been envisaged in RO building for operation and maintenance of RO modules (details available in material handling specification chapter 10 of volume IIB).

6.1.2.6.7 RCC pipe trenches has been envisaged in RO & UF building for

header piping. Interplant piping large size HDPE piping is envisaged to be laid in saddle pipe supports. Pipe rack and cable rack is envisaged for interplant piping and cabling. Operating & maintenance platform has been provided for maintenance and operation of valves & equipment.

6.1.2.6.8 Pump motors located outdoor is envisaged to have canopy.



6.1.2.6.9 Sound Pressure Level (SPL)

High pressure pumps and other noise production equipment will be housed or provided with acoustic banners or isolating material capable of reducing noise to a max level of 85 dB measured at a distance of one meter. Some equipment may exceed the above SPL. In such cases individual sound proofing devices may be installed in order to meet the prescribed limit.

6.2 PLANT LAYOUT DESIGN 6.2.1 Site development: Based on the topographic survey, geotechnical

survey, high flood level of the plot location and marine & oceanographic studies detailed in site details (chapter 3 of volume IIA) the general layout of the plant has been finalized.

The site is a trapezoidal strip of land with Bay of Bengal and Buckingham canal as the natural boundaries on the eastern and western sides respectively. The proposed strip of land is lying between Dolphin city and Sularikadu kuppam. The size of the land is approximately 16 hectares on the seashore. The total land is spread over in two villages and measures about 30 acres in Nemmeli and 10 acres in Krishnankaranai village. The general layout Drg. MEC/10EP/01/14/LAY/0376/R3 shows the optimized plant & equipment layout for the desalination plant and its associated plant facilities.

After evaluating the survey details, the plant site was examined in

detail and following assumptions were made for finalizing the site leveling and planning the various plant units and roads.

Generally the contours are varying form 3.5m to 5.0m near the sea on

the eastern side of the plot and the plant proper contours are varying from 5.0m to 6.5m.During the site visit the Tsunami level marked on the building located on the Housing Colony was taken into consideration for fixing the finished ground level of the plant area. The ground level near existing house building is 4.0m and the Tsunami level is 1.6m above the ground level i.e. 5.6m. The Finished ground level is fixed at 0.9m above the Tsunami level i.e. 6.5m absolute.

A Strip of 20m-width land is left adjacent to East Coast Road for future

expansion of East Coast Road. The existing Bench Mark near the East Coast Road with level 11.255m is taken for surveying and fixing FGL etc.

The plant area is 33.30 acres.



Since the level of the East Coast Road is at 11.30m level and the FGL of the plant is at 6.5m levels, the level difference is 4.8m. In view of this it is proposed to upgrade the existing kutcha road from 4m to 7m for taking the main plant entrance.

The burial ground area is left undisturbed for use by local population.

This area will be drained towards the sea through a kutcha drain along the existing compound wall of Dolphin Park.

Area of 2.0 acres on the southern side of the plant boundary is

earmarked for TNEB Sub-station.

The total plot area( including area for quarters and guest house) of 36.90 acres should be filled up to 6.5 m finished ground level. Area for future expansion is 9 acres.

Land development & boundary wall is planned for entire plot. The proposed plant units and associated facilities require 19.0 acres.

The pre-treatment & reverse osmosis units of the proposed plant have been planned for identical future modular expansion. Vacant space on southern side of the plot has been earmarked for future capacity expansion. On the north-western side of the plot, vacant space marked as “ area for township” has been envisage for which land development and boundary wall construction shall be carried under the scope of this contract. However, construction of township is planned to be taken up later by others.

Generally the plant roads are single lane with 4.0m carriage way with

1.5m berm on either side of road with side drains. 6.2.2 Plant & Equipment layout In developing the plant and equipment layout, a systematic approach

has been adopted to ensure that all the subsystems are optimally laid out both from the viewpoint of operational & maintenance flexibility, optimizing capital cost as well as running costs.

The total extent of land available for Desalination Plant is shown in

overall plant layout tender drawings no. MEC/10EP/01/14/LAY/0376/R3 Within this area, all the facilities under this package is planned and shall be executed.

Considering a well selected sea water intake system, integrated

membrane system approach has been adopted for the plant by having ultra filtration membranes as pre-treatment followed by Reverse Osmosis membrane system.

Layout of the desalination plant has been developed system wise

under the following heads/area:



1) Water conditioning system comprising of Intake underground sump, settling basin/sedimentation tank and degritted storage tank with vertical turbine pumps for onshore inter unit pumping and sludge disposal pumps are located at the shore end of the intake pipeline inside the plant premises.

2) Pre-treatment facility comprises of Ultra filtration building

housing automatic disc filters & backwashing system followed by ultra filtration skids. After evaluating all the options available for the UF membrane system vis- a-vis submerged, pressurized horizontal & vertical, only vertical pressurized UF membrane system has been selected for the plant.

3) RO building houses cartridge filters, high pressure pumping

and permeate transfer system & CIP system. On the south western part, adjacent to the RO building, control room, laboratory, warehouse & other utility plant building facilities are planned and on the north eastern side HT substation housing VFD panels has been envisaged.

4) Chemical storage, handling & dosing facility for pre-treatment

section & RO section are located at a safe distance from other facilities. Chemical building housing dosing and preparation system has been planned with an adjacent open area bulk chemical storage tanks with unloading and transfer facility. Emergency safety showers with eye wash units are provided in the Chemical Storage & Handling facility at strategic locations such as outdoor Chemical storage area, Chemical preparation & dosing building.

5) Intermediate UF permeate, reject storage, fire water storage

and pumping facilities have been kept together in an area strategically earmarked for them for optimized piping.

6) RO permeate storage & pumping including service water

pumps, Re-carbonation & re-mineralisation, limestone storage and charging system, potable water storage tanks & pumping system have been kept together for post treatment and potablisation of RO permeate. Limestone storage building is envisaged to have sufficient unloading space, wide corridors for movement & handling of limestone bags and charge preparation.

7) CO2 storage and injection system has been planned in fenced

boundary in compliance with the statutory regulation for Static & Moving Pressure Vessels rules.

8) Bulk chemical storage and liquid CO2 storage facility has been

located suitably in order to keep vehicular approach road from the non plant to plant premises minimum for easy unloading



and handling of chemicals delivered to the plant through trucks/vehicles. Additionally these facilities are located in such a way that lengths of chemical dosing pipelines to pre-treatment plant, RO plant, post treatment plant units are minimum.

9) City distribution pump house control and maintenance room is

planned adjacent to underground potable water storage tank. The City distribution pump house control and maintenance room construction, operation and maintenance is under the scope of others and has been plant to minimize interference with desalination plant operation.

10) Non plant building facilities comprising of car parking shed,

administrative building, amenity and canteen block, view gallery has been plant together under fenced area to avoid tress passers entry into the plant premises.

11) Repair shop, main receiving station and TNEB substation have

been located at one end of the plot with due consideration to future capacity expansion.

12) Sewage treatment plant with underground sewage network is

envisaged and is located the southern corner of the plot. Effluents from the plant shall not be connected to the storm water drainage system. Sewage pipes from toilets shall be connected to sewage network.

13) Outdoor piping has generally been planned to be laid above

ground to the extent possible on pipe sleepers/ pedestals or pipe trestles. Inter unit pipe rack and cable rack has been envisaged for inter unit piping for dia. up to 200 NB & inter unit cabling with overhead road crossings. Only top cable entry into the buildings to the extent possible has been considered. No underground cabling has been envisaged considering the sea shore plant location. Underground piping to the extent possible has been avoided except for the road crossing of the pipes greater than 450 NB & fire hydrant network pipeline which has been planned on aboveground concrete pedestals. In side the building it has been preferred that pipes be laid over ground for easy access and maintenance. Alternatively for larger dia. (above 450 NB) non metallic pipes, the pipe headers are planned to be laid in trenches. The trench shall be wide enough for easy inspection /repair/ replacement in future. Such pipe trenches have been designed in such a way that any leaked liquid/ /water is drained to plant drains to avoid accumulation of water in trench and also water entry (from outside the building) to the pipe trenches has been prevented by proper means. Operation and maintenance platforms, access ladders for overhead valves and instrumentation have



been provided inside the building. 14) Adequate clearance has been provided around equipment to

facilitate ease of operation and maintenance. It has been ensured that the clearance is not less than 0.9 m around pumps, and minimum 1.5 meters at drive end. Clearance between vessels has been kept in the order of 1.2 to 1.5m.

a. Approach roads/paving has been provided between each

facility and as well as around the complete Desalination plant depending on the type of service in that area and movement of traffic. The desalination plant is planned to be approachable from the existing East Coast road. Within each facility, approach to various equipments is envisaged.

b. Storm water drainage system has been provided for the complete plant and shall be let out into the sea at the eastern side. All the tanks are provided with vent, overflow, drain and sample connections. The tank overflow and drain is connected to the nearby storm water drain.

c. For all outdoor pumps and motors rain protection local

canopy/cover are envisaged. 16) Windows, ventilators & requisite rolling shutters with ramp are

envisaged in the plant buildings. Around chemical storage areas, required corrosion resistant (AR) tiles/ lining are provided to protect the surface from spillage / drains etc.

17) Spill containment wall (dyke) are provided around chemical

storage area in such a way with any chemical spill, during unloading, breakage/failure of tanks etc is isolated from adjoining area by providing dyke wall. The height of dyke wall is minimum 500 mm or to contain volume of biggest tank whichever is high. Storage area, equipment foundations and dyke wall shall be provided with corrosion resistant (AR) tiles/ lining to protect the surface from spillage / drains etc.

6.3 FEED & PROCDUCT QUALITY AND RECOVERY 6.3.1 Sea Water analysis:

The detailed characteristics and quality of inlet seawater from the sample analysis and product water are given in Table Nos. 6.1 and 6.2 respectively and the historical data for salinity and temperature is given in site data (chapter 3 of volume II A). However, the basic parameters that shall be considered for the design of pre-treatment units and reverse osmosis unit are as follows:



6.3.2 Basic design parameters of SWRO desalination plant:

a) Pretreatment section inlet parameters: (plant capacity design considered for worst conditions) i) Sea water intake capacity to pre-treatment unit– 11060

m3/hr (avg)

ii) TSS (total suspended solids) of sea water feed – 20 – 200 ppm, 50 ppm (avg), 200 ppm(peak)

iii) Total dissolved solids (TDS) – 33000 –41900 ppm, 40100-ppm avg, 41,900-ppm peak

iv) Temperature: 24oC (min.) , 32oC (max.)

vi) Specific gravity – 1.01- 1.02

b) Pretreatment unit (UF) outlet water quality:

i) UF permeate water quality - SDI < 3 ii) TSS - Nil iii) TDS at UF permeate outlet - 33000 –41900 ppm,

40100-ppm avg, 41,900-ppm peak iv) Net UF permeate Capacity – 9255 m3/hr v) UF recovery for each skid – 90% (min.)

c) RO section inlet parameters:

i) Inlet capacity for – 9255 m3/hr distributed equally in

twelve trains ii) TDS at RO inlet - 33000 –41900 ppm, 40100-ppm avg,

41,900-ppm peak

iii) Temp in deg centigrade - 240C (min.), 320C (max.). Temperature stabilisation and correction curves at various salinity levels and flux decline per year shall be furnished by the contractor with their contracts.

d) RO section and Post treatment outlet (product water)

parameters: i) TDS of RO permeate ≤ 375 ppm. ii) RO recovery of each train – 45.38% (min) i.e Net permeate from each train - 350 m3/hr. Total for 12 trains shall be 4200 m3/hr



iii) After post treatment, water quality shall be as per IS- 10500 & table 2. Langelier saturation index (LSI) of the entire drinking water (4167 cum/hr) shall be positive.

iv) TSS < NIL v) Net Product water Capacity measured at outlet of

underground RCC product tank – 4167 m3/hr (nominal)

vi) CO2 < 5 ppm



Table 6.1 Seawater quality parameters

Location

W1 W2 W3 Sl. No.

Parameters Units

Surface Bottom Surface Bottom Surface Bottom

1. Colour - Colour less Colour less

Colour less

Colour less

Colour less

Colour

less

2 Odour - Odour less Odour less

Odour less

Odour less

Odour less

Odour

less

3 Taste - Salty Salty Salty Salty Salty Salty

4 Turbidity NTU 0.4 0.7 0.2 0.4 0.5 0.6

5 pH - 8.3 8.2 8.2 8.2 8.2 8.2

6 Total Organic Carbon

mg/l 8.41 5.63 5.17 8.42 6.31 8.32

7 Conductivity @ 25

oC mS/cm 63.28 63.47 63.37 63.32 63.23 63.4

2

8 Total Hardness CaCo3

mg/l 6280 6320 6420 6400 6220 6240

9 Alkalinity CaCo3

mg/l 116 118 113 113 114 112

10

Total Suspended Solids

g/l 0.02 0.04 0.02 0.02 0.02 0.02

11 Salinity ppt (or) g/l 34.52 33.76 34.14 33.39 34.89 33.0

1

12 Temperature

oC 29.0 28.5 29.0 28.3 29.0 27.5

13 Total Dissolved Solids

g/l 38.2 40.6 38.8 (39.2*) 38.4 40.0 39.8



Table 6.1 Seawater quality parameters (contd)

Location

W1 W2 W3 Sl. No. Parameters Units


Anions

14 Sulphate (as So4)

mg/l 2358 2491 2202 2673 2600 2691

15 Nitrate (as N o3)

mg/l 1.09 1.62 1.24 1.36 0.98 1.63

16

Phenolic Compounds (C6 H2 OH)

mg/l BDL (DL:

0.001)

BDL (DL:

0.001)

BDL (DL:

0.001)

BDL (DL:

0.001)

BDL (DL: 0.001)

BDL (DL: 0.001)

17 Fluoride (as F) mg/l 1.88 1.74 1.86 1.74 1.86 1.92

18 Chloride (as Cl) mg/l 18810 18403 18607 18198 19016 17994

19 Residual Free Cl mg/l

BDL (DL: 0.1)

BDL (DL: 0.1)

BDL (DL: 0.1l)

BDL (DL: 0.1)

BDL (DL: 0.1)

BDL (DL: 0.1)

20 Bicarbonate mg/l 141 144 138 138 140 142

21 Sulphide (asH2S) mg/l

BDL (DL: 0.01)

BDL (DL: 0.01)

BDL (DL: 0.01)

BDL (DL: 0.01)

BDL (DL: 0.01)

BDL (DL: 0.01)

22 Boron (as B) mg/l 1.76 1.64 1.82 1.67 1.85 1.80

23 Phosphate (as P) mg/l 0.38 0.45 0.52 0.57 0.52 0.66




Location



24 Silica Total (as Sio2)

mg/l 0.40 0.40 0.40 0.44 0.41 0.52

25 Silica dissolved (as Sio2)

mg/l 0.34 0.36 0.09 0.10 0.32 0.50

26 Petroleum hydrocarbon mg/l

ND (DL: 0.01

µg/l)

ND (DL: 0.01 µg/l)

ND (DL: 0.01 µg/l)

ND (DL: 0.01

µg/l)

ND (DL: 0.01

µg/l)

ND (DL: 0.01

µg/l)

27 Oil & grease mg/l <1 <1 <1 <1 <1 <1

28 Algae Count Nos./litre 8 3 12 3 11 2

29 Coliform count cfu/ml <2 7 8 8 <2 <2

30 Faecal coliform

cfu/ml Absent Absent Absent Absent

Absent Absent

Cations

31 Calcium(as Ca) mg/l 353 357 357 365 365 369

32 Magnesium

mg/l 844. 777. 904 904 894. 898

33 Copper(as Cu) mg/l BDL (DL:

0.006) 0.04 0.01

BDL (DL:

0.006)

BDL (DL:

0.006)

BDL (DL:

0.006)

34 Manganese total (as Mn) mg/l

BDL (DL: 0.02)

BDL (DL: 0.02)

0.26 0.19 BDL

(DL: 0.02)

0.15

35 Manganese dissolved (as Mn)

mg/l BDL (DL: 0.02)

BDL (DL: 0.02)

BDL (DL: 0.02)

BDL (DL: 0.02)

BDL (DL: 0.02) 0.06




Location



36 Sodium (as Na) mg/l 11255 12510 11554 11607 11340 11487

37 Iron total (as Fe)

mg/l 0.27 0.36 0.28 0.28 0.14 0.14

38 Iron dissolved (as Fe)

mg/l 0.21 0.28 0.26 0.23 0.13 0.11

39 Potassium (as K)

mg/l 345 340 346 365 406 407

40 Ammonia (asNH3)

mg/l 0.86 1.23 1.09 0.97 1.01 1.34

41 Barium (as Ba)

mg/l

BDL (DL: 0.41)

BDL (DL: 0.41) BDL

(DL:0.41) BDL

(DL: 0.41) BDL

(DL:0.41) BDL

(DL:0.41)

42 Strontium (as Sr)

mg/l 18.15 18.85 6.75 7.10 7.0 7.9

43 Mercury (as Hg)

mg/l

BDL (DL:

0.001)

BDL (DL:

0.001) 0.07

BDL (DL:

0.001) 0.12

BDL (DL:

0.001)

44 Cadmium (as Cd)

mg/l

BDL (DL:

0.003)

BDL (DL:

0.003)

BDL (DL:

0.003)

BDL (DL:

0.003)

BDL (DL:

0.003)

BDL (DL:

0.003)

45

Selenium (as Se)

mg/l

0.09 0.11 BDL

(DL: 0.001 mg/l)

BDL (DL: 0.001

mg/l)

BDL (DL: 0.001 mg/l)

BDL (DL:

0.001 mg/l)




Location



46 Arsenic (as As)

mg/l 0.13 0.23 0.05 0.05 0.07 0.07

47 Cyanide (as CN)

mg/l

BDL (DL: 0.02)

BDL (DL: 0.02)

BDL (DL: 0.02)

BDL (DL: 0.02)

BDL (DL: 0.02

)

BDL (DL: 0.02)

48 Lead (as Pb)

mg/l BDL (DL: 0.01)

BDL (DL: 0.01)

BDL (DL: 0.01)

BDL (DL: 0.01)

BDL (DL: 0.01

)

BDL (DL: 0.01)

49 Zinc (as Zn)

mg/l BDL (DL:

0.003)

BDL (DL:

0.003) 0.42

BDL (DL:

0.003)

BDL (DL:

0.003)

BDL (DL:

0.003)

50 Anionic detergent

mg/l ND

(DL: 0.01)

ND (DL: 0.01)

ND (DL: 0.01)

ND (DL: 0.01)

ND (DL: 0.01)

ND (DL: 0.01)

51 Chromium (as Cr)

mg/l 0.19 0.16 0.17

BDL (DL: 0.03)

0.14 0.10

52 Mineral oil

mg/l BDL (DL: 0.01)

BDL (DL: 0.01)

BDL (DL: 0.01)

BDL (DL: 0.01)

BDL (DL: 0.01)

BDL (DL: 0.01)

53 Aluminium Total (as Al)

mg/l

BDL (DL: 0.03)

BDL (DL: 0.03) 1.63 BDL

(DL: 0.03)

BDL (DL: 0.03)

BDL (DL: 0.03)

54 Aluminium dissolved (as Al)

mg/l

BDL (DL: 0.03)

BDL (DL: 0.03)

BDL (DL: 0.03)

BDL (DL: 0.03)

BDL (DL: 0.03)

BDL (DL: 0.03)

55 PAH

µg/l ND (DL: 0.01)

ND (DL: 0.01)

ND (DL: 0.01)

ND (DL: 0.01)

ND (DL: 0.01)

ND (DL: 0.01)

56 Pesticides

mg/l ND

(DL: 0.0000

1)

ND (DL:

0.00001)

ND (DL:

0.00001)

ND (DL:

0.00001)

ND (DL:

0.00001)

ND (DL:

0.00001)

Note : BDL denotes below detectable limit



6.3.3 Potable water analysis

The potable water quality shall be as per IS 10 500 : 1991 (reaffirmed in 1993). The quality parameters as per IS 10 500 – 1991 are indicated in table 6.2.

Table 6. 2 - Drinking water Quality Requirements as per IS 10500-1991

Sl. No Substance or characteristic Requirement (Desirable

Limit) Essential Characteristics i. Color, Hazen units, Max. 5 ii. Odour Unobjectionable iii. Taste Agreeable iv. Turbidity, NTU, Max. 5 v. pH value 6.5 to 8.5 vi. Total Hardness (as CaCO3) mg/l,

Max. 300

vii. Iron (as Fe) mg/l, Max. 0.3 viii. Chlorides (as Cl) mg/l, Max. 250 ix. Residual, free chlorine ,mg/l, min. 0.2 x. Fluoride (as F) mg/l, max. 1.5 Desirable Characteristics xi. Dissolved solids mg/l, Max. 500 xii Calcium (as Ca) mg/l, Max. 75 xiii. Magnesium (as Mg) mg/l, Max. 30 xiv. Copper (as Cu) mg/l, Max. 0.05 xv. Manganese (as Mn) mg/l, Max. 0.1 xvi. Sulphate (as SO4) mg/l, Max 200 xvii. Nitrate (as NO2) mg/l, Max. 45 xviii. Phenolic compounds (as C6H5OH)

mg/l, Max 0.001

xix. Mercury (as Hg) mg/l, Max 0.001 xx. Cadmium (as Cd) mg/l, Max 0.01 xxi. Selenium (as Se) mg/l, Max 0.01 xxii. Arsenic (as As) mg/l, Max 0.01 xxiii. Cyanide (as CN) mg/l, Max 0.05 xxiv. Lead (as Pb) mg/l, Max 0.05 xxv. Zinc (as Zn) mg/l, Max 5 xxvi. Anionic detergents (as MBAS) mg/l,

Max 0.2

xxvii. Chromium (as Cr6+) mg/l, Max 0.05 xxviii. Polynuclear aromatic hydrocarbons

(as PAH) g/l, Max

xxix. Mineral oil mg/l, Max 0.01 xxx. Pesticides mg/l, Max Absent

Table 6. 2 - Drinking water Quality Requirements as per IS 10500-1991 (contd.)



Substance or characteristic xxxi Radioactive materials * a) Alpha emitters Bq/l, Max 0.1* b) Beta emitters pci/l, Max 1 * xxxi. Alkalinity mg/l, Max 200 xxxii. Aluminium (as Al) mg/l, Max 0.03 xxxiii. Boron mg/l, Max 1 xxxiv Langlier Saturation Index positive

* Permissible limit as per IS 10,500 7.0 PLANT DESCRIPTION

7.1 Project location The proposed plant site is located at Kancheepuram district, Chengalpattu taluk, Nemmeli and Krishnankaranai village in Tamilnadu state approximately 35km south of Chennai city on the East Coast Road (ECR). The site is accessible by ECR from Chennai via Muttukadu. Another road national Highway NH 45 running parallel to ECR can also be used to reach the site via Chengalpattu and Thirukalukundram. The nearest railway station is Chengalpattu about 37 km from the site.

7.2 Technological facilities

The technological facilities furnished in this chapter may be read in conjunction with the Mass balance diagram as per MEC/10EP/01/01/MFB/001 & P&IDs and plant layout drawing referred below. The process plant units have been divided into 7 areas (Area 100 to Area 700) as follows: 1. AREA 100: Covers the sea water intake offshore and onshore

units. The offshore units comprises of sea water intake system comprising of intake suction head fitted with NaOCL dosing & air bursting arrangement, nylon net, under sea bed intake and associated pipelines. The onshore water conditioning units comprises of sea water intake chamber with provision for sulphuric acid dosing, sea water intake vertical centrifugal long shaft pumps, underground filtering cum sedimentation basin for rapid removal of large particles , sludge water collection & pumping system, degritted water storage including the raw water vertical transfer pumps as per P&ID no. MEC/10EP/01/01/PID/0001& offshore sea water intake detail arrangement drg no. MEC/10EP/01/01/WOR/0166 & 0168 .



2. AREA 200: Covers automatic back washable disc filters and

ultrafiltration (UF) units, intermediate UF permeate storage tanks, backwash system for UF & disc filtration systems, low pressure cartridge filter feed pumps for feeding to cartridge filters and subsequently to high pressure pumping system of RO trains as per P&ID no MEC/10EP/01/01/PID/0004, sheet 1of 2, sheet 2 of 2, and 0005. The backwash pumps for UF will be of VFD controlled drives. 4 nos. of pipe trenches are envisaged for 2x15 UF and disc filter streams.

3. AREA 300: Covers high pressure pumping system comprising

of cartridge filters, VFD controlled high pressure pumps, pressure exchangers, booster pumps, 12 trains of RO skids operating in parallel, suck back tanks permeate transfer pumps and product storage tanks, Recarbonation tower feed pumps and service water pumps as per P&ID no. MEC/10EP/01/01/PID/0006, 0008 sheet 1of 2,sheet 2of 2,and 0009 . Covered pipe trench has been envisaged to accommodate the pipe headers.

4. AREA 400: Covers the facilities related to post treatment of

RO permeate for making it potable. The purpose of these facilities to achieve the desired alkalinity and hardness as well as positive Langlier saturation index for making it suitable for long distance transportation. The post treatment unit comprises of two sections i) Re-carbonation section, ii) Re-mineralisation section and iii) Degassing and potable water storage. The re-carbonation, re-mineralisation & Degassing and potable water storage comprises of RO permeate booster pumps, carbon dioxide absorber, carbon dioxide storage tanks, limestone filters, limestone handling, storage and recharging system comprising of limestone storage building , main hopper, filling hopper, screw feeder, bucket elevator, diverter gates, loading ejector, recharging booster pumps, air scouring root blower, atmospheric degasser, degasser air blower, potable water storage tank, vertical potable water transfer pumps, provision inline mixers and NaOCl & NaOH dosing from Area 700 for maintaining desired levels of residual chlorine (as disinfectant) & final pH adjustment respectively, sedimentation tank with partition, slurry disposal pump as per P&ID no. MEC/10EP/01/01/PID/0010 sheet1 to 4.

5. AREA 500: Covers the concentrate disposal system

comprising of UF&RO rejects tank, reject water transfer pumps and offshore under sea bed 1200mm diameter, 620 m long HDPE (PN10, PE 100) pipeline, on sea bed reject outfall diffuser system comprising of 18( 14 W+1S) nos. of 300 NB diffuser ports effective dispersion & diffusion of rejects up to



the inlet of outfall sea line as per P&ID no. MEC/10EP/01/01/PID/0011

6. AREA 600 : Covers the skid mounted CIP system comprising

of RO flushing and cleaning tank, 5 micron cartridge filter, chemical cleaning pumps as per P&ID no.MEC/10EP/01/01/PID/0013

7. AREA 700 : Covers the chemicals preparation & dosing

system comprising of chemical preparation and dosing tanks with agitators, electronic diaphragm dosing pumps housed in a civil building and open area bulk chemical storage tank farm comprising of horizontal (H2SO4) & vertical storage (for rest of the chemicals), unloading and transfer pumps. The chemicals envisaged for storage and dosing are sulphuric acid , sodium hypochlorite, sodium bisulphIte and sodium hydroxide. The bulk storage concentration of sulphuric acid , sodium hypochlorite, sodium bisulphate and sodium hydroxide are 98.5%, 10-12%, 35% & 45% respectively and the dosing concentration at the respective points are 98.5%, 10-12%, 10% and 45%. Apart from these chemicals, anti-scalant bulk storage and dosing system are also provided in the same area. This system is as per P&ID no. MEC/10EP/01/01/PID/0014 and 0015

7.3 Major System components description

a) Auto disc filter & UF Membranes

A total of 30 UF sets (UF-201-1-30) will be installed each containing 120 hollow fiber back washable in to out / out to in, cross flow, pressurized, hydrophilic membranes for a total membrane area of 1,250 to 1,400 m2. The active area of PES/PVC type membrane element is 450-500 sq ft with molecular weight cut off as 100,000 to 150,000 daltons (0.05 micron) having PVC housing material and design membrane flux as 50-65 l/m2/hr. UF backwash system comprises of back wash pumps (P-202A-D) and chemical feed arrangement for chlorinating with NaOCl during backwashing. Compressed air at 5 to 6 bar, free from oil is required during the backwashing sequence. Although, the backwash frequency is dependent on feed characteristics, a frequency of 60 minutes is envisaged wherein fast flush will be for 30 seconds; backwash for 60 seconds and second fast flush will last for 30 seconds.

The filtration process must be operated in three basic modes of operation filtration, backwash and Chemically Enhanced Backwash (CEB).



Feed flow into the membrane filtration system will be controlled to maintain a constant filtrate rate. The UF plant will be designed to produce a constant output. On the upstream of each UF, auto disc filter (DF-201-1-30) is provided for pre-treatment. Each unit /set of disc filter (DF-201-1-30) has 4 module filters with filter diameter 6” and 100 micron rating. The filtration cut off is 100 microns. The element & housing material is PP. Backwashing pumps (P-204A/B) will be provided for disc filters for automatic backwashing. Backwashing frequency is 30 to 60 min (adjustable) and the duration of backwash is 10 – 20 seconds (adjustable).

The UF membrane modules will be 8 inches diameter housed in housing of similar construction as RO type pressure vessels.

The membrane units will be operated in parallel and fed by common seawater supply pumps.

The membrane system will be designed with a fully automatic cleaning system to allow addition of chemicals to the backwash flow, on regular time intervals, in order to remove the foulants. Provision for manual backwashing will also be given apart from auto- backwashing.

b) RO Membranes and RO Vessels (Pressure tubes)

A total of 6048 seawater spiral wound RO membrane filtration

elements will be provided for the 12 RO trains (RO-301A-L), which will be contained in 864 pressure vessels. Each pressure vessels will contain 7 seawater membrane elements. 504 membranes will be installed (8 rows X 9 pressure vessels/row X 7elements/pressure vessels) in one RO skid. Each of the 12 RO trains (RO-301A-L) will be provided with emergency suck back flow tanks (V-301A-L). The active area per membrane element is 37 to 42 m2, maximum operating pressure is 83 bar, 8 to 8.8% recovery per element and minimum salt rejection is 99.6 to 99.75%. The membrane element shall be 8” dia and 40” long, polyamide thin film composite type and shall be suitable for pH range 2-11 for continuous operation. Membrane housings (RO pressure vessels) will be made of FRP as per ASME section X.

c) Automatic back flow system

All the RO. membrane modules will be flushed with product water during shut down by suck back action from the suck back tanks (V-301A-L) to displace all seawater and concentrated brine from all high-pressure piping, stainless steel materials and the membrane



surfaces. Piping arrangement will ensure even flow distribution over the available membrane units.

d) High Pressure Pumps

The RO high-pressure pumps (P-306A-O) pressurize the feed water to RO membranes up to 68 -70 bar (operating condition at 24°C). These pumps are multi-stage horizontal centrifugal pumps and each will have a capacity to deliver 357 m3/hr of seawater. The material of construction of the pump will be super duplex stainless steel having PREN >40. Balance 414 m3/hr of pre treated water per stream (total no. of streams –12 w + 3s.) will be pressurized to RO feed with the help of pressure exchangers and booster pumps.

e) Pressure Exchangers

The concentrate from each RO train, flows through a pressure exchanger (PX-305A-O), which recovers a high percentage of the energy remaining in the waste stream. A booster pump (P-307A-O) will be additionally provided with each pressure exchanger (PX-305A-O).

The brine flow rate through each of the pressure exchangers (PX-305A-O) will be 421 m3/h and the raw water feed will be 414 m3/hr at 2 bar which is discharged at pressure of 66 – 68 bar and is further boosted through PX booster pump (P-307A-O) to RO feed pressure of 68 – 70 bar. The reject outlet comes out of the PX exchanger (PX-305A-O) at around 1 bar, which is led to the UF cum RO reject tank (T-501). Considering that low energy consumption is of utmost importance for this project, special attention has been given to the energy recovery system. The energy recovery (ER) system using a PX exchanger will have high efficiency (95%) and reliability.

f) Piping

The pipe material will of Duplex 2205 stainless steel for high pressure feed and brine solution which has better resistance to seawater corrosion. The product piping will be of SS316 L. The MOC for low pressure pipe lines will be of HDPE (up to suction of high pressure pumps and pressure exchangers). The piping and valve specifications are given in chapter 5 of volume IIA.



g) Bulk Chemical Storage & Dosing

Bulk chemical storage tanks for sulphuric acid , sodium hypochlorite, sodium bisulphate and sodium hydroxide with unloading and transfer pumps located in the outdoor is envisaged in the bulk chemical storage area. Dyke walls and acid proof tiles have been provided in corrosive chemical area. The concentration of bulk chemical comprising of sulphuric acid , sodium hypochlorite, sodium bisulphate and sodium hydroxide are 98.5%, 10-12%, 35% & 45% respectively. The chemical preparation and dosing system are located inside the chemical dosing and pumping station building with RCC roof and acid proof lined floors with tiles. Limestone storage is envisaged in the limestone storage and recharging building located in the re-mineralisation area. Liquid carbon dioxide is envisaged to be stored in well insulated, pressurized, vertical, steel storage tanks (2 nos) in an area ear marked for it and fenced Other CIP chemicals are envisaged to be procured and stored in drums in chemical storage building located adjacent to RO building. The chemical dosing is divided into the following three sections:

i) Pre-treatment & SWRO system

Pre-treatment chemicals used are as follows: • Sodium hypochlorite (10-12%) for disinfecting of the intake

pipeline. • Sulphuric acid (98.5%) for feed water pH adjustment and water

conditioning. • Sodium bisulphate (10-12%) for reduction of any free residual

Cl2 present in the raw sea water • Antiscalant to protect the RO membrane from possible scaling

on the concentrate membrane surface. ii) Post treatment system • Limestone (CaC03) to be filled into the limestone filters will be

utilized for the remineralization of the desalinated water before it used as potable water..



• Sodium hypochlorite (10%) for disinfection of the product

potable water. • Caustic soda (45%) for basic neutralization. • Carbon dioxide for recarbonation c) Membrane Cleaning

The following typical chemicals will generally be used for membrane cleaning. However the same may vary depending on the membrane selected and their requirement.

• NaOH solution at 0.1% weight/weight with NaEDTA 0.1%

weight/weight at pH 12. This mixture will remove bio film, • Citric acid at 2% weight/weight to remove inorganic salts such

as CaCO3,CaSO4, and BaSO4, • Versene with pH increased to 10-11 at a temperature of 45°C.

7.4 System data and utility requirements

a) Plant Design product capacity The plant design product capacity shall be as per clause 6.3.2

b) Product Quality The quality of the product water will be as per clause 6.3.2.d

and table 6.2

c) Electrical consumption

The design of the RO high pressure pumps has been made for the minimum temperature of 24°C, and the maximum pressure needed to obtain the required capacity from the membrane elements.

Power Requirement:

The estimated power requirement of the proposed plant is as follows: Maximum Demand : 20 MW Annual Energy consumption : 144.8 Million Units The specific power consumption works out to 3.97 kw/m3 of product water. The breakup is as follows:



Water intake : 0.587 kW/m3 of potable water Pretreatment : 0.208 kW/m3 of potable water RO section : 2.716 kW/m3 of potable water Post treatment : 0.117 kW/m3 of potable water Auxiliaries : 0.075 kW/m3 of potable water Reject transfer pumping: 0.264 kW/m3 of potable water Final pumping : 0.346 kW/m3 of potable water ( excluded in the power consumption for production of potable water & scope of this contract )

d) Consumption of Chemicals

Chemical consumptions as follows:

mg/l t/day Sulphuric Acid (98%) : 93 .00 24.7

Sodium Bisulphite (100%) : 6. 75 1.5 Antiscalant (100%) : 4.65 1.03 Limestone (100% CaC03): 70.24 7.08 Sodium hypochlorite (10% Cl2): 56.50 15 Caustic soda (100%) : 1.00 0.1 Carbon di oxide:` 5.5 In addition to the above chemicals, cleaning chemicals for membranes will be needed intermittently. It must be noted that the consumption figures are based on flow rate of water stream at the dosing point. Bulk chemical storage facilities for 5 days capacity or minimum one truck load capacity has been provided with suitable unloading & transferring equipment. Detail specification and requirement for limestone storage and handling shall be as per the chapter 10 of volume II B.

e) Compressed air:

Plant air requirements for the plant and repair shop shall be met by 2 nos (1w + 1s) air compressors installed in the repair shop & instrument air requirements shall be met by compressors installed in compressor house adjacent to RO building. The detailed specification and requirement shall be as per chapter 12 of volume II B.

7.5 Auxiliary Facilities Description

a) Instrumentation & Automation

The complete plant facility will be monitored and controlled by means of fully automatic distributed control system with



necessary manual intervention as detailed in chapter 6 of volume II B.

b) Electrical System

The electrical facilities are described here in brief. The complete electrical system facilities shall be as detailed in chapter 3 (for power distribution) & chapter 4 (shop electrics) of volume II B.

i) Source of Power Supply

The power supply for the proposed plant will be availed at 110 kV from Siruseri 230 kV Grid Substation of TNEB. The existing 110 kV feeder from Siruseri 230 kV substation will be looped in and out at the proposed plant between Mambakkam and Alathur 110 kV substations. Alternatively, a direct 110 kV feeder will be drawn from the Siruseri grid substation, which is about 5 km from the proposed plant site.

ii) Power Distribution Scheme

The power required for the plant will be received at 110 kV Main Receiving Substation (MRSS) in the plant. Power will be stepped down to 11 kV by 2x20/25 MVA 110 kV/11.5 kV transformers at MRSS. A 11 kV switch board will be established at MRSS to receive power from the 20/25 MVA transformers and to further distribute the same to various loads/ load center substations. Another HT switchboard will be established near the R.O. Building to cater to the various pump ..loads. An ECR is planned to be established near Automatic disc Filters and UF Building to cater to the LT loads. The HT switchboard near the R.O.building substation will receive power at 11 kV from the 11 kV switchboard located in MRSS by 11 kV cable feeders. These cables shall be taken along pipe rack stockades. 11 kV system is envisaged to be resistance earthed. Neutral Grounding Resistors (NGRs) with isolators will be installed in the transformer neutrals to restrict the earth fault current. Neutrals of LT transformers (11 kV /0.433 kV, 2.5 MVA) will be solidly earthed. The proposed over all Single Line Diagram of the system is shown in Drg. MEC/10EP/01/09/SPE/0501 (sheet 1 0f 2 & sheet 2 of 2).

iii) Out Door switchyard



A 110 kV out door switchyard is proposed to be established to receive power from the utility. The switchyard will be equipped with two incoming line bays, two transformer bays and one bus coupler bay. It will have a single bus arrangement. The various bays of the switch yard will be equipped with Lightning arrestors, CVT, Isolators, CTs, Circuit Breakers and other hard ware etc. as required. The proposed layout of the main receiving substation out door switchyard equipment is indicated in Drg. No. MEC/10EP/01/09/SPE/0502

iv) MRSS 11 kV Substation The secondary of the power transformer will be connected to

11kV, 2000A, 40kA, 3 sec. HT switchgear through 11kV, 2000A HT bus duct. HT switchgear will be located in the MRSS building first floor. This 11kV Switchgear will feed power to Re-carbonation tower feed pumps, Potable water pumps, capacitor banks and RO HT substation HT switchgear through 11kV (UE) cables. All protections and metering equipment of 110kV system outdoor yard will be installed in Relay and control panel, which will be located in control room at first floor. Microprocessor based multi function meters with RS 485 connectivity will be provided for metering system. Numerical protection relay with communication capability will be provided for protective functions of various feeders. The energy data of the various 11kV feeders and the input energy data will be passed on to DCS system for energy accounting and periodic report generation. Remote tap changer control panels of 20/25 MVA transformers will be installed in the MRSS substation at first floor. Operation of RTCCs will be done from MRSS control room. Each power transformer will be rated for full load capacity of the plant. Hence under normal operating conditions each of the power transformer will be loaded to 50% of its rated capacity and under outage of any one transformer, the remaining one will meet the entire load.. Two numbers 1.5 MVAR capacitor banks along with series reactors are envisaged to be installed in the 110kV switchyard to improve the power factor to 0.95. Two-storied building is envisaged for MRSS substation. Ground floor consists of cable cellar. First floor consists of 11kV HT switchgear room, control room, Battery room and Office room. MRSS building will be 45 meters long, 10 metes wide and 9.5 meters High. Cable cellar, HT switchgear room will be provided with IPS flooring. PLC control room and Office room will be provided with ceramic tile flooring and false



ceiling. Battery room flooring will be provided with Acid resistant tiles and 1800mm height dadoing. MRSS HT Switchgear room will be provided with pressurized ventilation with duct ventilation. Ventilation system for Control room will be provided with Split type air conditioners. Ventilation system for Office room, Battery room, cable cellar, Toilets will be provided with Exhaust fans.

v) HT Substation Near R.O. Building

Considering the load distribution in and around RO building a separate 11kV HT switchgear room adjacent to the RO Building has been envisaged for feeding HT loads and lighting loads of entire plant. Power will be fed to the 11 kV switchgear in this building from MRSS 11kV switchgear through 11kV (UE) cables. These cables shall be taken along with pipe rack Stockades. HT switchgear will be located in the first floor. This 11kV Switchgear will feed power to Sea water intake pumps, Raw water transfer pumps, Cartridge filter pumps, Reject water transfer pumps, 2500 KVA Distribution Transformers, 630 kVA Lighting transformer and 15 numbers High pressure pumps converter duty transformers through 11kV (UE) cables. The converter transformers will be further connected to VFD’s located in separate VFD room for feeding to high-pressure pumps. Control supply voltage of 11kV board will be 110V DC. Plate type lead acid batteries are envisaged for DC Distribution system. The DC system will comprise of one DC Battery bank and two identical automatic float cum boost chargers with associated protection, control and annunciation equipment and D.C. board for HT substations. One set of DC distribution system will envisage for each HT substation (ie. MRSS substation & RO HT substation). Main PDB shall be located in LT sub station and individual PDBs/ACDB, MOV PDB shall be located in the respective buildings. Power supply for all these PDBs shall be fed from Main PDB.

11kV Switchboard will be installed in the HT substation-building first floor. RO HT substation building will be two-storied building. Ground floor will house cable cellar and 15 numbers Converter duty transformers. First floor will house 11kV HT switchgear room, VFD room, Battery room and AC plant room. RO HT substation building will be 115 meters long, 14.5 meters wide and 7.5 meters high. HT switchgear room, AC plant room, Cable cellar floor will be provided with IPS flooring. VFD room will be provided with ceramic tile



flooring and false ceiling. Battery room flooring will be provided with Acid resistant tiles and 1800mm height dadoing. Ventilation system for HT Switchgear room will be provided with pressurized ventilation with ducting. Ventilation system for VFD room will be provided with air conditioners. Ventilation system for Battery room, cable cellar, Toilets will be provided with Exhaust fans. The proposed layout of the RO building HT substation is indicated in Drg. No. MEC/10EP/01/09/SPE/0504

vi) LT Sub station :

LT sub station shall be located adjacent to the RO HT sub station building as a part of RO HT sub station. LT sub station consists of PMCC,2 nos. of 2500KVA,11KV/433V Distribution transformers. KV power supply for 2500KVA transformer shall be fed from HT sub station 11KV switch gear. LT supply from the transformers will feed PMCC through 433V, 4000A LT bus duct. PMCC will be located in the first floor of LT substation building. PMCC will in turn feed LT power to MCC’s –1 & 2 and LT motors above 55 kW using 1.1kV power cables. LT substation building will be two storied building. Ground floor will house cable cellar and Distribution Transformers. First floor will house PMCC .LT substation building will be 19 meters long, 15meters wide and 7.5 meters High. PMCC room, Cable cellar floor will be provided with IPS flooring. Ventilation system for PMCC room will be provided with pressurized ventilation with tube axial fans. Ventilation system for cable cellar will be provided with Exhaust fans

vii) Electrical control room ( LT Substation)

One number electrical control room has been considered for feeding the LT AC aux. Loads near the Automatic disc filters & UF building. Power for ECR will be fed from PMCC through LT cables.

Ventilation system for LT Switchgear room will be provided with pressurized ventilation with tube axial fans. Ventilation system for cable cellar will be provided with Exhaust fans.

c) Description of Other civil & structural facilities, plant and

non plant buildings i) Administrative Building (Size 24 m X 12 m X 7.1 m )

Proposed Administrative Building shall be a modern two storied RCC framed structure of size 24 M x 12 M with total



built up area of 576 sqm. Ground floor shall accommodate Entry Lobby, Security Incharge Room, First-aid Room, Store-Room, Workers Change Room and Toilets. Office-Incharge Room, Office areas, Conference Room, Pantry and Toilets are being located in the first floor. Adequate openable windows have been provided for cross-ventilation. Oil bound distemper paints shall be provided in all the internal walls and ceiling areas and external walls shall be painted with exterior emulsion paints. Main entry door shall be of anodized aluminium sections with glazed shutters. Internal doors shall be of block-board flush doors with lamination. All windows, ventilators shall be made out of anodized aluminium sections with glazed shutters and with MS grills. False ceiling will be provided in the first floor for officer’s room, meeting room, dining room. Layout Drawing no. MEC/ 10EP/01/35/WOR/0358 Sht 1 of 1 Rev 0 for the building is enclosed . The building will be with RCC frame, RCC roof and brick cladding, RCC flooring, all-round PCC apron with open RCC drains.

ii) Canteen Building (Size 24.15 m X 16.75 m X 4.4 m )

A single storied RCC framed structure canteen block with total built up area 365 sqm being proposed for total 80 diners. The workers dining hall shall have a capacity of 65 diners and a small officers dining hall is also planned for 15 diners. Adequate windows, ventilators have been planned for cross-ventilation, kitchen block with preparation area and with adequate store rooms have also been planned in this canteen block. Main entry doors shall be of anodized aluminium sections with glazed shutters. Internal doors shall be of block-board flush doors with lamination. All windows, ventilators shall be made of anodized aluminium sections with glazed shutters and with MS grills. Layout Drawing no. MEC/ 10EP/01/35/WOR/0351 Sht 1 of 1 Rev 0 for the building is enclosed . The building will be with RCC frame, RCC roof and brick cladding, RCC flooring, all-round PCC apron with open RCC drains.

iii) Plant Security Gate Complex (Size 13 m X 6.25 m )

Main gate Complex are been planned at the entry point of the Site. The main entry gate shall be double leaves of 7 M wide. One pedestrian entry gate is also proposed at the side of the vehicular entry gate. Both the gates shall have RCC flat slab at the top for rain protection with a 6 M clearance. Total plinth area of this security block shall be 63 sqm. Main entry doors



shall be of anodized aluminium sections with glazed shutters. Internal doors shall be of block board flush doors with lamination. All windows, ventilators shall be made of anodized aluminium sections with glazed shutters and with MS grills. The security room and an Office room with toilet facilities are proposed at the side of the main entry gate. The Doors and Windows shall be of anodized Aluminum section and glazed shutter. The Windows and Ventilators shall have M.S. Security guard bars. Layout Drawing no. MEC/ 10EP/01/35/WOR/0355 St 1 of 1 Rev 0 & MEC/ 10EP/01/56/WOR/0211 Sht 1 of 1 Rev 1 for the complex are enclosed . The building will be with RCC frame, RCC roof and brick cladding, RCC flooring, all-round PCC apron with open RCC drains.

iv) Security Cabin At Back Gate (Size 4 m X 4 m X 3 m)

Single story building with RCC frame, RCC roof and brick cladding, Columns supported on open foundations, RCC flooring, Steel Doors and Aluminium glazed windows, all-round PCC apron with open RCC drains. A typical drawing no. MEC/ 10EP/01/35/WOR/0357 Sht 1 of 1 Rev 0 is enclosed.

v) Chemical Dosing and Pumping System Building (Size

37.3m X 11m X 6.0 m)

Single story building with RCC frame, RCC roof and brick cladding, Columns / equipments / tanks supported on pile foundations, RCC flooring, Steel Doors and windows, all-round PCC apron with open RCC drains. 500 mm dia RCC piles of 80 T capacity are used for foundations. Layout drawing MEC/ 10EP/01/56/WOR/0241 Sht 1 of 1 Rev 1 for the building is enclosed .

vi) Automatic Disc Filters and UF Building (Size 61.5m X 56.2

m X 9 m)

Single story structural building with steel columns and structural roof with colour coated roof sheeting and brick side walls is envisaged. Columns / equipments / tanks are supported on pile foundations. RCC flooring, structural platform for maintenance of valves, steel Doors and windows, covered RCC pipe trench & cable trench and all-round PCC apron with open RCC drains is envisaged. Layout drawings MEC/ 10EP/01/56/WOR/0234 to 0239 ,Sht 1 of 1 for the building are enclosed .

vii) RO Building ( Size 146.5 m X 51 m X 12 m)



Single story structural building with steel columns, and structural roof with colour coated roof sheeting and brick side walls is envisaged. Columns / equipments / tanks are supported on pile foundations. RCC flooring, structural platform for maintenance of valves, steel Doors and windows, covered RCC pipe trench & cable trench, all-round PCC apron with open RCC drains is envisaged.

viii) Chemical Storage Building (Size 27.3 m X 10 m X 6 m)

Attached to RO building, single story structural building with steel columns, RCC roof and structural cladding, Columns / equipments / tanks supported on pile foundations, RCC flooring, Steel Doors and windows, all-round PCC apron with open RCC drains. 500 mm dia RCC piles of 80 T capacity are used for foundations.

ix) Warehouse, DG Room & Air Compressor Room (Size 32.3

X 10 m X 6 m)

These rooms are attached to RO building. All are single story structural buildings with steel columns, RCC roof and structural cladding, Columns / equipments supported on pile foundations, RCC flooring, Steel Doors and windows, all-round PCC apron with open RCC drains. In the warehouse, a racking system comprising steel & RCC racks will be provided for storage & materials. 500 mm dia RCC piles of 80 T capacity are used for foundations.

x) Workshop & Lab Building (Size 9.1 m X 10 m X 6 m & 9.1

X 10 m X 6 m)

Attached to RO building, single story structural building with steel columns, RCC roof and structural cladding, Columns / equipments / tanks supported on pile foundations, RCC flooring, Steel Doors and windows, all-round PCC apron with open RCC drains. 500 mm dia RCC piles of 80 T capacity are used for foundations. False Ceiling will be provided in the Laboratory Building.

xii) Control Room, Shift In-Charge Room & Toilet (Size 36.4 m

X 10 m X 6 m, 9.1m X 10m X 6m & 9.1 m X 10 m X 6 m)

Attached to RO building, single story structural building with steel columns, RCC roof and structural cladding, Columns / equipments / tanks supported on pile foundations, RCC flooring, Steel Doors and windows, all-round PCC apron with open RCC drains. 500 mm dia RCC piles of 80 T capacity are used for foundations. False Ceiling will be provided in the Shift



Incharge room. False Ceiling & False Flooring will be provided in the Control Room Building.

xiii) Recarbonation & Remineralisation Plant including Lime

Storage & recharging system building ( Size 80 m X 25 m) Potable Water storage tank having a size of 36 m X 25 m X 6 m is a part of this area. The potable water vertical transfer pumps and the Degasser Towers will be installed over the RCC cover of storage tank. The storage tank shall be directly resting on soil. A Lime Storage & recharging system building having a size of 20 m X 15 m X 6 m on the other side of the area is envisaged. It will be a single story structural building with steel columns, steel roof and structural roof colour coated roof sheeting and brick side walls is envisaged. Building Columns shall be supported on pile foundations. RCC flooring, Steel Doors and windows, all-round PCC apron with open RCC drains have been envisaged. The open yard between potable storage tank and lime storage area will house Carbon-Di-Oxide absorbers, lime stone filters, pumps & blowers Towers & Blowers. The foundations will be supported on piles, All round PCC apron with open RCC drains. Foundation for two no. of 30 t capacity CO2 vertical Storage tanks with chain link fencing shall be provided.

xiv) Main Receiving Sub-station Building (Size 45 m X 10 m X 9 m )

Double storied building comprising Cable Cellar, HT Switch Gear room, Control Room, Battery Room & Office room shall be constructed with RCC frame, RCC roof and brick cladding. Equipment shall be supported on pile foundations with RCC flooring, Steel Doors and windows, all-round PCC apron with open RCC

xv) 110kV Outdoor Switchyard (Size 82.4 m X 65 m )

It will be an open yard adjacent to MRSS building with pavement made of gravel above the sand. This will house 110kV switchyard equipment in 3 bays. Three sides of the area will be surrounded with fencing.

xvi) RO Building HT Sub-station (Size 106 m X 12 m X 7.5 m )

Double storied building comprising Cable Cellar, HT Switch Gear room, VFD panels room & Battery Room shall be constructed with RCC frame, RCC roof and brick cladding. Equipment shall be supported on pile foundations with RCC flooring, Steel Doors and windows, all-round PCC apron with



open RCC drains. 500 mm dia RCC piles of 80 T capacity are used for foundations. False Ceiling and Ceramic tile flooring will be provided in the VFD panels Room. Acid Resistance tiles shall be provided in the Battery Room.

xvii) Electrical Control Room (LT Sub-station Building) (Size 30

m X 12.5 m X 7.5 m ) Double storied building comprising Cable Cellar, LT Switch Gear room & VFD panels room shall be constructed with RCC frame, RCC roof and brick cladding. Equipment shall be supported on pile foundations with RCC flooring. Steel Doors and windows, all-round PCC apron with open RCC drains is envisaged. False Ceiling and Ceramic tile flooring will be provided in the VFD panels Room.

xviii) Repair Shop (Size 36 m X 24 m X 8 m)

Single story structural building with steel columns, steel roof and structural roof colour coated roof sheeting and side cladding is envisaged. Equipment shall be supported on pile foundations with RCC flooring. Steel Doors and windows, all-round PCC apron with open RCC drains is envisaged.

xix) Parking Area (Size 30 m X 9 m X 4 m)

Non-plant structural building with steel columns and steel roof with colour coated roof sheeting. Columns shall be supported on RCC pedestals, with open foundations. The area shall be paved with PCC.

xx) Liquid Bulk Storage And Unloading System (Tank data:

3nos 4.5 m dia, 1no. 3.5 m dia Vertical and 1no. 3.2m dia & 1no. 2 m dia Horizontal)

The storage area will be an open yard. Foundation for vertical tanks will be supported on piles with acid proof tile flooring and all round PCC apron & drain. The horizontal tanks will be supported on RCC saddles with open foundation. Interconnecting structural platform provided for tank tops shall be supported on structural columns with RCC foundations.

xxi) Product Storage Tanks (Tank data: 2no. 24 �Vertical , fixed

cone roof)

Tank foundations in open area supported on piles with all round PCC apron connected to open drain.

xxii) UF Product-Cum-Back Wash Tank (Tank data: 2no. 30 m

dia, Vertical , fixed cone roof



Tank foundations in open area supported on piles with all round PCC apron connected to open drain.

xxiii) UF & RO Reject Tank (Tank data: 1no , 22 m dia, fixed

cone roof , Vertical ) Tank foundations in open area supported on piles with all round PCC apron connected to open drain.

xxiv) Intake Chambers, Filtration-Cum-Sedimentation Basin,

Degritted Storage Tank (Size 23.85 m X 7.5 m X 14.7 m ,43 m X 12 m X 6 m and 43 m X 20 m X 7.1 m)

These tanks are underground RCC tanks. For Intake chambers and Degritted Storage Tank, RCC slab shall be provided for cover and vertical pumps will be mounted over these slabs. In take chamber (T-101) is a RCC, epoxy coated, top covered trapezoidal cross sectional tank. Its holding capacity is 1104 m3 Settling basin (SB-102) is a partially covered, epoxy coated tank having various layers of sand media. The upper bed consists of 12 to 50 mm washed gravel of 300 bed height. Below of this, the middle layer consists of 1 -2mm quartz sand with uniformity coefficient 1.4 to 1.7 & sphericity 0.8 of 2500 bed height. The bottom most layer is 6-12 mm of washed gravel of 2200 mm bed height. Vertical Sludge Transfer Pump will be mounted on the sludge sump in the sedimentation basin.

xxv) Fire Pump House and Fire Water Storage tank (Size 16 m

X 7.5 m X 5 m, 7,500 mm ID & 7,500 mm HT respectively)

Single story building with steel columns, steel roof .Equipment shall be supported on pile foundations with RCC flooring, Ramp, all-round PCC apron with open RCC drains is envisaged. Sand pad foundation is provided for fire water storage tank.

xxvi) Boundary Wall

Wall with RR masonry will be provided for plant and wall with RCC pre-cast panel will be provided for township area. The height of the boundary wall will be 5 m.

xxvii) Plant Roads

4 m wide Plant road section and drain arrangement along the road will be as per the enclosed drawing no. MEC/ 10EP/01/56/WOR/0377 Sht 1 of 1 Rev0.



xxviii) Plant Drains

Open rectangular RCC drains are planned for the plant and the township along roads. At road crossings, drains shall be taken through RCC box culverts. Discharge will suitably be connected to outlet.

xxix) Pipe Supports

Pipe shall be laid over RCC saddle supports with open foundations, pipe racks & structural supports .

xxx) Pipes Crossing Roads xxxi) Box culverts with saddle supports will be provided for road

crossing of the pipelines. xxxii) Pipe trestles & Cable Rack

Pipe trestle cum cable rack is envisaged for interunit piping and cabling. RCC footings with open foundation shall be provided for pipe trestles and cable rack supporting steel structures.

xxxiii) Visitors gallery

A modern two storied RCC framed structure with RCC roof , brick cladding, glass panels visitor’s gallery is envisaged in the plant premises. This will consist of facilities for authorized plant visitors including a viewing gallery, conference room, guesthouse, capsule lift, audio-visual displaying arrangements etc. The audio- visual display with PC operator station is envisaged so that the on line plant status/ historical data of the plant can be viewed.

xxxiv) Sewage Treatment plant and Sewage Network A sewage treatment plant is envisaged and the details are provided in chapter 13 of volume II B.

xxxv) Green Belt A 10 m wide strip green belt all along inside the boundary wall as per the statutory requirements and marked in the layout drawing is envisaged.

xxxvi) Inter unit pipelines & Fire network



Fire fighting facilities and fire network with hydrants, hoses, and chemicals have been envisaged. Fire water pipeline is envisaged above ground along the plant inside roads.

8.0 PROCESS DESCRIPTION

8.1 General

The complete sea water reverse osmosis desalination facility will be monitored and controlled by means of a fully automatic distributed control system (DCS) with necessary manual intervention and will consist of the following:

• Offshore sea water open intake facilities and onshore pumping

station, • Water conditioning system, • Pre-treatment system by means of automatic back washable

disc filters followed by in to out/out to in highly hydrophilic Ultra filtration membranes system,

• Desalting by reverse osmosis (RO membrane process), high pressure pumping and energy recovery system,

• Chemical cleaning system for RO and UF skids • Intermediate storage and pumping system • Interplant pipelines • Bulk chemical storage facilities and & centralized chemical

dosing systems, • Re-carbonation & Re-mineralisation systems including

limestone storage and re-charging system • Final Product storage & potable water transfer pumps, • Reject storage, pumping & outfall system • Instrumentation & controls • Electrical power distribution and its operation

The plant has been designed to produce 4,167 m3/h (1,00,000 m3/day) for 365 days a year of net quantity of potable water on uninterrupted basis for onward pumping to CMWSSB city distribution storage tank. However, the permeate production on continuous basis at the outlet of RO section before post treatment will be 4200 m3/h considering 33 m3/h of internal plant service water requirements. (In this 33 m3/h , 3 m3/h will be used for AC chiller plant make up for VFD units, 10 m3/h for fire water make up, 1 m3/h in chemical dosing building for preparation of chemical dosing solutions and balance for other in house non plant consumers & township). Two nos of service water pumps (P-304A/B) of capacity 40 m3/h (1w+1s) is provided for pumping the service water from permeate storage tank (T-301A/B) for catering to the needs of the internal plant consumption. The sea water intake system , water conditioning & pre-treatment unit is designed based on the proven state of art technology to produce



filter water feed to RO section, of the desired quality and in proportion to the demand of the downstream units. Due consideration has been given in the selection of process & technological equipment so as to achieve optimum energy efficiency in the plant operation as well as low cost to obtain uninterrupted potable water production. Energy saving devices like pressure exchangers & variable frequency drives on techno economic consideration has been envisaged in the various units of the process as deemed necessary to take care of the sea water quality parameter variations (TDS, TSS & temperature) & to obtain the best energy utilization ratio for production of potable water. Special considerations have been undertaken in providing adequate intermediate buffer storages, sufficient operating and installed standby equipment, optimal sizing of disc filters, ultrafiltration & RO train, re-carbonation & re-mineralisation units, material of construction of the plant & equipment, operating flexibility by suitable instrumentation & control, automation level so as to achieve maximum plant availability and reliability and have an uninterrupted potable water production throughout the year at the rated capacity. Automatic backwashing system for disc filtration & ultrafiltration system based on preset cyclic frequency as well as differential pressure across the skids without affecting the rated permeate production is the another salient feature of the process equipment selected. The disc filters & ultraflters capacity are selected so as to care of the peak total suspended solid load of 198 ppm and the frequency of backwash can be adjusted depending on the suspended solids load fluctuations. Suitable nos. of sampling points for laboratory analysis & online anlysers for measuring TOC (Total organic carbon), conductivity, pH, ORP (Oxidation Reduction Potential), turbidity, chlorine and flow measurements, level, pressure & temperature measurement along with automatic dosing control, have been envisaged at various stages of the process for smooth and uninterrupted operation of the plant. The process details are elaborated in the subsequent paragraphs below and the description of facilities along with design basis is detailed in chapter 5 of this document. The RO permeate after post treatment will conform to the current Indian Standard drinking water specification of IS 10500 : 1991 and shall be suitable for long distance transportation in pipelines. The potable water after post treatment is envisaged to be transported by vertical long shaft pumps through pipeline into the drinking water storage tank of CMWSSB for city distribution.

8.2 Detailed Process description

The detailed process description for the technological facilities are given below. Equipment tag numbers have been allotted on the basis of area numbering indicated above. Equipment tag numbers are given in the



process description below (in brackets) as well as in the P&IDs and list of equipment. The specifications of the equipment are given in the equipment list and respective datasheets enclosed as Annexure B&A in chapter 2, of volume II A. The piping and valve specifications are given in chapter 5 of volume IIA. 1. Area 100: Intake and Water Conditioning System

A study was carried out for establishing the optimal design of sea water intake type. The possibility of beach well intake has been ruled out as the ground water acquifer in the near vicinity is not sufficient for pumping the required quantity (11060 m3/h) on continuous basis. The results of the field studies carried out for sea water open intake and beach well intake are enclosed in chapter 3 of volume IIA. . Based on the results of onshore and offshore field studies including marine studies, the sea water open intake system has been adopted for the project and the intake point for drawl of water has been located at a distance of 1000m from shore line and the minimum water column available at this location will be 10m at all times throughout the year, round the clock. Seawater is brought from the sea to the plant through a intake suction head and a 1600 mm HDPE pipeline laid under the sea bed having minimum top cover of 1500mm. The minimum water depth available at the intake suction head/ intake filtering device (SC -101) is 5m (refer detail drg. no. MEC/10EP/01/01/WOR/0166 & 0168). 90NB two nos. HDPE pipeline is also laid along with intake pipeline, one for 10 to 12 % NaOCl dosing for chlorination & oxidation of bio-organisms and the other for periodic air burst cleaning of the intake head from accumulated marine growth. A level of 1 ppm of residual chlorine in the intake water is sufficient and the same is monitored by Cl2 analyser installed at the discharge of raw water vertical transfer pumps (P-102A/B/C/D). Based on the feed back from the chlorine analyzer the dosing rate is automatically adjusted by the auto adjustment of pump stroke through a 4-20 mA current signal. The dosing is in addition to the concrete blocks proposed to be installed at 25m periphery of the intake head, a buoy with a red lantern marks the location of the intake structures as safety measure from mariners and navigation. A nylon net of 10 mm sq opening is also installed at a radius of 25 meter for restricting the entry of large marine organisms. The velocity of sea water in the intake pipeline is 1.52 m/s and is considered to be adequate for the sea water open intake design. The pipeline is proposed to be laid below the sea bed on the natural pipe and sea bed profile with geo textile mat in such a way that there will be minimal obstruction



to navigation and the pipeline do not experience any buoyancy or unsupported spans leading to stress in the pipeline.

The total organic content analyzer installed at the intake chamber at onshore will provide signal to the seawater pumps through the supervision control system stating the level of hydrocarbon pollution of seawater. Sea water will flow, at a flow rate of 11060 m3/h, into an underground RCC intake chamber (T-101) with roof slab projecting 300 mm above finished ground level from where it will be pumped by sea water intake vertical pumps (P-101A-D) into a filtering cum sedimentation basin (SB-102). Sulphuric acid dosing for pH adjustment will be done at the intake chamber. This will also be an underground RCC tank having sand media resting on a PP screen for removal of large suspended solids. The filtering cum sedimentation basin has a partition for allowing the water to inter into the sand bed media from the bottom. The basin has a sufficiently sloped bottom which allows the heavier suspended particles to trickle down the sand media into the sump provided at one end of the sloped tank. The vertical sludge transfer pumps (P-103A/B) will pump the sludge water accumulated in the sump intermittently for removal of settled solids and sludge. Clear water free from large & heavy suspended solids from filtering cum settling basin (SB-102) will overflow from the top into a degritted covered (roof slab) storage tank (T-103) provided with raw water transfer pumps on the RCC roof slab (P-102A-D) and will pump the water to the disc filters (DF-201-1-30) in the ultra filtration unit. Sodium hypochlorite will be injected into the seawater intake filter to ensure complete disinfected raw seawater entering into the intake pipe. Sulphuric acid is dosed into the intake chamber (T-101) for pH adjustment. It is observed from the available literature and experience gained by industrial units located nearby that the population of jellyfish bloom increases in the warmer months. It is possible that jellyfish bloom may block the seawater intake filters. Hence, compressed air supply for periodic airburst cleaning will be provided to safe guard the filter. The air burst cleaning arrangement will take care of any blockages, which may occur due to jellyfish bloom. The dosing pipelines and compressed air pipeline will be laid along with the intake HDPE pipeline up to intake filters device located at intake point. The sodium hypo chlorite and sulphuric acid dosing will also prevent growth of bio fouling organisms in the plant as well as prevent blockages likely to be created by marine living organisms.



2. AREA-200: Pre-treatment System The conventional pretreatment methods have led way in the recent sea water reverse osmosis desalination to advanced and proven modern pretreatment equipment in sea water reverse osmosis plants comprising of Ultra filtration system with a suitable pre-filter at the up stream of UF. The purpose of the disc filter is filtration of large suspended particles greater than 100 micron. The fully conditioned raw sea water from the degritted storage tank (T-103) will be pumped at 4 bar pressure by raw water transfer pumps (P-102A-D) sized for a total flow rate of about 10,950 m3/h into 30 sets of automatic back washable disc filters (DF-201-1-30) having a micron rating of 100 microns. Two rows, each row having 15 sets of disc filter and UF skids are placed in the structural steel closed building. Each UF skid is provided at its upstream with a dedicated skid mounted disc filter set having 4 modules. The capacity of each set of disc filter skid and UF skid is 365 m3/hr. Each module of the disc filter is provided with three-way pneumatic diaphragm valve with actuator at the inlet and outlet and has a differential pressure switch. Normally these disc filters will operate automatically in sequential mode at the pre-defined filtration and backwash sequence & frequency and the same can be adjusted based on the feed quality total suspend solids at any point of time. Also backwash is initiated when the differential pressure on the module has exceeded the set point of differential pressure switch. Each row of disc filter skid is provided with a backwash tank (T-202) with level control and backwash pumps (P-204A/B). Normal backwash sequence is as follows: Backwash time per unit -10 secs, Backwash frequency -30 minutes.

The disc filter skid is followed by thirty ultra filtration (UF) membrane skids trains (UF-201-1-30) containing 3600 membranes and will process the disc filter outlet water produce 9855 m3/h of high quality UF permeate having silt density less than 3 with an overall recovery of 90% from the combination of disc filters and UF trains. The reject from the UF system at a flow rate of 1095 m3/h will be taken to the UF & RO reject tank (T-501). The UF product will be taken into UF product cum backwash tank (T-203 A/B). The buffer storage of the two tanks together is 3 hrs. Total 4 nos of VFD controlled UF backwash pumps (P-202 A-D) each having capacity of 300 m3/hr is envisaged. At any point of time, two nos. of backwash pumps would be in operation i.e. about 600 m3/h of the product will be utilized as a feed to the UF backwash devices. The net UF product for feed to RO section will be 9255 m3/h. On line injection of NaOCl is provided on the UF backwash pump discharge to keep the bacterial growth under control. Chemical tank with facility for chemical cleaning of UF membranes is



envisaged through backwash pumps as per the membrane fouling conditions and chemical cleaning requirement.

3. AREA – 300: RO Section

The balance UF product of 9255 m3/hr will be pumped by cartridge filter feed pumps (P-201A-D) at 2.5 bar pressure through 5 micron cartridge filters (CF-301A-O) to the high pressure VFD controlled RO feed pumps (P-306 A-O) and pressure exchangers (PX 305A-O) followed by VFD controlled booster pumps (P-307A-O). Sodium bi-sulphite will be dosed on line at the upstream of online static mixer to eliminate any possible traces of free chlorine (Cl2) into the feed to the RO (reverse osmosis) membranes. A total of 12 RO trains (RO-301A-L) operating in parallel, each containing 72 nos. of RO pressure tubes (8 rows, each row having 9 nos. of pressure tubes), each pressure tube housing 7 nos. of membranes of 8” dia x 40” long, (total – 6048 membranes) will process the UF permeate fed at a pressure of 70 bar by the RO feed pumps (P-306 A-O) and pressure exchangers (PX-305A-O)/booster pumps (P-307A-O), 3 sets of which will act as standby. For group of 4nos.of RO trains and high pressure pumping sets, 1 group of only pumping set is kept as standby. Total 9255 m3/h at 2 bar pressure for 12 RO train high pressure pumping sets, each train flow rate through cartridge filter will be 771 m3/h shall be split in two streams. The high pressure pump flow rate will be 357 m3/h and feed to pressure exchanger will be 414 m3/h. The feed pressure to RO will be 70 bar. The PX feed is pressurized by the concentrate stream entering the PX concentrate side at the flow rate of 421 m3/h at 68 bar. The energy is exchanged between the concentrate and UF permeate feed. The UF permeate feed is discharged from PX at the flow rate of 413 m3/h at 67 bar which is further boosted to 70 bar by booster pump for feeding to RO with high pressure pump discharge. The low pressure concentrate coming out at 1.2 bar from PX is taken to the UF + RO reject tank. The recovery obtained (ratio of permeate to RO feed) is 45.38%. The total permeate obtained from 12 RO trains is 4200 m3/h. The flow and pressure of the feed to RO depending on the TDS and temperature is controlled by VFD envisaged for high pressure pumps and booster pumps. The concentrate side flow and pressure of each PX is controlled by a pressure control valve provided at the low pressure concentrate outlet line. The minimum back pressure to be maintained at the low pressure concentrate outlet line is 1.0 bar. Flow meters & pressure transmitters is provided on the feed side as well as concentrate side to control the speed and thereby flow and pressure of streams. Sampling at the low pressure concentrate outlet will let the operator know about the



performance and efficiency of the PX as when the PX is performing to its full potential, mixing leading to TDS decrease will be below the prescribed limits of 3 %. The efficiency of PX estimated to be 95%. The only energy lost is by means of lubrication flow required for PX (1.7%) and 3 to 6% by means of mixing of fluid from concentrate to feed side. The permeate from each RO train will be led to horizontal dished end suck back tank (V-301A to L) kept on the top of each RO skid from where it is pumped to permeate tank by pumps (P-301A to 0), each having capacity of 350 m3/h and discharge pressure 2.5 bar. The permeate transfer pumps (12w +3s, i.e for every 4 pumps, 1 stand by pump) have been grouped for 12 RO trains along with the high pressure pumping sets. The permeate of 4200 m3/h is taken to permeate storage tank (2 nos) of capacity 8999 m3 (4hrs 17 minutes retention time) (T-301A/B). A total of 4200 m3/h permeate (1,00,000 m3/d) at an average recovery of 45.38% (in the RO section) will flow to the product water tanks (T-301A/B). Reject concentrate from RO will be led to the pressure exchangers (PX-305A-O) which have high efficiency and reliability. The brine outlet from these energy recovery devices goes to UF cum RO reject tank (T-501). Thanks to the recovery of energy obtainable from the RO concentrate stream, the installed power required to feed the pre-treated conditioned seawater at a pressure of 70 bar in 6048 RO membranes, will be less than 12,500 kW with an overall specific consumption of energy of about 2.96 kWh/m3 of permeate water in RO section. A 10 t EOT crane is envisaged in the pump & motor bay for maintenance of motors & pumps. A tyre mounted mobile platform (scissor crane) and lifting provision has been provided for operation and maintenance of RO skids.

4. AREA 400: Re-carbonation & Re-mineralisation, Carbon

Dioxide & Product water storage System The permeate from the product storage is pumped to the post

treatment section comprising of Re-mineralisation & Re-carbonation units for achieving the desired alkalinity (64.42 ppm as CaCO3 ) & hardness as (60.52 ppm CaCO3 ), pH adjustment by NaOH dosing to obtain the desired level residual chlorine by dosing of NaOCl as a disinfectant. The post treatment section helps to achieve the desired requirement of potable water quality and bring the LSI to positive for stabilization which is an essential parameter for transportation of water for city distribution. The re-mineralisation & recarbonation plant is designed for treatment



of 4536 m3/hr, around 10% excess than the permeate production (4167 m3/hr) in the RO plant so as to take care of some unforeseen eventualities & provide uninterrupted supply of potable water. Under normal operating condition on continuous basis, partial flow of 1240 m3/hr is taken to absorber feed booster pumps (P-401A/B/C) to boost the feed pressure to carbon dioxide absorber & limestone dissolution filters. 971 m3/hr of boosted feed is sent to four nos. working limestone filters (LF- 414 A/B/C/D/E) and the balance 269 m3/hr goes to carbon dioxide absorber (AB-403) and from then it goes to lime stone filters (LF- 414 A/B/C/D/E). The bypassed balance flow of 2927 m3/hr is sent directly to potable water storage tank (T-416). The flow to the limestone filters, carbon dioxide absorber and potable water storage tank is controlled by flow control valves provided at the carbon dioxide absorber.

Carbon dioxide is fed to the carbon dioxide absorber tower from two nos. of 27 ton carbon dioxide SS steel storage vertical tanks (T-417 A/B). The CO2 is stored at 24 bar pressure and the tanks have perlite vacuum insulation and necessary piping and valves for feeding to CO2 absorber. The CO2 absorber tower comprises of polypropylene pall rings of size 2” whereas the limestone filter contains packed limestone of 93% purity. The limestone consumption per filter is 73 kg/hr (12.4 t/week). The frequency of limestone charging is once in 7 days per filter. The total limestone consumption for the total flow to four filters is 49.6 t/week. Carbon dioxide consumption is 5.5 t/day. Since the storage comes under static and moving pressure vessels rule, the necessary clearances and safety requirements are planned. The limestone filters is backwash equipped with backwashing sequence having pneumatically operated valves at the inlet and outlet of backwash. The frequency of backwash is once in 10 days, for 30 minutes and the backwash water is taken from the re-carbonation feed header going to the potable water storage tank. The backwash water requirement is 380 m3/hr. The backwashing is accompanied by air scouring and the air requirement of 911.9 m3/hr at 0.55 barg is met by air compressors (root blowers AC- 401 A/B). The spent water from backwash is taken to the spent wash water recovery system comprising of sedimentation tank (ST-410).The RCC sedimentation tank (ST-410) consists of two chambers one for sludge and othe other for clear water. The recovered water is used as motive fluid for limestone charging system and the sludge water is disposed to the (UF + RO) reject tank (T-501) by pump P – 411 A/B.

The limestone powder (bulk density 1.150) is stored in bags in limestone storage building. The limestone handling, storage and recharging system comprises of the facilities like limestone



storage building, main loading hopper (H-404), filling hopper (H-408A/B), screw feeder (CON-405 A/B), two way diverter gates (GD-407), limestone ejector (E-406A/B), limestone recharging booster pumps (P-402 A/B). The limestone of 93% purity is taken to the main loading hopper through manually operated electric hoists from where it is taken to filling hopper (H-408A/B) via the two way gravity diverter and screw feeder at controlled flow rate of 4.13 t/hr. The limestone is transported to the limestone filters by limestone ejector E- 406 A/B using motive fluid by pumping the overflow clear water obtained from the portioned two chambered sedimentation tank (ST-410) The carbonated water from the limestone filters is led to atmospheric degasser tower (DGT-402) having polypropylene Pall rings 2” from the top for removal of excess carbon dioxide present in the re-carbonated water. Air is fed from the bottom of degasser tower by atmospheric degasser fan (DGF- 415A/B) at the flow rate of 2094 m3/hr at 0.21 mwc. NaOCl & NaOH dosing is done at the upstream of online static mixer on Recarbonation & re-mineralisation feed by pass header leading to potable water storage tank. 6 nos of vertical turbine potable water transfer pumps (4 working + 2 standby, P-404 A/B/C/D/E/F) of capacity 1089 m3/hr, 69.5 m head is provided (under CMWSSB scope) for onward transportation to CMWSSB storage tank for city distribution.

5. AREA 500 : Reject Storage & Disposal System The UF reject, backwash from the UF skids and RO rejects are

collected in the UF cum RO reject tank (T-501) from where it is mixed along with sludge water from filtering cum settling basin (SB -101) ,bypass line from the degritted storage tank & sludge from sedimentation tank (ST- 410 ) and pumped at 6860 m3/hr & 5 bar head by reject water transfer pumps (P-501A-D) into the offshore disposal system outfall comprising of under sea bed 1200 mm diameter. HDPE pipeline (PN -10, PE 100) and on the bed 18 port (14 w +4s) 300 NB diffuser system. designed for suitable dispersion into the sea. The reject outfall is located at 620m from the pump discharge. The TDS of the reject discharge would be to the tune of 64 600 ppm.

The net overall recovery of desalination plant considering the intake flow rate as 11060 m3/hr and RO potable water flow rate as 4167 m3/hr (final product) would be 37.7%.

6. AREA 600: Clean in Place System (CIP) For RO.



Chemical cleaning system facilities inside RO building will be provided for CIP for chemical cleaning of RO membranes. These facilities will include cleaning tank (T-602) with agitator, flushing tank (T-601), chemical dosing system (SC-601), and chemical cleaning pumps (P-601A-B) & 5 micron cartridge filters. The liquid chemical storage in drums is envisaged to be stored in Chemical storage building attached to the RO building and unloaded in the tanks as and when required with hand pumps.

7. AREA- 700:

The dosing chemicals required are sulphuric acid, sodium bisulphite, sodium hypochlorite and anti-scalant and caustic soda. Facilities for handling and storage, preparation and dosing of these chemicals at respective concentrations and points through automatic control and adjustment is envisaged and includes unloading-cum-transfer pumps, bulk storage tanks, daily tanks, and dosing pumps, preparation and dosing tanks including agitator for sodium bisulphite and anti-scalant in line with P&ID nos. MEC/10EP/01/01/PID/0014 and 0015.

9.0 SCOPE OF WORK 9.1 The contractors scope of work includes ascertaining the adequacy of

drawings, documents and datasheets, residual engineering, coordinated planning preparation of equipment fabrication drawings and piping isometrics including bill of quantities, procurement, manufacturing, inspection & shop testing, painting, packing and forwarding, supply, transportation to site, unloading & storage at site, site fabrication, assembly at site, erection of plant and machinery, supervision, pre-commissioning check, site testing & trial runs, final painting, integration, commissioning and performance guarantee testing, training of operating personnel, operation and maintenance for seven years and handing over of the complete facilities of the Sea water Reverse Osmosis desalination plant comprising of the offshore open intake and under sea bed pipeline, onshore intake facilities, pretreatment section, RO section, intermediate storages & pumping , post treatment section & product storage, bulk chemical storage, handling & dosing system, limestone & carbon dioxide storage & handling, plant buildings like UF & RO building, limestone recharging, fire pump house repair shop, compressor house, work shop, DG room, warehouse, chemical storage, control rooms, laboratory, electrical & instrumentation rooms like main receiving stations, transformers, switchyards, substations, PMCC & MCC, VFD rooms, electrical control room, HT substation buildings and non plant buildings like gate complex, security cabin, vehicle parking shed, administrative building, amenity building, viewing gallery etc including associated works and facilities like land development works, boundary



walls, roads & drains, electrical facilities like, cabling, illumination, earthing etc, automation and control, air conditioning & ventilation, material handling facilities, above ground & underground piping works, sewage network and sewage treatment plant, green belt interconnected piping, valves and fitting, utility systems, firefighting system, lab equipment Glassware & accessories , chemicals and furniture, mechanical hoisting and material handling equipment , etc, , etc as described herein in the plant description clause 5.0, process description clause 6.0, drawings, datasheets and technical specification volumes no. 1 to IV for various works enclosed with this document, with adequate safety features for automatic operation of the system individually and collectively to achieve the guaranteed performance of the system and production of net 100 MLD potable water quality as per IS-10500 and design basis as per clause. 6.0, complete with associated auxiliaries and facilities. The scope of work shall also include transit cum erection comprehensive insurance for the total system till handing over of the plant

9.2 The works to be provided by the contractor, unless otherwise

specified, shall include but not be limited to the scope and specifications stated for various works in this contract document. The shall also carryout and remain responsible for the work not explicitly mentioned in the specification but so required or/and incidental for covering the scope of work for the intended and guaranteed performance parameters.

9.3 The scope of work shall also include contractor’s foreign supervision

including manufacturer’s supervision as required during erection of imported equipment/supplies and supervision of erection and integration of indigenous supplies of the complete plant to achieve guaranteed product water.

9.4 The scope of work also includes preliminary operation, initial

operation, trial run, commissioning and performance guarantee test run, operation and maintenance and handing over of the plant/system, etc. as per specification, standards, P & ID’s, data sheets, drawings, etc. all complete for the desalination plant & associated plant facilities covered under this package and as mentioned in the relevant paragraphs and chapters of this document.

10.0 Detailed Scope of Work

The detailed scope of work for the contractor to achieve the performance guarantee consisting of residual design, procurement, supply, erection, testing, commissioning and performance guarantee, operation and maintenance of the plant are as follows:



10.1 The contractor is requested to carefully examine and understand the requirements of the specifications, drawings & conditions of the contract documents (volume I to IV) in totality and seek clarifications, if required, to ensure that they have understood the complete specifications and conditions spelt out in the contract documents. Such clarifications should be sought within the time period as stipulated in commercial part of this contract document.

10.2 Contractor’s offer should not carry any sections like clarifications,

interpretations and/or assumptions. However, if the contractor feels in his opinion, that an alternative to the equipment/certain features indicated in the contract is required and are superior to what has been specified for better recovery of the plant and the contractor shall stand guarantee for the plant performance, the same may be offered as deviation of this chapter, highlight separately along with suitable reasoning and justifications with necessary backup documents in line with clause 3.1 Any change from the contract specification without suitable and appropriate justification will not be considered.

10.3 Any additional equipment and materials which are not specifically

mentioned in the technical specifications but are required to make the plant complete in all respects for guaranteed performance and operation & maintenance and shall be under the scope of the contractor.

10.4 The scope of work also includes but not limited to the following:

a) Carrying out the residual engineering of the plant and systems

including ascertaining the adequacy of drawings, documents and datasheets, preparation manufacturing/fabrication drawings of equipment drawings and piping isometrics drawings including bill of quantities etc. Scope of work of the contractor shall cover the study of the process flow sheets, equipment schedule and capacity, equipment datasheet, process description, plant layout, intake and outfall design drawings, civil construction drawings, design drawings for structural and equipment, general arrangement layout drawings of different equipment and buildings, piping detail design drawings, electrical, instrumentation & automation drawings, material handling drawings etc. given along with the specification and make his own assessment of the additional requirement of plant & machinery to achieve the specified level of throughput, production as specified and operational efficiencies.

b) Based on various design & detail drawings and other

engineering documents given with the tender, fabrication/erection drawing for equipment, civil, structural, mechanical, material handling, hoisting and handling equipment, fire fighting facilities inside the plant, all



interconnected piping, valves and fitting, electrical, instrumentation, air conditioning, ventilation, illumination, utility system, drainage, etc. with adequate safety features may be required to be revised by the contractor based on the actual equipment requirement, adhering to requirement of the major facets of the drawings specification in the contract document.

c) The scope includes preparation fabrication drawings for all

structural works, fabrication drawings for equipment, pipe fabrication drawings (isometrics), construction drawings for material handling system, electrical & instrumentation drawings including cable routing drawings, panel wiring drawings etc.

d) Submission of RO & UF projections, vendor drawings &

datasheet progressively and obtaining prior approval from the purchaser/consultant before taking up of manufacturing & installation. All the basic engineering design, detail drawings, design calculations, vendor drawings and datasheets shall be thoroughly scrutinized and vetted by the contractor and its partner (as applicable), respective equipment manufacturer confirming the suitability of the system/equipment being offered in conjunction with the related engineering documents enclosed with the contract document.

e) The design calculations of UF & R.O SYSTEM (including

computer run out) proposed by the contractor shall be submitted for Purchaser’s review and acceptance along with normalization graphs w.r.t TDS variation, temperature variation and flux decline. The contractor shall indicate the fouling factor, flux decline per year and salt passage per year considered by him for the design and selection of RO membranes. The contractor shall get the membrane projection calculations prepared by them vetted by the membrane manufacturer before submission.

f) All drawings and documents before submission to the

purchaser/consultant shall be vetted and signed by the respective partners responsible for the activity as per the responsibility matrix submitted for pre-qualification.

g) Providing manufacturing drawings and datasheets, design

calculations, operation and maintenance manuals, as-built drawings and other information as applicable.

h) Providing on the job training to Purchaser’s personnel. i) Compliance with statutory requirements and obtaining

clearances from statutory authorities wherever required.



j) Finalisation of sub-vendors, manufacturing quality assurance plans (QAP) and field QAPs.

k) Complete manufacturing including conducting all shop and

routine tests and inspection. l) Civil and architectural, structural, power distribution, shop

electrics, illumination, earthing, instrumentation and control, automation, air condition & ventilation, material handling, repair shop, laboratory facilities, green belt, STP etc. to the extent applicable including construction and erection of the applicable facilities.

m) Packing and transportation from the manufacturer’s works to

the site including custom clearances port clearance, payment of port charges (if any), all applicable insurances etc.

n) Receipt, storage, preservation and conservation of equipment

at site including store management. o) Fabrication, pre-assembly, erection, testing, pre-

commissioning and commissioning and putting into satisfactory operation of all the plant and equipment including successful completion of initial operation.

p) Reliability and functional guarantee tests after successful

completion of trial operation.

q) Furnishing of commissioning spares and shall be included

along with the supply of equipment. r) Supply of critical spares & consumables as per the enclosed

annexure in volume-IV of the contract document. s) Satisfactory completion of the contract t) Making all connections at terminal points at the battery limits

including supply of necessary jointing/connecting materials etc. u) Supply of operating chemicals, consumables, lubricants for the

plants shall also be included in the contractors scope for trial run, testing, and commissioning and performance guarantee (PG) test until the guaranteed values are proved and are deemed to be included under the item trial run, commissioning and PG test of the complete plant facilities.

v) All the first fill and operating & maintaining year's topping

requirement of consumables such as oil, lubricants, greases etc. which will be required to put the equipment covered under



the scope of specifications for completion of facilities shall be supplied by the contractor. Suitable standard lubricants as available in India are desired. Effort should be made to limit the variety of lubricants to minimum.

w) Special tools and tackles, if any, required for maintenance of

the plant. x) Supply of operation spares & consumables for seven year

operation as per the requirement of operation & maintenance specification volume-1 to achieve guaranteed output and quality.

y) Supply of operating chemicals like, acid, alkali, sodium

hypochlorite, antisacalant, SMBS, RO & UF cleaning chemicals, etc required for entire operation & maintenance period (seven years) of the desalination plant described in volume 1 of this document, up to handing over of the plant with complete facilities.

z) Detailed scope and technical specification of works for civil,

structural, electrical, instrumentation, control and automation, AC & ventilation, Repair shop equipment & laboratory facilities, material handling, fire fighting facilities, compressed air facilities , sewage treatment plant shall be as per chapters 1,2,3&4,6,6,8,9,10,11,12,13 of volume II B respectively.

aa) Detailed scope & specification for Operation and maintenance

of plant shall be as per volume 1. bb) Total Five nos of eye wash fountain and safety showers are

included in the scope and shall be provided in the laboratory (1nos.), limestone recharging (2 no.) and in chemical buildings area (2 nos) etc and shall be included in items under safety equipment

10.5 PROCUREMENT AND SUPPLY: 10.5.1 The contractor shall procure, fabricate, assemble, shop test, getting

inspected by Purchaser/Consultant, pack & transport and deliver to site, all technological equipment like horizontal & vertical pumps, ultra filtration equipment, disc filters, RO pressure vessels, RO membranes, cartridge filters, pressure exchangers, FRP & mild steel storage tanks, dosing pumps, carbon dioxide absorber, limestone filters, degasser, carbon dioxide storage tanks, media for sedimentation tanks, victaulic couplings. , piping & valves, etc., in line with contract specification, schedule of quantities and as per relevant drawings & documents approved by Purchaser/ Consultant.



10.5.2 The scope also covers procurement of all materials related to civil, structural, mechanical tanks, piping, material handling & hoisting like conveyors , gantry crane , mobile scissor lift platform, fire fighting pumps & fire network including fire monitors and double headed hydrants, fire extinguishers, ac & ventilation, illumination, utility works, electrical, instrumentation, Repair shop, safety equipment, lab equipment furniture etc , in line with the contract specification, schedule of quantities and as per relevant drawings & documents approved by purchaser/consultant.

10.5.3 All equipment/ materials are to be supplied from vendors of Preferred

Makes. For those equipment / materials whose Preferred Makes have not been indicated in this document shall be supplied from reputed vendors after taking prior approval from Purchaser/ Consultant.

10.5.4 All supply shall be inclusive of commissioning spares and special tools

& tackles as required. Contractor shall submit the list of special tools & tackles along with the technical contract as per ANNEXURE-Ii.

10.5.5 The scope of work includes supply of critical spares as per the

schedule of quantities. 10.5.6 Purchaser/Consultant reserve rights to inspect the entire

materials/equipment prior to dispatch for site. Contractor shall submit to Purchaser/Consultant, Quality Assurance Plans (QAP) for supply covering all items. On finalisation of QAPs, stage/final inspection shall be carried out accordingly. For items where inspection may not be asked for, contractor shall satisfy themselves about the performance of the items and provide all documents as finalized in QAP along with any other documents that may be requisitioned by Purchaser/Consultant. All expenses related to conducting of shop inspection shall be borne by the contractor/manufacturer/vendor except for traveling & boarding expenses of Purchaser/Consultant representatives. For imported items where inspection is not being carried out by Purchaser/Consultant, the inspection of item is to be arranged through a reputed inspecting agency from the country of origin.

10.5.7 Inspection call letter is to be submitted to the Consultant at least two

weeks before for indigenous items and at least three weeks before for imported items.

10.5.8 If acceptance is obtained following the inspection, inspection

certificate will be issued after receiving all documents as per relevant QAP. Contractor has to prepare copies of Inspection Certificate along with its all attachments and submit 10 copies to Consultant for onward distribution.

10.5.9 For the items where inspection has not been asked for, all necessary

documents as per QAP are to be submitted in 10 copies.



10.5.10 Items shall be dispatched to site only after dispatch clearance is given

by Purchaser/Consultant. 10.6 ERECTION, TESTING & COMMISSIONING: 10.6.1 The contractor shall carry out unloading & storage at site of all supply

and complete site assembly, fabrication and erection of the total plant covering all technological equipment like horizontal & vertical pumps, ultra filtration equipment, disc filters, RO pressure vessels, RO membranes, cartridge filters, pressure exchangers, FRP & mild steel storage tanks, dosing pumps, carbon dioxide absorber, limestone filters, degasser, carbon dioxide storage tanks, media for sedimentation tanks, victaulic couplings. , piping & valves, etc. in line with contract specification, schedule of quantities and as per relevant drawings & documents approved by Purchaser/ Consultant.

10.6.2 The contractor shall also carry out all relevant all materials related to

civil, structural, mechanical tanks, piping, material handling & hoisting like conveyors , gantry crane , bucket elevators fire fighting pumps & fire network including fire monitors and double headed hydrants, fire extinguishers, ac & ventilation, illumination, utility works, electrical, instrumentation, Repair shop, safety equipment, furniture etc , inline with the contract specification, schedule of quantities and as per relevant drawings & documents approved by purchaser/consultant in order to complete the plant in all respect as per the provision of the specification.

10.6.3 All erection/ scaffolding accessories like nuts, bolts, gaskets, washer,

grease, welding electrodes, electrical glands, clips etc. to complete the erection works in all respects shall be provided by the contractor.

10.6.4 On completion of erection, contractor shall arrange for site testing of individual units as per prevailing engineering practices or as

recommended by the respective manufacturers/as specified in the specification. Records for acceptance following site testing shall be maintained and shall form a part of As-built documents to be submitted to purchaser/consultant on completion of the works.

10.6.5 Primer Painting shall be before site testing and final paintings shall be

applied after completion of successful site testing. 10.6.6 When the erection and site testing of the plant is completed in all respects, trial runs, integration and Commissioning of the Plant shall

be carried out by the contractor at a date to be finalized in consultation with Purchaser.

10.6.7 The contractor shall clear the site of all debris cart it to dump area to



be identified by the purchaser and maintain aesthetic upkeep of the site from time to time during the execution and at the time of final handing over of the plant.

10.6.8 When the erection and site testing of the plant is completed in all

respects, trial runs, integration and Commissioning of the Plant shall be carried out by the contractor at a date to be finalized in consultation with Purchaser/consultant.

10.6.9 Following CHAPTERS & ANNEXURES form the part of the Technical

Specification:

a) Technical specification for Mechanical systems/ Equipment

- chapter-2 of volume II A

b) Site Details - chapter-3 of volume II A c) Technical Specification for sea water

intake& out fall system - chapter-4 of volume II A

d) Technical Specification for Pipes, fittings & Valves


e) Technical Specification for Erection & Testing


f) Technical Specification for Paining - chapter-7 of volume II A g) Technical Specification for Internal

lining of pipes, tanks & vessels - chapter-8 of volume II A

h) Preferred make - chapter-9 of volume II A i) Technical Specification for Civil works -chapter-1 of volume II B j) Technical Specification for Steel &

Structural works -chapter-2 of volume II B

k) Technical Specification Power Distribution

- chapter-3 of volume II B

l) Technical Specification Shop Electrics - chapter-4 of volume II B m) Technical Specification for Illumination - chapter-5 of volume II B n) Technical Specification for

Instrumentation & automation -chapter-6 of volume II B

o) Technical Specification for AC & ventilation


p) Technical Specification for Repair shop - chapter-8 of volume II B q) Technical Specification for Laboratory - chapter-9 of volume II B r) Technical Specification for Material

handling equipment - chapter-10 of volume II B

s) Technical Specification for Fire fighting - chapter-11 of volume II B t) Technical Specification for air

compressor - chapter-12 of volume II B

u) Technical Specification for Sewerage treatment plant


v) Technical Specification for Safety equipments.




w) Technical specification for portable fire extinguisher- Chapter 15

of Volume-IIB x) Drawings - Volume III ,Folder 1 to 6 10.6.10 The contractor shall appoint an authorized site representative / project manager and ensure timely completion of work. 10.6.11 Quality of workmanship and materials shall be of best quality unless

otherwise specified in the technical specification, suitable for the purpose intended and in accordance with the highest standards and works indicated in the specification.

10.6.12 Deviation, if any, from the technical specification shall be allowed only

if prior approval is obtained from Purchaser/ Consultant in writing. The deviation shall be considered only after scrutinizing the justification submitted by the contractor clearly stating the reasons for deviation backed up with suitable design calculations, performance characteristics etc.

10.6.13 The Consultant / Purchaser shall have the right to depute his representatives to ascertain the progress of work at the premises of

works of the contractor or any of his Sub- contractors. 10.614 The contractor shall submit his detailed Network Schedule in

PRIMAVERA showing completion time of work packages, work breakdown structure (WBS) and organizational breakdown structure (OBS) which would indicate the responsibility matrix and starting & completion dates of all activities and sub activities of engineering, procurement, manufacture, inspection and dispatch, delivery at site, erection, testing, trial-run and commissioning ,operation & maintenance etc. for his scope of work.

10.6.15 The contractor shall furnish copies of all Purchase Orders without prices, placed by him on various sub suppliers/ contractors and work

orders issued to his own manufacturing units containing scope of work, technical specification, time schedule etc.

10.6.16 The contractor shall submit the Progress Report of each month in 3

(three) copies each to Purchaser and to Consultant by 25th of the current month. The report shall include Introduction, Progress summary, Status Report of all activities including those of sub-vendors as on date, Monthly Plan for supply activity, Inspection and Dispatch, weekly plan for site works, manpower deployment, payment status, major hold ups, updated bar/Gantt chart against the schedule. Additionally , contractor is required to provide with any other details as may be required by Consultant / Purchaser so as to enable them to monitor the progress of the Project effectively.

10.6.17 Arranging and obtaining all necessary statutory clearances from



statutory authorities both in India and abroad for completion of the work is in the scope of the contractor. However, statutory fees shall be reimbursed by CMWSSB based on production of documentary evidence by the contractor.

10.6.18 Contractor shall bring in any special instruments required for

performance testing at his own cost and then may be taken back after completion of P.G. tests.

10.6.19 Safety shower and Eye wash fountain shall be installed in the

chemical handling area. 10.6.20 All equipment shall be easily approachable with sufficient walking space between them (at least in clear space) for ease of

operation/maintenance. 10.6.21 Provision shall be made for easy access to the inside of process vessels for maintenance. 10.6.22 The contractor shall remove all the waste materials from and around the work site and leave the place thoroughly cleaned up ready for use.

10.7 QUALITY ASSURANCE, INSPECTION & TESTING: All materials, components and equipment covered under the Technical

specification for this job shall be procured, manufactured, tested, erected and commissioned as per a comprehensive Quality Assurance Programme. It shall be the primary responsibility of the contractor to draw up and implement such a programme which shall be duly approved by the Purchaser/Consultant/their authorised Inspection Agency.

The detailed Quality Assurance Plan (QAP) in the formats enclosed with this contract agreement for manufacturing and testing of equipment shall be prepared by the contractor and submitted for approval by the Purchaser/their authorised Inspection Agency.

10.8 Inspection and testing 10.8.1 The contractor shall make all necessary arrangements for the purchaser/consultant to carry out any stage inspection to ensure the

quality of the equipment being manufactured at the manufacturer’s works

10.8.2 Only on readiness of the equipment and approval of all relevant drawings & QAP, the equipment shall be inspected by the Purchaser

and / or their Inspection Agency at the manufacturer’s works prior to dispatch. The equipment will be inspected as per the tests pre-



identified in the approved QAP to ensure conformity of the same with relevant approved drawings, data sheets, technical specification, National/International Standard.

10.8.3 The contractor shall finalise the QAP within the stipulated schedule mentioned in the Purchase Order and the QAP shall be submitted in

four sets (Blank QAP formats enclosed shall be adopted). In case of any sub-contracting, the QAP shall be prepared by the contractor in consultation with his sub-contractor to avoid any lapse in quality and disputes and misunderstanding.

10.8.4 The contractor shall provide full and free access of the Inspection Agency contractor shall give inspection call to the Purchaser & the

Inspection Agency with a clear notice of 10 days for inspection. The inspection call shall be accompanied by the manufacturer’s internal inspection report, test certificates, purchase order, sub-purchase order, technical specification, approved QAP and approved drawings / data sheets. The inspection call without above documents shall be ignored. In case of any approved sub-contracting, only the main contractor shall give the inspection call enclosing internal inspection/ test reports of the sub-contractor duly verified by the main contractor. In case the equipment offered for inspection is found not ready, all the cost of the visit of the Inspection Agency shall be borne by the contractor.

10.8.5 The contractor shall furnish all relevant documents and test certificates as required by the Inspection Agency during inspection.

Materials shall be tested only in recognised Test House/Laboratory. 10.8.6 The contractor shall delegate a representative/ coordinator to coordinate with the Inspection Agency on all inspection matters. 10.8.7 No equipment shall be offered for inspection in the painted condition unless otherwise agreed to the purchaser. 10.8.8 The contractor shall ensure that the equipment and materials once rejected by the Inspection Agency are not reused in the manufacture

of plant and equipment. Where parts rejected by the inspection Agency have been rectified as per pre-agreed procedure, such parts shall be segregated for separate inspection and approval before being used in the work.

10.8.9 The contractor shall carry out their internal inspection and obtain clearance from Statutory bodies, CCE, TAC, Weights & Measures,

Safety, IE Rules, etc., as required for the equipment prior to offering any such equipment for Purchaser’s inspection.

10.8.10 The contractor shall provide all required instruments, tools, and necessary testing & inspection facilities, free of cost to carry out the

inspection. These instruments and testing machines shall be



calibrated by an agency of National/ International recognition and the calibration shall be valid during inspection period.

10.8.11 The inspection Agency shall have the right to demand for re-testing of any material re-calibration of the instrument and testing machine & the

charges for the above will be borne by the contractor. 10.8.12 Performance tests of any particular equipment which cannot be conducted / demonstrated either partially or wholly at the

manufacturer’s works, shall be conducted after erection at site in the presence of Purchaser and their Inspection Agency. In all the cases, prior approval of the Purchaser shall be obtained.

10.8.13 No equipment shall be dispatched before inspection and issue of Inspection Certificate and dispatch clearance from the Purchaser /

Inspection Agency. 10.8.14 In case of waiver category items, the same shall be pre-identified in the QAP itself. For such items, the contractor shall furnish necessary

certificate, test reports, etc., as agreed upon and indicated in the QAP. For these items also the contractor shall obtain “Inspection Waiver Certificate” and despatch clearance from the purchaser Inspection Agency before effecting despatch of equipment.

10.8.15 The issue of Inspection Certificate / Waiver Certificate for any equipment or component thereof does not absolve the contractor from

his contractual obligations towards subsequent satisfactory performance of the equipment at site. Should any equipment be found defective, In whole or part thereof after receipt at site or during erection/ commissioning and testing shall be made good by the contractor free of cost.

11.0 PERFORMANCE GUARANTEE GENERAL 11.1 The term “Performance Guarantees” wherever appears in the

Technical Specifications shall have the same meaning and shall be synonymous to “Functional Guarantees”. Similarly the term “Performance Tests” wherever appears in the Technical Specifications shall have the same meaning and shall be synonymous to “Guarantee Test(s)”.

11.2 The contractor shall guarantee that the complete

DESALTINATION PLANT and all the Equipments offered shall meet the ratings and performance requirement stipulated for various Systems & Equipments covered herein and other technical specifications (volume IIA& B).



11.3 All the guaranteed parameters indicated in this chapter shall be tested / demonstrated as per the detailed description given herein. The test procedure for the complete package shall be submitted by contractor and got approved from Purchaser/Consultant before conductance of Test. The performance tests to ascertain the guaranteed parameters shall be conducted by the contractor in the presence of the Purchaser/Consultant. Any special equipment, instruments, tools and tackles required for the successful completion of the Performance Test shall be provided by the contractor free of cost. Performance guarantee for any other subsystem of this plant shall be demonstrated as per the relevant technical specifications under volume IIA & B.

11.4 PERFORMANCE GUARANTEE (PG) TESTS 11.4.1 The responsibility of conducting the test will be with the successful

and contractor shall make all the arrangements for carrying out tests at site and all costs associated with the above tests shall be borne by the contractor. The performance guarantee parameters must be demonstrated by the contractor upon completion of integration, preliminary/initial operation, trial run and commissioning of the plant and equipment.

11.4.2 Performance Guarantee test at site shall be conducted within a

period of three months after successful completion of trial operation, commissioning, stabilization of the complete plant establishing the desired capacities and parameters in the presence of Purchaser's representative.

11.4.3 All instruments used during tests shall be of adequate accuracy for

the purpose in accordance with international standards. All the instruments required for the PG test should have been calibrated by the contractor from the client approved independent agency/ reputed laboratory /Institute prior to the start of the PG test, by standard methods and valid calibration certificates shall be submitted by the contractor before executing the test. In case of new instruments, manufacturer certificates shall be acceptable provided the validity of the certificate has not expired.

11.4.4 All necessary required tools & tackles, equipment, additional

equipments such as temporary piping valves, strainers, pressure reducing devices, etc required for PG test shall be arranged by the contractor at no additional cost to the Purchaser.

11.4.5 Tests shall be conducted by accredited representatives of the

contractors and the purchaser/consultant. The contractor shall inspect the plant in advance for its completeness and make it ready for the test. Contractor’s representatives shall witness all phases of the test



and record the data jointly with the client’s representatives. The performance test for pretreatment, RO, high pressure pumping & energy recovery and post treatment units particularly UF, RO & high pressure pumping and energy recovery units , Re-mineralisation and re -carbonation system including carbon di oxide system shall be conducted in presence of the respective skid/membrane and equipment supplier/manufacturer to monitor and demonstrate the performance of the units and respective equipment and shall make minor adjustments to the equipment/skid if required.

11.4.6 At the end of each test period, the contractor’s representative shall

prepare a test report which shall include daily operating and normalized performance data for each day of the test. For UF, RO & high pressure pumping and energy recovery units, the respective membrane & equipment manufacturer must submit for approval the proposed method for normalization of operating data.

11.4.7 Submission of the report and subsequent approval by the client

representative shall be required for completion. Test reports shall be submitted in booklet form showing all fields tests performed to adjust each component and all field tests performed to prove compliance with specified guarantee parameters.

11.4.8 For PG test of SWRO plant, the water analysis to be carried out during

the trial and performance test runs shall be in compliance with ASTMD 4195 – “Standard Guide for Water Analysis for Reverse Osmosis Applications” and ASTM-Standard Test Methods listed in this guide or equivalent methods of the AWWA/APHA Standard Methods for the United States Environmental Protection Agency (USEPA). Also following standard procedures as to Annual Book of ASTM Standards – Section 11 shall be used during the Performance Testing of the SWRO system. i) D 3739 – Calculation and Adjustment of the Langelier

Saturation Index for RO. ii) D 4189 – Silt Density Index (SDI) of Water D 4194– Operating

Characteristics of RO Devices. iii) D 4195– Water Analysis for RO Application D 4516 –

Standardizing RO Performance Data D4582–Calculation and adjustment of the Stiff and Davis Stability Index for RO.

iv) D 4692– Calculation and Adjustment of Sulfate Scaling Salts

for RO. v) D 4993– Calculation and Adjustment of Silica Scaling for RO

11.4.9 During testing the following readings are to be taken every two (2)

hours from the field instruments as well as from the control room panel



during the test period in the field log book as well as in the log book maintained in the control room.

1) At Disc Filter inlet & outlet: Flow, pH, turbidity, TSS,TDS,

Temperature, residual chlorine 2) At Ultrafilter inlet & outlet skids: Flow, Pressure, pH, turbidity,

SDI, residual chlorine, TOC, ORP 3) Feed Water inlet to RO Skids: Flow, Pressure, Temperature,

Conductivity, pH, TDS, SDI, residual chlorine, ORP & Boron. 4) Permeate flow from RO Skids: Flow, Pressure, Conductivity,

pH, TDS, SDI, ORP, Boron and LSI.

6) High pressure pump & PX inlet & outlet: flow, pressure and TDS

5) At Degasser inlet & outlet : Flow, pH, Conductivity, CO2, 6) Potable Water after post treatment (downstream of Potable

water storage tanks/transfer system): Complete inorganic analyses (Ionic concentrations), Flow, Conductivity, pH, Turbidity, TDS, Organics and residual chlorine, langlier saturation index (LSI) as per the parameters and their specified range stated in IS-10500 and table 6.2 of clause 6.0.

7) Chemical Consumption for pre-treatment, RO section and Post

treatment 8) Power consumption per cubic metre of product water

produced. .The readings for power consumption shall be logged from the energy meter installed at the plant.

11.4.10 Log sheets required for noting down of readings/results of various

tests shall be prepared well in advance by the contractor and shall be part of the PG test procedure approval from the client.

11.4.11 The test shall be carried out for each UF & RO train / skid, & high

pressure pumping and energy recovery units in sequence. 11.4.12 Should the PG test of SWRO plant be affected or interrupted for

reasons related to reliability or performance of equipment, the test shall be stopped and repeated in full when faults have been remedied by implementing adequate solutions.

11.4.13 In the event that the plant fails to meet the performance criteria, the

tests shall be re-run after whatever necessary corrective action has been taken. Should the results of the performance test show that the equipments have failed to meet the specified guarantees, the



contractor shall carry out the modification, at his own cost to meet the guaranteed values. In such a case, the performance & guarantee test shall be repeated by the contractor as soon as the equipment is ready after corrective actions. The corrective actions and the performance tests shall be carried out till the specified guarantee parameters are achieved.

11.4.14 The contractor even after repeat testing is not able to achieve the

performance guarantee parameters in the allotted time period decided by the purchaser, the rectification/modification shall be carried out by the purchaser and all expenses incurred shall be recovered from the contractor.

11.4.15 Contractor shall submit details of the proposed testing arrangement,

methodology of monitoring and logging of the parameters for Purchaser’s approval.

11.4.16 The test shall also include measurement of vibration, noise

level and bearing temperature rise for pumps and motors. 11.4.17 Calibration of instruments to be used in the test shall be

carried out by an independent agency. Calibration of instruments should be carried out prior to the test. The calibration certificate of the instruments shall be valid for the period of test. The following laboratories are acceptable for calibration of various instruments:

a) Flow Control Research Institute (FCRI), Palakkad. b) Indian Institute of Technology Bombay / Madras / Delhi /

Kanpur. c) Institute for design of electrical measuring instruments

(IDEMI) Bombay. d) Electronic Research & Testing laboratory (ERTL), New

Delhi. e) National Physical Laboratory (NPL), New Delhi. f) National Test House (NTH), Calcutta. g) Any other equivalent Government Institute / laboratory to be

approved by Purchaser. 11.4.18 All interlocks and protections relating to the pumps, motors

and motorised valves & pneumatic operated valves shall be demonstrated /tested as per control logic.



11.4.19 Noise level shall be less than 85 db A. Noise measurement shall be done as per Hydraulic Institute Standard. The tests shall be carried out with the machine operating at the rated speed and throughout the operation range. Correction for background noise and correction on account of test environment shall be considered in line with HIS. For this purpose all the additional data required as per this should be collected during the test.

11.4.20 Accuracy of instruments to be provided by the contractor for

testing shall be as follows:

Sl Parameters Instrument Accuracy

1 Power ( motor input power)

AC- Voltmeter + 0.5%

AC-Ammeter + 0.5% Frequency meter + 0.5% 2 Speed Tacho meter non-

contact type + 1 rpm

3 Temperature Digital thermo meter + 0.1 deg C 4 Vibration IRD 308 or

Equivalent + 3%

5 Noise level Sound level meter + 2 db 6 Pressure Bourdon type gauge/

Pressure transmitter + 0.5%

7 Level Level Gauge 8 Time Stop watch + 0.5% 9 Flow Flow element + 1.5%

11.4.21 The pumps shall be guaranteed to operate satisfactorily without

cavitations, pitting, excessive vibration, noise in single operation (one pump running) and or in parallel operation with other pumps or and when starting or shutting down a pump while others pump(s) is are in operation.

11.4.22 Current, voltage, motor input power, frequency, speed, bearing/motor

winding, temperature, vibration and noise level of pumps and their drives and parallel operation of pumps & blowers shall be demonstrated at site as a part of Performance guarantee test.

11.4.23 Contractor shall guarantee Specific Power Consumption furnished

along with the contract. 11.4.24 The guaranteed specific power consumption shall be furnished in the

contract for sea water design TDS of 41,900 ppm at 32 oC , at the end



of fifth year operation for 100 MLD (4167 m 3 /hr) product water having quality as per IS -10500 and table 6.2. The design year wise projections up to fifth year, TDS & temperature correction graphs shall also be submitted by the contractor along with the guaranteed specific power consumption figures. In case of lower or higher TDS & temperature during the performance guarantee test run, the specific power consumption shall be suitably corrected and modified by extrapolating & normalizing based on the normalizing TDS & temperature correction graphs furnished along with the contract.

11.4.25 The successful performance guarantee test run shall be for a

minimum of uninterrupted 72 hours operation of the complete plant. The tests shall be deemed to be accepted, if the guaranteed parameters are met without any deviation or stoppages. In case of any stoppage during performance test run or any deviation is recorded in the guaranteed parameters the test shall be repeated.

11.4.25 Power consumption for high pressure pumps and booster pumps shall

be measured at site at its motor input terminals for the rated capacity and rated head. To enable operation of VFD controlled HP Pumps & PX booster pumps at its rated duty point, during the test duration, additional pressure reducing device may be required as the system would be operating with membranes without any fouling or system may be treating sea water of lower TDS compared to design TDS. Such devices shall be provided / installed temporarily by the contractor for the test duration. However, during the test, operating head upto plus or minus 0.5% of rated Head at design flow is acceptable to meet this condition.

11.5 Guarantees

If equipment / system fail to meet the guaranteed values, all necessary modifications and / or replacements shall be carried out by the successful contractor without any extra cost to the Purchaser so that equipment / system comply with the guaranteed requirements.

11.6 Schedule of Guarantees: No deviation is allowed on parameters of Functional guarantees

specified below. Contract(s) with any deviation on these parameters shall not be considered for evaluation and shall be rejected.



11.6.1 Guarantee Parameters - Conformance to guarantees is

mandatory :

Sl. No. Description Unit Value inclusive of design , manufacture and all other tolerances including measurement uncertainty

1. Permeate Water quality & quantity at the outlet of SWRO skids at 41900 ppm inlet TDS and 32 deg. C

a) Boron ppm as B Max. 1 b) TDS ppm ≤ 375 Net permeate flow

from each UF skid m3/hr ≥315

c) Net permeate quantity for 12 skids.

m3/hr

≥ 4200

d) Recovery % ≥ 45.4% 2. Potable water after post treatment a) Potable water quality

parameters IS 10500 as per table 6.2

b) Langelier Saturation Index (LSI) positive

c) Residual chlorine ppm 1 d) Net product water

quantity m3/hr ≥ 4167

3 Pretreated water quality a) SDI of ultrafilter

permeate <3

b) Min. recovery in UF skids

90%

Net permeate flow from each UF skid

m3/hr ≥ 315

c) Net UF permeate quantity for 30 skids

m3/hr ≥ 9255

d) Chlorine inlet at RO Nil 4 For the complete

desalination plant

a) Specific power consumption for complete plant at sea water TDS 41900 ppm, 32oC at fifth year of operation

Kw/m3

3.83

b) Noise level of rotating equipment in Desalination plant

dbA ≤ 85



12.0 DRAWINGS, DOCUMENTS, CALCULATION, DATA & INFORMATION TO BE SUBMITTED BY THE CONTRACTOR

GENERAL 12.1 The contractor shall note that this technical data sheets & drawings

are for contracting purposes & construction only. During, construction /manufacturing , the contractor will be required to furnish all additional data about the equipment/system being supplied, even if such details are not asked for to ascertain the necessary minor adjustments that may be required for execution.

12.2 The contractor shall ensure that all information, data, performance

curves, technical literature and drawings furnished with the contract fully describe all equipment/systems.

12.3 RO, Pressure exchanger & UF projection with temperature and TDS

correction/normalisation curves at operating & design conditions as specified in the technical specifications. Literature on membrane & characteristics are to be furnished.

12.4 Performance Guaranteed parameters as specified in the Contract Specification

12.5 Power consumption calculation giving detail drive description, rated

kW, BkW, pump & motor efficiency, no. of working & standby, connected load, working hours/day and actual consumption in kW/day at operating and design conditions specified in technical specification.

12.6 Chemical consumption calculation in kg/day at 100% concentration

giving details of each chemical, dosing rate and location of dosing, duration of dosing in hours at operating and design conditions specified in technical specification.

12.7 The contractor shall furnish the specific chemical consumption figures

in the table below along with their contract.

*

*

Chemical consumption in Kg/Day at 100% concentration at sea water feed TDS of 41900ppm and 32 degree for 100MLD product water indic

1

a) Sodium hypo chlorite Kg/Day 15000 b) Sulfuric acid Kg/Day 24528 c) Sodium bi sulphate Kg/Day 1500 d) Antiscalant Kg/Day 1030 e) Caustic soda Kg/Day 132.8 f) Limestone Kg/Day 7080



12.8 Equipment list with quantity, capacity and specification and brochures/catalogues

12.9 Requirement of inside the plant water, compressed air and any other

utilities etc. along with quality required, breakup of requirement, type of use (intermittent / continuous), duration and frequency of use, etc.

12.10 Predicted characteristic performance curves for pump covering the

entire range of performance, efficiency, input power, speed, impeller size, shut-off head as applicable and as required.

12.11 List of all auxiliary equipment, accessories, tools etc. 12.12 Illustrative catalogues and literature for all major items, showing detail

of equipment, instruments, and method of operation. 12.13 Filled in questionnaire & datasheets, write up, drawings and

documents as specified in the respective technical specifications for technological, electrical, instrumentation, material handling etc.

12.14 General technical particulars (data sheets) shall be furnished in the

form set forth in respective volumes of the TS. 12.15 Schedule of deviation duly filled as per the specified format. 12.16 List and unpriced price schedule for: Tools and tackles

12.17 Time schedule of project showing various activities in a Network

schedule with details of activity particulars and interface schedule (PERT NETWORK- L1/L2)

12.18 Schedule of weights including the details of the heaviest equipment

and largest equipment in dimensions to be handled in the enclosed formats.

12.19 Project team organogram

13.0 Drawings, documents, calculation, data & information to be

submitted by the contractor after award of contract:

13.1 General Requirements a) The scope of work of the contractor includes submission of the

residual engineering/vendor drawings, design calculations and datasheets as specified in the relevant parts of specification Vol. II to Volume IV in requisite sets for approval of purchaser and the job shall be executed only as per approved drawings.



b) Within one month after award of contract, the contractor shall

submit to Purchaser preliminary list as complete as possible, of all drawings and data, by title, which the contractor expects to submit /. Furnish / supply against the contract. On receipt of the list Purchaser/Consultant and contractor shall jointly finalise a schedule for the submission of drawings. The contractor shall maintain his pace of work as required by the schedule. Drawing list shall be kept up-to-date, incorporating all new additions, cancellations and changes, and will be reissued periodically with Progress Report.

c) The actual schedule of these data/drawings shall be discussed

and mutually agreed to, between the Purchaser/Consultant and the contractor before start of manufacturing /construction.

d) All technical data/information already furnished as per clause

11 of this document shall be confirmed / resubmitted. Technical details not included in contract or revision of any data furnished earlier must be submitted after award of contract.

e) All fabrication drawings, specification, residual design

calculations and bills of material wherever applicable, prepared by the contractor shall comply with the following instructions unless otherwise directed in writing by Purchaser. The term "drawing" as used in this specification shall mean and include residual dosing calculations, specifications and bills of material unless otherwise defined. Residual design calculations to be submitted by the contractor shall include the working parameters, design parameters, the safety factor / margin used, codes and standards used etc. Drawings and data, furnished by the contractor for construction use, shall be certified as such and shall bear the signature of one of the authorised persons, whose names shall previously be given in writing to Purchaser / Consultant.

f) The contractor shall submit list and schedule of submission of

drawing / documents to the Purchaser. Contractor, in the list, shall clearly indicate the category of drawings and documents, i.e. “Approval” or “Information” Category. Such list will be mutually discussed between Purchaser / Consultant and the contractor and finalized.

g) Before starting manufacturing of the equipment, the contractor

shall have to take approval of the residual design drawings from the Purchaser / Consultant. Any manufacturing done prior to approval of the drawings shall be rectified in accordance with approved drawings by the contractor at his own cost, if



any discrepancy arises and the equipment shall be supplied within stipulated period.

h) It is understood that approval or release by

Purchaser/Consultant does not include the checking for drafting and other errors, but only review of basic concepts and general principles involved. Approval does not relieve the contractor of responsibility for correctness of design, details and dimensions.

i) All reproducible shall be sent to Purchaser/Consultant in CD

only. j) One set each of soft copies of all the approved drawings,

documents including as built drawings shall be furnished by the contractor to the Purchaser and Consultant in compact discs.

k) White prints or other non-reproducible drawings can be mailed

folded. Blue prints shall generally not be used. l) All drawings, prepared by the contractor shall be as per IS:696.

Supplier's standard drawings are exempted from the above size limitation, unless his "standard" includes drawings of very large size or length. All design drawings shall be oriented to match the plant arrangement drawings, and shall have a key plan identifying the plant area to which they apply. All situation drawings shall be made with the north arrow pointing to the top of the sheet or to the left. There shall be sufficient reference notes on the drawings to permit identification of all the drawings which are required for a proper understanding.

m) Bills of material and drawings shall be cross-referenced for

easy identification. n) All drawings shall be dimensioned in the metric system. Where

drawings are usually made in the British (or other) system, they shall also have metric system dimensions in parentheses or below dimension line. Titles and written notations shall be in English. If the original is in another language it shall carry English translation. The translations will appear immediately on the drawings. Attached lists of translated words shall not be accepted.

o) Drawings and bills of material shall be identified by a

numbering system to be mutually agreed later on. Any additional identification numbers or symbols that the contractor selects to use for his own purposes are permissible so long as Purchaser's number is the prime means of identification.



p) The scale of the drawing shall be shown clearly in the title block of the drawing. Wherever possible, scales of drawings shall be :-

1 : 1 1 : 2.5 1 : 5 1 :10 1 : 20 1 : 25 1 : 50 1 :100 1 : 200 1 : 300 1 : 500 1 : 1000 1 : 2000 1 : 5000

q) All revised drawing shall clearly indicate the number, date and subject to each revision. All the revisions carried out in the drawings shall be clearly identified and marked.

r) The contractor shall furnish all necessary drawings, data etc.,

of the plant/equipment with appropriate “ Status” stamped in adequate no. of copies as indicated in volume 1.

13.2 Methodology of drawing Approval

a) Contractor shall submit all drawings/documents /datasheets

/calculations etc. which require approval clearly indicating the category (Approval/Information) to consultant and prints to purchaser. The consultant shall compile the observation/comments along with purchaser’s comments and shall send stamped copies of the drawing/document to contractor for further action at their end.

b) Contractor shall send the Approved working drawings to

consultant and to purchaser for their record, reference and use.

13.3 Drawings & data for desalination plant

a) General arrangement and cross sectional drawings of all major components with bill of material along with the weight of equipments.

b) Single line flow and instrumentation diagram, showing all

equipment, piping, valves, fittings, instruments etc., suitably tagged for better identification. Scope of supply / Terminal Points shall also be clearly marked.

c) Foundation design /drawing for all equipment. d) Piping isometrics, stress analysis report, details of piping

supports, fittings and specialties, etc.



e) Layout of all systems, sub systems, equipment & plant as a whole as applicable and also area utilisation plan during the construction period.

f) Firmed up requirement of construction power and construction

water. g) Detailed dimension drawing of electric drive motor frame,

bearings, cable boxes, cable termination arrangements etc. h) Detailed dimension drawing of all instruments connected to

control & instruments, for example, pressure switches, flow elements, temperature elements, temperature switches, local isothermal boxes, cable termination arrangement, control valves, pneumatic dampers, pneumatic actuators, level gauges etc.

i) Structural, Civil, thermodynamic and pressure part

calculations showing compliance with specifications and codes as and when required.

j) Detailed specification of all the plant and equipment covered

under the scope of the package contractor. k) Interlock logic diagrams and schematics as applicable.

Detailed drawings of closed control loops with write-up and measurement loops alongwith schematic and wiring diagram and interconnection diagram.

l) Dimensioned drawings of the control panels/desk showing

arrangement of instruments, switches, push buttons, lamps terminals etc., along with schematic & wiring diagram and interconnection diagram. Dimensioned drawings of the system cabinets and all other cabinets coming in the control equipment room (CER) showing the arrangements of the system cabinets and all other cabinets in CER internal module location in the system cabinet and all other cabinet along with wiring diagram and interconnection diagram.

m) Firmed up drive list n) Cable schedules o) Erection drawings for all equipment and structures showing

complete erection details. p) Engineering and design calculations of installations and units.



q) Quality Assurance Plans (QAPs) for all the plant and equipment under the scope of the contractor in the enclosed format.

r) Technical data of all the plant, equipment, drive motors,

instruments, panels, etc. shall be furnished. s) Following lists/tables / write ups shall be furnished, complete

with tag nos. and brief specification. Proper numbering system as approved by Consultant/Purchaser shall be adopted.

i) Instrument schedule (with service, range, make of instrument). ii) Flow element schedule. iii) Valve schedule. iv) Pipe schedule. v) Cable schedule (Power & Control). vi) Schedule of actuators (electric/pneumatic) vii) Write-up on erection procedure for all equipment and

structures shall be furnished by contractor. viii) Detailed procedures for chemical cleaning, steam blowing,

hydraulic test, etc. ix) Detailed procedure for performance and acceptance test at

site. t) Preliminary foundation plans and loading data. u) Recommended interlock and protection write-up. v) Characteristic curves/ Predicted performance curves for all

pumps and calculation sheets for all fans, pumps, exhausters, blowers, drives etc. being supplied, covering the entire range of performance from zero to maximum capacity, speed, impeller size

w) General arrangement drawing including maintenance space

requirements. x) Detailed layout of the system. y) Schematic flow diagram with all necessary details, flow of

water, figures, tank capacities etc. including mass and material balance for water at each stage of processing.

z) P&ID showing details of all instruments with proper legend as

per ISO standards. aa) List of all equipment with broad parameters and relevant

IS/International standard numbers. bb) Process calculations and calculation for head of pumps.



cc) G.A and Cross sectional drawings of all equipment/tanks dd) Literature on membranes and their characteristics. ee) Inspection certificate and material test certificates. ff) Data sheets for all equipment, Valves, piping etc. gg) Design calculations for chemical dosing, pressure vessels and

atmospheric tanks, quantity and composition of effluents etc. hh) Quality assurance plan as per enclosed format and project

schedule. ii) Detail bar chart/schedule for completion of the job (PERT

NETWORK L1/L2 along with soft copy jj) Vessel schedule-technical characteristics, specifications &

dimensional drawings, fabrication drawings with design calculations.

kk) Manufacturing procedures. ll) Procedures/specification for fabrication, welding, stress

relieving erection, testing, painting, pre-commissioning, loop testing etc.

mm) Process write up with control philosophy with safety

interlocking schemes. nn) Detailed procedures of shop testing of all the items applicable

shall be submitted to the Purchaser/Consultant for approval before conducting tests.

oo) Following shop test certificates/test curves/data shall be

furnished. i) Materials and components test certificates ii) Performance test results and characteristics all fans, pumps

and electric drive motors iii) Hydraulic test result of pressure vessels, pipes, fittings, valves iv) Non destructive test results as applicable v) Reports and test certificates of shop test vi) Type tests & routine test certificates pp) Any other drawings and document mentioned in other relevant

specification (electrical, instrumentation, civil, AC & ventilation, material handling etc).



qq) Detailed quality assurance programme along with quality plan shall be submitted.

13.4 Instruction Manuals

Instruction manuals, presenting the basic categories of information for the operating and/or maintenance personnel, as detailed herein below shall be furnished by contractor.

a. The instruction manuals shall present the following basic

categories of information in particular complete and comprehensive manner and prepared for the use by operating and/or maintenance personnel.

- Instructions for initial commissioning, short duration and

long duration shut down. - Instruction for operation, routine inspection and

maintenance including preventive maintenance. - Recommendation for inspection points, method of

inspection and period of inspection. - Information on detection, cause and rectification of troubles

and faults. - Instructions on normal repairs and overhaul. - Complete parts list with proper and complete identification

(Tag nos./Serial nos. as shown in the respective approved drawings) and ordering information for all replaceable parts. The identification details of equivalent and alternative makes for these spare parts which are not manufacturer's own product shall also be listed.

- Lubrication charts. - List of all special tools and tackle & spares and instructions

for use of such tools and tackle & spares. - One complete set of as built drawings of the entire

systems. - Maintenance manuals for HT & LT motors shall also be

provided. b. The information shall be organized in a logical and orderly

sequence. A general description of equipment including significant technical characteristics shall be included to familiarize operating and maintenance personnel with the equipment. Such description and technical characteristics shall not differ from the approved data.

c. Necessary drawings, curves and other illustrations shall be

included or copies of appropriate approved drawings shall be bound in the manuals. Tests, adjustment and calibration information, as appropriate, shall be included. Safety and other warning notices and installation, maintenance and operating cautions shall be emphasized.



d. If a standard manual covering more than one equipment

and/or model, is furnished, the information for the model and equipment supplied shall be clearly marked and identified.

e. Write-up, figures, part list etc., shall be clearly legible. The

manuals shall be prepared on good quality paper securely bound in durable folders.

f. The instruction manuals shall be subject to Consultant's

approval in the same fashion as that for drawings. 13.5 The contractor shall furnish all the necessary drawings, data etc., of

the plant/equipment with appropriate "Status" stamp in adequate no. of copies as indicated below: i) All engineering drawings : 12 copies each ii) All erection drawings : 10 copies each iii) All instruction manuals / O&M

Manual/”as built drawing” : 10 copies each

Distribution pattern of the above mentioned copies will be mutually discussed and agreed upon.



ANNEXURE-IA

The typical particle size distribution of TSS are as follows: i) 11 micron & above - 10.4 ppm ii) 2.7 micron to 11 micron - 8.7 ppm iii) 1 micron to 2.7 micron - 9.3 ppm iv) 0.7 micron to 1 micron - 7 .6 ppm v) 0.45 micron to 0.7 micron - 3.1ppm



ANNEXURE-IB

Single water analysis' are as follows: NH4-0 ppm, K - 425.08 ppm, Na-12689 ppm, Mg- 1688 ppm, Ca-450 ppm, Sr-18.85 ppm, Ba - 0 ppm, HCO3 -280.07 ppm, N03-1.63 ppm, Cl-23275.1 ppm, F-1.86 ppm, SO4-3062.51 ppm, SiO2-1.02 ppm, Boron-1.85 ppm and CO2 – 0 ppm. Note-1: Contractor shall note that the other parameters shall remain same as indicated in Table 6.1& Table 3.05 of Chapter 1 & Chapter-3 of volume II A and addendum Sl.no.32,33,34 & 49.



ANNEXURE-II

LIST OF SPECIAL TOOLS & TACKLES TO BE FURNISHED BY THE

CONTRACTOR

List of special tools and tackles with broad specification and quantities required for operation and maintenance of the plant & equipment shall be furnished by the contractor in the format below .

SL. NO.

DESCRIPTION OF TOOLS & TACKLES QUANTITY BROAD SPECIFICATION

SIGNATURE

_________________________ NAME

_______________________________

COMPANY SEAL

DESIGNATION

__________________

COMPANY ___________________________

DATE



ANNEXURE-III FORM No. 11.20(DQM) F-10 REV. 0

CONTRACTOR

ORDER No. & DATE

PROJECT

SUB-CONTRACTOR

PACKAGE No. ORDER No. &

DATE

QUALITY ASSURANCE PLAN FOR

ELECTRICAL EQUIPMENT PACKAGE NAME INSTRUCTIONS FOR FILLING UP: CODES FOR EXTENT OF INSPECTION, TESTS, TEST CERTIFICATES & DOCUMENTS : 1. QAP shall be submitted for each of the equipment separately with break-up of assembly /

sub-assembly & part / component or for group of equipment having the same specification. 2. Use numerical codes as indicated for extent of inspection & tests and submission of test

certificates & documents. Additional codes & description for extent of inspection & tests may be added as applicable for the plant & equipment.

3. Separate identification number with quantity for equipment shall be indicated wherever

equipment having same specifications belonging to different facilities are grouped together.

4. Weight in tonnes (T) must be indicated under column 5 for each item. Estimated weights

may be indicated wherever actual weights are not available. ABBREVIATIONS USED : CONTR : CONTRACOR MFR : MANUFACTURER

Code

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

11.

Description

Visual Dimensional Fitment & Alignment Physical Test (sample) Chemical Test (sample) Ultrasonic Test Magnetic Particle Test (MPI) Radiography Test Dye Penetration Test Measurement of IR value : a) Before HV Test b) After HV Test Hi gh Dielectric test

Voltage test /

Code

12.

13.

14. 15. 16. 17. 18. 19. 20.

21. 22.

Description

Routine test as per relevant IS / other standard Type tests as per relevant IS / other standard Impulse Test Partial Discharge Test Heat run test / tempr. Rise Test Enclosure protection Test Calibration Noise & Vibration Test certificates for bought out components Tank pressure Test Paint shade verification

Code

23. 24. 25. 26. 27. 28

Description

Short time rating Operational & functional check Over speed Test Flame proof Test Clearance & creepage distance

D1. D2.

D3.

D4. D5. D6.

DOCUMENTS

Approved GA drawings Approved single line / schematic diagram Catalogues / Approved data sheet Approved bill of materials Unpriced P.O. copy Calibration Certificates of all measuring instruments and gauges

E Q U I P M E N T D E T A I L S I N S P E C T I O N AND T E S T S

Quantity Raw Material and inprostage inspection

cess Final Inspection / Test by Sl. No.

Description (with equipment heading,place of use & brief specifications)

Identification No.

No./M T

Manufacturer’s Name & address

Expected Schedule of Final Inspn. MFR CONTR. MECON MFR CONTR. MECON

Test Certificates & documents to be

submitted to Mecon

Acceptance Criteria Standards/IS/ BS/

ASME/ Norms and Documents

REMARKS/ SAMPLING

PLAN

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

(QAP No. TO BE ALLOTED BY MECON)

For MECON (Stamp & Signature) For CONTRACTOR / SUB-CONTRACTOR (Stamp & Signature)

No. REV.


SHEET OF CONTINUATION SHEET FORM No. 11.20(DQM) F-10 REV. 0

E Q U I P M E N T D E T A I L S INSPECTION AND TESTS

Quantity Raw Material and inprocess stage inspection Final Inspection / Test by Sl.

No.

Description (with equipment heading, place of use & brief specifications)

Identification No.

No./M T


Expected Schedule of Final Inspn. MFR CONTR. MECON MFR CONTR. MECON


submitted to Mecon



REMARKS/ SAMPLING

PLAN

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16


No. / / / E -

For MECON (Stamp & Signature)

For CONTRACTOR / SUB-CONTRACTOR (Stamp & Signature) SHEET OF

REV.




ANNEXURE-IV CONTRACTOR

ORDER No. & DATE

PROJECT

SUB-CONTRACTOR PACKAGE No.

ORDER No. & DATE

QUALITY ASSURANCE PLAN FOR

STRUCTURAL & MECHANICAL EQUIPMENT PACKAGE NAME INSTRUCTIONS FOR FILLING UP: CODES FOR EXTENT OF INSPECTION, TESTS, TEST CERTIFICATES & DOCUMENTS : 5. QAP shall be submitted for each of the equipment separately with break-up of assembly / sub-

assembly & part / component or for group of equipment having the same specification. 6. Use numerical codes as indicated for extent of inspection & tests and submission of test certificates &

documents. Additional codes & description for extent of inspection & tests may be added as applicable for the plant & equipment.

7. Separate identification number with quantity for equipment shall be indicated wherever equipment

having same specifications belonging to different facilities are grouped together. 8. Weight in tonnes (T) must be indicated under column 5 for each item. Estimated weights may be indicated wherever actual weights are not available.

ABBREVIATIONS USED : CONTR : CONTRACTOR MFR : MANUFACTURER

Code Description

1. Visual (Welding etc. ) 2. Dimensional 3. Fitment & Alignment 4. Physical Test (sample) 5. Chemical Test (sample) 6. Ultrasonic Test 7. Magnetic Particle Test (MPI) 8. Radiography Test 9. Dye Penetration Test 10. Metallographic Exam 11. Welder’s Qualification & weld

procedure Test 12. Approval of Test and Repair

procedure 13. Heat Treatment 14. Pressure Test

Code Description

15. Leakage Test 16. Balancing test 17. Vibration Test 18. Amplitude Test 19. Sponge Test 20. Dust / Water Ingress Test 21. Friction Factor Test 22. Adhesion Test 23. Performance Test / Characteristic curve 24. No Load / Free running Test 25. Load / overload Test 26. Measurement of speeds 27. Acoustical Test 28. Geometrical Accuracy 29. Repeatability & Positioning Accuracy

Code Description 30. Proving Test 31. Surface preparation & Painting 32. Manufacturer’s Test Certificates for bought out items 33. IBR / Other Statutory agencies Compliance certificate 34. Internal Inspection Report by Contractor 35. Hardness Test 36. Spark Test for Lining 37. Calibration 38. Safety Device Test 39. Ease of Maintenance

D1. D2.

D3. D4.

D5. D6. D7.

D8.

D9.

DOCUMENTS

Approved GA drawings Information and other reference drg. / stamped drgs. Released for mfg. Relevant catalogues Bill of matl. / Item No. / Identification Match mark details Line / Layout diagram Approved Erection procedures Unpriced sub P. O. with specification and amendments, if any. Calibration Certificates of all measuring Instruments and gauges

E Q U I P M E N T D E T A I L S I N S P E C T I O N AND T E S T S


No.


Identification No.

No./M T


Expected Schedule of Final Inspection MFR CONTR. MECON MFR CONTR. MECON


submitted to Mecon



REMARKS/ SAMPLING

PLAN

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

(QAP No. TO BE ALLOTED BY MECON) No.

For MECON (Stamp & Signature) For CONTRACTOR / SUB-CONTRACTOR (Stamp & Signature) SHEET OF

REV.

ISO9001 COM PAN Y



CONTINUATION SHEET FORM No. 11.20(DQM) F-09 REV. 0

E Q U I P M E N T D E T A I L S INSPECTION AND TESTS


No.


Identification No.

No./M T


Expected Schedule of Final Inspection MFR CONTR. MECON MFR CONTR. MECON


submitted to Mecon



REMARKS/ SAMPLING

PLAN

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16


No.

For MECON (Stamp & Signature)

For CONTRACTOR / SUB-CONTRACTOR (Stamp & Signature) SHEET OF

REV.

ATTACHMENT

- RO & UF PROJECTIONS - CORRECTION/NORMALISATION

CURVES - PERFORMANCE GUARANTEE - SP.CHEMICAL CONSUMPTION - SP. POWER CONSUMPTION



TECHNICAL SPECIFICATION

FOR

MECHANICAL SYSTEMS/EQUIPMENT


(i) ADECO TECHNOLOGIES MECON LIMITED

CONTENT

SL.NO DESCRIPTION PAGE NO.

1 Pretreatment system 1-4 2. Reverse osmosis system 5-15 3. Technical specification for horizontal centrifugal pumps 15-23 4. Technical specification for vertical turbine centrifugal pumps 23-35 5. Technical specification for submersible pumps 35-37 6. Technical specification for metering/dosing pumps 37-38 7. Pressure & storage vessels 38-48 8. Technical specification for agitators 48-53 9. ATTACHMENTS ANNEXURE- A

a. PUMPS DATA SHEET MEC / 10EP/ 01 / 01 / DS / 0001 1-3 MEC / 10EP/ 01 / 01 / DS / 0002 1-3 MEC / 10EP/ 01 / 01 / DS / 0003 1-3 MEC / 10EP/ 01 / 01 / DS / 0004 1-3 MEC / 10EP/ 01 / 01 / DS / 0005 1-3 MEC / 10EP/ 01 / 01 / DS / 0006 1-3 MEC / 10EP/ 01 / 01 / DS / 0007 1-3 MEC / 10EP/ 01 / 01 / DS / 0008 1-3 MEC / 10EP/ 01 / 01 / DS / 0009 1-2 MEC / 10EP/ 01 / 01 / DS / 0010 1-3 MEC / 10EP/ 01 / 01 / DS / 0011 1-3 MEC / 10EP/ 01 / 01 / DS / 0012 1-3 MEC / 10EP/ 01 / 01 / DS / 0013 1-2 MEC / 10EP/ 01 / 01 / DS / 0014 1-2 MEC / 10EP/ 01 / 01 / DS / 0015 1-2 MEC / 10EP/ 01 / 01 / DS / 0016 1-2 MEC / 10EP/ 01 / 01 / DS / 0017 1-2 MEC / 10EP/ 01 / 01 / DS / 0018 1-2 MEC / 10EP/ 01 / 01 / DS / 0019 1-2 MEC / 10EP/ 01 / 01 / DS / 0020 1-2 MEC / 10EP/ 01 / 01 / DS / 0021 1-3 MEC / 10EP/ 01 / 01 / DS / 0022 1-2 MEC / 10EP/ 01 / 01 / DS / 0023 1-3 MEC / 10EP/ 01 / 01 / DS / 0024 1-3 MEC / 10EP/ 01 / 01 / DS / 0025 1-3 MEC / 10EP/ 01 / 01 / DS / 0026 1-3 MEC / 10EP/ 01 / 01 / DS / 0027 1-3


(ii) ADECO TECHNOLOGIES MECON LIMITED

MEC / 10EP/ 01 / 01 / DS / 0028 1-3 MEC / 10EP/ 01 / 01 / DS / 0029 1-3

b. VALVES DATA SHEET MEC / 10EP/ 01 / 01 / DS / BV/01 1 MEC / 10EP/ 01 / 01 / DS / BV/02 1 MEC / 10EP/ 01 / 01 / DS / BV/03 1 MEC / 10EP/ 01 / 01 / DS / BV/04 1 MEC / 10EP/ 01 / 01 / DS / BV/05 1 MEC / 10EP/ 01 / 01 / DS / CH/06 1 MEC / 10EP/ 01 / 01 / DS / CH/07 1 MEC / 10EP/ 01 / 01 / DS / CH/08 1 MEC / 10EP/ 01 / 01 / DS / CH/09 1 MEC / 10EP/ 01 / 01 / DS / CH/010 1 MEC / 10EP/ 01 / 01 / DS / CH/011 1 MEC / 10EP/ 01 / 01 / DS / CH/012 1 MEC / 10EP/ 01 / 01 / DS / CH/013 1 MEC / 10EP/ 01 / 01 / DS / DV/014 1 MEC / 10EP/ 01 / 01 / DS / GTV/015 1 MEC / 10EP/ 01 / 01 / DS / GTV/016 1 MEC / 10EP/ 01 / 01 / DS / GTV/017 1 MEC / 10EP/ 01 / 01 / DS / GTV/018 1 MEC / 10EP/ 01 / 01 / DS / GTV/019 2 MEC / 10EP/ 01 / 01 / DS / GTV/020 1 MEC / 10EP/ 01 / 01 / DS / GTV/021 1 MEC / 10EP/ 01 / 01 / DS / GTV/022 1 MEC / 10EP/ 01 / 01 / DS / GV/023 1 MEC / 10EP/ 01 / 01 / DS / GV/024 1 MEC / 10EP/ 01 / 01 / DS / GV/025 1 MEC / 10EP/ 01 / 01 / DS / GV/026 1 MEC / 10EP/ 01 / 01 / DS / GV/027 1 MEC / 10EP/ 01 / 01 / DS / GV/028 1 MEC / 10EP/ 01 / 01 / DS / BV/029 1 MEC / 10EP/ 01 / 01 / DS / BT/030 2 MEC / 10EP/ 01 / 01 / DS / BT/031 1 MEC / 10EP/ 01 / 01 / DS / BV/032 1 MEC / 10EP/ 01 / 01 / DS / BV/033 1 MEC / 10EP/ 01 / 01 / DS / BV/034 1 MEC / 10EP/ 01 / 01 / DS / BT/035 2 MEC / 10EP/ 01 / 01 / DS / BT/036 1 MEC / 10EP/ 01 / 01 / DS / BV/037 1 MEC / 10EP/ 01 / 01 / DS / BV/038 1 MEC / 10EP/ 01 / 01 / DS / BT/039 2 MEC / 10EP/ 01 / 01 / DS / BT/040 1 MEC / 10EP/ 01 / 01 / DS / BV/041 1

c. TANKS DATA SHEET MEC / 10EP/ 01 / 01 / DS / 0050 1


(iii) ADECO TECHNOLOGIES MECON LIMITED

MEC / 10EP/ 01 / 01 / DS / 0051 1 MEC / 10EP/ 01 / 01 / DS / 0052 1 MEC / 10EP/ 01 / 01 / DS / 0053 1 MEC / 10EP/ 01 / 01 / DS / 0054 1 MEC / 10EP/ 01 / 01 / DS / 0055 1 MEC / 10EP/ 01 / 01 / DS / 0056 1 MEC / 10EP/ 01 / 01 / DS / 0057 1 MEC / 10EP/ 01 / 01 / DS / 0058 1 MEC / 10EP/ 01 / 01 / DS / 0059 1 MEC / 10EP/ 01 / 01 / DS / 0060 1 MEC / 10EP/ 01 / 01 / DS / 0061 1 MEC / 10EP/ 01 / 01 / DS / 0062 1 MEC / 10EP/ 01 / 01 / DS / 0063 1 MEC / 10EP/ 01 / 01 / DS / 0064 1 MEC / 10EP/ 01 / 01 / DS / 0065 1 MEC / 10EP/ 01 / 01 / DS / 0066 1 MEC / 10EP/ 01 / 01 / DS / 0067 1 MEC / 10EP/ 01 / 01 / DS / 0068 1 MEC / 10EP/ 01 / 01 / DS / 0069 1

d CARTRIDGE FILTER DATASHEET MEC / 10EP/ 01 / 01 / DS / 0100 1

e PRESSURE VESSEL DATA SHEET MEC / 10EP/ 01 / 01 / DS / 0101 1 f MX - STATIC MIXTURES DAT SHEET

MEC / 10EP/ 01 / 01 / DS / 0102 1 MEC / 10EP/ 01 / 01 / DS / 0103 1 MEC / 10EP/ 01 / 01 / DS / 0104 1

g REMINERALISATION AREA DATA SHEET MEC / 10EP/ 01 / 01 / DS / 0105 1 MEC / 10EP/ 01 / 01 / DS / 0106 1 MEC / 10EP/ 01 / 01 / DS / 0107 2 MEC / 10EP/ 01 / 01 / DS / 0108 2 MEC / 10EP/ 01 / 01 / DS / 0109 1 MEC / 10EP/ 01 / 01 / DS / 0110 2

h DISC FILTER DATA SHEET MEC / 10EP/ 01 / 01 / DS / 0111 1-4 i ULTRA FILTER DATA SHEET MEC / 10EP/ 01 / 01 / DS / 0112 1-6 j PRESSURE EXCHANGER DATA SHEET MEC / 10EP/ 01 / 01 / DS / 0113 1-4

k RO MODULES DATASHEET MEC / 10EP / 01 / 01 / DS / 0114 1 MEC / 10EP / 01 / 01 / DS / 0115 1 MEC / 10EP / 01 / 01 / DS / 0116 1

ANNEXURE-B TECHNOLOGICAL EQUIPMENT LIST 1-12


Page 1 of 53 ADECO TECHNOLOGIES MECON LIMITED

1.00 PRE-TREATMENT SYSTEM 1.01 GENERAL

This subsection describes general guidelines and technical requirements of various equipments that shall be used in Pre-treatment systems. Type of equipment and its minimum design parameter that shall be considered for this project is specified in “Technical Data Sheets” enclosed in this Technical Specification.

1.01 FILTERS

The type of filters to be employed for the project is indicated in “Technical Data Sheets” (annexure –A) enclosed in this technical Specification. The technical features of various types of filters are given below.

i) Sedimentation Basin (SB-102) a) Number of filters, design capacity, size and material of

construction shall be as described in equipment list with specification (annexure B) enclosed in this Technical Specification.

b) The filtering medium shall be washed, screened and hydraulically

graded sand .Details of various layers should be as follows:

i) The upper bed consists of 12 to 50 mm washed gravel of 300 bed height.

ii) Below of this, the middle layer consists of 1 -2mm quartz sand with uniformity coefficient 1.4 to 1.7 & sphericity 0.8 of 2500 bed height.

iii) The bottom most layer is 6-12 mm of washed gravel of 2200 mm bed height.

c) Sand shall have the following properties:

i) Sand shall be of hard and resistant quartz or quartzite and free of clay particles, soft grains and dirt of every description. Effective size shall be 0.45 to 0.70 mm.

ii) Uniformity coefficient shall not be more than 1.7 or less than

1.3 iii) Ignition loss should not exceed 0.7 per cent by weight.



iv) Soluble fraction in hydrochloric acid shall not exceed 5.0% by

weight. v) Silica content should not be less than 90%. vi) Wearing loss shall not exceed 3%. vii) Specific gravity shall be in the range between 2.55 to 2.65. viii) Sand should be clean and well graded. Filter sand shall have a

HCL solubility of less than 5% when tested in accordance with AWWA B 11.53.

ix) Dust content (passing 150 mesh Tyler screen) shall be less

than 0.5%. ii) AUTOMATIC BACKWASHABLE DISC FILTERS

Automatic back washable disc filter sets dedicated to each UF skid is provided for pre-treatment of sea water before ultrafiltration. Each unit/set of disc filter (DF-201-1-30) has 4 elements with filter diameter 6” and 100 micron rating. The filtration cut off disc filter elements is 100 microns. The element & housing material is PP. The disc filters shall designed for sequential operation including automatic backwash on preset time as well as forced backwash on high differential pressure and should be timed with filtration sequence of UF skids. Common Backwashing pumps and backwash water tank will be provided for disc filters for automatic backwashing. Backwashing frequency is 30- 60 min (adjustable) and the duration of backwash is 10 – 20 seconds. The back wash time is adjusted based on the load of suspended solids in the feed and frequency is adjusted based on the test conducted during daily operation. Arkal or Amiad make is preferred

iii) ULTRA FILTRATION

The UF skids shall be capable of handling feed turbidity range of 3 -40 NTU and total suspended solid range of 18 – 200ppm. The filtered water is pumped by vertical pumps to UF skids for removal of all colloidal suspended solids including bio-organisms. The vertical UF membranes has in to out or out to in, cross flow filtration features and is hollow fibre, pressurized membrane system to achieve an SDI (silt density index) < 3 and turbidity less



than 1NTU of RO feed (UF permeate). The ultra filtration membrane elements, housed in vertical PVC housing shall be designed to have design membrane flux range of 50- 65 litre/m2h and 4 no of UF train per 1 skid / set /stream is envisaged. Each skid shall be designed for nominal feed rate of 365 cum/hr at 2-2.5 bar. Pressurised UF poly ether sulphone/PVC, in to out/out to in hydrophilic membranes having filtering pore size 0 .05 micron (100000 to 150000 daltons) has been envisaged. The UF permeate obtained from each skid shall be 328.5 cum/hr (90% recovery), totaling to net UF permeate 9255 cum/hr (for 30 skids) is led to UF product cum backwash tank. The UF permeate is led to aboveground UF product cum backwash tank. The anticipated recovery of UF membranes is 90% minimum. A part of the UF permeate is used for preset sequential cyclic backwashing and fast flushing of UF membranes. Variable frequency drive backwashing pumps are envisaged for UF back washing. UF permeate shall be used as UF backwash wherein chlorine addition shall be done at the UF backwash pump discharge. The backwash & concentrate of UF system is led to brine/RO reject storage tank for onward disposal (onward pumping into reject outfall marine pipeline). Chemical cleaning system is also envisaged to be carried out through backwashing system.

Each UF skid is provided with pressure regulating valve, pressure transmitter, flow transmitter & flow control valve. Each trains of UF skids shall be provided with flow meter for the product and concentrate, pressure transmitters, pneumatic butterfly valves for feed, product, backwash inlet, concentrate outlet, backwash outlet, flushing inlet & flushing/backwash for automatic sequential operation (backwashing, fast flushing cycles) through the centralized DCS system. Manual butterfly valves can be considered for CIP (clean in place) inlet, CIP return valves. Oil free plant air at 5-6 bar shall be provided by the purchaser at the battery limit to the UF skid building. Sample points at the UF permeate outlet header of each skid shall be provide for SDI measurement through portable SDI kit. Online SDI measuring instrument is envisaged at the common outlet header of UF skids.

iii) Cartridge filters a) Number of filters, design capacity and material of construction

shall be as described in “Technical Data Sheets & equipment list with specification ”(Annexure A&B) enclosed in this Technical Specification



b) For the feed water, cartridge filter vessels shall have a capacity sufficient to hold the required number and size of the cartridge elements to filter.

c) Extent of filter fouling shall be identified from differential pressure

drop. Maximum allowable pressure drop shall be 0.8 kg/cm2. Cartridge vessel shall be provided with pressure relief valve, drain valve and vent valve.

d) The filter elements shall be cylindrical cartridges constructed from

continuously wound polypropylene fibres, which have a 5 micron nominal 90% efficient rating. The filter elements used in the membrane cleaning system shall be identical to the filter elements used to treat the RO feed water.

e) Cartridge shall be self-supporting with no reinforcing structures or

resins.

f) Polypropylene material shall be 100% polypropylene with no binders, resins lubricants or other residue from the manufacturing process. The polypropylene material shall be FDA approved for potable water usage.

g) The filter vessel shall be designed in accordance with ASME

boiler and pressure vessel code section VIII, division I. h) The cartridge filter vessel, cover, internals and all wetted parts

shall be fabricated of Duplex stainless steel material. i) Each vessel shall have type SS316L swing bolts and Xylan coated

nuts on the cover closure. j) Each vessel shall have a cover gasket with Buna N O rings. The

vessel shall be provided with both clean and dirty water drain nozzles, as well as an air vent at the top.

k) Each vessel shall be provided with a cover-lifting davit

arrangement capable of lifting the cover and swinging it to the side.

l) A flanged inspection port shall be installed on the clean side

plenum 90 degree from the inlet centreline.



2.00 REVERSE OSMOSIS SYSTEM 2.01 GENERAL

This subsection describes various equipment that are generally used in Reverse Osmosis Plant/ systems . Type of equipments to be used/applicable for this project is specified in “Technical Data Sheets” enclosed in this Technical Specification.

2.02 REQUIREMENTS OF RO PLANT

a) Data regarding number of RO/SWRO streams/ trains, capacity of each stream/train, number of working and standby streams/trains, recovery of RO plant etc shall be as specified in “Technical Data Sheets”(Annexure A) enclosed in this Technical Specification.

b) Treated and filtered sea water from Pre-treatment shall be fed to

the RO plant at the suction of the High-pressure feed pump. The high-pressure pump pressurizes and feeds the water it to the membrane assembly unit.

c) Train/stream of SWRO Plant shall comprise a set of high pressure

pump, associated Energy Recovery unit and the membrane element assembly.

d) The type of energy recovery unit to be provided is specified in

“Technical Data Sheets” enclosed in this Technical Specification

e) Each RO stream shall be provided with a dedicated HP pump. Each HP pump with its drive motor shall be mounted on a single base frame and a Pressure exchanger (PX) alongside with it. The HP pump shall be able to discharge brine against a backpressure without the need for additional pumping equipment. The discharge pressure and flow the HP feed pump shall be controlled to regulate the feed pressure to the membrane assembly according to the salinity of the feed water through a variable frequency control envisaged for each HP pump. The HP pump and Energy Recovery Energy units comprising of pressure exchanger and variable frequency drive PX booster pumps shall be designed to operate in the entire range of operation of the feed system. As pressure exchanger is being used for energy recovery, the PX booster pump shall be installed in parallel with main HP pump.

f) Filtered sea water shall be pressurized so that part of it is driven



through a semi permeable membrane, whereby the required driving force must exceed the osmotic pressure of the brine. Brine leaving the permeate outlet connection at a pressure close to the 1 bar after energy recovery shall be controlled by a pressure control valve. The permeate water is discharged to product water system, post treated for positive LSI, correction of pH, correction of alkalinity (for potabilisation) , degassed for removal of excess CO2 etc and stored. Stored product water is then transported to the consumption destination by product water system.

g) Permeate shall be delivered to respective dedicated Suck-back arrangement so that in the event of shut down of the RO/SWRO units, sufficient quality of product water is to be provided at the product effluent side of the train out of operation to enable the product backflow (product draw-back) from the permeate side to the brine side of the membranes, preventing deterioration of the membranes.

h) Chemical cleaning and automatic flushing systems by suck back tanks shall be provided for membrane protection. While the chemical cleaning system facilitates cleaning of the fouled membranes and the flushing system flushes the membranes off High TDS water with low TDS water during shutdown operation.

i) SWRO train or stream shall be a self contained section, with its own

feed, brine and product flow control equipment, operable through control system from the control room. Each train /stream shall be cleaned and treated separately, independent of other trains/streams production.

j) A train/stream is composed of one or more blocks (membrane

assembly unit) connected in parallel and each block comprises a group of modules in parallel. Each RO module is basically a cylindrical pressure vessel containing membrane elements. The term element means a single RO membrane element (permeator). Each block (membrane assembly unit) shall be provided with necessary valves and piping to facilitate block wise isolation, monitoring and cleaning facility.

k) Minimum service life of Membrane, guaranteed recovery and

availability factor of SWRO units are specified in the Technical Specification and datasheets.

l) Design feed water quality, permeate water quality, capacity of each



SWRO train/stream, capacity of RO train/stream and number of SWRO streams are specified in relevant chapters & clauses of the technical Specification chapter 1 of volume IIA.

m) All wetted parts in the plant shall be constructed with suitable corrosion resistant material compatible with the fluid handled.

2.02.01 RO MEMBRANE ASSEMBLY

a) Each stream shall be capable of operating either independently or in combination with the other ones. The streams shall be skid-mounted and be furnished complete with all headers and related piping, mounted on the skid. The skid shall contain all necessary supports, fixings and clamps required to support the permeators, headers and related piping. The skid shall be designed to provide ample room for servicing and monitoring the equipment. The removal of a single permeator or a major piece of the equipment must be possible, without removing surrounding equipment. The isolation or removal of an individual permeator for testing or servicing shall be possible while the RO-train is in operation, by means of flexible, self-closing couplings.

b) The contractor may divide a stream train into certain number of

equal blocks which independently can operate facilitating the following advantages:

i) Repair/maintenance of permeators/pipes/valves and chemical

cleaning in a particular block can be carried out without shutdown of the whole stream.

ii) For easier performance monitoring of permeators, simpler fault

identification to render permeators replacement activities easier. 2.02.02 RO MEMBRANE

a) The Reverse osmosis membrane shall be sea water membranes, spiral wound type. The membrane shall be non-telescopic, non flexing and leak free.

b) The SWRO/RO membranes shall be procured from manufacturers

well experienced in RO plant design (SWRO or brackish water RO as the case may be) of train/stream capacity comparable to that of this project. This shall be demonstrated by the contractor with adequate references of his selected membrane manufacturer(s). He also shall include a design calculation of the RO plant by his



preferred manufacturer(s). The membranes provided for the RO process of this project shall be one of the following membrane manufactures: Dow – Filmtec, Hydranautics, KOCH membranes and Toray.

Salt rejection of each SWRO membrane shall be minimum 99.6 to 99.75 %. Boron rejection required from the membranes is 80-90%.

c) The membrane system process design shall be provided by the

contractor and such calculations shall be vetted by the membrane manufacturer. The process design shall take into consideration specified fouling allowance i.e average flux decline per year (7% per year) and salt passage (7 to 10 % per year) during the guaranteed (specified) life of the membrane.

The process design shall ensure the specified capacity of permeate with an average flux rate as specified in data sheet MEC/10EP/01/01/DS/0114 ( in Annexure –A of this chapter)

d) The average flux rate shall be calculated on the basis of effective

membrane area considering standard length (40”) and diameter (8”) of the element. Average system design flux rate shall not be more than 19 liters/m2/hr. Standard length and diameter of membrane used for design should be available from at least three manufacturers to deliver water of specified quality so that Purchaser may install membranes from other manufacturers during operation stage of the plant. The design calculation shall furnish data regarding change in parameters of the SWRO plant such as design net output, recovery, energy consumption etc in case such alternative membranes are used later by Purchaser in the membrane assembly supplied by the contractor.

e) The minimum recovery per element shall be 8% and average

permeate flow per element shall be 16 to 22 m3/day. e) The SWRO trains shall be designed so that the membrane

element life is average 5 years f) For the designed sea water quality and the permeate water

capacity required, the SWRO plant and/or RO Plant shall be designed, tested to perform and guaranteed to have an undiminished overall recovery of value as specified in this Technical Specification.

g) Normalisation of performance during operation of the RO plant

with respect to variation in temperature, fouling at various design feed TDS shall be made using membrane manufacturers software



& graphs supplied as a part of the system. The exact methodology for the normalization of capacity shall be submitted by the membrane manufacturer and approved by the Purchaser/Consultant and made a part of the warranty.

2.02.03 PRESSURE VESSELS

a) Pressure vessels shall have a diameter and length so as to contain required numbers of standard diameter, standard length spiral wound elements.

b) Materials to be selected shall meet the following minimum

requirements:

SL.NO. ITEM MOC

i) Membranes

As per manufacturer

ii) Pressure vessels FRP iii) End caps or plates Non-metallic material of proven reliability may

also be used subject to approval; Flibre glass epoxy as minimum requirement.

iv) Segmental rings, connectors Fasteners & other wetted parts

Corrosion resistant material conforming to(Sea Water & Brine) ASTM A312 S31254 / ASTM A 744 CN3MN ASTM A995 Gr 5A / ASTM A1049 F56/F57/ ASTM 890 Gr 5A/ ASTM A182 F44 or ASTM A 473 S3260 (depending on form of product used) or equivalent

c) Details of the design, fabrication and testing requirements for the pressure vessels shall be in accordance with ASME Section X to allow a code stamp, or meet the minimum requirements of ASME Section X. However, manufacturer’s standard is acceptable under following condition:

i) Hydro test: pressure as per ASME section X ii) Microscopic test to be done at random samples after hydro test to

detect hairline cracks. d) Vessels shall be designed to allow membrane elements to be

connected to a permeate port at both ends of the vessel so that permeate can be taken from either ends. The unused pressure vessel permeate port shall be available and piped to permit



probing. End closures shall be approved for use in pressure vessel construction to the code requirements.

2.02.04 HIGH PRESSURE PUMP AND ENERGY RECOVERY UNITS

a) The HP feed pump shall be of a horizontal multistage opposed impeller, volute type with axial/radially split casing type having a variable frequency drive. During operation, the energy recovery unit along with the booster pump (variable frequency drive) provides part of the flow and rest is by the high pressure pump (variable frequency drive). The high-pressure pump shall be designed not to introduce flow and/or pressure pulsation in the feed or brine stream. The reverse osmosis system has to be operated with fluctuating feed salinity and feed temperature. An appropriate regulation of the feed pressure for each reverse osmosis train separately by a corresponding design of the high-pressure pumps and automatic feed pressure control through variable frequency drive is required. Number of high pressure pumps, booster pumps and energy recovery units shall be same as that of number of RO Streams / trains plus three common standby, one each for four RO trains .

b) Selection of parameters (capacity and head) of HP Pump, its drive

and associated Energy Recovery Units shall take into account requirements of membrane manufacturer and shall be designed to deliver required parameters throughout the design life of membrane. The power consumption to be guaranteed for the HP Pump shall be based on its parameters at the end of guaranteed membrane life.

c) The contractor shall take care of the concentrate back pressure

requirement at downstream of the energy recovery unit. d) Twin Isolation valves around the high pressure pumping and

energy recovery system shall be provided. e) The material of construction of high-pressure RO-feed pumps

shall be as defined/specified in “Technical Data Sheets” of annexure A of this chapter.

f) The complete unit shall include the pump, motor drive and the

lubrication system on a common base plate.



g) Maximum pump speed shall be 3000 rpm. Each pump shall be designed for full capacity of each service. The minimum pump running clearance shall be in accordance with API 610.

h) Type and arrangement:

All pump/turbine units shall be mounted horizontally above ground level. All runners or impellers shall be dynamically balanced. All units shall be equipped with lifting eyes or bolts or facilitate handling.

i) Bearing: Hydrodynamic thrust bearing / hydrostatic bearings shall

be capable of safely absorbing all static, dynamic and maximum possible hydraulic forces.

j) Sealing: Mechanical seal of approved type shall be used.

Selection of the seal/ suitability for the process shall be the responsibility of the contractor.

k) Lubrication and cooling: Each of the pumps/turbocharger units

shall be fitted with an independent lubrication system suitable for the type of operation associated with automatic switch in. To cool the lubricating oil, bearing cooling system shall be available.

l) Couplings(Guards) : Couplings guards shall be furnished. The

guards shall be rigidly fixed over the coupling and shall be easily detachable.

m) Motor: The motor power shall cover the maximum required

torques of the complete unit during start up and all operating conditions. The design margin of motor rating to be provided shall be as per the subsection titled “Pumps” in this Technical Specification and electrica (power distribution and shop electrics) specification chapter 3 & 4 of volume II B. The motor shall be variable frequency drive in order to take care of the salinity fluctuations, temperature and fouling factor changes.

n) Operation: All pumps/ERD (Energy Recovery Device) units shall

be suitable for continuous operation without shutdown over their entire range of capacities and heads.

o) The pump/turbo-charger units shall be free of vibration and shall

withstand all stresses that may develop throughout their entire operational ranges as well as stresses due to starting the stopping. The units shall be designed to eliminate the occurrence of cavitations at all normal operating conditions.



p) Tensional analysis (in accordance with API 610) shall be

performed for the complete train comprising the HP pump, ERD and motor. Excitation of frequencies in accordance with API 610 shall be evaluated.

2.02.05 PX BOOSTER PUMP AND PRESSURE EXCHANGER

a) In the case where pressure exchanger is considered for energy recovery, the main HP Pump shall be designed to deliver part of the total flow required and the rest of the flow shall be met by the PX booster pump installed in series with the pressure exchanger and parallel with the main HP pump. The booster pump shall boost the pressure of the outlet flow by 3 bar pressure so as to meet the pressure of the HP pump. The booster is required to boost the difference in pressure that occurs at the outlet of high pressure side of pressure exchanger due to some losses in pressure in pressure exchanger. The PX booster pump shall also have a variable frequency drive for flow and pressure control as required. Number of PX Booster pump and PX (pressure exchangers) array units shall be same as that of number of RO Streams / trains plus one common standby.

b) The PX booster pump shall be designed to make up the losses in

the permeator, piping up to the pressure exchanger and the losses in the pressure exchanger. The motor shall be variable frequency drive in order to take care of control in the high pressure pumping and energy recovery system.

c) The main pump shall be designed to make up the small losses in

brine flow. d) Maximum pump speed shall be 1500 rpm. e) Selection of parameters (Capacity & Head) of booster pump, its

drive& associated Energy Recovery Units (PX) shall take into account requirements of membrane manufacturer and shall be designed to deliver required parameters throughout the design life of membrane. The power consumption to be guaranteed for the PX Booster shall be based on its parameters at the end of guaranteed membrane life.

f) The pressure exchanger shall be of proven design, with minimal

moving parts and negligible losses.



g) The PX booster pump shall be of single / multistage centrifugal pump with independent motor drive. The material of construction of the pump shall be similar to the Main high pressure pump.

h) Each of the RO train shall be provided with bank of PX units by

arraying multiple PX units. i) The pressure exchanger rotor shall be constructed with corrosion

and wear resistant ceramic internal components. The pressure vessel housing shall be of Epoxy/glass reinforced (FRP) construction. All high pressure fittings shall be of corrosion resistant Duplex stainless material.

j) Selection of parameters of Pump & its drive shall take into account

requirements of membrane manufacturer and shall be designed to deliver required parameters throughout the design life of membrane

h) The pressure exchanger (PX) shall be provided with required

instruments like flow control valve at the low pressure sea water inlet, pressure control valve at the low pressure brine out let and flow transmitters at the high pressure sea water outlet as shown in P&ID drg MEC/10EP/01/01/PID/0006.

2.02.06 PERMEATE TRANSFER PUMPS

a) Permeate water from the RO trains shall be discharged to a suck back tank mounted on the top of the structure of each RO skid. The material of construction of suck back tank shall be FRP. The diameter of each suck back tank shall be 1500 mm and length (7.5 m) shall be same as RO skid. Net capacity of each suck back tank shall be 13 m3. The head of the permeate booster pump shall be as per the technical datasheet. The permeate booster pumps shall pump the permeate from the suck back tanks to the permeate storage tanks. Number of permeate booster pumps (permeate booster pumps) shall be same as that of number of RO Streams / trains plus three standby having similar configuration for high pressure pumping system.

b) The material of construction of these pumps shall be as specified

in data sheet MEC / 10EP/ 01 / 01 / DS / 0019 of annexure –A of this chapter.



2.02.07 CHEMICAL CLEANING SYSTEM (CIP)

a) The cleaning system shall be designed for cleaning and sterilizing of minimum one train of the RO system separately.

b) The RO-plant shall be provided with fixed type installed inside RO

building and fixed piping connections. The interconnections from the cleaning pipe work to the RO-trains shall be reached from the ground level, or sufficient and safe operating platform facilities for easy handling of the coupling of the permanently installed cleaning pipe work at the RO-racks and the fixed cleaning pipe work of the cleaning equipment provided.

d) The cleaning system shall be of fixed type and comprise all

necessary equipment for control of the necessary flow rate and pressure during cleaning and enable the recycling of brine and product to the cleaning tank, or alternatively, the discharge of these two effluents during the cleaning procedure.

e) The tank volume shall be sufficient to clean in minimum one RO

train/stream by utilization of only a single batch of cleaning solution.

f) Sizing considerations also shall include the minimization of batch

temperature and variation in solution concentration caused by blending cleaning solution with displaced feed water contained in the RO permeators.

g) One set of 5 micron cartridge filter shall be provided in the

cleaning system to prevent the reintroduction of any insoluble material into the membranes. A temperature control system shall be provided to prevent re-circulated fluid temperature from exceeding the maximum recommended operating temperature of the membrane.

h) The cleaning tanks shall be provided with level measurement for

safe operation i.e. tripping of cleaning system pumps under low water level.

i) For easy, safe and efficient handling of chemicals, a service

platform shall be provided if necessary. Sufficient venting equipment shall also be included in the scope of supply. Sufficient safeguard provisions shall be included, to prevent accidental over pressurization of cleaning system piping due to inherent interconnections with high pressure RO feed and brine piping.



j) Provisions must be made for the neutralization and disposal of chemical cleaning waste via the brine reject.

k) The material of construction of these pumps shall be as specified

in technical data sheets (annexure –A ) of this chapter. 2. 02.08 PIPING & VALVES

The Technical requirement of piping, Valves & fittings shall be as per chapter 5 of volume II A.

2.02.09 Air Blowers for Filters

Number of air blowers to be provided for air scouring of lime dissolution filter bed shall be as specified in “Technical Data Sheets” (annexure –A of this chapter) enclosed in this Technical Specification. Blower shall be a positive displacement twin lobed rotary blower. The blower shall be V-belt or directly coupled with electric motor. The blowers shall be oil free type. The blower casing shall be of one-piece construction with separate head plate and shall be made of close-grained cast iron suitably ribbed to prevent distortion under the specified operating conditions. Impellers shall be made of ductile iron and shall be of straight twin-lobed type and shall operate without rubbing or liquid seals or lubrication. The blower shaft shall be of alloy steel forging and shall be flanged attached to the impeller with high tensile strength cap screws. Each blower assembly shall be furnished with 97% down to one (1) micron inlet filters, inlet and exhaust silencers, and check valve at discharge, EPDM flexible connectors, and spring loaded pressure relief valves.

3.0 TECHNICAL SPECIFICATION FOR HORIZONTAL CENTRIFUGAL PUMPS

3.1 SCOPE 3.1.1 The specification covers general requirements in respect of design,

material, constructional features, manufacture, inspection, testing the performance at the Vendor’s/ Sub-Vendor’s works and delivery to site erection, field testing and commissioning of Horizontal Centrifugal Pumps.

3.2 CODES AND STANDARDS

The design, material, construction, manufacture, inspection and



performance testing of Horizontal Centrifugal Pumps shall comply with all currently applicable statutes, regulations and safety codes in the locality where the equipment will be installed. The equipment supplied shall comply with the latest applicable Indian standards listed below. Other National Standards are acceptable, if they are established to be equal or superior to the Indian Standards.

3.2.1 List of Applicable Standards

i) IS : 5120 -Technical requirements of rotodynamic special purpose pumps

ii) API – 610 -Centrifugal pumps for general refinery service. iii) IS : 5639 -Pumps Handling Chemicals & corrosion liquids. iv) IS : 5659 -Pumps for process water v) Hydraulic Institute Standards ; USA vii) ASTM-I-165-65-Standards Methods for Liquid Penetration

Inspection. 3.2.2 In case of any contradiction with aforesaid standards and the stipulations

as per the technical specifications as specified hereinafter, the stipulations of the technical specifications shall prevail.

3.3 DESIGN REQUIREMENTS 3.3.1 Specific requirements of High Pressure Feed pumps are described in

datasheets (annexure A of this chapter enclosed with this specification) & relevant part of the technical specifications.

3.3.2 The pump shall be capable of developing the required total head at rated

capacity for continuous operation. Also the pumps shall be capable of being operated to give satisfactory performance at any point on the H-Q characteristics curve over the operating range. Operating range for operation of pumps shall generally be 40% to 120% of rated flow for sustained period of operation. The maximum efficiency of pumps shall be preferably be within + 10% of the rated design flow indicated in data sheets enclosed.

3.3.3 The total head capacity curve shall be continuously rising from the

operating point towards shut – off without any zone of instability with the highest head at shut-off condition. Shut-off head shall be more than the rated design head and the percentage variation may vary depending on the specific speed of the pumps (i.e) 10-15% for pumps of specific speed upto1000 US units, about 15 to 20% for specific speed in the range of 1000 to 2000 US units, about 20% to 40% for specific speed of 2000 to 4000 US units and above 50% for specific speed of 4000 to 7000 US Units.



3.3.4 Pumps of a particular category shall be identical and shall be suitable for

parallel operation with equal load division. The head Vs capacity and BHP Vs capacity characteristics should match to ensure even load sharing and trouble free operation throughout the range. Components of identical pumps shall be interchangeable.

3.3.5 Pumps shall run smoothly without undue noise and vibration. Peak to

peak vibration limits shall be restricted to the following values during operation or as per Hydraulic institute Standards, as the case may be whichever is lower: -

Speed Antifriction bearing Sleeve bearing 1500 rpm and below 75.0 micron 75.0 micron 3000 rpm 50.0 micron 65.0 micron

3.3.6 The noise level shall not exceed 85 dBA at a distance of 1M from the

equipment surface. 3.3.7 The pumps shall be capable of starting with discharge valve fully open

and closed conditions. Motors shall be selected to suit to the above requirements.

3.3.8 Pumps shall be so designed that pump impellers and other accessories of

the pumps are not damaged due to flow reversal. 3.3.9 The contractor shall assume full responsibility for the operation of pump

and motor as a unit. 3.4 DESIGNS AND CONSTRUCTION 3.4.1 Design and construction of various components of the pumps shall conform

to the following general specifications. For material of construction of the components, data sheets shall be referred to.

3.4.2 Pump casing a) Casing shall have axially or radially split type construction. The casing shall

be designed to withstand the maximum shut – off pressure developed by the pump at the pumping temperature.

b) Pump casing shall be provided with a vent connection and piping with fittings& valves Casing drain as required shall be provided complete with drain valves, piping and plugs. It shall be provided with a connection for



suction and discharge pressure gauge as standard feature. It shall be structurally sound to provide for the pump assembly and shall be designed hydraulically to minimum radial load at part load operations.

3.4.3 Impeller

a) Impeller shall be closed or semi-closed as specified elsewhere and designed in conformance with the detailed analysis of the liquid being handled.

b) The impeller shall be secured to the shaft, and shall be retained

against circumferential movement by keying, pinning or lock rings. 3.4.4 Impeller/ Casing Wearing Rings

Replaceable type wearing rings shall be provided at suitable locations in the pumps as per the manufacturer’s standard practice. Suitable method of locking the wearing ring shall be used.

3.4.5 Shaft

a) The critical speed shall be well away from the operating speed and in no case less than 130% of the rated speed.

b) The shaft be ground and polished to final dimensions and shall be adequately sized to withstand all stresses from rotor weight hydraulic loads, vibration and torque coming in during operation.

c) The shaft shall be ground and polished to final dimensions and

shall be adequately sized to withstand all stresses from rotor. 3.4.6 Shaft Sleeves

a) Renewable type fine finished shaft sleeves shall be provided at the stuffing box beyond the outer faces of gland packing of seal and plates so as to distinguish between the leakage between shaft and shaft sleeve and that past the seals/ gland.

b) Shaft sleeves shall be fastened to the shaft to prevent any leakage

or loosening. Shaft and shaft sleeve assembly should ensure concentric rotation.

3.4.7 Bearings



a) Heavy duty bearings, adequately designed for the type of service specified in the enclosed pump data sheet and for long, trouble -free operation shall be furnished.

b) The bearings offered shall be capable of tanking both the radial and axial thrust coming into play during operation. In case, sleeve bearings are offered additional thrust bearings shall be provided. Anti-friction bearings of standard type, if provided, shall be selected for a minimum life 16,000 hrs. of continuous operation at maximum axial and radial loads and rated speed.

c) Proper lubricating arrangement for the bearings shall be provided

such that lubricating element does not contaminate the liquid pumped. Where there is a possibility of liquid entering the bearings, suitable arrangement in the form of deflectors or any other suitable arrangement must be provided ahead of bearing assembly.

d) Bearings shall be easily accessible without disturbing the pump

assembly. A drain plug shall be provided at the bottom of each bearing housing.

3.4.8 Stuffing Boxes

Stuffing boxes of packed ring construction type shall be provided wherever specified. Packed ring stuffing boxes shall be properly lubricated and sealed as per service requirements and manufacturer’s standard. If external gland sealing is required, it shall be done from the pump discharge. The contractor shall provide the necessary piping, valves, fitting etc. for the sealing connection.

3.4.9 Mechanical Seals

a) Wherever specified in pump data sheet, mechanical seals shall be provided. Mechanical seals shall be single type with either sliding gasket or bellows between auxiliary moving face and shaft sleeves or any other suitable type. The sealing face should be highly lapped surfaces of material known for their low frictional co-efficient and resistance to corrosion against the liquid being pumped.

b) The pump supplier shall coordinate with the seal maker in establishing the seal chamber of circulation rate of maintaining a stable film at the seal face. The seal piping system shall form on



integral part of the pump assembly. For the seals under vacuum service, the seal design must ensure sealing against atmospheric pressure even when the pumps are not operating. Necessary provision for seal water supply along with complete piping, fittings and valves as required shall form integral part of pump supply.

3.4.10 Pump Shaft Motor Shaft Coupling

The pump and motor shaft shall be connected with an adequately sized flexible coupling of proven design with a spacer to facilitate dismantling of the pump without disturbing the motor. Necessary coupling guards shall be provided.

3.4.11 Base Plate

A common base plate mounting both for the pump and motor shall be furnished. The base plate shall be of fabricated steel and of rigid construction, suitably ribbed and reinforced. Base plate and pump supports shall be constructed and the piping unit so mounted as to minimise misalignment caused by mechanical forces such as normal piping strain, internal differential thermal expansion and hydraulic piping strain, internal differential thermal expansion and hydraulic piping thrust. Suitable drain troughs and drip lip shall be provided.

3.4.12 Assembly and Dismantling

Assembly and dismantling of each pump with drive motor shall be possible without disturbing the grouting of base plate or alignment.

3.4.13 Drive Motor (Prime Mover)

Continuous Motor rating (at 50 0 C ambient) shall be at least ten percent (10%) above the maximum load demand of the pump in the entire operating range to take care of the system frequency variation and in no case less than the maximum power requirement at any condition of the entire characteristic curve of the pump. The kW rating of the drive unit shall be based on continuously driving the connected equipment for the conditions specified. However, in cases where parallel operation of the pumps are specified, the actual motor rating is to be selected by the contractor considering overloading of the pumps in the event of tripping of operating pump(s). The motor shall be as per the electrical technical specification vol. II

3.5 Vendor data to be Furnished by the contractor for each pump

i) Guaranteed design capacity cum/hr. :



ii) Guaranteed Total Head at design capacity in mWC : iii) Shut off head of the Pump (mWC) : iv) Rated Speed, r.p.m. : v) Pump Efficiency at design capacity, % : vi) Pump input Power at design capacity, in kW. : vii) Power consumption at duty point, at motor terminals, KW (Guaranteed) : viii) Maximum capacity upto which pump can be operated satisfactorily : ix) Minimum Capacity upto which pump can be operated satisfactorily : x) Maximum power consumption at motor terminals in the pump operating range : xi) Minimum Power Consumption at motor terminals in the operating range : xii) Pump input power at shut off head (KW) : xiii) Power consumption at motor terminals at shut off head (KW) : xiv) Pump input power at run-out flow (KW) : xv) Guaranteed noise level (dBA) : xvi) Guaranteed vibration level at motor top : xvii) NPSH required xviii) Motor Rating (at 50 deg C)- in KW : xix) Impeller type and design : Open / Semi-open/

closed xx) Material of construction



a) Casing : b) Impeller : c) Wearing rings or equivalent part : (Indicate the name of the Part) d) Pump shaft : e) Shaft coupling : f) Shaft sleeve : g) Matching flanges : h) Bolts, nuts : i) Base Plate

: j) Gaskets : k) Gland packing :

3.6 PAINTING

The requirements of painting shall conform to the detailed descriptions in the “Painting” chapter -7 of volume IIA

3.7 FIELD PERFORMANCE TESTS

After installation, the pumps offered shall be operated to prove satisfactory performance as described in the technical specification and respective manufacturing design and testing standards and codes.

3.7.1 PERFORMANCE GUARANTEE TESTS 3.7.1.1 Performance tests shall be carried out in two stages. After

manufacture of the pump, the first prototype pump shall be tested at shop and performance shall be verified.

3.7.1.2 After installation of all the pumps and completion of initial

operation/trial operations the second stage of performance test shall be conducted at site.



3.7.1.2.1 The detailed performance tests for shop and site shall be as per the

clause 4.6 of this chapter. 4.0 Technical Specification for Vertical Centrifugal Turbine Pumps 4.0 GENERAL 4.0.1 This specification covers the design, engineering, manufacture, shop

fabrication, testing at works, transportation to site, unloading and storage at site, fabrication at site, erection, testing and commissioning of Vertical Turbine pumps.

4.1 CODES AND STANDARDS 4.1.1 The design, manufacture, inspection and testing shall comply with all

currently applicable standards. In particular, the equipment shall conform to the latest edition of the following standards:

1) Hydraulic Institute Standards, U S A. 2) IS1710 - Vertical wet pit turbine pumps for clear and fresh water. 3) IS 5120 - Technical Requirement of Rotodynamic special Purpose

Pumps 4) ISO 2548 - Acceptance tests for centrifugal, mixed flow and axial

pumps . 5) JIS B 8301 - Testing methods for centrifugal pumps, mixed flow

pumps and axial flow pumps . 6) JIS B 8302 - Measurement methods of pump capacity. 7) JIS B 8327 - Pump performance testing method using model 8) B S – 3435 - Measurement of electrical power and energy in

acceptance testing. 9) Design Code: API 610 latest edition/ equivalent standard 4.2 DESIGN AND CONSTRUCTION REQUIREMENTS 4.2.1 Design Criteria



4.2.1.1 The pumps shall be vertical, constant speed, wet pit, mixed flow design,

with single stage/double stage impeller, suitable for continuous heavy duty.

4.2.1.2 Type of Pump/construction and type of discharge arrangement and

impeller shall be as specified in technical data sheets (annexure A of this chapter) enclosed with the specification.

4.2.1.3 For pull out type of pump, the pump design shall be such that all

the rotating elements with all wearing surfaces, diffuser and shaft enclosing tube can be withdrawn from the top without dismantling the column, discharge connection, and motor stool.

4.2.1.4 The pumps shall be designed to meet the duty conditions specified in

technical data sheets (annexure A of this chapter) enclosed with the specification.

4.2.1.5 The pumps shall be suitable for handling Sea water whose analysis is

given clause 4 (table 4.1) in chapter 1 of volume II A . 4.2.1.6 The pump shall be directly driven by a constant speed squirrel cage

induction motor. 4.2.1.7 The pump shall have a flanged discharge connection. 4.2.1.8 Suitable arrangement shall be provided to take care of the discharge

hydraulic thrust due to an untied expansion joint. This may be achieved either by sizing pump discharge head and base plate adequately to take care of the discharge hydraulic thrust or by providing a thrust block assembly to restrain the discharge hydraulic thrust.

4.2.1.9 The design, construction and speed of the pumps shall be such

as to minimize cavitation and ensure a long and trouble free service.

4.2.1.10 Contractor shall note that the design suction specific speed available

shall be based on actual operating experience of the contractor and the detailed experience list shall be enclosed with the contract justifying the selected suction specific speed available. Pump speed shall be based on the above suction specific speed available. However in any case, pump speed shall not exceed that indicated in the enclosed pump data sheet .(Annexure-A to this Section).



4.2.1.11 “Net Positive Suction Head (NPSH) required” shall be less than “NPSH available” during all operating conditions including run out condition.

4.2.1.12 The pumps shall have stable head capacity characteristic

continuously rising towards shut off conditions. Characteristics of the maximum and minimum diameter impellers, which may be fitted to the pump casing, shall also be indicated by the contractor.

4.2.1.13 The design shall ensure equal load sharing among the pumps operating

in parallel. All these pumps shall be identical to one another, shall have identical characteristic curves and shall be capable of running in parallel continuously without any restrictions.

4.2.1.14 The pump shall operate satisfactorily in isolation and in parallel with all

other working pumps without cavitation, any deleterious effects, undue vibrations and noise at all water levels, from minimum to maximum. The impeller shall be of non-over-loading type to restrict motor overloading during single pump operation.

4.2.1.15 The pump and motor (complete assembly) should be designed for

withstanding the run away speed attained with reverse rotation caused by reverse flow continuously even when all the remaining pumps are in operation. Necessary speed switches to detect reverse rotation shall be provided to prevent motor switching on while rotating in reverse direction. The indication shall also be provided for this purpose.

4.2.1.16 The pump shall also be designed to withstand the seismic loads as

given in Project Information. 4.2.1.17 The shaft shall be designed such that the complete pump and motor

assembly satisfies the following: The operating speed shall not be too close to the first critical speed, i.e. N should be less than 0.8 NC1 or N should be more than 1.3 NC1 Where N is the Operating Speed and NC1 First Critical speed.

4.2.1.18 Also, critical speed of pump-motor assembly shall be more than the

maximum reverse run away speed.

4.2.1.19 The length of shaft and column sections shall not exceed 3.0 metres.

The column pipe shall have a wall thickness of not less than 12 mm. 4.2.1.20 The impeller shall be fastened to the shaft such that the connections

withstand maximum torque and thrust that may occur under all operating conditions including maximum reverse rotation. The line shaft bearings shall be spaced so as to ensure smooth operation and to contain the



vibration within permissible limits. The bearings shall be amply proportioned to give long and satisfactory life.

4.2.1.21 The maximum efficiency of the pump and motor at design point shall be

limited to the value indicated in design data sheet. No credit shall be given during evaluation for pump and motor efficiency beyond specified efficiency.

4.2.1.22 Design life (minimum) of equipment supplied by contractor shall be 25

years. 4.3 Constructional Features 4.3.1 Material & construction of the pump & column shall be such as to

resist corrosion & erosion and give a long and satisfactory life to the plant. The materials used in construction of the various components shall not be inferior to those given below:

(a) Suction Bell:2% Nickel resist cast iron ASTM-A-439-

Gr-D2 (b) Casing: 2% Nickel resist cast iron ASTM-A-439-Gr-D2 (c) Impeller : Super duplex stainless steel having PREN >40 -

alloy 2507, UNS S32750/ J 93404 / A890 Gr. 5A (d) Wearing rings: Stainless steel ASTM-A-351-CF8M (e) Pump shaft: Super duplex stainless steel having PREN >40 -

alloy 2507, UNS S32750/ J 93404 / A890 Gr. 5A (f) Line shaft: Super duplex stainless steel having PREN >40 -

alloy 2507, UNS S32750/ J 93404 / A890 Gr. 5A (g) Shaft coupling: Super duplex stainless steel having

PREN >40 -alloy 2507, UNS S32750/ J 93404 / A890 Gr. 5A (h) Shaft sleeve: Super duplex stainless steel having PREN >40 -

alloy 2507, UNS S32750/ J 93404 / A890 Gr. 5A (i) Column pipe: Nickel resists cast iron ASTM-A-439-Gr- D2 j) Shaft enclosing tube: (if applicable)* 2% nickel resistant cast

iron ASTM A 439 Gr D2 (l) Discharge head: Nickel resist cast iron ASTM-A - 439–Gr-D2



(m) Matching flanges: Duplex steel SS 2205 (UNS S31803) (o) Thrust pads:Carbon steel with white metal lining (p) Bolts, nuts and lock washers: Stainless steel AIS I 316 L (q) Base plate and sole plate: Fabricated steel to IS 2062 with suitable Lining for seawater duty. (r) Gaskets: Neoprene rubber (s) Gland packing : Impregnated Teflon. (t) Ladder, platform

and related accessories: Fabricated steel as per IS : 2062

*Note: Any Carbon Steel surface exposed to sea water surface shall be

provided with coatings as specified elsewhere. 4.3.2 A ladder and platform arrangement shall be provided for each pump

and motor for inspection and maintenance of the thrust bearing and for approach to any other part of the pump / motor requiring frequent inspection.

4.3.3 The line shaft bearing shall be spaced so as to ensure smooth

operation. The bearing shall be amply proportioned to give long and satisfactory life.

4.3.4 Bearing lubrication: The type of lubrication shall be as given bellow. All interconnected

piping, valves, instruments and fittings for bearing lubrication shall be in contractor's scope of supply/work.

Self-Water Lubrication System:

i) The line shaft bearing shall be lubricated by the water

pumped or lubrication water shall be tapped from the pump discharge, passed through duplex filters and supplied through shaft enclosing tube for lubrication purpose.

ii) Pump design shall be such that line shaft bearings are below

minimum water level. However in case, pump design does not permit the same, the contractor shall use "Thordon type



bearing" which are above minimum water level. iii) Water required for cooling of pump-motor guide and thrust

bearing shall be taken from main pump discharge through duplex filter. Necessary piping valves, instrumentation etc. shall be included in contractor's scope of supply/work.

4.3.5 Thrust Bearing:

i) Pump design with single thrust bearing at motor top or separate thrust bearings at pump and motor (as per contractor's standard practice) is acceptable.

ii) Thrust bearing shall be of oil-lubricated, centrally pivoted

tilting pad type(Mitchell or Kingsbury) capable of absorbing axial thrust in both directions of rotation. Water required for cooling of thrust bearing shall be taken from main pump discharge. Necessary pumps, filters, piping, valves, accessories, specialties as required for such cooling purpose is in the scope of contractor. However the pump shall be suitable for starting without cooling water for thrust bearing.

iii) The thrust bearing shall be rated for continuous

operation with thrust as developed when impeller clearance is worn out up to four times the clearance when pump is new and working under shut off condition.

4.3.6 Column And Shaft : The pump column shall be provided with flanged joints to permit easy

disassembly. The line shaft coupling shall be of muff type or approved equivalent. Columns shall be provided with seating/lifting lugs.

4.3.7 Shaft Sleeves: Shaft sleeves shall be provided below the bearings to protect the

shaft from wear. Suitable locking arrangement shall be provided for all bolted connections.

4.3.8 Stuffing Box: Gland packing shall be provided at the top of the line shaft. Shaft

sleeves shall be provided at the stuffing box. The stuffing boxes shall be of sufficient depth to permit ample packing. The packing glands shall be split type to facilitate re-packing of the stuffing boxes. The space between the motor and the stuffing box shall be sufficient to



permit removal of the gland packing and insertion of new gland packing without dismantling the pump

4.3.9 Wearing Rings : Replaceable wearing rings/casing liners shall be provided in

impeller and casing. Design of wearing rings / casing liners may be as per manufacturer's standard practice. The diametrical clearance between casing and impeller at the wearing ring(s) when the pump is new shall not be less than 1.2 mm.

4.3.10 Coupling : The pump shall be connected to the motor shaft by a suitable

coupling. Coupling bolt and nuts shall be provided with locking devices to prevent the nut from becoming loose at normal and reverse rotation. Suitable arrangement shall be provided to adjust the vertical clearance of impeller. Contractor shall give necessary details of a proven arrangement in the offer.

4.3.11 Base Plate : Each pump shall be provided with a heavy structural steel base

plate. Separate heavy steel sole plates shall be provided for grouting and shall be designed to permit removal of entire pump along with discharge elbow head and base plate without disturbing the sole plate or grout.

4.3.12 Vibration limits: The vibration limits of the pump set when measured at motor end

shall not exceed100 microns (maximum) 4.3.13 Pump Motor Rating: Continuous motor rating (at 50 deg C ambient) for pump shall be at

least ten percent(10%) above the maximum load demand of the driven equipment in the complete operating range (including run-out condition of the pump and shut off condition in case pumps are envisaged to be started with the discharge valve closed) to take care of the system frequency variation.

4.4. PUMP CONTROLS & AUTOMATION 4.4.1 A local pushbutton switch shall be used for emergency tripping of the

motor.



4.4.2 The pump can be started either with pump discharge valve partially open or in closed position depending upon contractor's standard practice.

4.4.3 Pump can be started only when either at least one of the flow

circuits through the discharge pipe is established or re- circulation line to pump sump is open.

4.4.4 In case of high pressure at pump discharge due to accidental closure

of any of the butterfly valves in the system, an alarm shall be generated.

4.4.5 In case of normal stopping, when a pump control switch is turned

'OFF', the butterfly valve at its discharge first closes (25-30) % before the respective pump motor is de- energised.

4.4.6 On tripping of motor due to any reason, the butterfly valve at

the discharge shall close fully automatically. 4.4.7 If water level in pump sump is low, an alarm shall be initiated. Pump

shall be tripped in case of very low level of water in the intake sumps and very high discharge header pressure.

4.4.8 Contractor shall provide Duplex temperature elements for bearing &

simplex elements for winding temperature monitoring points. Pump shall be tripped from very high winding temperature of motor and very high metal temperature of thrust bearings. Alarm shall be provided for high motor winding temperature and high motor/ pump bearing temperature.

4.4.9 The operation philosophy as detailed above is suggestive only

and contractor shall furnish the complete control and interlock scheme for System equipment proposed by him along-with the contract . The control and interlock scheme to be adopted shall be finalised in consultation with the contractor after award of contract and shall be subject to Purchaser’s approval.

4.5 AIR RELEASE VALVE 4.5.1 A suitably sized automatic air-release valve shall be provided

on the discharge pipe of each pump. 4.5.2 In the pipe header, isolation valve shall be provided by the contractor

below the Air release valves to isolate the Air release valves. Air release valves shall be of kinetic air valve type as per IS:14845. Material of construction for air release valve shall be Austenitic Ductile iron toASTM-A-439 Gr-D2 and spindle material stainless



steel (SS 316L). 4.6 PERFORMANCE GUARANTEE TESTS 4.6.1 Performance tests shall be carried out in two stages. After

manufacture of the pump, the first prototype pump shall be tested at shop and performance shall be verified.

4.6.2 After installation of all the pumps and completion of initial

operation/trial operations the second stage of performance test shall be conducted at site.

4.6.3 Pump Performance Guarantee (I Stage) Tests At Shop 4.6.3.1 After the manufacture, first VT pump shall be subjected to Prototype

guarantee test at the manufacturer's works which will include establishing the pump performance curves (Head - Capacity, Power - Capacity, Efficiency -Capacity) and verifying the guaranteed parameters in the presence of Purchaser's representative and pump supplier/manufacturer.

The responsibility for conducting the test will be with the contractor and

contractor shall make all the arrangements for carrying out tests at site and all costs associated with the above test shall be borne by the contractor.

4.6.3.2 Prototype guarantee test shall be carried out as per requirements

of Hydraulic Institute standard (HIS) of USA and approved test procedure. Performance test at design duty point shall be done keeping minimum submergence of the pump identical to that specified for the site conditions.

4.6.3.3 Contractor shall submit the test procedure for Purchaser’s approval .

In case such test facilities are not available at manufacturer's works, the test may be carried out at any other test facility with the approval of Purchaser’s. All cost associated with testing at contractor's works or at any other test facility shall be included in the contract price.

4.6.3.4 Contractor shall submit details of the proposed test facilities available

for testing the pumps for Purchaser's approval. The details shall be enclosed with the contract . The details must include the capacity, head, maximum motor rating, voltage level, sanctioned load and permissible starting current.

4.6.3.5 It may be noted that during the performance tests, no negative

tolerance shall be permitted on head, capacity and the pump efficiency.



4.6.3.6 Accuracy of instruments used shall be ± 1.5% or better for

measurement of flow and± 0.5% or better for measurement of pressure and power.

4.6.3.7 Calibration of instruments to be used in the test shall be carried

out by an independent agency. Calibration of instruments should be carried out prior to test. The calibration certificate of the instruments should be valid for the period of test. The following laboratories are acceptable for calibration of various instruments:

a) Indian Institute of Technology Mumbai / Chennai / Delhi /

Kanpur. b) Institute for design of electrical measuring instruments (IDEMI)

Mumbai. c) Electronic Research & Testing laboratory (ERTL), New Delhi. d) National Physical Laboratory (NPL), New Delhi. e) National Test House (NTH), Kolkata. f) Flow Control Research Institute, Palakkad.

4.6.3.8 For carrying out performance test at shop actual motor shall be used.

The test result will be evaluated at actual speed achieved and speed correction shall be made only if there is a supply frequency variation with respect to 50 Hz.

4.6.3.9 Shop test shall also include measurement of vibration, noise level

and bearing temperature rise for reference. 4.6.3.10 Strip down examination shall be carried out to check visually

mechanical damages after performance test. 4.6.4 Performance (II Stage) Tests at Site 4.6.4.1 Performance Guarantee test at site shall be conducted on all the

vertical & horizontal centrifugal pumps within a period of two months after successful completion of trial operation in the presence of Purchaser’s representative and pump supplier/manufacturer. Should the results of the test deviate from the guaranteed values the contractor shall be given opportunity to modify the equipment as required to enable it to meet the guarantees. In such cases the PG test shall be repeated within one month from the date on which



the equipment is ready for retest and the cost of modification, including labour, materials and cost of additional testing shall be borne by the contractor.

4.6.4.2 The chance for repeat testing will be given only once during the

contract period. All the modification carried out in one pump to meet the contractual requirements shall be carried out in other pumps also, covered under this contract, free of cost to the Purchaser.

4.6.4.3 The responsibility for conducting the test will be with the contractor

and contractor shall make all the arrangements for carrying out tests at site and all costs associated with the above test shall be borne by the contractor.

4.6.4.4 Contractor shall submit detailed Performance Guarantee Test

procedure for Purchaser's approval. 4.6.4.5 The following parameters of the pumps will be measured during test

and shall be in line with approved data /manual.

a) Current, Voltage and Frequency

b) Speed of the pump

c) Suction level in sump/ Fore bay

d) Power at motor terminals

e) Discharge Pressure / Head

f) Vibration and Noise level

g) Bearing temperature and Motor winding temperature

4.6.4.6 All interlocks and protections relating to the pumps, motors and

motorised valves shall be demonstrated /tested as per control logic. 4.6.4.7 Parallel operation of the pumps shall be demonstrated / tested.

There should be equal load sharing between pumps running in parallel with no abnormal vibrations, sound or hunting of head and flow. Load sharing between any pumps running in parallel should be within 10%.

4.6.4.8 Vibration check shall be carried out as per HIS. Vibration will be

checked at motor top, motor bottom and pump top in the horizontal, radial and vertical directions. The acceptable vibration limits shall be as specified in relevant clause of this Sub- section. The instrument used would be IRD 308 or equivalent with velocity pickup.

4.6.4.9 Noise level shall be he less than 85 db A. Noise measurement shall



be done as per Hydraulic Institute Standard. The measurement shall be carried out with calibrated integrating sound level meter meeting the requirement of BS- 5969. Sound pressure level with be measured all around the pump and motor set at a distance of 1 m from the nearest surface of the machine and at a height of 1m from the floor level. A minimum of six points should be covered for measurement. The measurement shall be done with a slow response on the A-weighted scale. The average of the A-weighted sound pressure level measurement expressed in decibels to a reference of 0.0002 microbar shall not exceed the specified value. The tests shall be carried out with the machine operating at rated speeds and throughout the operation range. Correction for background noise and correction on account of test environment will be considered in line with HIS. For this purpose all the additional data required as per HIS should necessarily be collected during the test.

4.6.4.10 Opening and closing time of discharge butterfly valve will be checked

and it should be as per the approved data sheet. The capacity of the accumulator will be checked by opening and closing of valve after switching off the electric supply to the oil pump. It should be able to open and close the valve as per the specification requirement.

4.6.4.11 Accuracy of instruments to be provided by the contractor for

testing shall be as follows:

Sl.No

Parameters to be measured

Instruments Accuracy

1 Power (motor input power)

Wattmeter � 0.5%

AC-Voltmeter � 0.5% AC-Ammeter � 0.5% Frequency meter � 0.5% 2 Speed Tachometer non- contact type � 1 rpm 3 Temperature Digital Thermometer � 1 deg C 4 Vibration IRD 308 or Equivalent

� 3% 5 Noise Level Sound level meter � 2 dB 6 Pressure Measurement Bourdon type gauge / Pressure

transmitter � 0.5 %

7 Level gauge Existing plant instrument 8 Time Stop Watch � 0.5 %

The above list is not exhaustive. Any other instrument required for

the test will be arranged by the contractor along with valid calibration certificate.



4.6.4.12 Calibration of instruments that are to be used in the test shall be

carried out by an independent agency. Calibration of instruments should be carried out prior to test. The calibration certificate of the instruments should be valid for the period of test. The list of laboratories that are acceptable for calibration of various instruments shall as indicated above.

5.0 Technical Specification for Submersible Drainage Pumps

5.1 General: The Pump is meant to handle and pump out sludge water from the

sump (settling basin SB-102) on continuous/intermittent basis as required. As the water to be handled would be sea water, the material of construction of the wetted parts of the pump shall the compatible with sea water. The remaining parts of the pump shall be able to withstand highly corrosive marine coastal environment.

The capacity & head of the pump and other technical features shall be as

per the technical datasheet.

5.2 Design Features : The pump shall be self standing, single stage, single entry, mono

block, centrifugal pump. The pump shall have radially split casing with integral suction and

delivery nozzles. The impeller of the pump shall be single vane closed type.

The pump shall be provided with common shaft for the motor and the

pump. The pump shall also be provided with double special metal carbide

mechanical seals running in oil. The motor shall be 3 phase squirrel cage submersible motor cooled

by the liquid being handled by the pump. The motor shall be provided with class F insulation capable of

withstanding temperature upto 1550C.



The bearings shall be heavy duty anti friction type, grease lubricated for life.

All stationary joints shall be sealed for submersion upto 10 metres in

water.

5.3 Protections for the motor The motor shall be provided with IP 68 protections : The additional protections mentioned below shall also be provided for

the motor: - Moisture sensor which shall cut the power supply to the motor in case

moisture enters the stuffing box space. Heat protection: Thermistors provided in each of the phases shall stop

the motor if excessive heat is detected in any of the phase. Moisture protection: The stator of the motor shall be coated with

special water proof resin which will protect the windings from moisture damage.

5.4 Accessories: The submersible pump shall be supplied with the following

accessories: -

i) Control Panel: A control panel with the following features shall be supplied

with each pump: - a) Fully automatic DOL starter. b) Liquid level controller for fully automatic operation of the

pump. c) Control unit for thermistor. d) Control unit for moisture sensor. e) Switch fuse unit. f) Voltmeter. g) Ammeter. h) Single phase preventor. i) Indicating lamps for the following:-



1. Pump on 2. Motor off due to low water level. 3. Motor off due to excessive heating. 4. Motor off due to loss moisture in the stuffing box.

ii) Submersible cable: 20-metre long submersible cable shall be supplied with each

pump. The cable shall be copper conductor PVC insulated submersible type. The motor winding wire (lead wire) shall be spliced water tight to the submersible cable.

iii) Lifting chain: Galvanized lifting chain of 12 metre length shall be supplied

with each of the pumps.

IV) Discharge hose : Fifteen metre long hose with instantaneous coupling at one

end and branch pipe at the other end used in fire fighting applications (As per IS : 636 and IS : 903). The discharge outlet of the pump shall be suitable for connecting the instantaneous coupling.

5.5 Standards Manufacturing standard : As per manufacturers

standard Testing standard : ISO – 2548 Annexure B. 6.0 TECHNICAL SPECIFICATION FOR METERING/DOSING PUMPS 6.1 GENERAL

The specification covers general requirements in respect of design, material, constructional features, manufacture, inspection, testing of the positive displacement pumps with variable capacity to inject chemicals, generally used in water treatment plants.

6.2 GENERAL DESIGN FEATURES 6.2.1 Pumps shall be positive displacement diaphragm pumps, driven by

squirrel cage induction motor through suitable speed reduction unit. Maximum pump stroke speed shall not exceed 100 per minute.

6.2.2 The pumps should have the facility for automatic adjustment of dosing



rate by 4-20 mA current signal. 6.2.3 The stroke shall be continuously adjustable to give a capacity variation

10-100% range while the pumps are running or stopped. Adjustment of the capacity shall be done automatically from remote location and /or manually (micrometer adjusting type) locally for each pump as described elsewhere.

6.2.4 Capacity variation may be effected by changing eccentricity of the driving

crank or by suitable hydraulic circuit. Pump accuracy shall be industry standard ± 1% of capacity setting.

6.2.5 Guided, controlled travel, double – ball check valves or equivalent, shall

be provided both on the suction and discharge sides. 6.2.6 Material of construction of the various parts shall be as per the

datasheets (Annexure A of this chapter) enclosed. 6.2.7 Suitable gland seal shall be provided to prevent leakage. 6.3 TEST AT SITE

After erection at site, pumps as detailed under different groups shall be operated to prove satisfactory performance as individual component as well as a system. If the performance at site is found not to the requirements, then the equipment shall be rectified or replaced at no extra cost to the Purchaser.

7.0 PRESSURE & STORAGE VESSELS 7.1 GENERAL

This specification covers the design manufacture, construction feature, erection, inspection, testing the performance at vendor’s works/owner’s site of pressure and storage vessels.

7.2 CODES AND STANDARDS

The design, manufacture, shop testing, site fabrication and erection, testing and commissioning of the pressure and storage vessels shall conform to the latest revisions of the following standards, in addition to other standards mentioned elsewhere in the contract document subject to any modification and requirement, as specified here in after.



a) IS: 803 -Code of practice for design, fabrication and erection of Vertical Mild Steel cylindrical welded oil storage tanks.

b) IS: 816 -Code of practice for use of metal arc welding for general

construction in mild steel.

c) IS: 817 -Code of practice for training and testing of metal arc welders.

d) IS: 822 -Code of procedure for inspection of welds. e) IS:1363 -Black hexagonal bolts, nuts and locknuts (dia 6 to 39

mm) and black hexagon screws (dia to 24 mm). f) IS:1367 -Technical supply conditions for threaded fasteners.

g) IS:2062 -Specification for weldable structural steel. h) IS:2002 -Steel plates for pressure vessels for intermediate and

High temperature service including boilers. i) IS:2825 -Code of unfired pressure vessels.

j) IS:3133 -Manhole and inspection opening for chemical equipment. k) IS:4049 -Specification for formed ends for tanks and pressure

vessels. l) IS:4682 -Code of practice for lining of vessels and equipment for

chemical processes Rubber Lining. m) BS:2594 -Specification for carbon steel welded horizontal

cylindrical storage tanks. n) ASME -Boiler and pressure vessel Section VIII code.

o) ASTM -American Society for Testing and Materials. p) BS-5258 FRP TANKS/BS 4894

7.3 GENERAL DESIGN FEATURES

7.3.1 Design



7.3.1.1 Design of all pressure vessels shall conform to ASME Section VIII/ ASME

Section X/BS- (for FRP tanks) regulations or acceptable equivalent standard Design pressure shall be the maximum expected pressure to which the vessels may be subjected to plus 5% additional margin. Maximum expected pressure for vessels placed in the discharge line of pumps shall be based on the shut-off head of the pumps plus static head at pumps suction if any. Design pressure of vessels is indicated in Technical Data Sheets. For the vessels whose design pressure is not indicated in the respective technical datasheet enclosed with this chapter, (Annexure –A ,chapter 2 , volume IIA), the design pressure shall be at least 8 Kg/cm²(g).

7.3.1.2 Design of all vertical cylindrical atmospheric storage tanks (steel tanks)

containing water, acid, alkali and other chemicals shall conform to IS:803. 7.3.1.3 Design of all horizontal cylindrical atmospheric storage tanks (steel tanks)

containing water, acid, alkali and other chemicals shall conform to BS:2594.

7.3.1.4 Design temperature of all pressure vessels and storage tanks shall be 10

deg C higher than the maximum temperature that any part of the vessel/tank is likely to attain during operation.

7.3.1.5 In case, tank is subjected to vacuum, the same shall be taken care in

designing the tank. 7.3.1.6 The design of vertical storage tanks shall conform to IS:803. Supporting

frame where required shall be in accordance with IS:800. The tank shall be "Non-pressure" fixed roof type with atmospheric vents.

7.3.1.7 All vessels/tanks without inside (rubber / Polyurethane / Epoxy / Glass

Flake Polyester Acrylic Polymer) lining shall have a corrosion allowance of minimum 2 mm and mill allowance (minimum 0.3 mm) for shell and dished ends. Thinning allowance of 2 mm (minimum) shall be considered for dished end.

7.3.1.8 All the atmospheric tanks shall have sufficient free board above the “Level

High”/”Normal Level” as the case may be. The overflow level shall be kept at least 20 cm or 10% of vessel height above the “Level High”/”Normal Level” for all the tanks for which a minimum height of 300 mm shall be provided over the “High Level”. Further, a minimum 100 mm free board shall be provided above the top of overflow level to the top of the tank. Wall thickness of atmospheric tanks shall not be less than 6 mm.



7.3.1.9 The material of construction for various connections for all the lined unlined vessels / tanks shall be same as that of interconnecting piping material suitably lined wherever required. The nozzle flanges, manhole/manhole covers reinforcement pads etc. shall be fabricated out of the same material as that of one used for the vessel/tank. However, screwed fittings for instrumentation, sample connection, drain connection of size 25 NB and less shall be of stainless steel construction (ASME SA 479 Gr.316)

7.3.1.10 Interior surfaces of tanks shall be clear of stiffeners and other structural

supports. Tanks shall be of reinforced and stiffened externally as required 7.3.1.11 General Requirements for FRP Vessels and Tanks

a) Design of all FRP pressure vessels shall conform to ASME Section X standard.

b) Resins used for the tanks shall be a commercial grade corrosion-

resistant thermo set, fully tested and accepted for the service conditions. Resins shall not contain fillers, pigments, dyes or colorants. Clear UV absorbers shall be used in final resin coat. Tanks shall be covered top with suitable reinforcing and bracing.

c) Regardless of the theoretical design requirements, the minimum

total laminate thickness of the filament wound tank shall not be less than 12 mm.

d) All surfacing shall be finished as so to obtain complete cure of the

resin without air inhibition. Acetone sensitivity on any surface shall be considered evidence of unsatisfactory cure.

e) Unless otherwise specified, the inner surface shall consist of a

resin-saturated layer of 0.25 to 0.50 mm thick Type C glass surfacing mat. No resin gel coat shall be used.

f) The longitudinal strength of the cylindrical shell shall be at least

25% of the hoop strength No paints or pigmented, coloured, or dyed resins shall be used the outside surface of the tank.

g) Unless otherwise specified, nozzles shall have a flanged faces

perpendicular to the vertical center line of the tank / to radial center lines as the case may be.

h) There shall be no vertical joints (in axial direction) in the cylindrical

shell. The entire thickness of the cylindrical shell shall be built up prior to removal of the shell from the mandrel. Heads may be



fabricated integrally with the shell or may be fabricated separately; heads fabricated separately shall be moulded with an integral skirt. The minimum skirt length shall be 100 mm. The entire head including knuckle radius and skirt shall be fabricated in one piece. The tanks shall have bolted and gasketed covers.

i) Tanks shall be designed so that no external bracing, ribs, hoops

or support wires are required. j) Saddle supports or legs as specified and bolts for anchoring tank

to concrete pedestal shall be provided. k) Tanks shall have internal support members. The bulk storage

tanks shall be fabricated with that all edges having a minimum corner radius of 3.2 mm. Tanks shall have Teflon gaskets. All linings and coatings shall extend through all tank openings and nozzles and around to flange faces. Flanges shall be 1.034 bar class D meeting the requirements of AWWAC202.

l) Each tank shall have two support saddles with extend no more

than 150 mm at the center beyond the tank diameter. m) Each FRP tank shall be equipped with the following minimum

accessories: -Lifting lugs, -Required Nozzles for top fill, vent, overflows, with interior down pipe, drains, suction, connections for instruments, flange for mixer/ agitators. -Identification labels noting tank designation (150 mm high lettering)

7.4 MATERIAL OF CONSTRUCTION 7.4.1 The pressure vessels to be fabricated from carbon steel plates shall

conform to SA 515 Gr.70 or SA 516 Gr. 70 if the pressure vessels are designed as per ASME Section VIII.

If the pressure vessels are designed as per IS 2825 following criterion shall be followed :

The pressure vessels shall be fabricated of steel as per IS:2002 Gr. 3 (normalised condition) or SA:515/516 Gr. 70 (normalised), in case the vessels are designed as per Class 1 or Class 2 of IS:2825. If the pressure vessels are designed as per Class 3 of IS:2825, the material of construction shall conform to IS:2062 or IS:2002 Gr. 2 or Gr 3 (Normalised quality).or SA 515 /516 Gr 70

7.4.2 All atmospheric mild carbon steel tanks shall be fabricated of steel

conforming to IS: 2062



7.4.3 The material of construction for various connection, for all the lined or

unlined vessels/tanks shall be same as that of interconnecting piping material suitably lined wherever required. The pipe flanges, manhole/manhole covers reinforcement pads etc. shall be fabricated out of the same material as that one used for the vessel/tank. However, screwed fittings for instrumentation, sample connection, drain connection of size 25 NB and less shall be of stainless steel construction (SS: 316).

7.5 FABRICATION 7.5.1 The vessel ends for storage tanks of vertical type shall have flat bottom.

However, the ends of horizontal storage tanks, and all the pressure vessels shall be dished design of Torispherical type designed and constructed by forging, pressing or spinning. The dished ends shall have a minimum straight flange length of 60 mm. Conical or flat (with or without reinforcement) ends shall not be accepted.

7.5.2 Interior surfaces of all tanks shall be clear of stiffeners and other

structural supports. Tanks shall be reinforced and stiffened externally as required.

7.5.3 The plates to be used for fabrication shall preferably have a minimum

width of 1500 mm. 7.5.4 All the joints (circumferential/longitudinal) shall be double butt welded with

full penetration or single butt welded without backing strip. For joints involving small thickness 6 mm or less, back chipping to sound metal followed by DP test and re-welding shall be done to have full penetration.

7.5.5 Vessel/tanks seams shall be so positioned that they do not pass through

vessel connections and connections shall be flushed with inner surface and welded continuous on both sides of the shell. Sharp inside edges shall be rounded to a minimum 3 mm radius.

7.5.6 All welds or inner tank surface shall be free of voids, gaps craters, pits,

high spots, sharp edges, abrupt ridges and valleys or undercut edges. High spots, irregularities and sharp edges shall be removed by grinding. Inside weld seams shall be ground flush and smooth applicable for corrosion resistant costing or lining.

7.5.7 All internal baffles, wear plates, pipes etc. shall be continuously welded

on both sides at all contact points with full fillet welds which shall be free of voids, gaps, craters, high spots, sharp edges, and undercutting. Sharp edges shall be ground to a3 mm minimum radius.



7.5.8 Weld splatter shall be removed 7.5.9 All welding shall be performed by ASME qualified welders under Section-

IX of ASME Boiler and Pressure Vessel code and welding electrodes shall be as per relevant Codes/Standards viz. AISC Section 1.17 etc.

7.5.10 Welding sequence shall be adopted in such a way so as to minimise the

distortion due to welding shrinkage. Contractor shall indicate in his drawing the sequence of welding proposed by him which should meet prior approval of the engineers. Welding shall not be carried out when the surface of the parts to be welded are wet from any cause and during periods of rain and high winds unless the welder and work are properly shielded.

7.5.11 The plates for cylindrical tanks shall be accurately formed in bending rolls

to the diameters called for, and the completed shells be concentric and plump plates shall be cold-rolled by plate bending machine in a number of passes to true curvature and joined by welding.

7.5.12 All pressure vessels and storage tanks shall be fabricated complete and

tested at manufacturer’s works to ensure better workmanship. 7.6 APPURTENANCES 7.6.1 Manholes/Hand Holes

1. All the pressure vessels and horizontal type storage tanks shall be provided with at least one manhole of 500 mm diameter minimum size at the top head, complete with cover plate, lifting handle, davit cap, nuts, bolts, gaskets etc. to ensure leak tightness at the test pressure. Manhole covers of nominal weight more than 20 kg shall be provided with hinged arms. All tanks internals must be replaceable through the manhole. Prefabricated vessels must as a minimum have a coat of primer applied before transport. They shall be cleaned and internally dry. All openings must be secured closed before transport.

2. The vertical type storage tanks shall be provided with a manhole

of 500 mm dia on the top cover, if the diameter of the tank is 1200 mm or more. For the water storage tanks, manholes shall be provided as per IS:803.

3. All the vessels and tanks shall be normally provided with a hand

hole of 150 mm gasketted, located near the bottom of the straight side.



4. The required lining/coating for the inside surface of the man

hole/hand hole, nozzle and cover plate of the manhole/hand hole shall be same as that of the respective vessel/tank.

7.6.2 Tank Connections

1. Contractor shall furnish all pipe material required for tank connection for the process requirement. In addition to these, additional connections, if required by the Owner for the inter-connection of their piping, instrumentation etc. shall also be provided. Such additional requirement will be intimated to the contractor later and contractor shall provide these fittings to match with the Owner’s items. Adequate pipe support attachments in the external surface of the tank/vessel shall be provided for Owners pipes for all the vessels/tanks. All lined vessels connections shall be conform to ANSI 300 lb class. Nozzle material shall be ASTM-106 Grade B, Schedule 80.

2. All flanged connections should be supplied complete with

matching counter flanges, nuts bolts and gasket materials. The flange design, (thickness and drilling etc.) shall match with the interconnected piping flanges.

3. Bolts and nuts to be used externally to the vessels shall be of

hexagonal head conforming to IS:1367. However, internal fasteners if any, shall be of IS:316/SS304 or Hastalloy-B as per the duty conditions.

4. Gaskets shall be of full face type.

7.6.3 Sight glasses shall be provided for the tanks/vessels as specified in the

standard specification. The material for sight glass shall be high quality transparent PLEXIGLASS of sufficient thickness to withstand the test pressure. The sight glass shall be provided with suitable gaskets and bolts to ensure leak tightness at the test pressure.

7.6.4 Vessels Supports & Lifting Lugs

1. Adequate supporting arrangements like straps, saddles, skirt boards, pillars etc. shall be provided to transfer all loads to civil foundation. All foundation bolts, inserts etc. shall also be provided.

2. All vessels of internal, diameter of 1200 mm or greater shall be

provided with minimum four (4) lifting lugs for safe and effective



handling during erection. Smaller vessels shall be provided with at least two (2) lifting lugs.

3. Material of construction for these vessel supports, saddles, lugs

shall conform to IS:2062 of tested quality. 7.6.5 Special Accessories for Vessels /Storage Tanks

1. Vessel internals wherever required shall be provided as detailed out elsewhere in the specification.

2. All the pressure vessels and tanks shall be provided with drain

connections along with drain valves of suitable size. Further all the atmospheric storage tanks shall be provided with over flow connection designed for the filling rate of the respective tank.

3. All the pressure and tanks shall be provided with the vent

connections. The design shall be as to offer adequate area for venting. Venting area shall be such that over pressure/vacuum is not created in the tank during maximum filling/drain-off rate. The maximum draw off rate for the storage tanks shall be intimated later to the contractor.

4. Various instrumentation and the fittings required for the same shall

be supplied as elaborated in data sheets. 5. The vent and overflow lines of alkali preparation /measuring / day

tanks and vent line of storage tanks shall be provided with Carbon-di-oxide absorber of proven design to prevent contamination from atmospheric air. Carbon dioxide absorber shall preferably be located at ground level. The vent and overflow lines of Acid measuring tanks shall be provided with fume absorber using suitable packing material, such as pall rings/rasching rings.

6. Conservation vent valves shall be provided in the vent line of

storage tanks so that, at a vacuum to the extent of 65 mm water column, the valve shall open to relieve the vacuum. Body and trim of the valve shall be Die Cast Aluminium.

7.7 PROTECTIVE LININGS, PAINTING ETC. 7.7.1 Inside surfaces of all tanks/vessels shall be protected by anticorrosive

paints or rubber lining as required/specified in the technical datasheets ( annexure – A of this chapter) of respective tanks and vessels. External



surfaces of all tanks/vessels shall be protected by anti corrosive painting as per chapter 7 of volume II A.

7.7.2 All inside surface shall be cleared thoroughly by the wire brushing to

remove completely all loose dirt, rust, mill and any deleterious material. 7.7.3 For vessels requiring lining and epoxy painting all inside surface shall be

blast cleared using non-siliceous abrasive after usual wire brushing. 7.7.4 Natural rubber lining shall be provided on the inside of vessels and tanks

in three layers resulting in a total thickness not less than 4.5 mm. 7.7.5 Surface hardness of rubber lining shall be 65 +/-5 deg. A (shore). 7.7.6 Coating/Internal Lining of Polyurethane / Epoxy / glass flake polyester

acrylic polymer for vessels & tanks, if specified in data sheets shall generally conform to the requirements of coating/lining work of Pipes as described in chapter 5 of volume II A “Piping, Valves & Fittings” of this Technical Specification.

7.7.7 Specification for the application of Epoxy coating for internal protection of

Permeate water/ Potable Water Tanks shall be as follows:

Primer : One coat of unmodified epoxy resin along with polyamide hardener. Paint : Two (2) coats unmodified epoxy resin along with Aromatic adduct hardener. Total thickness of primer and paint should not be less than 400 microns.

7.7.8 Specification for application of paint for external protection vessel and

tanks shall be as follows :

i) For Indoor Vessel and Tanks a) Surface preparation shall be done either manually or by any other

approved method. b) Primer coat shall consist of one coat of chlorinated rubber based

zinc phosphate primer having minimum DFT of 50 microns. c) Intermediate coat (or under coat) shall consist of one coat of

chlorinated rubber based paint pigmented with Titanium dioxide with minimum DFT of 50 microns.



d) Top coat shall consist of one coat of chlorinated rubber paint of approved shade and colour with glossy finish and DFT of 50 microns. Total DFT of paint system shall not be less than 150 microns.

ii) For Outdoor Vessels/Tanks (a) Surface preparation shall be done by means of sand blasting,

which shall conform to Sa 2-1/2 Swiss Standard. (b) Primer coat shall consist of one coat of epoxy resin based zinc

phosphate primer having minimum DFT of 100 microns. (c) Intermediate coat (or under coat) shall consist of epoxy resin

based paint pigmented with Titanium dioxide with minimum DFT of 100 microns.

(d) Top coat shall consist of one coat of epoxy paint suitable

pigmented of approved shade and colour with glossy finish and DFT of 75 microns. Additionally finishing coat of polyurethane of minimum DFT of 25 microns shall be provided. The paint may be applied in one coat, in case high built paint is used, otherwise two coats shall be applied.

Total DFT shall not be less than 300 microns.

7.7.9 The following surfaces shall not be painted: Stainless steel, galvanised

steel, aluminum, copper, brass, bronze and other nonferrous materials. 7.7.10 No painting, or filler shall be applied until all repairs, hydrostatic tests and

final shop inspection are completed. 7.8 PROTECTION 7.8.1 After the lining is completed, the vessel shall not be subjected to any

prolonged exposure to direct sunlight in course of its transportation, erection etc. They shall not be stored in direct sunlight. No further lining or burning shall be carried out on the vessel, after application of the lining.

7.8.2 All lining projecting outside of the vessel shall be protected adequately

from mechanical damages during shipment, handling storage etc. 7.8.3 Suitable warnings, indicating the special care that must be taken with

respect to these lined vessels shall be stenciled on their outside surface with the letters at least 12 mm high.



8.0 Technical specification for Agitators

8.1 Design and construction :

8.1.1 The equipment is intended to handle the materials as indicated in the

respective tank drawing/data sheet and the design and construction has to take care of the fluid being handled.

8.1.2 Agitators shall be designed for continuous full load duty in outdoor service

unless otherwise specified. 8.1.3 In case of liquid-liquid mixing and slightly contaminated liquid, the torque

calculation should be based on 1.5 times the maximum horsepower of the driving unit. But in case of slurry service, the torque calculation must be based on 2.5 times the maximum H.P. of the driving unit and gearbox shall be selected accordingly. Selection of motor, gear boxes shall be as per the vendor list indicated in the respective specification.

8.1.4 The corrosion allowance for the agitator shall be as that for the vessel

and in any case should not be less than 3mm. 8.1.5 The assembly of the agitator unit shall be such as to enable replacement of bearings, shaft sealing devices, gear unit and driver without

dismantling other major parts. 8.1.6 Connection of the drive shaft to agitator shaft shall be made outside the

vessel. 8.1.7 Shaft shall be made of high quality shafting and straight within 0.125mm

at the shaft ends. Shaft shall be designed for minimum run out and diameter carefully selected to avoid critical speeds.

8.1.8 Oil lubricated bearing shall be equipped with constant level oiler.

Sufficiently large oil sumps may be fitted (if required) with an oil level-indicating gauge. A threaded oil filling connection shall be furnished in addition to a constant level oiler. The recommended oil level shall be clearly marked.

8.1.9 Sleeve bearings shall be of renewable insert type. 8.1.10 Shaft and shaft sleeves shall be accurately machined throughout the

entire length and properly finished at the bearing and seal surface such that under the service conditions, these shall resist wear, corrosion and erosion particularly in the area of the packing.



8.1.11 Shaft sleeves shall be securely locked to the shaft. 8.1.12 Shaft sleeves shall be sealed at one end. The end of the shaft sleeve

assembly shall extend beyond the other face of the packing gland so that any leakage between the shaft end sleeve cannot become confused with leakage through stuffing box packing.

8.1.14 Sleeve nuts, if used shall be made of material to withstand external

corrosion. 8.1.15 The Supplier shall determine the need for stabilizing rings on the mixing

element and shall furnish rings, if required for the services. 8.1.16 The first critical speed shall be not less than 140% of the maximum

operating speed. 8.1.17 Mechanical components of the agitator assembly shall be designed to

exceed rated duty by a minimum of 15% to take care of any fluctuation in load.

8.2 Shaft seals: 8.2.1 When stuffing boxes are required and specified as for pressure or vacuum

services, the assembly shall be designed with split gland and large accessible opening to stuffing box. Two extra set of packing shall be included.

8.2.2 Stuffing boxes shall be provided with seal cages and connections for the

introduction of a cooling medium or lubricant directly into the packing. 8.2.3 Stuffing boxes shall have not less than six rings of packing, plus seal

cage. The minimum packing size permitted shall be 6 mm square, however 10 mm square or larger is preferred.

8.2.4 Ample space shall be provided for packing replacement without, removing

or dismantling any part other than the gland and the seal cage. 8.2.5 Glands shall be designed so that the bolts cannot slip off if the packing

becomes loose. Where split glands are used, the halves shall be bolted together.

8.3 Coupling: 8.3.1 Flexible steel couplings shall be furnished between motor and reducer

and rigid coupling shall be furnished between the agitator shaft and driver.



8.3.2 Couplings shall be properly keyed in place and cylindrical interference its shall be light enough to permit easy and rapid removal of the hub without the need for heating above 1200C.

8.4 Agitator bed plate and, lifting lugs etc. : 8.4.1 The Agitator shall be mounted on a suitable bed plate or pedestal as

required for specified services. Bedplate shall be rigid enough to withstand all stresses caused by impeller and shaft. If pedestal type support is specified, access holes shall be provided to reach couplings or seals. Bolt holes shall be provided as required. All fasteners along with washers are included in the scope of supply.

8.4.2 The equipment shall be provided with suitable lifting attachments e.g.,

lifting lugs, eyebolts, etc. to facilitate erection and maintenance wherever necessary.

8.5 Gear reducers

8.5.1 Gear reducers shall be designed for agitator duty. Parallel shaft

arrangement with hardened and ground tooth precision helical gearing is preferred. Gearing shall be enclosed in rugged heavy-duty housing. The unit shall be designed so that no significant gear deflection shall result from impeller over hung loads or shaft thrust loads.

8.5.2 The lower output shaft bearing may be grease lubricated but shall have a

high quality lip type seal to prevent any possible grease leakage or contamination from external sources. The service factors shall be applied to motor horse power in sizing the agitator gear assembly. The service factor for deciding this is given in the datasheets.

8.6 Bearings: The agitator shaft shall not have any step bearings or steadying bearings.

The entire shaft and agitator assembly shall be cantilevered for the housing.

Bearing shall be selected so as to have a life of more than 30000 hrs at maximum rated horsepower.

8.7 Guards:

Guards shall be provided by vendor for couplings / V-belts. Guards for out of door service shall be weatherproof.

8.8 Drive motor:

The motor shall be sized so that it cannot be normally overloaded and



shall be at least 115% of the maximum absorbed power. However the full motor specification shall comply with the motor specification given under Electrical Specification. Suitable canopy shall be provided for the agitators which are coming at outdoors

8.9 Impellers: 8.9.1 Impeller shall be statically and dynamically balanced after assembly on its

own shaft to ensure smooth and vibration free running at operational speeds.

8.9.2 Impeller shall be firmly secured to the fan shaft and shall be retained

against movement by suitable method.

8.10 Following functional tests shall be done in addition to the other tests

applicable for other components.

a) Impeller shaft assembly shall be statically balanced. b) Operation of the assembled agitator under no-load for minimum

four hours or until the temperature of lubricant is saturated. c) Confirmation of gear ratio by measuring the input and output shaft

rotational speed. d) Inspection of temperature rise at the critical portion of the drive

unit. e) Unusual Noise and vibration. f) Amperage, voltage and consumption watt are measured. g) Check the lubrication for leakage etc..

8.11 List of preferred make:

a) Agitator

M/S REMI Process Plants & Machinery Ltd./ M/S Fibre & Fibre Products/ M/S CEECONS

b) Gear Box

Elecon Engineering Company Ltd / Essential Power Transmission Pvt Ltd / Flender Mcneil Gears Ltd / Gajra Gears Ltd / Gears (India) pvt Ltd / Greaves Ltd / Kirloskar Electric Company Ltd / Power Build Ltd / San Engineering Company Ltd / Shanthi Gears Ltd / Space age Engineering Industries Pvt ltd / Vulcan Engineering Industries Pvt Ltd. / Vulcan Industrial Engineering Industries Pvt Ltd / Walchandnagar Industries Ltd.



c) Coupling

Alliance Engineering Company Ltd / Associated Engineering Industries / Concord Marketing & Services pvt Ltd / Esbi Hi-Flex Pvt Ltd / Fenner(India) Ltd / GBN Manufacturing Pvt Ltd / Gear Reductor Pvt Ltd / Hi-Cliff Engineers / Kapsek Engineers Pvt Ltd / Rathi Transpower Pvt Ltd / Roma Mechanical Engineering Company Ltd / Techstar Engineers Pvt Ltd / Unique transmissions (India) ltd / Wellman Incandscent India Ltd.

d) Bearing

Asian Bearing Ltd / Fag Bearing India Ltd / National Engineering Industries Ltd / RBC Bearing India Ltd / SKF Bearing India ltd /Tata Timken Ltd / NRB Bearings Ltd.

8.12 Agitators shall be tested with test motor / the actual motor to be supplied,

for the testing of agitator. 8.13 MOC shall be as follows:

Shaft - SS 316L Impeller/Paddles - SS 316L (minimum thickness of Impeller Blades shall be 6 mm)



9. ATTACHMENTS


MEC/10EP/01/01/DS/0001

Page 1 of 3

ADECOO TECHNOLOGIES MECON LIMITED

PUMP DATA SHEET

PROJECT: 100 MLD SWRO DESALINATION PLANT DATA SHEET / DOCUMENT NO: MEC / 10EP/ 01 / 01 / DS / 0001 PUMP TAG NO: P-101A-D

1 Item description Sea water intake pump 2 Type Vertical, centrifugal suspended line

shaft/wet pit diffuser type turbine pumps

3 Design code API 610 latest edition/ equivalent standard

4 Location of installation outdoor-on the roof slab top from the bottom of intake chamber of onshore intake chamber having 15 m depth from the finished ground level

5 Humidity % Min. – 50% , max. – 100 % 6 Immersed liquid depth from the bottom of intake

chamber Min. 7.39 m & max. 8.65m

7 Number required 4 8 No of stages single stage 9 Duty continuous

Operating data 10 Fluid handled (%w/w) sea water (TDS – 41900ppm) 11 Type of fluid (corrosive/ non corrosive etc) corrosive 12 Specific gravity of fluid 1.01 13 Capacity m3/ h 5530 14 Discharge press. at outlet flange Bar 1.5 15 Suction Flooded 16 RPM 740 17 Operating temp. Deg 0 C 35 18 Specific gravity At flow temp 1.01 19 Viscosity at operating temp. Cp 1 20 pH 4.5-8.5 21 Minimum efficiency % 86.4 22 BkW at duty point kW 360 23 Starter type VCU 24 Motor kW 360 25 NPSH A MLC ample 26 Maximum allowable particle size mm <5mm sand


MEC/10EP/01/01/DS/0001

Page 2 of 3


27 Suction end location bottom 28 Discharge end location side top

Construction details / material of construction 29 Suction bell 2% nickel resistant cast iron ASTM A

439 Gr D2 30 Casing Type Single casing , pull out

Material of construction 2% nickel resistant cast iron ASTM A 439 Gr D2

31 Impeller Type Semi open

Material of construction Super duplex stainless steel having PREN >40 -alloy 2507, UNS S32750/ J 93404 / A890 Gr. 5A

32 Shaft

Material of construction Super duplex stainless steel having

PREN >40 -alloy 2507, UNS S32750/ J 93404 / A890 Gr. 5A

33 Line shaft

Super duplex stainless steel having PREN >40 -alloy 2507, UNS S32750/ J 93404 / A890 Gr. 5A

34 Shaft coupling


35 Shaft sleeve 2% nickel resistant cast iron ASTM A 439 Gr D2

36 Column pipe 2% nickel resistant cast iron ASTM A 439 Gr D2

37 Shaft enclosing tube (if applicable) 2% nickel resistant cast iron ASTM A 439 Gr D2

38 Seal Mechanical 39

Noise level dB (A)

<85 from one meter distance

40 flange A) suction NA

B) discharge 30” ANSI B 16.5 # 150 / RF

41 Matching flanges Duplex steel SS 2205 (UNS S31803)


MEC/10EP/01/01/DS/0001

Page 3 of 3


Note: 1) Painting wherever applicable shall be done as per the enclosed painting

specification, chapter 7 of the volume II A. 2) Commissioning spares shall be supplied by the tenderer. 3) Refer TS of vertical turbine pumps in chapter 2 of volume II A. 4) * Indicates vendor to furnish 5) Motor shall be as per electrical specification enclosed in chapter 3B

of volume II B. 6) Supply of pump and motor includes companion flange, gaskets,

fasteners, reducers/ expanders to match the main pipe size as per respective P&ID and piping GAD drawings. For interconnection with HDPE piping flange, material of construction for companion flange, reducers/expanders shall be Duplex stainless steel SS 2205 (refer P & ID & piping GADs).

Vendor to furnish

* Equipment GA drawing & cross sectional drawing * Performance curve

42 Base plate and sole plate Fabricated steel IS 2062 with suitable lining of sea water duty

43 Scope of supply of accessories Motor as per electrical specification enclosed

in chapter 3B of volume II B. Yes

Base frame Yes Coupling Yes Speed reducer (if any) Yes Foundation bolt Yes Suction filter (if any) Yes 44 Rated capacity in m 3 /hr * Rated discharge pressure in bar * Pump efficiency % * BkW * Selected kW


MEC / 10EP/ 01 / 01 / DS / 0002

Page1 of 3 ADECOO TECHNOLOGIES MECON LIMITED

PUMP DATA SHEET

Project: 100 MLD SWRO Desalination Plant Data Sheet / Document no: MEC / 10EP/ 01 / 01 / DS / 0002 Pump Tag No: P-102A-D

1 Item description Raw water transfer pump. 2 Type Vertical, centrifugal suspended line

shaft/wet pit diffuser type turbine pumps 3 Design code API 610 latest edition/ equivalent

standard 4 Location of installation Out door-On the roof slab of degritted

water storage tank having 6.0 m depth from the finished ground level

5 Humidity Min- 50% , Max. – 100% 6 Immersed liquid depth from the bottom of

degritted water storage tank Min. 0.8M & Max. 6.5M

7 Roof slab top from the bottom of degritted water storage tank. 7.4 M

8 Number required 4 9 No of stages Two stage 10 Duty Continuous

Operating data 11 Fluid handled Sea water (TDS –41900ppm) 12 Type of fluid (corrosive/ non corrosive etc) Corrosive 13 Specific gravity of fluid 1.01 14 Capacity m3/ h 5475 15 Discharge press at the outlet flange Bar 4 16 Suction Flooded 17 RPM 740 18 Operating temp. DEG 0 C 35 19 Specific gravity At Flow Temp 1.01 20 Viscosity at operating temp. C p 1 21 pH 4.5-8.5 22 Minimum efficiency % 82.3 23 BkW at duty point kW 764 24 Starter type VCU 25 Motor kW 800 26 NPSH A mLC Ample


MEC / 10EP/ 01 / 01 / DS / 0002


27 Maximum allowable particle size mm <5mm Sand

28 Suction end location Bottom 29 Discharge end location Side top CONSTRUCTION OF DETAILS / MATERIAL OF CONSTRUCTION 29 Suction bell 2% nickel resistant cast iron ASTM A

439 Gr D2 30 Casing Type Single casing , pull out

Material of construction 2% nickel resistant cast iron ASTM A 439 Gr D2

31 Impeller Type Semi open


32 Shaft

Material of construction Super duplex stainless steel having

PREN >40 -alloy 2507, UNS S32750/ J 93404 / A890 Gr. 5A

33 Line shaft


34 Shaft coupling




37 Shaft enclosing tube (if applicable)

2% nickel resistant cast iron ASTM A 439 Gr D2

38 Seal Mechanical 39 Noise level dB

(A) <85 from one meter distance

40 Flange A) suction NA

B) discharge 30” ANSI B 16.5 # 150 / RF

41 Matching flanges Duplex steel SS 2205 (UNS S31803)


MEC / 10EP/ 01 / 01 / DS / 0002



specification, chapter 7 of the volume II A. 2) Commissioning spares shall be supplied by the tenderer. 3) Refer TS of vertical turbine pumps in chapter 2 of volume II A. 4) * Indicates vendor to furnish

5) Motor shall be as per electrical specification enclosed in chapter 3B of volume II B.

6) Supply of pump and motor includes companion flange, gaskets, fasteners, reducers/ expanders to match the main pipe size as per respective P&ID and piping GAD drawings. For interconnection with HDPE piping flange, material of construction for companion flange, reducers/expanders shall be Duplex stainless steel SS 2205 (refer P & ID & piping GADs).

Vendor to furnish


42 Base plate and sole plate Fabricated steel IS 2062 with suitable lining of sea water duty

43 Scope of supply of accessories Motor as per electrical specification enclosed

in chapter 3B of volume II B. Yes

Base frame Yes Coupling Yes Speed reducer (if any) Yes Foundation bolt Yes Suction filter (if any) Yes 44 Rated capacity in m 3 /hr * Rated discharge pressure in bar * Pump efficiency % * BkW * Selected kW *


MEC / 10EP/ 01 / 01 / DS / 0003

Page1 of 3


PUMP DATA SHEET

Project: 100 MLD SWRO Desalination Plant Data Sheet / Document no: MEC / 10EP/ 01 / 01 / DS / 0003 Pump Tag No: P-103 A/B

1 Item description Dirty water discharge pump 2 Type Vertical, centrifugal

suspended line shaft/wet pit diffuser type turbine pumps

3 Design code MF STD. 4 Location of installation Out door-On the roof slab of

sedimentation tank having depth of 6 M from the finished ground level.

5 Humidity Min. 50% , Max. 100% 6 Immersed liquid depth from the bottom of

sedimentation tank. 5.5 M

7 Number reqd 2 8 No of stages Multistage 9 Duty Continuous

OPERATING DATA 10 Fluid handled Sea water with sludge content

of 5% & TDS 41900 ppm. 11 Type of fluid (corrosive/ non corrosive etc) Corrosive 12 Specific gravity of fluid 1.01 13 Capacity m3/ h 300 14 Discharge press. bar 5 15 Suction Flooded 16 RPM 740 17 Operating temp. DEG C 35 18 Specific gravity At Flow Temp 1.01 19 Viscosity at operating temp. C p 1 20 pH 4.5-

8.5 21 Minimum efficiency % 85 22 BkW at duty point kW 61.2 23 Starter type DOL 24 Motor kW 75 25 NPSH A mLC Ample


MEC / 10EP/ 01 / 01 / DS / 0003

Page2 of 3


26 Maximum allowable particle size mm

<5mm sand

27 Suction end location Bottom 28

Discharge end location Side top

CONSTRUCTION OF DETAILS / MATERIAL OF CONSTRUCTION 29 Suction bell 2% nickel resistant cast iron ASTM A

439 Gr D2 30 Casing Type Single casing , pull out Material of construction 2% nickel resistant cast iron ASTM A

439 Gr D2 31 Impeller Type Semi open


32 Shaft


33 Line shaft


34 Shaft coupling




37 Shaft enclosing tube (if applicable) 2% nickel resistant cast iron ASTM A 439 Gr D2

38 Seal Mechanical 39 Noise level dB

(A) <85 from one meter distance

40 flange A) suction NA B) discharge 10” ANSI B 16.5 # 150 / RF 41 Matching flanges Duplex steel SS 2205 (UNS S31803)


MEC / 10EP/ 01 / 01 / DS / 0003

Page3 of 3


Note: 1) Painting wherever applicable shall be done as per the enclosed painting specification in chapter 7 of volume II A. 2) Commissioning spares shall be supplied by the tendrer.

3) * Indicates vendor to furnish 4) Refer TS of vertical centrifugal turbine pumps in chapter 2 of volume II A. 5) Motor shall be as per the electrical specification enclosed in chapter 4 of

volume II B. 6) Supply of pump and motor includes companion flange, gaskets,


Vendor to furnish


35 Scope of supply of accessories

Motor as per the electrical specification enclosed in chapter 4 of volume II B.

Yes

Base frame Yes Coupling Yes Speed reducer (if any) Yes Foundation bolt Yes Suction filter (if any) Yes 36 Rated capacity in m 3 /hr * Rated discharge pressure in bar * Pump efficiency % * BkW * Selected kW *


MEC / 10EP/ 01 / 01 / DS / 0004

Page1 of 3


PUMP DATA SHEET


1 Item description Cartridge filter feed pump 2 Type Horizontal single stage

Centrifugal pump 3 Design code MF STD. 4 Location of installation Outdoor- On the ground

level 5 Humidity % Min. 50%, Max. 100% 6 Number reqd 4 7 No of stages Single stage 8 Duty Continuous

OPERATING DATA 9 Fluid handled Sea water(TDS –

41900ppm),UF permeate 10 Type of fluid (corrosive/ non corrosive etc) CORROSIVE 11 Specific gravity of fluid 1.01 12 Capacity m3/ h 4628 13 Discharge press. bar 2.5 14 Suction Flooded 15 Rpm 1500 16 Operating temp. DEG C 35 17 Specific gravity At flow temp 1.01 18 Viscosity at operating temp. C p 1 19 pH 4.5-8.5 20 Minimum efficiency % 85 21 BkW kW 350 22 Drive type VCU 23 Motor kW 400 24 NPSH A mLC Ample 25 Maximum allowable particle size mm <5mm

sand 26

Suction end location Side Suction end location

27 Discharge end location End

Discharge end location


MEC / 10EP/ 01 / 01 / DS / 0004

Page2 of 3


DETAILS OF CONSTRUCTION / MATERIAL OF CONSTRUCTION 28 Casing

Type Split Casing Axial Type


29 Impeller Type Enclosed


Diameter (max./rated/min.) * / */ * 30 Shaft & shaft sleeve


31 Seal Mechanical 32 Flange a) suction 24” ANSI B 16.5 #150, RF b) discharge 20” ANSI B 16.5 #150, RF 33 Noise dB < 85 from one meter distance 34 Lubrication Oil/Grease

35 Scope of supply of accessories Motor as per electrical specification

enclosed in chapter 3B of volume II B. yes

Base frame yes Coupling yes Foundation bolt yes Coupling guard yes 36 Rated capacity in m 3 /hr * Rated discharge pressure in bar * Pump efficiency % * BkW * Selected kW *


MEC / 10EP/ 01 / 01 / DS / 0004

Page3 of 3


Note: 1) Painting wherever applicable shall be done as per the enclosed painting specification in chapter 7 of volume II A. 2) Commissioning spares shall be supplied by the tendrer. 3) Refer TS of horizontal centrifugal pumps in chapter 2 of volume II A. 4) * Indicates vendor to furnish



Vendor to furnish



MEC / 10EP/ 01 / 01 / DS / 0005

Page1 of 3 ADECO TECHNOLOGIES MECON LIMITED

PUMP DATA SHEET


1 Item description UF back wash pump 2 Type Horizontal single stage centrifugal

pump. 3 Design code ISO-2858 4 Location of installation Out door-on the ground level 5 Number reqd 4 6 No of stages Single stage 7 Duty Continuous

OPERATING DATA 8 Fluid handled Sea water(TDS –41900ppm) ,UF

permeate 9 Type of fluid (corrosive/ non corrosive etc) Corrosive 10 Specific gravity of fluid 1.01 11 Capacity m3/ h 300 12 Discharge press. bar 2 13 Suction Flooded 14 RPM 1460 15 Operating temp. DEG C 35 16 Specific gravity At Flow Temp 1.01 17 Viscosity at operating temp. C p 1 18 pH 4.5-8.5 19 Minimum efficiency % 77.9 20 BkW at duty point kW 24.5 21 Starter type VFD 22 Motor kW 30 23 NPSH A mLC Ample 24 Suction end location End 25 Discharge end location Top


MEC / 10EP/ 01 / 01 / DS / 0005


CONSTRUCTION OF DETAILS / MATERIAL OF CONSTRUCTION 26 Casing Type Radially Split



Material of construction Super duplex stainless steel having PREN >40-alloy SAF 2507 (UNS S32750)

Diameter –max /rated /min * / * / * 28 Shaft & shaft sleeve


29 Seal Mechanical 30 Flange a) suction 8”,ANSI B 16.5 # 150 , RF b) discharge 6”ANSI B 16.5 # 150 , RF 31 Noise dB (A) < 85 from one meter distance 32 Lubrication Oil/grease

33 Scope of supply of accessories Motor as per the electrical specification

enclosed in chapter 4 of volume II B. yes

Base frame yes Coupling yes Foundation bolt yes Coupling guard yes 34 Rated capacity in m 3 /hr *

Rated discharge pressure in bar * Pump efficiency % * BkW * Selected kW *


MEC / 10EP/ 01 / 01 / DS / 0005


Note:

1) Painting wherever applicable shall be done as per the enclosed painting specification in chapter 7 of volume II A. 2) Commissioning spares shall be supplied by the tenderer. 3) Refer TS of horizontal centrifugal pumps in chapter 2 of volume II A. 4) * Indicates vendor to furnish

5) Motor shall be as per electrical specification enclosed in chapter 4 of volume II B.


Vendor to furnish



MEC / 10EP/ 01 / 01 / DS / 0006

Page1 of 3


PUMP DATA SHEET

Project: 100 MLD SWRO Desalination Plant

Data Sheet / Document no: MEC / 10EP/ 01 / 01 / DS / 0006

Pump Tag No: P-204 A/B

1 Item description Backwash pump for disc filters 2 Type Horizontal centrifugal pump 3 Design code ISO- 2858 4 Location of installation Indoor 5 Humidity% Min. 50%, Max. 100% 6 Number reqd 2 7 No of stages Single

8 Duty Continuous OPERATING DATA

9 Fluid handled

Filtered sea water with TDS 41900 ppm

10 Type of fluid (corrosive/ non corrosive etc) Corrosive

11 Specific gravity of fluid 1.01 12 Capacity m3/ h 200 13 Discharge press. bar 4.5 14 Suction Flooded 15 RPM 1460 16 Operating temp. DEG C 35 17 Specific gravity At Flow Temp 1.03 18 Viscosity at operating temp. C p 1 19 Ph 4.5-

8.5 20 Minimum efficiency % 85 21 BkW at duty point kW 37 22 Starter type DOL 23 Motor kW 45 24 NPSH A mLC Ample


MEC / 10EP/ 01 / 01 / DS / 0006

Page2 of 3


Note:


25 Maximum Allowable Particle Size mm 26 Suction end location End 27 Discharge end location Top

CONSTRUCTION OF DETAILS / MATERIAL OF CONSTRUCTION 28 Casing Type Radially split



Material Of Construction Super duplex stainless steel having PREN >40 -alloy 2507, UNS S32750/ J 93404 / A890 Gr. 5A



31 Flange A) suction 125 MM,ANSI B 16.5 # 150, RF B) discharge 100MM,ANSI B 16.5 # 150, RF 32 Noise dB < 85 from one meter distance

33 Scope of supply of accessories Motor as per the electrical specification

enclosed in chapter 4 of volume II B. yes

Base frame yes Coupling yes Foundation bolt yes Coupling guard yes 34 Rated capacity in m 3 /hr *

Rated discharge pressure in bar * Pump efficiency % * BkW * Selected kW *


MEC / 10EP/ 01 / 01 / DS / 0006

Page3 of 3




Vendor to furnish



MEC / 10EP/ 01 / 01 / DS / 0007

Page1 of 3


PUMP DATA SHEET



Pump Tag No: P-303A/B

1 Item description Re carbonation tower feed pump 2 Type Horizontal centrifugal pump 3 Design code MN STD 4 Location of installation Out door-On the ground level 5 Humidity % Min. 50%, Max. 100% 6 Number reqd 4 7 No of stages Single 8 Duty Continuous

OPERATING DATA 9 Fluid handled RO product water 10

Type of fluid (corrosive/ non corrosive etc) Corrosive

11 Specific gravity of fluid 1.0 12 Capacity m3/ h 2100 13 Discharge press. bar 2 14 Suction Flooded 15 RPM 1480 16 Operating temp. DEG C 35 degree C 17 Specific gravity At Flow Temp 1.01 18 Viscosity at operating temp. C p 1.0 19 pH 4.5 –8.5 20 Minimum efficiency % 89.6 21 BkW at duty point kW 143 22 Starter type VCU 23 Motor kW kW 160 24 NPSH A mLC Ample 25 Maximum Allowable Particle Size mm NA


MEC / 10EP/ 01 / 01 / DS / 0007

Page2 of 3


Note



26 Suction end location End 27 Discharge end location End CONSTRUCTION OF DETAILS / MATERIAL OF CONSTRUCTION 28 Casing

Type Split Casing Axial Type

Material of construction AISI 316 L 29 Impeller Type Enclosed Material Of Construction AISI 316 L Diameter –max /rated /min * / * / * 30 Shaft & shaft sleeve Material of construction AISI 316 L 31 Flange A) suction 400 MM,ANSI B 16.5 # 150 , RF B) discharge 300 MM,ANSI B 16.5 # 150, RF 32 Noise dB < 85 from one meter distance 33 Scope of supply of accessories Motor as per the electrical specification

enclosed in chapter 4 of volume II B. Yes

Base frame Yes Coupling Yes Foundation bolt Yes Coupling guard Yes Suction filter(if any) Yes 34 Rated capacity in m 3 /hr * Rated discharge pressure in bar * Pump efficiency % * BkW * Selected kW *


MEC / 10EP/ 01 / 01 / DS / 0007

Page3 of 3



Vendor to furnish



MEC / 10EP/ 01 / 01 / DS / 0008

Page1 of 3


PUMP DATA SHEET




1 Item description Service water pump 2 Type Horizontal centrifugal pump 3 Design code ISO- 2858 4 Location of installation Out door-On the ground level

5 Number reqd 2 6 No of stages Single 7 Duty Continuous

OPERATING DATA 8 Fluid handled RO permeate 9


10 Specific gravity of fluid 1.01 11 Capacity m3/ h 40 12 Discharge press. Bar 4 13 Suction Flooded 14 RPM 1500 15 Operating temp. Deg C 35 16 Specific gravity At Flow Temp 1.01 17 Viscosity at operating temp. C p 1 18 pH 4.5- 8.5 19 Minimum efficiency % 67 20 BkW at duty point kW 9.7 21 Starter type DOL 22 Motor kW kW 15 23 NPSH A mLC Ample

24 Maximum allowable particle size mm NA


MEC / 10EP/ 01 / 01 / DS / 0008

Page2 of 3


25 Suction end location End 26 Discharge end location Top CONSTRUCTION OF DETAILS / MATERIAL OF CONSTRUCTION 27 Casing Type Radially split Material of construction AISI 316 L 28 Impeller Type Enclosed Material of construction AISI 316 L Diameter –max /rated /min * / * / * 29 Shaft & Shaft Sleeve Material of construction AISI 316 L 30 Flange

a) suction 80 MM,ANSI B 16.5 # 150 , RF b) discharge 50MM,ANSI B 16.5 # 150 , RF 31 Noise dB < 85 from one meter

distance

32 Scope of supply of accessories

Motor as per the enclosed electrical specification in chapter 4 of volume II B.

Yes

Base frame Yes

Coupling Yes

Foundation bolt Yes

Coupling guard Yes

33 Rated capacity in m 3 /hr *

Rated discharge pressure in bar *

Pump efficiency % *

BkW *

Selected kW *


MEC / 10EP/ 01 / 01 / DS / 0008

Page3 of 3


Note:

1) Painting wherever applicable shall be done as per the enclosed painting specification in chapter 7 of volume II A.

2) Commissioning spares shall be supplied by the tenderer. 3) Refer TS of horizontal centrifugal pumps in chapter 2 of volume II A. 4) * Indicates vendor to furnish



Vendor to furnish



MEC / 10EP/ 01 / 01 / DS / 0009

Page1 of 2


PUMP DATA SHEET




1 Item description Permeate transfer pump 2 Type Horizontal centrifugal pump 3 Design code ISO- 2858 4 Location of installation Indoor

5 Humidity% Min. 50%, Max. 100% 6 Number reqd 15(12W+3S) 7 No of stages Single


9 Fluid handled Service water


11 Specific gravity of fluid 1 12 Capacity m3/ h 350 13 Discharge press. bar 2.5 14 Suction FLOODED 15 RPM 1450 16 Operating temp. DEG C 35 17 Specific gravity AT FLOW TEMP 1 18 Viscosity at operating temp. C p 1 19 pH 4.5-8.5 20 Minimum efficiency % 85

21 BkW at duty point kW 35.7 22 Starter type DOL 23 Motor kW 45

24 NPSH A mLC AMPLE 25 Maximum Allowable Particle Size mm NA


MEC / 10EP/ 01 / 01 / DS / 0009

Page2 of 2



specification in chapter 7 of volume II A. 2) Commissioning spares shall be supplied by the tenderer. 3) Refer TS of horizontal centrifugal pumps in chapter 2 of volume II A. 4) * Indicates vendor to furnish


6) Supply of pump and motor includes companion flange, gaskets, fasteners, reducers/ expanders to match the main pipe size as per respective P&ID and piping GAD drawings.

Vendor to furnish


26 Suction end location End 27 Discharge end location Top

CONSTRUCTION OF DETAILS / MATERIAL OF CONSTRUCTION 28 Casing Type Radially Split Material of construction SS 316L 29 Impeller Type enclosed Material of construction SS 316L Diameter –max /rated /min * / * / * 30 Shaft Material of construction SS 316L 31 Flange a) suction 5,”ANSI B 16.5 # 150 , RF b) discharge 6”,ANSI B 16.5 # 150 , RF 32 Noise dB < 85 from one meter distance

33 Scope of supply of accessories Motor shall be as per the electrical

specification enclosed in chapter 4 of volume II B.

YES

Base frame Yes Coupling Yes Foundation bolt Yes Coupling guard Yes 34 Rated capacity in m 3 /hr * Rated discharge pressure in bar * Pump efficiency % * BkW * Selected kW *


MEC / 10EP/ 01 / 01 / DS / 0010

Page1 of 3


PUMP DATA SHEET



Pump Tag No: P-306 A-O

1 Item description High Pressure pump

2 Type Horizontal multi stage centrifugal pump

3 Design code API-610, latest edition. 4 Location of installation On the ground level 5 Number reqd 15 6 No of stages 6 7 Duty Continuous

OPERATING DATA 8

Fluid handled Filtered Sea water(TDS –41900ppm) ,UF Permeate


10 Specific gravity of fluid 1.01 11 Capacity m3/ h 360 12 Discharge pressure bar 70 13 Suction bar 2 14 RPM 2950 15 Operating temp. Deg C 35 16 Specific gravity At flow temp 1.01 17 Viscosity at operating temp. C p 1 18 pH 4.5-8.5 19 Minimum efficiency % 80.6 20 BkW at duty point kW 834.5 21 Starter type VFD 22 Motor kW 900 23 NPSH A mLC AMPLE


MEC / 10EP/ 01 / 01 / DS / 0010

Page2 of 3


24 Maximum allowable particle size mm NA 25 Suction end location Side 26 Discharge end location Side 27 Casing Type Split casing axial type

Material Of Construction Super duplex stainless steel having PREN >40-alloy SAF 2507 (UNS S32750)





30 Seal Mechanical 31 Flange a) suction 8”ANSI B 16.5 # 600 RF b) discharge 6”,ANSI B 16.5 # 600 RF 32 Noise DB < 85 from meter distance

33 Lubrication Grease/ pumped liquid

34 Scope Of Supply Of Accessories Motor as per the enclosed electrical

Specification in chapter 3B of volume II B.

Yes



MEC / 10EP/ 01 / 01 / DS / 0010

Page3 of 3


Note:

1) Painting wherever applicable shall be done as per the enclosed painting specification in chapter 7 of volume II A. 2) Commissioning spares shall be supplied by the tendrer. 3) Refer TS of horizontal centrifugal pumps in chapter 2 of volume II A. 4) * Indicates vendor to furnish



Vendor to furnish



MEC / 10EP/ 01 / 01 / DS / 0011

Page1 of 3


PUMP DATA SHEET

Project: 100 MLD SWRO Desalination Plant Data Sheet / Document no: MEC / 10EP/ 01 / 01 / DS / 0011 Pump Tag No: P-307 A-O

1 Item description Booster pump 2 Type Horizontal single stage

centrifugal pump

3 Design code ISO 2858 4 Location of installation Indoor-On the ground level 5 Number reqd 15 6 No of stages Single 7 Duty Continuous

OPERATING DATA 8

Fluid handled Filtered Sea water(TDS –41900ppm) ,UF Permeate


10 Specific gravity of fluid 1.01 11 Capacity m3/ h 413 12 Discharge press. bar 70 13 Suction bar 67 14 RPM 1480 15 Operating temp. Deg C 35 16

Specific gravity At Flow Temp 1.01

17 Viscosity at operating temp. C p 1 18 pH 4.5 –8.5 19 Minimum efficiency % 80 20 BkW at duty point kW 44 21 Starter type VFD 22 Motor kW 55 23 NPSH A mLC AMPLE 24 Maximum allowable particle size mm NA


MEC / 10EP/ 01 / 01 / DS / 0011

Page2 of 3



CONSTRUCTION OF DETAILS / MATERIAL OF CONSTRUCTION 27 Casing Type Radially split Material of construction Super duplex stainless steel having

PREN >40-alloy SAF 2507 (UNS S32750) 28 Impeller Type Enclosed Material of construction Super duplex stainless steel having

PREN >40-alloy SAF 2507 (UNS S32750) Diameter –max /rated /min * / * / * 29 Shaft & shaft sleeve


30 Seal Mechanical 31 Flange a) suction 200 MM,ANSI B 16.5 # 150, RF b) discharge 150 MM,ANSI B 16.5 # 150, RF 32 Noise level dB (A) <85 from one meter distance.

33 Scope of supply of accessories Motor as per the enclosed electrical

specification in chapter 4 of volume II B.

yes

Base frame yes Coupling yes Foundation bolt yes Coupling guard yes 34 Rated capacity in m 3 /hr * Rated discharge pressure in bar * Pump efficiency % * BkW * Selected kW *


MEC / 10EP/ 01 / 01 / DS / 0011

Page3 of 3


Note:




Vendor to furnish



MEC / 10EP/ 01 / 01 / DS / 0012

Page1 of 3


PUMP DATA SHEET




1 Item description RO Membrane Chemical Cleaning pump

2 Type Horizontal centrifugal pump 3 Design code API-610 4 Location of installation On the ground level 5 Humidity% Min. 50%, Max. 100% 6 Number reqd 2 7 No of stages Single 8 Duty Continuous

OPERATING DATA 9 Fluid handled Chemical + RO permeate water 10


11 Specific gravity of fluid 1.01 12 Capacity m3/ h 300 13 Discharge press. bar 5 14 Suction Flooded 15 RPM 1475 16 Operating temp. DEG C 35 degree C 17 Specific gravity At flow temp 1.01 18 Viscosity at operating temp. C p 1 19 pH 1 to 12 20 Minimum efficiency % 80 21 BkW at duty point kW 51.5 22 Starter type DOL 23 Motor kW 55 24 NPSH A mLC Ample 25 Maximum allowable particle size mm NA


MEC / 10EP/ 01 / 01 / DS / 0012

Page2 of 3


26 Suction end location End 27 Discharge end location Top CONSTRUCTION OF DETAILS / MATERIAL OF CONSTRUCTION 28 Casing Type radially split


29 Impeller Type ENCLOSED




31 Seal Mechanical 32 Flange a) suction 10”ANSI B 16.5 # 150, RF b) discharge 8” ANSI B 16.5 # 150, RF 33 Noise DB < 85 from one meter distance 34 Scope of supply of accessories Motor shall be as per the electrical


Yes



MEC / 10EP/ 01 / 01 / DS / 0012

Page3 of 3


Note: 1) Painting wherever applicable shall be done as per the enclosed painting specification in chapter 7 of volume II A. 2) Commissioning spares shall be supplied by the tenderer.

3) * Indicates vendor to furnish 4) Refer TS of vertical wet pit pumps in chapter 2 of volume II A. 5) Motor shall be as per the electrical specification enclosed in chapter 4 of



Vendor to furnish



MEC / 10EP/ 01 / 01 / DS / 0013

Page1 of 2


PUMP DATA SHEET

Project: 100 MLD SWRO Desalination Plant Data Sheet / Document no: MEC / 10EP/ 01 / 01 / DS / 0013 Pump Tag No: P-701A/B

1 Item description 98 % Sulfuric acid unloading cum transfer pump

2 Type Horizontal centrifugal pump 3 Design code ISO-2858 4 Location of installation On the ground level 5 Humidity% Min. 50%, Max. 100% 6 Number reqd 2 7 No of stages Single 8 Duty Continuous

OPERATING DATA 9 Fluid handled 98 % Sulfuric acid. 10


11 Specific gravity of fluid 1.834 12 Capacity m3/ h 20 13 Discharge press. bar 1.5 14 Suction Flooded 15 Rpm 2900 16 Operating temp. DEG C 35 degree C 17 Specific gravity At flow temp 1.834 18 Viscosity at operating temp. C p 1 19 pH <1 20 Minimum efficiency % 85 21 BkW at duty point kW 3.2 22 Starter type DOL 23 Motor kW 5.5 24 NPSH A mLC Ample 25 Suction end location End 26 Discharge end location Top


MEC / 10EP/ 01 / 01 / DS / 0013

Page2 of 2



3) * Indicates vendor to furnish 4) Refer TS of horizontal centrifugal pumps in chapter 2 of volume II A. 5) Motor shall be as per the electrical specification enclosed in chapter 4 of


fasteners, reducers/ expanders to match the main pipe size as per respective P&ID and piping GAD drawings

Vendor to furnish * Equipment GA drawing & cross sectional drawing

* Performance curve

CONSTRUCTION OF DETAILS / MATERIAL OF CONSTRUCTION 28 Casing Type Radialy split Material of construction Alloy 20 29 Impeller Type Enclosed Material of construction Alloy 20 Diameter –max /rated /min * / * / * 30 Shaft Material of construction Alloy 20 31 Seal Mechanical 32 Flange a) suction 50 MM,ANSI B 16.5 # 150, RF b) discharge 32MM,ANSI B 16.5 # 150, RF 33 Noise dB (A) < 85 from one

meter distance

34 Scope Of Supply Of Accessories

Motor shall be as per the electrical specification enclosed in chapter 4 of volume II B.

Yes



MEC / 10EP/ 01 / 01 / DS / 0014

Page1 of 2


PUMP DATA SHEET




1 Item description 35% Sodium Bisulphite unloading and transfer pump

2 Type Horizontal centrifugal pump 3 Design code ISO-2858 4 Location of installation Outdoor-On the ground level 5 Humidity % Min. 50%, Max. 100% 6 Number reqd 2 7 No of stages Single 8 Duty Continuous

OPERATING DATA 9 Fluid handled 35 % Sodium Bisulphite 10


11 Specific gravity of fluid 1.35 12 Capacity m3/ h 12 13 Discharge press. bar 1 14 Suction Flooded 15 RPM 1420 16 Operating temp. DEG C 35 17 Specific gravity At flow temp 1.35 18 Viscosity at operating temp. C p 1 19 pH 10-12 20 Minimum efficiency % 85 21 BkW at duty point kW 1.102 22 Starter type DOL 23 Motor kW 1.5 24 NPSH A mLC Ample 25 Suction end location End 26 Discharge end location Top


MEC / 10EP/ 01 / 01 / DS / 0014

Page2 of 2







* Performance curve

CONSTRUCTION OF DETAILS / MATERIAL OF CONSTRUCTION 27 Casing Type Radially Spilt Material of construction SS316L 28 Impeller Type Enclosed Material of construction SS316L Diameter –max /rated /min * / * / * 29 Shaft Material of construction SS316L 30 Seal Mechanical 31 Flange a) suction 2”,ANSI B 16.5 # 150, RF b) discharge 1 ½”ANSI B 16.5 # 150, RF 32 Noise dB < 85 from meter distance 33 Scope of supply of accessories Motor shall be as per the electrical


Yes



MEC / 10EP/ 01 / 01 / DS / 0015

Page1 of 2


PUMP DATA SHEET




1 Item description 12% Sodium hypochlorite unloading cum transfer pump

2 Type Horizontal centrifugal pump 3 Design code ISO-2858 4 Location of installation Outdoor-On the ground level 5 Humidity% Min. 50%, Max. 100% 6 Number reqd 2 (1W+1S) 7 No of stages Single 8 Duty Continuous

OPERATING DATA 9 Fluid handled 12 % Sodium Hypochlorite 10


11 Specific gravity of fluid 1.12 12 Capacity m3/ h 20 13 Discharge press. bar 1 14 Suction Flooded 15 RPM 1420 16 Operating temp. Degree C 35 17 Specific gravity At flow temp 1.12 18 Viscosity at operating temp. C p 1 19 pH >8.5 20 Minimum efficiency % 85 21 BkW at duty point kW 1.632 22 Starter type DOL 23 Motor kW 2.2 24 NPSH A mLC Ample 25 Suction end location End 26 Discharge end location Top


MEC / 10EP/ 01 / 01 / DS / 0015

Page2 of 2


Note:





* Performance curve

CONSTRUCTION OF DETAILS / MATERIAL OF CONSTRUCTION 27 Casing Type Radially Split Material of construction SS316L 28 Impeller Type Enclosed Material of construction SS316L Diameter –max /rated /min * / * / * 29 Shaft Material of construction SS316L 30 Seal Mechanical 31 Flange a) suction 2”,ANSI B 16.5 # 150, RF b) discharge 1 ½”,ANSI B 16.5 # 150, RF 32 Noise dB (A) < 85 from one meter

distance 33 Scope of supply of accessories Motor shall be as per the electrical specification

enclosed in chapter 4 of volume II B. Yes



MEC / 10EP/ 01 / 01 / DS / 0016

Page1 of 2


PUMP DATA SHEET


1 Item description Antiscalant unloading cum transfer pump

2 Type Horizontal centrifugal pump 3 Design code ISO-2858 4 Location of installation Outdoor-On the ground level 5 Humidity% Min. 50%, Max. 100% 6 Number reqd 2(1W+1S) 7 No of stages Single 8 Duty Continuous

OPERATING DATA 9 Fluid handled Antiscalant 10 Type of fluid (corrosive/ non corrosive etc) Corrosive 11 Specific gravity of fluid 1.53 12 Capacity m3/ h 12 13 Discharge press. bar 1 14 Suction Flooded 15 RPM 1420 16 Operating temp. degree C 35 17 Specific gravity At flow temp 1.53 18 Viscosity at operating temp. C p 1 19 pH - 20 Minimum efficiency % 85 21 BkW kW 1.2 22 Starter type DOL 23 Motor kW 1.5 24 NPSH A mLC Ample 25 Suction end location End 26 Discharge end location Top

CONSTRUCTION DETAILS / MATERIAL OF CONSTRUCTION 27 Casing

Type Radially spilt Material of construction SS316L


MEC / 10EP/ 01 / 01 / DS / 0016

Page2 of 2



specification in chapter 7 of volume II A. 2) Commissioning spares shall be supplied by the tendrer. 3) * Indicates vendor to furnish 4) Refer TS of vertical wet pit pumps in chapter 2 of volume II A. 5) Motor shall be as per the electrical specification enclosed in chapter 4 of volume

II B. 6) Supply of pump and motor includes companion flange, gaskets, fasteners,

reducers/ expanders to match the main pipe size as per respective P&ID and piping GAD drawings. For interconnection with HDPE piping flange, material of construction for companion flange, reducers/expanders shall be Duplex stainless steel SS 2205 (refer P & ID & piping GADs).

Vendor to furnish


28 Impeller Type Enclosed Material of construction SS316L Diameter –max /rated /min * / * / * 29 Shaft Material of construction SS316L 30 Seal mechanical 31 Flange a) suction 2”,ANSI B 16.5 # 150, RF b) discharge 1 ½”,ANSI B 16.5 # 150, RF 32 Noise dB (A) < 85 from one meter

distance

33 scope of supply of accessories


Yes



MEC / 10EP/ 01 / 01 / DS / 0017

Page1 of 2


PUMP DATA SHEET


1 Item description 45% Caustic soda unloading cum transfer pump

2 Type Horizontal centrifugal pump 3 Design code ISO 2858 4 Location of installation Outdoor-On the ground level 5 Humidity% Min. 50%,Max. 100% 6 Number reqd 2 7 No of stages Single 8 Duty Continuous

OPERATING DATA 9 Fluid handled 45 % Caustic soda 10 Type of fluid (corrosive/ non corrosive etc) Corrosive 11 Specific gravity of fluid 1.53 12 Capacity m3/ h 12 13 Discharge press. bar 1 14 Suction Flooded 15 RPM 1420 16 Operating temp. Degree C 35 17 Specific gravity At flow temp 1.5 18 Viscosity at operating temp. C p 1 19 pH 9-13 20 Minimum efficiency % 85 21 BkW at duty point kW 1.2 22 Starter type DOL 23 Motor kW 2.2 24 NPSH A mLC Ample 25 Suction end location End 26 Discharge and location Top


MEC / 10EP/ 01 / 01 / DS / 0017

Page2 of 2






Vendor to furnish


CONSTRUCTION DETAILS / MATERIAL OF CONSTRUCTION 28 Casing Type Radially spilt Material of construction SS316L 29 Impeller Type Enclosed Material of construction SS316L Diameter –max /rated /min * / * / * 30 Shaft Material of construction SS316L 31 Seal MECHANICAL 32 Flange A) suction 2",ANSI B 16.5 # 150, RF B) discharge 1 ½”ANSI B 16.5 # 150, RF 33 Noise dB(A) < 85 from one meter

distance

32 scope of supply of accessories


Yes



MEC / 10EP/ 01 / 01 / DS / 0018

Page1 of 2


PUMP DATA SHEET

Project: 100 MLD SWRO Desalination Plant Data Sheet / Document no: MEC / 10EP/ 01 / 01 / DS / 0018

Pump Tag No: P-401A/B/C 1 Item description Absorber feed booster pump 2 Type Horizontal centrifugal pump 3 Design code ISO- 2858 4 Location of installation Indoor 5 Humidity% Min. 50%, Max. 100% 6 Number reqd. 3 7 No of stages Single 8 Duty Continuous

OPERATING DATA 9 Fluid handled Filtered sea water 10


11 Specific gravity of fluid 1 12 Capacity m3/ h 680 13 Discharge press. bar 4 14 Suction Bar 2 15 RPM 1480

16 Operating temp. DEG C 35

17 Specific gravity AT FLOW TEMP

1

18 Viscosity at operating temp. C p 1 19 pH 4.5-8.5 20 Minimum efficiency % 82.4 21 BkW at duty point kW 50 22 Starter type DOL 23 Motor kW 55

24 NPSH A mLC Ample



MEC / 10EP/ 01 / 01 / DS / 0018

Page2 of 2


Notes: 1) Painting wherever applicable shall be done as per the enclosed painting





* Performance curve


CONSTRUCTION DETAILS / MATERIAL OF CONSTRUCTION 28 Casing Type Radially Split Material of construction SSS316L 29 Impeller Type Enclosed Material of construction SSS316L Diameter –max /rated /min * / * / * 30 Shaft & Shaft Sleeve Material of construction SS 316L 31 Flange a) suction 8”ANSI B 16.5 # 150 , RF b) discharge 6”ANSI B 16.5 # 150 , RF 32 Noise dB < 85 from one meter distance

33 Scope of supply of accessories Motor as per the enclosed electrical

specification in chapter 4 of volume II B. Yes



MEC / 10EP/ 01 / 01 / DS / 0019

Page1 of 2


PUMP DATA SHEET




1 Item description Lime stone recharging booster pump

2 Type Horizontal centrifugal pump 3 Design code ISO- 2858 4 Location of installation Indoor 5 Humidity% Min. 50%, Max. 100% 6 Number reqd 2 7 No of stages Single 8 Duty Continuous

OPERATING DATA 9 Fluid handled Service water 10 Type of fluid (corrosive/ non corrosive etc) CORROSIVE 11 Specific gravity of fluid 1.01 12 Capacity m3/ h 135 13 Discharge press. bar 8 14 Suction Flooded 15 RPM 1450 16 Operating temp. OC 35 17 Specific gravity AT FLOW TEMP 1.01 18 Viscosity at operating temp. C p 1 19 Ph 6.5-7.5 20 Minimum efficiency % 65 21 BkW at duty point kW 45 22 Starter type DOL 23 Motor kW 55 24 NPSH A mLC AMPLE



MEC / 10EP/ 01 / 01 / DS / 0019

Page2 of 2


Note:

1) Painting wherever applicable shall be done as per the enclosed painting specification in chapter 7 of volume II A. 2) Commissioning spares shall be supplied by the tendrer. 3) Refer TS of horizontal centrifugal pumps in chapter 2 of volume II A. 4) * Indicates vendor to furnish



Vendor to furnish



CONSTRUCTION OF DETAILS / MATERIAL OF CONSTRUCTION 28 Casing Type Radilly Split Material of construction SS 316L 29 Impeller Type Closed/Semi Open Material of construction SS 316L Diameter –max /rated /min * / * / * 30 Shaft & shaft sleeve Material of construction SS 316L 31 Flange a) suction 6’,ANSI B 16.5 # 150, RF b) discharge 4”,ANSI B 16.5 # 150, RF

32 Noise dB (A) < 85 from one meter distance 33 Scope of supply of accessories Motor shall be as per the electrical


Yes



MEC / 10EP/ 01 / 01 / DS / 0020

Page1 of 2


PUMP DATA SHEET




1 Item description Slurry disposal pump 2 Type Horizontal centrifugal pump 3 Design code ISO- 2858 4 Location of installation Outdoor



9 Fluid handled Slurry

10 Type of fluid (corrosive/ non corrosive etc) Corrosive 11 Specific gravity of fluid 1.2 12 Capacity m3/ h 10 13 Discharge press. bar 2.2 14 Suction Flooded 15 RPM 1450 16 Operating temp. DEG C 35 17 Specific gravity At Flow Temp 1.2 18 Viscosity at operating temp. C p 19 pH 6.5-8.5 20 Minimum efficiency % 85

21 BkW at duty point kW 1.7 22 Starter type DOL 23 Motor kW 2.2

24 NPSH A mLC AMPLE 25 Maximum Allowable Particle Size mm 5-10


MEC / 10EP/ 01 / 01 / DS / 0020

Page2 of 2


Note:





* Performance curve


CONSTRUCTION OF DETAILS / MATERIAL OF CONSTRUCTION 28 Casing Type Radially Split Material of construction SS 316L 29 Impeller Type Semi open Material of construction SS 316L Diameter –max /rated /min * / * / * 30 Shaft Material of construction SS 316L 31 Flange a) Suction 4”,ANSI B 16.5 # 150, RF b) Discharge 2 ”ANSI B 16.5 # 150, RF 32 noise dB < 85 from one meter distance

33 Scope of supply of accessories Motor shall be as per the electrical


Yes



MEC / 10EP/ 01 / 01 / DS / 0021

Page 1 of 3


PUMP DATA SHEET



Pump Tag No: P-501A-D

1 Item description Reject water transfer pump 2 Type Horizontal centrifugal pump 3 Design code Manufacturing standard 4 Location of installation On the ground level 5 Humidity% Min. 50%, Max. 100% 6 Number reqd 4 7 No of stages Single 8 Duty Continuous

OPERATING DATA 9

Fluid handled RO reject water with TDS 80000 ppm.


11 Specific gravity of fluid 1.01 12 Capacity m3/ h 3430 13 Discharge press. bar 5 14 Suction Flooded 15 RPM 1480 16 Operating temp. Deg C 35 17 Specific gravity AT FLOW TEMP 1.01 18 Viscosity at operating temp. C p 1 19 pH 6.1-8.7 20 Minimum efficiency % 90.7 21 BkW kW 530 22 Starter type VCU 23 Motor kW 600 24 NPSH A mLC Ample 25 Maximum allowable particle size mm NA


MEC / 10EP/ 01 / 01 / DS / 0021

Page 2 of 3


26 Suction end size and location End 27 Discharge end size and location End

CONSTRUCTION OF DETAILS / MATERIAL OF CONSTRUCTION 28 Casing

Type Split casing axial type

Material of construction

Super duplex stainless steel having PREN >40-alloy SAF 2507 (UNS S32750)





Material Of Construction


31 Seal Mechanical 32 Flange

a) suction 28”ANSI B 16.5 # 150, RF b) discharge 24”ANSI B 16.5 # 150, RF

33 Noise dB (A) < 85 from one meter distance

34 Lubrication Grease 34 Scope of supply of accessories

Motor shall be as per the electrical specification enclosed in chapter 3B of volume II B.

YES

Base frame Yes Coupling Yes Foundation bolt Yes Coupling guard Yes Suction filter Yes 35 Rated capacity in m 3 /hr * Rated discharge pressure in bar * Pump efficiency % * BkW * Selected kW


MEC / 10EP/ 01 / 01 / DS / 0021

Page 3 of 3



3) * Indicates vendor to furnish 4) Refer TS of vertical wet pit pumps in chapter 2 of volume II A. 5) Motor shall be as per the electrical specification enclosed in chapter 3B of



Vendor to furnish



MEC / 10EP/ 01 / 01 / DS / 0022

Page1 of 2


PUMP DATA SHEET

Project: 100 MLD SWRO Desalination Plant Data Sheet / Document no: MEC / 10EP/ 01 / 01 / DS / 0022 Pump Tag No: P-602 A/B

1 Item description Skid mounted RO chemical pump 2 Type Horizontal centrifugal pump 3 Design code ISO- 2858 4 Location of installation Indoor 5 Humidity% Min. 50%, Max. 100% 6 Number reqd 1 7 No of stages Single 8 Duty Continuous

OPERATING DATA 9 Fluid handled RO chemical 10 Type of fluid (corrosive/ non corrosive

etc) Corrosive

11 Specific gravitry of fluid 1.3 12 Capacity m3/ h 2 13 Discharge press. bar 0.5 14 Suction Flooded 15 RPM 1450 16 Operating temp. DEG C 35 degree C 17 Specific gravity At Flow

Temp 1.3

18 Viscosity at operating temp. C p 1 19 pH 1-14 20 Minimum efficiency % 85 21 BkW at duty point kW 0.37 22 Starter type DOL 23 Motor kW 0.55 24 NPSH A mLC Ample 25 Maximum allowable particle size mm NA 26 Suction end location End Suction end

location 27 Discharge end location Top Discharge end

location


MEC / 10EP/ 01 / 01 / DS / 0022

Page2 of 2



3) * Indicates vendor to furnish 4) Refer TS of vertical wet pit pumps in chapter 2 of volume II A. 5) Motor shall be as per the electrical specification enclosed in chapter 4 of


fasteners, reducers/ expanders to match the main pipe size as per respective P&ID and piping GAD drawings.

Vendor to furnish


CONSTRUCTION OF DETAILS / MATERIAL OF CONSTRUCTION 28 Casing Type Radilly split Material of construction SS 316L 29 Impeller Type Semi open / Enclosed Material of construction SS 316L Diameter –max /rated /min * / * / * 30 Shaft & shaft sleeve Material of construction SS 316L 31 Flange a) suction 150MM,ANSI B 16.5 # 150, RF b) discharge 100MM,ANSI B 16.5 # 150, RF 32 Noise dB < 85 from one meter distance

33 scope of supply of accessories Motor shall be as per the electrical


YES



MEC / 10EP/ 01 / 01 / DS / 0023

Page1 of 3


PUMP DATA SHEET




1 Item description SSooddiiuumm hhyyppoo cchhlloorriittee ddoossiinngg ppuummpp ffoorr iinnttaakkee ssyysstteemm

2 Type Hydraulic Diaphragm 3 Design code API 675 4 Location of installation Indoor

5 Humidity% Min. 50%, Max. 100% 6 Number reqd 2 (1W+1S) 7 No of stages Single


9 Fluid handled 10 -12% Sodium hypochlorite solution


11 Specific gravity of fluid 1.12 12 Capacity LPH 400 13 Discharge press. bar 4 14 Suction Flooded 15 Plunger/Diaphragm speed (strokes/min) 100 * (bidder to confirm) 16 Operating temp. degree C 35 17 Specific gravity At flow temp 1.12 18 Viscosity at operating temp. C p 1

19 pH - 20 Volumetric Efficiency % > 80

21 Mechanical Efficiency % > 65



MEC / 10EP/ 01 / 01 / DS / 0023

Page2 of 3


25 NPSH A ( mLC) Ample 26 Maximum allowable particle size NA 27 Suction end location Bottom 28 Discharge end location Top

CONSTRUCTION DETAILS / MATERIAL OF CONSTRUCTION 29 Liquid end PP Hydraulic diaphragm PTFE faced nitrile

Plunger Alloy 20 Diameter of plunger (mm) 105 Valve PVC/PP Valve body PVC/PP Valve seat PTFE Frame MS Fabricated (Epoxy Coated) 30 Stroke adjustment Manual & Auto (0-100%) 31

Capacity Control manual & auto (0-100%) by stroke adjustment (4-20 Ma signal from DCS)

32 Flange PVC/PP/HDPE a) suction 1.5”, ANSI B 16.5 # 150,RF b) discharge 1.5” , ANSI B 16.5 # 150,RF 33 Noise dB < 85 from one meter distance 34 Set Pressure of Relief valve 4.5 Kg/cm2 Gear Box ratio 15:1 (bidder to confirm)* Coupling Love –Joy

35 SCOPE OF SUPPLY Motor shall be as per the electrical


Yes

Base frame Yes Coupling(lov joy) Yes Speed reducer Yes Gear Box Yes Foundation bolt Yes Internal relief valve( in built) Yes Coupling guard Yes Suction filter (y strainer) Yes 36 Rated capacity in m 3 /hr * Rated discharge pressure in bar * Pump efficiency % * Selected kW *


MEC / 10EP/ 01 / 01 / DS / 0023

Page3 of 3


Note:

1) Painting wherever applicable shall be done as per the enclosed painting

specification, chapter 7 of the volume II A. 2) Commissioning spares shall be supplied by the tenderer.

3) * Indicates vendor to furnish 4) Refer TS of Metering/Dosing pumps in chapter 2 of volume II A.

5) Motor shall be supplied as per the electrical specification enclosed in chapter 4 of volume II B.

6) The pump shall be provided with inbuilt safety valve 7) Supply of pump and motor includes companion flange, gaskets, fasteners,

reducers/ expanders to match the main pipe size as per respective P&ID and piping GAD drawings.

Bidder to Furnish * Equipment GA drawing & cross sectional drawing * Performance curve


MEC / 10EP/ 01 / 01 / DS / 0024

Page1 of 3


PUMP DATA SHEET




1 Item description SSooddiiuumm hhyyppoo cchhlloorriittee ddoossiinngg ppuummppss ffoorr UUFF bbaacckkwwaasshh




9 Fluid handled 10-12% Sodium hypochlorite solution


11 Specific gravity of fluid 1.12 12 Capacity LPH 150 13 Discharge press. bar 2.2 14 Suction Flooded 15 Plunger/diaphragm speed (strokes/min) 100 * (bidder to confirm) 16 Operating temp. degree C 35 17 Specific gravity At flow temp 1.12 18 Viscosity at operating temp. C p 1 19 pH 9-13 20 Volumetric Efficiency % > 80




MEC / 10EP/ 01 / 01 / DS / 0024

Page2 of 3


Note:

1) Painting wherever applicable shall be done as per the enclosed painting specification, chapter 7 of the volume II A.

25 NPSH A mLC 26 Maximum Allowable Particle Size mm 27 Suction end location Bottom 28 Discharge end location Top


Plunger Alloy 20 Diameter of plunger (mm) 105 Valve PVC/PP Valve body PVC/PP Valve seat PTFE MS Fabricated (Epoxy Coated) MS Fabricated (Epoxy Coated) 29 Stroke adjustment Manual & Auto (0-100%) 30


30 Flange PVC/PP/HDPE a) suction 1”,ANSI B 16.5 # 150-RF b) discharge 1” ,ANSI B 16.5 # 150-RF 31 Noise dB < 85 from one meter distance 32 Set Pressure of Relief valve 2.7 Kg/cm2 Gear Box ratio 15:1 (bidder to confirm)* Coupling Love –Joy

32 scope of supply of accessories Motor shall be as per the electrical


Yes

Base frame Yes Coupling(Lov joy) Yes Speed reducer Yes Foundation bolt Yes Internal relief valve( in built) Yes Coupling Guard Yes Suction Filter (y strainer) Yes 33 Rated capacity in m 3 /hr * Rated discharge pressure in bar * Pump efficiency % * Selected kW *


MEC / 10EP/ 01 / 01 / DS / 0024

Page3 of 3


2) Commissioning spares shall be supplied by the tenderer. 3) * Indicates vendor to furnish 4) Refer TS of Metering/Dosing pumps in chapter 2 of volume II A.




Vendor to furnish



MEC / 10EP/ 01 / 01 / DS / 0025

Page1 of 3


PUMP DATA SHEET




1 Item description 98%Sulfuric acid dosing pump 2 Type Hydraulic Diaphragm 3 Design code API 675 4 Location of installation Indoor



9 Fluid handled 98% Sulfuric acid


11 Specific gravity of fluid 1.834 12 Capacity LPH 850 13 Discharge press. bar 2.5 14 Suction Flooded 15 Plunger/Diaphragm speed (strokes/min) 100 * (bidder to confirm) 16 Operating temp. Degree C 35 17 Specific gravity At flow temp 1.834 18 Viscosity at operating temp. C p 15 19 pH <1 20 Volumetric Efficiency % > 80


22 BkW at duty point kW 1.064 23 Strter type DOL 24 Motor kW 1.5

25 NPSH A mLC Ample


MEC / 10EP/ 01 / 01 / DS / 0025

Page2 of 3


26 Maximum Allowable Particle Size NA 27 Suction end location End 28 Discharge end location Top




32 Flange PVC/PP/HDPE a) suction 1.5”,ANSI B 16.5 # 150-RF b) discharge 1.5” ,ANSI B 16.5 # 150-RF

33 Noise dB < 85 from one meter distance Set Pressure of Relief valve 4.5 Kg/cm2 Gear Box ratio 15:1 (bidder to confirm)* Coupling Love –Joy SCOPE OF SUPPLY Motor shall be as per the electrical


Yes

Base frame Yes 34 Coupling(lov joy) Yes Speed reducer Yes Gear Box Yes Foundation bolt Yes Internal relief valve( in built) Yes Coupling guard Yes Suction filter (y strainer) Yes 35 Rated capacity in m 3 /hr * Rated discharge pressure in bar * Pump efficiency % * Selected kW *


MEC / 10EP/ 01 / 01 / DS / 0025

Page3 of 3


Note:





6) The pump shall be provided with inbuilt safety valve 7) Supply of pump and motor includes companion flange, gaskets,


Vendor to furnish



MEC / 10EP/ 01 / 01 / DS / 0026

Page1 of 3


PUMP DATA SHEET




1 Item description Sodium bi sulphite dosing pump 2 Type Hydraulic Diaphragm 3 Design code API 675 4 Location of installation Indoor



9 Fluid handled 10% Sodium bi sulphite solution


11 Specific gravity of fluid 1 12 Capacity LPH 450 13 Discharge press. bar 2.7 14 Suction Flooded 15 Plunger/Diaphragm speed (strokes/min) 100 * (bidder to confirm) 16 Operating temp. Degree C 35 17 Specific gravity At flow temp 1 18 Viscosity at operating temp. C p 19 pH 9.5-12.5 20 Volumetric Efficiency % > 80



25 NPSH A mLC Ample


MEC / 10EP/ 01 / 01 / DS / 0026

Page2 of 3


26 Maximum allowable particle size NA 27 Suction end location End 28 Discharge end location Top




32 Flange PVC/PP/HDPE a) suction 1”, ANSI B 16.5 # 150,RF b) discharge 0.75 ”, ANSI B 16.5 # 150,RF

33 Noise dB < 85 from one meter distance 34 Set Pressure of Relief valve 3.2 Kg/cm2 Gear Box ratio 15:1 (bidder to confirm)* Coupling Love –Joy 35 SCOPE OF SUPPLY Motor shall be as per the electrical


Yes



MEC / 10EP/ 01 / 01 / DS / 0026

Page3 of 3








Vendor to furnish



MEC / 10EP/ 01 / 01 / DS / 0027

Page1 of 3


PUMP DATA SHEET




1 Item description AAnnttiissccaallaanntt ddoossiinngg ppuummpp 2 Type Hydraulic Diaphragm 3 Design code API 675 4 Location of installation Indoor



9 Fluid handled 10% Antiscalant solution

10 Type of fluid (corrosive/ non corrosive etc) CORROSIVE

11 Specific gravity of fluid 1.53 12 Capacity LPH 450 13 Discharge press. bar 2.7 14 Suction Flooded 15 Plunger/Diaphragm speed (strokes/min) 100 * (bidder to confirm) 16 Operating temp. Degree C 35 17 Specific gravity At flow temp 1.53 18 Viscosity at operating temp. C p 1 19 pH 1-14 20 Volumetric Efficiency % > 80



25 NPSH A mLC Ample


MEC / 10EP/ 01 / 01 / DS / 0027

Page2 of 3


Note:

26 Maximum allowable particle size NA 27 Suction end location Bottom 28 Discharge end location Top




32 Flange PVC/PP/HDPE a) suction 1”, ANSI B 16.5 # 150,RF b) discharge 0.75” , ANSI B 16.5 # 150,RF 33 Noise dB < 85 from one meter distance 34 Set Pressure of Relief valve 3.2 Kg/cm2 Gear Box ratio 15:1 (bidder to confirm)* Coupling Love –Joy



Yes



MEC / 10EP/ 01 / 01 / DS / 0027

Page3 of 3








Vendor to furnish



MEC / 10EP/ 01 / 01 / DS / 0028

Page1 of 3


PUMP DATA SHEET




1 Item description CCaauussttiicc ssooddaa ddoossiinngg ppuummpp 2 Type Hydraulic Diaphragm 3 Design code API 675 4 Location of installation Indoor



9 Fluid handled 45% Caustic soda


11 Specific gravity of fluid 1.5 12 Capacity LPH 20 13 Discharge press. bar 2.7 14 Suction Flooded 15 Plunger/Diaphragm speed (strokes/min) 100 * (bidder to confirm) 16 Operating temp. Degree C 35 17 Specific gravity At flow temp 1.5 18 Viscosity at operating temp. C p 4 19 pH 10.5-12.5 20 Volumetric Efficiency % > 80



25 NPSH A mLC Ample


MEC / 10EP/ 01 / 01 / DS / 0028

Page2 of 3


26 Maximum allowable particle size NA 27 Suction end location Bottom 28 Discharge end location Top




32 Flange PVC/PP/HDPE a) suction 1”, ANSI B 16.5 # 150,RF b) discharge 0.75 ” , ANSI B 16.5 # 150,RF 33 Noise dB < 85 from one meter distance 34 Set Pressure of Relief valve 3.2 Kg/cm2 Gear Box ratio 15:1 (bidder to confirm)* Coupling Love –Joy



Yes

Base frame Yes Coupling(lov joy) Yes Speed reducer Yes Gear Box Yes Foundation bolt Yes Internal relief valve( in built) Yes Coupling guard Yes Suction filter (y strainer) Yes 36 Rated capacity in m 3 /hr *

Rated discharge pressure in bar * Pump efficiency % * Selected kW * Liquid end PP


MEC / 10EP/ 01 / 01 / DS / 0028

Page3 of 3


Note:







Vendor to furnish



MEC / 10EP/ 01 / 01 / DS / 0029

Page1 of 3


PUMP DATA SHEET




1 Item description SSooddiiuumm hhyyppoo cchhlloorriittee ddoossiinngg ppuummppss ffoorr ppoottaabbllee wwaatteerr


5 Humidity% Min. 50%, Max. 100% 6 Number reqd 2(1W+1S) 7 No of stages Single 8 Duty Continuous

OPERATING DATA 9 Fluid handled 10-12% Sodium hypochlorite

solution 10

Type of fluid (corrosive/ non corrosive etc) CORROSIVE

11 Specific gravitry of fluid 1.12 12 Capacity LPH 30 13 Discharge press. bar 2.7 14 Suction Flooded 15 Plunger/Diaphragm speed (strokes/min) 100 * (bidder to confirm) 16 Operating temp. Degree C 35 17 Specific gravity At flow temp 1.12 18 Viscosity at operating temp. C p 1 19 pH 9-13 20 Volumetric Efficiency % > 80


22 BkW at duty point kW 0.37 23 Starter Type DOL 24 Motor kW 0.55


MEC / 10EP/ 01 / 01 / DS / 0029

Page2 of 3


25 NPSH A (mLC) Ample 26 Maximum allowable particle size NA 27 Suction end location Bottom 28 Discharge end location Top




32 Flange PVC/PP/HDPE a) suction 1”, ANSI B 16.5 # 150,RF b) discharge 0.75” , ANSI B 16.5 # 150,RF 33 Noise dB < 85 from one meter distance 34 Set Pressure of Relief valve 3.2 Kg/cm2 Gear Box ratio 15:1 (bidder to confirm)* Coupling Love –Joy



Yes



MEC / 10EP/ 01 / 01 / DS / 0029

Page3 of 3


Note:





6) The pump shall be provided with inbuilt safety valve 7) Supply of pump and motor includes companion flange, gaskets,


Vendor to furnish



Page 1of 1


Valve Type Flanged Make *

Fluid Handled 98% sulphuric acid solution, RO permeate , carbon di oxide ,service water

Piping material SS 316 L Size range 2 “ - 16 “ Rating #150 Max. Operating Pressure Kg/ cm 2 10 Operating Temp. ° C 22-35 Material Body & Side/Tail Piece ASTM A351 CF8M Ball ASTM A351 CF8M Seat ASTM A351 CF8M Spindle ASTM A351 CF8M Stem packing & seats ring PTFE Hand lever Ductile iron Studs & nuts SS 316 Gasket Spirally wound SS 316 L with CAF

End connection Flanged as per ANSI B 16.5,RF #150,125 -250 AARH

Design Code BS: 5351 Testing Code BS: 6755 part -1 Test Pressure As per manufacturing standards Operation Manual Note: 1) Vendor to submit dimensional G.A. drawings indicating Part Numbers & MOC

along with offer. 2) All the valves shall be supplied with companion flanges, nuts, bolts & gaskets

and the same shall be included alongwith the valve BOQ . 3) * Denotes vendor to indicate.

DATA SHEET FOR BALL VALVES

Project: 100 MLD SWRO Desalination Plant Data Sheet/ Document no: MEC / 10EP/ 01 / 01 /DS /BV/01


Page 1of 1


Valve Type Ball Make *

Fluid Handled High pressure filtered sea water from Pressure exchangers, high pressure reject brine from RO

Piping material SS 2205 Size range 2 “ - 16 “ Rating # 600

Operating Pressure Kg/ cm 2 70

Operating Temp. ° C 22-35

Material

Body , Side piece ASTM A 890 Gr 5A / UNS J 93404/ UNS S 31254 (ALLOY -2507 ) having PREN > 40

Ball & stem ASTM A 473 S 32760 Seat ring PTFE Seat ASTM A 276 S 31700 / ASTM A 890 J 93404 Hand lever Ductile iron Bolts & nuts SS 316 Gasket Spirally wound SS 316 L with CAF

End connection Flanged # 600 as per ANSI B 16.5,RF ,125 -250 AARH

Design Code BS: 5351 Testing Code BS: 6755 part -1 Test Pressure As per manufacturing standards Operation Manual Note: 1) Vendor to submit dimensional G.A. drawings indicating Part Numbers & MOC along

with offer. 2) All the valves shall be supplied with companion flanges, nuts, bolts & gaskets and

the same shall be included alongwith the valve BOQ 3) * Denotes vendor to indicate.




Page 1of 1


Valve Type Ball Make *


Piping material SS 2205 Size range 1 /2 “ - 1 ½ “ Rating # 800



Material

Body , Side piece ASTM A 182 Gr 5A / UNS J 93404/ UNS S 31254 (ALLOY -2507 ) having PREN > 40

Ball & stem ASTM A 473 S 32760 Seat ring PTFE Seat ASTM A 182 F317 Hand lever Ductile iron Bolts & nuts SS 316 Gasket Spirally wound SS 316 L with CAF

End connection

Socket weld end (weld end of the valve shall be as per the corresponding fitting ends of the piping class, unless otherwise specified )

Design Code BS: 5351 Testing Code BS: 6755 part -1 Test Pressure As per manufacturing standards Operation Manual Note: 1) Vendor to submit dimensional G.A. drawings indicating Part Numbers & MOC along

with offer. 2) * Denotes vendor to indicate.




Page 1of 1


Valve Type Ball valve Make *

Fluid Handled Calcium carbonate slurry feed to limestone filters & sodium hydroxide

Piping material CS & CSRL Size range 1 / 2 “ - 1 1/2 “ Rating #800

Max. Operating Pressure Kg/ cm 2 10


Material

Body & Disc ASTM A 216 Gr WCB / Equivalent and internally lined with natural rubber

Ball & stem Stainless steel ANSI 410 Seat & seat ring PTFE Hand lever Ductile iron Studs & nuts A 193 Gr B 7 and nut shall be A 194 Gr 2 H Gasket Spirally wound SS 316 L with CAF

End connection RF, 150# as per ANSI B 16.5 , 125 -250 AARH

Design Code BS: 5351 Testing Code BS: 6755 Test Pressure As per manufacturing standards Operation Manual Note: 1) Vendor to submit dimensional G.A. drawings indicating Part Numbers & MOC along





Page 1of 1


Valve Type Ball valve Make *

Fluid Handled 98% sulphuric acid solution, RO permeate , carbon di oxide , service water

Piping material SS 316 L Size range 1 / 2 “ - 1 1/2 “ Rating #800



Material

Body & Side/Tail Piece ASTM A182 CF8M Ball ASTM A182 CF8M Seat ASTM A182 CF8M Spindle ASTM A182 CF8M Stem packing & seats ring PTFE Hand lever Ductile iron Bolts & nuts SS 316 Gasket Spirally wound SS 316 L with CAF

End connection


Design Code BS: 5351 Testing Code BS: 6755 Test Pressure As per manufacturing standards Operation Manual Note: 1) Vendor to submit dimensional G.A. drawings indicating Part Numbers & MOC along





Page 1of 1


Valve Type Swing check flanged Make * Fluid Handled Plant air , instrumentation air Piping material GI Size range 2 ”- 6” Rating # 150



Material

Body & Cover, hinge disk /door CI IS:210Gr.FG260/BS 1452 Gr 220 or equivalent

Hinge pin & door / disk pin ASTM A 216 Gr WCB Body seat ring & disc facing ring SS 316 Bearing bushes SS 316 Bolt & Nuts A 193 Gr B 7 and nut shall be A 194 Gr 2 H Gasket Spirally wound SS 316 L with CAF


Design Code BS-1868/API-594 Testing Code BS – 6755 Part -1/API-598 Test Pressure As per manufacturing standards Operation Manual Note:

1) Vendor to submit dimensional G.A. drawings indicating Part Numbers & MOC along with offer.

2) All the valves shall be supplied with companion flanges, nuts, bolts & gaskets and the same shall be included alongwith the valve BOQ

3) * Denotes vendor to indicate.

DATA SHEET FOR CHECK VALVES

Project: 100 MLD SWRO Desalination Plant Data Sheet/ Document no: MEC / 10EP/ 01 / 01 /DS /CH/06


Page 1of 1


Valve Type Check Make *

Fluid Handled Permeate water from RO (TDS below 500 ppm), sulphuric acid solution ,carbon di oxide, service water

Piping material SS 316 L Size range 1/ 2 “ – 1 ½ “ Rating #800



Material

Body ASTM A 182 Gr CF8M Cover ASTM A 182 Gr CF8M Hinge ASTM A 182 Gr CF8M Disc ASTM A 182 Gr CF8M Seat ring ASTM A 182 Gr CF8M Hinge pin ASTM A 182 Gr CF8M Pin plug ASTM A 182 Gr CF8M Bolt & Nuts SS 316 Gasket Spirally wound SS 316 L with CAF

End connection Socket weld end (weld end of the valve shall be as per the corresponding fitting ends of the piping class, unless otherwise specified )

Design Code BS-5352 Testing Code BS – 6755 Part -1 Test Pressure As per manufacturing standards Operation Manual Note: 1) Vendor to submit dimensional G.A. drawings indicating Part Numbers & MOC along with offer.





Page 1of 1


Valve Type Swing check flanged Make * Fluid Handled Plant air , instrumentation air Piping material GI Size range 1 /2 ”- 1 1/2” Rating #800



Material

Body & Cover, hinge disk /door CI IS:210Gr.FG260/BS 1452 Gr 220 or equivalent

Hinge pin & door / disk pin ASTM A 216 Gr WCB Body seat ring & disc facing ring SS 316 Bearing bushes SS 316 Bolt & Nuts A 193 Gr B 7 and nut shall be A 194 Gr 2 H Gasket Spirally wound SS 316 L with CAF




DATA SHEET FOR CHECK(NON RETURN VALVE) VALVES



Page 1of 1




Piping material CSRL & CS Size range 1 /2 ”- 1 ½ ” Rating #800



Material

Body & Cover, hinge disk /door CI IS:210Gr.FG260/CS, ASTM-A216 GR WCB and shall be internally lined with soft natural rubber/PTFE / viton

Hinge pin & door / disk pin ASTM A 216 Gr WCB and shall be coated with PVDF or suitable elastomer or SS 316

Body seat ring & disc facing ring SS 316 Bearing bushes SS 316 Bolt & Nuts A 193 Gr B 7 and nut shall be A 194 Gr 2 H Gasket Spirally wound SS 316 L with CAF




DATA SHEET FOR CHECK (NON RETURN ) VALVES



Page 1of 1


Valve Type Swing check flanged Make *


Piping class CSRL & CS Size range 2”-6” Rating 150#



Material

Body & Cover, hinge disk /door CI IS:210Gr.FG260/CS ASTM-A216 GR WCB and shall be internally lined with soft natural rubber/PTFE / viton

Hinge pin & door / disk pin ASTM A 216 Gr WCB and shall be coated with PVDF or suitable elastomer or SS 316

Body seat ring & disc facing ring SS 316 Bearing bushes SS 316 Bolt & Nuts A 193 Gr B 7 and nut shall be A 194 Gr 2 H Gasket Spirally wound SS 316 L with CAF


Design Code BS-1868/API-594 Testing Code BS – 6755 Part -1/API-598 Test Pressure As per manufacturing standards Operation Manual Note:




DATA SHEET FOR CHECK (NON RETURN) VALVES



Page 1of 1





Fluid Handled

Highly corrosive sea water having TDS from 35,000 to 64000 , filtered water from Disc filer & Ultra filter , low pressure brine outlet from pressure exchanger, Antiscalant solution, Sodium hypochlorite solution and sodium bisulphate solution

Piping class HDPE Size range 2”-48” Rating 150 #

Maximum operating Pressure Kg/ cm 2 10


Material

Body, Cover, Hinge, Seat ring, Disc ASTM A 890 Gr 5A / UNS J 93404/ UNSS 31254 (ALLOY -2507 ) having PREN > 40

Hinge pin & door /Disc pin ASTM A 473 SS 316L Bearing bushes, disc facing ASTM A 473 SS 316L Body seat ring ASTM A 473 SS 316L Bolt & Nuts SS 316 L End connection RF, #150 as per ANSI B 16.5 ,125 -250 AARH Design Code API –594/BS 1868/API 6D Testing Code BS-6755 part 1/API-598 Test Pressure As per manufacturing standards Operation Manual Note:


2) All the valves shall be supplied with companion flanges, nuts, bolts & gaskets and the same shall be included alongwith the valve BOQ .Companion flanges/ installation joints including gaskets, fasteners for valves on HDPE pipes shall comprise of HDPE flanges / flange adaptors with SS 316 backing flanges 10mm thick.



Page 1of 1




Piping class SS2205 Size range 2”-24” Rating 600#



Material

Body, Cover, Hinge, Seat ring, Disc ASTM A 890 Gr 5A / UNS J 93404/ UNSS 31254 (ALLOY -2507 ) having PREN > 40

Hinge pin & door /Disc pin ASTM A 473 SS 316L Bearing bushes, disc facing ASTM A 473 SS 316L Body seat ring ASTM A 473 SS 316L Bolt & Nuts SS 316 L

End connection RF, 600# as per ANSI B 16.5 ,125 -250 AARH

Design Code API –594/BS 1868/API 6D Testing Code BS-6755 part 1/API-598 Test Pressure As per manufacturing standards Operation Manual Note:







Page 1of 1






Piping class SS 316 L Size range 2”-24” Rating 150#



Material

Body ASTM A 351 Gr CF8M Cover ASTM A 351 Gr CF8M Hinge ASTM A 351 Gr CF8M Disc ASTM A 351 Gr CF8M Seat ring ASTM A 351 Gr CF8M Hinge pin SS 316 L Pin plug SS 316 L Bolt & Nuts SS 316 Disc washer/Nut SS 316 L Gasket Spirally wound SS 316 L with CAF


Design Code BS-1868/API-594 Testing Code BS– 6755 Part -1/API-598 Test Pressure As per manufacturing standards Operation Manual Note:





Page 1of 1




Piping class CSRL & CS Size range 2” – 10” Rating 150# Max Operating Pressure Kg/ cm 2 10


Material

Body & Bonnet CI IS:210Gr.FG260/CS ASTM-A216 GR WCB and body shall be internally lined with soft natural rubber/ PTFE / viton

Diaphragm Reinforced rubber / Hypalon Stem, compressor& bush Stainless steel

Hand wheel CI Gasket Spiral wound SS 316 L + CAF Bolt & Nuts SA 193 Gr. B7 / SA 194Gr. 2H End connection Flanged as per ANSI B 16.5, RF #150, 125 – 250 AARH Design Code BS- 5156 Testing Code BS- 6755 part 1 Test Pressure As per manufacturing standard Note:




DATA SHEET FOR DIAPHRAGM VALVES

Project: 100 MLD SWRO Desalination Plant Data Sheet/ Document no: MEC / 10EP/ 01 / 01 /DS /DV/14


Page 1of 1


Valve Type Flanged Make * Fluid Handled Plant air , instrumentation air Piping class GI Size range 2 ” – 24 “ Rating # 150



Material

Body & Bonnet ASTM A 216 Gr WCB ,13 % Cr TRIM Stem, Seat ring, Back seat & Wedge disc SS 316L

Gland packing Grafoil Gasket Spirally wound SS 316 L with CAF Hand lever Ductile iron Bolts & nuts A 193 Gr B 7 and nut shall be A 194 Gr 2 H

End connection Flanged as per ANSI B 16.5, RF #150, 125 -250 AARH

Design Code API-600/API-6D Testing Code API - 598 Test Pressure As per manufacturing standards Operation Manual Note: 1) Vendor to submit dimensional G.A. drawings indicating Part Numbers & MOC along



DATA SHEET FOR GATE VALVES

Project: 100 MLD SWRO Desalination Plant Data Sheet/ Document no: MEC / 10EP/ 01 / 01 /DS /GTV/15


Page 1of 1




Valve Type Gate valve Make *

Fluid Handled

Highly corrosive sea water having TDS from 35,000 to 64000 , filtered water from Disc filer & Ultra filter , low pressure brine outlet from pressure exchanger, Antiscalant solution, Sodium hypochlorite solution and sodium bisulphite solution

Piping class HDPE Size range ½ ” – 1 ½ “ Rating # 800



Material

Body& bonnet ASTM A 890 Gr 5A / UNS J 93404/ UNSS 31254 (ALLOY -2507 ) having PREN > 40

Stem , Seat ring, Back seat & Wedge disc UNS J 93404

Gland packing UNS J 93404 Gasket Spirally wound SS 316 L with CAF Hand lever Ductile iron Bolts & nuts SS316

End connection

screwed / flanged/Socket weld end (weld end of the valve shall be as per the corresponding fitting ends of the piping class, unless otherwise specified )

Design Code API-602 Testing Code API - 598 Test Pressure As per manufacturing standards Operation Manual Note: 1) Vendor to submit dimensional G.A. drawings indicating Part Numbers & MOC along



Page 1of 1




Piping class SS 2205 Size range ½ ” – 1 ½ “ Rating # 800



Material

Body& bonnet ASTM A 890 Gr 5A / UNS J 93404/ UNSS 31254 (ALLOY -2507 ) having PREN > 40

Stem , Seat ring, Back seat & Wedge disc UNS J 93404

Gland packing UNS J 93404 Gasket Spirally wound SS 316 L with CAF Hand lever Ductile iron Bolts & nuts SS316

End connection







Page 1of 1



Fluid Handled Permeate from RO (TDS below 500 ppm), sulphuric acid solution, carbon di oxide, service water

Piping class SS 316 L Size range ½ ” – 1 ½ “ Rating # 800



Material

Body & Bonnet ASTM A 182, SS 316L Stem SS 316L Trim A 473 SS 316L Wedge disc SS 316L Seat ring SS 316L Back seat SS 316L Gland packing Grafoil Gasket Spirally wound SS 316 L with CAF Hand lever Ductile iron Bolts & nuts SS316

End connection


Design Code API-602/IS:778 Testing Code API - 598 Test Pressure As per manufacturing standards Operation Manual Note: 1) Vendor to submit dimensional G.A. drawings indicating Part Numbers & MOC along





Page 1of 2



Project: 100 MLD SWRO Desalination Plant Data Sheet/ Document no: MEC / 10EP/ 01 / 01 /DS /GTV/19 Valve Type Flanged Make *

Fluid Handled


Piping class HDPE Size range 2” – 20 “ Rating # 150

Maximum operating pressure Kg/ cm 2 10


Material

Body & Bonnet ASTM A 890 Gr 5A / UNS J 93404/ UNSS 31254 (ALLOY -2507 ) having PREN > 40

Stem UNS J 93404 Wedge disc UNS J 93404 Seat ring UNS J 93404 Back seat UNS J 93404 Gland packing UNS J 93404 Gasket Spirally wound SS 316 L with CAF Hand lever Ductile iron Bolts & nuts SS316

End connection Flanged as per ANSI B 16.5,RF #150, 125 -250 AARH

Design Code API-600 /BS:5150/BS:5163/IS:14846 Testing Code API - 598 Test Pressure As per manufacturing standards Operation Manual Note:



Page 2of 2


2)) All the valves shall be supplied with companion flanges, nuts, bolts & gaskets and the same shall be included alongwith the valve BOQ. Companion flanges/ installation joints including gaskets, fasteners for valves on HDPE pipes shall comprise of HDPE flanges /flange adaptors with SS 316 backing flanges 10mm thick .



Page 1of 1





Fluid Handled Permeate from RO (TDS below 500 ppm), sulphuric acid solution carbon di oxide, service water

Piping class SS 316 L Size range 26” – 42 “ Rating # 150



Material

Body & Bonnet ASTM A 351 Gr CF8M Stem SS 316L Wedge disc SS 316L Seat ring SS 316L Trim A 473 SS 316L Back seat SS 316L Gland packing Grafoil Gasket Spirally wound SS 316 L with CAF Hand lever Ductile iron Bolts & nuts SS316


Design Code BS-1414 Testing Code API - 598 Test Pressure As per manufacturing standards Operation Manual Note: 1) Vendor to submit dimensional G.A. drawings indicating Part Numbers & MOC along




Page 1of 1



Fluid Handled Permeate from RO (TDS below 500 ppm), sulphuric acid solution carbon di oxide, service water

Piping class SS 316 L Size range 2” – 24 “ Rating # 150



Material

Body & Bonnet ASTM A 351 Gr CF8M Stem SS 316L Wedge disc SS 316L Seat ring SS 316L Back seat SS 316L Gland packing Grafoil Gasket Spirally wound SS 316 L with CAF Hand lever Ductile iron Bolts & nuts SS316


Design Code API-600 /BS:5150/BS:5163/IS:14846 Testing Code API - 598 Test Pressure As per manufacturing standards Operation Manual Note: 1) Vendor to submit dimensional G.A. drawings indicating Part Numbers & MOC along






Page 1of 1


Valve Type Gate Make * Fluid Handled Plant air , instrumentation air Piping class GI Size range ½ ” – 1 1/2 “ Rating # 800



Material

Body & Bonnet ASTM A 105 ,13 % Cr TRIM Stem, Seat ring, Back seat & Wedge disc SS 316L

Gland packing Grafoil Gasket Spirally wound SS 316 L with CAF Hand lever Ductile iron Bolts & nuts A 193 Gr B 7 and nut shall be A 194 Gr 2 H

End connection







Page 1of 1


Valve Type Globe valve Make *


Piping class SS 2205 Size range ½ ” – 1 ½ “ Rating # 800



Material

Body, disc, seat, seat ring ASTM A 182 Gr 5A / UNS J 93404/ UNS S 31254 (ALLOY -2507 ) having PREN > 40

shaft ASTM A 473 S 32760 Back seat Duplex Gland packing SS 316L Seal Nitrile rubber ,EPDM ,Hypalon Gasket Spirally wound SS 316 L with CAF Hand lever Ductile iron Bolts & nuts SS316

End connection


Design Code BS-5352 Testing Code BS -6755 PART 1 Test Pressure As per manufacturing standards Operation Manual Note: 1) Vendor to submit dimensional G.A. drawings indicating Part Numbers & MOC along


DATA SHEET FOR GLOBE VALVES

Project: 100 MLD SWRO Desalination Plant Data Sheet/ Document no: MEC / 10EP/ 01 / 01 /DS /GV/23


Page 1of 1


Valve Type Globe Make *


Piping class CSRL & CS Size range 2” – 6” Rating #150



Material

Body & disc CI IS:210Gr.FG260/CS ASTM-A216 GR WCB and shall be internally lined with soft natural rubber/PTFE / viton

Stem AISI 410/ 13 % Cr Seat & seat ring Nitril rubber,EPDM,Hypalon Gasket Spiral Wound SS 316L Grafoil Filled Gland packing Grafoil/PTFE Bolt & Nuts A 193 Gr B 7 and nut shall be A 194 Gr 2 H Hand Wheel Ductile iron


Design code BS-1873 Testing Code BS: 6755 PART-1 Test Pressure As per manufacturing standards Operation Manual Note:







Page 1of 1




Piping material SS 2205 Size range 2 “ – 14” Rating #600



Material

Body, disc, seat, seat ring ASTM A 890 Gr 5A / UNS J 93404/ UNS S 31254 (ALLOY -2507 ) having PREN > 40

Shaft ASTM A 473 ,S 32760 Seal Nitrile rubber, EPDM, Hypalon Gasket Spiral Wound SS 316L Grafoil Filled Gland packing SS 316L Bonnet Bolt & Nuts SS316 Hand Wheel Ductile iron

End connection Flanged #600 ,ANSI B 16.5 , RF 125-250 AARH








Page 1of 1




Piping material SS 316 L Size range 2 “ – 8” Rating #150



Material

Body, spindle & Seat ASTM A351CF8M Shaft ASTM A 473 SS316L Disc SS 316L Seat Ring SS 316L Seal Nitril rubber, EPDM, Hypalon Gasket Spiral Wound SS 316L Grafoil Filled Gland packing Grafoil Bonnet Bolt & Nuts SS316 Hand Wheel Ductile iron

End connection Flanged #150 ,ANSI B 16.5 , RF 125-250 AARH








Page 1of 1




Piping class CSRL & CS Size range ½” – 1 ½” Rating #800



Material

Body & disc CI IS:210Gr.FG260/CS ASTM-A216 GR WCB and shall be internally lined with soft natural rubber/PTFE / viton

Stem AISI 410/ 13 % Cr Seat & seat ring Nitril rubber,EPDM,Hypalon Gasket Spiral Wound SS 316L Grafoil Filled Gland packing Grafoil/PTFE Bolt & Nuts A 193 Gr B 7 and nut shall be A 194 Gr 2 H Hand Wheel Ductile iron End connection Socket weld Design code BS-5352 Testing Code BS: 6755 PART-1 Test Pressure As per manufacturing standards Operation Manual Note: 1) Vendor to submit dimensional G.A. drawings indicating Part Numbers & MOC along





Page 1of 1




Piping class SS 316 L Size range ½” – 1 ½” Rating #800



Material

Body & Seat ASTM A182 CF8M Shaft ASTM A 473 SS316L Disc SS 316L Seal Nitril rubber,EPDM,Hypalon Gasket Spiral Wound SS 316L Grafoil Filled Gland packing Grafoil Bonnet Bolt & Nuts SS316 Hand Wheel Ductile iron


Design code BS-5352 Testing Code BS: 6755 PART-1 Test Pressure As per manufacturing standards Operation Manual Note: 1) Vendor to submit dimensional G.A. drawings indicating Part Numbers & MOC along





Page 1of 1


Valve Type Flanged Make * Fluid Handled Plant air , instrumentation air Piping class GI Size range 2”-64” Rating #150



Material

Body & disc ASTM A 216 Gr WCB or equivalent Shaft ASTM A 296 Gr CF8M Seating ring Nitrile rubber/ EPDM/Hypalon Packing Graphite Bolt & Nuts SA 193 Gr. B7 / SA 194Gr.2H


Seat leakage tight shut off

Design Code API – 609 (up to 24”)/BS 5155/ISO-5752(Above 24”)

Testing Code BS-6755 PART 1/API-598 Test Pressure As per manufacturing standards Note:




DATA SHEET FOR BUTTERFLY VALVES



Page 1of 2



Project: 100 MLD SWRO Desalination Plant Data Sheet/ Document no: MEC / 10EP/ 01 / 01 /DS /BT/30


Fluid Handled

Highly corrosive sea water having TDS from 35,000 to 64000 , filtered water from Disc filer & Ultra filter , CIP for RO & UF, **Conecntrate inlet –outlet of UF, low pressure brine outlet from pressure exchanger, Antiscalant solution, Sodium hypochlorite solution and sodium bisulphite solution

Piping material HDPE Size range 2”-48” Rating # 150 Maximum Operating Pressure Kg/ cm 2 10 Operating Temp. ° C 22-35

Material

Body , Disc, Seat & Stem ASTM A 890 Gr 5A / UNS J 93404/ UNS S 31254 (ALLOY -2507 ) having PREN > 40

Shaft ASTM A 473 ,S 32760 Seal Nitrile rubber, EPDM, Hypalon Bolt & Nuts SS 316 End connection RF, 150# as per ANSI B 16.5,125-250 AARH

Seat leakage Up to DN 300 - tight shut off, DN 350 & above - ANSI B 16.104 Class V

Design Code API –609 ( up to 24”) / BS 5155 ,ISO5752(above 24”)

Testing Code API 598 /BS 6755 part 1 Test Pressure As per manufacturing standards Operation Manual Note:



Page 2of 2


2) All the valves shall be supplied with companion flanges, nuts, bolts & gaskets

and the same shall be included alongwith the valve BOQ. Companion flanges/ installation joints including gaskets, fasteners for valves on HDPE pipes shall comprise of HDPE flanges /flange adaptors with SS 316 backing flanges 10mm thick .

3) * Denotes vendor to indicate. 4) ** One no. of limit switch each shall be provided only for the manual valves in

concentrate outlet of all the UF for interlocking with other on-off valves.


Page 1of 1




Piping class SS2205 Size range 3”-48” Rating 600# Operating Pressure Kg/ cm 2 70 Operating Temp. ° C 22-35

Material




Design Code API –609 / BS 5155 Testing Code API 598 /BS 6755 part 1 Test Pressure As per manufacturing standards Operation Manual Note:



3)* Denotes vendor to indicate.




Page 1of 1



Fluid Handled Permeate water from RO (TDS below 500 ppm), sulphuric acid solution and carbon di oxide, service water

Piping class SS 316L Size range 2”-24” Rating #150



Material

Body ASTM A 351 Gr CF8M Disc ASTM A 351 Gr CF8M Shaft ASTM A 473 SS 316L Seat ASTM A 182 SS 316L Seating ring PTFE Packing Graphite Bolt & Nuts SS316

End connection Flanged as per ANSI B 16.5, RF #150, 125 AARH

Design Code API – 5155/API-609 Testing Code BS-6755 PART-1,API-598 Test Pressure As per manufacturing standards Note:







Page 1of 1



Fluid Handled Permeate water from RO (TDS below 500 ppm), sulphuric acid solution , carbon di oxide, service water




Material



Design Code API-609(up to 24”),ISO-5752( above 24”) Testing Code BS-6755 PART-1,API-598 Test Pressure As per manufacturing standards Note:




.




Page 1of 1


DATA SHEET FOR MOTORISED BUTTERFLY VALVES





Material



Actuator Electric actuator along with manual override (lever/handwheel), including positioner for feedback to the control room.

Seat leakage tight shut off Design Code API – 609/BS 5155 Testing Code BS-6755 PART 1/API-598 Test Pressure As per manufacturing standards Note:



3) * Denotes vendor to indicate. 4) Actuator shall be as per the “technical specification for actuator’ enclosed in

Chapter 5 of Volume II A of Annexure-A. 5) For field interconnection to DCS refer notes given in ‘Annexure-C ‘, Chapter 5

of Volume II A.


Page 1of 2



Fluid Handled


Piping material HDPE Size range 2”-48” Rating # 150 Maximum Operating Pressure Kg/ cm 2 10 Operating Temp. ° C 22-35

Material





Design Code API –609 / BS 5155 Testing Code API 598 /BS 6755 part 1 Test Pressure As per manufacturing standards Note:





Page 2of 2


2) All the valves shall be supplied with companion flanges, nuts, bolts & gaskets and

the same shall be included alongwith the valve BOQ. Companion flanges/ installation joints including gaskets, fasteners for valves on HDPE pipes shall comprise of HDPE flanges / flange adaptors with SS 316 backing flanges 10mm thick


Chapter 5 of Volume II A of Annexure-A. 5) For field interconnection to DCS refer notes given in ‘Annexure-C,Chapter-5 of

Volume II A.


Page 1of 1




Piping class SS2205 Size range 3”-48” Rating 600# Operating Pressure Kg/ cm 2 70 Operating Temp. ° C 22-35

Material








3)* Denotes vendor to indicate. 4) Actuator shall be as per the “technical specification for actuator’ enclosed in chapter

5 of volume II A of Annexure-A. 5) For field interconnection to DCS refer notes given in ‘Annexure-C, Chapter-5 of

volume II A.




Page 1of 1








Operating Temp. ° C 22-35 Material




Design Code API – 5155/API-609 Testing Code BS-6755 PART-1,API-598 Test Pressure As per manufacturing standards Note:




Chapter 5 of Vol. II A of Annexure-A . 5) For field interconnection to DCS refer notes given in ‘Annexure-C,Chapter-5 of

Vol. IIA


Page 1of 1


Data Sheet For Pneumatic Butterfly Valves





Material



Actuator Pneumatic along with manual override (lever/handwheel), including positioner for feedback to the control room..

Seat leakage tight shut off Design Code API – 609/BS 5155 Testing Code BS-6755 PART 1/API-598 Test Pressure As per manufacturing standards Note:




“Annexure-B’ of Chapter 5 in Volume II A. 5) For field interconnection to DCS limit switch & solenoid valve requirement refer

notes given in ‘Annexure-‘B’ & ‘C’ of Chapter-5 in Vol. IIA.


Page 1of 2



Project: 100 MLD SWRO Desalination Plant Data Sheet/ Document no: MEC / 10EP/ 01 / 01 /DS /BT/39 Valve Type Flanged Make *

Fluid Handled


Piping material HDPE Size range 2”-64” Rating # 150 Maximum Operating Pressure Kg/ cm 2 10 Operating Temp. ° C 22-35 Material





Design Code API –609 ( up to 24”) / BS 5155 ,ISO:5752 (above 24”)

Testing Code API 598 /BS 6755 part 1 Test Pressure As per manufacturing standards Note:



Page 2of 2


2) All the valves shall be supplied with companion flanges, nuts, bolts & gaskets and the same shall be included alongwith the valve BOQ. Companion flanges/ installation joints including gaskets, fasteners for valves on HDPE pipes shall comprise of HDPE flanges /flange adaptors with SS 316 backing flanges 10mm thick .





Page 1of 1




Piping material SS2205 Size range 3”-48” Rating 600# Operating Pressure Kg/ cm 2 70 Operating Temp. ° C 22-35

Material











Data Sheet For Pneumatic Butterfly Valves



Page 1of 1 ADECO TECHNOLOGIES MECON LIMITED





Piping class SS 316L Size range 2”-32” Rating #150 Max. Operating Pressure Kg/ cm 2 6

Operating Temp. ° C 22-35 Material Body ASTM A 351 Gr CF8M Disc ASTM A 351 Gr CF8M Shaft ASTM A 473 SS 316L Seat ASTM A 182 SS 316L Seating ring PTFE Packing Graphite Bolt & Nuts SS316


Actuator Pneumatic along with manual override (lever/handwheel), including positioner for feedback to the control room...

Design Code BS – 5155,ISO-5752( above 24”)/API-609 (up to 24”)

Testing Code BS-6755 PART-1,API-598 Test Pressure As per manufacturing standards Note:



3) * Denotes vendor to indicate. 1) 4) Actuator shall be as per the “technical specification for actuator’ enclosed in




Page 1 of 1


TANK DATA SHEET



TANK Tag No: T-203 A/B

SERVICE UF PRODUCT & BACKWASH TANK LOCATION NEMMELI, TAMIL NADU

TYPE OF TANK TRUSS SUPPORTED VERTICAL CONE ROOF

TANK

QTY 2 NOS

TOTAL CAPACITY 14,250 m3

NET CAPACITY 13,800 m3

PRODUCT STORED FILTERED WATER FROM UF SIZE 30,000 mm ID & 21,000 mm HT

REF. DRG. NO. MEC/10EP/01/01/WOR/0100 DESIGN DATA

CODE CONSTRUCTION API 650, TENTH EDITION

OPERATING. PRESSURE: ATM DESIGN PRESSURE: ATM

DESIGN TEMPERATURE: 45 0

C OPERATING. TEMP: 22 - 35 0

C

CORROSION ALLOWABLE

2 mm FOR ROOF 3 mm FOR

SHELL & BOTTOM

TEST PRESSURE FULL OF WATER

THK MOC

SHELL

6-22

mm IS 2062 GR. B OR A36

ROOF 8 mm IS 2062 GR. B OR A36

BOTTOM PLATE 10 mm IS 2062 GR. B OR A36

MANHOLE NECK &FLANGE IS 2062 GR. B OR A36

NOZZLE FLANGE SA 105

NOZZLE FLANGE (FAB.) IS 2062 GR. B OR A36

NOZZLE PIPES <=250 NB SA 106 GR. B

NOZZLE PIPES (FAB.) >250 NB IS 2062 GR. B OR A36

R.F PADS, GUSSETS, WIND GIRDER

PLT IS 2062 GR. B OR A 36

BOLTS & NUTS (NOZZLES) A307 GR. A&A563 GR. A

BOLTS & NUTS (STRUCTURE) A325 & A563 GR. A

INTERNALS IS 2062 GR. B OR A 36 GASKET 3 mm THK BUTYLE RUBBER

PAINTING AS PER SPECIFICATIONS STAIR CASE HANDRAIL&ROOF HAND RAIL BLACK MS PIPE MEDIUM (IS 1239)

NOZZLE SCHEDULE

NOZZLE MARK SERVICE QTY/TANK SIZE NB RATING

N1 FILTERED WATER INLET 1 1000 150#

N2 BALANCE 2 700 150#

N3 FILTERED WATER OUTLET 1 1000 150#

N4 VENT 1 250 150#

N5 OVERFLOW 1 700 150#

N6 WATER DRAW - OFF 1 200 150#

N7 LEVEL INDICATOR CONNECTION 1 100 150#

N8 MANHOLE 2 600 150#

N9 RESERVE 1 400 150#

N10 SEA WATER OUTLET 1 400 150#


Page 1 of 1 ADECOO TECHNOLOGIES MECON LIMITED

TANK DATA SHEET



TANK Tag No: T -301 A/B

SERVICE PRODUCT STORAGE TANK LOCATION NEMMELI, TAMIL NADU

TYPE OF TANK TRUSS SUPPORTED VERTICAL CONE

ROOF TANK

QTY 2 NOS

TOTAL CAPACITY 9,225 m3 NET CAPACITY 9,000 m

3

PRODUCT STORED RO PERMEATE (PRODUCT WATER FROM

REVERSE OSMOSIS) SIZE 24,000 mm ID & 21,160 mm HT



OPERATING PRESSURE: ATM DESIGN PRESSURE: ATM


C OPERATING TEMP: 22 - 35 0

C

CORROSION ALLOWABLE

2 mm FOR ROOF 3 mm FOR

SHELL & BOTTOM


THK MOC

SHELL 6-20 mm IS 2062 GR. B OR A36





NOZZLE FLANGE (FAB.) IS 2062 GR. B OR A 36


NOZZLE PIPES (FAB.) >250 NB IS 2062 GR. B OR A 36

R.F PADS, GUSSETS, WIND GIRDER PLT IS 2062 GR. B OR A 36


BOLTS & NUTS (STRUCTURAL SUPPORT) A325 & A563 GR. A



NOZZLE SCHEDULE


N1 RO PERMEATE INLET 1 750 150#

N2 RO PERMEATE OUTLET 1 800 150#


N4 VENT 1 250 150#


N6 WATER DRAW OFF 1 200 150#


N8 MANHOLE 2 600 150#

N9 RESERVE 1 200 150#

N10 SERVICE WATER OUTLET 1 100 150#

N11 BALANCE 2 750 150#


Page1 of 1


TANK DATA SHEET



TANK Tag No: T-501

SERVICE UF + RO REJECT TANK LOCATION NEMMELI, TAMIL NADU

TYPE OF TANK TRUSS SUPPORTED VERTICAL CONE

ROOF TANK

QTY 1 NO

TOTAL CAPACITY 3,210 m3 NET CAPACITY 3,000 m

3

PRODUCT STORED REJECT WATER FROM UF &RO SIZE 22,000 mm ID & 9,000 mm HT

REF. DRG. NO. MEC/10EP/01/01/ WOR/0102 DESIGN DATA





C

CORROSION ALLOWABLE

2 mm FOR ROOF 3 mm FOR SHELL &

BOTTOM


THK MOC

SHELL 6-10 mm IS 2062 GR. B OR A36





NOZZLE FLANGE (FAB.) IS 2062 GR. B OR A 36


NOZZLE PIPES (FAB.) >250 NB IS 2062 GR. B OR A 36

R.F PADS, GUSSETS, WIND GIRDER PLT IS 2062 GR. B OR A 36


22000 mm

9000

mm


INTERNALS IS 2062 GR. B OR A36 GASKET 3 mm THK BUTYLE RUBBER


NOZZLE SCHEDULE

NOZZLE

MARK SERVICE QTY/TANK SIZE NB RATING

N1 REJECT BRAIN WATER INLET 1 1200 150#

N2 REJECT WATER FROM UF 1 500 150#

N3 RESERVE 1 550 150#

N4 REJECT WATER OUTLET 1 1200 150#

N5 VENT 1 250 150#


N7 WATER DRAW-OFF 1 200 150#

N8 LEVEL INDICATOR 1 100 150#

N9 MANHOLE 2 600 150#

N10 RESERVE 1 200 150#

N11 BACK WASH INLET 1 350 150#


Page 1 of 1


TANK DATA SHEET



TANK Tag No: T-601

SERVICE RO FLUSHING TANK LOCATION NEMMELLI, TAMIL NADU

TYPE OF TANK CYLINDRICAL VERTICAL CONE ROOF TANK QTY 1 NO

TOTAL CAPACITY 21.2 m3

NET CAPACITY 17.48 m3

PRODUCT STORED RO FLUSHING FLUID SIZE 3,000 mm ID, 3,000 mm HEIGHT

REF. DRG.NO. MEC/10EP/01/01/WOR/0113 DESIGN DATA

CODE CONSTRUCTION BS 4994




C

TEST PRESSURE F ULL OF WATER

THICKNESS MOC

SHELL 9-11 mm FRP

ROOF 12 mm FRP

BOTTOM PLATE 11 mm FRP

MANHOLE NECK &FLANGE FRP

NOZZLE FLANGE FRP

NOZZLE FLANGE (FAB.) FRP

NOZZLE PIPES <=250 NB FRP

NOZZLE PIPES (FAB.) >250 NB FRP

BOLTS & NUTS (NOZZLES) A307 GR. A & A563 GR. A


INTERNALS FRP

PAINTING AS PER SPECIFICATIONS

GASKET 3 mm THK BUTYLE RUBBER

ROOF HANDRAIL MS PIPE (IS 1239)

LADDER MS (IS 2062)

ANCHOR BOLT MS

NOZZLE SCHEDULE

NOZZLE

MARK. SERVICE

QTY/TAN

K SIZE NB RATING

N1 RO CHEMICAL INLET 1 300 150#

N2 RO CHEMICAL OUTLET 1 350 150#


N4 DRAIN 1 50 150#


N6 MANHOLE 1 600 150#

N7 VENT 1 100 150#


Page 1 of 1


TANK DATA SHEET



Tank Tag No: T-602

SERVICE RO CLEANING TANK LOCATION NEMMELI, TAMIL NADU

TYPE OF TANK CYLINDRICAL VERTICAL DISHED END TANK QTY 1 NO



PRODUCT STORED RO CHEMICAL SIZE 1,500 mm ID, 2,000 mm HEIGHT






C


THK MOC

SHELL 11 mm FRP

DISHED END 11 mm FRP

BOTTOM PLATE THK 11 mm FRP


NOZZLE FLANGE FRP






INTERNALS FRP




LADDER MS (IS 2062)

ANCHOR BOLT MS

NOZZLE SCHEDULE


N1 RO CHEMICAL INLET 1 300 150#

N2 RO CHEMICAL OUTLET 1 350 150#


N4 DRAIN 1 50 150#


N6 MANHOLE 1 600 150#

N7 VENT 1 50 150#

N8 RECIRCULATION INLET 1 300 150#


Page 1 of 1


TANK DATA SHEET



Tank Tag No: T-701 A/B

SERVICE 98 % SULPHURIC ACID BULK STORAGE

TANK

LOCATION NEMMELI, TAMIL NADU

TYPE OF TANK HORIZONTAL DISHED END TANK QTY 2 NO


NET CAPACITY 61.5m3

PRODUCT STORED 98 % SULPHURIC ACID SOLUTION SIZE 3,200 mm ID & 7,000 mm LENGTH


CODE CONSTRUCTION IS 2825: 2002




C

TEST PRESSURE WATER FILLED

CORROSION ALLOWANCE 3 mm

THK MOC

SHELL 10 mm IS 2062

DISHED END 12 mm IS 2062

SADDLE IS 2062

MANHOLE NECK &FLANGE IS 2062


NOZZLE FLANGE (FAB.) IS 2062, GR. B OR A36


NOZZLE PIPES (FAB.) >250 NB IS 2062, GR. B OR A36


BOLTS & NUTS (STRUCTURAL

SUPPORT) A325 & A563 GR. A

R.F. PADS IS 2062, GR. B OR A 36

INTERNALS SS 316


GASKET PTFE

NOZZLE SCHEDULE

NOZZLE


N1 SULPHURIC ACID SOLUTION INLET 1 80 150#

N2 SULPHURIC ACID SOLUTION OUTLET 1 80 150#

N3 BALANCE 2 100 150#

N4 DRAIN 1 100 150#


N6 MANHOLE 1 600 150#

N7 RESERVE 1 80 150#

N8 INLET 1 80 150#


Page 1 of 1


TANK DATA SHEET



Tank Tag No: T-703

SERVICE 35% SODIUM BISULPHITE BULK STORAGE

TANK



TOTAL CAPACITY 111.3 m3 NET CAPACITY 107.3 m

3

PRODUCT STORED 35 % SODIUM BISULPHITE SOLUTION SIZE 4,500 mm ID & 7,000 mm HEIGHT






C


THICKNESS MOC

SHELL 9-20 mm FRP

ROOF 10 mm FRP


MANHOLE NECK&FLANGE FRP

NOZZLE FLANGE FRP


NOZZLE PIPES <=250

NB

FRP

NOZZLE PIPES (FAB.) >250

NB

FRP



GASKETS BUTYLE RUBBER OF 3 MM THK

INTERNALS FRP

LADDER MS (IS 2062)



ANCHOR BOLTS MS

NOZZLE SCHEDULE


N1 PRODUCT INLET 1 80 150#


N3 PRODUCT OUTLET 1 80 150#

N4 DRAIN 1 100 150#


N6 MANHOLE 2 600 150#

N7 VENT 1 100 150#


Page 1 of 1


TANK DATA SHEET



TANK Tag No: T-704

SERVICE 12% SODIUM HYPOCHLORITE BULK STORAGE

TANK


TYPE OF TANK CYLINDRICAL VERTICAL CONE ROOF QTY 1 NO

TOTAL CAPACITY 111.3 m3 NET CAPACITY 107.3 m

3

PRODUCT STORED 12% SODIUM HYPOCHLORITE SOLUTION SIZE 4,500 mm ID & 7,000 mm HEIGHT






C



THK MOC

SHELL 9-20 mm FRP

ROOF 10 mm FRP



NOZZLE FLANGE FRP






GASKETS BUTYLE RUBBER OF 3 MM THK

INTERNALS FRP

LADDER MS (IS 2062)



ANCHOR BOLTS MS

NOZZLE SCHEDULE

NOZZLE





N4 DRAIN 1 100 150#


N6 A/B MANHOLE 2 600 150#

N7 VENT 1 100 150#


Page 1 of 1


TANK DATA SHEET



TANK Tag No: T-705

SERVICE ANTISCALANT BULK STORAGE TANK LOCATION NEMMELI, TAMIL NADU

TYPE OF TANK VERTICAL CONE ROOF TANK QTY 1 NO


NET CAPACITY 94 m3

PRODUCT STORED ANTISCALANT SOLUTION SIZE 4,500 mm ID & 6,300 mm HT


CODE CONSTRUCTION API-650, TENTH EDITION




C

CORROSION ALLOWABLE

2 mm FOR ROOF 3mm FOR SHELL &

BOTTOM


THK MOC

SHELL 6 mm SS 316

ROOF 8 mm SS 316

BOTTOM PLATE 10 mm SS 316

MANHOLE NECK&FLANGE SS316

NOZZLE FLANGE SS316

NOZZLE FLANGE (FAB.) SS316

NOZZLE PIPES <=250 NB SSS316

NOZZLE PIPES (FAB.) >250 NB SS316

BOLTS & NUTS (NOZZLES) SS304

BOLTS & NUTS (STRUCTURE) SS304

GASKETS PTFE

INTERNALS SS316

R.F PADS, GUSSETS, WIND

GIRDER PLATE SS316

ROOF HANDRAIL BLACK MS PIPE MEDIUM (IS 1239)


CAT LADDER IS 2062

ANCHOR CAHIR SS316

NOZZLE SCHEDULE


N1 ANTISCALANT INLET 1 80 150#

N2 ANTISCALANT OUTLET 1 80 150#



N5 DRAIN 1 100 150#


N7 MANHOLE 1 600 150#

N8 VENT 1 100 150#


Page 1 of 2


TANK DATA SHEET



TANK Tag No: T-706

SERVICE 45% CAUSTIC SODA BULK STORAGE TANK LOCATION NEMMELI, TAMIL NADU

TYPE OF TANK VERTICAL CONE ROOF TANK QTY 1 NO

TOTAL CAPACITY 28 m3 NET CAPACITY 26 m

3

PRODUCT STORED 45 % CAUSTIC SODA SOLUTION SIZE 3,500 mm ID & 3,000 mm HT


CODE CONSTRUCTION API-650, 10TH EDITION




C


CORROSION ALLOWABLE

2 mm FOR ROOF 3mm FOR SHELL &

BOTTOM

THICKNESS MOC

SHELL 6mm IS 2062 GR.B OR A36

ROOF 8 mm IS 2062 GR.B OR A36

BOTTOM PLATE 10 mm IS 2062 GR.B OR A36

MANHOLE NECK &FLANGE IS 2062 GR.B OR A36


NOZZLE FLANGE (FAB.) IS 2062, GR. B OR A 36


NOZZLE PIPES (FAB.) >250 NB IS 2062, GR. B OR A 36



R.F. PADS, GUSSETS, WIND GIRDER

PLATE IS 2062, GR. B OR A 36

INTERNALS IS 2062 GR.B OR A36


GASKET BUTYL RUBBER OF 3 mm THK

ROOF HANDRAIL BLACK MS PIPE MEDIUM (IS 1239)

CAT LADDER IS 2062

3000

mm

3500 mm

ANCHOR CHAIR IS 2062

NOZZLE SCHEDULE


N1 CAUSTIC SODA SOLUTION INLET 1 80 150#


N3 INLET 1 80 150#


N5 CAUSTIC SODA SOLUTION OUTLET 1 80 150#

N6 WATER DRAW - OFF 1 100 150#


N8 MANHOLE 1 600 150#

N9 VENT 1 100 150#


Page 1 of 1


TANK DATA SHEET



TANK Tag No: T-711

SERVICE 12% SODIUM HYPOCHLORITE DOSING

TANK





PRODUCT STORED 12% SODIUM HYPOCHLORITE SOLUTION SIZE 3,000 mm ID & 3,000 mm HEIGHT






C


THK MOC

SHELL

9-11

mm

FRP




NOZZLE FLANGE FRP






INTERNALS FRP




LADDER MS (IS 2062)

ANCHOR BOLTS MS

NOZZLE SCHEDULE






N5 DRAIN 1 50 150#

N6 VENT 1 80 150#

N7 MANHOLE 1 600 150#


Page 1 of 1


TANK DATA SHEET



TANK Tag No: T-713

SERVICE 98% SULPHURIC ACID DOSING TANK LOCATION NEMMELI, TAMIL NADU

TYPE OF TANK HORIZONTAL DISHED END TANK QTY 1 NO


NET CAPACITY 21 m3

PRODUCT STORED 98% SULPHURIC ACID SOLUTION SIZE 2,250 mm ID & 5,000 mm LENGTH






C



THICKNESS MOC

SHELL 10 mm IS 2062


SADDLES IS 2062 GR. B

MANHOLE NECK &FLANGES IS 2062


NOZZLE FLANGE (FAB.) IS 2062


NOZZLE PIPES (FAB.) >250 NB SA 106 GR. B



R.F. PADS IS 2062, GR. B OR A 36

INTERNALS IS 2062, GR. B OR A 36


GASKET 3 mm THICK NEOPRENE

NOZZLE SCHEDULE





N4 BALANCE 1 80 150#

N5 DRAIN 1 50 150#

N6 MANHOLE 1 600 150#





Page 1 of 1


TANK DATA SHEET




SERVICE 10 % SODIUM BISULPHITE DOSING TANK LOCATION NEMMELI, TAMIL NADU



NET CAPACITY 20 m3

PRODUCT STORED 10 % SODIUM BISULPHITE SOLUTION SIZE 3,000 mm ID & 3,000 mm HT






C


THICKNESS MOC

SHELL 9-11mm FRP




NOZZLE FLANGE FRP






INTERNALS FRP




LADDER MS (IS 2062)

ANCHOR BOLT MS

NOZZLE SCHEDULE





N4 BALANCE 1 80 150#

N5 DRAIN 1 50 150#


N7 MANHOLE 1 600 150#

N8 SERVICE WATER INLET 1 80 150#

N9 VENT 1 100 150#


Page 1 of 1


TANK DATA SHEET




SERVICE ANTISCALANT DOSING TANK LOCATION NEMMELI, TAMIL NADU

TYPE OF TANK VERTICAL TANK WITH TORISPHERICAL HEAD QTY 2 NO


NET CAPACITY 10 m3

PRODUCT STORED ANTISCALANT SOLUTION SIZE 2,100 mm ID & 2,900 mm HT


CODE CONSTRUCTION IS 2825:2002




C

CORROSION ALLOWABLE 3 mm


THICKNESS MOC

SHELL 6mm AISI 316

DISHED END 10 mm AISI 316

BOTTOM PLATE 10 mm AISI 316

MANHOLE NECK &FLANGE AISI 316

MANHOLE DAVIT SS 316

NOZZLE FLANGE AISI 316

NOZZLE FLANGE (FAB.) AISI 316

NOZZLE PIPES <=250 NB AISI 316

NOZZLE PIPES (FAB.) >250 NB AISI 316

BOLTS & NUTS (NOZZLES) SS 316

R.F. PADS SS 316

INTERNALS SS 316


GASKET CAF

ANCHOR CHAIR SS 316

NOZZLE SCHEDULE

NOZZLE


N1 ANTISCALANT INLET 1 80 150#

N2 ANTISCALANT OUTLET 1 25 150#


N4 LT CONNECTION 1 65 150#

N5 DRAIN 1 50 150#

N6 VENT 1 25 150#

N7 MANHOLE 1 600 150#


N9 SERVICE WATER INLET 1 80 150#


Page 1 of 1


TANK DATA SHEET



TANK Tag No: T-716

SERVICE 45% CAUSTIC SODA DOSING TANK LOCATION NEMMELI, TAMIL NADU

TYPE OF TANK VERTICAL TANK WITH TORISPHERICAL HEAD QTY 1 NO

TOTAL

CAPACITY 2.03m3

NET CAPACITY 1.8 m3

PRODUCT

STORED

45% CAUSTIC SODA SOLUTION SIZE 1,200 mm ID & 1,800 mm HEIGHT





C OPER. TEMP: 22 - 35 0C

CORROSION ALLOWABLE

2 mm FOR ROOF AND 3 mm

FOR SHELL & BOTTOM


THICKNESS MOC

SHELL 6mm IS 2062


BOTTOM PLATE 10 mm IS 2062

MAN HOLE NECK &FLANGE IS 2062 GR.B


NOZZLE FLANGE (FAB.) IS 2062 GR. B

NOZZLES PIPES <=250 NB SA 106 GR. B

NOZZLES PIPES (FAB.) >250 NB IS 2062 GR. B

R.F.PADS, GUSSETS, WIND GIRDER

PLATE

IS 2062 GR. B

GASKETS

BUTYL RUBBER OF 3MM

THICK

NUTS & BOLTS (NOZZLES) A 307 GR. A & A 563 GR. A

NUTS & BOLTS (STRUCTURE) A 325 GR. A & A 563 GR. A


ANCHOR CHAIR IS 2062 GR. B

NOZZLE SCHEDULE

NOZZLE


N1 CAUSTIC SODA SOLUTION INLET 1 80 150#

N2 CAUSTIC SODA SOLUTION OUTLET 1 25 150#

N3 DRAIN 1 40 150#


N5 VENT 1 25 150#

N6 MANHOLE 1 600 150#



Page 1 of 1


TANK DATA SHEET



TANK Tag No: V-301 A-L

SERVICE SUCK BACK TANKS LOCATION NEMMELI, TAMIL NADU

TYPE OF TANK HORIZONTAL CYLINDRICAL DISHED END

TANK

QTY 12 NOS

TOTAL CAPACITY 13.24 m3 NET CAPACITY 13 m

3

PRODUCT STORED REVERSE OSMOSIS PERMEATE (PRODUCT

WATER FROM RO)

SIZE 1,500 mm ID & 7,500 mm LENGTH





C OPERATING TEMPERATURE: 22 - 35 0C



THICKNESS MOC

SHELL 11mm FRP

DISHED END 11mm FRP


NOZZLE FLANGE FRP




R.F PADS, GUSSETS, WIND

GIRDER PLT FRP



INTERNALS FRP



NOZZLE SCHEDULE

NOZZLE

MARK. SERVICE QTY SIZE NB RATING

N1 RO PERMEATE INLET 1 200 150#


N3 DRAIN 1 50 150#


N5 MANHOLE 1 600 150#

N6 VENT 1 200 150#


Page 1 of 1


NOTE: TANK SHALL BE SUPPLIED WITH ALL NECESSARY TANK MOUNTED VALVES , INSTRUMENTATION & CONTROLS ETC.

TANK DATA SHEET




SERVICE CARBON DIOXIDE STORAGE TANK LOCATION NEMMELI, TAMIL NADU

TYPE VERTICAL CYLINDRICAL QTY 2 NOS

TOTAL CAPACITY 28.2 Tons NET CAPACITY 26.9 Tons

FLUID HANDLED LIQUID CARBON DIOXIDE SIZE 2,900 mm ID & 7,290 mm HT

DESIGN DATA

CODE CONSTRUCTION ASME SECTION VIII DIV I

MAX ALLOWABLE

WORKING PRESSURE 24.1 BAR

INNER VESSEL: PRESSURE TEST

ACCORDING TO ASME CODE TESTING STANDARD

INNER & OUTER JACKET HELIUM

RETENTION TEST, 72 HRS.

MOC

INNER VESSEL CARBON STEEL (SA 612N)

INEER PIPING STAINLESS STEEL 304

INTERNAL SUPPORTS STAINLESS STEEL 304

OUTER JACKET CARBON STEEL

OUTER JACKET PADS STAINLESS STEEL 304

INSULATION PERLITE / FULL VACUUM


Page 1 of 1


TANK DATA SHEET



TANK Tag No: T-202

SERVICE DISC FILTER BACKWASH TANK LOCATION NEMMELI, TAMIL NADU




PRODUCT STORED CLEANING CHEMICAL FOR UF OR SEA WATER SIZE 2,500 mm ID, 2,300 mm HEIGHT






C


THICKNESS MOC

SHELL 9-11 mm FRP

ROOF 12 mm FRP



NOZZLE FLANGE FRP






INTERNALS FRP




LADDER MS (IS 2062)

ANCHOR BOLT MS

NOZZLE SCHEDULE

NOZZLE





N4 DRAIN 1 50 150#


N6 MANHOLE 1 600 150#

N7 VENT 1 100 150#


Page 1 of 1


TANK DATA SHEET



Tank Tag No: T-204

SERVICE CLEANING IN PLACE TANK LOCATION NEMMELI, TAMIL NADU




PRODUCT STORED CLEANING CHEMICAL FOR UF OR SEA WATER SIZE 2,500 mm ID & 2,300 mm HEIGHT






C


THICKNE

SS MOC

SHELL 9-11 mm FRP

ROOF 12 mm FRP



NOZZLE FLANGE FRP






INTERNALS FRP




LADDER MS (IS 2062)

ANCHOR BOLT MS

NOZZLE SCHEDULE

NOZZLE





N4 DRAIN 1 50 150#


N6 MANHOLE 1 600 150#

N7 VENT 1 100 150#


Page 1 of 1


TANK DATA SHEET



TANK Tag No: T- 801

SERVICE FIRE WATER STORAGE TANK LOCATION NEMMELI, TAMIL NADU

TYPE OF TANK OPEN TOP VERTICAL TANK QTY 1 NO

TOTAL CAPACITY 324 m3

NET CAPACITY 313 m3

PRODUCT STORED SEA WATER SIZE 7,500 mm ID & 7,500 mm HT






C

CORROSION ALLOWABLE 3 mm FOR SHELL & BOTTOM


THK MOC

SHELL 6 mm IS 2062 GR. B

BOTTOM PLATE 10 mm

IS 2062 GR. B OR

A36



NOZZLE FLANGE (FAB.) IS 2062 GR. B OR A36


NOZZLE PIPES (FAB.) >250 NB IS 2062 GR. B OR A36

R.F PADS, GUSSETS, WIND GIRDER

PLT IS 2062 GR. B




PAINTING AS PER SPECIFICATIONS STAIR CASE HANDRAIL & PLATFORM BLACK MS PIPE MEDIUM (IS 1239)

NOZZLE SCHEDULE


N1 INLET 1 80 150#

N2 OUTLET 1 250 150#


N4 HIGH LEVEL SWITCH CONNECTION 1 100 150#

N5 LOW LEVEL SWITCH CONNECTION 1 100 150#

N6 BYPASS 1 100 150#

N7 WATER DRAW OFF 1 150 150#

N8 MANHOLE 2 600 150#


MEC / 10EP/ 01 / 01 / DS / 0100

Page 1 of 1


CARTRIDGE FILTER DATA SHEET Project: 100 MLD SWRO Desalination Plant Data Sheet / Document no: MEC / 10EP/ 01 / 01 / DS / 0100 Cartridge Filter Tag No: CF- 301 - A to O

1 FLUID HANDLED UF TREATED SEA WATER 2 QUANTITY REQUIRED 15 3 NO OF CARTRIDGE FILTERS

WORKING 12

4 NO OF CARTRIDGE FILTERS STAND-BY

3

5 NO. OF FILTER ELEMENT PER CARTRIDGE FILTER WITH HOUSING DIA- 1220MM :

180 to 220

6 TOTAL FLOW RATE TO BE HANDLED 770 M3 /HR 7 DEGREE OF FILTRATION 5 MICRONS 8 OPERATING PRESSURE 1.5 TO 2 BAR 9 DESIGN TEMPERATURE 45 0 C 10 ALLOWABLE MAX. PRESS. DROP 0.8 BAR * (BIDDER TO

CONFIRM) 11 NO. OF FILTER CARTRIDGE 180 to 220 FOR FLOW OF

770M3/HR. 12 FILTER CARTRIDGE LENGTH 40 “

MATERIAL OF CONSTRUCITON 13 BODY/HOUSING Duplex SS - 2205 14 FILTER ELEMENTS POLYPROPYLENE 15 END CONNECTIONS ANSI-B 16.5#150,250NB

BOLTS AND NUTS INTERNAL SS 317L

16

EXTERNALS SS 316 (NON WETTED) NOTE * BIDDER TO CONFIRM


Page 1 of 1


PRESSURE VESSELS DATA SHEET

Project: 100 MLD SWRO Desalination Plant Data Sheet / Document no: MEC / 10EP/ 01 / 01 / DS / 0101

1 ITEM DESCRIPTION PRESSURE VESSEL 2 FLUID HANDLED UF TREATED SEA WATER 3 DESIGN CODE ASME SECTION X 4 LOCATION 100 MLD SWRO

DESALINATION PLANT, NEMMELI, TAMILANADU

5 NUMBER REQD 864 6 NO. OF ELEMENTS PER PRESSURE

VESSEL 7

7 SIZE 9” OD AND LENGTH 303.15” 8 PRESSURE RATING 1200 PSI 9 TEST PRESSURE 1320 PSI 10 MOC OF PRESSURE TUBES FRP 11 PORT CONFIGURATION SIDE PORT 12 F/C PORT SIZE 1.5 “ 13 NO OF F/C PORTS 2


Page 1 of 1


STAIC MIXER DATA SHEET

Project: 100 MLD SWRO Desalination Plant Data Sheet / Document no: MEC / 10EP/ 01 / 01 / DS / 0102 Static Mixer Tag No: MX-418 SERVICE INLINE MIXING NO. REQUIRED 1

PROCESS DATA FLUID REVERSE OSMOSIS PERMEATE (PRODUCT

WATER FROM RO) TOTAL DISSOLVED SOLIDS (TDS) ≤ 470 ppm FLUID DENSITY 1,010 Kg/m3 FLUID VISCOSITY 1 Cp FLOW PATTERN UNIFORM JACKET REQUIRED NO PURPOSE TO MIX THE REVERSE OSMOSIS PERMEATE

( RO PRODUCT WATER) WITH 45 % CAUSTIC SODA SOLUTION & 12 % SODIUM HYPOCHLORITE SOLUTION

CHEMICALS TO BE MIXED 45 % CAUSTIC SODA SOLUTION & 12 % SODIUM HYPOCHLORITE SOLUTION

FILTERED WATER FROM UF

45 % CAUSTIC SODA SOLUTION

12 % SODIUM HYPOCHLORITE SOLUTION

AVERAGE FLOWRATE m 3 / hr 4200 0.02 0.03 OPERATING PRESSURE bar 2.5 2.7 2.7 FLUID TEMPERATURE 0 C 22-35 22-35 22-35

STATIC MIXER DESIGN TYPE INLINE MAX.PRESSURE DROP 0.14 BAR DESIGN CODE ASME VIII,DIV 1 REQUIRED MIXING DEGREE >95% DIAMETER 26 “ DN DESIGN PRESSURE 7 BAR INSTALLATION HORIZONTAL DESIGN TEMPERATURE 45 0C MIXING ELEMENTS

NON REMOVABLE CHEMICAL DOSING POINTS 2

MIXER TYPE WITH FLANGES CHEMICAL PIPIES EACH OF 3 /4 “ DN

LOOSE FLANGE,ANSI B 16.5 &12 MM THICK ( FOR SODIUM HYPOCHLORITE )

FLANGE TYPE ANSI B 16.5 CHEMICAL FLANGES

ANSI B 16.5 (FOR CAUSTIC SODA)

MATERIALS BODY SS 316L MIXING DEVICES SS 316L SS 316L SS 316L INTERNAL LINING NO EXTERNALFINISHING UV RESISTANT PAINT


Page 1of 1


STAIC MIXER DATA SHEET Project: 100 MLD SWRO Desalination Plant Data Sheet / Document no: MEC / 10EP/ 01 / 01 / DS / 0103 Static Mixer Tag No: MX-201 SERVICE INLINE MIXING NO. REQUIRED 1

PROCESS DATA FLUID FILTERED WATER FROM UF SALINITY 35,000 ppm TOTAL DISSOLVED SOLIDS (TDS) 40,150 ppm FLUID DENSITY 1,010 Kg/m3 FLUID VISCOSITY 1 Cp FLOW PATTERN UNIFORM JACKET REQUIRED NO PURPOSE TO MIX THE UF TREATED SEA WATER

WITH 10 % ANTISCALANT SOLUTION & 10 % SODIUM BISULPHITE SOLUTION

CHEMICALS TO BE MIXED 10 % ANTISCALANT SOLUTION & 10 % SODIUM BISULPHITE SOLUTION


10 % ANTISCALANT SOLUTION

10 % SODIUM BISULPHITE SOLUTION

AVERAGE FLOWRATE m 3 / hr 9255 0.45 0.45 OPERATING PRESSURE bar 2.5 2.7 2.7 FLUID TEMPERATURE 0 C 22-35 22-35 22-35

STATIC MIXER DESIGN TYPE INLINE MAX.PRESSURE DROP 0.14 BAR DESIGN CODE ASME VIII,DIV 1 REQUIRED MIXING

DEGREE >95%

DIAMETER 40 “ DN DESIGN PRESSURE 7 BAR INSTALLATION HORIZONTAL DESIGN

TEMPERATURE 45 0C

MIXING ELEMENTS

NON REMOVABLE

CHEMICAL DOSING POINTS

2

MIXER TYPE WITH FLANGES CHEMICAL PIPIES EACH OF ¾ “ DN FLANGE TYPE LOOSE

FLANGE,ANSI B 16.5 &12 MM THICK

CHEMICAL FLANGES LOOSE FLANGE,ANSI B 16.5 &12 MM THICK

MATERIALS BODY HDPE MIXING DEVICES HDPE FLANGES HDPE INTERNAL LINING NO EXTERNALFINISHING UV RESISTANT PAINT


Page 1 of 1


STAIC MIXER DATA SHEET Project: 100 MLD SWRO Desalination Plant Data Sheet / Document no: MEC / 10EP/ 01 / 01 / DS / 0104 Static Mixer Tag No: MX-202 SERVICE INLINE MIXING NO. REQUIRED 1

PROCESS DATA FLUID FILTERED WATER FROM UF SALINITY 35,000 ppm TOTAL DISSOLVED SOLIDS (TDS) 40,150 ppm FLUID DENSITY 1,010 Kg/m3 FLUID VISCOSITY 1 Cp FLOW PATTERN UNIFORM JACKET REQUIRED NO

PURPOSE

TO MIX THE UF TREATED SEA WATER WITH 10 % SODIUM HYPOCHLORITE SOLUTION

CHEMICALS TO BE MIXED 10 % SODIUM HYPOCHLORITE SOLUTION


10 % SODIUM HYPOCHLORITE SOLUTION

AVERAGE FLOWRATE m 3 / hr 600 0.0211

OPERATING PRESSURE bar 2 2.2

FLUID TEMPERATURE 0 C 22-35 22-35 STATIC MIXER DESIGN

TYPE INLINE MAX.PRESSURE DROP 0.14 BAR

DESIGN CODE ASME VIII,DIV 1 REQUIRED MIXING DEGREE >95%

DIAMETER 14 “ DN DESIGN PRESSURE 7 BAR

INSTALLATION HORIZONTAL DESIGN TEMPERATURE 45 0C

MIXING ELEMENTS NON REMOVABLE CHEMICAL DOSING POINTS 1

MIXER TYPE WITH FLANGES CHEMICAL PIPIES 1 “ DN

FLANGE TYPE LOOSE FLANGE,ANSI B 16.5 &12 MM THICK

CHEMICAL FLANGES

LOOSE FLANGE,ANSI B 16.5 &12 MM THICK

MATERIALS BODY HDPE MIXING DEVICES HDPE FLANGES HDPE INTERNAL LINING NO EXTERNALFINISHING UV RESISTANT PAINT


MEC / 10EP/ 01 / 01 / DS / 0105



specification, chapter 7 of the volume II A. 2) Commissioning spares shall be supplied by the tenderer. 3) * Indicates vendor to furnish

4) Supply with companion flange, gaskets, fasteners, reducers/ expanders to match the main pipe size & limestone hopper outlet as per respective P&ID and piping drawing

Vendor to furnish

* Equipment GA drawing & cross sectional drawing

LIMESTONE EJECTOR DATA SHEET

Project: 100 MLD SWRO Desalination Plant Data Sheet / Document no: MEC / 10EP/ 01 / 01 / DS / 0105 Ejector tag no E-406 A/B Number of units 2 (1w +1s) Purpose For Recharging of limestone (2-5mm)

from limestone filling hoppers to Limestone filters

Motive Fluid Clarified water from ST 410 Sucked CaCO3 design flow rate Kg/hr 4,133 Suction pressure Bar a 1 Motive water design flow rate m3/hr 135 Motive water pressure Bar a 4.5 Delivery pressure Bar a 2.2 Material of construction of ejector AISI 316 L Companion Flanges Included Max. Pressure drop * Velocity at ejector outlet *


Page 1 of 1


CARBON DIOXIDE ABSORBER DATA SHEET



Absorber Tag No: AB-403

Design Standard As per Technical specification for Pressure & storage vessels of chapter 2 of vol II A

Number of vessels 1

Number of vessel working 1 Design Flow rate of permeate water to absorber m3/hr 295

Material of construction of vessel ASTM A 516 Gr.60

Lining Rubber lining of 3 mm thickness as per TS for rubber lining

Packing material Polypropylene

Diameter mm 1270

Straight side height mm 8000

Pressure design bar g 5

Working pressure bar g 3.5

Test pressure bar g 7.5 Design flow rate of permeate water from absorber m3/hr 295

CO2 flow rate Kg/hr 208.5

Packing type PALL RING 2”

Packing depth mm 2500

Water distributor AISI 316 L

Gas distributor AISI 316 L

Allowable pressure drop 0.5 bar * (vendor to confirm) Note: 1). The equipment shall be supplied with necessary platforms for valve & instruments maintenance.


MEC / 10EP/ 01 / 01 / DS / 0107

Page 1 of 2


AIR COMPRESSOR DATA SHEET

Project: 100 MLD SWRO Desalination Plant Data Sheet / Document no: MEC / 10EP/ 01 / 01 / DS / 0107 AIR COMPRESSOR TAG NO: AC-401 A/B PROCESS DATA GAS HANDLED AIR NUMBER 2(1W+1S) RATED FLOW RATE m3/hr 911.9 SUCTION PRESSURE MWC ATMOSPHERIC SUCTION TEMPERATURE (Max./Min)

OC 50/22

DISCHARGE PRESSURE bar g 0.55 RELATIVE HUMIDITY MAX 100% at 35 oC DISCHARGE TEMPERATURE OC * LOCATION OUTDOOR SERVICE DUTY CONTINUOUS COMPRESSIBILITY 1 PRESSURE RATIO Cp/Cv 1.6 GD2 OF BLOWER AT FAN SPEED Kg/m2 2.5 * (VENDOR TO CONFIRM) NOISE LEVEL dB (A) 85 @ 1 M FROM DRIVE UNIT MECHANICAL DATA MANUFACTURER * MODEL * TYPE ROTARY TWIN LOBE (ROOTS) SPEED RPM 1600*(VENDOR TO

CONFIRM) RATED POWER BKW AT 45OC 13 *(VENDOR TO

CONFIRM) SELECTED kW kW * DRIVE TYPE BELT DRIVEN SAFETY VALVE TYPE SPRING LOADED (API 526) SAFETY VALVE SET PRESSURE bar g 0.61 TYPE OF COUPLING FLEXIBLE VOLUMETRIC MINIMUM EFFICIENCY

81%

VOLUMETRIC EFFICIENCY OFFERED

*

SUCTION FILTER, SUCTION SILENCER, DISCHARGE SILENCER, MOTOR

INCLUDED


MEC / 10EP/ 01 / 01 / DS / 0107

Page 2 of 2



specification, chapter 7 of the volume II A. 2) Commissioning spares shall be supplied by the tenderer. 3) Refer TS of Air Blower in chapter 2 of volume II A. 4) * Indicates vendor to furnish

5) Motor shall be as per electrical specification enclosed in chapter 4 of volume II B

6) Safety Valve, suction filter, suction silencer, discharge silencer, common base plate, motor, rain hood canopy, ant vibration pads, foundation bolts, motor fixing bolts, motor slide rails, motor pulley and blower pulley, v-belt, v-belt guards

7) Supply with companion flange, gaskets, fasteners, reducers/ expanders to match the main pipe size as per respective P&ID and piping drawing

Vendor to furnish

* Equipment GA drawing & cross sectional drawing * Performance curve * Torque speed curve

DIRECTION OF ROTATION FROM DRIVE END

CLOCKWISE

LUBRICATION OIL/GREASE VIBRATION LEVEL MM/SEC * BEARING TYPE BALL/ROLLER* (VENDOR TO CONFIRM) SUCTION FLANGE/DISCHARGE FLANGE RATING

150#/150#

SUCTION FLANGE/DISCHARGE FLANGE SIZE

*

TESTING STANDARD BS 1571 PART (II) MATERIAL OF CONSTRUCTION CASING CAST IRON IS 210 Gr. FG 260 LOBE CAST IRON IS 210 Gr. FG 260 SHAFT ALLOYED STEEL GEAR EN 353/BS 970 SUCTION FILTER, SUCTION SILENCER, DISCHARGE SILENCER

AISI 304

SAFETY VALVE ALUMINIUM, SPRING LOADED BASE PLATE MS IS 2062 Gr.B , EPOXY COATED


MEC / 10EP/ 01 / 01 / DS / 0108

Page1 of 2


ATMOSPHERIC DEGASSER FAN DATA SHEET

Project: 100 MLD SWRO Desalination Plant Data Sheet / Document no: MEC / 10EP/ 01 / 01 / DS / 0108 Degasser Fan Tag No: DGF-415 A/B PROCESS DATA GAS HANDLED AIR NUMBER 2(1W+1S) RATED FLOW m3/hr 2,094 SUCTION PRESSURE Bar ATMOSPHERIC SUCTION TEMPERATURE (Max./Min) OC 50/22 DISCHARGE PRESSURE mwc 0.21 DISCHARGE TEMPERATURE OC * RELATIVE HUMIDITY MAX 100% at 35 oC LOCATION OUTDOOR SERVICE DUTY CONTINUOUS MOLECULAR WEIGHT 29 SPECIFIC WEIGHT AT SUCTION Kg/m3 1.2 GD2 OF BLOWER AT FAN SPEED Kg/m2 2.5 * (VENDOR TO

CONFIRM) NOISE LEVEL dB (A) 85 @ 1 M FROM DRIVE UNIT MECHANICAL DATA MANUFACTURER * MODEL * TYPE ATMOSPHERIC DEGASSER FAN,

CENTRIFUGAL SUCTION SINGLE TYPE OF IMPELLAR BACKWARD INCLINED WITH RADIAL

TIP IMPELLAR DIAMETER MM * SPEED RPM 1450 RATED POWER BKW AT 45OC 1.5 *(VENDOR TO

CONFIRM) SELECTED kW kW * DRIVE TYPE DIRECT TYPE OF COUPLING FLEXIBLE MINIMUM EFFICIENCY 66% EFFICIENCY OFFERED * DAMPER TYPE OUTLET


MEC / 10EP/ 01 / 01 / DS / 0108

Page2 of 2



specification, chapter 7 of the volume II A. 2) Commissioning spares shall be supplied by the tenderer. 3) Refer TS of Air Blower in chapter 2 of volume II A. 4) * Indicates vendor to furnish

5) Motor shall be as per electrical specification enclosed in chapter 4 of volume II B

6) Suction screen, common base plate, motor, dampers, rain hood canopy, foundation bolts, motor fixing bolts, coupling with non sparking guards

7) Supply with companion flange, gaskets, fasteners, reducers/ expanders to match the main pipe size as per respective P&ID and piping drawing

Vendor to furnish


DIRECTION OF ROTATION FROM DRIVE END

CLOCKWISE

LUBRICATION GREASE BEARING BALL VIBRATION LEVEL MM/SEC < 7.1 (AS PER

CODE & STD) SUCTION FLANGE/DISCHARGE FLANGE RATING

150#/150#

SUCTION FLANGE/DISCHARGE FLANGE SIZE

*

TESTING STANDARD IS 4894 MATERIAL OF CONSTRUCTION CASING AISI 304 IMPELLAR AISI 304 SHAFT AISI 410 SUCTION FILTER ELEMENTS/HOUSING AISI 304 DAMPERS AISI 304 BASE PLATE MS IS 2062 Gr.B , EPOXY

COATED


MEC / 10EP/ 01 / 01 / DS / 0109

Page1 of 1


DEGASSER DATA SHEET



Degasser Tag No: DGT - 402

Service Degasser tower

Number of working vessels 1

Number of vessels-standby 0

Material vessel ASTM A 516 GR.60

Lining Rubber 3 mm thick

Packing Poly Propylene

Water distributor type Perforated pipe

Water distributor AISI 316 L

Air distributor AISI 316

Sump capacity of degasser m3 16 Minimum capacity based on operating low water level m3 13

Diameter of degasser mm (ID)3700

Height of degasser mm 7500

Thickness of degasser mm 5/7

Design flow rate of carbonated water m3/hr 1360

Packing type Pall ring 2”

Design pressure Bar g Atmospheric

Working pressure Bar g Atmospheric Note: 1). The equipment shall be supplied with necessary platforms for valve & instruments maintenance.


MEC / 10EP/ 01 / 01 / DS / 0110

Page1 of 2


LIMESTONE FILTERS DATA SHEET

Project: 100 MLD SWRO Desalination Plant Data Sheet / Document no: MEC / 10EP/ 01 / 01 / DS / 0110 LimeStone Filter Tag No: LF-414 A-E

Design Standard As per Technical specification for Pressure & storage vessels of chapter 2 of vol II A

Number of working vessels 4 Number of stand-by vessels 1 Type of vessel Vertical cylindrical

Shell / heads ASTM A 516 Gr.60 Lining Rubber lining of 3

mm thickness as per TS for rubber

lining


Internal AISI 316 L Carbonated water design flow rate( for each vessel)

m3/hr 340.2

Diameter of vessel mm 4,400 Height of vessel mm 4,893 Bulk density of limestone Ton/m3 1.450 Depth of limestone - minimum mm 3731 Depth of limestone – maximum mm 4293 Total limestone consumption (at due purity) per filter

Kg/hr 73.80

Limestone charging volume per each filter m3 8.55 Frequency of recharge Days 7 Quantity of substitute /addition per filter Kg 12398.3 Total quantity of substitute / adding Kg 61,992 Maximum water velocity through bed m/hr 22.39 Minimum distillate contact time Min 10 after 7 days Duration of recharge Hrs 3 Recharge motive water source Acidified distillate from carbon dioxide

absorber Recharge motive water design flow rate m3/hr 90 Backwashing water design flow rate m3/hr 379.9 Air sourcing design flow rate m3/hr 911.9 Frequency of backwashing hrs 240 Duration of backwashing (average) Min 30 total Backwash water source Distillate from

header


MEC / 10EP/ 01 / 01 / DS / 0110

Page2 of 2


Empty weight tons 32.0 Working weight tons 190.0 Pressure design bar g 5.0 Working pressure bar g 2.8 Test pressure bar g 7.5

Backwashing water system 1st operating time with air Min 5 1st operating flow rate of water m3/hr 379.9 2nd operating time with air Min 10 2nd operating design flow rate of water m3/hr 379.9 Required amount of filling water m3 84.4 Backwashing water flow Number of units Direct from header Design flow rate m3/hr 380 Head MWC 18 Material AISI 316 L


MEC / 10EP/ 01 / 01 / DS / 0111


DISC FILTERS DATA SHEET

Project: 100 MLD SWRO Desalination Plant Data Sheet / Document no: MEC / 10EP/ 01 / 01 / DS / 0111 Disc Filter Tag No: DF-201 – 1 TO 30 Quantity: 30 sets


MEC / 10EP/ 01 / 01 / DS / 0111


SPECIFICATION FOR DISC FILTER SYSTEM

* SPECIFICATION FOR ONE DISC FILTER SET ONLY Process & Performance data Purpose Filtration of larger suspended particle sizes

greater than 100 micron Nominal Flow rate per set: 365.0 m3/h Liquid handled Sea water Sp. Gravity of feed water 1.01 Anticipated Recovery: 100 % Design Temperature: 22 - 35 0C Location of installation Indoor, one set each at the upstream of UF

skid pH of feed water 5.5 – 6.5 Total Suspended solids in Feed water 18 – 200 ppm Particle size range >0.4 micron Disc Filter Skid: No. of units per set: 4 Manufacturer: Arkal or equivalent Model: Arkal Galaxy Ø6” or equivalent Amiad make Type: Black Disc Material of element: PP Filtration cut off/Micron rating: 100 micron Housing material: PP Manufacturer: Arkal, Amiad Materials of Construction: Materials of construction: Piping material: HDPE Frame material: Carbon steel enamel coated Clamps: Stainless Steel Spring: Hastealloy (C 276, C22), 904L Piston / Cartridge & support for mounting of elements: PP Installation and Utility Requirements for each set: Inlet: 10” Flange Outlet: 10” Flange Backwash water Inlet/Drain: 4” Flange Inlet water pressure: 3 bar, minimum Air pressure needed: 5 to 6 bar, oil free from plant air Drain to be sized (for backwash step): 60 m3/h per disc filter skid


MEC / 10EP/ 01 / 01 / DS / 0111


Approximated skid dimension: 1.60m H x 1.80m W x 1.10m D Approximated shipping weight: 865 Kg Instrumentation: Pressure indicators: (1) Inlet filter, (1) Outlet filter, (1) Backwash pump discharge Differential pressure switch: (1) Between Inlet & Outlet Valves per set of disc filter: Automatic Pneumatic 3-Way Butterfly with actuator (Note-1 &2 ) Nos. of three way valves 8 (one each at inlet and outlet of each unit-(Note-1) Material: ASTM A 890 Gr. A/ UNS J 93404/UNS S 31254 (Alloy 2507)

having PREN>40. Connection type: Clamps Inlet/ Outlet; Union Drain Valve size: 3"/4” /6" (Note-1 & 2) line pressure: Water: 3 to 4 bar Air pressure on actuator: 4 bar Note-1 : Size and numbers of valves shall be as required. Note-2 : Alternatively instead of a 6" 3-ways valves, two numbers of Butterfly valves can be supplied and installed. Installation and Utility Requirements: Inlet: 10” Flange Outlet: 10” Flange Backwash water Inlet/Drain: 4” Flange Inlet water pressure: 3 bar, minimum Air pressure needed: 5 to 6 bar, oil free from plant air Drain to be sized (for backwash step): 60 m3/h per disc filter skid Approximated skid dimension: 1.60m H x 1.80m W x 1.10m D Approximated shipping weight: 865 Kg Note: 1. Normal Backwash sequence anticipated is as follows: **Backwash time per unit: 10 to 20 second 2. Backwash frequency: 30 to 60 minutes

** Backwash frequency and time can be adjusted. The same Shall depend on the load of suspended solids in the feed and the frequency shall be adjusted based on lab test conducted daily during operation.

Backwash Pump Skid requirement: One common backwash pump for 30 sets

of Automatic Disc Filter Systems. .


MEC / 10EP/ 01 / 01 / DS / 0111


(Typical description for backwash pump skid) Pump tag no: P-204 A/B Pump description : Backwash pump for disc filters Pump quantity: 2 nos. No of pumps working: 1 no Material of construction : (casing and wetted parts): Super duplex having PREN>40 Anticipated motor kW: 37 KW Motor enclosure: As per electrical technical specification Design flow rate 200 m3/h Discharge pressure: 4.5bar Tank tag no: T-202 Tank description: Disc filter back wash tank Tank quantity : 1 no. Feed with: Disc filter outlet water Material: FRP Accessories: Level control valve on tank Capacity of tank: 10 m3 Note: Backwash sequence shall be one unit of the set at a time while leaving other units in service. Controls Automation & controls: Fully automatic including backwashing

sequence through common PLC based system installed for the entire desalination plant


MEC / 10EP/ 01 / 01 / DS / 0112


ULTRAFILTRATION MACHINE

ULTRA FILTRATION DATA SHEET

Project: 100 MLD SWRO Desalination Plant Data Sheet / Document no: MEC / 10EP/ 01 / 01 / DS / 0112 Ultra Filter Tag No: UF-201 – 1 TO 30 Quantity: 30 sets Description: Ultra Filtration skids with UF membranes


MEC / 10EP/ 01 / 01 / DS / 0112


SPECIFICATION FOR

ULTRAFILTRATION MACHINE * TYPICAL SPECIFICATION FOR ONE SET ONLY. Process & performance data: Purpose: Pretreatment to reverse osmosis membrane

system feed by filtration of suspended particles of sizes 100 micron up to 0.1micron including micro-organisms

Liquid handled: Sea water Specific gravity of feed water 1.01 pH of feed water 5.5 – 6.5 Nominal product flow rate (See note): 328.5 m3/h Nominal Feed flow rate: 365.0 m3/h Concentrate flow rate: 36.5 m3/h Minimum product recovery: 90 % Backwash flow rate: 20 m3/h Net product flow rate (forward feed to RO skid): 308.5 m3/h Design temperature: 22 - 35 0C Total suspended solids in feed water: 18 – 200 ppm Feed turbidity: 3- 40 NTU Filtration type out to in / in to out, cross flow Required product turbidity: <1NTU Silt density index of product water < 3 Bacteria, virus log removal log 4 TOC 10 ppm max. Note: Nominal product flow rate make a provision for the UF product to be used for backwash purpose. Materials of Construction: Piping material: HDPE Frame material: Carbon steel enamel coated as per TS for

corrosive environment Clamps/Fittings: SS/Zinc coated Membrane Elements: Quantity of elements: 120 elements Quantity of trains: (4) train(s) Quantity of elements / train: (30) elements Manufacturer: Norrit, Memcor, Koch, Hydranatic, Inge Active area: 40 to 50 m 2


MEC / 10EP/ 01 / 01 / DS / 0112


Type: Hollow Fiber, (hydrophilic), in to out/out to in, cross flow

Material: PES/ PVC MWCO: 100000 to 150000 daltons (0.05 micron) Housing material: PVC Design membrane flux range: 50 – 65 L/m2h UF membrane height 1.680 to 1.920 m UF membrane diameter 180 to 220 mm UF BACKWASH SYSTEM DETAILS (comprising of pumps, CIP/CEB tank & NaOCl dosing system) UF Backwash Pumps: Total (4) backwash pumps, two nos

operating during backwashing cycle. Datasheet for each backwash pump (P-202 A-D); Refer pump data sheet no: MEC / 10EP/ 01 / 01 / DS / 0005 Material of construction: Super Duplex Steel having PREN > 40 Motor rating: 30 KW Power absorbed: 24.5 KW Nominal flow rate 300 m3/h Discharge pressure: 2 bar Required pump inlet pressure: Flooded to 1 bar Starter type: V.F.D Chemical Feed System: Purpose: Chlorination during: Backwash Max dosing requirement : 63 LPH at the discharge of backwash pump CIP Tank: Quantity: 1 set Material: FRP Capacity: 10.00 M3 Location: Mounted on the UF backwash skid Approximated skid dimension: 2.00m H x 2.50m W x 2.40m D Approximated shipping weight: 800 Kg PIPING SYSTEM DETAILS FOR UF SYSTEM & UF BACKWASH SYSTEM Valves (Automatic): Pneumatic Butterfly valve, flange type Material: Super duplex steel having PREN>40 Connection: Flange


MEC / 10EP/ 01 / 01 / DS / 0112


Manufacturer: Refer preferred vendors list, chapter 9 volume IIA. Actuator: Pneumatic with lift limiter Required air pressure on actuator: 4 bar Feed valve Quantity: 4 sets Type: Butterfly valve Diameter: 6” Product valve Quantity: 4 sets Type: Butterfly valve Diameter: 6” Backwash Inlet valve Quantity: 4 sets Type: Butterfly valve Diameter: 10” Backwash Outlet valve Quantity: 4 sets Type: Butterfly valve Diameter: 10” Flushing Inlet valve Quantity: 4 sets Type: Butterfly valve Diameter: 8” Flushing and Backwash Outlet valve Quantity: 4 sets Type: Butterfly valve Diameter: 8” Concentrate valve Quantity: 4 sets Type: Ball valve Diameter: 2” Valves (Manual): Manual Butterfly valve, flange type Material: Super duplex steel having PREN>40 Connection: Flange Actuator: Ratchet handle CIP Inlet valve


MEC / 10EP/ 01 / 01 / DS / 0112


Quantity: 4 sets Type: Butterfly valve Diameter: 6” CIP Return valve Quantity: 4 sets Type: Butterfly valve Diameter: 6” CIP Product Return valve Quantity: 4 sets Type: Butterfly valve Diameter: 3” Inlet Pressure Control Valve: Purpose: To avoid eventual water hammer and to control the feed inlet pressure Refer control valve data sheet enclosed in chapter 6 of volume II B of bid document. Number of valves: one per skid Connection type: Flange Adjustment down stream pressure: 2 bar Inlet Flow Control Valve: Purpose: To maintain & control the feed flow inlet to the each UF skid. Refer control valve data sheet enclosed in chapter 6 of volume II B of bid document. Number of valves: one per skid Flow transmitter: Purpose: To measure l the feed flow inlet to the each UF skid. Refer flow transmitter data sheet enclosed in chapter 6 of volume II B of bid document. Number of flow transmitters: one per skid Installation and Utility Requirements for UF SYSTEM: Inlet: 10” Flange Product: 10” Flange Concentrate: 3” Flange Backwash Inlet / Outlet: 10” Flange CIP Return: 6” Flange Inlet water pressure: 1 bar, minimum


MEC / 10EP/ 01 / 01 / DS / 0112


Air pressure needed: 5 to 6 bar, oil free from plant air Drain to be sized (for backwash step): 300 m3/h per UF skid Approximated skid dimension: 2.40m H x 12.00m W x 2.10m D Approximated shipping weight: 8,100 Kg Note: 1. Backwash sequence will be factory adjusted as follow: Fast Flush #1: 30 second Backwash: 60 second Second Fast flush: 30 second 2. Backwash frequency: 60 minutes (Frequency will depend of feed water characteristic) Control & Automation requirement: Common to all UF Sets Automation & controls: Fully automatic including backwashing

sequence through common PLC based system installed for the entire desalination plant

Location centralized control room Mimic diagram: C/W - light symbolizing UF step positions Location Mounted on the front of the central control

panel


MEC / 10EP/ 01 / 01 / DS / 0113


PRESSURE EXCHANGER DATA SHEET

Project: 100 MLD SWRO Desalination Plant Data Sheet / Document no: MEC / 10EP/ 01 / 01 / DS / 0113 Presssure exchanger Tag No: PX-305 – A to O Quantity: 15 (12 W+ 3S)


MEC / 10EP/ 01 / 01 / DS / 0113


Data sheet for Pressure exchangers

Typical Operating data:

A B C D E F G H Flow

m 3 / hr 770 413 357 413 770 350

420 420

psi 29 29 1,015 971 1,015 0 986 18 Pressure bar 2.0 2.0 70.0 67.0 70.0 0.0 68.0 1.2

TDS (Total dissolved solids)

Mg/l 40,500 40,500 40,500 42,525 41,586 250

76,033 72,042


MEC / 10EP/ 01 / 01 / DS / 0113


PRESSURE EXCHANGERS

PX Units/Array qty 10 Unit flow M3/hr 42.0 Unit flow US gpm 185 Lead flow % 0% Lubrication flow/PX m3/hr 0.71 Lubrication flow/PX US gpm 3.1 Lubrication flow % 1.7% Lubrication flow/Array m3/hr 7 Differential HP side bar 1.0 Differential LP side bar 0.8 Salinity increase @ membranes 2.7% Salinity increase @ PX 5.0% Volumetric Mixing @ PX % 6.0% PX overall efficiency % 95.9% PX net transfer efficiency % 95.7% PX power savings kW 795 Booster pump Pump efficiency % 80% Power kW 44 Cartridge filter feed pump Cartridge filter DP bar 0.5 Pump efficiency % 85 Power kW 64 High Pressure pump Pump efficiency % 80.6% Power kW 834.5 Total power kW 1253.5 Specific energy kWh /m 3 2.692

DESIGN DATA

Feed TDS 33000 TO 41900 ppm Max. temp. 49 Degree C Max. High press. Inlet flow 50 m3/hr Max. low press. Outlet flow 40.8 m3/hr Max. outlet high press. 82.7 bar Max. outlet low press. 20.7 bar Max. inlet high press. 82.7 bar Min. inlet low press. NA Min. discharge press. 0.6 bar Max. speed 1400 rpm Operating speed 1200 rpm Max. noise 85 dBA


MEC / 10EP/ 01 / 01 / DS / 0113


MATERIAL OF CONSTRUCTION

Sl. No. PARTS DESCRIPTION MOC

1. Internal components Ceramic wear resistant 2. Housing Epoxy glass reinforced

pressure vessel. 3. Rotor Ceramic Alumina 4. Low pressure, high pressure inlet & outlet port

fitting Corrosion resistant Al-6XN (equivalent to 254 SMO alloy)

Internal low pressure inter-connector/nipple Titanium/Al-6XN 5. Connections Victualic 6. Fastners/ hardware( non wetted) SS316 7. Tension rod assembly C-276


MEC / 10EP / 01 / 01 / DS / 0114


RO Modules Data Sheet

Project : 100 MLD SWRO Desalination Plant

Data Sheet / Document no : MEC / 10EP / 01 / 01 / DS / 0114 1 Description Reverse Osmosis

Membrane Modules 2 Seawater intake type Open intake 3 Permeate capacity of the plant 100 MLD 4 Anticipated recovery 45.4 % 5 Feed to RO membrane UF treated sea water 6 Sea water TDS 41,900 ppm 7 NaCl Concentration in seawater 35964.1 ppm 8 Calcium 450 ppm 9 Sulphate 3062.51 ppm 10 Boron 1.85 11 Max. /Min temperature degree C 32/24 RO TRAIN/MEMBRANE PARTICULARS

12 Number of RO trains proposed 12 13 No of membrane elements per pressure

vessel 7

14 Membrane array 9 X 8 X 7 i.e. 504 membranes per RO trains

15 Total no. of sea water membranes 6048 16 Size of each membrane proposed 201.9 mm dia and 1016 mm

length 17 Max. Operating Pressure 1200 psi 18 Membrane type Thin film,Spiral wound,

Composite, Polyamide polymer type

19 Active area per membrane 400 -450 sq. feet 20 Total number of installed membrane 6048 21 Minimum Recovery per element 8% 22 Average system design flux rate (Max.) 19 Litres/m2/hr

23 Average Permeate flow per element 16/22 m 3 /day 24 Minimum salt rejection 99.6 to 99.75%


MEC / 10EP / 01 / 01 / DS / 0114


25 Boron rejection required 80-90% 26 Salt passage per year 7 to 10 % 27 Average flux rate decline per year 7% 28 Membrane model Sea water membrane 29 Min membrane element age 5Years 30 RO skid/ piping GA drg no. MEC/10EP/01/01/WOR/0159


MEC / 10EP / 01 / 01 / DS / 0115


Intake expansion Joint Data Sheet


Data Sheet / Document no : MEC / 10EP / 01 / 01 / DS / 0115 1 Description 1600 mm ID Single Flanged Expansion Joint at Intake 2 Size 1600 mm 3 Media Sea water 4 Design Pressure 5.28 bar (g) 5 Design Temperature 35 0 C 6 Code EJMA 7 Axial compression 76.2 mm ( 3.0 Inch) 8 Lateral Movement 127 mm ( 5.0 Inch) 9 Angular Movement 10 0 10 Cycle life 3000 min 11 Pressure thrust 27080 kg (59780 lb) 12 Ends Flanged 13 Flanges size, material 3.7”(94mm) thick x 63.125 “ID x 77 “ OD, MONEL 400 14 Bellows material, size B168-600 (Alloy 600), 0.036 “ thick x 63 “ ID x 67.0 “ OD x

1 PLY x 6 CONVS x 10.375 “ Length 15 Liner material, size MONEL 400, 0.105 “ thick x 62.25” OD x 17” L 16 Tests Standard Soap bubble 17 Axial S/R 2370 LBS/IN 18 Lateral S/R 89000 LBS/IN 19 Angular S/R 12700 IN LBS/DEG

Note: Supply with companion flange, gaskets, fasteners to match the main pipe size as per piping drg. MEC/10EP/01/01/WOR/0168


MEC / 10EP / 01 / 01 / DS / 0116


Outfall Expansion Joint Data Sheet


Data Sheet / Document no : MEC / 10EP / 01 / 01 / DS / 0116 1 Description 1200 mm ID Single Flanged Expansion Joint at

Outfall 2 Size 1200 mm 3 Media Sea water 4 Design Pressure 5.28 bar (g) 5 Design Temperature 35 0 C 6 Code EJMA 7 Axial compression 76.2 mm ( 3.0 Inch) 8 Lateral Movement 127 mm ( 5.0 Inch) 9 Angular Movement 10 0 10 Cycle life 3000 min 11 Pressure thrust 14632 kg 12 Ends Flanged 13 Flanges size , material 74mm(2.913”) thick x 47.375 “ ID x 60 “ OD,

MONEL 400 14 Bellows material, size B168-600 (Alloy 600), 0.036 “ thick x 47.25 “ ID x

50.75 “ OD x 1 PLY x 6 CONVS x 7.875 “ Length 15 Liner material, size MONEL 400, 0.105 “ thick x 46.5” OD x 13.5 L 16 Tests Standard Soap bubble 17 Axial S/R 1830 LBS/IN 18 Lateral S/R 104000 LBS/IN 19 Angular S/R 6540 IN LBS/DEG

Note: Supply with companion flange, gaskets, fasteners to match the main pipe size as per piping drg. MEC/10EP/01/01/WOR/0167


Page 1 of 12


TECHNOLOGICAL EQUIPMENT LIST


Page 2 of 12


SL. NO. EQUIPMENT EQUIPMENT NO.

QUANTITY

BRIEF EQUIMENT SPECIFICATION

Product, reject, process tanks & vessels

11.. Product Storage tanks

TT --330011AA//BB 22 Carbon steel (IS 2062 Gr.B or A36) cylindrical truss supported vertical cone roof tank, internally coated with epoxy paint, each tank of total capacity 9225 m3 and net capacity 9,000 m3. Dimension: 24,000 mm ID x 21,160mm Height

22.. Ultra filtration Product & backwash tank

TT -- 220033 AA//BB 22 Carbon steel (IS 2062 Gr.B or A36) cylindrical truss supported vertical cone roof tank, internally coated with epoxy paint, total capacity 14,250 m3 and net capacity 13,800 m3.Dimension: 30,000 mm ID x 21,000 mm Height

33.. UF+ RO Reject tank

TT -- 550011 11 Carbon steel (IS 2062 Gr.B or A36) cylindrical truss supported vertical cone roof tank, internally coated with epoxy paint, total capacity 3,210 m3 and net capacity 3,000 m3.Dimension: 22,000mm ID x 9,000mm Height

44.. PPoottaabbllee wwaatteerr ssttoorraaggee ttaannkk

TT -- 441166 11 RCC under ground epoxy coated storage tank with covered roof slab and degasser tower mounted on it. Dimension: 36,000 mm width x 25,000 mm breadth x 6,000 mm depth.

55.. SSeeddiimmeennttaattiioonn TTaannkk

SSTT--441100 11 RCC, above ground sedimentation tank with two chambers. Dimensions of the tank 19,400mm length x 8,000 width x 3,000 ht.

66.. Suck back Tanks

VV--301/A/B/C/D/E/F/G/H/I/J/

K/L

1122 Cylindrical horizontal dished end FRP tank mounted above each RO skid. The total capacity 13.24 m3 and net capacity of tank 13 m3. Dimension: 1,500 mm ID x 7,500 mm length. Capacity at 50% full shall be 6.62m 3.


Page 3 of 12


SL. NO. EQUIPMENT EQUIPMENT

NO. QUANT

ITY BRIEF EQUIMENT SPECIFICATION

77.. RROO MMeemmbbrraannee CClleeaanniinngg ttaannkk SSkkiidd

SSKK -- 660011 11 Trolley type Skid comprising of one chemical tank with agitator & one pump and one 5-micron cartridge filter. Tank capacity 2m3, ID 1,000mm x 2,600 height, MOC FRP. Dimensions of skid 3700mm X 3700mm

88.. RROO CClleeaanniinngg ttaannkk TT --660022 1 FRP cylindrical vertical dished end tank, total capacity 3.53 m3 and net capacity 2.72 m3.Dimension: 1500 mm ID X 2000 mm height

99.. RROO FFlluusshhiinngg TTaannkk TT-- 660011 11 FRP cylindrical vertical cone roof tank, total capacity 21.2 m3 and net capacity 17.48 m3.Dimension: 3,000 mm ID X 3,000 mm height

1100.. DDiisscc FFiilltteerr bbaacckkwwaasshh ttaannkk

TT--220022 11 FRP cylindrical vertical cone roof tank having total capacity 11.3 m3 and net capacity 9.66 m3.Dimension: 2500 mm ID X 2,300 mm height

1111.. CClleeaanniinngg iinn ppllaaccee ttaannkk

TT--220044 11 FRP cylindrical vertical cone roof tank having total capacity 11.3 m3 and net capacity 9.66 m3. Dimension: 2500 mm ID X 2,300 mm height.

1122.. CCOO22 SSttoorraaggee ttaannkk TT--441177AA//BB 22 27 Ton, CS (SA612N) Storage tank at 24 Bar pressure with perlite insulation at full vacuum. ID: 2,900mm,Height. 7,290 mm.

Intake system tanks

1133.. IInnttaakkee cchhaammbbeerr TT --110011 11 RCC, epoxy coated, Underground, partially covered intake chamber having trapezoidal cross section, depth of 14,700mm, holding capacity 1,104 m3 having retention time as 6 minutes.


Page 4 of 12


SL. NO.

EQUIPMENT

EQUIPMENT NO.

QUANTITY BRIEF EQUIMENT SPECIFICATION

1144.. SSeettttlliinngg BBaassiinn // SSeeddiimmeennttaattiioonn ttaannkk

SSBB -- 110022 11 RCC epoxy coated, Underground sedimentation tank having various layers of sand media with sloped bottom. The upper bed consists of 12 mm –50 mm washed gravel of 300 mm bed height, below of which 1mm-2mm quartz sand with uniformity coefficient 1.4-1.7 and sphericity 0.8 of 2,500 bed height, the bottom most layer is 6mm-12mm washed gravel.. Length 43,000mm x width 12,000m x depth 4,900 -6,900 mm. Retention time 15 minutes

1155.. DDeeggrriitttteedd ssttoorraaggee ttaannkk

TT --110033 11 RCC epoxy coated, Underground, top covered conditioned water storage tank. Tank dimensions - Length 43000 mm x 20,000mm width x 7,100 mm depth.

Bulk storage & dosing tanks

1166.. 9988%% SSuullpphhuurriicc AAcciidd bbuullkk SSttoorraaggee ttaannkk

TT --770011AA//BB 22 Cylindrical horizontal dished end carbon steel (IS 2062) tank with total capacity 61.8 m3 and net capacity 61.5 m3. Dimension: 3,200 mm ID x 7,000 mm height

1177.. 3355%% SSooddiiuumm bbiissuullpphhiittee bbuullkk ssttoorraaggee ttaannkk

TT --770033 11 Cylindrical vertical cone roof FRP tank with total capacity of 111.3 m3 and net capacity 107.3 m3. Dimension: 4,500 mm ID x 7,000 mm Height

1188.. 1122%% SSooddiiuumm hhyyppoocchhlloorriittee bbuullkk ssttoorraaggee ttaannkk

TT --770044 11 Cylindrical vertical cone roof FRP tank with total capacity of 111.3 m3 and net capacity 107.3 m3. Dimension: 4,500 mm ID x 7,000 mm Height


Page 5 of 12


SL. NO.

EQUIPMENT

EQUIPMENT NO. QUANTITY BRIEF EQUIMENT SPECIFICATION

1199.. AAnnttiissccaallaanntt bbuullkk ssttoorraaggee ttaannkk

TT --770055 11 Cylindrical vertical cone roof SS 316 tank with total capacity of 100.14 m3 and Net capacity of 94 m3. Dimension: 4,500 mm ID x 6,300 mm Height

2200.. 4455%% ccaauussttiicc ssooddaa bbuullkk ssttoorraaggee ttaannkk

TT --770066 11 Cylindrical vertical cone roof CS (IS 2062 Gr. B or A36) tank with total capacity of 28 m3 and net capacity of tank 26 m3. Dimension: 3,500 mm ID x 3,000 mm Height

2211.. 1122%% SSooddiiuumm HHyyppoocchhlloorriittee ddoossiinngg TTaannkk

TT -- 771111 11 Cylindrical vertical dished end FRP tank with total capacity of 21.2 m3 and net capacity of 20.1 m3, dimensions: 3,000 mm ID x 3,000 mm Height

2222.. 9988%% SSuullpphhuurriicc AAcciidd ddoossiinngg ttaannkk

TT -- 771133 11 Cylindrical horizontal CS (IS 2062) tank with total capacity of 21.5 m3 and net capacity of 21 m3, Dimensions: 2,250mm ID x 5,000 mm length.

2233.. 1100 %% SSooddiiuumm BBiissuullpphhiittee DDoossiinngg TTaannkk

TT--771144 AA//BB 22 Cylindrical vertical dished end FRP tank with agitator with total capacity of 21.2 m3 and 20 m3. Dimensions: 3,000 mm ID x 3,000 mm Height

2244.. AAnnttii ssccaallaanntt ddoossiinngg ttaannkk

TT –– 771155 AA//BB

22 AISI 316, Cylindrical vertical tank with torispherical head having agitator,with total capacity of 10.8 m3 and net capacity of 10 m3, Dimensions: 2,100 mm ID x 2,900 mm Height.

2255.. 4455%% CCaauussttiicc ssooddaa ddoossiinngg ttaannkk

TT --771166 11 CS (IS 2062) cylindrical vertical tank with torispherical head, with total capacity of 2.03 m3 and 1.8 m3 Dimensions: 1,200 mm ID x 1,800 mm Height

2266.. FFiirree WWaatteerr SSttoorraaggee TTaannkk

TT --880011 11 Cylindrical open top vertical tank with total capacity of 324 m3 and net capacity of 313 m3. Dimension: 7,500 mm ID x 7,500 mm Height.


Page 6 of 12



NO. QUANTITY BRIEF EQUIMENT SPECIFICATION

Unloading transfer pumps & dosing pumps

2277.. 9988 %% SSuullpphhuurriicc aacciidd UUnnllooaaddiinngg ccuumm ttrraannssffeerr ppuummpp

PP -- 770011AA//BB 22** Horizontal centrifugal pump with a design capacity of 20m3/hr. Discharge pressure 1.5 bar, BkW 1.5 kW. MOC of casing &impeller Alloy 20

2288.. 3355%% SSooddiiuumm bbiissuullpphhiittee uunnllooaaddiinngg ccuumm ttrraannssffeerr ppuummpp

PP --770033 AA//BB 22** Horizontal centrifugal pump with a design capacity of 12m3/hr, discharge pressure 1.0 bar. BkW 1.1 kW. MOC of casing &impeller SS316L

2299.. 1122%% SSooddiiuumm hhyyppoocchhlloorriittee uunnllooaaddiinngg ccuumm ttrraannssffeerr ppuummpp

PP -- 770044 AA//BB 22** Horizontal centrifugal pump with a design capacity of 20m3/hr, discharge pressure 1.0 bar. BkW 1.632 kW. MOC of casing &impeller SS316L

3300.. AAnnttiissccaallaanntt uunnllooaaddiinngg ccuumm ttrraannssffeerr ppuummpp

PP-- 770055 AA//BB 22** Horizontal centrifugal pump with a design capacity of 12m3/hr, discharge pressure 1.0 bar. BkW 1.2 kW. MOC of casing &impeller SS316L

3311.. 4455%% CCaauussttiicc ssooddaa uunnllooaaddiinngg ccuumm ttrraannssffeerr ppuummpp

PP -- 770066AA//BB 22** Horizontal centrifugal pump with a design capacity of 12m3/hr, discharge pressure 1.0 bar. BkW 1.2 kW. MOC of casing &impeller SS316L

3322.. SSooddiiuumm hhyyppoo cchhlloorriittee ddoossiinngg ppuummppss ffoorr iinnttaakkee ssyysstteemm

PP -- 771111AA//BB 11WW++11SS

Hydraulic diaphragm dosing pumps with a design capacity of 400 liters/hr, discharge Pressure 4 bar. MOC of diaphragm PTFE, plunger MOC EN8. BkW- 0.3 kW.

3333.. SSooddiiuumm hhyyppoo cchhlloorriittee ddoossiinngg ppuummppss ffoorr UUFF bbaacckkwwaasshh

PP -- 771122AA//BB 11WW++11SS

Hydraulic diaphragm dosing pumps with a design capacity of 150 liters/hr, discharge Pressure 2.2 bar. MOC of diaphragm PTFE, plunger MOC EN8. BkW- 0.37 kW.

3344.. SSooddiiuumm hhyyppoo cchhlloorriittee ddoossiinngg ppuummppss ffoorr ppoottaabbllee wwaatteerr

PP -- 771188AA//BB 11WW++11SS



Page 7 of 12


SL. NO. EQUIPMENT EQUIPMEN

T NO. QUANTITY BRIEF EQUIMENT SPECIFICATION

3355.. SSuullpphhuurriicc aacciidd ddoossiinngg ppuummppss

PP -- 771144 AA//BB 11WW++11SS Hydraulic diaphragm dosing pumps with a design capacity of 850 liters/hr, discharge Pressure 2.5 bar. MOC of diaphragm PTFE, plunger MOC EN8. BkW- 1.064 kW.

3366.. SSooddiiuumm BBiissuullpphhiittee DDoossiinngg ppuummppss

PP -- 771155 AA//BB 11WW++11SS


3377.. AAnnttiissccaallaanntt ddoossiinngg ppuummppss

PP -- 771166 AA//BB 11WW++11SS Hydraulic diaphragm dosing pumps with a design capacity of 450 liters/hr, discharge Pressure 2.7 bar. MOC of diaphragm PTFE, plunger MOC EN8. BkW- 0.37 kW

3388.. CCaauussttiicc ssooddaa ddoossiinngg ppuummppss

PP -- 771177 AA//BB 11WW++11SS

Hydraulic diaphragm dosing pumps with a design capacity of 20 liters/hr, discharge Pressure 2.7 bar. MOC of diaphragm PTFE, plunger MOC CI FG 220. BkW- 0.37 kW.

Agitators 3399.. Agitator for

sodium bisulphite dosing tank

AAGG -- 771144 AA//BB 2W Gear driven Agitators. BkW- 3.7 kW.

4400.. Agitator for antiscalant dosing tanks

AAGG -- 771155 AA//BB 22W Gear driven Agitators. BkW- 3.7 kW .

4411.. Agitator for RO cleaning tank

AAGG--660022 11W Gear driven Agitators. BkW- 5.5 kW.

Vertical centrifugal Process pumps

4422.. Sea water Intake vertical pumps

P- 101A/B/C/D

2W + 2S

Vertical centrifugal pumps, capacity 5530 m3/hr, discharge Pressure 1.5 bar. BkW – 360,MOC of casing & impeller super duplex stainless steel (SAF 2507).


Page 8 of 12




4433.. Raw water vertical transfer pumps

P -102 A/B/C/D

2W +2S

Vertical centrifugal pumps, capacity 5475m3/hr, discharge Pressure 4 bar. BkW-764. MOC of casing & impeller super duplex stainless steel (SAF 2507).

4444 Dirty water transfer pumps

P - 103 A/B 1W * + 1S

Vertical centrifugal pumps, capacity 300 m3/hr, discharge Pressure 5 bar. BkW-61.2. MOC of casing & Impellor super duplex SS.

Horizontal centrifugal process pumps

4455 CCaarrttrriiddggee FFiilltteerr ffeeeedd ppuummppss PP –– 220011 AA//BB//CC//DD

22WW ++22SS MOC of casing & Impellor super duplex stainless steel (SAF 2507). Each pump capacity 4628 m3/hr, discharge Pressure 2.5 bar, BkW-350

4466 UUFF bbaacckk wwaasshh ppuummppss PP --220022 AA//BB//CC//DD 22WW ++ 22SS MOC of casing & impellor super duplex SS (SAF 2507), each pump capacity 300 m3/hr, discharge Pressure 2bar, BkW-24.5. VFD controlled.

4477 BBaacckkwwaasshh ppuummpp ffoorr ddiisscc ffiilltteerrss

PP -- 220044 AA//BB 11WW ++ 11SS MOC of casing & impellor super duplex SS (SAF 2507). Each pump capacity 200 m3/hr, discharge pressure 4.5bar, BkW-37.

4488 HHiigghh pprreessssuurree ppuummppss PP -- 330066 AA//BB//CC//DD //EE//FF//GG //HH//II//JJ//KK// LL//MM//NN//OO

1122 WW ++ 33SS Multi stage centrifugal high-pressure pump with capacity 360m3/hr, discharge Pr 70 bar. BkW-835. MOC of casing, impeller &shaft super duplex SS (SAF 2507). VFD controlled.

4499 BBoooosstteerr ppuummppss PP -- 330077 AA//BB//CC//DD//EE//FF //GG//HH//II//JJ//KK//LL

//MM//NN//OO

1122 WW ++ 33SS Each pump capacity 413m3/hr, discharge Pr 70 bar. BkW- 44, MOC of casing, impeller &shaft super duplex SS (SAF 2507). VFD controlled.


Page 9 of 12




5500 PPeerrmmeeaattee ttrraannssffeerr ppuummppss

PP--330055 AA--00 1122WW++33SS MOC of casing & Impellor SS 316L.Each pump capacity 350 m3/hr, discharge Pressure 2.5 bar, BkW-36 kW.

5511 RRee--ccaarrbboonnaattiioonn ttoowweerr ffeeeedd ppuummppss

PP -- 330033 AA//BB//CC//DD

22 WW ++ 22SS MOC of casing & Impellor SS 316L, each pump capacity 2100 m3/hr, discharge Pressure 2 bar. BkW-143.

5522 SSeerrvviiccee WWaatteerr ppuummppss PP –– 330044 AA//BB

11WW**++ 11SS Each pump capacity 40 M3/hr, discharge Pressure 4 bar. BkW –9.7. MOC of casing &impeller SS316L

5533 RReejjeecctt wwaatteerr ttrraannssffeerr ppuummppss

PP --550011AA//BB//CC//DD

22 WW ++ 22SS MOC of casing & impellor super duplex SS (SAF 2507), each pump capacity 3430 m3/hr, discharge pressure 5 bar. BkW-530.

54

AAbbssoorrbbeerr ffeeeedd bboooosstteerr ppuummppss

PP -- 440011 AA//BB//CC

22WW ++ 11SS MOC of casing & Impellor SS316L. Each pump capacity 680 m3/hr, discharge Pressure 4 bar, BkW-50 kW.

5555 LLiimmee ssttoonnee rreecchhaarrggiinngg bboooosstteerr ppuummppss

PP -- 440022 AA//BB 11WW ++ 11SS MOC of casing & impellor SS 316L. Each pump capacity 135 m3/hr, discharge Pressure 8 bar. BkW-45 kW.

5566 SSlluurrrryy DDiissppoossaall ppuummpp PP--441111 AA//BB 11WW ++ 11SS Designed flow rate 10 m3/hr, discharge Pressure 2.2 bar. BkW-1.7 kW. MOC casing & impeller SS 316L.

5577 RO Membrane chemical cleaning pump

PP --660011 AA//BB 22WW** Capacity 300 m3/hr, discharge Pr 5 bar. MOC of impeller & casing super duplex SS (SAF 2507). BkW –51.5

58 Skid mounted RO chemical pump

PP--660022 11WW** Skid mounted pump along with 5-micron cartridge filter, capacity 2 m3/hr, discharge pressure 0.5 bar. BkW - 0.37. MOC of casing &impeller SS316L.


Page 10 of 12




Air blowers & Compressors

5599.. AAttmmoosspphheerriicc DDeeggaasssseerr FFaann

DDGGFF -- 441155 AA//BB

11 WW ++11SS Centrifugal, flow rate 2,094 m3/hr. Discharge pressure 0.21 mwc. BkW-1.5 kW. MOC is SS 304.

6600..

AAiirr CCoommpprreessssoorr ((rroooott bblloowweerr)) ffoorr lliimmeessttoonnee ffiilltteerrss

AACC--440011 AA//BB 11 WW ++11SS Root blower, flow 911.9 m3/hr. Discharge pressure 0.55 bar. BkW-13 kW. MOC is CI

Filters 6611 UUllttrraa ffiillttrraattiioonn

sskkiidd wwiitthh UUFF mmeemmbbrraanneess

UUFF --220011 --11 ttoo 3300

3300 sseettss Hollow fiber membranes -3600 nos, dia 180 to 220 mm & length 1,680 to 1,920 mm. Hydrophilic Membrane material – PVC/PES, housing material - PVC, molecular weight cut off – 100,000 to 150,000 Daltons, having design membrane flux of 50-65 l/m2h, active area 450 sq ft Overall recovery - 90%. No. of membrane elements/set - 120, no. of sets –30

6622

DDiisscc FFiilltteerrss DDFF --220011-- 11 ttoo 3300

3300 sseettss Automatic disc filters, 4 modules per set, MOC PP, automatic back wash, micron rating 100 microns. Maximum flow rate for one set of filter 365 m3/hr

6633 RReevveerrssee OOssmmoossiiss ttrraaiinnss wwiitthh RROO mmeemmbbrraanneess

RROO --330011-- AA ttoo LL

1122 ttrraaiinnss Membrane diameter 201.9 mm &1016 mm length. Membrane per train 504 no. Recovery ratio 45.4 %. The membrane will be of spiral wound configuration, composite polyamide polymer type, having 400 ft2 of nominal area. No. of elements per pressure vessel 7, total no. of installed membranes 6048, min. recovery per element 8% & average permeate flow per element 16-22 m3/day. Minimum salt rejection 99.75%

6644 CCaarrttrriiddggee FFiilltteerr CCFF -- 330011 -- AA ttoo OO

1122WW++ 33SS Housing MOC SS2205. Filter elements polypropylene. No of elements per cartridge filter-180, total flow rate to be handled 770 m3 /hr.


Page 11 of 12


SL. NO. EQUIPMENT EQUIPMEN

T NO. QUANT

ITY BRIEF EQUIMENT SPECIFICATION

6655 CCaarrttrriiddggee FFiilltteerr ffoorr RROO cchheemmiiccaall

CCFF--660011 11WW Housing MOC SS 2205. Filter elements polypropylene. Total flow rate to be handled 770 m3 /hr.

Miscellaneous equipments 6666 Pressure

Exchangers PPXX-- 330055 -- AA

ttoo OO 1122WW++33

SS GRP housing and ceramic wear resistant internal components, ceramic alumina rotor pressure exchangers, overall efficiency 95.9 %, feed inlet/outlet rate-413 m3/hr, concentrate inlet/outlet rate 420 m3/hr, feed inlet/outlet pressure in bar 2/67, concentrate inlet/outlet pressure 68/1.2 bar.

6677 PPrreessssuurree VVeesssseellss PPVV 886644 FRP pressure tubes, 9" OD, length 303.15”, MOC-FRP. Test pressure - 1320 psi, design code ASME X

6688 Static Mixture MMXX--220011 11W Designed flow rate -9255 m3/hr. MOC is HDPE.

6699 Static Mixture MMXX--220022 11W Designed flow rate -600 m3/hr. MOC is HDPE.

Intake & Outfall pipelines & devices 7700 Intake

screens/filtering device

SSCC -- 110011 11 sseett Intake suction head, dia 5.5 m, height 1.3 m, 30 mm dia round bars spaced at 100 mm, MOC – SAF 2507/ UNS 32750 including geo-textile reinforcement nylon net.

7711 Diffuser system DDSS 1 set Diffuser length 43 m, 18 ports (14 W+ 4 Dummy) having dia 300 mm x 12.7 mm thickness, diffuser interport distance 5m. MOC- SAF 2507 /UNS 32750.

7722 Sea water intake pipeline

IIPP DN 1600, HDPE pipe line, dimensional standard- IS 4984, PN 10, PE-100 & material IS 7328.Length 1,042 m

7733 Sodium hypochlorite pipe line for intake system

CCPP DN 90, HDPE pipe line, dimensional standard- IS 4984, PN 10, PE-100 & material IS 7328.Length 1,042 m

7744 Compressed air pipe line for intake system

AAPP DN 90, HDPE pipe line, dimensional standard- IS 4984, PN 10, PE-100 & material IS 7328.Length 1,042 m


Page 12 of 12




7755 Reject pipeline RRPP DN 1200, HDPE pipe line, dimensional standard- IS 4984, PN 10, PE-100 & material IS 7328.Length 620 m

7766 Welded closure ,

injector

AAPP--CCPP 22 sseettss Welded closure pipe sleeves, chlorination & air injector (MOC : SS 2507) at intake head

Re-carbonation system & Degassing system

7777 Carbon - di -oxide absorber

AB-403 1W MOC of vessel ASTM A 516 Gr.60 with 3 mm rubber lining and packed with polypropylene. ID of vessel 1,270mm x 8,000 height.

7788 Lime stone filters LF- 414A-E 4W+1S Vertical cylindrical vessel with MOC ASTM A 516 Gr.60 with 3 mm rubber lining. ID of vessel 4,400mm x 4,893 height..

7799 Limestone ejector E-406 A/B 1W+1S Design flow rate of sucked limestone 4,133 kg/hr. Discharge pressure 2.2 bar. MOC is SS 316 L.

8800 Degasser tower DGT-402 1W MOC of vessel ASTM A 516 Gr.60 with 3 mm rubber lining and packed with polypropylene. ID of vessel 3,700mm x 7,500 height..

8811 Static Mixture MMXX--441188 1W Designed flow rate is 4200 m3/hr. MOC is SS 316L

Notes: 1) For Laboratory, Mechanical repair shop, Material handling, Electrical power

distribution& shop electrics, Illumination, Instrumentation, Fire fighting, Sewerage treatment plant, Civil, Structural, Green belt and Air conditioning & ventilation refer respective technical specifications of volume II.

2) *Denotes intermittent operation. 3) W indicates working &S indicates standby. 4) ID indicates inner diameter.



SITE DETAILS


(i)


CONTENTS

Clause No. Description Page

nos. 03.01.1 General 1-1

03.01.01 Basic Geotechnical Information 1-10

03.02 Marine Characteristics 10-32

03.03 Meteorology 32-47

03.04 Water Environment 47-49

03.05 Surface Water Quality 49-57

03.06 Demarcation of HTL and LTL 57-63

03.07 Seismic Survey 63-70


Page 1 of 70


03.01.1 General

MECON has entered into an agreement with ADECO Technologies for basic engineering. Finalization of basic engineering as well as detailed engineering has been taken up. Action for site surveys has also been initiated and orders for the surveys were placed on the following agencies. The interpretations obtained through the site studies are considered as part of input for design basis of SWRO and are explained in this chapter.

Sl.No Description of survey Agency

1. Hydrographic survey M/s Indomer Coastal Hydraulics ( P) Ltd, Chennai.

2. Soil Investigation M/S F.S Engineers, Chennai

3. Topographical survey M/s Geoglobal Consultants (P) Ltd, Chennai

4. On shore geophysical studies and hydrogeological studies

M/s Anna Unversity, Guindy, Chennai

5. Environmental base line data survey

M/s Green Circle Inc, Bangalore

6. Marine bio logical studies M/s Manonmanium Sunderanar Univeristy, Kanyakumari district

03.01.01 Basic Geotechnical information

(i) Geology of the study area Detailed studies conducted by GSI in the 1994 have helped establish the geological set up of Kancheepuram district of Tamilnadu. It consists of charnockite suite of rocks and pyroxcene granulites of Archaean age as basement. Recent coastal marine/fluvial alluvium with an unconformity is overlain on the basement. There are dolerite dyke intrusions of the post charnockitisation period in the charnockite rock mass associated with shear and fractures. Based on a field study of the rock types and the structural aspects, a district geological map has been prepared by GSI covering about 2500km2 area. This is shown in Fig. 03 - 01.


Page 2 of 70


Fig. 03.01 Geological map of Kanchipuram district


Page 3 of 70


The bedrock occurs at about 10-15 m depth in this region. Along the coast, where the proposed SWRO plant is to be located, the formation is the coastal alluvium with sand, silt and sandy clay. Generally, the bedrock occurs as wave cut platform or ridge in parallel to the coast. The rock mass in this area strikes at about N 20o – 25oE and S 20o – 25oW. The rock masses are covered by the alluvium except for a few rock outcrops in the surrounding region, viz., Manamai, Mamallapuram, Karumarapakkam and Thirukkalukundram areas. In the area between the East Coast Road and the Bay of Bengal, the soil cover is sandy, and silty along the beach and along the Buckingham Canal and the backwater. The soil is weathered product of charnockite rock in the areas to the west of East Coast Road.

ii) Site survey In order locate the various facilities envisaged for SWRO plant the latitude and longitude or grid lines are necessary to mark the units. Hence a detailed topographic survey work pertaining to site was carried out by M/S Geo Global Consultants under the guidance of MECON. Based on the site readings a topographical drawing was prepared and the same is shown in Fig. 03 –02. Based on the topographic drawing the general layout of the plant is finalized The ground contours vary between 3.5. m and 11.25 m between the Bay of Bengal and the ECR with peak height of 11.25 m at and along the ECR ridge. The contours at the proposed area also fall within this range. Along the beach, the ground contour is 4.5 m.

The following points have emerged from the topographic survey.

• The site is located on the eastern side of East Coast Road at 12 ° 42 ″ 13′ North, 80°13″ 24′ East at 37 km south of Chennai and the road is at +11.30m level.

• Generally the contours are varying form 3.5m to 5.0m near the sea

on the eastern side of the plot and the plant proper contours are varying from 5.0m to 6.5m.

• Two numbers of existing ponds are located on the side of the plot.

One pond is partly coming inside and the other outside the plant boundary.

• A housing colony of Sulerikadu kuppam is located on the North

Eastern side of the plot and is connected by 4m wide kutcha road connecting the East Coast Road. One drain is located by the side of the kutcha road and pipe culvert is provided for cross drainage of the kutcha road.

• Over head electric lines are running across the East Coast Road

connecting the pump room located near the burial ground and also to the transformer located near the kutcha road.


Page 4 of 70


• A burial ground is located on the South Western side of the plant adjacent to ECR which is excluded from the proposed site .

• One above groundwater storage, pumphouse and overhead tank exist

at the plot area.

After evaluating the survey details the plant site was examined in detail and following assumptions were made for finalizing the site leveling and planning the various plant units and roads. During the site visit the Tsunami level marked on the building located on the Housing Colony was taken into consideration for fixing the finished ground level of the plant area. The ground level near existing house building is 4.0m and the Tsunami level is 1.6m above the ground level i.e. 5.6m. The Finished ground level is fixed at 0.9m above the Tsunami level i.e. 6.5m absolute. A Strip of 20m-width land is left adjacent to East Coast Road for future expansion of East Coast Road. The existing Bench Mark near the East Coast Road with level 11.255m is taken for surveying and fixing FGL etc. The plant area of 33.38 acres should be filled upto 6.5m finished ground level. Since the level of the East Coast Road is at 11.30m level and the FGL of the plant is at 6.5m levels, the level difference is 4.8m. In view of this it is proposed to upgrade the existing kutcha road from 4m to 7m for taking the main plant entrance. The burial ground area is left undisturbed for use by local population. This area will be drained towards the sea through a kutcha drain along the existing compound wall of Dolphin Park. Area of 2.0 acres on the southern side of the plant boundary is earmarked for TNEB Sub-station. The total plant area including area for quarters and guest house is 36.9 acres. Generally the plant roads are single lane with 4.0m carriage way with 1.5m berm on either side of road with side drains. iii) Tectonics and seismicity Experts from the Geological Survey of India and various other organisations (for collection of seismic reflection survey data) have identified the faults and other lineaments covering Tamilnadu and Andhra Pradesh encompassing different offshore seismotectonic conditions.The sources of earthquake data relevant to the site are Gauribidanur Array (GBA), CWPRS and the Indian Meteorological Department (IMD) and data cited in open literature.

If macro view of the site is taken, the site lies in seismic zone III of the seismic zone mapping of India (IS –1893 – Part I – 2002). There is no Capable Fault


Page 5 of 70


within 15 km radius of the site, which forms one of the screening criteria for site selection.

Since the civil structures proposed for the site are coming under normal industries category, the civil foundations will be designed to meet the seismic zone III.

Seismic data pertaining to the proposed site is not available however, the Madras Atomic Power Station and the other -facility are located about 10 km south of the site. As mandated by AERB, microseismic activity of Kalpakkam site is being monitored by departmentally. Five micro-seismic monitoring stations have been made operational and the data pertaining to site are being recorded regularly. The installation, operation and maintenance of the stations as well as analysis of data from the stations are reportedly carried out by NGRI, Hyderabad. Data obtained to date do not indicate any micro seismic activity so far.

The inferences obtained from the above data can be presumed to applicable to the proposed SWRO site too due to its proximity.

iv) Subsoil information

Site-specific geotechnical investigations were carried out by M/S F.S engineers, Chennai under the guidance of MECON. The study was carried out during September - October -2007 to establish the sub-soil characteristics. A total of nine numbers of boreholes were drilled at the site to know the soil profile. A soil profile was arrived based on seismic refraction survey and the bore log details. Three distinct layers are observed in both seismic refraction survey and geotechnical investigation carried out at the proposed SWRO site. In general, the top layer consists of loose to dense sand with thickness varying from 0.4m to 13 m and standard penetration N value of this layer ranges from 8 to >50. The topsoil layer is followed by sand. A weathered rock layer having a thickness of 1.5 m to 9 m is encountered. The fresh hard rock is encountered at a depth of 13 m to 15 m below the ground level.

During the investigation, ground water table was encountered at a depth of 1.0 m to 2.0m bgl at various boreholes.

Compression wave velocity of bedrock is of the order 5,200 m/s to 6000 m/s. This order is that of good quality granite gneiss. The compression wave velocity obtained from seismic refraction survey and the RQD values obtained are matching. No undesirable subsurface features like shear zones and faults were delineated along these traverses. Typical soil profile with three distinct layer obtained from seismic refraction survey is shown in Fig. 03 - 03. The observed soil bearing capacity for a minimum width of foundation of 1m at he site at different depth are as follows:

Depth SBC ( Kg/cm2) 1.5 m 1.0


Page 6 of 70


2.0 1.5

3.0 Limited to down 2.0

The settlement would be within 25 mm. If the above-suggested SBCs are not adequate to transfer the load, regular pile foundation is recommended.

For the proposed structure, shallow foundation can be at any depth from 1.5m, resting the foundations on the sand and as alternative pile foundation is recommended with length of pile of 12 to 14 m.

V) Physiography and drainage The study area is situated on eastern coast of Tamilnadu and is characterised by the Buckingham canal in the west and bay of Bengal in the east.

The sudden disappearance of drainage pattern in the coastal track indicates that the area is located on highly permeable beach zone. The shallow backwater intrusion into the land receives the rainwater directly from the land, which also leads to disappearance of drainage markings. However the buffer zone is characterized by dendrite drainage pattern. The area is also distinguished by numerous monsoon dependant fresh water lakes/irrigation tanks. The predominant direction of drainage is towards east. There is no major perennial river or dam in the vicinity of the site and therefore there is no risk of flooding of the site from these sources.

vi) Coastal environment The landforms along the coast are beach, beach ridge, sand and sand dunes. The Buckingham backwater meets with the Bay during monsoon. After the monsoons, the formation of longitudinal bar cuts it off from the Bay. The bar indicates sediment deposition from the sea. There are tidal mud flats and marshy area in the backwater zone between Kilakalani and peria Nemmeli area.

Shoreline stability is important from a safety point of view. Littoral drift studies were conducted for the proposed site by M/s Indomer during the month of September 2007. The littoral drift is northward from April to October and southward from November to March. The annual sediments transport along this stretch of this coast is estimated as 0.98 X 10 6 m3 in northerly direction and 0.51 X 10 6 in southerly direction. The volume of the littoral drift in each month is presented in Table 03.01

Table 03.01. Monthly volume of littoral drift

Month Quantity (m3/month)

January 155790 February 84199


Page 7 of 70


March 7376 April -91894 May -198016 June -178516 July -125861 August -149160 September -157813 October -76053 November 68486 December 196906

(-) Transport in northerly direction (+) Transport in southerly direction

Similar type of studies is not generally conducted for all projects since these are special type of studies and project specific in nature. Hence site-specific data are not available in the public domain for comparison. However, a detailed studies were carried out for MAPS and observed data are as follows.

Both short and long-term changes have been evaluated in 2000 by MAPS with respect to existing MAPS site. Short-term changes were monitored by beach survey and GPS data. Long-term changes were obtained from a study of satellite data coupled with topo sheets. The main observations are:

The coastal stretch has either been undergoing accretion or erosion remaining stable during 1941–1999.

Grain size analysis of beach sediment suggests a stable to depositional environment.

Generally the coast is undergoing accretion excepting in some stretches where sporadic erosion episodes have been reported like in Oyyalikuppam and CISF barracks area in the DAE Township and near Mamallapuram shore temple.

The above observations can be presumed to be also applicable to the proposed SWRO site due to its proximity. The coast is stable and any type of erosion is not observed at site. This also confirmed during the site visit of NIO officials for marking High Tide Line (HTL) and Low Tide Line (LTL).

vii) Hydrogeology A separate study for the SWRO site was done by Anna University. From the results it is observed that the aquifer is an unconfined aquifer in the coastal alluvium and the fractured crystalline rock for a few metres depth. It is a leaky aquifer and occurs all along the ridge parallel to the coast. The ground water table fluctuates with seasons and the rainfall. The ground water level at SWRO varies between 1 – 2 m below ground level during the study period ie in September 2007 which is considered as pre-monsoon season. The groundwater level would be nearing to surface level during rainy season. At the coastal tract of Sularikadu & Patipulam it was varying between 1 m to 2 m during September 2007. It indicates the availability of sedimentary aquifer and the extraction of groundwater in this area is lesser than recharge The fresh water and seawater equilibrium is well maintained.


Page 8 of 70


The groundwater table data collected from the Ground Water Division, PWD, for a well at Sadras, is 5.38 m and 7.51 m below ground level in January and September, respectively.

Studies on groundwater velocity and direction using different tracers indicate that the average velocity is 4 cm/d. However, for individual tracers it was varying – Sodium chloride 3.6 cm/d, Tritium 4.4 cm/d and Rhodomine B 10.9 cm/d and the velocity estimated using hydraulic gradient is 4.5 cm/d. The ground water flow direction is generally following ground topography. It flows towards NE during September and discharges to sea. During rainy season ie is in November, it flows predominantly towards east.


Page 9 of 70



Initial results from pumping tests and modeling shows that drawing 11,060 m3/hr is leading to dry cell of the bore wells and the existing fresh water and seawater interface equilibrium likely to be reversed. Hence, taping of saline water through beach well is not considered.

(viii) Engineering geology The proposed SWRO site was evaluated using the joint properties like spacing, orientation and dip for rock outcrops and from joint roughness, filings, and rock mechanical properties of rock mass such as insitu stress and in-situ permeability data from boreholes drilled at site. The fractures have undulating, rough or planar, smooth surfaces with 0.5 mm to 3 mm and occasionally 5-mm thick pseudotachylites. The joint planes are seen with dip, in near vertical and oblique angles. The rock mass shows weathering and alterations along with joint planes and fractured zones.

The results obtained for physical properties of the charnockite rock samples from surrounding areas indicate the variation in bulk density from 2,580 to 2,990 kg/m3 (2.58 to 2.99 T/m3), specific gravity from 2.60 to 3.00, total porosity from 0.32% to 11.6% and water absorption from 0.22 to 0.84%.

Rock mass evaluations for engineering applications for site using the borehole data and laboratory results yield the Rock mass rating (RMR) as 77 and Q-systems as 17. This indicates the quality of rock formations in and around site area to be good. The noted crushing strength of the rock at depth of 13.5 to 15m & 15 - 16.5m ranges from 64 to 72 kg/cm2 respectively.

The chemical analysis of the soil indicates the following results.

Parameters Range

pH 7.06 to 7.15

Sulphate SO3 in % 0.08 to0.12

Chloride in % 0.10 to0.15

Carbonate in % 0.05 to 0.08

The result indicates the soil and groundwater is good and special cement like sulphate or chloride resistance need not be used.

The permeability tests of the various rocks encountered at the site for Sand, cemented sand, cemented silt and disintegrated rock are 1.24X 10-2, 2.23X10-4, 1.25X10-4 and disintegrated rock 1.32X10-3 cm/sec respectively.

All the above geological parameters indicate the suitability of the site for engineering applications of the proposed plant.

03.02 Marine characteristics Prediction of design basis flood level and effluent dispersion characteristics in the sea call for data on waves, tides, seawater temperature, salinity and bathymetry. Such data were gathered for the construction of SWRO plant. For SWRO, data on coastline mapping, HTL & LTL, beach profiles, bathymetry and land survey, tide and currents, soil characteristics were generated. Bathymetric studies were carried out by M/s Indomer Coastal Hydraulics Pvt



Ltd., Chennai under the guidance of MECON. These studies includes seimic study, side scan survey, float trajectory, current measurements, chart datum level, analysis of sea sediments etc. The results obtained are used as base to estimate the Design Basis Flood (DBF) level, for laying of pipe lines for intake and discharge arrangement and for brine dispersion analysis of the SWRO discharge.

(i) Waves and currents

Wave data for the proposed site is not available. The wave atlas for the Indian coast prepared by the National Institute of Oceanography, Goa, covers the Chennai coast under grid 4, which also includes proposed site. The data for Chennai are shown in Fig. 03 - 04 and 03 - 05, as wave rose diagrams for wave periods and wave heights.

The direction of the current is mainly along the coast, either northward or southward depending on the season and the monsoon. Fig. 03 - 06 shows the current rose diagram. The current velocity in this region generally varies between 16.7 to 41.7 cm/s (600 m/h to 1500 m/h). The currents are mostly influenced by the circulation in the bay. More recent data indicate the current to vary between 100 m/h and 1800 m/h.

Since the sea currents are playing major role for dispersion of brine solution which is likely to be discharged the behavior of the current at the site was measured during the study period at two locations. These locations are indicated in the Fig 03 - 07 and Table 03 - 02 The observed results are discussed in the following paragraph.

The current measurements were carried out at 2 locations for 14 days i.e., covering one week in each location. The measurement locations are shown in Fig. 03-07 and details are given in Table 03 - 02. The measurement covered a neap to spring tidal cycle, i.e. from 6.9.07 to 12.9.07 at station C1 (1000 m offshore) and a spring to neap tidal cycle, i.e. from 13.9.07 to 21.9.07 at station . C2 (2000 m offshore). Aanderaa RCM7 Self recording current meter was used for the measurement. It is manufactured by Aanderaa Instruments, Norway. It is a self recording current meter intended to be moored and record the vector averaged speed, direction and temperature of ocean currents. As an option it can be furnished with sensors for conductivity and water pressure (tides).

An advantageous feature of Aanderaa current meters is that the calibration of a sensor is valid for the entire life duration. The instrument records data internally in a removable and reusable solid state Data Storage Unit (DSU) 2990. A built in quartz clock triggers the measuring cycle at regular programmed intervals. The measuring cycle consists of 6 channels in sequence, which are: (i) Reference, (ii) Temperature, (iii) Conductivity (if installed), (iv) Pressure (if installed), (v) Current direction and (vi) Current speed.



The measurable speed range is 2 to 295 cm/s with an accuracy of + 1 cm/s or + 2% of actual speed whichever is greater. The current direction is measured with a resolution of 0.35° and accuracy of + 5° for speeds from 5 to 100 cm/s, and + 7.5° for current speeds more than 100 cm/s. The Clock is of Quartz crystal having an accuracy of less than + 2 s/day within 0 to 20° C.

The variation of current speed and direction at stn. C1 (1000 m offshore) measured during 6.9.07 to 12.9.07 is shown in Fig. 03.08. It shows that the current speed varies with tides and reached upto 0.23 m/s during the measurement period. The current direction remained almost unidirectional towards 30° irrespective of tidal phase.

The variation of current speed and direction at station. C2 (2000 m offshore) measured during 13.9.07 to 21.9.07 in Fig. 03.09. It shows that the current speed varies with tides and reached upto 0.44 m/s during the measurement period. The current direction remained almost unidirectional towards the sector between 10° and 60° irrespective of tidal phase.



Fig. 03 - 04 Wave rose diagram for wave height



Fig. 03 - 05 wave rose diagram for wave periods



Fig. 03 - 06 Current rose diagram



Fig 03 – 07 Measurement locations of current , water and sediments



Table 03 - 02. Measurement locations and details

Geographical Coordinates (WGS 84) Stn. No.

Distance from shore (m) Latitude N Longitude E

Water depth (m)

Measurement depth

from surface (m)

CURRENT MEASUREMENTS

C1 1000 12042’01” 80014’11” 10.5 1.5

C2 2000 12041’52” 80014’43” 13.4 1.5

WATER SAMPLING

W1 1000 12042’01” 80014’11” 10.5 S, B

W2 2000 12041’52” 80014’43” 13.4 S, B

W3 3000 12041’43” 80015’15” 16.8 S, B

SEDIMENT SAMPLING

S1 500 12042’06” 80013’55” 7.5 B

S2 1000 12042’01” 80014’11” 10.5 B

S3 1500 12041’57” 80014’27” 11.7 B

S4 2000 12041’52” 80014’43” 13.4 B

S5 2500 12041’47” 80014’59” 15.1 B

S6 3000 12041’43” 80015’15” 16.8 B

S7 3500 12041’38” 80015’30” 18.3 B

S8 520 12041’55” 80013’52” 7.8 B

S9 1020 12041’50” 80014’08” 10.1 B

S10 510 12042’17” 80013’58” 7.8 B

S11 1000 12042’12” 80014’14” 9.6 B

S= Surface, B = Bottom



(ii) Tides The variation of tides at Nemmeli during 5.9.07 to 21.9.07 is shown in Fig.03. 10. The various tide levels with respect to Chart Datum (CD) for Chennai region as presented in Surveyor General of India publications are given below:

Mean High water Spring

1.15 m

Mean High Water Neap 0.84 m Mean Sea Level 0.65 m Mean Low Water Neap 0.43 m Mean Low Water Spring 0.14 m

The data on tides were collected between 20-5-2005 and 22-6-2005 at Kalpakkam. Tide reaches its maximum of 1.4 m above chart datum (CD) in the open sea. Long-term prediction by tidal flow model indicates that High Water Level would reach 1.5 m above CD.

In the field study by CWPRS, tides were seen to be semi-diurnal with low amplitude with a spring tidal range of 1.22 m and neap tidal range of 0.25 m.

Fig. 03- 08 Variation in current and direction at STN.C1-1000 m off shore



Fig. 03- 09 Variation in current and direction at STN.C2-2000 m off shore

Fig 03 - 10 Variation of tides at Nemmeli



In earlier studies, data on tide levels were collected at Kalpakkam during 16th November to 9th December 1994 and again during 22nd March to 13th April 1995. No significant variations were noticed between the observed tide levels and that predicted for Chennai coast. The predicted levels were for the years 1982 and 1994, obtained from the Surveyor General of India, Dehradun.

In the light of all these, the tidal level variation of 0.80 m above and below CD has been adopted for all design purposes at Kalpakkam

The proposed SWRO site is about 10 km north of Kalpakkam. The data recorded at Kalpakkam are compared with the data recorded during September 2007 at site and it is observed the data is more or less matching. Hence the 0.65m above CD is considered for SWRO as Mean Sea Level ( MSL) design basis since the plant is non hazardous water treatment plant.

(iii) Bathymetry

The survey area is 500 m along the coast and 3500 m into the sea. The bathymetry surveys were carried out along the transects with 50 m spacing perpendicular to the coast. But during survey, it was observed that wide rocky patches were present on this stretch, and hence it has extended the area of survey to cover 700 m width to identify the clear picture on seabed variation. In addition, tie up line parallel to the coast at 200 interval was considered for better accuracy. a) Reference spheroid The datum in WGS 84 spheroid is used for the entire survey and map preparation. b) Horizontal control The DGPS Beacon Transmitter operated from Pulicat Lake by Department of Lighthouse and Navigation is taken as reference station. The transmitting frequency of this reference Beacon transmitter is 319 kHz. The tracks followed for the bathymetry survey are shown in Fig. 03 - 11. The bathymetry map prepared in 1:2000 scale is presented in Fig. 03 - 12. The distance of occurrence of different water depths from the coastline is shown in Table 03 - 03. The survey indicates:

• The water depth contours of 4 m, 6 m, 8 m, 10 m, 12 m, 14 m, 16 m,

18 m occurs at distance of 170m, 300 m, 550 m, 900 m, 1600 m, 2150 m, 2750 m, and 3400 m respectively.

• The seabed falls steep close to the coast upto 5m water depth with a slope of 1:20, and thereafter with relatively flat(1:100) slope till 18 m water depth.

• There are three types of slope is occurring at site. The closer contour

from 0 – 5 m indicates steep slope (1:20) at coast. The contours from


80°13'45" E80°14'00" E

80°14'15" E80°14'30" E

80°14'45" E80°15'00" E

80°15'15" E80°15'30" E

12°42'15" N12°42'00" N12°41'45" N12°41'30" N

416500 m X

417000 m X

417500 m X

418000 m X

418500 m X

419000 m X

419500 m X

1403500 m Y 1404000 m Y 1404500 m Y

SO

UTH

ER

N BO

UN

DAR

Y

B A

Y O F B

E N G

A L

NO

RTH

ER

N BO

UN

DAR

YS

ULERIK

ATTU K

UPPAM

PR

OJE

CT SITE

PLA

NT

LINE-01

LINE-02

LINE-03

LINE-04

LINE-05

LINE-06

LINE-07

COA ST LINE

COA ST LINE

DRAWING TITLE :

SURVEYED BY :

CLIENT :FIG. 03 - 11

BA

THYM

ETRY TR

AC

K A

T NEM

MELI SITE

MEC

ON

LIMITED

IND

OM

ER C

OA

STAL H

YDR

AULICS (P) LIMITED

PROJECT TITLE :

SCALE :

Notes :

Geodetic Details :

LegendGeneral

100 MLD

SWR

O D

ESALIN

ATIO

N

PLAN

T AT N

EMM

ELI

PA

GE

NO

. 20 A

BAN

GA

LORE

80°13'45" E80°14'00" E

80°14'15" E80°14'30" E

80°14'45" E80°15'00" E

80°15'15" E80°15'30" E

12°42'15" N12°42'00" N12°41'45" N12°41'30" N

416400 m X

1403400 m Y

416200 m X

416600 m X

416800 m X

417000 m X

417200 m X

417400 m X

417600 m X

417800 m X

418000 m X

418200 m X

418400 m X

418600 m X

418800 m X

419000 m X

419200 m X

419400 m X

419600 m X

1403200 m Y 1403600 m Y 1403800 m Y 1404200 m Y 1404400 m Y 1404600 m Y1404000 m Y

PR

OJE

CT

SITE

SO

UT

HE

RN

BO

UN

DA

RY

NO

RT

HE

RN

BO

UN

DA

RY

SU

LERIK

ATTU

KUPP

AM

PLA

NT

COA ST LINE

COA ST LINE

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

B A

Y O F B

E N G

A L

DRAWING TITLE :

SURVEYED BY :

CLIENT :

FIG. 03 - 12

BA

THYM

ETRY M

AP A

T NEM

MELI SITE

MEC

ON

LIMITED

IND

OM

ER C

OA

STAL H

YDR

AU

LICS (P

) LIMITED

PROJECT TITLE :

SCALE : Geodetic Details :

LegendGeneral

100 MLD

SWR

O D

ESALIN

ATIO

N

PLAN

T AT N

EMM

ELI

NOTE :

PA

GE

NO

. 20 B


6 to 10 m indicates moderate slope (1:40). At 10 to 18 m depth of water the slope is almost flat( 1: 100).

Table 03 - 03. Water depth with approximate distance from the shore

Water Depth in

(m) Distance from the shore into sea

(m)

3 150

4 170

5 200

6 300

7 400

8 550

9 700

10 900

11 1250

12 1600

13 1900

14 2150

15 2400

16 2750

17 3050

18 3400

iv) Flood levels Based on all the information presented in this section and other data such as rainfall, the Design Basis for finished floor level of plant proper was estimated to be 6.95 m RL. The finished ground level will be 6.5 m RL. This figure is due to a combination of tide, storm surge and rainfall. The maximum water level rise in sea above CD is 4.16 m due to storm surge compared 4.08 m for tsunami. Summary of the results are given in Table 03 - 04.

Table 03 - 04 Estimated flood levels for postulated events

Flood level (m) Region Scenario Above CD RL Tide+Storm Surge +Wave runup 1.15+4.16+0.07=5.38 6.95 Sea side

Tide+Storm

Surge+Rainfall 1.15+4.16+1.0 = 6.31 7.5 ON ECR side




vii) Side Scan Survey

Tide+Storm Surge 1.15+4.16 = 6.61 6.9 Proposed site entrance

CD – Chart Datum; RL – Reduced Level

V) Water samples

In order to design the SWRO, testing of the seawater samples testing is necessary. A total number of six seawater samples (3 Nos. of numbers of surface & 3 Nos bottom water samples) were collected from the site. The location of the samples are shown in Fig 03 – 07. The results of the water samples collected at 6 locations viz., stn.W1 (surface and bottom), stn. W2 (surface and bottom) and stn. W3 (surface and bottom) are shown in Table 03 - 05.

vi) Temperature and salinity

Similar to bathymetry the side scan surveys were carried out along the transects with 100 m side spread, i.e. 50 m on either side of the scanning track for area of 500 m along the coast and 3500 m into the sea.. But during survey, it was observed that wide rocky patches were present on this stretch, and hence it the survey was extended the area of survey to cover 700 m width to identify the clear picture on seabed feature.

SIS-1600 Series Side Scan Sonar of SIS-1624 dual frequency model with TTV-196D tow vehicle manufactured by BENTHOS, INC., USA was used for carrying out the shallow seismic survey. It is a fully integrated system that uses both advanced Chirp and conventional continuous wave (CW) technologies and an advanced high-speed communications link to acquire high resolution side scan sonar images.

Historical seawater temperature of this coast varies between 27° C and 32° C. Salinity varies from 25 to 35 ppt. During the study period September 2007 the temperature varies from 27.5 to 29 ° C. Historical features of the coast, obtained during the study period are indicated in Table 03 - 06.

In general Side Scan Sonar surveys are needed for identifying the items viz., anchors, rocks and shipwrecks lying on the seafloor which are obstacles for dredging and navigations. This survey can be undertaken for the region having water depth more than 3 m as the minimum submergence needed for the tow vehicle sensor is not less than 3 m.



Table03. 05 Seawater quality parameters

Location



1 Colour - Colour less Colour less Colour less Colour less Colour less Colour less

2 Odour - Odour less Odour less Odour less Odour less Odour less Odour less

3 Taste - Salty Salty Salty Salty Salty Salty 4 Turbidity NTU 0.4 0.7 0.2 0.4 0.5 0.6 5 pH - 8.3 8.2 8.2 8.2 8.2 8.2

6 Total Organic Carbon mg/l 8.41 5.63 5.17 8.42 6.31 8.32

7 Conductivity @ 25 oC mS/cm 63.28 63.47 63.37 63.32 63.23 63.42

8 Total Hardness CaCo3 mg/l 6280 6320 6420 6400 6220 6240

9 Alkalinity CaCo3 mg/l 116 118 113 113 114 112

10 Total Suspended Solids g/l 0.02 0.04 0.02 0.02 0.02 0.02

11 Salinity ppt (or) g/l 34.52 33.76 34.14 33.39 34.89 33.01

12 Temperature oC 29.0 28.5 29.0 28.3 29.0 27.5

Page 23 of 70



• value while repetition

Location



13 Total Dissolved Solids g/l 38.2 40.6 38.8 (39.2*) 38.4 40.0 39.8

Anions

14 Sulphate (as So4) mg/l 2358 2491 2202 2673 2600 2691

15 Nitrate (as N o3) mg/l 1.09 1.62 1.24 1.36 0.98 1.63

16 Phenolic Compounds (C6 H2 OH) mg/l BDL

(DL: 0.001) BDL

(DL: 0.001) BDL

(DL: 0.001) BDL

(DL: 0.001) BDL

(DL: 0.001) BDL

(DL: 0.001)

17 Fluoride (as F) mg/l 1.88 1.74 1.86 1.74 1.86 1.92

18 Chloride (as Cl) mg/l 18810 18403 18607 18198 19016 17994

19 Residual Free Cl mg/l BDL (DL: 0.1)

BDL (DL: 0.1)

BDL (DL: 0.1l)

BDL (DL: 0.1)

BDL (DL: 0.1)

BDL (DL: 0.1)

20 Bicarbonate mg/l 141 144 138 138 140 142

21 Sulphide (asH2S) mg/l BDL (DL: 0.01)

BDL (DL: 0.01)

BDL (DL: 0.01)

BDL (DL: 0.01)

BDL (DL: 0.01)

BDL (DL: 0.01)

22 Boron (as B) mg/l 1.76 1.64 1.82 1.67 1.85 1.80

23 Phosphate (as P) mg/l 0.38 0.45 0.52 0.57 0.52 0.66

Page 24 of 70



Location



24 Silica Total (as Sio2) mg/l 0.40 0.40 0.40 0.44 0.41 0.52

25 Silica dissolved (as Sio2)

mg/l 0.34 0.36 0.09 0.10 0.32 0.50

26 Petroleum hydrocarbon mg/l

ND (DL: 0.01

µg/l)

ND (DL: 0.01

µg/l)

ND (DL: 0.01

µg/l)

ND (DL: 0.01

µg/l)

ND (DL: 0.01

µg/l)

ND (DL: 0.01

µg/l)

27 Oil & grease mg/l <1 <1 <1 <1 <1 <1

28 Algae Count Nos./litre 8 3 12 3 11 2

29 Coliform count cfu/ml <2 7 8 8 <2 <2

30 Faecal coliform cfu/ml Absent Absent Absent Absent Absent Absent

Cations

31 Calcium(as Ca) mg/l 353 357 357 365 365 369

32 Magnesium mg/l 844. 777. 904 904 894. 898

33 Copper(as Cu) mg/l BDL

(DL: 0.006)

0.04 0.01 BDL (DL: 0.006)

BDL (DL: 0.006)

BDL (DL: 0.006)

34 Manganese total (as Mn) mg/l

BDL (DL: 0.02)

BDL (DL: 0.02) 0.26 0.19 BDL

(DL: 0.02) 0.15

Page 25 of 70



Location



35 Manganese dissolved (as Mn) mg/l BDL

(DL: 0.02)

BDL (DL: 0.02)

BDL (DL: 0.02)

BDL (DL: 0.02)

BDL (DL: 0.02) 0.06

36 Sodium (as Na) mg/l 11255 12510 11554 11607 11340 11487

37 Iron total (as Fe) mg/l

0.27 0.36 0.28 0.28 0.14 0.14

38 Iron dissolved (as Fe)

mg/l 0.21 0.28 0.26 0.23 0.13 0.11

39 Potassium (as K) mg/l 345 340 346 365 406 407

40 Ammonia (asNH3) mg/l 0.86 1.23 1.09 0.97 1.01 1.34

41 Barium (as Ba)

mg/l BDL

(DL: 0.41) BDL

(DL: 0.41) BDL

(DL:0.41) BDL

(DL: 0.41) BDL

(DL:0.41) BDL

(DL:0.41)

42 Strontium (as Sr) mg/l 18.15 18.85 6.75 7.10 7.0 7.9

43 Mercury (as Hg)

mg/l BDL

(DL: 0.001) BDL

(DL: 0.001) 0.07 BDL (DL: 0.001) 0.12 BDL

(DL: 0.001) Location



Page 26 of 70



44 Cadmium (as Cd)

mg/l BDL (DL: 0.003)

BDL (DL: 0.003)

BDL (DL: 0.003)

BDL (DL: 0.003)

BDL (DL: 0.003)

BDL (DL: 0.003)

45 Selenium (as Se) mg/l

0.09 0.11 BDL

(DL: 0.001 mg/l)

BDL (DL: 0.001

mg/l)

BDL (DL: 0.001 mg/l)

BDL (DL: 0.001

mg/l)

46 Arsenic (as As)

mg/l 0.13 0.23 0.05 0.05 0.07 0.07

47 Cyanide (as CN)

mg/l BDL

(DL: 0.02) BDL

(DL: 0.02) BDL

(DL: 0.02) BDL

(DL: 0.02) BDL

(DL: 0.02 ) BDL

(DL: 0.02)

48 Lead (as Pb)

mg/l BDL (DL: 0.01)

BDL (DL: 0.01)

BDL (DL: 0.01)

BDL (DL: 0.01)

BDL (DL: 0.01 )

BDL (DL: 0.01)

49 Zinc (as Zn)

mg/l BDL

(DL: 0.003)

BDL (DL: 0.003) 0.42 BDL

(DL: 0.003) BDL

(DL: 0.003) BDL

(DL: 0.003)

50 Anionic detergent

mg/l ND

(DL: 0.01) ND

(DL: 0.01) ND

(DL: 0.01) ND

(DL: 0.01) ND

(DL: 0.01) ND

(DL: 0.01)

51 Chromium (as Cr)

mg/l 0.19 0.16 0.17 BDL

(DL: 0.03)

0.14 0.10

52 Mineral oil

mg/l BDL

(DL: 0.01) BDL

(DL: 0.01) BDL

(DL: 0.01) BDL

(DL: 0.01) BDL

(DL: 0.01) BDL

(DL: 0.01)

Page 27 of 70



Location



53 Aluminium Total (as Al)

mg/l

BDL (DL: 0.03)

BDL (DL: 0.03) 1.63 BDL

(DL: 0.03) BDL

(DL: 0.03) BDL

(DL: 0.03)

54 Aluminium dissolved (as Al)

mg/l

BDL (DL: 0.03)

BDL (DL: 0.03)

BDL (DL: 0.03)

BDL (DL: 0.03)

BDL (DL: 0.03)

BDL (DL: 0.03)

55 PAH

µg/l ND

(DL: 0.01) ND

(DL: 0.01) ND

(DL: 0.01) ND

(DL: 0.01) ND

(DL: 0.01) ND

(DL: 0.01)

56 Pesticides

mg/l ND (DL:

0.00001)

ND (DL: 0.00001)

ND (DL:

0.00001)

ND (DL: 0.00001)

ND (DL:

0.00001)

ND (DL: 0.00001)



Mon

th

Mon

soon

Cur

rent

s

(Win

d Sp

eed:

10 –

40km

/hr)

Nov

Dec

Jan

Feb

Mar

Apr

May

Jun

Jul

Aug

Sep

Oct

Nor

th-E

ast M

onso

on(N

EM)

NEM

Sout

h –

Wes

t Mon

soon

Sout

herly

Cur

rent

0.1

–1.

3km

/hr

Transition

Transition

Nor

ther

ly C

urre

nt0.

2 –

1.8k

m/h

r

Sand

bar

<350

m to

0m

Max

imum

2.0

km

June

–D

ec >

350m

Sea

Surf

ace

Tem

p.

(am

bien

t) va

riatio

n

320 C

270 C

Mon

th

Mon

soon

Cur

rent

s

(Win

d Sp

eed:

10 –

40km

/hr)

Nov

Dec

Jan

Feb

Mar

Apr

May

Jun

Jul

Aug

Sep

Oct

Nor

th-E

ast M

onso

on(N

EM)

NEM

Sout

h –

Wes

t Mon

soon

Sout

herly

Cur

rent

0.1

–1.

3km

/hr

Transition

Transition

Nor

ther

ly C

urre

nt0.

2 –

1.8k

m/h

r

Sand

bar

<350

m to

0m

Max

imum

2.0

km

June

–D

ec >

350m

Sea

Surf

ace

Tem

p.

(am

bien

t) va

riatio

n

320 C

270 C

Table 03 – 06 Historical Marine characteristics at SWRO site



The side scan tracks followed for the side scan sonar surveys are shown in Fig. 03 - 13. The data collected were analyzed for the geological nature of the seabed. Based on the data derived from the side scan records, the sea floor image map has been prepared in 1:5000 scale and presented in Fig. 03 – 14. The mosaic map of the sea floor based on the side scan records depicting the geology of seabed is shown in Fig. 03 - 15.

The side scan survey record shows that the seabed is widely covered with sandy clay till 2.5 km distance into the sea. Further offshore, i.e. from 2.5 km to 3.5 km distance, it is mostly covered with coarse sand. Patches of compact sand with silt were observed close to the coast within 1 km distance. Similarly patches of coarse sand with more shell fragments were observed at 2.5 km distance from the shore. Suspected rock outcrops were noticed at 1 km and 3 km distance on the northern side of the survey area, which are to be confirmed by seismic survey. There are some strong indications that bed rocks can be present below these sediment layers which has to be confirmed by seismic survey and boreholes.

The study establishes the suitability of the site for constructing SWRO plant. The initial results indicates that the diffuser can be kept at a distance of 500m from the shore. The intake point will be 1000 m from the shore However, a detail dispersion analysis will carried out to locate the intake and diffuser points.

viii ) Float studies The polyethylene drogue specially made with neutral density was used for float study. The drogues were released at sea and the tracks were followed at every 5 minutes using DGPS. The study was conducted from 0600 hours to 1800 hours on 12.9.2007 to represent the spring tide and on 21.9.2007 to represent the neap tide.

The float tracks followed during the spring tide on 12.9.07 is shown in Fig. 03 - 16. Similarly, the float tracks followed during the neap tide on 21.9.07 is shown in Fig. 03 - 17 It shows that the drogue was drifting with the average speed of 0.10 to 0.15 m/s, but in unidirectional trend towards NNE – NE both during neap and spring tides.

The study indicates non existence of swirl or obstruction in the sea or any turbulence in the vicinity of the proposed site.

ix) Sediment analysis The seabed sediment samples were collected

12°41'45" N12°41'30" N

80°13'45" E80°14'00" E

80°14'15" E80°14'30" E

80°14'45" E80°15'00" E

80°15'15" E80°15'30" E

12°42'15" N12°42'00" N

416500 m X

417000 m X

417500 m X

418000 m X

418500 m X

419000 m X

419500 m X

1403500 m Y 1404000 m Y 1404500 m Y

SO

UTH

ER

N BO

UN

DAR

Y

B A

Y O F B

E N G

A L

NO

RTH

ER

N BO

UN

DAR

YS

ULERIK

ATTU K

UPPAM

PR

OJE

CT SITE

PLA

NT

LINE-01

LINE-02

LINE-03

LINE-04

LINE-05

LINE-06

LINE-07

LINE-08

LINE-09

LINE-10

LINE-11

LINE-12

LINE-13

LINE-14

LINE-15

COA ST LINE

COA ST LINE

DRAWING TITLE :

SURVEYED BY :

CLIENT :

FIG. 03 - 13

SIDE SC

AN

TRA

CK

MA

P

MEC

ON

LIMITED

IND

OM

ER C

OA

STAL H

YDR

AU

LICS (P

) LIMITED

PROJECT TITLE :

SCALE :

Notes :

Geodetic Details :

LegendGeneral

100 MLD

SWR

O D

ESALIN

ATIO

N

PLAN

T AT N

EMM

ELI

BAN

GA

LOR

E

80°13'45" E80°14'00" E

80°14'15" E80°14'30" E

80°14'45" E80°15'00" E

80°15'15" E80°15'30" E

12°42'15" N12°42'00" N12°41'45" N12°41'30" N

416500 m X

417000 m X

417500 m X

418000 m X

418500 m X

419000 m X

419500 m X

1403500 m Y 1404000 m Y 1404500 m Y

Notes :

Geodetic Details :

Legend

DRAWING TITLE :

SURVEYED BY :

CLIENT :

FIG

. 03 - 14

SEA

BED M

AP O

FF NEM

MELI

MEC

ON

LIMITED

IND

OM

ER C

OA

STAL H

YDR

AU

LICS (P

) LIMITED

100 MLD

SW

RO

DE

SA

LINA

TION PLANT AT NEM

MELI

PROJECT TITLE :

SCALE :

SC

ALE

1 : 5000

PR

OJE

CT S

ITE

SO

UTH

ERN

BO

UN

DAR

Y

NO

RTH

ERN

BO

UN

DAR

Y

W A V E B R E A K I N G Z O N E

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

SU

LER

IKA

TTU

KU

PP

AM

PLA

NT

COASTLINE

1212

B A

Y O F B

E N G

A L

COASTLINE

RO

CK

OU

TCR

OP

S

CO

AR

SE

SA

ND

SA

ND

YC

LAY

SA

ND

CO

MP

AC

T SA

ND

SH

ELLS

CLA

YP

ATC

H

SU

LER

IKA

TTU

KU

PP

AM

PRO

POSED

INTA

KE CO

RRIDO

R

PRO

PO

SED O

UTFALL CORRID

OR

1000 m

600 mR

OC

K O

UTC

RO

PS

CO

AR

SE

SA

ND

SA

ND

SA

ND

YC

LAY

SH

ELLS

CO

MP

AC

T SA

ND

80°13'45" E80°14'00" E

80°14'15" E80°14'30" E

80°14'45" E80°15'00" E

80°15'15" E80°15'30" E

12°42'15" N12°42'00" N12°41'45" N12°41'30" N

416500 m X

417000 m X

417500 m X

418000 m X

418500 m X

419000 m X

419500 m X

1403500 m Y 1404000 m Y 1404500 m Y

Notes :

Geodetic Details :

LegendGeneral

DRAWING TITLE :

SURVEYED BY :

CLIENT :

FIG. 03 - 15

SID

E SCAN

SO

NAR

MO

SAIC M

AP

MEC

ON

LIMITED

IND

OM

ER C

OA

STAL H

YDR

AU

LICS (P

) LIMITED

PROJECT TITLE :

SCALE :

SC

ALE

1 : 5000

SO

UTH

ERN

BO

UN

DAR

Y

B A

Y O F B

E N G

A L

100 MLD

SW

RO

DE

SA

LINA

TION PLANT AT NEM

MELI

NO

RTH

ERN

BO

UN

DAR

YS

ULE

RIK

ATT

U K

UP

PA

M

PR

OJE

CT S

ITE P

LANT

S1

S3

S2

EX

TRA

S6

S7

S8

S9

S10

S13

S12

EX

TRA

S11

S4

S5

PA

GE

NO

. 30 C



Fig. 03- 16 & 17 Float trajectory for spring and neap tide

1404

000

m Y

1406

000

m Y

12°4

2'30

" N12

°42'

00" N

12°4

1'30

" N

B A Y O F B E N G A L

1405

000

m Y

12°4

3'00

" N

1403

000

m Y

0900

0930

1000

1030

1100

1130

1200 Hrs

0830

0800

0730

0700

Coa

st lin

e

Coa

st lin

e

1800 Hrs

1730

1700

1630

1600

1530

1500

1430

1400

Spheroid - WGS 84Scale - 1:30000

0 300 600 m

1407

000

m Y

Coa

st li

ne

12°4

2'30

" N12

°42'

00" N

12°4

1'30

" N12

°43'

00" N

12°4

3'30

" N

417000 m X 418000 m X 419000 m X416000 m X

1404

000

m Y

1406

000

m Y

80°13'30" E 80°14'00" E 80°14'30" E 80°15'00" E

FIG. 14. FLOAT TRAJECTORY - NEAP TIDE (21-9-2007)

1405

000

m Y

1403

000

m Y

Spheroid - WGS 84

(21.09.07)

0730

Coas

t lin

e

Scale - 1:30000

0 300 600 m

0800

0830 0845

0900

0930

1000

1030

1100

1130

1200 Hrs

0715

0700

0645

0630

0615

0600 Hrs


0745

0815

0915

0945

1015

1045

1115

1145

1230 Hrs

1245

1300

1315

1330

1345

14001415

1430

1445

1500

1515

15301545

1600

1615

1630

1645

1700

1715

1730

1745

1800 Hrs



at 11 locations as shown Fig. 03 - 07 and Table 03 – 02.The sediment samples were collected from seafloor using Van Veen Grab. These sediment samples were dried and sieved for fractions: 2µ, 75µ, 425µ, 2000µ, 4750µ and 20000µ. The fractions retained in each mesh size were weighed and analyzed. The pipette analysis were carried out for silt and clay fraction The median size (d50) of the sediments are also presented in Table 03 - 07. The graphical representation of sea sediments is shown in Fig. 03 – 18. It shows that it varies from 0.052 mm to 2.1 mm. The seabed at 200 m from the shore consist of clay and silt fraction. But the clay fraction ranges from 3.5 to 4 %. Beyond 200m from the shore the sediment-distributed region is predominantly comprised of fine to medium sand. Careful interpretation of results indicates sand fractions are predominantly occurring near to rock region.

03.03 Meteorology The wind direction, wind speed and the atmospheric stability conditions at the site govern the dispersion and dilution of air pollutants, which in turn will decide the direction and distance of the potentially affected zone from the new activity. Data on maximum wind speed forms an essential input for the design of tall structures such as RO buliding and stacks. In the absence of thermal discharges and heat island effects, information on temperatures is relevant mainly for assessing air conditioning loads and thermal stresses on vessels and piping exposed to ambient conditions. Rainfall information is needed for proper design of storm drains so as to avoid flooding under extreme conditions. Information on humidity serves to assess the intake of pollutant from inhalation pathway.

Weather data was collected at site for three months from late August to October 2007 by installing micro meteorological station at Sularikadu kuppam. These data are short term data and the data can be used as reference in absence of long term data These data are generated to meet the statutory requirements too.

Long-term data with site specific are collected and those data described below.

Weather data is being collected regularly at the nearest micro meteorological station, since September 1967. Meteorological parameters such as maximum and minimum temperatures, relative humidity, wind direction, wind speed, cloud cover are recorded continuously. The report below presents the meteorological data for the period 1990 –2005.



Table 03 - 07. Sediment size distribution

Classifications of Soil

Mea

n di

amet

er

(mm

)

Gra

vel

(%

)

Coa

rse

San

d (%

) M

ediu

m

San

d (%

)

Fine

San

d

(%)

Silt

(%

)

Cla

y

(%)

Loca

tions

Type d50 G CS MS FS Silt Clay

S1 Yellowish grey silty fine sand 0.150 - 4.2 81.4 14.4 0.0

S2 Greyish fine sandy silt 0.070 - 2.6 33.6 60.3 3.5

S3 Greyish silty fine sand 0.100 - 13.6 48.4 34.5 3.5

S4 Greyish fine sandy silt with some clay 0.052 - 7.9 35.6 52.5 4.0

S5 Brownish grey fine to coarse sand with shells 2.100 - 17.3 74.2 6.8 0.9 0.0

S6 Yellowish grey fine to medium sand 0.795 - 4.6 66.6 25.0 3.8 0.0

S7 Yellowish grey dirty fine to medium sand 0.370 - 2.5 52.9 41.9 2.7 0.0

S8 Yellowish grey silty fine sand 0.140 - 3.4 77.2 19.4 0.0

S9 Yellowish grey silt 0.035 - 20.5 75.5 4.0

S10 Yellowish grey very fine sandy silt 0.067 0.6 43.3 56.1 0.0

S11 Yellowish grey fine sand 0.310 12.8 85.5 1.7 0.0



Fig. 3.18 Graphical representation of sea sediments S1 to S11



i) Wind speed and direction The quarterly and annual frequency distribution of wind direction data averaged over 10 years (1990 - 2000) at 30 m level is shown in Table 03 - 08. The predominant wind direction is seen to be south with a frequency of 16.2%. The predominant wind speed class is 12-19 km/h with a frequency of 39.7%.

The highest instantaneous wind speed (over 1 minute period) recorded was 182 km/h on 12.11.85 when a cyclonic storm crossed the east coast near Kalpakkam. The maximum wind speed at 60 m elevation is 100 km/h, recorded during May 1990, during another cyclonic weather condition. An extreme value analysis was carried out by SERC, Chennai, using 110 years (1891-2000) of observed cyclonic data, covering IMD stations around the study area. Of the cyclonic disturbances that have crossed the Tamil Nadu coast during this period, 15 were designated as severe storms. Seven storms of varying severity have occurred during 1990 – 2000. None crossed the Tamil Nadu coast during 2001 – 04. Based on all the available information, and IS 875 (Part3-1987), 50 m/s is used as wind speed. This will be used as the basic wind speed for SWRO plant. To arrive at the design wind speed, the above value has to be modified taking into account the height of structure, topography, terrain roughness etc.

Table 03 - 08 Frequency distribution of predominant wind direction

at 30 m (1990- 2000) Period Direction Frequency (%)

January – March NE NNE SSE

13.7 10.9 10.2

April – June S SSE SSW

30.6 15.5 12.4

July – September S SW SSW

21.3 14.8 14.6

October – December NNE NE NNW

19.9 17.0 10.6

January – December S SSE NE

16.2 9.2 7.9

Fig. 03 - 19 shows the quarterly wind rose diagrams (1990-2000) at study area. The annual wind rose diagram is shown in Fig. 03 - 20.



ii) Temperature

Tables 03 - 09 and 03- 10 present the monthly and annual distribution of the measured data of the temperature (in degree Celsius) during 1970 – 2005. The tables present the maximum, minimum and the mean temperature recorded during the observation period. Fig. 03 - 21 depicts monthly variation of ambient temperature as a trend chart.

An extreme value analysis of the maximum and minimum dry bulb temperatures was made using Gumbel’s distribution, and the results indicate that maximum and minimum temperatures expected would be 46.4º C and 15.7º C for a return period of 100 years.

iii) Humidity The measured data on relative humidity for the period of 1970 –2005 is given in Table 03 - 11. Monthly variation of the average relative humidity observed over the same period is shown Fig. 03 - 22.

iv) Rainfall The annual rainfall and the number of rainy days averaged during the period 1968 - 2005, are 1332.32 mm and 82.89 days, respectively. The highest annual rainfall of 2112.0 mm was recorded during the year 1985 and the lowest of 567.1 mm during 1968. The study area receives about 62% of its annual rainfall during the N-E monsoon (Oct. to Dec.), and 33% during the SW monsoon (Jun. - Sept.). Tables 03 - 12 and 03 - 13 give the average monthly and annual rainfall (1968 - 2005). The monthly rainfall trend is shown in Fig. 03 - 17.

(V) Air environment The operation of the proposed SWRO process will not result in emission of any conventional pollutants like SPM, RPM, SO2, CO etc. However, SOX emission is expected since DG sets are to be used for emergency requirement. Since conventional pollutants are essential to be monitored for the project, it has been decided to carry out the ambient air quality (AAQ) survey for the other conventional pollutants as well. Monitoring stations were set up to monitor the ambient air quality and the observations are discussed below in brief.



Fig. 03 - 19 Quarterly wind rose diagram at Kalpakkam



Fig. 03 - 20 Annual wind rose diagram



Table 03 - 09 Average monthly variation of ambient temperature

Month Max of Max

Min of Max

Mean of Max

Max of Min

Min of Min

Mean of min

Max of Mean

Min of Mean

Mean of Mean

JAN 34.0 27.5 29.9 23.7 17.5 20.1 28.2 23.3 25.7 FEB 34.2 29.5 31.2 23.0 18.0 20.7 28.5 24.6 26.7 MAR 36.0 31.5 33.0 24.9 19.2 22.2 29.8 26.5 28.2 APR 42.0 32.5 35.1 26.7 22.7 24.5 31.7 27.5 30.0 MAY 44.5 33.8 40.1 28.5 22.5 25.3 32.4 29.2 30.7 JUN 41.4 35.2 38.7 27.2 22.3 24.8 31.8 29.1 30.5 JUL 40.0 34.2 37.4 27.3 22.2 24.1 31.4 27.7 29.6 AUG 39.1 34.6 36.3 25.3 22.2 23.7 30.6 27.8 29.2 SEP 38.9 33.8 35.7 25.8 22.0 23.8 30.5 27.8 28.9 OCT 36.4 31.8 34.0 24.7 20.8 23.3 29.2 19.0 27.8 NOV 34.5 29.7 31.6 24.2 18.9 21.8 27.9 25.6 26.7 DEC 34.0 27.9 30.1 24.3 18.2 20.9 27.9 23.8 25.9

Summary 44.5 27.5 34.4 28.5 17.5 22.9 32.4 19.0 28.3

Monthly Maximum, Minimum and Mean Temperature (1970 -2005)

Fig. 03 - 21 Trend chart for monthly max, min and mean temperature

0.0

5.0

10.0

15.0

20.0

25.0

30.0

35.0

40.0

45.0

50.0

Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec

Calender Month

Tem

pera

ture

(deg

C)

Max of Max Min of Min Mean of Mean



Table 03 - 10 Average annual variation of ambient temperature

Year Max of

Max

Min of Max

Mean of

Max

Max of Min

Min of Min

Mean of min

Max of

Mean

Min of Mean

Mean of

Mean 1970 39.5 28.1 33.8 24.4 18.2 22.2 30.5 23.8 27.8 1971 41.6 27.9 33.5 23.9 18.6 21.5 30.1 24.2 27.3 1972 41.4 27.9 34.1 24.4 18.3 21.8 30.3 24.3 27.6 1973 43.2 29.2 34.7 26.0 19.7 22.4 30.8 25.2 28.2 1974 38.5 28.3 33.6 24.7 18.2 21.8 29.9 24.0 27.5 1975 39.8 28.5 33.4 25.9 18.2 22.1 30.8 24.7 27.7 1976 42.5 27.8 34.1 26.5 18.8 22.3 30.3 24.4 27.7 1977 38.1 29.0 33.5 25.5 20.2 22.9 30.2 25.2 28.0 1978 41.5 29.5 34.3 25.3 17.5 22.7 31.1 25.8 28.2 1979 38.5 29.5 34.1 24.8 21.1 23.4 30.4 26.0 28.5 1980 43.5 29.5 34.5 26.4 20.2 23.3 31.2 25.8 28.5 1981 42.0 29.4 34.0 25.0 18.9 22.6 31.2 25.2 28.3 1982 40.0 28.8 33.8 25.1 20.5 23.3 30.7 25.3 28.4 1983 41.2 28.3 34.0 28.5 18.8 23.2 31.8 25.2 28.4 1984 39.8 28.7 33.8 27.6 20.5 24.1 31.5 25.6 28.6 1985 40.7 28.2 33.7 27.3 22.0 24.0 31.5 25.9 28.5 1986 42.2 27.5 34.1 26.3 20.7 23.8 31.0 25.2 28.7 1987 40.5 29.0 33.6 26.3 19.7 23.3 30.8 25.8 28.4 1988 40.7 29.0 34.4 26.6 19.3 23.1 31.0 25.5 28.4 1989 39.5 29.3 34.6 25.0 18.5 22.6 30.4 25.1 28.1 1990 38.3 31.1 34.9 25.5 18.1 23.0 30.5 25.6 28.5 1991 38.3 31.5 34.9 27.5 20.6 23.3 31.1 26.2 28.7 1992 39.2 30.9 34.4 26.7 19.9 23.4 31.4 26.0 28.7 1993 41.0 30.4 34.9 27.3 21.0 23.8 31.4 25.7 28.8 1994 42.5 31.3 34.9 26.0 19.8 23.1 31.1 26.2 28.7 1995 38.7 30.3 34.6 26.0 21.0 23.4 30.7 26.0 28.6 1996 40.5 31.2 34.5 24.7 19.5 22.7 30.6 25.8 28.3 1997 41.7 31.2 35.2 26.6 20.2 23.6 30.4 26.1 28.6 1998 40.2 31.3 35.5 27.0 21.7 24.2 31.9 26.4 29.2 1999 42.0 31.0 35.4 26.7 19.5 23.3 30.8 25.9 28.7 2000 41.5 31.0 35.4 25.0 20.8 22.9 31.6 25.4 28.6 2001 41.2 29.8 36.0 27.1 20.7 24.2 32.4 26.5 29.5 2002 44.0 31.0 35.8 25.0 20.0 23.0 31.2 26.5 29.0 2003 44.5 29.7 35.6 26.0 18.7 22.6 32.2 24.2 28.8 2004 37.7 28.9 33.8 25.1 17.9 21.8 30.0 23.3 27.4 2005 40.4 29.1 35.0 25.7 18.0 22.3 30.8 19.0 27.3

Summary 44.5 27.5 34.4 28.5 17.5 23.0 32.4 19.0 28.3



Table 03 - 11

Average monthly variation of relative humidity (%)

Month Max. of Max.

Min. of Max

Mean of Max.

Max. of Min.

Min. of Min.

Mean of Min. Mean

Jan 100.0 90.0 96.6 60.0 39.0 49.2 75.0

Feb 100.0 91.0 96.6 61.0 29.0 47.6 75.2

Mar 98.0 91.0 96.4 59.0 32.0 50.1 75.5

Apr 100.0 90.0 96.1 60.0 21.0 49.4 76.6

May 100.0 87.0 94.9 58.0 15.0 29.9 75.1

Jun 100.0 88.0 96.0 51.0 24.0 31.6 69.7

Jul 100.0 90.0 97.8 44.0 22.0 34.1 72.5

Aug 100.0 94.0 98.3 52.0 31.0 38.5 74.9

Sep 100.0 95.0 98.8 55.0 33.0 41.8 78.4

Oct 100.0 95.0 98.9 60.0 26.0 48.8 80.8

Nov 100.0 94.0 99.0 66.0 27.0 48.3 80.9

Dec 100.0 95.0 98.7 61.0 36.0 49.5 77.6

0.0

20.0

40.0

60.0

80.0

100.0

120.0

Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec

Calender Month

Rel

ativ

e H

umid

ity (%

)

Max of Max Min of Min Mean of Mean

Fig. 03 - 22 Trend chart for monthly max, min and mean relative humidity



Table 03 - 12 Average monthly rainfall data

Month Rainfall (mm) Rainy days

Jan 23.00 2.42

Feb 13.57 1.11

Mar 3.95 0.34

Apr 19.58 1.45

May 35.58 2.50

Jun 51.99 6.18

Jul 99.69 10.29

Aug 139.37 12.08

Sep 132.30 10.03

Oct 273.03 14.00

Nov 375.82 13.87

Dec 164.44 8.63

Annual 1332.32 82.89

0

50

100

150

200

250

300

350

400

1 2 3 4 5 6 7 8 9 10 11 12Month

Rai

nfal

l (m

m)

Fig. 03 - 23 Trend chart of monthly rainfall



Table 03 - 13 Average annual rainfall

Rainfall (mm)

S.No Year Annual

Monthly max.

Daily max.

Rainy days

1 1968 567.1 138.2 35.6 67 2 1969 1672.4 746.0 305.9 77 3 1970 1968.5 976.5 255.4 83 4 1971 1245.4 375.4 109.2 95 5 1972 1306.8 354.9 107.7 81 6 1973 1130.3 277.2 85.4 70 7 1974 666.8 142.6 49.1 76 8 1975 1224.5 420.7 119.1 81 9 1976 1882.8 831.1 281.3 83

10 1977 1695.3 770.3 209.8 84 11 1978 1923.3 697.5 214.0 102 12 1979 1197.5 508.4 93.8 74 13 1980 1065.1 335.1 134.7 72 14 1981 1049.3 235.5 98.2 83 15 1982 707.5 187.0 75.6 63 16 1983 1526.0 410.1 120.8 68 17 1984 1341.1 268.9 106.0 88 18 1985 2112.0 951.2 132.8 99 19 1986 977.6 218.1 94.4 75 20 1987 1096.2 334.9 78.4 78 21 1988 1077.4 402.9 139.4 73 22 1989 1085.6 563.3 105.2 84 23 1990 1423.2 451.1 145.4 99 24 1991 1484.9 625.1 154.2 76 25 1992 1042.1 558.4 128.0 74 26 1993 1456.9 535.9 192.8 93 27 1994 1483.3 659.5 220.0 79 28 1995 1339.9 270.1 99.7 97 29 1996 1593.2 394.4 228.7 90 30 1997 1748.0 575.3 150.2 97 31 1998 1726.0 647.1 140.4 89 32 1999 1432.8 321.5 152.8 85 33 2000 1085.8 213.6 92.4 98 34 2001 1246.0 316.9 94.5 98



Table 03 - 13 Average annual rainfall

Rainfall (mm)

S.No Year Annual

Monthly max.

Daily max.

Rainy days

35 2002 991.1 291.3 102.9 74 36 2003 981.2 293.0 110.9 80 37 2004 1185.5 407.1 157.5 84 38 2005 1881.4 596.7 140 96

a) Area of evaluation

The study area for the air quality survey was identified based on the principle of 50 times the stack height around the plant as suggested in T.A. Luft, 1986. As the stack height of SWRO is expected to be 30 m, the recommended study area is up to a distance of 4 km. A screening model was also run to find out the variation of ground level concentration (GLC) with distance for various stability classes. It was observed that under neutral stability condition, the maximum GLC would occur at 3 km from the source. In the light of both these considerations, it was decided to locate all the stations within a radius of 4 km.

The number of monitoring stations within the evaluation area has been determined using US-EPA norms [Guideline for air quality monitoring and data reporting under EPA, 1976] which specify that minimum number of monitoring stations should be four for SPM, three for SO2 & NOX and four for CO for a population of less than 1,00,000 within evaluation region. The population within 7 km (evaluation area) is 41,363, based on 2001 census. Thus, minimum four AAQ monitoring stations would be adequate. It was decided to select four stations. Six prospective AAQ stations, were screened before finalizing the four stations.

b) Location of AAQ monitoring stations

The screening procedure is in line with the method of Houghland and Stephens (1976) (Ref. "The Design of Air Quality Monitoring Network", R.E. Munn, 1981). In this method, wind direction frequencies are used. Prospective monitoring stations were selected all around the project site with due consideration to the wind direction and distance from the site. A coverage factor is then calculated for all the potential stations according to the following equation:

Ajk = FREQ (K)(1 + D )j

where, Ajk = Coverage factor of the jth monitoring site in the

kth downwind sector from source. FREQ (K) = Frequency of the wind direction in the Kth sector



Dj = Distance of the site from the source

The results of calculations are presented in Table 03 - 14.

Table 03 - 14 Selection of AAQ monitoring locations

Sl. No.

Prospective AAQ Stations Dj (km) Direction Frequency

(%) Ajk

1 * Perur 0.937 N 14.8 10.27

2 * Suleri kadu 0.937 SW 14.8 7.6

3 * Nemmeli 2.187 N 17.0 5.37

4 * Patipulam 2.812 SW 14.8 3.8

5 Tandalam 3.593 W 14.8 3.2

6 Alattur 5.63 SW 21.3 2.7

7 Salavankuppam 6.8 S 14.8 2.23

(*) Station selected

The stations, which gave higher `Ajk’ values, were identified in general as monitoring stations. Besides the coverage factor Ajk, other aspects such as population, data availability, sites with archaeological monuments were also taken into consideration while choosing the location of the AAQ stations. For instance, Mamallapuram is a nationally important Notified Archaeological site and also a World Heritage site. But two years data for Mamallapuram station is already available for comparison. Considering all the facts and logic, the stations selected have been those with serial nos 1 to 4.The location of these stations concentrated near the SWRO plant.

c) AAQ parameters and monitoring frequency

Background level of pollutants in the atmosphere was monitored at the above four stations. Monitoring was done twice a week for four weeks and samples were collected for 24 hours a day for studying parameters like SPM, SO2, NOx, HC and CO. The samples were collected for 24 hours duration in a day. Samples for analysing respirable particulate matter (RPM), lead in RPM, particle size distribution were also collected from each station. In addition, the dust fall has also been measured in all these locations. The sampling and testing were carried out as per relevant norms of CPCB ( National Ambient Air Quality Standard of CPCB dt. 11.04.94). The monitoring of CO was done for one hour average. The methodology of sampling analysis and the equipment used are given in Table 03 - 15.



Table 03 - 15 Methodology of sampling, analysis & equipment used

Sl. No.

Parameters Instrument/ Apparatus used Method followed

1. Suspended particulate Matter (SPM) a

High Volume Air Sampler (HVAS), Filter Paper (EPM - 2000), Balance

Gravimetry

2. Respirable Particulate Matter (RPM) a

Respirable Dust Sampler (RDS), Filter Paper (EPM-2000), Balance

Gravimetry

3. Nitrogen Oxides (NOX) a

HVAS with Impinger tubes, spectrophotometer

Jacobs & Hochheiser modified (Na-arsenite) Method

4. Sulphur di Oxide (SO2) a

HVAS with Impinger tubes, spectrophotometer

Improved West & Gaecke method

5. Lead in RPM a HVAS, Filter Paper, Balance, Atomic Absorption Spectrophotometer

Gravimetry followed by AAS

6. Carbon Monoxide a

CO Analyser NDIR Method

7. Particle size b Fractionating HVAS Gravimetry 8. Dust fall c Dust fall jar Gravimetry

a CPCB Notification of 11.04.99 b OSHA & EPA, ASTM D2009 c IS:5182 The detection limits for the systems/analysis procedures used are given below:

Detection limit for SO2 & NOx: 10 µg/m3

Detection limit for CO : 1140 µg/m3

Detection limit for Pb : 0.003 µg/m3

When the values are below the detection limits, other sensitive instruments have been used to measure, but these measurements have been done for a few representative samples only. Moreover, precision of these instruments is relatively less. Therefore, values that are below detection limits are to be regarded as rough indicators.

d) Results

The first and second maximum, minimum, and average monitored values for the monitored pollutants at different locations are presented in Table 03 - 16. The monitored results have been compared with prescribed statutory (CPCB) norms for "Residential, Rural and Other Areas". The comparison indicates that all values of SPM, RPM, SO2, NOX, CO, Pb are much below the norms.

Particle size analysis in SPM has been done using a sophisticated fractionating high volume sampler of "Anderson" make. The results of this analysis are given in Table 03 - 17. As there are no norms for particle size



distribution, these may be used as back ground values for future reference only. The respirable particulates fraction can be deduced from this study also. It can be observed that of the total SPM, 85 to 90% is respirable. SPM being low, the RPM also is well within the limits of 150 µg/m3.

e) Dust fall

Dust fall was estimated by using "Dust fall kits" for collection of particulate matter settling from the atmosphere at each AAQ station continuously for a period of 30 days during the monitoring month i.e. August ' 2007. Results are given in Table 03 - 18.

As there is no prescribed Indian Standard for dust fall, comparison can be made with German norms. The German norms as published in T.A. Luft, 1986 are as follows:

Annual Arithmetic Mean = 350 mg/m2/d 98 percentile value = 650 mg/m2/d

The monitored results show that dust fall is almost uniform throughout the area and is insignificant.

f) Status of air environment The AAQS values confirm that there is no significant release of conventional pollutants in the study area.. Nor is there any other industrial source of such emission in the surrounding area of the site. The values recorded are due to common sources like traffic, and local domestic and farming activities. The observed values are in conformity with those found in the earlier survey at this area in the year 2005.

03.04. Water environment The volume of liquid discharges into the sea resulting from operation of the SWRO is almost equal to half of the water taken for treatment. The salinity in the form of TDS will be present in the discharge brine to the tune of 68640 ppm which will be taken in to account in the dispersion analysis.



Table 03 - 16 Maximum, minimum and average values of pollutants in ambient air

Concentration μg/m3 SPM SO2 NOX Station 1st

Max 2nd Max

Min. Avg. 1st Max

2nd Max

Min. Avg. 1st Max

2nd Max Min. Avg.

Perur 76.4 69.4 33.6 49.09 37 11.21 2.69 9.19 61.53 59.73 BDL 44.54 Patipulam 114.4 90.4 27.9 54.1 7.98 6.6 2.3 4.4 52.5 50.21 21.9 37.49 Nemmelikuppam 72.3 53.1 15.8 41 16.2 12.3 2.43 7.7 57.91 52.42 19.07 45.00 Sularikadu 194.4 129.93 32.2 78.10 6.27 5.58 2.69 4.13 53.84 48.56 11.81 30.19

National Standards in μg/m3 Industrial area 500 120 120 Residential area 200 80 80

Concentration μg/m3 RPM CO HC Station 1st

Max 2nd Max Min. Avg. 1st Max 2nd

Max Min. Avg. C 98 %

Sularikadu 84.8 BDL BDL Patipulam 72.5 BDL BDL Nemmelikuppam 40.6 BDL BDL Perur 32.7 BDL BDL

National Standards in (μg/m3) Industrial area 500 10,000 1.5 Residential area 200 4,000 1.0



Table 03 – 17

Particle size (µm) analysis of SPM in ambient air MONITORING

LOCATION 7.0 & above

3.3 - 7.0

2.0 -3.3

1.1 – 2.0

< 1.1

Perur (%) 8.8 6.6 12.3 13.8 58.5 Cumulative (%) 100 91.2 84.6 72.3 58.5 Suleri kadu (%) 8.4 9.5 5.5 19.2 57.4 Cumulative (%) 100 91.6 82.1 76.6 57.4 Nemmeli (%) 15.3 16 14.7 18.9 36.1 Cumulative (%) 100 84.7 68.7 54 36.1 Patipulam (%) 9.9 22 11.1 10.2 47.6

Cumulative (%) 100 90.1 68.1 57.8 47.6

Table 03 - 18 Monitored dust fall rate

Sl. No. Location Dust fall rate (mg/m2/d)

1. 2. 3. 4.

Perur Patipulam Nemmeli kuppam Sularikadu

71 84 71 80

The other major effluent is from the sewage water from the plant site and the quarters. These effluents are treated before being discharged in to the land or sea.

Various uses of water were taken into account while planning for water quality survey. Surface and groundwater sources in the study area are used for domestic consumption and agriculture. There is fishing activity in coastal waters; some of the surface water sources are also used as fishing grounds. Suitable sampling stations for surface water and groundwater sources were identified.

03.05 Surface water quality

The sampling locations are selected in such a way that it adequately covers the major water sources in the study area. A total of 3 locations, listed in Table 03 - 19, were selected for sampling.

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Table 03 - 19 Surface water sampling locations

Sample No. Location Direction from

the site Distance from the

proposed site SW1 Buckingham canal up

stream N 500m

SW2 Backingham canaldown stream

S 500 m

SW3 Seawater at site - -

To assess physical, chemical and bacteriological characteristics of surface water in the study area, attempts have been made to collect the samples from the above locations once during the monitoring season. The surface water sources are small tanks / ponds with scanty amount of water but under pressure of common usage by the villagers. As far as the project is concerned, the stress on the surface water restricted to sea. However, Buckingham canal is another big surface water source and since no other stream/river is existing in the site it has been decided to collect the surface water from Buckingham canal up- and down stream. Samples have been collected and are tested for pH and dissolved oxygen at the time of collection and the samples are preserved with the addition of nitric acid for testing metal constituents at the laboratory. The collected samples were analyzed in accordance with Indian Standards and the results have been compared with recent MOEF norms for surface water quality criteria for Class A to E, given in Table 03 - 20. The surface water source is sea water and can be compared with Class E.Analytical results, shown in Table 03 - 21, indicate that all the parameters are within the recent norms. The results are discussed below.

a) At location SW- 3 (source of drinking water) the values of chloride TDS and sulphate are higher. It may be noted that the location falls as seawater and naturally the water will contain higher concentration of salts. Since the seawater forms the source water for the proposed SWRO plant a test inlne with MoEF requirement is conducted. The excess values are due to the high concentration of salts available in the seawater.

b) Other parameters of water samples do not show any variation when compared to the norms.

c) The observed Boron concentrations are within the limit. Table 03 - 20

Water quality criteria as per Central Pollution Control Board

Parameters Class A

Class B

Class C

Class D

Class E

1. pH 6.5–8.5

6.5–8.5

6.0-9.0

6.5–8.5

6.5–8.5

2. Dissolved oxygen, mg/l, min 6 5 4 4 - 3. BOD, 5 days at 20° C, max 2 3 3 - - 4. Total coliform, MPN/100 ml,

max 50 500 5000 - -

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5. Free ammonia (as N), mg/l, max

- - - 1.2 -

6. Electrical conductivity, μmhos/cm, max

- - - - 2250

7. Sodium absorption ratio, max.

- - - - 26

8. Boron (as B), mg/l, max. - - - - 2 Class A: Drinking water source without conventional treatment but after

disinfection Class B: Outdoor bathing (organised) Class C: Drinking water source after conventional treatment and after

disinfection Class D: Propagation of Wild life and Fisheries Class E: Irrigation, Industrial Cooling, and Controlled Waste Disposal Below E: Not meeting A, B, C, D & E Criteria

Table 03 - 21 Results of Surface Water Analysis

Sl. no. Parameter SW 1 SW 2 SW 3

Physico- chemical characteristics 1. pH Value 8.19 8.15 8.11 2. Dissolved Oxygen (as O2), mg/l 1.0 1.1 1.5 3. BOD, 5 days at 20° C, mg/l 7 6.5 6.9 4. Free ammonia Nil Nil Nil 5. Electrical Conductivity, μmhos/cm 200 320 1000 6. Boron, mg/l, Max. 0.68 0.7 0.93 7. Colour, Hazen units, Max. 20 20 4 8. Turbidity, NTU, Max. 31 50 <1 9. Total Hardness (as CaCO3), mg/l,

Max. 1970 2400 4000

10. Chloride (as Cl), mg/l, Max. 6950 7250 20750 11. Fluoride (as F) mg/L, Max. 1.4 1.2 <1.7 12. Dissolved Solids mg/l, Max. 11678 12720 33,720 13. Sulphate (as SO4), mg/l, Max. 8.86 10.35 22.57 14. Nitrate (as NO3), mg/l, Max. 0.09 0.012 0.003 15. Alkalinity (as CaCO3) mg/l, Max. 36 40 48 16. Aluminium (as A1) mg/l, Max. < 0.01 < 0.01 < 0.01 17. Iron (as Fe), mg/l, Max. 0.019 0.049 0.28 18. Manganese (as Mn), mg/l, Max. <0.01 <0.01 <0.01 19. Copper (Cu), mg/l, Max. 1.551 1.318 1.935 20. Calcium (as Ca), mg/l, Max. 360.72 400.8 509.01 21. Magnesium (as Mg), mg/L, Max. 260.01 340.2 663.39

Heavy metals 22. Mercury (as Hg), mg/l, Max. < 0.001 < 0.001 < 0.001 23. Cadmium (as Cd), mg/l, Max. < 0.0005 < 0.0005 <

Page 51 of 70



Table 03 - 21 Results of Surface Water Analysis

Sl. no. Parameter SW 1 SW 2 SW 3

Physico- chemical characteristics 24. Selenium (as Se), mg/l, Max. < 0.005 < 0.005 < 0.005 25. Arsenic (as As), mg/l, Max. < 0.005 < 0.005 < 0.005 26. Cyanide (as CN), mg/l, Max. < 0.03 < 0.03 < 0.03 27. Lead (as Pb), mg/l, Max. < 0.01 < 0.01 < 0.01 28. Zinc (as Zn), mg/l, Max. < 0.63 < 0.120 < 0.066 29. Chromium (as Cr6 +), mg/l, Max. < 0.01 < 0.01 < 0.01

Organic compounds 30. Mineral oil mg/l, Max. < 0.1 < 0.1 < 0.1 31. Phenolic Compounds (as C6

H5OH), mg/l Max. <0.001 <0.001 <0.001

Bacteriological characteristics 33. Coliform organisms, MPN/100ml 18 26 34. Temperature oC 25 25 24

a) Ground water quality Samples for ground water were drawn from existing bore wells and dug wells located in the area surrounding the proposed site. Three sampling locations for groundwater were identified and they are as follows.

Table 03 - 22 Ground water sampling locations

Station Location Direction Distance from the proposed

site in m GW1 Sulerikadu kuppam (H pump) - At site GW2 Kalkuppam (H pump) N 1.0 GW3 Tandalam(Dug well) W 3.0

Samples of groundwater are being collected once in the monitoring season from all the 3 locations, and are being analyzed to determine the physical, chemical, and bacteriological characteristics. Results of the analyses are given in Table 03 - 23. These have been compared with IS: 10500 (1993), specification for drinking water, and are discussed below:

a) The essential characteristics of the all groundwater samples are generally within the desirable limits. Exceptions are with respect to the parameters of turbidity and total hardness (as CaCO3 ). In the samples drawn from GW-1,the value of total hardness is exceeding the norms of desirable limit but falls within the relaxed limit in the absence of alternative source. The hardness value recorded was 400 mg/l. Similarly the turbidity exceeds the desirable limit and relaxed limit at GW-3. The recorded value was 29.

b) With respect to desirable characteristics almost all parameters are within desirable limits, exceptions being TDS and calcium.

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c) TDS is exceeding the limit at GW1,& 3. However, all are within the relaxed limit in absence of alternative source.

d) At GW 1 caicium was recorded 132 mg/l against the norm of 75. But it is within the permissible limit in absence of alternative source.

Table 03 - 23 Results of ground water analysis

Results

Sl. No. Characteristics Requirement

(Desirable limits)

Permissible limits in the absence of alternate source

GW - 1 (DW)

GW -2 (DW)

GW - 3

(DW)

Essential Characteristics 1. Colour, Hazen Units,

Max. 5 25 <2 <5 <5

2. Odour Unobjectionable - Unobj. Unobj. Unobj.3. Taste Agreeable - Agr. Agr. Agr. 4. Turbidity, NTU, Max. 5 10 <1 <2 29 5. pH Value 6.5 to 8.5 No

Relaxation 7.9 7.8 7.8

6. Total Hardness (CaCO3), mg/l, Max.

300 600 400 144 60

7. Iron (Fe), mg/l, Max. 0.3 1.0 0.05 0.05 0.03 8. Chloride (Cl), mg/l,

Max. 250 1000 186 77 121

9. Residual Free Cl, mg/l Min.

0.2 - - - -

10. Fluoride (F) mg/L, Max.

1.0 1.5 0.1 0.9 0.7

Desirable Characteristics : 11. Dissolved Solids mg/l,

Max. 500 2000 620 500 850

12. Calcium (Ca), mg/l, Max.

75 200 132 40 16.03

13. Magnesium (Mg), mg/l, Max.

30 100 17.01 10.6 4.86

14. Copper (Cu), mg/l, Max.

0.05 1.5 <0.01 <0.01 <0.01

15. Manganese (Mn), mg/l, Max.

0.1 0.3 <0.01 0.074 0.084

16. Sulphate (as SO4), mg/l, Max.

200 400 52 146 35

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Table 03 - 23 Results of ground water analysis

Results Permissible limits in the absence of alternate source

GW - 1 (DW)

GW -2 (DW)

GW - 3

(DW)

Sl. No. Characteristics Requirement

(Desirable limits)

17. Nitrate (as No3), mg/l, Max.

45 100 0.14 0.046 0.005

18. Phenolic Compounds (as C6 H5OH), μg /l Max.

1 2 <1 <1 <1

19. Mercury (as Hg), μg/l, Max.

1 No relaxation

<0. 5 <0. 5 <0. 5

20. Cadmium (as Cd), μg /l, Max.

10 No relaxation

<0.5 <0.5 <0.5

21. Selenium (as Se), μg /l, Max.

10 No relaxation

<0.5 <0.5 <0.5

22. Arsenic (as As), mg/l, Max.

0.05 No relaxation

<0.03 <0.03 <0.03

23. Cyanide (as CN), mg/l, Max.

0.05 No relaxation

<0.01 <0.01 <0.01

24. Lead (as Pb), mg/l, Max.

0.05 No relaxation

<0.05 <0.05 <0.05

25. Zinc (as Zn), mg/l, Max.

5.0 15 <0.05 <0.31 <0.81

26. Anionic detergent (MBAS) mg/l, Max.

0.2 1.0 <0.1 <0.1 <0.1

27. Chromium (Cr6 +), mg/l, Max.

0.05 No relaxation

<0.01 <0.01 <0.01

28. Mineral oil mg/l, Max. 0.01 0.03 <0.01 <0.01 <0.01 29. Alkalinity (CaCO3)

mg/l, Max. 200 600 40 32 36

30. Aluminium (as A1) mg/l, Max.

0.03 0.2 <0.01 <0.01 <0.01

31. Boron, mg/l, Max. 1.0 5 0.9 0.76 <0.54 Note :- IS 10500 ( 1991) : Norms for Drinking Water is used for comparison DW → Dug Well; BW → Bore Well

e) Among the three samples collected from the site, extremely good quality of groundwater was observed at GW-2. The collected samples show that all the parameters are within the desirable limits.

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On the whole, the groundwater quality in the study area except is observed to be good and suitable for domestic consumption.

b) Seawater analysis Seawater samples were collected and analysed for its quality. The parameters analysed and the range of values is given in the following table. These values are representative of the samples collected over a period of about a year (January to November, 2006) with a frequency of once in 15 days. The range of values quoted indicates the minimum and the maximum recorded during the period.

Table 03 - 24 Seawater quality – Conventional parameters

Parameter Values (range)

Salinity (ppt) 25 to 35

Temperature (°C) 25 to 31.5

DO (mg/l) 4.5 to 7.0

Chloride (g/kg) 11 to 19

Bromide (mg/l) 50 to 65

Suspended matter (mg/l) 25 to 50

Nitrate (μg/l) 25 to 300

Nitrite (μg/l) BDL to 150

Phosphate (μg/l) 25 to 150

Silicate (μg/l) 150 to 600

Chlorophyll 'a' (μg/l) 1 to 5

These values will be used as baseline values for comparison once SWRO comes in to operation.

03.05 Noise survey In order to know the existing ambient noise levels in the study area, noise levels were measured at ten locations. These monitoring locations were selected based on the following criteria:

− Locations where noise generation is restricted (e.g. near hospitals, health centres, and educational institutions).

− Locations where ambient noise levels are affected by existing sources such as commercial activities, public gathering places, and road traffic.

− Background settings i.e. locations where there are no sources of man-made noise except natural activities. Locations like the proposed site will serve as background ambient noise level for the study area.

The ten monitoring stations selected are listed below:

Table 03 – 25 Noise monitoring stations

Page 55 of 70



Station Name of Place Direction Distance from site

N1 Sulerikadu village W 1.2 N2 Pattipulam SSW 1.5

N3 Nemmeli kuppam N 3.7

N4 Perur village N 1.5

N5 Near Buckingham canal W 1.5

N6 At proposed site 0

N7 Sulerikadu kuppam E 0

N8 Suleri kadu on road W 0.3

N9 Tandalam W 3.1

N10 Allatur SW 5.0 A Precision Integrating Sound Level Meter (Model 2221, manufactured by Bruel and Kjaer of Denmark) was used to measure the noise levels. Sampling was done at hourly intervals for a 24-hour period. Noise monitoring was carried out at the six locations for a day during the base line data generation period.

Table 03 - 26 MoE & F Norms for noise

Type of Area Day (0600 - 2100 hrs)

Night (2100 - 0600 hrs)

Industrial area 75 70 Commercial area 65 55 Residential area 55 45 Silence zone 50 40

Values are given in dB(A) units The noise levels recorded are summarized in Table 03 - 27.

Table 03 - 27

Summarised monitored noise levels Sound level pressure in leq dB (A)

September 05

Day time Night time Station Max Min Leq

Avg Max Min Leq

Avg N1 65 47.9 56.2 50.1 42.1 46.3 N2 59.3 40.9 52.6 46.8 37.8 42.1 N3 65.0 55.5 59.4 52.5 48.6 50.3

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Table 03 - 27 Summarised monitored noise levels

N4 72.8 49.2 67.0 64.8 48.4 56.7 N5 68.9 49.8 59.8 56.7 41.8 50.0 N6 59.3 40.1 55.3 47.1 38.7 42.7 N7 73.1 50.2 66.0 53.9 46.3 50.7 N8 68.8 52.6 64.7 58 40.7 50.7 N9 89.7 60.4 81.0 82.6 58.4 77.5

N10 68.8 58.8 64.6 65.5 49.8 59.7

It can be observed from Table 03 - 27 that most of the values of the measured noise levels are exceeding the day and night time norms for residential areas and commercial areas except for a few values. The observance of higher values may be due to frequent traffic at ECR.

03.06 Demarcation of High Tide Line (HTL) and Low Tide Line (LTL)

Regional Centre of National Institute of Oceanography, Visakhapatnam has carried out the required surveys and field measurements for the demarcation of CRZ boundaries from 26th to 27TH September 2007. The details of those investigations are as follows.

Keeping in view, the requirement of coastal regulation zone legislation, National Institute of Oceanography has undertaken the project with the following scope of work.

• To delineate the relevant HTL and LTL as per the prescribed policy,

practice and procedure of MoEF. • To measure the set back lines of 200 m and 500 m from the HTL

boundary.

Based on the above objectives, studies had been carried for land use pattern, morphological features and environmentally sensitive areas to predict the response of the proposed development with in CRZ. Integration of all this information led to conclude the suitability vis-à-vis coastal regulations. The physical demarcation of HTL and restricted development boundaries are presented in the form of a CRZ map Fig.03 24). (i) Data source The following data sources were used for compilation of the final map and preparation of the CRZ report.

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1 Hydrographic chart of Survey of India and land use map of the study area.

2 CZMP of Tamilnadu

3 Tide data as obtained from the Indian Tide Tables (2007).

4 Field mapping.

A brief description of the Coastal Regulation Zone (CRZ) notification subsequently revised through several amendments related to CRZ III is presented below.

ii) Regulation of permissible activities in CRZ-III

(i) The area upto 200 meters from the High Tide Line is to be earmarked as 'No Development Zone' provided that such area does not fall within any notified Port limits or any notified Special Economic Zone. No construction shall be permitted within this zone except for repairs of existing authorized structures not exceeding existing FSI, existing plinth area and existing density, and for permissible activities under the notification including facilities essential for such activities. However, the following 55 [uses/activities] may be permissible in this zone - agriculture, horticulture, gardens, pastures, parks, playfields, forestry, projects relating to the Department of Atomic Energy, mining of rare minerals and salt manufacture from sea water facilities for receipt and storage of petroleum products and liquefied natural gas as specified in Annexure-III appended to this notification and facilities for regasification of liquefied natural gas subject to the conditions as mentioned in para 2(ii), facilities for generating barge mounted power by non conventional energy sources, desalination plants, weather radars and construction of and construction of airstrips and associated facilities in the Islands of Lakshadweep and Andaman and Nicobar (ia) Construction of dispensaries, schools, public rain shelters, community toilets, bridges, roads and provision of facilities for water supply, drainage, sewerage which are required for the local inhabitants may be permitted, on a case to case basis, by the Central Government or Coastal Zone Management Authority constituted for the State/Union Territory. Provided that construction of units or ancillary thereto for domestic sewage treatment and disposal shall be permissible.(ib) the No Development Zone may be reduced to a minimum of 50 mts in the identified stretches of the Islands in the union Territory of Andaman and Nicobar Islands selected and declared by the Central Government for promotion of tourism, based on an integrated coastal zone management study conducted or commissioned by the Ministry of Environment and Forests (ii) Development of vacant plots between 200 and 500 meters of High Tide Line in designated areas of CRZ-III with prior approval of Ministry of Environment and Forests (MoEF) permitted for construction of hotels/beach resorts for temporary occupation of tourists/visitors subject to the conditions as stipulated in the guidelines. (ii. a) facilities for receipt and storage of petroleum products and liquefied natural gas as specified in Annexure-III appended to this notification and facilities for regasification of liquefied natural gas subject to the conditions. (ii. b) storage of non hazardous cargo such as edible oil, fertilizers and food grain in notified ports. (ii. c) desalination plants (ii. d) facilities for generating barge mounted power by non conventional energy sources (ii. e) construction of airstrips and associated facilities in the Island of Lakshadweep

Page 58 of 70



and Andaman & Nicobar. (ii. f) construction and operation of jetties in the Union territory of Lakshadweep. (iii) Construction/reconstruction of dwelling units between 200 and 500 metres of the High Tide Line permitted so long it is with in the ambit of traditional rights and customary uses such as existing fishing villages and goathans. Building permission for such construction/reconstruction will be subject to the conditions that the total number of dwelling units shall not be more than twice the number of existing units; total covered area on all floors shall not exceed 33 per cent of the plot size; the overall height of construction shall not exceed 9 metres and construction shall not be more than 2 floors (ground floor plus one floor). Construction is allowed for permissible activities under the notification including facilities essential for such activities. An authority designated by State Government/Union Territory Administration may permit construction of public rain shelters, community toilets, water supply, drainage, sewerage, roads and bridges. The said authority may also permit construction of schools and dispensaries, for local inhabitants of the area, for those panchayats the major part of which falls within CRZ if no other area is available for construction of such facilities.

(iv) Reconstruction/alterations of an existing authorized building permitted subject to (i) to (iii) above.

(v) In notified SEZ, construction of non–polluting industries in the field of information technology and other service industries, desalination plants, beach resorts and related recreational facilities essential for promotion of SEZ as approved in its Master Plan by SEZ Authority may be permitted.]

Construction is allowed for permissible activities under the notification including facilities essential for such activities. An authority designated by State Government/Union Territory Administration may permit construction of public rain shelters, community toilets, water supply, drainage, sewerage, roads and bridges. The said authority may also permit construction of schools and dispensaries, for local inhabitants of the area, for those panchayats the major part of which falls within CRZ if no other area is available for construction of such facilities.

In notified SEZ, construction of non–polluting industries in the field of information technology and other service industries, desalination plants, beach resorts and related recreational facilities essential for promotion of SEZ as approved in its Master Plan by SEZ Authority may be permitted.

(iii) Management plan of Tamilnadu

As per the Coastal Zone Management Plan (CZMP) of Tamilnadu, the present study area has been categorized as CRZ – III.

(iv) Equipment and methods used for surveys

For the purpose of meeting the requirement of the CRZ notification, the high tide line means the line on the land up to which the highest water line reaches during the spring tide. Here the word “highest water line reaches during the spring tide” refers to the mean high water spring (19 years average of spring

Page 59 of 70



water) that is the regular water level fluctuations caused by changes in relative position of Sun, Moon and the Coastal stretches of seas, bays, estuaries, creeks, rivers and back waters which are influenced by tidal action (on land ward side) are included in Coastal Regulation Zone (CRZ). Highest range of spring tide and its horizontal run up on the land was identified by way of morphological features, permanent vegetation line and flotsam along the open sea and along the creek as per the existing guideline of MOEF. Delineation of HTL was carried out by using the Differential Global Positioning System techniques (CEEDUCER, Australia) and the data were collected by following the established principles in survey of this nature. For demarcation of Low Tide Line (LTL), we have considered the reference level provided by sponsor in the study area with reference to MSL. LTL position was demarcated with reference to the Chart datum (0.000 m) which lies (-) 0.65 m below the MSL. The Everest 1830 Datum and Transverse Mercator Projection have been used for presenting the HTL, LTL on the map and also for preparing the CRZ classification map. Finally the positions of HTL, LTL and CRZ boundary lines were marked on the local CZM maps in 1: 2000 scale.

(v) Differential Global Positioning System (DGPS) The Differential Global Positioning System (DGPS), which is a satellite based navigation and surveying system, was deployed for the determination of precise positions. DGPS is primarily a navigation system for real-time positioning. However, with transformation from the ground-to-ground survey measurements made possible by DGPS (and other space geodetic surveying techniques). This technique overcomes the numerous limitations of terrestrial surveying methods,

like the requirement of inter-visibility of survey stations, dependability on weather, difficulty in night observations, etc. These advantages over the conventional methods and the economy of operations made DGPS the most promising surveying equipment of the future. With the well established high

accuracy achievable with DGPS in positioning of points separated by few hundreds of meters to few hundreds of kilometers, this unique surveying techniques have found important applications in diverse fields.

For the present studies, the CEEDUCER DGPS system with the help of radio beacon signal is used for acquiring the geographical position. This works on the basis of differential calculation through Satellite Communications gives an accuracy of ± 1m.

(vi) Total station

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Total station TOPCON GPT – 3002N used for the survey automatically calculates the horizontal distance, vertical distance and slopes and stores in internal memory. The stored data will be downloaded on to computer using the interface.

Technical specification Display Resolution :

1”

Data storage and transfer : 24000 points

System Accuracy : 2’’

(Vii) CRZ Components

MoEF has declared the stretches of seas, bays, estuaries, creeks, rivers and backwaters which are influenced by tidal action (in the landward side) up to 500 m, in case of the open sea and minimum 100 m in the estuaries, rivers, creeks and back waters from High Tide Line (HTL) and the land between the Low Tide Line (LTL) and the High Tide Line as Coastal Regulation Zone, and imposes with effect from the date of the notification, the restrictions on setting up and expansion of industries, operations or processes etc; in the said Coastal Regulation Zone (CRZ). A key component of the coastal regulation zone is the setback lines measured from the high tide line through which coastal development is regulated in a protected zone contiguous to HTL. These setback lines are with reference to the HTL and act as buffer zones between the ocean and the upland property. Thus precision is required in delineating the high tide line which forms the base to define the setback.

viii) Survey detail The HTL and LTL were demarcated in the study area as per the MoEF guidelines. Accordingly, the HTL was demarcated with ground truth data by physical survey. The horizontal position of HTL, associated with wave run up at preceding high tides and forming geomorphic features and the features such as boundary of perennial natural terrestrial vegetation, flotsam, and drift have been considered. The identification of these markings enabled a reasonably accurate assessment of High Tide Line. Survey data were acquired with range and azimuth system. On demarcation of High Tide Line and Low Tide Line, the plan annexed to this report was prepared in the scale of 1: 5000. Physical demarcation of HTL, LTL and the delineation of CRZ boundaries relevant to the project site was carried out.

(ix) Presentation of maps

The observations in respect of HTL, LTL and set back lines are presented in the map in the scale of 1:2000 Fig. 03 - 24. The legend for different demarcations like HTL, LTL, and CRZ boundaries are given. Since the whole area is adjacent to the open coast, the set back lines of 200 m and 500 m from the HTL are drawn in the map.

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(x) Salient observations from the CRZ map

The following salient features were outlined through the perception and judgment of the team of NIO carrying out the CRZ mapping. Factors considered to make decisions are placed below.

Factors considered to make decisions are placed below:

• Physical demarcation of HTL and CRZ boundaries relevant to the project site was carried out on 26th September 2007.

• Desalination Plant boundaries near Nemmeli vilage were shown by the

MECON, Chennai.

• Approved CZMP plan of Government of Tamilnadu was referred for the preparation of this report.

• The whole stretch of above described shoreline and the property falls within the rural area. • Along the coastline, Sulari kadu Kuppam village is existing along the

HTL. • Proposed Plant is bounded by the HTL and village in the eastern side

and road in the western side. In the southern side is bounded by Dolphins city and vacant land is bonded in the northern side.

• At present, the plant boundary area is vacant with sparse vegetation

• That the property described above falls within the CRZ boundary of 500

m. Thus falls within the ambience of CRZ legislation.

• The proposed development work will not alter the topography of the land surface and thus will not interfere with the drainage from the upland or sea sources.

• The proposed development site does not fall or contain the

environmentally sensitive areas like National Park and sanctuaries, mangroves, Coral or coral reefs, Area rich genetic diversity existence of sand dunes.

(xi) Summary and conclusions

The following conclusions were drawn based on the précised policy, practice and procedure of MoEF. Whenever there was a ambiguity, the perception and judgment of the team of NIO carrying out the CRZ mapping prevailed.

• HTL and CRZ mapping was done for the CMWSSB to set up the desalination plant along the coastal front near Nemmeli village, Tamilnadu.

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415600 E416200 E

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1403800 N

1404000 N

1404200 N

1404400 N

1404600 N

LTL

HTL

200m LINE

500m Line

Geodetic Details :

TIDAL INFORMATION :

Legend:General

Benchmark Details :

BE

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CRZ Details :

CRZ-I : LTL TO HTL

CONSULTANT:IN

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PROJECT TITLE :

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SONS BAY COLONY,VISAKHAPATNAM - 530017PHONE : (0891) 2539180 E-MAIL :

[email protected]

URL :

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mailto:[email protected]

http://www.nio.org



• The position of HTL, LTL and CRZ boundaries are demarcated in the scale of 1:5000.

• That the surroundings of this land is undeveloped rural area. That the

proposed land for development meets the CRZ – III criteria. • The setback line of 500 metres landward side of High Tide Line

indicates that the development site does fall with in the 500 metres from the high tide line which is a land ward boundary of the coastal regulation zone.

• Intake and outfall water pipe lines are fall in the set back lines and

between HTL and LTL. • The whole stretch of the relevant high tide line along the coast is

demarcated by considering the geomorphic signatures that were discernible in the field.

• The development area does not fall or contain the environmentally sensitive areas as specified in the Coastal Regulation Zone Notification.

• The proposed area is vacant land covered with sparse vegetation. • In adjacent to the plant boundary, village is existing. On western side of

the plant boundary is bounded by the east coast road. Vacant land is existing in the northern side and Dolphins city is existing in the southern side.

• The development area does not fall or contain in the vicinity of any

environmentally sensitive and important ecosystem eligible to be categorized as CRZ I except the inter-tidal zone which is in CRZ I(ii) category.

• The whole area falls between 500 m set back line and HTL. As per the

MoEF notification, setting up of desalination plants are permissible activity in CRZ Zone except CRZ I (i).

03.07 Seismic survey

Available literatures on the offshore investigation off the Mahabalipuram coast delineates folded and faulted basement. The inner shelf in this region is mostly covered with sandy sediments. The continental shelf of Mahabalipuram has twofold morphological divisions separated by a terrace around 120 m water depth. The shelf off Mahabalipuram is about 40 km wide and the shelf break occurs around 135 m depth and is covered by carbonate-dominated sediments in the outer shelf and sandy silt and silty clay in the other parts (Sundaresh, et.al.2004). The offshore area of the project region was covered by 15 longitudinal transects, i.e. Line 1 to Line 15. The track map of the seismic survey is shown

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in Fig. 03 – 25 . In general, on interpretation of the high resolution shallow seismic sections, the impermeable layer below the sediment layer is generally considered as acoustic hard bottom, acoustic basement or hard rock or basement rock. Based on the study of the collected seismic records, the description along each survey transect is given below.

Line No

Inference

Line-1

A thin (~1.5m) reflector is observed at the shoreward end of this line. This layer appears to consist of hard and compact fine sand. It pinches out to the sea bed at about 8 m water depth. The water depth along this line varies from 5.0 m to 17.0 m below CD (Chart Datum). Rock exposures are observed at two locations, i.e. at 9.5 m and 16.5 m water depths along this line. The acoustic signatures of the sandy clay and sand at > 10.0m water depth appear to be non-distinguishable and so marked as total sediment thickness in the isopach map. The depth to the acoustic basement along this line varies from 6.0 m to 21.0 m below sea bed.

Line-2

The thin hard and compact fine sand layer recorded in the previous line is also traced in this line. The water depth along this line varies from 5 m to 17.0 m below CD. Rock exposures are observed at two locations, i.e. at 9.5 m and at 16.0 m water depths along this line. The acoustic signatures of the sandy clay and sand at >10.0m water depth appear to be non-distinguishable, therefore, inferred as total sediment thickness in the isopach map. The depth to the acoustic basement along this line varies from 6.0 m to 21.0 m below sea bed.

Line-3

The water depth along this line varies from 5 m to 17.0 m below CD. The thin hard and compact fine sand layer recorded in the previous line could not be traced in this line. Again rock exposures are observed at 9.5 m and at 16.5 m water depths along this line. The acoustic signatures of the sandy clay and sand at >10.0m water depth appear to be non-distinguishable and so marked as total sediment thickness in the isopach map. There appears to be shell layer at 10 m and 15.5 m water depth which are characterized by porous speckled acoustic signatures and are superficial. The depth to the acoustic basement along this line varies from 5.0 m to 22.0 m below sea bed.

Line-4

The hard compact sand reflector recorded in the first line could not be traced in this line. The water depth along this line varies from 5 m to 17.0 m below CD. Two rock exposures are observed at 9.5 m and at 16.5 m water depths along this line. The acoustic signatures of the sandy clay and sand at >9.0m water depth appear to be non-distinguishable and so marked as total sediment thickness in the isopach map. The shell layer recorded at 12m and 16.0m water depth are characterized by porous speckled acoustic signature. The signature of the shelly layer and the underlying coarse sand layer

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PRO

POSE

D INTA

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IKATTU

KUP

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SCALE :

PROJECT TITLE :

MEC

ON

LIMITED

SEISM

IC TR

AC

K M

AP

FIG. 7

CLIENT :

SURVEYED BY :

DRAWING TITLE :

General

Legend

Geodetic Details :

Notes :

1404500 m Y1404000 m Y1403500 m Y

419500 m X

419000 m X

418500 m X

418000 m X

417500 m X

417000 m X

416500 m X

12°41'30" N 12°41'45" N 12°42'00" N 12°42'15" N

80°15'30" E80°15'15" E

80°15'00" E80°14'45" E

80°14'30" E80°14'15" E

80°14'00" E80°13'45" E

LINE-01

LINE-02

LINE-04

LINE-05

LINE-06

LINE-07

LINE-08

LINE-12

LINE-13

LINE-14

LINE-03

LINE-09

LINE-10

LINE-11

LINE-15

B A

Y

O F

B E N

G A L

PRO

POSE

D OU

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FIG. 03 - 25

SEISMIC

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appears to be amalgamated. The depth to the acoustic basement along this line varies from 6.0 m to 21.0 m below sea bed.

Line-5

At about 9.0m and 10.0m. the hard compact sand reflector recorded in the first three lines could be traced again in this line. The water depth along this line varies from 5 m to 17.0 m below CD. Two rock exposures observed in the first three lines are not traceable in this line. The acoustic signatures of the sandy clay and sand at >10.0m water depth appear to be non-distinguishable and so marked as total sediment thickness in the isopach map. The shell layer recorded at 12m and 16.0m water depth are characterized by porous speckled acoustic signature. The signature of the shelly layer and the underlying coarse sand layer appears to be amalgamated. The depth to the acoustic basement along this line varies from 7.0 m to 20.0 m below sea bed. This line is positioned almost along the orientation of the proposed outfall pipeline.

Line-6

The hard compact sand reflector recorded first three lines could be traced again in this line. It occurs intermittently between 6.25m and 8.0m and again between 8.5m and 10m. The water depth along this line varies from 5 m to 17.0 m below CD. No rock exposures are noticed along this line. Similarly the shell carpets are also appear to be sporadic and superfluous. The depth to the acoustic basement along this line varies from 6.0 m near shore to 16.0 m near the seaward end of the lines. The proposed outfall corridor is located in between this line and the previous line.

Line-7

The hard compact sand reflector described in the previous line could be traced in this line as well. It occurs intermittently between 5.25m and 7.5.0m and again at 8.5m. This veneer of fine sand depicted close to shore in the previous lines could not be traced as a unique reflector and so can be inferred as too thin and localized. The water depth along this line varies from 4.5 m to 18.0 m below CD. No rock exposures are noticed along this line. Similarly the shell carpets are also appearing to be sporadic and superfluous. The depth to the acoustic basement along this line varies from 5.50 m near shore to 16.50 m near the seaward end of the lines.

Line-8

The hard compact sand reflector described the bed in the previous line is not traceable in this line; it appears to have ceased in between this line and the line-7. The water depth along this line varies from 4.5 m to 18.0 m below CD. No rock exposures are noticed along this line. Similarly the shell carpets are also appearing to be sporadic and superfluous. The recoded layer appear to consists of sandy silt till the acoustic basement varying from 5.0 m at nearshore to 15.5 m at seaward end of the line.

Line-9

The water depth along this line varies from 4.5 m to 18.0 m below CD. No rock exposures are noticed on the sea bed along this line. The shell carpets are also appearing to be sporadic and superfluous. The depth to the acoustic basement along this line varies from 5.5 m near shore to 16.0 m near the seaward end of the lines.

Line-

10

No rock exposures are noticed along this line. The shell carpets are also appearing to be sporadic and superfluous. The water depth along this line varies from 4.5 m to 18.0 m below Chart Datum (CD).The depth to the acoustic basement along this line varies from 5.0 m near shore to 15.50 m near the seaward end of the lines.

Page 65 of 70



Line-

11

This line is positioned in alignment with the proposed in take corridor. The water depth along this line varies from 4.5 m to 18.0 m below CD. No rock exposures are noticed on the sea bed along this line. The hard compact fine sand patch encountered in the Lines – 1,5 & 6 is occurring around 6.0m water depth along this line and it is ~ 1.0m thick. A thin patch of shelly (<0.5.0 m) material is encountered around the proposed in-take point. The depth to the acoustic basement along this line varies from 5.5 m near shore to 16.0 m near the seaward end of the lines.

Line-

12

This line is positioned at about 500 south of the proposed sea water in take corridor. The water depth along this line varies from 4.0 m to 18.0 m below CD. No rock exposures are noticed on the sea bed along this line. A distinguishable reflector of clay layer is noticeable in this corridor. Thickness of this clay layer varies from 1.0 m near at 5.0m. depth to 1.5 m below 6.0m. water depth. A thin patch of shelly (<0.50 m) material is also encountered around the proposed in-take point. The depth to the acoustic basement along this line varies from 4.5 m near shore to 16.0 m near the seaward end of the lines.

Line-

13

The water depth along this line varies from 4.5 m to 18.0 m below CD. No rock exposures are noticed on the sea bed along this line. The hard compact fine sand patch encountered in the Lines – 1,5 & 6 is occurring around 6.0m water depth along this line and it is ~ 1.0m thick. The clay layer is noticed in the line-12 is also encounter in this line, though in less with less prominence. Thickness of this clay layer varies from 1.0 m at 5.5m. depth. A thin patch of shelly (<0.5.0 m) material is encountered around the proposed in-take point. The depth to the acoustic basement along this line varies from 4.5 m near shore to 16.0 m near the seaward end of the lines.

Line-

14

This line is positioned in alignment with the proposed in take corridor. The water depth along this line varies from 4.5 m to 18.0 m below CD. No rock exposures are noticed on the sea bed along this line. The depth to the acoustic basement along this line varies from 4.0 m near shore to 15.50 m near the seaward end of the lines.

Line-

15

This line is positioned in alignment with the proposed in take corridor. The water depth along this line varies from 4.5 m to 18.0 m below CD. No rock exposures are noticed on the sea bed along this line. The hard compact fine sand patch encountered in the Lines – 1,5 & 6 is occurring around 6.0m water depth along this line and it is ~ 1.0m thick. The depth to the acoustic basement along this line varies from 4.5 m near shore to 16.0 m near the seaward end of the lines. A vertical profile has been presented in Fig.03 - 27.

Page 66 of 70



Fig. 03 – 26 Vertical profile Along Line -1

Page 67 of 70



Fig. 03 – 27 . Vertical profile Along Line - 15

Based on the compactness of the sediment derived from the seismic records, an isopach map (also called acoustic basement map or minimum sediment thickness map) has been prepared and presented in Fig. 03 – 28. The level of the maximum penetration of the signal or acoustic bottom w.r.t. seabed is taken as criteria to prepare this map. The map thus prepared in 1:5000 scale presents the acoustic basement contour at 1 m interval.

Page 68 of 70

13

12

10

13

8

16

16

16

14

17

9

11

80°13'45" E80°14'00" E

80°14'15" E80°14'30" E

80°14'45" E80°15'00" E

80°15'15" E80°15'30" E

12°42'15" N12°42'00" N12°41'45" N12°41'30" N

416500 m X

417000 m X

417500 m X

418000 m X

418500 m X

419000 m X

419500 m X

1403500 m Y 1404000 m Y 1404500 m Y

Notes :

Geodetic Details :

LegendGeneral

DRAWING TITLE :

SURVEYED BY :

CLIENT :

FIG. 23

ISOPA

CH

MA

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MEC

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LIMITED

IND

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STAL H

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LICS (P

) LIMITED

PROJECT TITLE :

SCALE :

SO

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N B

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100 MLD

SW

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10

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12

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9

12

11

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11

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8

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FIG. 03 - 28

ISOPA

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P 100 M

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Sediment thickness for the project area was calculated as the thickness from the seabed up to the acoustic base in the subbottom profiles. Inferred thickness of the seabed varies from about 5 m in the shoreward end of most of the lines and to about 15 m at the seaward end of the profiles. The seabed thickness within 11 m water depth varies from 5 m to 9 m. Both the intake and outfall points of the proposed desalination plant are located within 11 m water depth, hence, would possibly rest on a sediment column of at least 5 m to 9 m thickness. As expected the sediment column thins down to almost zero around the rock out crop points located at the northern edge of the study area and increases to a certain extent at the seaward end of the profile lines.

Another important morphological feature noticed is the occurrence hard rock exposures. These rock exposures are confined to the northern most lines (lines 1 and 2). Of these two rock exposures, exposure-1 is located around 10 m water depth and the exposure 2 is located around16.5 m water depth. Of the two rock outcrops identified in the project area, only the exposure -1 is located in the vicinity of proposed intake and outfall pipelines. It is located at about a distance of 425 m from the proposed outfall diffuser, and at about 450 m from the proposed seawater intake head.

Discussion on seabed geology

The dominant surface material that covers the sea floor of the project area is sandy clay that occupies sea bottom between 10 m and 14 m water depth. Sandy clay covers about 63.6% of the total area investigated. This sandy clay area generally occupies the shoreward half of the study area. Coarse sand with patches of shelly material is found to be occupying the sea floor deeper than 14 m depth. This coarse sandy area covers about 36.4% of the area investigated.

Biogenic agglomerates that constitute shelly patches consist of bivalves and gastropods in that order of dominance. Such seaward coarsening could be due to considerable supply of terrigenous fines flushed through the openings of Kalpakkam backwater located at south and Muttukadu backwater at north of the project site. Supply of terrigenous fine sediments is also possible through the seasonal openings of Buckingham canal and the backshore pond located between the project site and the Sulerikadu kuppam village.

A clayey silt patch of about 0.15 km2 could be observed seaward of breaker zone at about 5 to 7 m water depth on the southern part of the survey region. This patch of fine sediment is oriented in alignment with the proposed seawater in-take pipeline. This clayey silt carpet has an oblong shape with long axis perpendicular shoreline, therefore, indicates topographic low or depressive basin like configuration which provides shelter to the fine sediments. Origin of such niches along this coast can be attributed to the backwash of Tsunami waves that hit this coast during December 2004. Numerous such scour ponds can be noticed on the backshore of beaches between Chennai and

Page 69 of 70



Mahabalipuram and are attributed to tsunami backwash (Chada et.al. 2005; Rajendran et.al 2006).

A few patches of fine hard compact sand are noticeable in sub bottom profiles at north and mid segments of the survey region (lines 1, 5, 6, 7, 11 and 15). These patches of sand are also noticeable in the side scan sonar profiles and confirmed by surface sampling. The side scan sonar profiles of this sand bodies exhibit sand waves oriented parallel to shore.

Morphologically this neritic zone appears to be generally featureless. However a few shore parallel sand bars of insignificant prominence are noticed around 10 m water depth and in the area less than 10m water depth. Such sand bars could be ephemeral and are common feature particularly during the northeast monsoon season when annual maximum wave dynamism prevails. Slope break is noticeable around 10 m contour. The surf zone, wave breaker zone and the immediate seaward littoral zone have bottom slope of 1: 125, whereas the sea floor between 10 m and 18 m contours appears to be more gentle with 1: 300 slope.

Page 70 of 70




FOR

SEA WATER INTAKE & OUTFALL SYSTEM


CONTENT

SL. NO D E S C R I P T I O N PAGE NO.

01. General 1-3

02. Scope of Work 3-4

03. Definitions 4

04. System Description 4-6

05. Contractor’s Responsibilities 6-7

06. Procedure and qualification requirements 7-8

07. Material supply and handling specification 8-11

08. Installation specification 11-20

09 Contractor Equipment, Personel & HSE requirement

20-23

(i)



ADECO TECHNOLOGIES 1 of 23 MECON LIMITED

1.0 GENERAL This specification covers the requirement for design, construction feature, erection, testing, commissioning, performance test for submarine installations of intake and outfall pipelines.

The proposed 100 MLD Sea Water Reverse Osmosis Desalination Plant located in Nemmeli village on the East Coast road, approximately 35 km south of the town of Chennai requires 265 mld of feed water from reliable source of water of consistent quality. The rejects having TDS of 67000 ppm from the SWRO plant is designed for 165 mld. The following were taken into consideration for selection & design of sea water and intake facilities.

a) The feed water salinity, suspended solid loads and organics are the determining factors in the selection of pre-treatment section and RO recovery for consistent and reliable working of the SWRO plant. The fluctuation in feed water quality parameters and impact on flora and fauna shall be minimum.

b) Drawing sea water from the sea from an area at a distance from the shore, unaffected by inflows from land leads to more consistent salinity, lower suspended solids, entrainment and impingement of marine organisms.

c) The sea water open intake system has been located at sufficient dept to avoid sediment from bottom being entrained by wind or waves. The intake head of adequate design shall be located at sufficient depth for ensuring reliable and consistent quantity and quality of feed water supply even at low tide level.

d) The depth of intake and outfall disposal system shall be sufficient to provide clearance for navigation, minimise entrainment and impingement of marine organisms.

e) Intake point shall be located at a sufficient distance from the reject disposal point to prevent short-circuiting.

f) The reject outfall pipeline system with adequate diffuser system shall be provided at suitable depth for efficient and effective dispersion.

In order to determine and design the type of intake i.e beach well (sub surface intake) and open surface intake for the proposed SWRO plant onshore and offshore studies were carried out. The onshore geotechnical studies and pumping tests were carried to study the feasibility of beach well and it was established that required water quantity of about 265 MLD cannot be obtained from the beach wells due to terrain hydrogeology of that area. Hence the design of the plant is based on open sea water intake.

In order to determine and design the suitable open surface intake and outfall system, the following offshore studies and computer modelling were carried out:



a) Bathymetry survey covering an area of 3.5 km perpendicular to the coast and 0.5 km along the coast.

b) Side scan survey covering an area of 3.5 km perpendicular to the coast and 0.5 km along the coast.

c) Seismic survey covering an area of 3.5 km perpendicular to the coast and 0.5 km along the coast.

d) Collection of sea bed sediment samples and carryout sieve analysis.

e) Collection of sea water samples at locations between 1 km to 3 km and analysis of various water quality parameters required for plant design.

f) Demarcation of HTL/LTL by approved agency.

g) Current & tide measurement

h) Float tracking study

i) Determination and understanding of density of jelly fish based on available literature

j) Establishing the littoral drift in the region based on available literature.

k) Selection & design of reject outfall design for initial dilution using CORMIX model and DHI – MIK 21 FLOW AD model for subsequent dispersion.

Based on the above studies, suitable pipeline route alignment for laying of intake and outfall pipelines with intake screen and reject outfall diffusers has been designed and the details of the same are indicated in the drawings listed in the table below.

Table-1

S. No. Drawing/Document no Description

1 MEC/10EP/01/01/WOR/0166 Sea water intake & outfall pipe line details

2 MEC/10EP/01/01/WOR/0167 Reject outfall diffuser details

3 MEC/10EP/01/01/WOR/0168 Details of sea water intake filter facilities

4 Chapter 3 site details of contract document volume II

A

Site details



The Sea Water Intake HDPE pipeline of a diameter of 1600 mm and of an approximate length of 1000 m shall be installed from the shoreline to an approximate water depth of 10 metres.

The submarine 1200 OD mm Outfall HDPE pipeline shall have an approximate length of 600 m at a water depth of 8 m with a terminal section diffuser head of approximately 50 m length, equipped with eighteen nos. of ports 300 x12.7 mm (14 working + 4 S) and blind flanged at ends.

The intake screen and outfall diffuser section shall be connected to the main HDPE pipelines by means of appropriate pipe expansion spool pieces to be installed after the final positioning of the intake to suite levels.

The sea bed characteristics of the area surrounding the Sea Water Intake and the Outfall is generally constituted by loose sand with some areas of compact sand and some sporadic clay patches. The report comprising of the data & results w.r.t to offshore studies as listed above based on which the detail design drawings for sea water intake and outfall system has been prepared are enclosed with this contract document.

2.0 SCOPE OF WORK

The aim is to specify minimum preliminary standards applicable to the installation of the above mentioned Sea Water intake and reject outfall system with all relevant ancillary structures in order to allow potential contractors to evaluate the construction of the offshore portion for the Desalination Plant.

Scope of Works includes the supply by contractor of all material, machinery, plant site, supervision, labour, safety personnel and all expenses necessary for the installation, testing and commissioning of the Sea Water Intake and the reject outfall system.

Moreover, the scope includes but is not limited to:

The review of the contract documents related to design and construction of sea water intake and outfall system comprising of offshore and onshore field study reports, data and related analysis, computer modelling reports, design drawings etc.

Review of the oceanographic survey data enclosed in chapter-3, volume IIA, and if felt necessary, carryout the survey of the area offshore to verify the nature of the sea bottom in order to confirm the results of the boreholes and stratigraphic data enclosed with the contract document and to find the correct means for the marine works.

Excavation of the appropriate trench in the sea bottom as per design drawing with appropriate equipment and supply and receive the HDPE pipes along with associated accessories constituting the intake and the outfall.

Backfilling of the trench, supply and installation of the various sizes stones & materials in the areas indicated in the drawings enclosed with this contract specification.



Supply, welding, laying and connection of the High Density Polyethylene (HDPE) pipes in the submarine trench in accordance with the specifications.

Prefabrication and installation of concrete blocks for the anchorage of the pipes.

Prefabrication and installation of the concrete blocks for the system towards protection against trawling fishing and other possible causes of damage.

Fabrication and installation of the intake screen (head) at the extremity of the sea water intake pipeline and connection of the pipeline with special expansion spool piece joint as indicated in the drawing.

Fabrication and installation of the reject outfall diffusers section and connection with special expansion spool piece joint as indicated in the drawing.

Fabrication and installation of the expansion special spool pieces connecting the 1600 mm dia. and the 1200 mm dia. pipelines for intake and outfall system respectively with the structures at their extremities onshore and offshore. The selection of spool pieces shall be done based on previous experience of similar installation and the same shall be procured from a reputed manufacturer after prior approval from client/consultant.

Supply and installation of all necessary flanges, pipes and structures for the completion of the system in accordance with the drawings.

Supply and installation of the necessary Navigational Aids like buoy with red lantern marks to mark the position of the structures as per drawings.

3.0 DEFINITIONS

Sea water Intake -- The system relevant to the supply of sea water for the purpose of feeding the desalination plant located onshore at Nemmeli village (herein referred as to Intake).

Reject Outfall -- The system relevant to the discharge of reject water of the

desalination plant (herein referred as to Outfall).

4.0 SYSTEM DESCRIPTION

4.1 Sea water Intake

The sea water intake facilities covers the sea water intake offshore and onshore units.

The offshore units comprises of sea water intake system comprising of intake suction head fitted with NaOCL dosing & air bursting arrangement, nylon net, under sea bed intake and associated pipelines. The onshore water conditioning units comprises of sea water intake chamber with provision for sulphuric acid dosing, sea water intake vertical centrifugal long shaft pumps, underground filtering cum sedimentation basin for rapid removal of large particles, sludge water collection & pumping system, degritted water storage including the raw water vertical transfer



pumps as per P&ID no. MEC/10EP/01/01/PID/0001& offshore sea water intake detail arrangement drg no. MEC/10EP/01/01/WOR/0166 & 0168.

Seawater is brought from the sea to the plant through a intake suction head and a 1600 mm HDPE pipeline (PN-10, PE-100, SDR -26, C – 1.25, series 1) laid under the sea bed having minimum top cover of 1500mm. The minimum water depth available at the intake suction head/intake filtering device (SC -101) is 5m (refer detail drg. no. MEC/10EP/01/01/ WOR/0166 & 0168) . 90 DN two nos. HDPE pipeline is also laid along with intake pipeline, one for 10% NaOCl dosing for chlorination & oxidation of bio-organisms and the other for periodic air burst cleaning of the intake head from accumulated marine growth. A level of 1 ppm of residual chlorine in the intake water is sufficient and the same is monitored by Cl2 analyser installed at the discharge of raw water vertical transfer pumps (P-102A/B/C/D). Based on the feed back from the chlorine analyzer the dosing rate is automatically adjusted by the auto adjustment of pump stroke through a 4-20 mA current signal. The dosing is in addition to the concrete blocks proposed to be installed at 25m periphery of the intake head, a buoy with a red lantern marks the location of the intake structures as safety measure from mariners and navigation. A nylon net of 10 mm sq opening is also installed at a radius of 25 meter for restricting the entry of large marine organisms. The velocity of sea water in the intake pipeline is 1.52 m/s and is considered to be adequate for the sea water open intake design. The pipeline is proposed to be laid below the sea bed on the natural pipe and sea bed profile with geo textile mat in such a way that there will be minimal obstruction to navigation and the pipeline do not experience any buoyancy or unsupported spans leading to stress in the pipeline. A floating surface oil monitor and the total organic content analyzer installed at the intake chamber at onshore will provide signal to the seawater pumps through the supervision control system stating the level of hydrocarbon pollution of seawater. Sea water will flow, at a flow rate of 11060 m3/h, into an underground RCC intake chamber (T-101) with roof slab projecting 300 mm above finished ground level from where it will be pumped by sea water intake vertical pumps (P-101A-D) into a filtering cum sedimentation basin (SB-102). Sulphuric acid dosing for pH adjustment will be done at the intake chamber. This will also be an underground RCC tank having sand media resting on a PP screen for removal of large suspended solids. The filtering cum sedimentation basin has a partition for allowing the water to inter into the sand bed media from the bottom. The basin has a sufficiently sloped bottom which allows the heavier suspended particles to trickle down the sand media into the sump provided at one end of the sloped tank. The vertical sludge transfer pumps (P-103A/B) will pump the sludge water accumulated in the sump intermittently for removal of settled solids and sludge. Clear water free from large & heavy suspended solids from filtering cum settling basin (SB-102) will overflow from the top into a degritted covered (roof slab) storage tank (T-103) provided with raw water transfer pumps on the RCC roof slab (P-102A-D) and will pump the water to the disc filters (DF-201-1-30) in the ultrafiltration unit. The filtration cum



sedimentation basin is covered with chequred plates. A 10 ton capacity EOT crane is provided for removal, replacement and maintenance of sand media, vertical pumps (P101A/B/C/D, P-102 A/B/C/D & P-103A/B) Sodium hypochlorite will be injected into the seawater intake filter to ensure complete disinfected raw seawater entering into the intake pipe. Sulphuric acid is dosed into the intake chamber (T-101) for pH adjustment. It is observed from the available literature and experience gained by industrial units located nearby that the population of jellyfish bloom increases in the warmer months. It is possible that jellyfish bloom may block the seawater intake filters. Hence, compressed air supply for periodic airburst cleaning will be provided to safe guard the filter. The air burst cleaning arrangement will take care of any blockages, which may occur due to jellyfish bloom. The dosing pipelines and compressed air pipeline will be laid along with the intake HDPE pipeline up to intake filters device located at intake point. The sodium hypo chlorite and sulphuric acid dosing will also prevent growth of bio fouling organisms in the plant as well as prevent blockages likely to be created by marine living organisms.

4.2 Reject Outfall The UF reject, backwash from the UF skids and RO rejects & sludge from sedimentation tank (ST- 410 A/B) are collected in the UF cum RO reject tank (T-501) installed onshore within plant premises from where it is mixed along with sludge water from filtering cum settling basin (SB -101) and pumped at 6860 m3/hr & 5 bar head by reject water transfer pumps (P-501A-D) into the offshore disposal system outfall comprising of under sea bed 1200 mm diameter HDPE pipeline (PN-10, PE-100, SDR -26, C – 1.25 , series 1) and on the bed 18(14 W+1S) port 300 NB diffuser system designed for suitable dispersion into the sea. The reject outfall is located at 620m from the pump discharge. The TDS of the reject discharge would be to the tune of 67000 ppm.

5.0 CONTRACTOR’S RESPONSIBILITIES

Contractor is responsible of the supply of material, machinery, marine equipment, supervision, labour, safety personnel and all expenses necessary for the installation of the structures part of the Contract.

Nothing contained herein shall be construed as relieving the contractor of his obligation to provide a structure capable of performing its intended service for a submerged life as defined in the Contract.

Client or its representatives reserve the right to inspect and reject at all stages of the Works the manufactures not in compliance with this specification.

Contractor shall give Client and/or its representative's full and unrestricted access to all areas of the work prior to and during coating/painting operations.



If any inspection or testing defined by or referenced in this Specification reveals that the work is non-compliant, then the entire preparation and application procedure shall be redone from the point where the contractor can demonstrate compliance to the satisfaction of Client. All remedial work shall be at the contractor's expense.

Client reserves the right to use still photography or video cameras to document visual inspection at any stage of manufacture.

Contractor shall be in possession of the current revisions and addenda of all codes, standards and specifications required for the Works. All such documents shall be made readily available to Client Representatives upon request.

Contractor shall employ only qualified and experienced personnel for the work. Client shall determine the competence of personnel and shall retain the right to have replaced any contractor's personnel if in Client's opinion they are not working in accordance with Contract, approved procedures or plans.

Contractor shall maintain all equipment in good conditions at all times and where necessary fully calibrated. Client shall inspect equipment and all deficiencies shall be corrected by contractor at his sole expense and to the satisfaction of the Client.

Contractor shall maintain identification of every component and/or section of the pipe constituting the Intake and Outfall. These marks shall be recorded by contractor and the daily logs provided to Client site representative as requested.

All tests performed by the contractor or his suppliers to prove materials characteristics shall be in accordance with the listed codes, standards and specifications or tests referenced herein. In all other cases the contractor is to get Client written approval prior to testing.

At Client’s discretion, contractor shall be required to carry out tests to prove compliance of materials. All such tests shall be to contractor's account.

Contractor shall clearly state every exception to the requirements of this specification prior to Contract award, if no exceptions are stated full compliance should be confirmed.

6.0 PROCEDURE AND QUALIFICATION REQUIREMENTS

6.1 Procedures

Prior to award of Contract along with the techno-commercial offer, contractor shall prove to the Purchaser his ability to install submarine pipelines, to perform the necessary underwater works fulfilling the requirements of this specification.

After award of contract and before start of work, contractor shall submit a detailed written description of the procedures, materials, personnel, tests and safety controls for Client approval. The description shall be accompanied by full details of test results on similar works performed by contractor.

Contractor shall submit to Client for review and approval the following procedures:



1. Construction Plan. 2. Client and Site Organization Chart. 3. Work Schedule and progress. 4. Quality Manual and Project Quality Plan. 5. Safety Execution Plan and procedures. 6. Installation procedure and Manual. 7. Utilization of construction equipment. 8. Marine Operation Manual. 9. Mooring arrangements procedure and marine spread anchor pattern. 10. Critical Lift study. 11. Emergency and Medical Evacuation Plan.

7.0 MATERIALS SUPPLY & HANDLING SPECIFICATION 7.1 Sea water intake material of construction

Sea water Intake High density polyethylene pipe (black) - As per IS 4984/EN 12201/AS NZS 4130 / ISO-4427 Nominal size - 1600 mm, PN -6/6.3 PE – 100, SDR (Standard dimension ratio) – 26, C (overall design coefficient) – 1.25, min. thickness/max. thickness – 61.2 mm/67.5 mm. Pipe Piece length -12 m approx. NaOCl dosing & compressed air high density polyethylene pipe (black) – As per IS 4984 , Nominal Diameter – 90 mm, PN -10, PE – 100, Pipe Piece length -12 m approx. Intake screen – Duplex (SS 2507) Pipe special - Duplex (SS 2507)

7.2 Reject Outfall material specification

Sea water reject outfall High density polyethylene pipe (black) As per IS 4984 /EN12201/AS NZS 4130/ISO 4427, Nominal size - 1200 mm, PN -10, PE – 100, SDR (Standard dimension ratio) – 17 , C (overall design co-efficient) – 1.25, min. thickness/max. thickness – 67.9 mm ( Min.)/74.8 mm ( Max.), Pipe Piece length -12 m approx.

7.3 Acceptance Of Pipes Contractor shall supply the HDPE pipes (PN 10, PE 100) as per IS 4984, shall keep them in custody in a safe and protected area, shall check all pipes for damage, dents, out of roundness, gouges and flat ends etc. All damage and other defects noted shall be recorded by contractor and witnessed by Client.



Damage caused to pipe whilst in the custody of contractor shall be reported to Client and repaired by contractor to the satisfaction of Client. The cost of such repair work and the cost of any material lost shall be at contractor expense.

The history and details of each pipe, including the pipe identification number shall be recorded by contractor before commencement of installation and a unique cross reference number shall be painted by contractor on the inside of the pipe. All documents related to the pipes shall be preserved by contractor for inclusion into the final certification documents.

7.4 Pipe Handling HDPE pipes shall be handled at all times in a manner, which avoids damage. All line pipes shall be lifted clear and moved without being dragged over the ground or any obstructions.

Alternate lifting equipment or specially manufactured lifting hooks may be permitted after approval has been given by Client and under the supervision of the pipe manufacturer.

Pipes shall not be rolled or dropped. Line pipe shall be positioned with care so as not to cause out-of-roundness of the pipe, damage to the ends, bending of the pipe etc.

Any pipe suffering impact damage during handling shall be immediately quarantined and the Client representative advised for their inspection and eventual subsequent acceptance and/or repairs.

Lifting equipment shall be approved by Client. Wire ropes alone shall not be used to lift pipes. Where fork lift trucks are to be used to transport the pipe, they shall be suitably padded to prevent damage.

All pipe handling equipment and procedures shall be subject to approval of the Client prior to their use.

7.5 Pipe Stacking Bare pipe shall not be stacked more than two layers high. The pipe shall be stacked, either on properly constructed and maintained pipe racks, inspected and approved by Client, or on a minimum of two coal tar enamel covered loose graded sand windrows. The sand windrows shall at least be 15 cm deep and not less than 2 m wide (each), approximately 7 m apart, and shall not be separated by bearers.

Contractor shall submit proposed stacking arrangement, including stacking heights pipe end supports and stacking surface to the Client for approval, prior to use and installation.

If contractor requires to stack the pipes in a different number of layers shall submit to the Client all relevant calculations certifying the new proposed configuration.



End supports need to be placed at either end of the stack to prevent to pipe joints from rolling. If pipes are to be stored for an extended period, precautions shall be taken to prevent damage of pipe ends and interiors.

The pipe shall be carefully lowered to prevent impact damage and stacked in such a way that water and mud cannot accumulate within the pipe.

7.6 Damage To Pipes All damage to pipes if the damage is within the acceptable limit as per codes/standard shall be repaired by in accordance with manufacturer specification and with the approval of the Client.

Pipe identification numbers shall be preserved during repair and due allowance for eventual possible cut-off shall be made.

7.7 Concrete Cement, sand, aggregate for concrete works shall be as per enclosed Civil specifications of the contract document and in case of conflict between the enclosed Civil specification and broad guidelines mentioned herein, the main Civil specification shall prevail. The concrete blocks to be installed for the support and ballast of the Outfall diffusers and intake screen, for the cast in situ inside the prefabricated caisson at the elbow of the Intake pipeline and for the anti-trawl fishing protections, anti- buoyancy saddles for intake and outfall pipeline as per the span & load mentioned in the respective intake and outfall pipeline construction drawings shall be of the type for underwater marine sea water environment construction and shall be dense concrete not less than M30. The concrete shall be suitable for marine installations and cement used shall be resistant to sulphate and chloride attack under submerged sea water conditions.

7.8 Cement Sulphate resisting Portland cement conforming to BS 4027 shall be used. Cement shall be suitable for use with seawater and shall have a Tri-Calcium Aluminate (C3A) content of not more than 3.5% and an alkali content of less than 0.6%.

All cement batches shall be covered by manufacturer's test certificates which shall be submitted to Client. These shall cover the physical and performance characteristics of the cement.

Cement shall be stored in such a way that provides satisfactory protection from ambient elements. Cement that has hardened, become partially set or has become lumpy shall be rejected and removed from the site by contractor.

7.9 Sand Sand used for concrete coating mix shall be silica type conforming to BS EN 12620 and shall be well graded from fine to coarse grains.



7.10 Crushed Stone Crushed stone shall be clean and free from any chemicals or soils or organic material that could impair the concrete strength.

7.11 Agregate Mix Grading Aggregate mix shall be clean and free from injurious amount of clay, salt, and alkali, organic or other deleterious material. Alkali compatibility is essential for aggregate.

7.12 Material Control Records The contractor shall maintain a material traceability system to record properly the receipt, return or disposal of all materials eventually supplied by Client and their location within the coating yard on a real-time basis. Contractor shall permit inspection of these records by Client at any time. The system shall reference the unique pipe identification number stamped on the end of each pipe.

The contractor shall submit details of his material traceability procedure to the Client for approval prior to commencement of coating.

8.0 INSTALLATION SPECIFICATION 8.1 Shore Approach Preparation

Contractor shall reclaim and prepare the Site where he intends to constitute the yard for the assembly and preparation of the structures.

He is responsible for the construction of the required access roads and the installation of all services relevant to the Works.

Contractor, with the assistance of the Client, shall liaise with the onshore civil works contractor for the definition of the responsibilities at the tie-in points between the submarine pipeline and the plant works.

The start of the excavation of the trench at the shoreline shall be executed in such a way to prevent damages to the shore structures and appropriate sheet pile walls shall be installed (if necessary) to avoid that the action of the waves can cause difficulties to the works carried out by others onshore.

8.2 Pre-Work And Pre-Lay Site Survey

Contractor shall carry out a pre-works survey to confirm that the site conditions, including sea bottom profile, are the conditions described as per the bathymetries and side scan supplied by the Client.

Contractor is responsible to highlight to Client any eventual discrepancy with the original data and all eventual variations due to a lack in the execution of this survey and communication to the Client shall not constitute origin for any claim whatsoever.

Prior to trenching operations, Contractor shall ensure that the pipeline is not subjected to excessive spanning as per the requirements of specific Standards. For that purpose, contractor shall conduct a post-lay survey using divers and/or ROV



depending on the work area. Accordingly, contractor shall propose procedures for the trenching equipment to negotiate areas of pipeline spanning (if any) such that the pipeline is not over-stressed.

Prior to mobilizing for the trenching activities, contractor shall review soils data along the pipeline route to ensure the adequacy of the proposed trenching method and that no adverse conditions, which could affect the trenching operations efficiency, are anticipated well in advance.

8.3 EXCAVATION AND BACKFILLING CRITERIA

8.3.1 Trenching Method Contractor shall propose its preferred method(s) for trenching the pipeline taking into consideration the involved soils and seabed features along the offshore route included in the Side Scan Survey and seismic survey carried out by Indomer Coastal Hydraulics (P) Limited (Client’s agency) for which the full report is enclosed along with the contract.

The proposed method shall include procedures for negotiating seabed features, the direction of trenching, trenching sequence and split and the entire trenching methodology shall be established by contractor in conjunction with Client to guarantee efficient operation of the trenching spread.

8.3.2 Trenching Requirements Contractor shall proceed with the excavation of the trench of the 1600 mm dia. and

1200 mm dia. respectively sub sea pipeline taking into consideration the following:

Contractor shall dredge the trench to a depth from the sea bottom in order to give a vertical distance of 1.5 m (pipe top cover) between the top of the respective intake and outfall pipes and the surrounding natural undisturbed seabed level.

Lateral walls of excavation shall have a slope with a minimum inclination of 1 : 4 as per the characteristics of the fine sand.

Contractor shall maintain a maximum trench out-of-straightness “OOS” of 0.25 m all over the route in order to mitigate upheaval buckling in case of natural backfilling.

Any pipeline portions not satisfying the above mentioned “OOS” value shall be adequately corrected in accordance with contractor procedures and at his sole expense.

The bottom of the trench shall be filled with a levelling fine sand bed having a minimum thickness of 0,2 m. Eventual material protruding out of this layer shall be duly recorded and Client informed to agree with the contractor for the necessary remedies.



The shape of the trench shall be always in control of the contractor and designed section restored when and if necessary at the sole expense of the contractor.

If, during trenching operations, contractor encounters obstacles (not likely), he shall-at his sole expense and to the satisfaction of Client, immediately cease trenching operations on that portion of the pipeline and report to Client the details of the obstructions along with his recommended solution.

Any obstacles such as boulders or wrecks, preventing trenching the line shall be removed by contractor.

8.3.3 Trench-Out Of Straightness- Survey (OOS) As soon as possible after completion of trenching operations, contractor shall conduct a post-trenching survey to determine the out-of-straightness of the pipeline and ensure that it does not exceed 0.25 m for the entire route.

contractor shall acquire, record and map all necessary data required to determine the “As-trenched” position. contractor shall perform imperfection out of straightness “OOS” surveys, which shall constitute the basis for “OOS” Assessment, to ensure that the required cover depths for the two pipelines are maintained along their route. The required “OOS” survey should accurately define the pipeline profile after completion of trenching operations.

Prior to the “OOS” survey, repeatability trials should be undertaken to assess the accuracy of the OOS measurements.

8.3.4 Trench Grading And Profile The trench shall be graded such that the minimum vertical radius of curvature of the pipeline does not generate excessive stresses in the pipeline. Any trench transitions for the pipelines (at spool pieces) shall be smoothly profiled back to the undisturbed natural seabed level so as to ensure that the pipeline is not subjected to over-stress while exiting or entering the trench. The bottom of the trench in a transition zone shall be at a constant smooth gradient providing a gentle continuous surface to support the pipeline.

Unsupported pipe spans caused by trenching (despite being unlikely) shall not be in excess of the maximum allowable free span lengths given in the relevant standards. Unsupported pipeline spans greater than the allowable span lengths shall be corrected by contractor.

Contractor is required to adjust the bottom profile of the excavation in the eventuality that the onshore civil works contractor has to modify the elevation of the Intake chamber of the desalination plant. In this case the slope of the trench shall smoothly be modified in accordance with the final defined elevation.

For the Outfall line there is no necessity to modify the sea bed profile during trenching but only make the necessary adjustment to the spool piece at tie-in point.



8.3.5 Levelling Sand Bed Contractor shall describe in detail the method he intends to use for the distribution of the fine sand in the bottom of the trench in order to have a perfectly levelled and smooth surface.

Contractor shall provide, at his own expense, to the correction of any eventual differences in level of the fine sand bottom trench bed.

8.4 SINKING OF SUBMARINE HDPE PIPELINE

8.4.1 The following specifications deals with the sinking process and necessary precautions to be taken to secure a safe installation at the bottom. There are two different methods to be used, one for the pipeline itself and another for the intake screen/diffuser. Sinking of the pipeline is mainly carried out by nature’s own forces i.e. gravity, buoyancy and air pressure while sinking of the diffuser, involves use of cranes.

8.4.2 During sinking of the intake and outfall pipeline, the following factors shall be taken

into consideration: a) Detailed sinking procedure must be worked out including technical

parameters, necessary resources, communication systems and emergency procedures.

b) Detail calculations of the sinking curvatures must be carried out by computer programs.

c) The pulling force in the end shall be calculated and minimum shall be 40 tons. Necessary equipment should be arranged for the same.

d) The sinking speed shall not exceed 0.3m/s. e) The compressor required for air filling in pipeline shall work up to 10 bar. f) Air pressure curve as a function of depth shall be calculated. g) The critical radius of curvature is approximately 50m & 65 m respectively for

outfall and intake pipeline . h) The sinking shall be carried out in an continuous basis. i) Concrete weights must be fixed securely. j) The weather conditions must be satisfactory. k) The diffuser and intake screen must be installed as a beam system by use of

cranes. l) The static system during lowering of the intake screen and diffuser must be

calculated. m) The intake screen and diffuser must be ‘mated’ to the main pipeline at sea

bottom (in the trench) with the special spool joint. n) The sinking shall be carried out under assistance of experience personnel in

this field. o) Use of divers shall be minimised and minimum possible work related to

installation must be carried inside the sea.



8.4.3 The pipe string will be towed from the production area by tugboats to the installation site. The contractor shall prepare a detailed sinking procedure before installation.

8.4.4 The concrete weights shall be fixed to the pipeline at the centre to centre distance

indicated in the design drawing. The weights can be installed onshore or offshore. The concrete weights shall be fixed properly to prevent sliding during installation. To increase the co-efficient of friction and to avoid scratches in the surface of pipe, an EPDM rubber gasket between the pipe and concrete weights shall be fixed. When all the pipe sections are fitted together, the pipeline is ready for sinking process. The pipeline is equipped with blind flanges in each end. At the outmost end, the blind flange is also equipped with pipes and valves for air evacuation and air filling.

8.4.5 Before start of the sinking process, the route shall be marked properly by buoys

floating at sea surface. Particular care should be taken for the weather forecast as very little wind and waves should exist during the sinking process. The entire pipeline shall be positioned in the correct route by boats, barges and small boats.

8.4.6 The pipelines shall be equipped with blind flanges in each end. At the outmost end

the blind flange is equipped with pipes and valves for air evacuation and air filling. The inmost blind end of the pipeline is also connected with valve and pipe for controlled water pumping inside the pipeline through pump during sinking The air pressure inside the pipe shall be adjusted depending on the depth through the air valve and compressor to prevent any “run way”.

8.4.7 The calculated pulling force must be applied in the outmost end (end near shore) of

the pipe before the sinking starts. This force can vary during the sinking operation and shall be specially calculated beforehand.

8.4.8 The sinking starts by opening of the air valve in the outmost end carefully and

controlling the inside pressure by a manometer if required to charge the pipe with compressed air. The contractor shall before staring the sinking operation will prepare the curve showing the necessary air pressure as it is the function of sinking depth. The sinking speed shall be a controlled sped and shall not exceed 0.3m/s.

8.4.9 All precautions should be taken to avoid buckling of pipe section. The sinking

operation shall be continuous process. If for any reason, there is an interruption in the sinking operations, the reverse sinking process should start immediately by starting the compressor and must be completed within 15 minutes.

8.4.10 When the sinking reaches the outmost end of the pipeline, the S- configuration will

transform to J-configuration and at this position, very precise and correct pulling force and sinking speed shall be applied to prevent dynamic acceleration forces when the last volume of air leaves the pipe



AS-LOWERED SURVEY (POST-TRENCH SURVEY)

As-lowered survey shall be conducted in order to meet the following objectives:

To provide all relevant documentation necessary to demonstrate and to prove that the pipelines have been lowered in accordance with the acceptance criteria.

Video inspection of the physical condition of top and sides of the As-lowered pipeline for detection of possible damage, pipeline suspensions, ….etc.

Determination of As-lowered pipeline position.

8.4.11 MAGNETIC SUPPORT The decoded and validated digital data shall be supplied on CD-ROM, IBM compatible, ASCII format, operating system MS-DOS.

The CD-ROM shall contain the following files:

Longitudinal profile. Event data

Longitudinal profile The information contained in this file shall be:

KP along the theoretical design route. Sea bottom depth along the pipe axis. Pipe depth. Easting and Northing coordinate.

These files shall be delivered for the “before post trenching activities survey” (As-lowered).

Event data The information contained in this file shall be:

KP along the theoretical design route. Event code and event description.

8.5 Inspection

Contractor shall perform stage wise inspection and testing of all equipment/material used to carry out the survey work and the same shall be witnessed by client/client’s representative. Certified test reports of the instrument used shall be provided.

Contractor shall carry out onshore pressure testing (hydrotesting) of the intake and outfall pipeline at 1.5 times the rated pressuse prior to marine installation of the pipelines. Hydrostatic testing of the system should be carried out as per IS-7634 – 1975/equivalenet European standard.



Contractor shall provide a means of remotely monitoring the trenching operations. A full video record of trenching operations shall be obtained. The operations observed will depend on the trenching equipment being used. Trenching shall proceed only when video monitoring is available.

Contractor shall continuously monitor the status of trenching operations, the lowered depth of pipe and the position of the pipelines in the trench to ensure satisfactory performance of the equipment being used. Trenching shall not proceed unless the monitoring equipment is available.

8.5.1 DIVING OR ROV REPORTING As part of the trenching spread, contractor shall provide an experienced diving team and/or ROV with all required facilities to perform the Scope of Work.

Facilities for continuous video monitoring of trenching machine operations shall be provided. VHS recording facilities including sufficient tape supplies shall be provided to record all video pictures.

During the trenching operations, contractor divers or ROV shall periodically report to Client at least once every 24 hours on the operation of the trenching machine. This check shall be increased to every 8 hours after the initial start up for the first 24 hours. The submitted report shall include the following information:

Condition of the pipe and joints. Depth and profile of trench. Video inspection back-up when requested by Client.

8.6 PIPE LAYING

Laying of the Intake and Outfall pipelines is expected to be with the “Bottom Pull” system carried out by an appropriate pulling barge equipped with a suitable pulling winch.

The two accessories 90 mm dia. hypochlorite and 90 mm dia. compressed air respectively submarine pipelines can be laid simultaneously with the main 1600 mm dia. line or with a separate launching. In this case the intake line shall be firmly anchored to the sea bottom and natural backfilling due to current and/or storm shall always be under control and reclaim by contractor.

With the utilization of the above system the contractor is responsible to prepare a suitable area onshore for the transportation, storage and assembly of the pipeline strings. contractor shall submit to Client, for approval, a detailed layout of the Site including the description of the sources of power, water, aggregates etc. he intend to utilize for the Project.

If contractor intends to utilize a different system of laying, he may be allowed to do so but shall propose the alternative procedure to the Client for their approval. The proposed procedure for installation shall describe in details about the methodology and equipment required for Client’s review and approval.



In any case, the contractor shall deliver to Client the full description of the marine equipment proposed to be deputed for the execution of the marine operations clearly indicating whether the equipment is owned, hired or at a temporary disposal.

The HDPE pipeline is to be lowered in the open trench starting at the Intake chamber for the Intake pipe and in the vicinity of the pump discharge for the reject Outfall pipe. The pipe spool piece shall therefore cover the misalignment between pipe and the pump discharge nozzle.

8.6 BACKFILLING

8.6.1 INTAKE PIPELINE Once the 1000 m long 1600 mm dia. pipeline has been laid and the final position controlled by positioning system is assured, the sand backfilling can start ensuring that the extremities of the line at the intake chamber and spool piece end respectively remains free for the future connection to the onshore equipment and to the offshore intake screen installation.

Backfilling shall be carried out using the natural original as backfilling material sand, restoring to the original situation.

Contractor shall take due care during backfilling that together with the fine sand, coarse material that can damage the Intake pipe is not used.

Measurements of the backfilling shall be continuously under control of the contractor and report and diagrams of the profile submitted daily to Client.

The backfilling shall be carried out in subsequent stages in order to allow the sand to be deposited duly compacted and to give, as final result, the original sea bottom configuration and water depth.

8.6.2 INTAKE STRUCTURE AREA After the installation of the Intake structure and its connection to the HDPE submarine pipeline with special spool piece, the area surrounding the Intake structure shall be covered by a layer of approximate weight of stones of 5-100 Kg size up to 1.3 m below the natural sea bed level.

On top of this small size stones layer another layer 1.0 m thick of 200-500 Kg stones shall be installed. The area covered by these two layers shall have a diameter of 50 m having origin in the centre of the Intake screen structure. Nylon net shall be installed all around with floating buoys as indicated in the installation drawing enclosed with the contractor.

8.6.3 OUTFALL PIPELINE AND DIFFUSERS AREA Similarly, the backfilling operations for the 600 m long and 1200 mm dia Outfall line, shall be carried out by contractor in order to return to the original configuration of the seabed.



The area where the diffuser’s manifold has to be installed, having approximate dimensions of 50 x 13.0 m and a thickness of 2,0 m average, shall be covered by a layer of 200-500 Kg stones.

8.7 INTAKE STRUCTURE INSTALLATION

Among the contractors responsibilities is the fabrication and the installation of the offshore Intake steel structure which is composed of a 5.50 m dia. and 2.30 approx high steel structure connected to the pipeline by means of a stainless steel 1600 mm dia. 22 mm thk 3.0 m radius elbow.

The structure shall be prefabricated in one single piece and shall be installed using the following suggested procedure:

a. Positioning on the prepared sand bed layer on the sea bottom of the 5.0 x 5.0 x 4.50 m concrete caisson and levelling of the same in the correct position.

b. Inserting, inside the concrete caisson of the stainless steel elbow. c. Cast in situ the underwater concrete to refill the space between the caisson

and the elbow complete with the chlorination and compressed air submarine lines and relative flanges mounted.

d. Install the top Intake structure (Screen) and flange it to the already installed elbow.

e. Weight for any possible settlement of the complete structure. f. Transport offshore and install the Special spool piece between the 1600 dia.

Pipeline and the elbow. g. Properly backfill the area with the specified stones.

8.8 INTAKE ANTI-TRAWL BARRIERS

Within the Scope of Work of this project is the installation of 16 nos. 2.20 x 2.20 x 1.50 m anti-trawling fishing concrete blocks in two concentric lanes having origin in the centre of the Intake structure. The external protection barrier of blocks is connected by a nylon net 0.02 dia. 10 mm sq opening of an approximate growth of 160 m.

The installation of these concrete blocks shall be carried out at the real end of the construction, when the Intake structure is installed by using the crane of the installation barge with the assistance of the underwater equipment.

Any different solution in the installation proposed by contractor shall be approved by Client.

8.9 OUTFALL DIFFUSERS INSTALLATION

The Outfall diffuser is constituted by a steel manifold 1500 mm dia. of an approximate length of 50.0 m and having on the upper middle circumference 16



nos. 355.6 x 12.7 mm steel pipe diffusers inserted with an angle of 50° in respect of the upper tangent of the pipe.

A double elbow connecting the diffuser to the pipeline is bringing the elevation of the diffuser system from -9.70 m to -8.20 m.

All diffusers are blind flanged and flanges shall be removed by divers after the installation of the Outfall and of the Intake is completed.

8.10 DIFFUSERS ANTI-TRAWL FISHING PROTECTION

The Outfall complex is completed by a protection of 22 nos. 2.20 x 2.20 x 1.50 anti-trawl prefabricated concrete blocks.

These concrete blocks shall be, similarly to the Intake ones, installed by the crane barge with the assistance of the underwater equipment and personnel.

Positioning shall be ensured by an appropriate system controlled either by onshore station or by satellite DGPS equipment.

8.11 HDPE PIPE & FITTINGS WELDING & TESTING

The welding and testing of the HDPE pipe and fittings shall be carried out as per enclosed piping specification.

9.0 CONTRACTOR EQUIPMENT, PERSONNEL & HSE REQUIREMENT

9.1 EQUIPMENT

Contractor shall furnish a complete details of machinery to be deployed for the trenching spread capable of working in the involved water depths, seabed conditions and environmental conditions. Contractor trenching equipment and its operation shall be such that the pipelines and their joints do not sustain damage.

Contractor shall present all design and operation calculations demonstrating that the machine is appropriate, safe and efficient for the trenching works. Documentation shall include results of all field trials, including description of location, soil types and trenching performance.

9.2 SUPPORT MACHINERY

All vessels required for carrying out of the Scope of Work shall be in full working order and in good conditions. Contractor shall provide to Client descriptions and technical information on all proposed trenching vessels.

The vessel used for the Works shall have the following characteristics:

Ensure a good operating stability.



Have installed a suitable capacity for the job requirements crane. Satisfy international safety rules applicable in the work area. Have all the permits required to operate in the work area. Hold certificates issued by Lloyds or Bureau Veritas or others. Ensure suitable board and lodgings for 2 Client technicians. Radio equipment with frequencies capable of establishing reliable links with

local radio stations. Allow suitable space with the necessary equipment and facilities for divers

activities. Provide a workshop for instrument maintenance. Allow suitable space for the installation of the Data Acquisition System and

Data Processing equipment. Provide office space for Client with all the necessary facilities including, but

not limited to, stabilized power supply, video monitors and recorders to allow either the on-line monitoring of the survey or the review of tapes, work space for at least two people, general good office consumables and access to good quality photocopier.

Provide air-conditioned working areas.

9.3 PERSONNEL

Contractor shall submit his own organization chart for the Scope of Work and made a part of this Contract as presented in all the issued documents and drawings contained in this project, updates, revisions and modifications. All personnel shall be qualified and knowledgeable in their field taking into account the need to perform processing, data quality control and interpretation directly on board.

Consequently contractor, in order to satisfy the scope of work, shall propose:

A Project Manager for the job having at least 10 years experience. A Marine Superintendent onboard at least 5 years experience. A QA Supervisor with at least 5 years relevant experience. A Safety Supervisor with at least 5 years relevant experience. An ROV supervisor with at least 5 years relevant experience. An adequate number of divers, ROV pilots, surveyors and technicians

having full documented relevant experience (at least 3 years).

9.4 HS&E REQUIREMENTS

9.4.1 GENERAL

Contractor shall prepare and submit to the Client detailing the project Health, Safety and Environment (HSE) plan as well as site emergency plan. Contractor shall maintain a full time HSE representative responsible for carrying out the HSE plan



construction work phase, hereafter a brief on the contractual minimum requirements of HSE.

Contractor shall comply with all Indian laws, regulations, legislations and standards having jurisdiction at site, and shall also comply with all applicable international codes, standards, regulations and legislations related to site activities.

9.4.2 HEALTH

Contractor shall prepare a procedure to ensure that all his personnel engaged in the work are medically fit and healthy, registers of all medical care of employees should be available at site.

Contractor shall avoid injuries and accidents to the health of all personnel at all work sites and related facilities.

9.4.3 SAFETY

Site HSE meeting shall be held every week (or upon Client) and arranged by Client and contractor HSE coordinator, Discipline Engineers shall be invited to the meeting as required.

Contractor shall be responsible to immediately report to Client all accidents, resulting in injuries to employees/properties or incidents with infraction of environmental protection regulations. Client will be entitled to see copies of reports and invited to witness investigations by contractor.

Contractor shall identify in the project HSE plan the hazard substances likely to be used along with its material safety data sheets.

9.4.5 ENVIRONMENT

Contractor shall comply with the applicable National Environmental Laws and Regulations, legislations and Client relevant instructions and requirements.

Contractor shall exert his best effort to minimize the adverse Environmental Impacts related with his activities at site by preparing waste management program for the following:

Reducing harmful emissions to air discharges to water and contamination of land.

Improving the use and consumption of energy, natural resources and materials.

Minimizing the waste of the marine spread by recycling and, in any case, by a daily delivery to the in charged authorities.

Contractor shall provide at site during the execution of the project, a responsible nominated person who is qualified and authorized to handle the Environmental requirements of the National Laws and regulations and Client instructions and requirements.



If during execution of any project activity, contractor violates any Environmental Requirements, Client Site Manger shall have the right to stop the activity till contractor takes the necessary corrective actions.

Client Site HSE Coordinator shall follow-up all environmental issues at site and the HSE meeting shall include agenda of “Environmental Related Issues”.

9.4.6 SITE EMERGENCY PLAN

Contractor shall be responsible for preparing a site emergency plan(s) specifying the actions to be taken in the event of emergencies that might occur during trenching and marine operations. The plan(s) are to be submitted to Client prior to Work Commencement.

Site Emergency Plan may include, but not be limited to, actions to be taken in the event of an incident causing or likely to cause environmental pollution as well as clean-up procedure which shall follow.

Emergency plan shall be tested at regular intervals to check its adequacy and to ensure that personnel are trained on the procedures to be followed in case of emergency.




FOR

FOR PIPE FITTINGS & VALVES



CONTENT

SL . NO. DESCRIPTION PAGE NO. 1 General scope of work 1 2 Scope 1-3 3 Design, Construction & erection of piping, Valves & fittings 3-14 4 Construction, Erection & Testing 14-26 5 Valve, Gate & Miscellaneous accessories 26-39 6 Testing for valves 39 7 List of Standards 39-41 8 Piping material specification (MOC of pipes, fittings & valves TABLE-8.1 42-48 TABLE-8.2 49-55 TABLE-8.3 56-60 TABLE-8.4 61-64 TABLE-8.5 64-70

9 Rubber expansion joints 71-73 ANNEXURES ANNEXURE-A 74-79 ANNEXURE-B 80-81 ANNEXURE-C 82-83



PIPING,FITTINS & VALVES

1.0 GENERAL SCOPE OF WORK

1.01 This specification covers the minimum technical requirements for the design, preparation of piping design (general arrangement) and fabrication (sectional details and isometric) drawings, preparation of bill of quantities, supply of materials, fabrication, erection, testing, flushing and cleaning, corrosion protection, painting and commissioning of pipe work for the complete desalination plant and water treatment plant within the battery limits, in accordance with the requirements of this specification, approved drawings and as directed by purchaser/consultant.

1.02 Piping system includes all in plant interconnecting and transport piping, The

term `piping & valves’ referred herein generally covers pipes, fittings (such as bends, equal and unequal tees, reducers, plugs, nipples, sockets, unions, flanges, blinds, end caps, saddles, crosses etc), valves (butterfly, gate, globe, plug, ball, diaphragm, pressure regulating, flow control, relief, safety, electrically operated, pneumatically operated etc), traps, strainers, spectacle blinds, flexible hoses, hose couplings, hose clamps, hose nozzles, pipe supports (trestles, pipe bridges, pipe racks, brackets, hangers, U-bolts, clamps, spring supports etc), culvert and hume pipe crossing (underground crossings), corrosion protection (painting, lining, wrapping and coating etc.

1.03 The design and construction of all piping and valves system shall be suitable in

every way for the service intended and shall be such as to necessitate minimum maintenance. The Design, manufacture, shop testing, supply, erection, testing, and commissioning of the piping and valve system shall conform to the latest revisions of the Indian / International Standards & Codes as referred in below and elsewhere in the contract documents subject to any modification and requirement as specified hereinafter.

1.04 The supply shall be complete in all respects. All components shall be

manufactured from quality material and workmanship as per the relevant codes and standards.

2.0 SCOPE 2.01 The scope of work covered under this specification shall include but not limited

to design, fabrication, manufacture and assembly, inspection, shop testing at manufacturers works and transportation to site, supply, erection of In-plant piping system for desalination plant herein called the piping and valve system and shall cover the following:

a) Residual engineering as applicable/required in preparation of Piping



and instrumentation drawing for the complete system, line sizing & material selection, datasheets and obtaining approval from the purchaser/consultant.

b) Residual engineering as applicable/required in preparation of pipe

routing drawings, general piping arrangement drawings including pipe rack with sectional details & isometrics bill of quantities, support details etc. and obtaining approval from purchaser/consultant.

c) All types and sizes of piping, which includes but not limited to Duplex,

SS 316L, , HDPE, Mild steel, rubber lined MS, Galvanised MS piping. d) Piping embedded in concrete within a structure or foundation, all

embedded parts required for all tanks/water retaining structures made of RCC including puddle pipes.

e) All valves including gates, drains valves and air vent valves, specials,

Strainers, sleeves, wall pipes and floor pipes shown, specified or required and incorporate them into the piping systems.

f) Fittings such as bends, elbows, tees, branches laterals, crosses,

reducers, expanders, unions, couplings, cap, expansion joints, flanges, reducing flanges, blank flanges, weldolets/sockets/sockolets, Gaskets, O-rings, sampling connections, nipples etc. necessary for making a reliable piping system.

g) Specialties such as expansion joints, manifolds, etc h) All joints, specials, couplings, flanges, pipe spools and matching pipes

to connect flow measuring orifice, nozzles etc., branches/ instrument tapping connection, for installing measurements stub and thermo-wells, Gaskets, ring joint, backing rings, jointing material etc. as required to complete installations of piping.

i) All supporting attachments like saddles, shoes, braces, guides, rollers,

slides, anchors, clamps etc. j) Bolts, nuts, fasteners as required for interconnecting piping, valves and

fittings, blind flanges (for future interconnection) as well as for terminal points.

k) Anchor block (for buried/over-ground piping), Thrust Blocks, support

brackets, clamps, support trestles, hangers, Tie Rods, Rigids, bottom rigids etc., secondary steel for pipe supports/trestles and embedded steel for the piping under the scope of the contract.

l) Painting, anti-corrosive coatings, etc. inside and outside of pipes as



necessary. m) Testing, cleaning and inspection. n) All materials required to complete the piping and valve system in

compliance with these specifications shall be supplied and erected in accordance with the provisions of the specification.

2.02 The design, fabrication, erection and testing requirements specified for in plant

piping and valve system for desalination plant and water treatment plant under this chapter are indicative only and contractor shall take full responsibility for system sizing based upon actual equipment to be provided. All materials and components of valves, piping and other equipment and appurtenances shall be compatible with the respective fluid chemicals and shall comply with the guidelines stipulated in this chapter and respective datasheet/equipment specification (companion flanges & fittings, puddle pipes etc) . Piping shall be fabricated,/supplied assembled, installed in proper operating condition in full conformity with the approved basic and detail drawings, datasheets, specifications, engineering data, instructions and recommendations of the equipment manufacturer as approved by the purchaser/consultant. To facilitate the future operation and maintenance, products to the extent possible shall be of the same major manufacturer (in their manufacturing range), with devices of the same type and model.

3.0 DESIGN, CONSTRUCTION AND ERECTION OF PIPING, VALVES &

FITTINGS 3.1 Design Criteria 3.1.1 General Design Criteria 3.1.1.1 All piping systems shall be capable of withstanding the maximum pressure in

the corresponding lines at the relevant temperatures. The minimum thickness for pipes and fittings for each piping class (pressure and temperature rating) as detailed in this specification or as per the actual design calculation, whichever is greater shall be adhered to. Higher thickness in equivalent material is acceptable with prior approval from the purchaser/consultant. However, no additional compensation will be given for higher thickness.

3.1.1.2 All the piping systems, fittings and accessories supplied under this package

shall be designed to operate without replacement and with normal maintenance for a plant service life of about 25 years and shall withstand the operating parameter fluctuations and cyclic fluctuations which can be normally expected during this period.

3.1.1.3 All piping systems shall be properly designed to take care of hydraulic shocks

and pressure surges which may arise in the system during operation. Special



precaution shall be taken while designing high pressure piping systems. contractor should provide necessary protective arrangement like anchor blocks/anchor bolts, etc. for the safeguard of the piping systems under above mentioned conditions. External and internal attachments to piping shall be designed so as not to cause flattening of pipes, excessive localised bending stresses or harmful thermal gradients in pipe walls.

3.1.1.4 Wherever contractor's piping coming under this specification, terminates at an

equipments or terminal point not included in this specification, the reaction and the thermal movement imposed by contractor's piping on equipment terminal point shall be kept within limits by providing anchor supports within the terminal point to isolate the system from loads imposed by the piping system designed and erected by others.

3.1.1.5 Piping and fittings shall be manufactured by an approved firm of repute. They

should be truly cylindrical of clear internal diameter specified, of uniform thickness, smooth and strong, free from dents, cracks and holes and other defects. They shall allow ready cutting, chipping or drilling, welding etc.

3.1.1.6 The design, dimensional standards, testing standards and material specifications of piping & valves of various systems will be as specified in the specification of the components.

3.1.1.7 All phases of work pertaining to piping design, fabrication, testing and

installation shall be carried out in accordance with the latest edition of ANSI B 31.3. Contractor shall bear the cost of repair, modifications and replacements, if any, becoming necessary due to non-compliance of codes, this specification or due to disregard of purchaser/consultant’s instructions.

3.1.1.8 The primary consideration in a piping arrangement shall be to provide an

economical, safe piping layout which allows ease of operation and maintenance of the plant. Adequate space shall be provided around the equipment and valves for taking up convenient operation and maintenance.

3.1.1.9 All the piping shall be arranged with due consideration to pipe expansion, valve

locations, pipe supports and access to accessories for maintenance. 3.1.1.10 In general, to the extent possible above ground piping shall be envisaged and

the piping system shall be routed over pipe pedestals. Where access and maintenance space is required pipe racks shall be considered. Pipe bridges shall be considered while crossing the roads/ cable /drain trenches and only under unavoidable circumstances these crossings shall be carried in box culverts or hume pipes below ground level at a minimum cover of 1.5.

3.1.1.11 The arrangement of piping systems and support structures shall be designed to

provide for future expansion of the plant piping wherever specified/required



with minimum disruption / disturbance to the existing piping systems with due importance given to the functional and aesthetic arrangement of present and future piping systems.

3.1.1.12 For easy handling & removal of equipments, valves etc. and for maintenance

purpose, break up flanges for piping 65 NB and above sizes and suitable type of compression flexible coupling or flanged joints for piping of 50 NB and below size shall be provided.

3.1.1.13 The over-ground piping wherever routed inside building, shall have a clear

head room of minimum 2.1 meter from operating floor. Pipes shall be to the extent possible be routed above ground but where specifically required and is unavoidable, the pipes may be laid in RCC trenches with removable RCC covers/FRP grating (inside plant building) or buried (outside plant building, inter unit) with prior approval from the consultant/purchaser. Buried piping shall be generally installed so that the top of pipe is 1.0 meter below the ground level unless otherwise specifically mentioned. Full length of buried piping shall be provided with 100 mm thick sand bed at the bottom as padding material in case of metallic piping. However, incase of non metallic piping, 150 mm thick sand cushion shall be provided all around the pipes. .

3.1.1.14 Inside the building, the overhead portion of the pipe line may be supported from the building structures and the building structures and equipment foundation shall be designed to take care of all possible loads that will be generated in the piping system. To the extent possible, support from the brick wall shall be avoided. Incase it is necessary, the same shall be envisaged during the brick wall design. Crossing of the road shall be on a pipe bridge with a clear height of at least 8.0 meters over the top of the road surface. All the steel structure for the pipe bridge and the supporting posts/trestles along with all necessary hangers clamps, connecting auxiliary steel, fixing bolts, nuts etc. shall be supplied and erected by the contractor.

3.1.1.15 Hangers and supports shall be capable of carrying the sum of all concurrently

acting loads. They shall be designed to provide the required supporting effects and allow pipe line movements as necessary. All guides, anchors, braces, dampener, expansion joint and structural steel to be attached to the building/structure, trenches etc. shall be provided. Type of hangers and components for all piping shall be selected and approval obtained from the purchaser/consultant.

3.1.1.16 For large size pipes/ducts, at high point and bends/change of direction of flow,

air release valves shall be provided. Sizing criteria for air release valves shall be generally on the basis of valve size to pipe diameter ratio of 1:8. Requirement shall be decided as per relevant code

3.1.1.17 Sufficient up stream and down stream lengths for the pipeline shall be

provided for flow measuring devices, control valves and other specialties as per the requirement instrument and control.



3.1.1.18 All local instruments shall be located on pipe lines as to render them

observable from the nearest available platforms or floor. 3.1.1.19 Openings provided in the wall for pipelines must be closed with bricks and

mortar with 10-12 mm clearance between brick work and pipe after taking care of insulation and thermal movement, if any. The clear space must be filled with felt or asbestos or approved filling compound.

3.1.1.20 Suitable slope shall be provided for all pipelines towards drain points. It is

contractor responsibility to identify the requirements of drains and vents, and supply the necessary pipe work, valves, fittings, hangers and supports etc. In addition to the system requirement, all low points in the pipelines shall be provided with suitable draining arrangement and all high points shall be provided with vent connections where air or gas pockets may occur. Vent for use during hydrostatic test shall be plugged after the completion of the test. Vent shall not be less than 15 mm size.

3.1.1.21 Drains shall be provided at low points and at pockets in piping such that

complete drainage of all systems is possible. Drain shall not be less than 15 mm for line size up to 150 mm, not less than 20 mm up to 300 mm and not less than 25 mm for 350 mm to 600 mm pipes and not less than 50 mm for 600 mm and above pipes.

3.1.1.22 Air piping shall be sloped so that any part of the system can be drained through

the shut-off drain valve or drain plugs. 3.1.1.23 Air release valves shall be provided in the High Pressure pumping & Pressure

exchanger assembly and wherever required. 3.1.1.24 The outlet pipes for purging lines, exhaust pipe work blowing points etc will be

routed upwards along columns/ gable end walls to a height of 1000 mm above the adjacent roof levels.

3.1.1.25 Platforms and access ladders shall be provided for operation and maintenance

of valves, instruments and controls. 3.1.1.26 All pipe work shall be designed to provide sufficient flexibility and to prevent

development of undesirable forces or moments at points of connection to equipment, at anchorage or at guide points due to thermal expansion.

3.1.1.27 Flexibility shall be provided by changes of direction or by the use of bends,

loops or offsets. Expansion joints of the slip joint or corrugated types may be used in some cases with prior approval.

3.1.1.28 Valves shall be provided on pipe work for line and equipment isolation, control

of pressure, flow and level of fluids, venting, draining, pressure relief etc. They



shall be suitable for the service conditions in all aspects and located considering easy operation and maintenance.

3.1.1.29 The valves provided shall include, but not be limited to the following:

i. Isolating valves at the limits of design, at each sub-header and at each tapping connection;

ii. Isolating and by-pass valves for flow meters, filters, trap assembly etc;

iii. Check valves on all pipelines requiring unidirectional flow; iv. Safety shut-off valves on gas and air lines to furnaces etc;

v. Pressure regulating valves, together with isolating, by-pass and relief

valves;

vi. Manual drain valves at low points and manual vent valves at all high points of pipe work.

3.1.1.30 All valves shall be located with the operating handle/lever/wrench within easy

reach; where necessary, operating platforms shall be provided. Valves located in inaccessible locations such as basements, tunnels, etc shall have remote actuation by means of electric motors, solenoids etc. Such valves shall include all accessories incorporated in the drive assembly for voltage conversion and rectification to suit the power supply.

3.1.1.31 Valves of 250 mm dia. size and above shall be provided with integral by-pass

arrangement for pressure equalization before operation, where required. 3.1.1.32 For all water services with sizes NB 100 and above, butterfly valves may be

used. In addition to the above, diaphragm valves (rubber lined) for all chemicals services are acceptable.

3.1.1.33 All piping shall be grouped where practicable and shall be routed to present a

neat and aesthetic appearance. 3.1.1.34 The piping will be arranged to provide clearance for the removal of equipment

requiring maintenance and for easy access to valves and other piping accessories required for operation and maintenance. Layout drawings will indicate valve orientations and availability of access to valves and specialties. Layout of all piping will ensure that all valves including pneumatic operated & control valves are located as to be accessible conveniently for operation. Valves for operation and maintenance will have 1.0 m clear approach space. The operating hand wheel/ lever centre line shall be kept within 1.2m. If any of the valves are not accessible, suitable access platform will be provided by the contractor.



3.1.2 DEFINITIONS 3.1.2.1 WORKING PRESSURE:

It is the effective operating pressure in kg/cm2g of a piping system. For safety reasons, it shall not exceed the maximum pressure which could develop during abnormal operating conditions in the system under consideration.

3.1.2.2 NOMINAL PRESSURE (Maximum Allowable Working Pressure in

kg/cm2g/design pressure)

It is the pressure in kg/cm2g at which design of all piping elements shall carried out. It shall be obtained by increasing the working pressure of the system to suit the temperature and type of the fluid being carried, as per clause 3.1.2.5. It shall be designated by PN: the typical designation of a piping system where the nominal pressure is 40 kg/cm2g shall be PN40.

3.1.2.3 TEST PRESSURE:

It is the pressure in kg/cm2g to which all the elements of a piping system shall be subjected, to determine their adequacy. The test pressures against various nominal pressures are given in clause 3.1.2.5.

3.1.2.4 NOMINAL DIAMETER (DN)/ Nominal Bore (NB):

Every part of a piping system manufactured by hot and cold rolling methods and/or by piercing and cold drawing shall be identified by its nominal diameter. Up to 300 mm nominal diameter is derived from the approximate inside diameter and in larger sizes this is approximately equal to the outside diameter of the pipe. The nominal diameter of parts of a piping system obtained through fusion and/or casting shall be the inside diameter. This shall be designated DN: the typical designation of a pipeline system where nominal diameter is 50 mm shall be DN 50.

3.1.2.5 PRESSURE-TEMPERATURE RATING PIPE WORK:

Hydraulic systems shall be designed for a nominal pressure of 33.3 per cent above the normal working pressure and tested at twice the nominal pressure; for other systems nominal and test pressures shall be as follows:

Maximum Allowable Working Pressure in kg/cm2g

Nominal Pressure kg/cm2g

Class I For fluids considered

not chemically dangerous and at

Class II For temperatures of 120°C to 300°C and

chemically dangerous

Test pressure kg/cm2g



temperatures not exceeding 120°C

fluids at temperatures below 120°C

1 1 1 2

2.5 2.5 2 4 3.2 3.2 2.5 5 4 4 3.2 7 6 6 5 10

10 10 8 16 16 16 13 25 25 25 20 40 40 40 32 60 64 64 50 95

100 100 80 150 125 125 100 190 160 160 125 240 200 200 160 300

3.1.3 Pipe Sizing 3.1.3.1 P & IDs furnished as contract drawings showing the equipment and valve

requirements are indicative . Contractors are required to carry out the tentative line sizing and furnish the P & ID along with the contract document. Pipe sizing shall be done based on the following velocities as indicated below and the sizes of pipelines will be selected such that the velocity of fluid in pipes does not exceed the velocities indicated herein under conditions of maximum possible volumetric flow.

SL No. Description Velocity in metres/ second Pipe size

below 50 mm Pipe Size 50 to 100 mm

Pipe Size 200 mm & above

a) Pump suction 1.2 – 1.5 1.2 – 1.5 1.2 – 1.8 b) Pump Discharge 1.2 – 1.8 1.8 – 2.4 2.1 – 2.5 (*) c) Header 1.5 -2.4 1.5 -2.4 2.1 -2.4 d Compressed air below

2 Kg/cm2(g) 15 – 20 20– 30 25– 35

e) Compressed air 2 Kg/cm2(g) & above

20 – 30 25– 40 35– 45

f) Suction to compressor/ Blowers

7–8 7–8 7–8

Note (*): Velocity for High Pressure (30 bar& above) Sea Water& Brackish water may be in the range of 2.1 to 3.1 m /sec 3.1.3.2 Pipe line under gravity flow shall be restricted to a flow velocity of 1 m/sec



generally. Channels under gravity flow shall be sized for a maximum flow velocity of 0.6 m/sec.

3.1.3.3 For re-circulation pipes of pumping system intended for agitation, the velocity

limit up to 3.0 to 3.5 m /sec is acceptable. The re-circulation pipes of pumping system shall be sized for a flow as recommended by the pump manufacturer, however the same shall be about 40 to 50% of design flow of one pump.

3.1.3.4 Pipe sizing shall be done considering the above indicated economic velocities. Lower values of velocities than those stated above will be used to determine line size if dictated by considerations of pressure drop, NPSH, surges, water hammer, etc. Consideration shall be given to the available line pressure and the pressure requirement at the point of discharge. Also, liquid lines shall be designed to avoid `hammer’.

3.1.3.5 The design flows considered in line sizing will not be less than the rated capacities of equipment to which the piping is connected such as pumps, valves, flow limiting orifices, clarifiers, sand filters, UF & RO skids etc.

3.1.3.6 The following " C" Value shall be used in WILLIAM & HAZEN formula for

calculating the friction loss in piping systems.

Sl. No Pipe Type “ C” Value i) Carbon Steel pipe 100 ii) Carbon Steel pipe internally lined with

Polyurethane/Solvent free epoxy/ Glass flake polyester acrylic polymer

120

iii) C.I Pipe / Ductile Iron 100 iv) Rubber lined steel pipe 120 v) PVC / HDPE / GRP / CPVC / PP / steel pipe with

cement mortar lining 140

v) Stainless Steel 100 3.1.3.7 For calculating the pump head at the rated capacity, at least 10% margin shall

be taken over the pipe friction losses. 3.1.4 Wall Thickness, Material & Dimensional Standards for Piping & Valves 3.1.4.1 Material of construction for pipes carrying various fluids shall be as detailed in

clause 8.0 of this specification. 3.1.4.2 All piping system shall be capable of withstanding the maximum pressure and

temperature in the corresponding line. The pressure rating of individual piping system component such as valves, flanges etc shall however be not less than



that specified in this specification for the service. 3.1.4.3 Based on the inside diameter established, pertaining to the design velocity

criteria indicated above for line sizing, thickness calculation for metallic pipes subject to internal and/or external pressure shall be made as per ANSI B 31.3. Wherever HDPE piping is envisaged, the pipes that shall be considered shall have pressure rating PN 10, PE 100 as per IS 4984 latest edition.

3.1.4.4 Outside diameter and thickness of metallic pipes shall then be selected as per

the relevant design & dimensional standard of pipes i.e. B 36.10, B 36.19, API 5L, IS 1978, IS 1239, IS 3589 etc). The wall thickness selection for a given pipeline diameter shall be such that the stresses in the pipe wall resulting from the most un-favourable expected combination of loading conditions described are within the permissible limits. The wall thickness selection shall take into consideration the corrosion allowances as recommended by ANSI 31.3 and AWWA and adequate allowances will be made towards corrosion, erosion, thinning due to bending, weakening at branch connections, threading, commercial tolerances on pipe wall thickness, etc. and the same will be subject to approval by Purchaser / Consultant. These corrosion allowances should be subtracted from the wall thickness when calculating stresses for operational conditions However Corrosion allowance of minimum 2 mm shall be included for unlined/ uncoated pipes and 1 mm for lined/coated pipes. Negative tolerance of pipes if any specified by the standard/Code shall be added to arrive at the final thickness. Details of calculations will be furnished.

3.1.4.5 Line thickness for HDPE pipes shall be as per IS 4984/ /EN 12201/AS NZS

4130/ISO 4427 for PN 16/PN 10, PE 100 as per Table 8.3. Incase of steel materials (SS 316L, Duplex steel, Carbon steel, GI), the nominal wall thickness of pipeline will be not less than the minimum acceptable values given in Table -8.1, 8.2, 8.4 & 8.5.

3.1.4.6 Under ground pipe crossings if any (only after approval of

purchaser/consultant) shall be designed for the highest total loading expected. The maximum expected long term radial deflection of the pipe due to dead and live loads shall be calculated using appropriate equations such as the Spangler equation. The maximum circumferential fibre stress in the pipe wall due to the external load shall be calculated using appropriate equations as defined by the design code (API 1102). The design shall be governed by the maximum value of the sum of hoop stress due to internal pressure and the corresponding circumferential tensile stress due to external loading. AWWA-M-11 may be considered as a guideline for such design.

3.1.4.7 All carbon steel metallic pipes up to DN150 mm shall be seamless. Continuous

welded/electric welded/spirally welded pipes as per API – 5 L or IS:3589 shall be acceptable for pipe of size 200 NB and above only. Minimum acceptable length of each pipe shall be 6m. High pressure pipes (600#) with Duplex SS material of construction grade 2205 (UNSS No. 31803) shall be seamless



irrespective pipe diameter. 3.1.4.8 Preferably all steel pipes & valves shall be supplied from the approved

manufactures from their works. 3.2 Fittings & Flanges 3.2.1 Branch connections in piping will be made by the use of wrought or forged

seamless fittings such as tees, laterals and crosses etc . Small stubs as may be required for instrument, drain and vent connection may be provided in the form of weld outlet fittings (for 600# piping class) or forged couplings. Intersection welds are acceptable only in the case of non-standard sizes.

3.2.2 Wherever pipe bends are employed for change of direction the same will be to

a radius of 1.5 times the pipe diameter. 3.2.3 Miter bends will be adopted for piping systems up to a design pressure 10 bar

(g) only. Miter angle will not exceed 22.5°. 3.2.4 Slip-on type of flanges will be used only up to a maximum pressure rating of

ANSI 150 lbs. In case of higher pressure ratings (above 150#) and also for steam applications for all ratings, weld-neck type of flanges shall be employed.

3.2.5 The flanges & fittings thickness and material of construction shall be

compatible and match the pipe thickness (schedule and piping class rating) and material of construction.

3.2.6 The socket welded fittings shall be used only up to 1.5” size and shall have

pressure rating of 1500 lbs & 6000 lbs for 150# piping class & 600# piping class respectively. Butt welded fittings for 2” size and beyond shall be used.

3.2.7 For HDPE fitting and flanges, refer clauses 4.1.4 to 4.1.9 specified herein. 3.2.8 Flanges

a) Flanged connections for pipes are to be kept to the minimum and used only for connections to vessel, equipments, flanged valves and other fittings like strainer/traps/orifices etc. for ease of connection and maintenance etc. However for galvanised pipe for 150 NB and above flange-joined pipes shall be adopted as described above

b) Rubber Lined pipes shall be jointed through flanged connections only c) The field joints of internally glass flake polyester acrylic polymer)

coated smaller size pipes (diameter 150 to 400 NB) may be of flanged type to avoid manual coating at joints.



d) Steel pipe flanges shall be generally slip on flat face/raised face type. Weld neck flanges shall be used when flange follows immediately after a butt welding or where it is required with respect to service conditions. When weld neck or socket weld flanges are used, their bore must be made the same as that of the pipe being welded to. Socket welded or threaded flanges may be used, with the appropriate piping system for connection of pipe to the flanged equipment.

e) All the piping flanges and counter flanges & their drilling shall generally

conform to ANSI B 16.5 of relevant pressure & temperature class. Drilling on flanges of flanged valves must correspond to the drilling of flanges on the piping system on which the valves are installed. However wherever the interference is involved with the Purchaser’s pipe, the flange/interconnection details shall be designed to match the piping and the details of which will be intimated later.

3.2.9 Steel Fittings (Bends/ Elbows/ Mitre Bends/Tees/ Reducers etc):

a) Unless otherwise specified elbows shall be of long radius type b) For pipe sizes up to 65 NB, long radius forged elbows or seamless pipe

bends shall be used. Pipe bends, if used, shall be cold bent to a radius measured to the centre line of pipe of 3 to 5 times the pipe diameter

c) For steel pipes 80 NB and above, seamless long radius forged elbows

shall be used. For pipe size 350 NB and above mitre bends may be used for all pipes except rubber lined or internally coated/ lined pipes. The bend radius shall be 1½ times the nominal pipe diameter. For 90 deg. bends (mitre) 4 pieces (3 cuts) shall be adopted and 45 deg. mitre bends shall be in 3 pieces 22½ deg. Fabrication of mitre bends shall be as detailed in BS 2633/BS534. Mitre bends are not acceptable in case of rubber lined mild steel pipes

d) For carbon steel pipe fittings such as reducers and tees, the material

shall be to ASTM-A234 Gr. WPB up to 300 NB. However, for carbon steel pipes up to 150 NB, pipe fittings may be supplied with material and dimension conforming to IS 1239 in case parent pipes also conform to IS 1239. For pipe reducers and tees above 300 NB, the fittings may be fabricated conforming to parent pipe material. Provision of compensation pads shall be kept as per ANSI B 31.1. The fitting shall conform to the dimensional standard of ANSI B-16.9. For Duplex Stainless steel & SS 316L piping, fittings and flanges shall be forged (wrought) or casting having the same schedule and equivalent material of construction having similar grade. For HDPE piping, the fittings and flanges shall have same PN designation and the flanges shall have carbon steel backing flanges. Nuts & bolts/studs shall be of SS 317 for installation of backing flanges for HDPE piping system.



e) For pipes, above 1200 NB, reducer and tees shall be to dimensional

standard of AWWA-C-208. f) For Mitered fittings to be employed in internally coated (Polyurethane/

Solvent free Epoxy / glass flake polyester acrylic polymer/rubber lining/frp lining) special care shall be taken to ensure that no weld burns, protrusions/ projections or surface irregularities remain before lining material application for internal coating. Such burrs/projections shall be ground smooth to radius of at least 3mm as specified in the relevant clause for surface preparation for lining.

g) For SS 304 & SS 316 piping if applicable, stainless steel fittings shall

conform to either ASTM-A-182 Gr. 304/316 or ASTMA-403 Grade WP. 304/316 Class-S, for sizes up to and including 50 mm NB, i.e. the fittings shall be of seamless construction. However, for stainless fittings above 50 mm NB, the same shall conform to ASTM-A-403 Gr. WP 304/316 Class W i.e. the fittings shall be of welded construction strictly in accordance with ASTM-A-403

h) Unless otherwise shown eccentric reducers shall be installed with

straight side at the top of piping connection. 4.0 Construction, Erection, Testing 4.1 Fabrication 4.1.1 All fabrication shall be carried out in accordance with piping general arrangement

drawings, (prepared by contractor and approved by purchaser/consultant) including this specification and codes as specified in this specification.

4.1.2 Contractor shall be responsible for working to the exact dimensions as per the

approved drawings. Dimensional tolerances to be adopted during implementation of fabrication work shall be as per attached sketch "TOLERANCES FOR FABRICATION".

4.1.3 All pipelines with size greater than NB 50 mm are considered as shop

fabricated piping and detailed piping layout (isometric) drawings will be prepared and submitted for all such pipelines. The drawings will be to scale and will be prepared as plan & sections and will carry the following minimum details:

a) Fully dimensioned layout with locating dimensions referred to plant axes

and coordinates.

b) Details of all stub connections and other welded attachments as required for anchors, restraints, hangers, supports, etc.



c) Mounting and orientation of valves and specialties and maintenance

space requirements. 4.1.4 HDPE pipes shall be jointed with butt, heat fusion joints as outlined ASTM D2657.

All joints shall be made in strict compliance with the manufacturer recommendations. A factory qualified joining technician as designated by the pipe manufacturer or experienced, trained technician shall perform all heat fusion joints in the presence of purchaser/consultant representative.

4.1.5 The HDPE joints shall be made from the same class and type of raw material.

Joints spacing between the walls of two ends shall be minimum 1/16” to a maximum 3/16”.The joints shall be visually inspected as to continuity of “ beads” from the melted material.

4.1.6 The manufacturer of the HDPE pipe shall supply all HDPE fittings, flanges, flange

adaptors and accessories as well as any adaptor and/or specials required to perform the work as shown in the approved drawings and specified herein.

4.1.7 All HDPE fittings and flange materials shall be PE 100, IS 7328 and design

standard shall be relevant parts of IS 8360 or ASTM standards. All fittings shall be butt fused fittings, thermo fused fittings/couplings, (up to 4” pipe dia, socket fused fittings can be used for branches) or flange adaptors.

4.1.8 The HDPE flange adaptors at pipe material transitions shall be backed up by

stainless steel flanges conforming to ANSI B 16.5 and shaped as necessary to suit the outside dimensions of the pipe. The flange adaptors assemblies shall be connected with corrosion resisting bolts & nuts of type SS 316. All bolts shall be tightened to the manufacturer’s specified torque. After installation, bituminous mastic coating to bolts and nuts shall be applied. Flange connections shall be provided with a full face neoprene gasket.

4.1.9 The HDPE pipe support span & installation shall be as per IS 7634 part II. 4.1.10 Flange bolt holes shall generally straddle the established centre lines unless other

orientation is required and as specified in approved drawings. 4.1.11 Threading shall be NPT to ANSI B 1.20.1. Threading shall preferably be done

after bending, forging or heat treatment operation. However if it is not possible, precaution shall be taken to protect threading against deformation. Thread shall be clean cut with no burrs or stripping. Dies shall be new, sharp and properly designed for piping material. Ends shall be reamed to remove burrs.

4.1.12 All threaded joints shall be aligned properly. The pipe entering unions shall be

true to centerlines so as to avoid forcing of union coupling during make up.



Damaged threads shall be cut from the end of run and the pipe shall be rethreaded.

4.1.13 Immediately before testing the piping, all threads of pipe and fittings shall be

thoroughly cleared of cuttings, fuel oil or other foreign matter. The male threads shall be sealed with thread sealant and the piping made up sufficiently for the thread to seize. Sealant shall be teflon tape.

4.1.14 Seal welding of threaded connections when specified shall include the first block

valve, cover all threads. The joint shall be cleaned of all cutting oil and other foreign material and made up dry to full thread engagement. Instrument threaded connections which are frequently subjected to testing and maintenance shall not be seal welded.

4.1.15 All threaded connections shall be protected from rusting by applying greases or oil

when in operating condition. 4.1.16 When socket weld fittings or valves are used, pipe shall be spaced approximately

1/16" to avoid bottoming which could result in excessive weld stress. 4.1.17 Where the ends of the piping components being welded have an internal surface

misalignment exceeding 1.6 mm, the wall of the component extending internally shall be trimmed by machining so that the adjoining internal surface will approximately flush.

4.1.18 Flanges shall be provided on straight lengths at intervals not exceeding 30

metres and at other joints as required for easy erection and maintenance. Flanged joints shall also be provided to match the connecting ends of equipment, valves, fittings etc. Where specific equipment connection necessitates, screwed joints and unions shall be provided.

4.1.19 Galvanized steel pipe work up to DN 65 mm shall be of screwed and socket

construction. Galvanized screwed unions shall be provided at 30 metre spacing on straight lengths and at other joints as necessary for easy erection. Screwed unions shall also be provided at connection to valves etc as required.

4.1.20 All cast iron, ductile iron pipes and fittings shall have socket and spigot ends

and joints made by lead caulking/with rubber ring. Flanged tail pieces shall be provided for mounting of valves or any other flange accessory. Branches up to DN 40 mm shall be made by tapping. In case of a larger branch, socket and spigot tee shall be installed in the line.

4.1.21 All lined pipe work shall have flanged joins. Flanges shall also be provided at both ends of pipe fittings, e.g. bends, tees, reducers etc as well as for connection to equipment and valves.

4.1.22 All stainless steel pipelines shall be of butt or socket welded construction using

shielded arc welding process. Flanges shall be provided on straight lengths at



intervals not exceeding 30 m and at other joints as required for easy erection and maintenance.

4.1.23 Special joints such as flare and compression joints, Victaulic couplings, lapped

joints, bell and spigot joints etc shall be used where required. Such joints shall conform to Indian Standards or other recognized codes such as ANSI code for pressure piping for the services for which they are intended.

4.1.24 Joints shall be assembled with the inside of all pipes and fittings smooth, clean

and free from burrs, blisters, scale, welding slag, sand and dirt. The inside edges of pipes and tubing shall be reamed after cutting to remove burrs. Where required, the inside of weld without backing rings shall be ground smooth.

4.1.25 Flanges shall be drilled off-centre. Flange faces shall be free from particles of

weld metal. Screwed orifice flanges shall be screwed on tight with end of pipe projecting beyond the face of the flange and then the flange face and projecting end of pipe shall be machined to permit both pipe and flange to bear against the gasket.

4.1.26 Screwed Joints (for steel pipes)

Threaded joints shall be made up with a sealing compound, suitable for the service for which the pipe work is intended.

a) Threading of pipes shall be carried out after bending, heat treatment

etc. If not possible, threading may be done prior to these operations but proper care should be taken to protect them from damage.

b) Galvanised pipe shall generally be joined by screwing into sockets. The

exposed threaded portion on the outside of the pipes shall be given a zinc silicate coating. Galvanised pipes shall not be joined by welding. Screwed ends of GI pipes shall be thoroughly cleaned and painted with a mixture of red and white lead before jointing. For galvanized pipe sizes above 150 mm NB, screw & socket jointing as per ASTM-A-865 shall be employed for both pipe-to-pipe and pipe-to-fitting jointing. For pipe to fitting connection since no direct threading can be done on the fittings (supplied as per ASTM-A-234 Gr. WPB and ANSI B-16.9) necessary straight pipe lengths acting as match pieces shall be welded to the fitting at both ends and subsequently the free ends of the straight lengths shall be threaded as per ASTM A-865 for jointing with main pipe. Once welding of fittings with match pieces and threading of free ends of match pieces are over, the entire fabricated piece shall be galvanised, or in case match pipes and fittings are already galvanised before the above mentioned fabrication then suitable application of Zinc-Silicate paste adequately at the welded surface (both in side & out side) after welding with zinc rich electrode, along with the nascent threaded metal portions at both free ends given the same application of



Zinc Silicate paste. Alternatively flanged jointing may be employed for pipe sizes 150 NB and above. However, the contractor shall ensure that the galvanized pipe joints do not fail during hydro test.

c) Teflon tapes shall be used to seal out screwed joints and shall be

applied to the male threads only. Threaded parts shall be wiped clean of oil or grease with appropriate solvent if necessary and allowing proper time for drying before applying the sealant. Pipe ends shall be reamed and all chips shall be removed. Screwed flanges shall be attached by screwing the pipe through the flange and the pipe and flange shall be refaced accurately.

d) For GI pipe sizes from 350 mm NB to 550 mm NB (including 350 NB &

550 NB) wherever applicable, the GI pipes shall be of flanged connection. However, the pipes after welding of flanges shall be completely galvanised. Any site welding done on galvanised pipes shall be done with zinc-rich special electrodes and the welded surfaces whether inside or outside shall be coated with zinc-silicate paste. Seal welding of flanges with zinc-rich electrode will be permitted only when any flange is leak-prone during hydro testing.

e) For pipe sizes 600 mm NB and above, the GI pipes shall be of welded

connection (with zinc-rich special electrodes) followed by application of zinc silicate coating at welded surfaces both inside and outside the pipe, except for the last blank/blind flange, or, equipment connection where application of zinc-silicate paste after welding cannot be done due to inaccessibility of the inside welded surface and where galvanic protection has been impaired due to welding of pipe-to-pipe joint. Thus the last erection joint shall be flanged joint.

4.1.27 Non Metallic Piping System

Non-metallic Pipes shall be fabricated and laid as per recommendations of the Design Standard of the manufacturer adopting proven practice and as per the guidelines elaborated in clause 4.1.4 to 4.1.9 of this specification. Type of Joints shall be selected based on service / pressure and recommendation of design standard joining method, type of preparation of jointing procedure, installation and testing procedure shall be furnished by the pipe manufacturer as per Design Standard,/their proven practice and the same shall be approved by Purchaser/Consultant. Installation and testing shall be carried out under the supervision of the supplier.

4.1.28 Laying, Cutting and Fitting up Extensive use of templates, gauges, plumb lines shall be made for laying, cutting

and fitting up of various piping components for fabrication.



Pipe joints shall be accomplished by butt welding for pipe sizes 2" and above and by screwed coupling for pipes 1½" and below with the exception for utilities piping which shall have socket weld coupling for size up to 1½".

4.1.28.1 Edge preparation for butt weld joints shall conform to ANSI B 16.25. Cutting of

edges shall preferably be done by machine. 4.1.28.2 Pipe bends for piping system below 1½" NB shall be used when called for in

approved arrangement drawings. Cold bending will be implemented with special bending tools with guides to avoid flattening. The minimum radius allowed shall not be less than five times the outside diameter of pipe. Contractor shall obtain COMPANY's approval of bending tool to be used.

4.1.28.3 All branch connection shall be joined to header with full penetration weld.

Reinforcement pads where required shall be added only after external and internal visual inspection of the attachment. Reinforcement pad shall be provided with ¼" tapped weep hole. Weep holes shall be plugged.

4.1.28.4 On completion of both shop and field fabrication, all sub-assemblies shall be

cleaned from the inside and outside by suitable mechanical means ensuring that they are free from all loose foreign materials such as scales, sand, weld spatters, oil, grease, cutting chips etc.

4.2 WELDING (METALLIC PIPING)

For metallic pipes, all heat treatment, welding, post and pre weld temperatures will be as per the code ANSI B31.3, ASME sections V, VIII, IX, IS:823 and IS:1323 and I, & annexure 1.

4.2.1 All joints by electric arc and gas welding processes shall be as per approved

Welding procedure specification (WPS) & Procedure Qualification Record (PQR) (Annexure-1). All welding work shall be carried out by qualified welders as per standard code ASME Section IX (Annexure-1); All filler materials, edge preparation, post-weld treatment etc shall be as per relevant standards. All welds shall be made in such a manner that complete fusion and penetration are obtained without an excessive amount of filler metal beyond the root area. The voltage, amperage and polarity of welding current shall be in accordance with the electrode manufacturer’s recommendations. Reinforcement, if provided, shall be applied in such a manner that it will have a smooth contour merging gradually with the surface of adjacent pipe and welded fittings. Backing rings shall be used where shown in drawings or as directed by the purchaser/consultant or his representative.

4.2.2 Pipe and attachments shall be aligned properly by accurate and permanent

methods prior to welding. If tack welds are used, the tacks shall be either fused into the first layer of weld or else chipped out. All welds shall be built up by the application of multiple beads or passes; the thickness of metal deposited in



each bead or pass shall not exceed 3 mm. Each bead shall be cleaned and, if not a work hardening material, shall be lightly peened before the next bead is laid. The completed weld shall be cleaned of slag and spatter metal on all surfaces and the inside beads shall be ground smooth where practicable.

4.2.3 All welding by the shielded electric arc process shall be done using electrodes

in accordance with the relevant standards. Composition of consumable electrodes or filler rods, in case of non-consumable electrodes, shall be same as that of the parts being welded so that there is no dilution of the alloying components at the welded joints.

4.2.4 Welded carbon steel, SS 316L & duplex/super duplex stainless steel piping

need not be stress relieved except where specified in PQR. Such stress relieving may be done by uniformly heating welded area with nichrome/induction coil to 660± 15° C, holding the temperature for one hour for each 25 mm of wall thickness or fraction thereof, and then cooling at a rate not in excess of 315° C per hour in still air.

4.2.5 Bends, branches, reducers etc may be fabricated from pipe, by cutting and

welding as above, where permitted by the service conditions. Such gusted bends shall have minimum three cuts for an angle above 60° and up to 90° and two cuts above 30° and up to 60°.

4.2.6 Field welding of pipe supports to primary structural members of building and

crane rails etc and field burning or patching of structural members shall not be carried out without approval of the purchaser/consultant.

4.2.7 The blank format for WPS, PQR, welder qualification, electrode qualification

record is given in ASME SECTION IX and contractor shall strictly adhere to these formats and requirements.

4.2.8 In general all steel pipe lines for liquid application of DN 65mm and above, are

to be joined generally by butt welding except the locations where valves/fittings are to be installed with flanged connections. All air lines shall be of screwed or flanged connection as the case may be.

4.2.9 Pipes of 50 NB and smaller shall have socket welded joints for chlorine line.

For water, air and other services where steel pipes are used, joints of this size range shall be screwed/flanged type.

4.3 ERECTION 4.3.1 Pre-fabrication and Field Assembly Extent of pre-fabrication shall be purely at the discretion of contractor keeping in

view the following :-



4.3.1.1 Field joint shall be decided by contractor keeping in view the transportation of pre-fabricated pieces to site.

4.3.1.2 There can be some variations in the dimensions and level appearing in the

arrangement drawings and those actually occurring at site due to minor variations in the location of equipments, structures, cut out etc. Adequate field joints shall be provided, permitting assembly and erection of pipe work without major modification.

4.3.2 Supporting 4.3.2.1 Location and design of pipe supports shown in approved drawings and support

drawings shall be strictly followed. In establishing the location of pipe supports, the contractor should be guided by two requirements (i) The horizontal span must not be so long that sag in the pipe will impose an excessive stress in the pipe wall and (ii) the pipe line must be pitched downwards so that outlet of such span is lower than maximum sag in the span in order to facilitate drainage. The following table gives the spacing for standard weight pipe supports and shall be used in design of metallic piping as a guideline. This tabulation assumes that concentrated loads such as valves and flanges are separately supported. The spacing is based on the pipe filled with water.

Normal pipe size mm 80 100 150 200 250 300 250 400 Maximum span in M 3.66 4.27 5.18 5.79 6.71 7.01 7.62 8.23 Normal pipe size in mm 450 500 600 Maximum span in mm 8.53 9.14 9.75

4.3.2.2 Supports shall be installed in such a way that they do not contribute to over

stressing of a line. 4.3.2.3 Fabrication and erection of additional supporting elements and structural fixtures

which in purchaser/consultant view are required for proper supporting of the system, shall be carried out by contractor at no extra cost.

4.3.2.4 All temporary supports, elements required for alignment, erection and assembly

shall be removed after completion of work. 4.3.3 Equipment hook-up 4.3.3.1 Prior to hook-up, the alignment and trueness of flange faces shall be checked to

ensure that no undue stresses shall be induced in the system while hooking up. 4.3.4 INSPECTION 4.3.4.1 Contractor shall provide all facilities/ assistance to COMPANY for proper

execution of their inspection without any extra charge.



4.3.4.2 All piping work shall be subjected to inspection by purchaser/consultant at any time during fabrication. Contractor shall furnish to purchaser/consultant detailed work programme sufficiently in advance, in order to enable purchaser/consultant to arrange for inspection.

4.3.4.3 The contractor shall prepare a detailed Quality assurance plan (bought out items

& field) in the format attached with the contract and approval shall be obtained from purchaser/consultant well in advance before the start of manufacture/fabrication of items.

4.3.5 Radiography and Inspection of Welds

10% spot radiography with gamma ray or X ray shall be carried out for butt welded joints for piping system of class 600 #. Radiography examination of welds for pipelines, limits of acceptability, repair and removal of defects shall be conducted as per ASME section VIII, ASME SECTION V, API-1104, ASTM E-9 and ASTME-142. Radiographic examination will be carried out by a third party arranged by the contractor.

Weld areas to be radiographed shall be designated by the purchaser/consultant or his representative. Overall 10% of the joints shall be radiographed. Cost towards radiography of the pipelines shall be included in the erection cost of pipeline.

Repeat radiography due to contractors fault or additional radiography necessitated due to poor performance of contractors / welders as per standard procedure for 10% spot radiography shall be done at contractors cost.

Welds found faulty as a result of radiographic, visual or other tests must be chipped off to the satisfaction of the Engineer-in-Charge or his representative and re-welded as per specifications and instructions. The re-welded portion shall be re-tested as per the instructions of the purchaser/consultant or his representative. No claims for compensation whatsoever shall be entertained by the Engineer-in-Charge or Purchase on this account. 100% DP (dye penetrant) test for root pass and other successive pass for but weld and socket welds shall be carried for all metallic pipe joints (carbon steel, SS, duplex steel) of any class rating and the records of such inspection shall be maintained by the contractor and submitted to the client progressively for review.

4.4 PROTECTIVE COATING 4.4.1 All above ground piping system shall be applied with protective coating in

accordance with specification for shop & field painting and specified herein. 4.4.2 Specific technical requirement of laying buried pipe under with anti corrosive



treatment is described in Chapter -8, volume-IIB and specified herein. Pipes laid inside a Hume pipe (in Road/pipe or trench crossings) shall be also be given protective coating as described in this Chapter -8, Volume-IIB

4.4.3 Internal Protection of Steel Pipes: 4.4.3.1 For rubber lined pipe, lining should be applied in two (2) layers, giving a total

thickness not less than 3 mm or as especially specified in the relevant section whichever is maximum. Surface hardness of rubber lining shall be 65 + 5A class.

4.4.3.2 Specific technical requirement of Coating/Internal Lining (glass flake polyester

acrylic polymer) of Piping is described in Chapter-9, Volume IIB.

4.4.4 External Protection of Pipes 4.4.4.1 For Indoor Piping

1) Surface preparation shall be done either manually or by any other approved method.

2) Primer coat shall consist of one coat of chlorinated rubber based zinc

phosphate primer having minimum DFT of 50 microns. 3) Intermediate coat (or under coat) shall consist of one coat of

chlorinated rubber based paint pigmented with Titanium dioxide with minimum DFT of 50 microns.

4) Top coat shall consist of one coat of chlorinated rubber paint of

approved shade and colour with glossy finish and DFT of 50 microns. Total DFT of paint system shall not be less than 150 microns.

4.4.4.2 For Outdoor Piping

1) Surface preparation shall be done by means of grit blasting, which shall

conform to Sa 2-1/2 Swiss Standard. 2) Primer coat shall consist of one coat of epoxy resin based zinc

phosphate primer having minimum DFT of 100 microns. 3) Intermediate coat (or under coat) shall consist of epoxy resin based

paint pigmented with Titanium dioxide with minimum DFT of 100 microns.

4) Top coat shall consist of one coat of epoxy paint suitable pigmented of

approved shade and colour with glossy finish and DFT of 100 microns. Additionally finishing coat of polyurethane of minimum DFT of 25



microns shall be provided. Total DFT shall not be less than 300 microns.

4.4.4.3 Surfaces of insulation, Stainless steel, nickel, copper, brass, gun metal, monel,

aluminium, hastelloy, lead, plastic materials such as HDPE, CPVC, GRP Valve stem, pump shafts, gauges, Bearing and control surfaces, lined or clad surfaces etc need not be painted. However, the external surface of galvanised steel pipe shall be painted as per the above clause.

4.4.4.4 All under ground portion of piping system shall be coated with coal tar primer,

coal tar enamel, inner wrap of fiberglass and final outer wrap of enamel impregnated fibreglass. Total thickness of coating will not be less than 4.0 mm. with coal tar tape or coal tar wrapping. The anticorrosive coal tar tape of 4 mm thick shall conform to IS-10221 and AWWA C 203-93. Contractor shall prepare a procedure for coal tar tape/ coal tar wrapping of buried pipeline for approval of purchaser/consultant. The procedure shall include surface preparation, brand and type of coating to be adopted. Coating of pipes shall not commence without approval of coating procedure. Total thickness to be achieved shall not be less than that specified in the specification herein. Compatible primer and finish coat as recommended by coating manufacturer shall only be applied. Coating integrity shall be checked by "Holiday detector" over full length of coated pipe work. Bond adhesion test shall also be conducted. Coating to be supplied by contractor shall be suitable for design temperature. Where pipelines are buried, underground protection will be provided for the piping system as indicated by any one of the methods specified herein.

4.4.4.5 Once the coating has been accepted by purchaser/consultant, backfiling

operation can be started. In order to protect coated pipe from damage, the excavated trench shall be examined for stone, rock and any other hard substance detrimental to coating. All such substances shall be removed before lowering the pipe in the trench. The sand padding as specified in this specification shall be part of the underground laying of pipelines. No additional payment on account of padding shall however be admissible.

4.5 FLUSHING 4.5.1 Completed piping systems shall be flushed by contractor with fresh water, to

clean the pipe of all dirt, debris, and foreign material. contractor shall prepare a procedure for flushing of the system for approval of purchaser/consultant. Flushing shall not be commenced without approval of flushing procedure.

4.5.2 Contractor shall perform all activities like dismantling and reinstalling of all

strainers, in line instruments etc. before and after completion of flushing. 4.5.3 Flushing shall be considered as complete only after inspection and approval by

purchaser/consultant.



4.5.4 Disposal of muck and flushing media shall be arranged by contractor as directed by purchaser/consultant, in such a manner that it does not spoil the adjacent installation. Contractor shall obtain purchaser/consultant approval regarding the place and method to be adopted for disposal of debris.

4.5.5 Record of flushing giving following details shall be submitted by contractor to

purchaser/consultant for its approval and records :

a) Date of flushing b) Identification of line : flushed-line number

4.6 HYDROSTATIC TESTING 4.6.1 Completed piping system as approved by purchaser/consultant shall be

hydrostatically tested in the presence of purchaser/consultant. The general requirements of hydrostatic testing shall be in accordance with design requirements of this specification and standard codes specified herein.

4.6.2 Contractor shall prepare hydrostatic test procedure based on specified codes.

The hydrostatic test shall commence only after approval of procedure by purchaser/consultant.

4.6.3 Piping system shall be hydrostatically tested to a pressure corresponding not less

than 1.5 times the design pressure. 4.6.4 Fresh water shall be used as test media. Contractor shall locate the source of

water supply and arrange for transportation of water to test site. Contractor shall arrange at his own cost the water analysis and confirm that water is suitable for testing. In case any corrosion inhibitor is to added, the same shall be done after approval of purchaser/consultant.

4.6.5 Lines repaired subsequent to hydrostatic test shall be retested using the same

procedure as originally adopted. However purchaser/consultant may waive such retest in case of minor repairs by taking precautionary measures to ensure sound construction.

4.6.6 All equipment and instruments used for hydrostatic test shall be approved by

purchaser/consultant before start of tests. 4.6.7 Pressure gauges shall be installed on line to measure test pressures. In case of

longer lines two or more pressure gauges shall be installed as directed by purchaser/consultant. One gauge shall be installed at the discharge of the pressurising pump. Pressure gauge used for hydrostatic testing shall be calibrated with dead weight tester in the presence of Engineer-in-charge. Range of pressure gauge shall generally be 1.5 times the test pressure.



4.6.8 Orifice plates and restriction orifices shall not be installed until hydrostatic testing is completed. Temporary gaskets shall be used during testing.

4.6. 9 First block valve of pressure instruments shall be half open & plugged at the time

of hydrostatic testing. Temperature connections shall be blanked off during testing.

4.6.10 All equipments, in line instruments and relief valves shall be disconnected from

piping system by means of blinds during testing. Control valves shall be replaced by spool pieces during testing.

4.6.11 High point vents and low point drain required for testing in addition to those

marked in the drawings shall be provided by contractor at his own cost. 4.6.12 All welded and screwed joints shall be kept clean for detecting leaks during

testing. Test pressure shall be maintained long enough to facilitate complete inspection of the system. Minimum duration of test shall be 6 hours unless other wise specified. Pressurising equipment shall be isolated immediately after test pressure is attained.

4.6.14 After successful completion of hydrostatic testing, the piping system shall be dewatered. All lines shall be completely dried using compressed air. Contractor shall make his own arrangement for supply of compressed air. Drying of lines shall be considered complete on approval by the purchaser/consultant

4.7 Test Records The records in duplicate shall be prepared and submitted by contractor as below :

a) Date of test

b) Identification of pipe tested - line number c) Test pressure

d) Test results

e) Signature of contractor f) Approval signature by purchaser/consultant.

5.0 VALVES, GATES & MISCELLANOUS ACCESSORIES 5.1 General

a) All the equipments such as Valves, Gates and Accessories such as Strainers etc shall be of proven design for the duty conditions and the contractor or manufacturer shall have sufficient experience in using the



above equipments in water treatment application in the plants supplied earlier by them.

b) In case purchase/consultant desires, the experience list/feed back from

the users shall be made available to purchaser/consultant r for any or all the equipments during the detailed engineering phase.

. c) Sizes of the valves shall be same as that of the pipe sizes on which

they are mounted except for the control valves. d) The various equipments shall be installed so that they are easily

approachable for the operating and maintenance personnel. Generally Valves shall be located about 1.2 metre to 1.5 metre from the operating platform and also they shall not preferably be located below the ground level such as in trenches etc. In such cases, extended spindle shall be provided with chain operating from operating floor. Valves which are installed below the ground floor shall be provided with a floor mounted pedestal at the top of the operating floor. The position indicator for such valves shall be also provided along with the stand. However valves which are provided (in the buried pipe line) with a valves chamber, shall have manual operator/Hand wheel inside the valve chamber. The valve chamber shall be provided with built in ladders/staircases and sufficient operating space within the chamber shall also be provided for easy operation of such valves. Wherever necessary for safety purpose, locking device shall be provided. Further, if the valve is not accessible from a nearby available floor, grating or platform, necessary small platforms taking support from available structure for facilitating easy valve operation shall be provided by the contractor wherever necessary in consultation with purchaser/consultant.

e) All the valves, strainers etc. shall be provided with external painting as

that of the interconnected piping as specified in Clause 4.4.4 above. No paint or filter shall be applied until all repairs, hydrostatic tests and final shop inspections are completed, but shall be applied prior to shipment If during transport, unloading/unpacking or erection at site any part of the painted surface gets damaged, the same shall be made good by the contractor by repainting to the satisfaction of the purchaser/consultant.

5.2 Valves

Valves will be used to start/stop or control flow. Gates will be primarily used for isolation of flow in open channels although these should be capable of throttling the flow too. Sample valves will be used in sample collection lines. Unless otherwise specified all the Valves shall be supplied with counter flanges by the contractor compatible to the pipe material of construction.



5.3 Types of Valves and Material of construction for Valves carrying various fluids shall be as per Tables- 8.1,8.2,8.3,8.4,8.5 of this specification and indicative P &ID no. MEC /10EP/ 01 /01 /PID /0001, 0004, 0005, 0006, 0008, 0009, 010, 0011, 0013, 0014,0015,16 & valves data sheet enclosed with the contract document.

5.4 General Design & Construction Requirements of Valves 5.4.1 All valves, shall be suitable for service conditions i.e. flow, temperature and

pressure under which they are required. All the valves shall be of standard pressure rating of the relevant design standard. Non standard pressure rating shall not be accepted. The pressure and temperature rating of the valve shall be selected based on than the maximum expected pressure and temperature of the system in which valves are proposed to be installed.

5.4.2 Type of Actuators shall be as per the valve tag number & legend indicated in

the P&ID number MEC/10EP/01/01/PID/0001,0004,0005,0006,0008,0009, 0010,0011,0013,0014,0015,0016. The motorized/pneumatic actuator requirement shall be as per the bill of quantities Vol.-IV, enclosed valve data sheets-Chapter-2, Annexure-A of Vol.-II A. The motorized/pneumatic actuator specification requirement and its relevant Instrumentation , control & automation shall be as per Annexure A,B & C of this specification . All the actuators of the valves shall be designed to handle the maximum expected pressure differential across the valves and to overcome friction forces including that of the bearing surfaces and unbalance forces due to the flow through valve. Pneumatic actuated valves shall be used unless and until special technical requirement calls for other type of actuators.

5.4.3 The valves as well as all accessories shall be designed for easy disassembly

and maintenance. 5.4.4 All rising stem valves shall be provided with back seat to permit repacking (of

glands) with valves in operation. All valves shall preferably be of outside screw and yoke type.

5.4.5 All valves shall be closed by rotating the hand wheel in the clockwise direction

when looking at the face of the hand wheel. Suitable gearing arrangement shall be provided wherever input torque at hand wheel rim exceeds 25 kgf or provision of gear is standard practice of the valve manufacturer.

5.4.6 All valves shall have indicators or direction clearly marked on the hand-wheel

so that the valves opening/closing can be readily determined. 5.4.7 Special attention shall be given to operating mechanism for large size valves

with a view to obtaining quick and easy operation ensuring that a minimum of maintenance is required.



54.8 The valves coming in vacuum lines shall be of extended gland type and/or water sealed.

5.4.9 The actuator-operated valves shall be designed on the basis of the following:

(1) The internal parts shall be suitable to support the pressure caused by the actuators;

(2) The valve-actuator unit shall be suitably stiff so as not to cause

vibrations, misalignments, etc. (3) All actuator operated valves shall be provided with manual override

having hand wheel or lever with or without gear mechanism as per the torque limits. All actuator operated valves shall be provided with hand operated gearing mechanism also.

(4) All actuators operated valves shall open/ close fully within time required

by the process but not later than 60 seconds after actuators starts. 5.4.10 All valves shall be of the same pressure rating as piping class in which it is

envisaged to be installed. 5.4.11 All valves shall be provided with embossed name plate giving details such as

tag number, type, size etc. 5.4.12 All valves except those with rising stems shall be provided with continuous

mechanical position indicators; rising stem valves shall have only visual indication through plastic/metallic stem cover for sizes above 50 mm nominal bore.

5.4.13 End Connections

The end connections, shall comply with the following:

a) Socket welding (SW) -ANSI B 16.11 b) Butt Welding (BW) -ANSI B 16.25.

c) Threaded (SC) -ANSI B 2.1

d) Flanged (FL)-ANSI B 16.5& AWWA-C-207(steel flanges), ANSI B 16.1

(Cast Iron flanges), BS-EN -1092.

All cast iron\ ductile-Ni iron body valves (gate, globe and non-return) shall have flanged end connections, (screwed ends for cast iron or D.2NI body valves are not acceptable). All steel and stainless steel body valves of sizes 65 mm and above shall



generally have flanged or butt welding ends. Valves of sizes below 65 mm shall have flanged or socket welded ends. Compatibility of welding between valve body material and connecting pipe material is a pre-requisite in case of butt-welded joints. All gun metal body valves shall have screwed ends. All flanged end valves/specialties. shall be furnished along with matching counter flanges, fasteners, gaskets etc. as required to complete the joints.

5.5 GATE /SLUICE VALVES

a) Gate/sluice valves shall be used for isolation of flow. Gate valves shall be provided with the following accessories in addition to other standard items:

(1) Hand wheel (2) Position indicator (for above DN 50 mm valve size). (3) Manually operated Valves of size DN 200 mm and above shall be

provided with gear operator. Gear operator for lower size of valves may be provided if the system parameters so warrant or manufacturer so recommends.

(4) Bypass Valve as required wherever high differential across the valves. (5) Draining arrangement wherever required. b) All gate valves shall be of the full-way type, and when in the full open

position the bore of the valve shall not be constricted by any part of the gate. Gate valves shall be of the solid/elastic or articulated wedge disc and rising stem type, but shall be of proven design and usage in similar services.

c) Sluice /Gate Valves shall conform to BS:5150/ BS:5163 / IS:14846/ API

600/ANSI B 16.34. Gate valves for sizes DN 50 NB mm and below shall conform to IS:778.

d) Sluice/Gate Valves shall be provided with back seating bush to facilitate

gland renewal during full open condition. e) All gate valves shall preferably be rising stem type and shall have limit

switches for full OPEN and full CLOSED indication wherever required. This will include motor-operated valves also wherever required.

f) For Cast Iron gate valves wherever thickness of body/bonnet is not

mentioned in the valves standards, thickness mentioned in IS-1538 for



fitting shall be applicable.

5.6 GLOBE VALVES

(a) Globe valves shall be generally used for regulation purposes. They shall be provided with hand wheel, position indicator, draining arrangement (wherever required) and arrow indicating flow direction.

b) Globe Valves shall conform to BS:5352 up to 1.5” valves & 2” and

above BS: 1873 . c) All globe valves shall preferably be rising stem type and shall have limit

switches for full OPEN and full CLOSED indication wherever required. This will include motor-operated valves also wherever required. In such cases the limit switches shall form an integral part of the valve.

d) Manually operated Valves of size 200 mm NB and above shall be

provided with gear operator. e) For Cast Iron globe valves wherever thickness of body/bonnet is not

mentioned in the valves standards, thickness mentioned in IS-1538 for fitting shall be applicable.

e) The globe valves shall have the following characteristics:

i) Straight conveyed flow. ii) Right angle preferably, the valves shall be of the vertical stem type. iii) Globe valves shall preferably have radial or spherical seating and discs

shall be free to revolve on the spindle. iv) The pressure shall preferably be under the disc of the valve. However,

globe valves, with pressure over the disc shall also be accepted provided no possibility exists that flow from above the disc can remove either the disc from stem or component from disc and manual globe valves can easily be operated by hand. If the fluid load on the top of the disc is higher than 40-60 KN, bypass valve shall be provided which permits the downstream system to be pressurised before the globe valve is opened.

f) Globe valves with Nominal Bore smaller than or equal to 50 mm NB

shall be preferably of the integral body type. Valves of this type shall be so as to permit the easiest disassembly of the internals (stem and disc).

g) For the regulating valves, valves with regulating plug & parabolic outline

disc type is preferred.



h) All motorised globe valves with regulating plug for which indication of percentage (%) opening are required in the control room shall be provided with necessary position transmitter.

i) Design Standard of Globe Valves shall be generally IS:778/ BS 5152/

ANSI B 16.34 / Equivalent

5.7 CHECK VALVES a) Check valves shall be used for non-return service. They shall be swing.

check type or double door (Dual plate)check type with a permanent arrow inscription on the valve body indicating the fluid flow direction.

b) In long distance pipe-lines with possibility of surge-occurrence, dual

plate check valves are preferable for its spring controlled opening /closing of flaps/doors against flow reversals.

c) However, dual plate check valves shall not be used for sizes more than DN 600 mm. d) Design Standard of Check Valves shall be IS:778 / IS:5312/ BS:1868/

BS:5153 / API 594/ API 60(6D) or Equivalent. e) For Cl check valves wherever thickness of body/bonnet is not

mentioned in the valves standards, thickness mentioned in IS-1538 for fitting shall be applicable.

f) Check valves shall generally comply with the following characteristics:

i) For bore greater than 2" the valves must be swing check type or dual

plate check type suitable for installation in all positions (vertical and horizontal);

ii) For bore smaller than or equal to 2" the valves must be of the piston

type to be installed, in horizontal position. iii) In the case of swing check valves, the body seat shall be inclined at

such an angle from the vertical as will facilitate closing and prevent chatter.

iv) Dual Plate check valves shall be double flanged type. However up to

150 NB size, Dual plate check valves of lugged wafer construction are also acceptable.

v) Drilling on flanges of flanged valves must correspond to the drilling on

flanges of the piping system on which the valves are to be installed.



vi) All flanged valves intended for installation in steel piping systems shall have their flanges drilled to ANSI B 16.5 (or equivalent) and according to the pressure class.

vii) Counter flanges to be installed on air pipes shall be screwed-on type

irrespective of size or welded flanges followed by hot-dip galvanising to ensure Zinc Layer.

5.8 BALL VALVES

a) Design Standard of Ball valves shall be BS-5351 latest version. b) Ball Valves shall be with welded / flanged ends, Split Body & Seat

supported construction. c) Manually operated Valves of size DN150 mm and above for class 150#

rating and 100 NB and above for other higher class rating shall be provided with gear operator.

d) All the valves shall be provided with an indicator for showing the

position of the ball port. e) Valves shall be designed to be directly operable by a wrench/ Hand

lever. Suitable stops shall be provided for both the fully open and close condition.

f) Anti-static device shall be provided for the ball valves. g) Valves shall be generally Full Bore type. However for sizes below 80

NB the reduced-bore design may be provided for handling clear fluid. h) If the Ball valves are used for hazardous chemicals, air etc where

leakage is not tolerated, they shall be of Fire safe design & tested to API-607

5.9 BUTTERFLY VALVES

a) The valve rating of butterfly valves shall be selected based on the for

the design pressure/temperature. b) The design standard of butterfly valves shall conform to latest revision

of AWWA C –504 or BS: EN:593 or API 609. Lug and wafer type category A valves shall be used for sizes up to 2” and for 3” and above, category B double flanged valves for 3” to 24” (double flanged) of required class/rating. For sizes above 24”, the valves of suitable class



and rating as per ISO 5752, MSS-SP-68 shall be used. c) Fabricated steel butterfly valves instead of cast Iron body valves are

also acceptable for large size i.e. 600 mm NB and above for ordinary water application other than sea-water, Brackish Water and DM water.

d) Proof of Design (P.O.D.) test certificates shall be furnished by the

contractor for all applicable size-ranges and classes of Butterfly valves supplied by them. In the absence of certificated, actual P.O.D. test shall be conducted by the contractor in the presence of Purchaser/client's representative. All valves that are designed and manufactured as per AWWA-C-504 shall be governed by the relevant clauses of P.O.D. test in AWWA-C-504. For Butterfly valves designed and manufactured to EN-593 or API 509.or SO 5752, MSS-SP-68 , the P.O.D test methods and procedures shall generally follow the guidelines of AWWA-C-504 in all respect except that Body & seat hydro test and disc-strength test shall be conducted at the pressures specified in EN-593 or API 509.or SO 5752, MSS-SP-68 as per the applicable code. Actuators shall also meet requirement of P.O.D. test of AWWA-C-504.

e) The valves shall be suitable for installation in any position

(horizontal/vertical etc.) and shall be of double-flanged construction. However, for sizes DN 50 mm and below the valves may be of double flanged or lugged wafer construction.

f) The Geometry, overall dimensions, laying length, body shell thickness,

shaft diameter, shaft torque value shall be as per design standard adopted and of applicable design class. For Valves of sizes not covered in AWWA C-504 (which are designed as per AWWA C-504), the same shall be extrapolated. For valves designed as per AWWA C-504, valve flanges shall conform to ANSI B16.1 Class 125 for Cast Iron Valves and AWWA C 207 Class D for fabricated type. The counter flanges shall conform to AWWA C-207 Class D. For Valves designed as per BS: EN: 593 or API 509.or SO 5752, MSS-SP-68, the flanges shall conform to relevant pressure class/rating.

g) For all types of valves, the design with shaft eccentric to the disc is

preferred. The shaft shall be solid type and shall pivot on bushings. Bushings/sleeve type bearings shall be contained in the hub of valve body. The bearing shall be self-lubricated type with low coefficient of friction and should not have any harmful effect on fluid handled and on valve components.

h) All the butterfly valves shall be provided with Hand wheel or lever as per

the requirements. i) For larger sizes i.e. 150 NB and above hand wheel shall be provided.



For lever/wrench operated valves, means shall be provided for positively holding the disc in not less than three intermediate positions.

j) Valves shall be provided with reduction gear unit for valves of size 250

NB and above. Valve provided with motorised or pneumatic actuator shall also be provided with a hand wheel & Gear reduction unit for manual operation. Manual operation of valve shall be through gear arrangement having totally enclosed gearing with hand wheel diameter and gear ratio designed to meet the required operating torque It shall be designed to hold the valve disc in intermediate position between full open and full closed position without creeping or fluttering. All the valves shall be provided with adjustable stops shall be provided to prevent over travel in either direction.

k) The seals, both on the body (sleeve) and on the disc shall be of the

material specified. Necessary shaft seal shall be provided and adequately designed to ensure no leakage across the seal. This seal shall be designed so that they will allow replacement without removal of the valve shaft. The sealing ring on the disk shall be continuous type and easily replaceable.

l) The design of the shaft shall be such that it will safely sustain maximum

differential pressure across the closed valve. The shaft and any key (taper pin etc.) for transmitting the torque between shaft and disc shall be capable of withstanding the maximum torque required to operate the valve. However ,the shaft diameter shall not be less than the minimum shaft diameter specified in relevant code. Necessary Torque Calculation and the torque class selected on the basis of the same shall be furnished to the Purchaser/client for information if required.

m) The disc shall rotate from the full open to the tight shut position. The

disc shall be contoured to ensure the least possible resistance to flow and shall be suitable for throttling operation. While the disc is in the throttled position, valve shall not create any noise or vibration.

n) The operating mechanism shall be mounted directly on or supported

from the valve body. o) All valves shall be complete with Position indicator (located in a visible

place) arrow indicating the flow direction and adjustable mechanical stop limiting devices to prevent over-travel of valve disc in open/close position.

p) Hand operated valves shall have local hand controls to close the valve

with clockwise rotation & to provide an easy maneuver under most severe conditions. The hand controls shall be provided with locking systems suitable to avoid the disc assuming a non-desirable position



during the operation. q) Hand wheel shall be with arms and rims of adequate strength. The hand

wheel of diameters 300 mm or less shall be provided with handles for ease of operation. The pulling force required on the hand wheel rim shall not exceed 25 Kgf when operating the valve under full flow and operating pressure.

r) Valves DN 350 mm and above shall have pressure equalizing bypass

valves, wherever system parameters warrant the same. s) Limit and torque switches (if applicable) shall be enclosed in water tight

enclosures along with suitable space heaters for valves, which may be either for On-Off operation or inching operation with position transmitter.

5.10 FLOAT OPERATED VALVES

a) Valve shall automatically control the rate of filling and will shut off when

a predetermined level is reached and close to prevent over flow on pre-set maximum water level. Valve shall also open and close in direct proportion to rise or fall of water level.

b) Design and Construction Features

i) Valves shall be right angled or globe pattern. ii) Valves shall be balance piston type with float ball. iii) Leather liner shall not be provided.

c) For raw / clarified water /filtered water application, the body and cover

material shall be cast iron conforming to ASTM-A 126 Grade 'B' or IS:210 Grade 200 or equivalent, and Float shall be of copper with epoxy painting of two (2) coats.

d) Valves shall be suitable for flow velocities of 2 to 2.5m/sec. e) The valves shall have flanged connections.

5.11 PRESSURE SAFETY/RELIEF VALVES

The safety valves / relief valves at the down stream of positive displacement type metering pumps shall be of the standard type manufactured by the pump manufacturer and the material of construction shall suit to the fluid handled .the safety relief valve/pressure safety valve shall be as per API 520.



5.12 Automatic Air Release Valves

a) The automatic air release cum vacuum breaker valves shall be of automatic double air valve with two orifices and two floats conforming to IS : 14845. The float shall not close the valve at higher air velocities. The Orifice Contact joint with the float shall be leak tight joint. An isolation valve shall be provided for each release valve. The Air release valve in cross country application shall be provided with a suitable enclosure with locking arrangement so that the same is not tampered.

b) Air release valves shall not have any integral isolation device within

them. Each Air release valve shall be mounted, preceded by a separate isolation gate/ butterfly valve.

c) The valve shall efficiently discharge the displaced air automatically form

ducts/ pipes while filling them and admit air automatically into the duct/ pipes while they are being emptied. The valve shall also automatically release trapped air from ducts/ pipes during normal working at the normal working pressure.

d) Material of construction of automatic air release valves for other than

corrosive water such as sea water, brackish & brine water shall be as follows.

i) Body & Cover : Cast iron IS-210 Gr. FG 260 ii) Ball, small orifice : Nitrile Rubber iii) Ball, large orifice : Vulcanite(ebonite) iv) Splash Cover : Cast iron IS-210 Gr. FG 260 v) Ball seat : 13% Cr. Stainless steel vi) Spindle : SS 316 vii) Gasket Nitrile Rubber

e) However, for corrosive fluids such as sea-water, brackish & brine water

Body of the air release valves shall be ASTM-A-439 (D2-NI) and internals of Stainless Steel -Super Duplex SS

5.13 MISCELLANEOUS PIPING ACCESSORIES

5.13.1 Basket type Strainers

a) The strainer shall be provided with screwed blow off connection fitted

with a removable plug and vent connections.



b) The free area of the strainer element shall be at least four (4) times the internal area of the connecting pipe lines. Flow area in any portion of Basket strainer assembly shall not be less than the pipe cross sectional area.

c) The strainer element shall be 20 mesh. Pressure drop in clean condition

shall not be more than 4.0 MWC d) Wire mesh of the strainers shall be suitably reinforced, to avoid buckling

under operation. Strainer shall have screwed blow off connection fitted with a removable plug.

e) The strainer will have a permanent stainless steel tag fixed on the

strainer body indicating the strainer tag number and service and other salient data.

f) The size of the strainer and the flow direction will be indicated on the

strainer body casting. g) Thickness of the strainer element should be designed to withstand the

pressure developed within the strainer due to 100% clogged condition exerting shut-off pressure on the element.

h) The material of construction of various parts shall be as follows:

i) Body a) For potable water application

IS: 318, Gr.2 upto DN 50 mm, and IS:210 Gr. FG 260 or Fabricated mild steel : IS:2062 Gr B/ ASTM-A-515 Gr 70/75 (Tested quality) for sizes above 50 mm NB

b) For DM water & Alkali

Carbon steel IS: 2062 Gr B/ CI IS :210 FG Gr 260 internally lined with 4.5 mm thick rubber OR Stainless Steel AISI 316.

c) For Sea Water & Brine

A-439 D2-Ni/ Duplex SS (2205) for Size above 50 NB with epoxy painted internals and AISI 316L / Duplex SS (2205) for size DN 50 mm & below

ii) Strainer Element

Wire shall be stainless steel (AISI:316) for non-sea water application and Duplex SS-2205 for sea water application

iii) Drain plugs/ Nuts

SS-316L



i) Ends shall be screwed up to DN 50 mm and flanged above DN 50 mm. Gasket shall be of full face type

j) Duplex type Strainer shall be provided with lifting lugs Duplex strainers

shall not be supported on pipes but shall be supported on a concrete foundation.

k) Duplex type strainers shall have manual / auto change-over facility for

each strainer section by means of 3-way valve or flow diverter arrangement, supplied as a standard feature along with the Duplex strainer both at inlet and outlet of the strainer. Change-over of each strainer section (basket) shall be done based on Differential Pressure across the strainers

5.14 Y-Type Strainers

a) Y-Type strainers shall in general conform to requirements specified for Basket strainers under Clause. 5.14 (a) to (i) above.

b) Ends of Y-type strainers shall be flanged: c) For acid services, apart from the rubber lined body material, the screen

material, shall be Polypropylene or HDPE wire cloth of suitable mesh and thickness.

5.15 Strainers for the application of chlorine gas (Wet / Dry) and liquid chlorine shall

be of standard make and type of the chlorination plant manufacturer and material of construction shall be suitable for the duty conditions.

6.0 TESTING FOR VALVES 6.1 TESTS AT SITE

All valves, Gates, strainers and other fittings after erection at site shall be tested to hydraulically test pressure along with piping as per Field Quality Plan and as specified in this piping specification. All valves/gates (Manual/Automatic) shall be operated through-out 100% of the travel manually and as well as from control panel (if applicable) and these should function without any trouble whatsoever.

7.0 LIST OF STANDARDS

MAJOR STANDARDS AND CODES



IS :5 Colour ready made paints and enamels IS : 210 Specifications for grey CI Castings IS : 554 Pipe thread for pressure tight joints IS : 778 Gunmetal gate, globe and check valves for general purpose IS : 800 Code of practice for use of structural steel in general building

construction IS : 816 Code of practice for use of metal arc welding for general construction

in mild steel. IS : 817 Code of practice for training and testing of metal arc welders IS : 822 Code of procedure/practice for inspection of welds IS : 1079 Hot rolled carbon steel sheet and strip. IS : 1239 Mild steel tubes and fittings -Part I & II IS : 1363 Black hexagon bolts, nuts and lock nuts. IS : 1367 Technical supply condition for threaded steel fasteners introduction

and general information. IS : 1364 Precision and semi-precision hexagon bolts, screws, nuts and lock

nuts. IS :1367 Technical supply condition for threaded steel fasteners introduction

and general information IS : 1477 Code of practice for painting of ferrous metals in building IS : 1538 Cast iron fittings for pressure pipes for water, gas and sewage IS: 1703 Ball valves (horizontal) plunger type including floats for water supply

purposes. IS : 1875 Specification for carbon steel billets,, blooms,, slabs and bars for

forging. IS : 2016 Plain washers IS : 2062 Structural steel fusion welding quality IS : 2379 Colour for the identification of pipe line. IS : 2685 Code of practice for erection, installation, and maintenance of sluice

valves IS : 2712 Gaskets. IS : 2825 Code of unfired pressure vessels IS : 2937 Specification for enamel, synthetic, exterior type-1.

i) Under coating ii) Finishing IS : 3042 Single faced sluice gates (200 to 1200 mm) IS : 3114 Code of practice for CI Pipes IS : 3138 Hexagonal bolts and nuts (M -42 to M 150). IS : 3589 Electrically welded steel pipes for Water gas & sewage (200 to 2000

mm). IS : 4038 Foot valve for water works purposes. IS: 4682 Code of practice for lining of vessels and equipment for chemical

processes Part 1 Rubber lining IS : 4736 Hot dip zinc coating on steel tubes. IS : 4984 High Density polyethylene pipes IS : 4985 Unplasticised PVC Pipes



IS : 5312 Swing check type reflux (non-return) valve Part-I. IS : 9404 Colour code for identification of pipelines used in thermal power plants IS : 10221 Code of practice for coating and wrapping of underground mild steel

pipelines IS : 14846 Sluice valves for water purpose. BS : 534 Steel pipe fittings and specialties for water, gas sewage BS : 916 Black bolts, screws and nuts BS : 1868 Specification for steel check valves flange and butt welding ends. BS : 2633 Specification for class -I arc welding of ferritic steel for pipe work

carrying fluids BS : 4360 Weldable structural steel. BS : 4504 Flanges and bolting for pipes, valves and fittings metric series BS : 5142 Cl globe valve BS : 5150 Cast iron wedge and double disc gate valves for general purposes BS : 5152 Specification for CI globe, stop and check valves for general purpose BS : 5153 Cast iron check valves for general purpose. BS : 5154 Copper alloy globe/globe stop and check and gate valves for general

purpose BS: EN 593 Industrial Valves – Metallic Butterfly Valves BS : 5156 Standard for Diaphragm valve. ASTM-A 106 Gr.C Seamless carbon steel pipe ASTM -53 Seamless carbon steel AWWA-C 200 Steel water pipe 6" and above. AWWA-C 203 Coal tar protection coating and lining of steel water pipelines AWWA-C-504 Rubber seated butterfly valve AWWA M11 Steel Pipe – A Guide for design and installation ANSI B 2.1 Dimensions of American taper pipe threads ANSI B 16.1 Cast Iron Pipe flanges and flanged fittings ANSI B 16.5 Steel pipe flanges ANSI B 16.9 Factory made wrought steel butt welding fittings ANSI B 16.10 Face to face and end to end dimension of ferrous valves ANSI B 16.11 Forged steel fittings (socket-welding and threads) ANSI B 16.21 Non-metallic gaskets for pipes flanges ANSI B 16.25 Butt welding ends. ANSI B 16.28 Steel short radius fittings ANSI B 16.34 Steel valves flanged and butt welding ends ANSI B31.1 Power piping code ANSI B31.3 Process Piping ASTM A-36 Structural steel ASTM A-5 Pipe, steel block and hot dipped zinc coated welded and seamless.



8.0 PIPING MATERIAL SPECIFICATION (MOC OF PIPES,FITTING & VALVES)

TABLE:8.1

PIPE CLASS SS 316L RATING ANSI CLASS # 150 BASE MATERIAL STAINLESS STEEL –SS316L CORROSION ALLOWANCE: 0MM TEMP.( DEG.C) & PRESS.( KG/CM2) RATING

TEMP. 15 45 PRESS. 19.38 18.26

SERVICE: REVERSE OSMOSIS PERMEATE,SERVICE WATER, SULPHURIC ACID,CARBON DI-OXIDE.

SPECIAL NOTES: SINGLE PIPE LENGTH SHALL BE 12 M. ITEM SIZE DESCRIPTION

MAINT. JOINT ALL FLANGED TO BE KEPT MINIMUM 1.5" & BELOW SW COUPLING , 3000 lbs PIPE JOINTS 2.0" & ABOVE BUTT WELDED

ON LINES < =1.5" AS PER P & ID DRAINS ON LINES>=2.0" AS PER P & ID

ON LINES < =1.5" AS PER P & ID VENTS ON LINES < 2" AS PER P & ID

TEMP. CONN. 1.5"NB FLANGED INSTALLATION PRESS. CONN. 0.75" SW SC # 80 NIPPLE WITH GATE VALVE



36 E 36 34 E R 34 32 E R R 32 30 E R R R 30 28 E R R R R 28 26 E R R R R R 26 24 E R R R R R R 24 22 E R R R R R R R 22 20 E R R R R R R R R 20 18 E R R R R R R R R R 18 16 E R R R R R R R R R R 16 14 E R R R R R R R R R R R 14 12 E R R R R R R R R R R R R 12 10 E R R R R R R R R R R R R R 10 8 E P R R R R R R R R R R R R R 8 6 E P P R R R R R R R R R R R R R 6 5 5 4 E P P P R R R R R R R R R R R R R 4

3.5 3..5 3 E P P P P R R R R R R R R R R R R R 3

2.5 2..5

BR

AN

CH

PIP

E S

IZE

( SI

ZE

IN IN

CH

ES)

2 E P P P P P R R R R R R R R R R R R R 2 1.5 T H H H H H H H H H H H H H H H H H H H 1..5 1.25 1..25 1 T T H H H H H H H H H H H H H H H H H H H 1 0.75 T T T H H H H H H H H H H H H H H H H H H H 0.75 0.5 T T T T H H H H H H H H H H H H H H H H H H H 0.5 0.

5

0.8 1 1.3

1.5 2 2.5 3 3.5 4 5 6 8 10

12

14

16

18

20

22

24

26

28

30

32

34

36

RUN PIPE ( SIZE IN INCHES )

CODE DESCRIPTION T : TEES SW E : TEE BW H : HALF COUPLING P : PIPE TO PIPE R : REINFORCED



Pipe Group

Input Id. ITEM TYPE

Lower size

( inch)

Upper size

( inch) Sch/Thk Dmn. Std Material Description

PIP PIPE 0 1 ½”" 40 S / S 40(STD.)

ANSI B-36.19M/B36.1

0M ASTM A 312 TP 316L SEAMLESS

PIP PIPE 2” 6" 10 S ANSI B-36.19M ASTM A 312 TP 316L SEAMLESS

PIP PIPE 8” 12" S20. ANSI B-36.10M ASTM A 312 TP 316L Welded

PIP PIPE 14” 18" STD. ANSI B-36.10M ASTM A 312 TP 316L Welded

PIP PIPE 20” 24" S20 (STD.) ANSI B-36.10M ASTM A 312 TP 316L Welded

PIP PIPE 26” 36" S20 (XS) ANSI B-36.10M ASTM A 312 TP 316L Welded

Fitting Group

ELB 90 ELBOW 90 1/2" 1 1/2”

Fittings thickness & tolerance shall match with the pipe thickness &

tolerance

Forged steel SW and

threaded -ASME/ANSI

B 16.11.

ASTM A 182 GR.F. 316L

SW

Flange Group

FLG FLNG. Slip on 1/ 2" 1 1/2”

Flange thickness shall match with pipe thickness

ANSI B-16..5 ASTM A 182 GR.F 316L

150#,RF/125-250u IN AARH

FLG FLNG. Slip on 2" 24”



150#,RF/125-250u IN AARH

FLG FLNG. Slip on 28" 36”


ANSI B-16..47

series B ASTM A 182 GR.F 316L

150#,RF/125-250u IN AARH

FLB FLANGE

BLIND 2" 24" Flange thickness shall match with pipe thickness


150#,RF/125-250u IN AARH

FLB FLANGE

BLIND 26" 30" Flange thickness shall match with pipe thickness


150#,RF/125-250u IN AARH



ELB 90 ELBOW 90 2" 36” “ BW fittings- ASME/ANSI

B 16..9

ASTM A 403 GR.WP 316L BW

Input Id. ITEM TYPE

Lower size

( inch)

Upper size


ELB 45 ELBOW 45 4" 12" “

BW fittings- ASME/ANSI

B 16..9


T EQ T. EQUAL 2" 30” “ BW fittings- ASME/ANSI

B 16.9


TUNEQ. T.UNEQUAL 2” 30” “


B 16.9


REDC REDUC. CONC 1 1/2" 2" “

Forged steel SW and

threaded -ASME/ANSI

B 16.11.

ASTM A 182 GR.WP 316L SW

REDC REDUC. CONC 3" 30" “


B 16..9


REDE REDUC. ECC 2" 24" “


B 16.9


HC HALF

COUPLING

1 / 2 “ 1 1/2 “ 3000 lbs ASME/ANSI B 16.11

ASTM A 182 Gr F 316 L BW



Valve Group

CHV-

VLV. CHECK 3/4" 1 ½” # 800 BS-5352

BS-6755, PART-1

Body & Cover,hinge disk/Door-ASTM A 182 GR. SS 316L

Hinge pin & Door/disc pin -

ASTM A 182Gr.SS316L

Socket Weld end (weld end of the valve shall be as per the corresponding fitting ends of the piping class, unless otherwise specified

CHV-

VLV. CHECK 2” 24” # 150 BS-1868

BS-6755, PART-1

Body & Cover-ASTM A 351 GR. SS316L Hinge-

ASTM A 351 Gr.SS316L

FLGD #150/B.16.5 RF/125 AARH

GTV

VLV. GATE 1/2" 1 ½” # 800 API-

02/IS:778 API-598

Body & bonnet-ASTM A 182

SS316L,Stem,Wedge disc, Seat ring,

Back seat-SS316L,Gland

packing- Grafoil.

Socket Weld end (weld end of the valve shall be as per he corresponding fitting ends of the piping class, unless otherwise specified

GTV

VLV. GATE 2” 24” # 150

API-00/BS:515/BS:5163/IS:14846

API-598

Body/Bonnet-ASTM A 351 GR. 316L,Trim -A 473 316L,Stem,seat ring and wedge

facing ring-SS316L, Gland packing- Grafoil.

FLGD #150, B.16.5 RF/125 AARH

GTV

VLV. GATE 26” 42” # 150 BS-1414

API-598/BS-

6755,PART-1

Body-ASTM A 351 GR. 316L,Trim A

473 316L,Stem,seat

ring & wedge facing ring-

SS316L,Gland packing- Grafoil.

FLGD #150/B.16.5 RF/125 AARH



Input Id. ITEM TYPE

Lower size

( inch)

Upper size

( inch)Sch/T

hk DESIGN

STD. TESTING

STD. Material Description

BFV

VLV. BUTTERFLY

3" 24" # 150BS-

5155/API-609

API-598/BS-

6755 PART-1

Body & Disc - ASTM A 351 GR. SS316L ,Seat- ASTM A182 SS 316L, Shaft mat.-ASTM A 473 SS316L,

FLGD, #150, B165 RF/125 AARH

BFV

VLV. BUTTERFLY

26" 48" # 150ISO

5752,MSS-SP-68

API-598/BS-

6755 PART-1

Body & DISC - ASTM A 351 GR. SS316L ,Seat- ASTM A182 SS 316L, Shaft mat.-ASTM A 473 SS316L,,

FLGD, #150, B165 RF/125 AARH

GV GLOBE VALVE ½” 1 ½” # 800 BS-5352 BS-6755

PART-1

Body ,Seat -ASTM A 182 CF 8 M, 316L,Shaft- ASTM A 473 SS316L seal- Nitrile rubber,EPDM,Hypalon

FLGD,#800 B16.5 RF/125 AARH

GV

GLOBE VALVE 2” 8” # 150 BS-1873 BS-6755

PART-1

Body-ASTM A 351 CF 8 M, Spindle-ASTM A 351 CF 8M,Disc-SS316L,Seat ring -SS 316L, Back seat-SS 316L, shaft-ASTM A 473 SS316L,Seal- Nitrile rubber,EPDM,Hypalon.

FLGD, #150, B16.5 RF/125 AARH

BV

BALL VALVE ½” 1 ½”” # 150 BS-5351 BS-6755

Body, side piece, Ball& Seat-ASTM A 182 CF 8 M, Seat ring-PTFE, Hand wheel- ductile iron.

SW

BV

BALL VALVE 2” 16” # 150 BS-5351 BS-6755

Body, side piece, Ball& Seat-ASTM A 351 CF 8 M, Seat ring-PTFE, Hand wheel- ductile iron.

FLGD, #150, B16.5 RF/125 AARH



Input Id. ITEM TYPE

Lower size

( inch)

Upper size

( inch) Sch/T

hk DESIGN

STD. TESTING

STD. Material Description

Bolt Group

BOS

BOLT.&STUD

Dimensional std as per

ANSI B 16.5/16.47

SS 316

- Bolt conform to B 18.2.1, nuts to be B 18.2.2 and for studs B 16.5.Thread shall conform B 1.1 having class 2A tolerance for bolts & studs and class 2B tolerance for nuts. - Threads for threaded pipes ,fittings, flange and valves shall be accordance with B 1.20.2 taper threads, unless otherwise specified.

Gasket Group

GAS GASKET 2” 48"

- Non metallic gasket as per B-16.21-ANSI B16..5 up to 24” and B16.21 ( corresponding to API -605) above 24”.

- Spiral wound gasket as per API-601/B 16.20.

SP. WND SS

316L+CAF

SPIRAL #300



TABLE:8.2

PIPE CLASS SS 2205 RATING ANSI CLASS # 600 BASE MATERIAL DUPLEX STAINLESS STEEL CORROSION ALLOWANCE: 0MM TEMPERATURE ( DEG . C) & PRESS. ( KG/CM2 G) RATING.

TEMP. 15 45

PRESS. 101.

2 97.82 SERVICE: High Press. Feed water to RO,Reject water from RO to PX.

SPECIAL NOTES: ITEM SIZE DESCRIPTION

MAINT. JOINT All Flanged (To be kept minimum) 1.5” & Below SW Coupling PIPE JOINTS 2” & Above Butt welded

On lines < =1.5" As per P & ID DRAINS

On lines>=2.0" As per P & ID

On lines < =1.5" As per P & ID VENTS On lines < 2" As per P & ID

TEMP. CONN. 1.5"NB Flanged (600#) installation PRESS. CONN. 0.75" SW SCH. 80 nipple with Gate valve



14 E 14 12 E R 12 10 E R R 10 8 E R R R 8 6 E R R R R 6 5 5 4 E R R R R R 4

3.5 3.5 3 E R R R R R R 3

2.5 2.5 2 E R R R R R R R 2

1.5 T E H H H H H H H 1.5 1.25 1.25

1 T T H H H H H H H H 1 0.75 T T T H H H H H H H H 0.75 0.5 T T T T H H H H H H H H 0.5

B

RA

NC

H P

IPE

SIZ

E (

SIZ

E IN

INC

HE

S)

0.5

0.8 1 1.3

1.5 2 2.5 3 3.5 4 5 6 8 10

12

14


CODE DESCRIPTION T : TEES SW/SCRD H : HALF COUPLING E : TEES B.W. R : REINFORCED



ITEM TYPE Lower size

( inch)

Upper size


PIPE 1/2" 1 1/2” 80S/S80 ASME/ANSI B -36.19M/B36.10M

ASTM UNSS 31803(SAF 2205) (*) (Refer note-2*)

SEAMLESS

PIPE 2" 14" 40S/S40 ASME/ANSI B- 36.10MASTM UNSS

31803(SAF 2205) (*) (Refer note-2*)

SEAMLESS

FLNG. WN 2" 24"

Flange thickness

shall match with pipe thickness

ASME/ANSI B-16.5 ASTM UNSS 31803(SAF 2205)

#600,RF/125 u in AARH

FLNG. WN 26" 64"

Flange thickness



#600,RF/125 u in AARH

FLANGE .BLIND 2" 24"

Flange thickness



#600, RF/125u in

AARH

FLANGE .BLIND 26" 40”

Flange thickness



#600, RF/125u in

AARH

ELBOW 90 2" 14"

Fittings thickness & tolerance

shall match with the pipe thickness & tolerance

ASME/ANSI B-16..9

ASTM UNSS 31803

(SAF 2205) BW

ELBOW 45 2" 14" “ ASME/ANSI B-16..9 ASTM UNSS

31803 (SAF 2205)

BW

T. EQUAL 2" 14" “ ASME/ANSI B-16..9 ASTM UNSS

31803 (SAF 2205)

BW




( inch)

Upper size


T.UNEQUAL 2” 14” “ ASME/ANSI B-16..9 ASTM UNSS

31803 (SAF 2205)

BW

REDUC. CONC 4" 40" “ ASME/ANSI B-16..9

ASTM UNSS 31803

(SAF 2205)

BW

REDUC. ECC 5" 32" “ ASME/ANSI B-16..9

ASTM UNSS 31803

(SAF 2205)

BW



ITEM TYPE

Lower size

( inch)

Upper size

( inch)

Sch/ThkDesign

Std. Testing

Std. Material Description End/Facing

VLV. CHECK 3/4" 1 ½” #800

BS:5352/API

594/API 6D

BS-6755, PART-1

Body , Cover, Hinge, Disc/Door, Seat ring-ASTM A 182 Gr. 5A UNSJ 93404(*) (Refer note-1*)Hinge pin & Door/Disc pin, bearing bushes, Disc facing & Body seat ring- ASTM A 473 SS 316L

Socket weld end(weld end of the valve shall be as per the corresponding fitting ends of the piping class ,unless otherwise specified.

VLV. CHECK 2” 24” # 600

BS 1868/API 594/API

6D

BS-6755,PART-1

Body , Cover, Hinge, Disc, Seat ring--ASTM 890 Gr. 5A UNSJ93404(*) (Refer note-1*) Hinge pin & Door/Disc pin, bearing bushes, Disc facing & Body seat ring- ASTM A 473 SS 316L .

FLGD # 600, B16..5 RF/125AARH

VLV. GATE 1/2" 1 ½” # 800 API-602 API-598

Body & bonnet-ASTM A 890 Gr. 5A UNSJ93404 (*) ( Refer note-1*) ,Stem, Wedge disc, Seat ring, Back seat-UNSJ93404,Gland packing-UNSJ93404.

Socket Weld end ( Weld end of the valve shall be as per the corresponding fittings ends of the piping class, unless otherwise specified).

VLV. GLOBE 1/2" 1 ½”" 800# BS-5352 BS-6755

PART-1

Body, Disc, Seat, Seat ring-ASTM A 182 Gr.5A UNSJ 93404(*) ( Refer note*-1), Shaft-ASTM A 473 UNS J 93404,Back seat-Duplex, Gland packing-SS316L,Seal-Nitrile rubber,EPDM,Hypalon.- shaft – ASTM 890 Gr. A 473 S 32760

Weld end ( Weld end of the valve shall be as per the corresponding fittings ends of the piping class, unless otherwise specified)




(inch)

Upper size

( inch) Sch/thk Design

std. Testing std. Material description

End/facing

GLB.V 2" 8”" 600# BS-1873 BS-6755, PART-1

Body, Disc, Seat, Seat ring-ASTM A 890 Gr.5A UNSJ 93404(*) ( Refer note*-1),,Back seat-Duplex, Gland packing-SS316L, Seal-Nitrile rubber,EPDM,Hypalon. shaft – ASTM 890 Gr. A 473 S 32760

FLGD, #600, B16..5 RF/125 AARH

BFV 3" 48" # 600

BS-5155/API-

609

API-598/ BS-6755 PART-

1

Body ,Disc, Seat, Stem-ASTM A 890 UNSJ 93404(*)(Refer note*-1),,Seat ring-PTFE, Seat –Duplex, Shaft- ASTM A 473 UNSJ 93404, Seal-Nitrile rubber,EPDM,Hypalon

FLGD, #600, B16..5 RF/125 AARH

BV ½” 11/2” #800 BS-5351 BS-6755

Body, side piece, & Seat-ASTM A 182 Gr. 5A UNSJ 93404(*) ( Refer note*-1), Ball & Stem-ASTM A 473 UNSJ 93404,Seat ring-PTFE, Seat-ASTM A 182 F 317/ASTM A 276 S 31700

FLGD, #600, B16..5 RF/125 AARH

BV 2” 16” #600 BS-5351 BS-6755

Body, side piece, & Seat-ASTM A 890 Gr. 5A UNSJ 93404(*) ( Refer note*-1), Ball & Stem-ASTM A 473 UNSJ 93404,Seat ring-PTFE, Seat-ASTM A 890 J 93404/ A 276 S 31700

FLGD, #600, B16..5 RF/125 AARH



NOTE-1

• UNS J 93404/ASTM A 890 GR.5A/UNSS 31254( ALLOY -2507) Having PREN (Pitting resistance equivalent no.) greater than 40.

NOTE-2

• UNSS 31803 (SAF-2205) having PREN(Pitting resistance equivalent no.) greater than 35.

Bolt Group

BOS BOLT. STUD


ANSI B 16.5/16.47

SS316

- Bolt conform to B 18.2.1, nuts to be B 18.2.2 and for studs B16.5.Thread shall conform B 1.1 having class 2A tolerance for bolts & studsand class 2B tolerance for nuts. - Threads for threaded pipes ,fittings, flange and valves shall be accordance with B 1.20.2 taper threads, unless otherwise specified.

Gasket Group

GAS GASKET 2” 48"

B- 16.2 -ANSI B16.5- Non metallic gasket as per B-16.21-ANSI B16..5 up to 24” and B16.21 ( corresponding to API -605) above 24”. - Spiral wound gasket as per API-601/B 16.20.

SP. WND SS 316+CAF SPIRAL #300



TABLE:8.3

PIPE CLASS HDPE RATING PN-10 BASE MATERIAL HDPE /PE 100 CORROSION ALLOWANCE: 0MM TEMP.( DEG.C) & PRESS.( KG/CM2g) RATING AS PER IS: 4984: 1995

REJECT WATER FROM UF, REJECT BRINE FROM PE, FILTERED WATER FROM UF, SERVICE: BACKWASH WATER, REJECT WATER TO SEA,ANTISCALNET, NaOCL,RO CHEMICALS,NaHSO3

SPECIAL NOTES: SINGLE PIPE LENGTH SHALL BE 12 M & COLOUR SHALL BE BLACK. ITEM SIZE DESCRIPTION

Maint. Joint All Flanged to be kept minimum Pipe joints All Butt fusion joints*

On lines < 25 NB ½”. Drains On lines > 25 NB As per P & ID On lines < 25 NB ½” Vents On lines > 25 NB As per P & ID

Temp. conn. 40 NB Saddle with flanged adaptor installation Press. conn. 15 NB Saddle

• NOTE: For jointing pipes of ½” to 4” ,socket fusion shall be used. Butt jointing can be used for jointing of all the sizes.

CODE DESCRIPTION T: EQUAL TEES C: UN EQUAL TEE WITH REDUCER S: SADDLE FITTING



48 T 48

46 T C 46

44 T C C 44

42 T C C C 42

40 T C C C C 40

38 T C C C C C 38

36 T C C C C C C 36

34 T C C C C C C C 34

32 T C C C C C C C C 32

30 T C C C C C C C C C 30

28 T C C C C C C C C C C 28

26 T C C C C C C C C C C C 26

24 T C C C C C C C C C C C C 24

22 T C C C C C C C C C C C C C 22

20 T C C C C C C C C C C C C C C 20

18 T C C C C C C C C C C C C C C C 18

16 T C C C C C C C C C C C C C C C C 16

14 T C C C C C C C C C C C C C C C C C 14

12 T S C C C C C C C C C C C C C C C C C 12

11 T S S C C C C C C C C C C C C C C C C C 11

10 T C C C C C C C C C C C C C C C C C C C C 10

8 T C C S S S S S S S S S S S S S S S S S S S 8

7 T C C S S S S S S S S S S S S S S S S S S S S 7

6 T C C C S S S S S S S S S S S S S S S S S S S S 6

5.5 T C C C C S S S S S S S S S S S S S S S S S S S S 5.5

5 T C C C C C S S S S S S S S S S S S S S S S S S S S 5

4 T C C C C C C S S S S S S S S S S S S S S S S S S S S 4

3.5 T C C C C C C C S S S S S S S S S S S S S S S S S S S S 3.5

3 T C C C C C C C C S S S S S S S S S S S S S S S S S S S S 3

2.5 T S C C C C C C C C S S S S S S S S S S S S S S S S S S S S 2.5

2 T S S C C C C C C C C S S S S S S S S S S S S S S S S S S S S 2

1.5 T S S S C C C S S S S S S S S S S S S S S S S S S S S S S S S S 1.5

1.3 T C S S S C C C S S S S S S S S S S S S S S S S S S S S S S S S S 1.3

1 T C C S S S C S S S S S S S S S S S S S S S S S S S S S S S S S S S 1

0.8 T C C C S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S 0.8

0.5 T C C C C S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S 0.5

BR

AN

CH

PIP

E S

IZE

( SI

ZE

IN IN

CH

ES)

0.5

0.8 1 1.3

1.5 2 2.5 3 3.5 4 5 5.5 6 7 8 10

11

12

14

16

18

20

22

24

26

28

30

32

34

36

38

40

42

44

46

48




Pipe group

PIP PIPE 1/2" 1 1/2" PN 16 IS 4984 PE 100: IS :

7328 PE

PIP PIPE 2” 48” PN 10 IS 4984 PE 100: IS : 7328 PE

Flange Group

FLG SLIP- ON-

RING FLANGE

1/2” 24”

Fitting thk. &

tolerance shall

match with the pipe thk.

& tolerance

ANSI B 16.5

ASTM A 536 Gr 65/45/12

#150 /MAX1000

AARH

FLG SLIP- ON-

RING FLANGE

26” 48” “ ANSI B 16.47

ASTM A 536 Gr 65/45/12

#150 /MAX1000

AARH

FLB

FLANGE.BLIND

2” 24” “ ANSI B 16.5

PE 100: IS : 7328

#150

FF/125 AARH

FLB

FLANGE.BLIND

26” 48” “ ANSI B 16.47

PE 100: IS : 7328

#150

FF/125 AARH

EC END CAP ½” 8” “ ANSI B 16.5

PE 100: IS : 7328

Fitting Group

FLA

FLANGE ADAPTOR

WITH BACKING FLANGE

1/2” 12”

Flange adaptor as per the manufacturer std. HDPE flanges / flange adaptors with SS 316 backing flanges 10mm thick & other dimensional std. as per B 16.5/B 16.47 for #150 rating

IS:8008 PART-6

PE 100: IS : 7328

Adaptor PE,

“Moulded .



Fitting Group

FLA FLANGE ADAPT

OR 14” 40” “ IS:8008

PART-6 PE 100: IS : 7328

PE, Machin

ed

REDC.

REDUCER-

CONC/ECC

1” 12”

The wall thickness of fittings shall not be less

than that of pipe to which it is welded.

IS:8008 PART-4 PE 100: IS : 7328

PE, Moulde

d

REDC.

REDUCER-

CONC/ECC

14” 32” “

IS:8008 PART-4 up to

24”/manufacturing std. for sizes

greater than 24”

PE 100: IS : 7328

PE, Machin

ed

ELB 90

ELEBOW 90 1” 6” IS:8008

PART-2 PE 100: IS : 7328

PE,

Moulded

ELB 90

ELEBOW 90 8” 64”


20”/manufacturing std. for sizes

greater than 20”

PE 100: IS : 7328

PE, Fabrica

ted

ELB 45 ELEBOW 45 1” 6” “ IS:8008

PART-2 PE 100: IS : 7328 PE, Moulded

ELB 45 ELEBOW 45 8” 48” “


20”/manufacturing std. for sizes greater than 20”

PE 100: IS : 7328 PE, Fabricated

TEQ T. EQUAL 1” 6” “ IS:8008 PART-2 PE 100: IS : 7328 PE, MOULDED

TEQ T. EQUAL 8” 48” “


20”/manufacturing std. for sizes greater than 20”

PE 100: IS : 7328 PE,

FABRICATED



Bolt

BOS BOLT. STUD


ANSI B 16.5/16.47

SS316

- Bolt conform to B 18.2.1, nuts to be B 18.2.2 and for studs B 16.5.Thread shall conform B 1.1 having class 2A tolerance for bolts & studs and class 2B tolerance for nuts. - Threads for threaded pipes ,fittings, flange and valves shall be accordance with B 1.20.2 taper threads, unless otherwise specified.

Bolt Group

GAS GASKET 2” 48"

B- 16.2 -ANSI B16.5- Non metallic gasket as per B-16.21-ANSI B16..5 up to 24” and B16.21 ( corresponding to API -605) above 24”. - Spiral wound gasket as per API-601/B 16.20.

SP. WND SS 316+CAF

SPIRAL #300



TABLE:8.4

PIPE CLASS CS /CSRL RATING ANSI CLASS # 150 BASE MATERIAL CARBON STEEL CORROSION ALLOWANCE: 1.5 MM TEMP.( DEG.C) & PRESS.( KG/CM2) RATING

TEMP. 0 38 93

PRESS. 10.5

5 10.55 10.55 SERVICE: Na OH

SPECIAL NOTES: 1) SINGLE PIPE LENGTH SHALL BE 12 M. 2) CARBON STEEL INTERNAL RUBBER LINING FOR CSRL PIPE CLASS SHALL BE LINED WITH 3 MM THICK NATURAL RUBBER OF SHORE HARDNESS 65± 50A. CSRL PIPE SHALL BE USED FOR CALCIUM CARBONATE SERVICE.

ITEM SIZE DESCRIPTION MAINT. JOINT ALL FLANGED TO BE KEPT MINIMUM

1.5" & BELOW SW COUPLING PIPE JOINTS 2.0" & ABOVE BUTTWELDED

ON LINES < =1.5" AS PER P & ID DRAINS ON LINES>=2.0" AS PER P & ID

ON LINES < =1.5" AS PER P & ID VENTS ON LINES < 2" AS PER P & ID

TEMP. CONN. 1.5"NB FLANGED INSTALLATION PRESS. CONN. 0.75" NIPPLE WITH GATE VALVE

6 T CODE DESCRIPTION 4 T P 3 T P P T : TEES 2 T P P P H : HALF COUPLING

1.5 T T H H H R : REINFORCED 1 T T H H H H P : PIPE TO PIPE

0.75 T T T H H H H BR

AN

CH

PIP

E S

IZE

(SIZ

E IN

INC

HE

S)

0.5 T T T T H H H H

0.5

0.75

1 1.5 2 3 4 6

RUN PIPE SIZE (SIZE IN INCHES)



Input Id.

ITEM TYPE

Lower size

( inch) Upper size

( inch) Sch/T

hk Dmn. Std Material Descripti

on END/FACING Remarks

Pipe group

PIP PIPE 1/2" 1 ½” HVY IS-1239 PART-1

IS-1239-PART-1 (BLACK)

Seamless Seamless

PIP PIPE 2” 6” HVY IS-1239

PART-1

IS-1239-PART-1 (BLACK)

Seamless Seamless

Flange Group

FLG FLNG. Slip on 1/2" 1 1/2"

Flange thickness shall match with pipe

thickness

ASME/ANSI B-16.5 ASTM A 105 150#,RF/125A

ARH

FLG FLNG. Slip on 2" 6"


thickness

ASME/ANSI B-16.5 ASTM A 105 150#,RF/125

AARH

FLB FLANGE BLIND 1/2” 6”


thickness

ASME/ANSI B-16.5 ASTM A 105 150#,RF/125

AARH

Fitting group

ELB 90 ELBOW 90 1/2" 1.5"

Fittings thickness & tolerance shall match with the pipe thickness &

tolerance

Forged steel SW and threaded -ASME/ANSI B

16.11.

ASTM A 105 SW

ELB 90 ELBOW 90 2" 6" “ ASME/ANSI B

16..9 ASTM A 234 GR WPB BW

TEQ T. EQUAL 2” 6” “ ASME/ANSI B 16..9

ASTM A 234 GR WPB BW

TRED T. RED 2" 3" “ ASME/ANSI B 16..9

ASTM A 234 GR WPB BW

REDC REDUC. CONC 1/2" 1 ½”" “ A SME/ANSI B

16..9 ASTM A 234 GR WPB

SW

REDC REDUC. CONC 2" 3" “ A SME/ANSI B

16..9

ASTM A 234 GR WPB SW



Input Id.

ITEM TYPE

Lower size

( inch)

Upper size

( inch) Sch/Thk Dmn.

Std TESTING

STANDARD Material

Description END /

FACING

Valve Group

DV

DIAPHRAGM VALVE

2” 6” #150 BS-5156

BS-6755-

PART-1

Body & bonnet-CI IS: 210Gr. FG 260/CS ASTM A 216Gr. WCB and body shall be internally lined with soft natural rubber/PTFE or Viton Diaphragm-Reinforced bber/Hypalon, Stem, Compressor & bush-Stainless steel construction.

FLGD, #150 B16..5 RF/125 AARH

CHV CHECK VALVE ½” 1 ½” #800 BS-

5352

BS-6755-

PART-1

Body & Cover,hinge disk/Door-CI IS:210 GR.FG 260/BS:1452 GR. 220 or Eqvt. Hinge pin & Door/disc pin –ASTM A 216 Gr.WCB and shall be coated with

PVDF or suitable elastomer or SS316,Body ring & disc facing shall be SS, Bearing bushes shall

be SS316

FLGD, #150 B16..5 RF/125 AARH

CHV CHECK VALVE 2” 6” #150 BS-

1868

BS-6755-

PART-1

Body & Cover,hinge disk/Door-CI IS:210 GR.FG 260/BS:1452 GR. 220 or Eqvt. Hinge pin & Door/disc pin –ASTM A 216 Gr.WCB and shall be coated with

PVDF or suitable elastomer or SS316,Body ring & disc facing shall be SS, Bearing bushes shall

be SS316

FLGD, #150 B16..5 RF/125 AARH

GLB GLOBE VALVE ½” 1 ½” #800 BS-

5352

BS-6755-

PART-1

Body & disc –CI:IS 210 Gr.FG 260 or Eqvt. And

internally lined with natural rubber ,Stem-stainless steel AISI

410/13% Cr.,packing-PTFE,Seat & seat ring-Nitrile rubber/Hypalon

FLGD, #150 B16..5 RF/125 AARH



Input Id.

ITEM TYPE

Lower size

( inch)

Upper size


Std

TESTING

STANDARD

Material Description END / FACING

GLB GLOBE VALVE 2” 6” #150 BS-

1873

BS-6755-

PART-1

Body & disc –CI:IS 210 Gr.FG 260 or Eqvt. And

internally lined with natural rubber ,Stem-stainless steel AISI

410/13% Cr.,packing-PTFE,Seat & seat ring-Nitrile rubber/Hypalon

FLGD, #150 B16..5 RF/125 AARH

BV BALL VALVE ½” 11/2” #800 BS-

5351

BS-6755-

PART-1

Body –A 216 GR. WCB & Eqvt. and internally lined with natural rubbe,Ball & stem- SS410, Seat & seat

ring-PTFE or eqvt.

FLGD, #150 B16..5 RF/125 AARH

BV BALL VALVE 2” 6” #150 BS-

5351

BS-6755-

PART-1

Body –A 216 GR. WCB & Eqvt. and internally lined with natural rubbe ,Ball & stem- SS410, Seat & seat

ring-PTFE or eqvt.

FLGD, #150 B16..5 RF/125 AARH

Bolt Group

BOS BOLT. STUD

Dimensional std as per ANSI B 16.5/16.

47

Bolt , studs -A 193 Gr. B

7& nuts shall be A 194

Gr, 2 H

- Bolt conform to B 18.2.1, nuts to be B 18.2.2 and for studs B 16.5

- Thread shall conform B 1.1 having class 2A tolerance for bolts & studs and class 2B tolerance for nuts.

- Material for Bolt , studs shall be A 193 Gr. B 7& nuts shall be A 194 Gr, 2 H

Gasket Group

GAS GASKET 3/4" 12"

- Non metallic gasket as per B-16.21-ANSI B16..5 up

to 24” and B16.21 ( corresponding to API -605)

above 24”. - Spiral wound gasket as per API-601/B 16.20.

SP. WND SS 316L+CAF

SPIRAL # 150



TABLE:8.5

PIPE CLASS GI RATING #150 BASE MATERIAL CS( GAL) CORROSION ALLOWANCE: 0MM

TEMP.( DEG.C) & PRESS.( KG/CM2) RATING

TEMP. 65

PRESS. 10.55

SERVICE: AIR

SPECIAL NOTES: 1) SINGLE PIPE LENGTH SHALL BE 12 M. 2) ALL THREADED JOINTS SHALL BE WITH 1” WIDTH PTFE JOING TAPE 3) SURFACES WERE GALVANISING HAS BEEN BURNT OFF SHALL BE WIRE BRUSHED &

COLD GALVANISED WITH ZINC COATING COMPOUND. ITEM SIZE DESCRIPTION

Maint. Joint All Flanged to be kept minimum

1.5” & Below SW Coupling 3000lbs Pipe joints 2.0" & Above Butt welded

Drains ALL As per P & ID Vents ALL As per P & ID Temp. conn. 1.5"NB Flanged installation

Press. conn. 0.75" Socket weld nipple with gate valve



12 E 10 E R 8 E P R 6 E P P R 5 4 E P P P P

3.5 3 E P P P P P

2.5 2 E P P P P P P

1.5 T E H H H H H H 1.25

1 T T H H H H H H H 0.75 T T T H H H H H H H 0.5 T T T T H H H H H H E

BR

AN

CH

PIP

E S

IZE

(S

IZE

IN IN

CH

ES)

0.5 0.75 1 1.25 1.5 2 2.5 3 3.5 4 5 6 8 10 12

CODE

DESCRIPTION

E – Tees B.W

R –Reinforced

P – Pipe to pipe

T – Tees

H – Half Coupling




Input Id. ITEM TYPE

Lower size

( inch)

Upper size

( inch) Sch/Thk Dmn. Std Material

Description END/FACING Remarks

Pipe group

PIP PIPE 1/2" 6" HVY IS-1239- PART-I

IS-1239-PART- I (BLACK)-

GALV TO IS 4736

½” to 1 ½” ,PE & 2” & above-BE

ERW

PIP PIPE 8” 12" 6MM IS-3589 IS-3589 GR.

330, GALV TO IS 4736

BE ERW

Flange Group

FLG FLNG. 1 1/2" 12" #150LB B-16.5 ASTM A 105, GALV TO IS

4736

150#,RF/125 AARH

FLB FLANGE

BLIND 1 1/2" 12” #150LB B-16.5 ASTM A 105, GALV TO IS

4736

150#,RF/125 AARH

EC END CAP.SCRD. ¾” 1 ½’ #150LB B-16.11

ASTM A 105, GALV TO IS

4736

Thread shall be in accordance with

B1.20.2 taper threads, unless

otherwise specified.

Fitting group

ELB 90 ELBOW 90 1/2" 1.5"

Fittings thickness & tolerance

shall match with the

pipe thickness & tolerance

ASME/ANSI B-16.11

ASTM A 105, GALV TO IS

4736

SW

ELB 90 ELBOW 90 2" 12" “ B-16.9

ASTM A 234

Gr. WPB, GALV TO IS

4736

BW

ELB 45 ELBOW 45 1/2" 1.5" “ ASME/ANSI B-16.11

ASTM A 105 , GALV TO IS

4736

SW



Input Id. ITEM TYPE

Lower size

( inch)

Upper size


Std Material End / facing Remarks

ELB 45 ELBOW 45 2" 12" “ B-16.9

ASTM A 234 Gr. GALV TO IS

4736WPB,

BW

TEQ T. EQUAL 1/2" 1.5" “ ASME/ANSI B-16.11

ASTM A

105 , GALV TO IS 4736

SW

TEQ T. EQUAL 2" 12" “ B-16.9

ASTM A 234 Gr. GALV TO IS

4736WPB,

BE

REDC REDUC. CONC 1 1/2" 12" “

ASME/ANSI B-16.11

ASTM A 105,

GALV TO IS 4736

SW

REDE REDUC. ECC 3" 12" “ B-16.9

ASTM A 234 Gr.

GALV TO IS 4736 WPB,

BE



CHV CHECK VALVE ½” 1 ½” #800 BS-5352

BS-6755-PART

-1

Body & Cover,hinge disk/Door-CI IS:210 GR.FG 260/BS:1452 GR. 220 or Eqvt. Hinge pin & Door/disc pin -ASTM A 216Gr.WCB,Disc facing ring & body seat ring shall be stainless steel.

SW

CHV CHECK VALVE 2” 6” #150 BS-1868

BS-6755-PART

-1

Body & Cover,hinge disk/Door-CI IS:210 GR.FG 260/BS:1452 GR. 220 or Eqvt. Hinge pin & Door/disc pin -ASTM A 216Gr.WCB,Disc facing ring & body seat ring shall be stainless steel

FLGD, #150 B16.5 RF/125 AARH

BFV

VLV. BUTTERFLY

2" 24" # 150 BS-5155 /API-609

API-598 / BS-

6755 PART-

1

Body & Disc - ASTM A 216 Gr. WCB , Shaft mat.-ASTM A 296 Gr. CF8M, Seat ring- Nitrile Rubber/EPDM/Hypalon.

FLGD, #150, B16.5 RF/125 AARH

GTV

VLV. GATE 1/2" 1 ½” # 800 API-

602/IS:778 API-598

Body & bonnet-ASTM A 105,13% Cr. Trim, .Stem,Wedge disc, Seat ring, Back seat-SS316L,Gland packing- Grafoil.

Weld end (weld end of the valve shall be as per he corresponding fitting ends of the piping class, unless otherwise specified

GTV

VLV. GATE 2” 24” # 150

API-600/BS:5150/BS:5163/IS:14846

API-

598

Body/Bonnet-ASTM A 216 GR. WCB, 13% Cr.Trim ,Seat ring and wedge facing ring-SS316L, Gland packing- Grafoil.

FLGD #150 B.16.5 RF/125 AARH



Bolt Group

BOS BOLT. STUD

Dimensional std

as per

ANSI B

16.5/16.47

Bolt , studs -A 193 Gr. B

7& nuts shall be A

194 Gr, 2 H

- Bolt conform to B 18.2.1, nuts to be B 18.2.2 and for studs B 16.5.Thread shall conform B 1.1 having class 2A tolerance for bolts & studs and class 2B tolerance for nuts. - - - Threads for threaded pipes ,fittings, flange and valves shall be accordance with B 1.20.2 taper threads, unless otherwise specified.

Gasket Group

GAS GASKET 3/4" 12"

- Non metallic gasket as per B-16.21-ANSI B16..5 up to 24” and B16.21 ( corresponding to API -605) above 24”.

- Spiral wound gasket as per API-601/B 16.20.

SP. WND SS 316L+CAF SPIRAL #300



9.00 RUBBER EXPANSION JOINT 9.01 DESIGN AND CONSTRUCTION REQUIREMENTS 9.02 All parts of the expansion joints shall be amply proportioned for all

stresses that may occur during continuous operation and for any additional stresses that may occur during installation and also during transient conditions.

9.03 The expansion joints shall be single bellow rubber expansion joints. The design shall be suitable for the pressure and type of fluid as specified in the Design data sheet enclosed.

9.04 Each joint shall have a permanently attached brass or stainless steel

metal tag indicating the tag number and other salient design features. Technical Data Sheet for RUBBER EXPANSION JOINT

i) General

1. Service : Sea water

2. Type: Single Expansion Joint

3. Design standard : EJMA (ii) Design Parameters

1. Design pressure: Pump shut off head + suction pressure

2. Design temperature: 50 °C

3. Minimum cycle life: 5000

4. Pressure drop across expansion joint:Not to exceed 0.1 MWC

5. Bursting Pressure: Four times the design pressure

6. End connection: SOFF flange as per

AWWA C-207 CLASS-D

7 Installation position: Horizontal pipe

8. Steel retaining ring thk. : Minimum 10 mm



9. No. of control units (mm): 6 (Contractor shall check

adequacy of No. of control units and submit the design

calculation in support of the No. of control units provided). iii) Material of construction 1. Bellow Abrasive resistant rubber

compound with adequate reinforcement of canvas and rayon piles with neoprene inner & outer cover including metal ring reinforcement (10 mm² annular steel rings min.) in the carcass.

2. Bellow interior: Neoprene, minimum 3mm /6mm thk.

3. Bellow exterior: Neoprene, minimum 3mm/6mm thk.

4. Stretcher plate: SS316 L

5. Stretcher bolt / nuts & washers SS-316L

6. Steel retaining ring SS-316L

7. Gasket material Neoprene

9.05 INSPECTION AND TESTING

All materials used for construction shall be of tested quality. Physical and chemical tests on materials shall be done to ensure the quality of the material offered. Test procedures and sampling shall be guided by the applicable test codes and standards.

The following tests shall be conducted on the Rubber expansion joints:

i) Tensile, Elongation ii) Shore hardness iii) Adhesion test of fabric to rubber iv) Accelerated ageing test v) Fatigue life set vi) Cycle life set vii) Hydraulic test at the following conditions at 1.5 times the design

pressure



a) Free position of bellows b) With design elongation and lateral deflection c) With design contraction and lateral deflection viii) Vacuum test at 700 mm Hg.



ANNEXURE-A

TECHNICAL SPECIFICATION FOR MOTOR OPERATED VALVE ACTUATORS

This specification covers the requirements for design, manufacture, testing and supply of electrics for electrical motor operated valve actuators intended for only fully/partially opening/closing valve duty.

All supply and execution shall confirm to relevant standards & technical features indicated below and as per approved QAP.

1.0 STANDARDS

The design, manufacture and performance of equipment covered by this specification shall conform to the relevant Indian/International standards and codes. In particular the equipment offered shall conform to the following standards with latest revision.

IS:325-1978 Specifications for three phase Induction Motors. IS: 4691-1985 Degree of protection provided by enclosures for rotating

electrical machinery IS:4722-1992 Specification for rotating electrical machines. IS: 9334-1986 Specification for Electric Motor Operated Actuators IS:2147-1962 Degrees of protection provided by enclosures for low

voltage switch gear & control gear IS: 13947-1993 Part 1 to 7.

Specification for LV switchgear & control gear.

2.0 SERVICE CONDITIONS AND SITE CONDITIONS

The offered actuator shall be suitable for operating under service conditions and system conditions as specified below:

2.1 Power supply system

Voltage 415V + 10 %, 3 phase & neutral. Frequency 50 Hz + 3 %. Combined variation of voltage & frequency

+ 9 %.

System Neutral Solidly earthed. System short circuit level 32Ka for 1 second.

2.2 Ambient conditions

Maximum Ambient temperature. 50 deg. C.



Humidity 100 % not occurring with maximum temperature.

Height Less than 1000M. Environment Explosion hazardous and corrosive due to

near by facilities. 3.0 ELECTRICS TO BE INCLUDED AS INTEGRAL PART OF VALVE

ACTUATOR 3.1 Electrical drives motor.

3.2 All devices required for safe operation and control of actuator including but not limited to the following :

i) Electrically and mechanically interlocked contactors for opening and closing operations.

ii) Local / Remote control selector switches & push buttons for opening, closing & stopping of valve operations.

iii) Separate torque and position limit switches for both OPEN and CLOSE positions. Additional intermediate position limit switches shall also be provided where ever required. The switches shall be provided with heavy-duty type with 2 NO+ 2 NC potential free contacts rated for 5A at 240V AC

iv) Indicating lamps for valve fully open, fully closed & in travel condition. Potential free contacts for indication on remote panel for valve ‘Open’, 'Close', 'In travel' & ‘Jammed’ condition required.

v) Local continuous position indicator.

vi) Terminal block fully pre wired up to contacts on individual devices.

vii) Control transformer.

viii) 2 Nos. earthing terminals.

ix) De clutchable hand wheel for manual operation, suitably interlocked to prevent simultaneous manual and electrical operation.

3.3 The valve actuators shall have following minimum protections - Motor overload protection. - Over heating protection by embedded thermostat in the winding. - Anti hammer protection. - Valve Jamming protection ( Both directions) - Instantaneous reversal protection. - Single phasing protection.

3.4 Enclosure class of electrical actuator for weather protection shall be IP 67.

4.0 MOTOR



4.1 Motor shall be 3-phase squirrel cage induction type. Motor shall be totally enclosed, non-ventilated, high torque low inertia type embedded with thermostats.

4.2 The motor shall be rated for S2-15 minute duty or twice the valve stroking time, whichever is the longer, at an average load of at least 33% of maximum valve torque. The motor shall conform to IS:325-1978. Voltage rating of motor shall be 415V, 3 phase, 50Hz, AC.

4.3 The motor shall conform to relevant Indian/International standards.

4.4 In any case the motor shall be suitable for following requirements :

• Minimum 3 nos. of consecutive starts in hot condition. • Minimum 8 nos. of starts distributed over 15 minutes. • The motor shall be able to operate the actuator at 75% of specified voltage.

4.5 Motor shall have Class 'F' or better insulation with temperature rise limited to Class-B. Winding shall be treated to resist corrosive agent and also moisture.

4.6 Motor bearing shall be anti friction type & permanently lubricated.

5.0 GEARING 5.1 The actuator gearing shall be totally enclosed in oil filled gear case/ grease bath

suitable for operating at any angle.

5.2 All main drive gearing must be of metal construction.

5.3 The drive shall incorporate a lost motion hammer blow feature where the actuator operates gate valves or large diameter ball or plug valves.

5.4 The output shaft shall be hollow to accept a rising stem for rising spindle valves and incorporate a thrust base with lubricated bearing of the ball or roller type.

5.5 The design shall be such as to permit the gear case to be opened for inspection or disassembled without releasing the stem thrust or taking the valve out of service.

6.0 WIRING & TERMINALS

6.1 All devices provided in the actuator shall be wired up to the terminal block. Contacts for remote operation and indication shall be wired up to the terminal block. Internal wiring shall be suitable for the conditions listed in the specification and sized for a minimum of 10A rating on control circuit and appropriately for 3-phase motors. Each wire shall be carefully tagged and identified at each end. The terminal compartment shall be designed so that the actuator electrical components are protected from the ingress of moisture and foreign materials.

6.2 The internal circuits associated with the remote control and monitoring functions are to be designed to withstand simulated lightning impulses of up to 1.1kV.

6.3 Minimum three numbers of cable entries shall be provided one for power supply and other three for remote control and annunciation purposes. The cable entries



shall be plugged with flame roof plugs. Power supply cable shall be 4 x 6 mm2

AYFY cable. The cable glands shall be provided suiting the over all diameters of the cables selected.

6.4 A durable terminal identification card showing plan of terminals shall be provided attached to the inside of the terminal box cover indicating :

♦ Serial No. ♦ External voltage values ♦ Wiring diagram No. ♦ Terminal layout The terminal block shall be suitable for with standing 40KA fault current for 0.25 secs.

7.0 CONTROL REQUIREMENTS

7.1 The actuator shall be provided with two modes of control viz. ‘Local’ & ‘Remote’.

7.2 Under Local mode, the actuator shall be controlled from the ‘Open’, ‘Close’ and ‘Stop’ push buttons provided on the actuator local control station as part of the integral starter.

7.3 Under Remote mode, the DCS Station shall acts as Remote Control station . The actuator shall have single integrated logic control circuit which shall communicate to the DCS. This Fieldcontrol Unit (Fcu) shall be preferably supplied as integral part of actuator or as a separate unit to be mounted near the actuator in a dust proof enclosure. The field control unit shall be interfaced with DCS through field bus with necessary interface cards to exchange signals both analog and digital to provide information as required and control as indicated in the specification.

7.4 Alternatively, the field control unit may be interfaced with DCS through Master Station fulfilling the above requirements and the communication between DCS and master station & Master station and actuator shall be through open protocol.

7.5 The following inputs are to be ensured to the DCS. ♦ Valve position – 4 to 20 mA signal ♦ Valve jammed. ♦ Valve open. ♦ Valve closed. ♦ Open Torque switch status ♦ Close Torque switch status ♦ Emergency Stop buttons status ♦ Motor running feed back. ♦ Mains failure. ♦ Remote position selection

8.0 MASTER STATION

Microprocessor based redundant Master station (2 Nos.) shall be provided to



control and monitor all motor operated valve actuators. Master station shall be located in main control room and interfaced with Main plant DCS through RS-485 redundant serial communication link with Modbus protocol. The valve field units/ actuators shall be connected on twisted pair loop to the master station.

Each Master station shall have the following minimum features: -

a. It shall have capacity to connect and control minimum 200 motor actuated

valves. It shall have provision for extending the no .of nodes in case required in future.

b. It shall have REDUNDANCY in communication, processor and power supply and

there shall be bump less transfer in case of failure of any one of the above. c. It shall have LCD/LED display unit with provision of operating the valves from

master station in stand-alone. d. It shall have facilities to set parameters like baud rate, address, skipping of few

actuators during maintenance, etc. e. It shall have capacity to receive at least 25 digital signals and 3 analog signals

through communication link from each valve actuator. f. It shall have it's dedicated self diagnostic features to find out faults like cable fault

(for cable open and cable short or grounded), actuator communication is not reached and all actuator faults and alarms, etc) and it shall have real time clock to monitor alarm events/data/faults.

g. It shall include necessary software and hardware and any special programming

tool is required to achieve the above. 9.0 SIZING OF ACTUATOR

9.1 The actuator shall be sized to guarantee valve closure at the specified differential pressure.

9.2 The safety margin of the motor power available for seating and unseating the valve shall be sufficient to ensure torque switch trip at maximum valve torque with the supply voltage 10% below normal.

9.3 The operating speed shall be designed to ensure valve closing and opening operation as per process requirements with out causing damage to the system.

9.4 The contractor shall submit sizing calculations indicating how the particular actuator model quoted has been selected for the specified pressure. The following shall be indicated in the offer:

9.5 Torque calculation with stem diameter and lead screw thread.

9.6 Time considered for closing the valve.



9.7 Details of actuators like motor HP, RPM & efficiency also shall be shown in the calculations.

10.0 WIRING AND TERMINALS - Wiring Shall be done with PVC insulated (tropical grade) stranded copper

wires. - Wiring from internal components shall be brought out to separate sealed

terminal block compartment. - Vibration proof connectors shall be used. - Terminal block shall have adequately spaced studs/screws Power and control terminals shall be segregated. - Terminal block compartment shall have internal Ground Terminal. - The Valve actuator units shall be suitable for AYRY 4 x 6 Sq. mm cable.

11.0 QUALITY ASSURANCE PLAN (QAP) Quality Assurance Plans shall be submitted by the contractor, based on the sample QAP’s included with this specification (Annexure-1). The contractor’s QAP’s shall include all tests/ inspection procedures indicated in the sample QAP’s, as minimum, which, after finalization, shall form the basis of inspection procedures to be followed and complied with.

Type test certificates for the offered models shall be enclosed with the offer, Stage wise inspection for specified items, calibration and test report should be provided.

12.0 DOCUMENT / INFORMATION REQUIRED a) SLD and control scheme indicating motor KW rating, electrical components ratings cable sizes etc.,

b)GA drawing for electrical actuators along with actuator data sheet.

c)G.A. & BOM with ratings & make of components for the actuator

d)Motor data sheet along with motor performance curves QAP for motor & actuator]

e)QAP

For Reference a) G.A. and terminal plan & connection detail for terminal box b) Torque switch setting range and recommended setting for the intended application c) Actuator sizing calculation c) Wiring diagrams along with diagram number, control schematic and detailed write-up on offered equipments. d) Manufacturer’s catalogues & application information e) Spare part list and ordering information for actuator components. f) List of recommended spares and quantity recommended,



ANNEXURE-B

TECHNICAL SPECIFICATION FOR PNEUMATIC OPERATED VALVE ACTUATORS

This specification covers the requirements for design, manufacture, testing and supply of pneumatic actuators intended for only fully/partially opening/closing valve duty. The offered actuator shall be suitable for operating under service conditions and system conditions as specified below:

1. Pneumatic Actuators 1. Actuators shall be preferably microprocessor based and field bus compatible. 2. Actuators shall be sized for 1.5 times of shut-off differential pressure. 3. For spring-opposed diaphragm type actuators, the spring shall be corrosion-

resistant and cadmium or nickel-plated. 4. Actuator operating range shall be 0.2 to 1.0 kg/cm2. 5. I/P converters shall be preferably microprocessor based and working on Field

bus. The PID control block shall be in-built in all I/P converter/ Smart positioners.

6. Valve positioners or boosters may be considered for actuators for the following applications:

• To split-range of the controller output to more than one valve. • To amplify the controller output beyond the standard signal range (i.e., 0.2-

1kg/cm2), in case of actuators with greater thrust or stiffness. 7. In all the above applications, whether or not a positioner or booster is to be

used shall depend on the speed of response of the system. 8. Actuator casing and diaphragm shall be designed to withstand 7.0 kg/cm2 (g)

air pressure. 9. Actuator sizing shall be done considering Instrument air pressure of 3

kg/cm2(g). 10. Valve manufacturer shall provide control valve actuator diaphragm fabrication

drawing to Purchaser.

2. Positioners 1. Valve positioners, wherever required, shall be side-mounted on the control

valves and shall be direct-acting type, unless otherwise indicated. 2. Wherever the operating range of the actuator is the same as that of the control

signal, the positioner shall be provided with an integral bypass switch. 3. All valve positioners shall have integral pressure gauges to indicate input

supply, control signal and positioner output pressures. 4. All pneumatic connection points shall be of ¼” NPT (F), in accordance with

ANSI B 20.1. In case they are different, suitable adapters shall be provided. 5. Positioners shall have corrosion-resistant linkages and rugged brackets. 6. Control valves positioners shall have repeatability within 0.5% of stroke, for a

given input signal.



3. Limit Switches 1. Limit switches, wherever specified, shall be suitable for mounting on the valve

and shall be supplied along with all mounting accessories. 2. Limit switch enclosures shall be weatherproof to NEMA 4, or suitable for the

specified hazardous area classification. 3. Limit switches shall be SPDT type, silver-alloy-plated, hermetically sealed and

rated for minimum 230 VAC, 2A (inductive). 4. Flying leads are not acceptable. Terminal blocks of limit switches shall be

located inside the switch housing.

4. Position Transmitter All control valves shall be provided with position transmitters. Position Transmitter shall be capacitive / inductive type and shall work on Field bus.

5. Solenoid Valves

Solenoid valves wherever specified will meet the following requirements as minimum:

1. Shall have resilient soft seat providing tight shut off. 2. Coils shall be hermetically sealed, continuous duty type and wired to a terminal

block located inside the housing, flying leads are not acceptable. 3. Coils shall be suitable for +/- 10% variation in power supply. Minimum holding

voltage shall be 70% of rated supply voltage 24V DC. 4. Coil insulation shall be class F minimum. 5. Unless otherwise specified solenoid valves shall be 3 way universal type. 6. Solenoid valves shall be full-bore type with minimum bore size 3 mm. 6. Air Filter Regulator

2 nos. of air filter regulator shall be provided with each control valve. One regulator for I/P converter and the other for positioner.



ANNEXURE-C

Notes on valves for instrumentation & control

The following shall be included along with the Valves:

Field Interconnection to DCS: 1. All the mounted Instruments for the valves as required shall be provided. 2. All Solenoids shall be 24V DC operated. 3. All Limit switches (Open/Close) shall be wired to be to a common JB. These

shall be of FRP of thickness 2.5mm and shall be weather proof, & with IP 65 protection. Three cable entries entries ( for 1 no. 5Cx1.5 Sqmm & 2 nos. 3Cx1.5) Sqmm shall be considered.

4. JB for SOV & LS shall be separate . A. MANUAL VALVES

1 no. of Limit switch shall be provided for the manual valves in the concentrate outlet of all the UF for interlocking with other On-Off valves.

B PNEUMATIC ON-OFF VALVES

Both Open and Close Limit switches shall be considered for all Pneumatic on-off valves and the following shall be considered for solenoid operation:

SOLENOID VALVEs:

1. Solenoid valve shall be provided in the pilot air supply line to pneumatic

actuator. 2. The service gas shall be Instrument Air at 4.0 Bar. 3. The solenoid configuration shall be 3 port, 2 way. 4. Solenoid Excitation voltage shall be 24 V dc. 5. The coil shall be hermetically sealed and shall be class H insulated. 6. The solenoid for direct acting SV shall be suitable for the maximum operating

differential pressure and safe static pressure as per process condition. 7. Electrical connection shall be terminated in a dust proof junction box. 8. Terminal connection of 1.5 sq. mm and cable entry of ½" NPT (F) shall be

considered. 9. Mounting shall be on the actuator's body. 10. Material of the body shall be of suitable for applicable environment. 11. Diameter of the hole shall be sufficient to guarantee the stroke time of the

valve. 12. Port size of the solenoid valve for pneumatic valves shall be adequate capacity

for quick operation of the valve. This shall be reputed make as indicated in the list of preferred makes.



C Electrical ON-OFF VALVES

Motorised actuators shall be used for electrical On-Off Valves . The detailed specification for the same is included under Chapter-9 of Volume-II A



TECHNICAL SPECIFICATION FOR UNLOADING,STORAGE,ERECTION, TESTING & COMMISSIONING



CONTENT

SL. NO.

DESCRIPTION PAGE NO.

1.0 UNLOADING & STORAGE AT SITE: 1

2.0 ERECTION 1-4 3.0 COMMISSIONING AND PERFORMANCE TESTING 4 4.0 PERFORMANCE GUARANTEE AND

WARRANTEE 4



01.00 UNLOADING & STORAGE AT SITE:

Unloading of plant / equipment etc, and their storage & safe custody at site will be done by the contractor with his manpower and machinery. Purchaser shall provide the designated site “on as and where is as basis” for carrying construction works which includes space for storage, pre-fabrication, temporary site office etc. Contractor shall make the requisite storage facilities for construction materials, equipments etc. and shall plan the schedule for procurement, fabrication and erection in such a way that all materials can be stored within the respective planned storage space and it will not create any obstruction towards construction schedule, neither will cause inconvenience for other working agency.

02.00 ERECTION: 02.01 SCOPE 02.01.01 The contractor shall carryout complete erection, testing and

commissioning of the plant and equipment under his scope of work. 02.01.02 The contractor shall arrange for all labour, all machinery, tools and

tackles, safety items, consumables and other items required to enable loading, handling, fabrication, erection etc.

02.01.03 Construction power and water shall be arranged by the contractor at his

own cost. 02.01.04 Service of competent personnel for supervision and execution of site

fabrication, erection, testing, commissioning etc. shall be provided by the contractor.

02.01.05 All expenses incurred towards erection, trial run, testing & commissioning

shall be included in scope of work and same shall deemed to be covered in the respective item/equipment considered under the head “erection” in the bill of quantities.

02.01.06 After completion of work contractor shall remove all the waste materials

or rubbish from and around the work site and leave the place thoroughly cleaned up making it ready for use.

02.02 EQUIMENT ERECTION

The contractor shall carry out the following for equipment erection:



02.02.01 Receiving equipment /material from company’s site, unpacking, storage,

loading, transporting the same to respective erection points. 02.02.02 Safe storage of equipment/material received till those are installed. 02.02.03 Cleaning, flushing and lubricating equipment/material before assembly,

erection and testing. 02.02.04 Checking of foundation levels, center lines, orientation, locations etc. 02.02.05 Carrying out minor leveling and alignment of equipment foundation and

supports including chipping of concrete foundation, if required, upto thickness of 50mm.

02.02.06 Assembling coupling, fitting, fixing, jointing, aligning various sections of

equipment including “V” belts, pulleys etc. by welding / bolting etc. as per the drawings.

02.02.07 Servicing of anchor bolts. 02.02.08 Supply and fabrication of liner plates, shim plates. 02.02.09 Installing the equipment on foundation/structures / platforms / walls

/columns as the case may be in proper orientation. 02.02.10 Orientating and leveling the equipment including supply and fabrication of

packing plates if required. 02.02.11 Fixing and grouting of anchor bolts and base frame. 02.02.12 Assembly, positioning, fixing of all accessories (platform, ladder,

internals) on the main equipment. 02.02.13 Providing temporary supports, scaffolding, staging around or inside the

equipment as required during the construction, installation, erection or testing. Removing the same after the job completion and keeping the area clean. Wooden ladders are not acceptable. Contractor shall use metallic ladders only.

02.02.14 Protecting properly all installed and uninstalled equipment / material from

damage, pileferage and becoming a hazard to life and property. Protecting nozzles, flanges, machined parts, open pipe ends etc. by



covering with polythene sheets, wooden blanks included in the scope of contractor.

02.02.15 Fabrication and erecting of all temporary or secondary supports,

assemblies etc. that are required for supporting, fixing equipment, pipes, ducts etc.

02.02.16 In case of any shortage, errors, damages of equipment included in

erection scope, found during the erection and testing the detailed report to be submitted to corporation/site engineer and rectifying the defects free of change.

02.02.17 Cleaning of equipment (Internal & External) before testing. 02.02.18 Testing of equipment as per the requirement, specifications and

standards. 02.02.19 Draining, emptying and cleaning the equipment after testing. 02.02.20 Opening/closing manholes/nozzles etc. as required during pre

commissioning. 02.02.21 ROTARY EQUIPMENT ERECTION 02.02.21.1 In addition to points 02.02.01 to 02.02.20 following points are to be

attended by the CTONRACTOR. 02.02.21.2 Servicing of coupling, stuffing box, bearings. 02.02.21.3 Installation of equipment, motor on the base frame. 02.02.21.4 Checking the motor, equipment for free rotation. 02.02.21.5 Aligning and coupling equipment with motor before piping. 02.02.21.6 Alignment after piping. 02.02.21.7 Decoupling for testing motor 02.02.21.8 Recoupling of equipment with motor after testing. 02.02.21.9 Hot alignment during trial run.



02.02.21.10 Installation of mechanical seal and pump/seal accessories to be carried out under the supervision of manufacturer

02.02.21.11 Fixing, aligning of equipment shall be done by skilled millwright fitter who

will be approved by the Purchaser/Consultant. 02.02.22 PIPING, VALVES & OTHERS 02.02.22.1 Erection of piping & valves and other equipment shall be as per the

respective relevant technical specifications. 03.00 COMMISSIONING AND PERFORMANCE TESTING

Commissioning shall mean when the plant / unit is put into operation to produce good products / outputs after successful testing and trail runs of the integrated system. The same is detailed in volume1 & chapter1 of volume IIA.

Performance testing for individual equipment, pressure testing of piping, ducting at site are to be carried by the contractor as per relevant standards / approved drawings.

Performance testing for the system should be carried out by the contractor for the continuous and smooth running of the plant, equipment and generating material throughput for 72 hours to the full satisfaction of the purchaser / consultant. If the satisfactory results are not achieved, the contractor shall take complete responsibility to do necessary modifications in the installation at his own cost in order to meet the performance requirements.

04.00 PERFORMANCE GUARANTEE AND WARRANTEE:

Complete plant & equipment shall be guaranteed for material and workmanship as per the Conditions of Contract, volume 1 . The guarantee shall include demonstration of satisfactory performance of individual components I equipment I systems as covered in the respective technical specification chapters under volume IIA & B. The performance guarantee and testing for the parameters for complete desalination plant shall be as per chapter 1 of volume IIA and chapter 13 of IIB for sewage treatment plant.




FOR

SHOP & FIELD PAINTING



CONTENTS Sl. No.

Description Page No.

1.0 GENERAL 1 2.0 SCOPE 1-3 3.0 CODES & STANDARDS 3-4 4.0 EQUIPMENT 4 5.0 SURFACE PREPARATION 5-17 6.0 PAINT MATERIALS 17-21 7.0 PAINTING SYSTEMS 21-22 7.1 PRE-ERECTION/ PRE-FABRICATION AND SHOP PRIMING FOR

CARBON STEEL, LOW TEMPERATURE CARBON STEEL & LOW ALLOY STEEL, STEEL STRUCTURES, PIPING AND EQUIPMENT ETC.

23

7.2 REPAIR OF PRE-ERECTION/ FABRICATION AND SHOP PRIMING AFTER ERECTION/ WELDING FOR CARBON STEEL, LOW TEMPERATURE CARBON STEEL & LOW ALLOY STEEL, ITEMS IN ALL ENVIRONMENTS.

23

8.0 FIELD PAINT SYSTEM FOR NORMAL CORROSIVE ENVIRONMENT (FOR CARBON STEEL, LOW TEMPERATURE CARBON STEEL & LOW ALLOY STEEL)

24-25

9.0 FIELD PAINT SYSTEM FOR NORMAL CORROSIVE ENVIRONMENT (FOR CARBON STEEL, LOW TEMPRETURE CARBON STEEL AND LOW ALLOY STEEL)

26-27

10.0 FIELD PAINT SYSTEM FOR HIGHLY CORROSIVE AREA (FOR CARBON STEEL, LOW ALLOY STEEL) EXTERNAL SURFACE OF UNINSULATED COLUMNS, VESSELS, HEAT EXCHANGERS, BLOERS, PIPING, PUMPS, TOWERS, COMPRESSORS, FLARE LINES, STRUCTURAL STEEL ETC.

28

11.0 FIELD PAINT SYSTEM FOR CARBON STEEL STORAGE TANKS (EXTERNAL) FOR ALL ENVIRONMENTS

29

12.0 FIELD PAINT SYSTEM FOR CARBON STEEL AND LOW ALLOY STEEL STORAGE TANK (INTERNAL)

30-32

13.0 COATING SYSTEM FOR EXTRNAL SIDE OF UNDERGROUND CARBON STEEL, PLANT PIPING AND TANKS.

33-34

14.0 PAINTING UNDER INSULATION FOR (HOT, COLD & SAFETY) CARBON STEEL LOW TEMPERATURE CARBON STEEL & STAINLESS STEEL PIPING AND EQUIPMENT IN ALL ENVIRONMENT

35-36

15.0 INTERNAL PROTECTION OF CARBON STEEL WATER BOXES AND TUBE SHEETS OF COOLERS/ CONDENSERS.

37

16.0 FIELD PAINTING SYSTEM FOR GI TOWERS/ NON-FERROUS TUBE SHEET

37-38


(ii) ADECO TECHNOLOGIES MECON LIMITED

17.0 STORAGE 39 18.0 COLOURS CODE FOR PIPING 39-42 19.0 IDENTIFICATION OF VESSELS, PIPING ETC. 42-43 20.0 PAINTING FOR CIVIL DEFENCE REQUIREMENTS 43 21.0 INSPECTION AND TESTING 43-45 22.0 GUARANTEE 45-46 23.0 QUALIFICATION CRITERIA O PAINTING CONTRACTOR. 46 24.0 PROCEDURE FOR APPROVAL OF NEW PAINT MANUFACTURERS. 46-47 ANNEXURE-I- LIST OF RECOMMENDED MANUFACTURES 48 ANNEXURE-II- LIST OF RECOMMENDED MANUFACTURE’S

PRODUCTS. 49-54



1.0 GENERAL 1.1 This general technical specification for painting shall be applicable for the work

covered in the contract document and without prejudice to the various codes of practice, standard specifications etc. it is understood that contractor shall complete the work in all respects with the best quality of materials and workmanship and in accordance with the best engineering practice and instructions of Purchaser/Consultant.

1.2 Wherever it is stated in the specification that a specific material is to be supplied

or a specific work is to be done it shall be deemed that the same shall be supplied or carried out by the contractor.

Any deviation from this standard without within deviation permit from appropriate

authority will result in rejection to job. 1.3 The painting scheme applicable for Desalination plant and equipment , piping

systems shall be “FIELD PAINT SYSTEM FOR HIGHLY CORROSIVE AREA”. However as a general rule, in case any paint system has been specifically specified in the respective drawing/datasheet/technical specifications, the same shall prevail over this general technical specification for painting herein.

2.0 SCOPE

Scope of work covered in the specification shall include, but not limited to the following.

2.1 This specification defines the requirements for surface preparation, selection and

application of paint on external surfaces of equipment, vessels, machinery, piping, ducts, steels structures, external & internal protection of storage tanks for all services RCC Chimney & MS Chimney with or without refractory lining and flare lines etc.

2.2 Extent of Works 2.2.1 The following surface and materials shall require shop, pre-erection and field

painting.

a. All uninsulated C. S. & A.S. equipment like columns, vessels, drums, storage tanks, heat exchangers, pumps, compressors, electrical panels and motors etc.



b. All uninsulated carbon and low alloy piping fitting and valves (including painting of identification marks), furnace, ducts and stacks.

c. All items contained in a package unit as necessary.

d. All structural steel work, pipe, structural steel supports, walkways,

handrails, ladders, platforms etc.

e. RCC/ MS chimneys with or without refractory lining & Flare lines.

f. Identification colour bands on all piping as required including insulated aluminium clad, galvanised, SS and non-ferrous piping.

g. Identification lettering/ numbering on all painted surface of equipment/

piping insulated aluminium clad, galvanised, SS and non-ferrous piping.

h. Marking/ identification signs on painted surfaces of equipment/ piping for hazardous service.

i. Supply of all primers, paints and all other materials required for painting

other than owner’s supply.

j. Over insulation surface of equipments and pipes wherever required.

k. Painting under insulation for carbon steel and stainless steel as specified.

l. Repair work of damaged/ pre erection/ fabrication shop primer and weld joints at field.

2.2.2 The following surface and materials shall not be painted unless otherwise

specified:

a. Uninsulated austentic stainless steel. b. Plastic and/ or plastic coated materials.

c. Non ferrous materials like aluminium, galvanised “piping”, “gratings” and

“handrails” etc. except G. I. Towers. 2.3 Documents 2.3.1 The contractor shall perform the work in accordance with the following

documents issued to him for executions of work.



a. Bill of quantities for piping, equipment, machinery and structure etc.

b. Piping line list.

c. Painting specifications including special civil defence requirement.

2.4 Unless otherwise instructed final painting on pre-erection/ shop primed pipes and

equipments shall be painted in the field, only after mechanical completion and testing on system are completed as well as, after completion of steam purging wherever required.

2.5 Changes and deviations required for any specific job due to clients requirement

or otherwise shall be referred to EIL for deviation permit. 3.0 CODES & STANDARDS 3.1 Without prejudice to the provision of clause 1.1 above and the detailed

specifications of the contract, the following codes and standards shall be followed for the work covered by this contract.

IS:5 : Colour coding IS-101 : Methods of test for ready mixed paint and enamels.

IS-2379:1990 : Indian standard for pipe line

Identification –Colour code. ASTM : American standard test methods for

Paints and coatings. ASA A 13.1-1981 : Scheme for Identification of piping

Systems : American National Standard Institution.

3.2 Surface Preparation Standards:

Following standards shall be followed for surface preparations: 3.2.1 Swedish Standard : SIS-05 5900-1967/ ISO-8501-1-1998

(Surface preparation standards for painting steel surfaces).



This standard contains photographs of the various standards on four different degrees of rusted steel and as such is preferable for inspection purpose by the Purchaser/Consultant.

3.2.2 Steel structure painting Council, U.S.A (surface preparations specifications

(SSPC-SP). 3.2.3 British standard (surface finish or Blast-cleaned for painting) BS:4232 3.2.4 National Associations of Corrosion Engineers, U.S.A. (NACE) 3.2.5 Various International Standards equivalent to swedish Standard for surface

preparation are given in Table-I. 3.3 The contractor shall arrange, at his own cost, to keep a set of latest edition of any

one of the above standards and codes at site. 3.4 The paint manufacturer’s instructions shall be followed as far as practicable at all

times. Particular attention shall be paid to the following:

a. Instructions for storage to avoid exposure as well as extremes of temperature.

b. Surface preparations prior to painting.

c. Mixing and thinning.

d. Application of paints and the recommended limit on time intervals

between coats. 4.0 EQUIPMENT 4.1 All tools, brushes, rollers, spray guns, abrasive materials hand/ power tools for

leaning and all equipments, scaffolding materials, shot/ wet abrasive blasting, water blasting equipments & air compressors etc. required to be used shall be suitable for the work and all in good order and shall be arranged by the contractor at site and in sufficient quantity.

Mechanical mixing shall be used for paint mixing operations in case of two pack systems except that the Purchaser/Consultant may allow the hand mixing of small quantities at his discretion.



5.0 SURFACE PREPARATION, SHOP COAT, COATING APPLICATION & REPAIR AND DOCUMENTATION

5.1 General 5.1.1 In order to achieve the maximum durability, one or more of following methods of

surface preparation shall be followed, depending on condition of steel surface and as instructed by Purchaser/Consultant. Adhesion of the paint film to surface depends largely on the degree of cleanliness of the metal surface. Proper surface preparation contributes more to the success of the paint protective system: a. Manual or hand tools cleaning. b. Mechanical or power tool cleaning. c. Blast cleaning.

5.1.2 Mill scale, rust, rust scale and foreign matter shall be removed fully to ensure that

a clean and dry surface is obtained. The minimum acceptable standard in case of manual or hand tool cleaning shall be St. 2 or equivalent, in case of mechanical or power tool cleaning it shall be St. 3 or equivalent, in case of blast cleaning it shall be Sa 2½ or equivalent as per Swedish Standard SIS-055900-1967/ ISO-8501-1-1988. Where highly corrosive condition exits, then blast cleaning shall be Sa3 as per Swedish Standard.

Remove all other contaminants, oil, grease etc. by use of an aromatic solvent prior to surface cleaning.

5.1.3 Blast cleaning shall not be performed where dust can contaminate surfaces

undergoing such cleaning or during humid weather conditions having humidity exceeding 85%.

5.1.4 Irrespective of the method of surface preparation, the first coat of primer must be

applied on dry surface. This should be done immediately and in any case within 4 hours of cleaning of surface. However, at times of unfavourable weather conditions, the Purchaser/Consultant shall have the liberty to control the time period, at his sole discretion and / or to insist on recleaning, as may be required, before primer application is taken up. In general, during unfavourable weather conditions, blasting and painting shall be avoided as far as practicable.

5.1.5 The external surface of R.C.C. chimney to be painted be dry and clean. Any

loose particle of stand, cement, aggregate etc. shall be removed by rubbing with soft wire brush if necessary, acid etching with 10-15% HCL solution about 15



minutes shall be carried out and surface must be thorought washed with water to remove acid & loose particles then dry completely before application of paint.

5.2 Procedure of Surface Preparation. 5.2.1 Blast Cleaning 5.2.1.1 Air Blast Cleaning

The surface shall be blast cleaned using one of the abrasives: AL202 particles chilled casts iron or malleable iron and steel at pressure of 7kg. Cm2 at appropriate distance and angle depending on nozzle size maintaining constant velocity and pressure. Chilled cast iron, malleable iron and steel shall be in the form of shot or grit of size not greater than 0.055” maximum in case of steel and malleable iron and 0.04” maximum in case of chilled iron. Compressed air shall be free form moisture and oil. The blasting nozzles should be venturi style with tungsten carbide or boron carbide as the material for liners. Nozzles orifice may vary from 3/16” to ¾”. On completion of blasting operation, the blasted surface shall be clean and free from any scale or rust and must show a grey white metallic lusture. Primer or first coat of paint shall be applied within 4 hours of surface preparation. Blast cleaning shall not be done outdoors in bad weather without adequate protection or when there is dew on the metal which is to be cleaned, surface profile shall be uniform to provide good key to the paint adhesion (i.e.35to 50μ). If possible vacuum collector shall be installed for collecting the abrasive and recycling.

5.2.1.2 Water Blast cleaning

Environmental, health and safety problems associated with abrassive blast cleaning limit the application of air blast cleaning in many installations. In such case water blast cleaning is resorted to. Water blast cleaning can be applied with or without abrassive and high-pressure water blasting. The water used shall be inhibited with sodium chromate/ phosphate. The blast cleaned surface shall be washed thoroughly with detergents and wiped solvent and dried with compressed Air. For effective cleaning abrassives are used. The most commonly used pressure for high pressure water blast cleaning for maintenance surface preparation is 3000 to 6000 psi at 35-45 liters/ minute water volume and pressure upto 10000 psi and water volume of 45 liters/ minute provide maximum cleaning.



The waste blast cleaned surface shall be comparable to SSPC-SP-12/ NACE No. 5. The operation shall be carried out as per SSPC guidelines for water blast cleaning. The indicative values for sand injection is Air : 300 to 400 Cu.ft/ min. Water : 5-10 liter/ min. with corrosion inhibitor Sand : 200-400 lbs/ hr. Nozzle : 0.5 to 1” dia

Special equipments for water blast cleaning with abrasives now available shall be used.

5.2.2 Mechanical of Power tool cleaning

Power tool cleaning shall be done mechanical striking tools, chipping hammers, grinding wheels or rotating steels wire-brushes. Excessive burnish of surface shall be avoided as it can reduce paint adhesion. On completion of cleaning, the detached rust mill scale etc. shall be removed by clean rags and/ or washed by water or stream and thoroughly dried with compressed air jet before application of paint.

5.2.3 Manual or hand tool cleaning

Manual or hand tool cleaning is used only where safety problems limit the application of other surface preparation procedure and hence dones not appear in the specifications of paint systems. Hand tool cleaning normally consists of the following: a. Hand descaling and/ or hammering b. Hand scraping c. Hand wire brushing Rust, mill scale spatters, old coating and other foreign matter, shall be removed by hammering, scrapping tools, emery paper cleaning, wire brushing or combination of the above methods. On completion of cleaning, loose materials shall be removed from the surface by clean rags and the surface shall be brushed, swept, deducted and blown off with compressed air/ steam to remove all loose matter. Finally the surface may be washed with water and dried for effective cleaning.

5.3 Non compatible shop coat primer



The compatibility of finishing coat should be confirmed from the paint manufacturer. In the event of use of primer such as zinc rich epoxy, inorganic zinc silicate etc. as shop coat the pant system shall depend on condition of shop coat, if shop coat is in satisfactory condition showing no major defects, the shop coat shall not be removed. The touch up primer and finishing coat(s) shall be identified for application by Purchaser/Consultant.

5.4 Shop coated (coated with primer & finishing coat) equipment should not be

repainted unless paint is damaged. 5.5 Shop primed equipment and surface will only be ‘spot cleaned’ in damaged areas

by means of power tool brush cleaning and then spot primed before applying one coat of filed primer unless otherwise specified. If shop primer is not compatible with field primer then shop coated primer should be completely removed before applications of selected paints system for particular environment.

5.6 For packaged units/ equipment, shop primer should be as per the paint system

given in this specification. However, manufacturer’s standard can be followed after review.

5.7 Coating Procedure and Application: 5.7.1 Surface shall not be coated in rain, wind or in environment where injurious

airbone elements exists, when the steel surface temperature is less than 5° F above dew point when the relative humidity is greater then 85% or when the temperature is below 40° F.

5.7.2 Blast cleaned surface shall be coated with one complete application of primer as

soon as practicable but in no case later than 4 hrs. the same day. 5.7.3 To the maximum extent practicable, each coat of material shall be applied as a

continuous film uniform thickness free of probes. Any spots or areas missed in application shall be recoated and permitted to dry before the next coat is applied. Applied paint should have the desired wet film thickness.

5.7.4 Each coat shall be proper state of cure or dryness before the application of

succeeding coat. Material shall be considered dry for recoating when an additional coat can applied without the development of any detrimental film irregularities such as lifting or loose of adhesion of the under coat. Manufacturer instruction shall be followed for intercoat interval.

5.7.5 When the successive coat of the same colour have been specified, alternate coat

shall be tinted, when practical, sufficiently to produce enough contrast to indicate



complete coverage of the surface. The tinting material shall be compatible with the material and not detrimental to its service life.

5.7.6 Air spray application shall be in accordance with the following:

a. The equipment used shall be suitable for the intended purpose, shall be capable of properly atomizing the paint to be applied, and shall be equipped with suitable pressure regulators and gauges. The air caps, nozzles, and needles shall be those recommended by the manufacturer of the equipment for the material being sprayed. The equipment shall be kept in satisfactory condition to permit proper paint application.

b. Traps or separators shall be provided to remove oil and condensed water

from the air. These traps or separators must be of adequate size and must be drained periodically during operations. The air from the spray gun impinging against the surface shall show condensed water or oil.

c. Ingredients shall be kept properly mixed in the spray pots or

containers during application by continuous mechanical agitation.

d. The pressure on the material in the pot and of the air at the gun shall be adjusted for optimum spraying effectiveness. The pressure on the material in the pot shall be adjusted when necessary for change in elevation of the gun above the pot. The atomizing air pressure at the gun shall be high enough to properly atomize the paint but not so high as to cause excessive fogging of paint, excessive evaporation of solvent, or less by overspray.

e. Spray equipment shall be kept sufficiently clean so that dirt, dried paint,

and other foreign materials are not deposited in the paint film. Any solvents left in the equipment shall be completely removed before applying paint to the surface begin painted.

f. Paint shall be applied in a uniform layer, with overlapping at the edge of the spray pattern. The spray patterns shall be adjusted so that the paint is deposited uniformly. During application the gun shall be held perpendicular to the surface and at a distance which will ensure that a wet layer of paint is deposited on the surface. The trigger of the gun should be released at the end of each stroke.

g. All runs and sags shall be brushed out immediately or the paint shall be

removed and the surface repainted.



h. Areas inaccessible to the spray gun shall be painted by brush: if not

accessible by brush, daubers or sheepking shall be used.

i. All nameplates, manufacturer’s identification tags, machined surface instrument glass, finished flange faces, control valve items and similar items shall be masked to prohibit coating disposition. If these surface are coated, the component shall be cleaned and restored to its original condition.

j. Edges of structural shapes and irregular coated surface shall be coated

first and an extra pass made later.

k. If spray gun shown choking, immediately de choking procedure shall be followed.

5.7.7 Airless spray application shall be in accordance with the following procedure: as

per steel structure paint manual vol. 1 & vol. 2. By SSPC, U.S.A., Air less spray relies on hydraulic pressure rather than air atomization to produce the desired spray. An air compressor or electric motor is used to operate a pump to produce pressures of 1,000 to 6.000 psi. Paint is delivered to the spray gun at this pressure through a single hose within the gun, a single paint stream is divided into separate streams, which are forced through a small orifice resulting in atomization of paint without the use of air. This result in more repaid coverage with less overspray. Airless spray usually is faster, cleaner, more economical and easier to use than conventional air spray.

Airless spray equipment is mounted on wheels, and paint is aspirated in a hose that sucks paint from any container, including drums. The unit shall have in built agitator that keep the paint uniformly mixed during the spraying. The unit shall consists of in built strainer. Usually very small quantities of thinning is required before spray. Incase of High Build epoxy coating (two pack), 30:1 pump ratios and 0.020-0.023” tip size will provide a good spray pattern. Ideally fluid hoses should no be less than 3/8” ID and not longer than 50ft to obtain optimum results. In case of gun choking, decoking steps shall be followed immediately.

5.7.8 Brush application of paint shall be in accordance with the following:

a. Brushes shall be of a style and quality that will enable proper application of paint



b. Round or oval brushes are most suitable for rivets, bolts, irregular surfaces and rough or pitted steel. Wide flat brushes are suitable for large flat areas, but they shall not have width over five inches.

c. Paints shall be applied into all corners.

d. Any runs or sags shall be brushed out.

e. There shall be minimum of brush marks left in the applied paint

f. Surface not accessible to brushes shall be painted by spray, duubers, or

sheepkin. 5.7.9 Manual application by sling (where 6 O’ clock position of pipe is not

approachable)

A canvas strip (alternatively a tinplate strip) about 450mm wide and 1.5m longs is hold under the pipe by two men. Liquid coating poured on the sling at each side of the pipe. The men holding this sling move it up and down and walk slowly forward while fresh coating is poured on the pipe and they manipulate the sling so that an even coating is ontained all round the bottom. This work shall be done very carefully and by experienced personnel. There shall not be any formation of “Whiskers” and holes in the coating. The coating film shall be inspected by mirror.

5.7.10 For each coat the painter should know the WFT corresponding to the specified

DFT and standardise the paint application technique to achieve the desired WFT. This is to be ensured in the qualification trial.

5.8 Drying of Coated Surface 5.8.1 No coat shall be applied unit the preceding coat has dried. The material shall be

considered dry for re-coating when another coat can be applied without the development of any film irregularities such as lifting or loss of adhesion of undercoats. Drying time of the applied coat should not exceed maximum specified for it as a first coat; if it exceeds the paint material has possible deteriorated or mixing is faulty.

5.8.2 No paint shall be force dried under condition which will cause checking, wrinkling

blistering formation of pores, or detrimentally after the condition of the paint.

No drier shall be added to a paint on the job unless specifically called for in the manufacturer’s specification for the paint.



Paint shall be protected from rain, condensation, contamination snow and freezing until dry to the fullest extent practicable.

5.9 Repair of damaged paint surface. 5.9.1. Where paint has been damaged in handling and in transportation, the repair of

damaged coating of pre-creation/ fabrication shall be as given below. 5.9.2. Repair of damaged inorganic zinc silicate primer after erection/ welding:

Quickly remove the primer from damaged area by mechanical scraping and emery paper to expose the white metal. Blasts clean the surfaces possible. Feather the primer over the intact adjacent surface surrounding the damaged area by emery paper.

5.9.3 Repair of damaged pre-erection and shop priming in the design temperature of

90° C to 500° C.

- Surface preparation shall be done as per procedure 5.9.2 - One coat of F-9 shall be applied wherever damaged was observed on

pre-erection/ pre-fabrication/ shop primer of inorganic zinc silicate coating (F-9) shall not be applied if damaged area is not more than 5 x 5 cm.

5.10 PAINT APPLICATION 5.10.1 Shop priming/ pre-erection priming with F9 of F12 shall be done only on blasted

surface. 5.10.2 Shop priming/ pre-erection priming with F-9 or F-12 shall be done only with

airless spray. 5.10.3 For large flat surface field painting shall be done by airless spray otherwise brush

can be used. 5.11 Documentation.

1. A written quality plan with procedure for qualification trials and for the

actual work. 2. Daily progress report with details of weather condition, particular of

application no of coats and type of materials applied, anomalies, progress of work versus program me.



3. Result of measurement of temperature relative humidity, surface profile, film thickness, holiday detection, adhesion tests with signature of appropriate authority.

4. Particular of surface preparation and paint application during trials and during the work.

5. Details of non-compliance, rejects and repairs. 6. Type of testing equipments and calibration. 7. Code and batch numbers of paint material used.



TABLE-I (for clause 5.0) SURFACE PREPARATION STANDARDS

VARIOUS INTERNATIONAL

STANDARDS (EQUIVALENT) S. NO.

DESCRIPTION

SWEDISH

STANDARD SIS-05-5900

1967

SSPC-SP

USA

NACE USA

BRITISH

STANDARD BS-

4232: 1967

REMARK

1. MANUAL OR HAND TOOL CLEANING REMOVAL OF LOOSE RUST LOOSE MILL SCALE AND LOOSE PAINT, CHIPPING, SCRAPING, SANDING AND WIRE BRUSHING, SURFACE SHOULD HAVE A FAINT METALLIC SHEEN.

ST.2 SSPC-SP-2 - -

THIS METHOD IS APPLIED WHEN THE SURFACE IS EXPOSED TO NORMAL ATMOSPHERIC CONDITION WHEN OTHER METHODS CANNOT BE ADOPTED AND ALSO FOR SPOT CLEANING DURING MAINTENANCE PAINTING.

2. MECHANICAL OR POWER TOOL CLEANING REMOVAL OF LOOSE RUST, LOOSE MILL SCALE AND LOOSE PAINT TO DEGREE SPECIFIED BY POWER TOOL CHIPPING, DESCALING, SANDING, WIRE BRUSHING AND GRINDIN, AFTER REMOVAL OF DUST, SURFACE SHOULD HAVE A PRONOUNCED METALLIC

ST.3 SSPC-SP-3 - - -DO-



SHEEN.

TABLE-I (for clause 5.0)

SURFACE PREPARATION STANDARDS VARIOUS INTERNATIONAL


DESCRIPTION

SWEDISH


1967

SSPC-SP

USA

NACE USA

BRITISH STANDARD BS-

4232: 1967

REMARKS

3. BLAST CLEANING (AIR & WATER) THERE ARE FOUR COMMON GRADES OF BLAST CLEANING

3.1 WHITE METAL BLAST CLEANING TO WHITE METAL CLEANLINESS REMOVAL OF ALL VISIBLE RUST, MILL SCALE PAINT & FOREIGN MATTER 100% CLEANLINESS WITH DESIRED SURFACE PROFILE.

SA-3

SSPC-SP-5

NACE#1

FIRST QUALIT

Y

WHERE EXTREMELY CLEAN SURFACE CAN BE EXPECTED FOR PROLONG LIFE OF PAINT SYSTEMS.

3.2 NEAR WHITE METAL BLAST CLEANING TO NEAR WHITE METAL CLEANLINESS, UNIT AT LEAST 95% OF EACH ELEMENTS OF SURFACE AREA IS FREE OF ALL VISIBLE RESIDUES WITH DESIRED SURFACE PROFILE.

SA 2 ½ SSPC-SP-10

NACE #2

SECOND

QUALITY

THE MINIMUM REQUIREMENT FOR CHEMICALLY RESISTANT PAINT SYSTEM SUCH AS EPOXY, VINYL, POLYURETHANE BASED AND INORGANIC ZINC



SILICATE PAINTS, ALSO FOR CONVENTIONAL PAINT SYSTEM USED UNDER FAIRLY CORROSIVE CONDITIONS TO OBTAIN DESIRED LIFE OF PAINT SYSTEM.

TABLE-I (for clause 5.0)

SURFACE PREPARATION STANDARDS VARIOUS INTERNATIONAL


DESCRIPTION

SWEDISH


1967

SSPC-SP

USA

NACE USA

BRITISH STANDARD BS-

4232: 1967

REMARKS

3.3 COMMERCIAL BLAST BLAST CLEANING UNIT AT LEAST TWO—THIRD OF EACH ELEMENT OF SURFACE AREA IS FREE OF ALL VISIBLE RESIDUES WITH DESIRED SURFACE PROFILE.

SA-2 SSPC-SP-6 No. 3

THIRD QUALIT

Y

FOR STEEL REQUIRED TO BE PAINTED WITH CONVENTIONAL PAINTS FOR EXPOSURE TO MILDLY CORROSIVE ATMOSPHERE FOR LONGER LIFE OF THE PAINT SYSTEMS.

3.4 BRUSH-OFF BLAST BLAST CLEANING TO WHITE METAL CLEANLINESS, REMOVAL OF ALL VISIBLE RUST, MILL SCALE , PAINT & FOREIGN MATTER,

SA-1 SSPC-SP-7

No. 4



SURFACE PROFILE IS NOT SO IMPORTANT.

6.0 PAINT MATERIALS

Paint manufacturers shall furnish all the characteristics of paint material on printed literature, alongwith the test certificate for all the specified characteristics given in this specifications. All the paint materials shall be of first quality and conform to the following general characteristics as per the table 6.1, 6.2 and 6.3.



PAINT MATERIALS TABLE NO.: 6.1 PRIMERS

S. No.

DESCRIPTION P-2 P-4 P-6

1. Technical Name Chlorinated rubber Zinc Phosphpate primer

Etch primer/ wash primer

Epoxy zinc phosphate primer

2. Type and composition Single pack, air drying chlorinated rubber based medium plasticised with unsaponlfiable plasticizer, plgmented with Zic phosphate.

Two pack polyvinyl butyral resin medium cured with phosphoric acid solution pogmented with zic tetroxy choromate.

Tow component polyamide cured epoxy resin medium, pigmented with zinc phosphate.

3. Volume solids (approx) 40% 7-8% 40% 4. DFT (Dry film thickness) per coat

(approx) 40-50μ 8-10μ 40-50μ

5. Theoretical covering capacity in M2/ coat/ liter (approx)

8-10 8-10 8-10

6. Weight per liter in kgs/ liter (approx)

1.3 1.2 1.4

7. Touch dry at 30° C (approx) 30 minutes 2 hrs. After 30 mins. 8. Hard dry at 30° C (approx) Min.: 8 hrs.

Max.: no limitation Min.: 2 hrs. Max.: 24 hrs.

Min.: 8 hrs. Max.: 3-6 months

9. Over Coating Interval (approx.) Min : 8 hrs Max : No limitation

Min : 4.6 hrs Max : 24 hrs

Min : 8 hrs Max : 3-6 months

10.

Pot life (approx) at 30° C for two component paints (approx).

Not applicable Not applicable 8 hrs.



PAINT MATERIALS TABLE NO.: 6.2FINISH PAINT

S. No

DESCRIPTION F-2 F-3 F-6 F-7

1. Technical Name Acrylic polyurethane finish paint

Chlorinated rubber based finish paint

Epoxy-High build finish paint

High build coaltar epoxy coating.

2. Type and composition Two-pack aliphatic isocynate cured acrylic finish paint

Single pack plasticised chlorinated rubber based medium with chemical and weather resistant pigments.

Tow- pack polyamide/ ployamine cured epoxy resin medium suitable pigmented.

Tow pack polyamide cured epoxy resin blended with coal/ tar medium, suitably pigmented.

3. Volume solids (approx) 40% 40% 62% 65% 4. DFT (Dry film thickness)

per coat (approx) 30-40μ 40-50μ 100-125μ 100-125μ

5. Theoretical covering capacity in M2/ coat/ liter (approx)

10-13 8-10 5-6 5-2-6.5


1.3 1.2 1.4 1.5

7. Touch dry at 30° C (approx)

1 hrs. 30 minutes 3 hrs. 4 hrs.

8. Hard dry at 30° C (approx)

Overnight 8 hrs. Overnight 48 hrs.

9. Over coating interval (approx)

Min.: Overnight (12) hrs. Max.: Unlimited

Min.: Overnight Max.: Unlimited

Min.: Overnight Max.: 5 day

Min.: 24 hrs. Max.: 5 day

10. Pot life at 30° C for two component paints (approx).

6-8 hrs. Not applicable 4-6 hrs. 4-6 hrs.



PAINT MATERIALS TABLE NO.: 6.3 FINISH PAINTS

S. No

DESCRIPTION F-8 F-9 F-11 F-12

1. Technical Name Self priming type surface tolerant high build epoxy coating (Complete rust control coating)

Inorganic Zinc Slicate coating

Heat resistant synthetic medium based two pack aluminum paint suitable upto 250°C dry temperature

Heat resistant silicone aluminum paint suitable upto 500° C temperature

2. Type and composition Two-pack epoxy resin based suitable pigmented and capable pigmented and capable of adhering to manually prepared surface and old coating

A two-pack air drying self-curing solvent based inorganic zinc silicate coating.

Heat resistant synthetic medium based two pack aluminum paint suitable upto 250°C

Single pack silicone resin based medium with aluminum flakes.

3. Volume solids (approx)

72% 60% 25% 20%

4. DFT (Dry film thickness) per coat (approx)

100-125μ 65-75μ 20-25μ 20-25μ

5. Theoretical covering capacity in M2/ coat/ liter

6.0-7.2 8-9 10-12 8-10


1.4 2.3 1.2 1.1

7. Touch dry at 30° C (approx)

3 hrs. 30 min. 3 hrs. 30 min.

8. Hard dry at 30° C (approx)

24 hrs. 12 hrs. 12 hrs. 24 hrs.

9. Over coating interval (approx)

Min.: 10 hrs. Max.: 6 months

Min.: 8 hrs. at 20°C and 50% RH. Max.:

Min.: 16 hrs. Max.: Unlimited

Min.: 16 hrs. Max.: Unlimited



Unlimited 10.

Pot life (approx) at 30° C for two component paints (approx).

90 min. 4-6 hrs. Not applicable Not applicable

11.

Temperature resistance

- - 250° C 500° C

F-14: Specially formulated polyamine cured coal tal epoxy suitable for-45°C to 125°C for application under insulation F-15: Two pack cold curved epoxy phenolic coating suitable for 45°C to 125°C for application under insulation F-16: Epoxy siloxane anser coat 738

Notes: 1. Covering capacity and DFT depends on method of application. Covering capacity

specified above are theoretical. Allowing the loose during the application, minimum specified DFT should be maintained.

2. All primers and finish coats should be cold cured and air drying unless otherwise

specified. 3. All paints shall be applied in accordance with manufacturer’s instruction for

surface preparation, intervals, curing and application. The surface preparation, quality and workmanship should be ensured.

4. Technical data sheets for all paints shall be supplied at the time of submission of

quotations. 6.4 List of recommended manufacturers

The paint shall conform to the specifications given above and the best quality in their products range of the manufacturers listed in Annexure-I.

7.0 PAINT SYSTEM

The paint system should vary with type of environment envisaged in and around the plants. Three types of environment as given below are considered for selection of paint system. The paint system is also given for specific requirements.



Primers & finish coats covered in table nos. 7.0 to 15.0 PRIMERS P-2 : Chlorinated Rubber Zinc Phosphate Primer P-4 : Etch Primer/ Wash Primer P-6 : Epoxy Zinc Phosphate Primer FINISH COATS/ PAINTS F-2 : Acrylic- Polyurethane finish paint F-3 : Chlorinated Rubber Finish Paint F-6 : High Build Epoxy finish coating F-7 : High Build Coal Tar epoxy coating F-8 : Self-priming surface tolerant high build epoxy coating F-9 : Inorganic Zinc Silicate Coating. F-11 : Heat resistant Synthetic medium based Aluminum paint. F-12 : Heat resistant Silicone Aluminum paint. F-14 : Specially formulated polyamine-cured coal for Epoxy coating F-15 : Epoxy phenolic coating F-16 : Epoxy Siloxane Coating : Amercoat 738



TABLE 7.1: PRE-ERECTION/ PRE-FABRICATION AND SHOP PRIMING FOR CARBON STEEL, LOW TEMPERATURE CARBON STEEL & LOW ALLOY STEEL, STEEL STRUCTURE, PIPING AND EQUIPMENT ETC.

S. No.

DESIGN TEMPERATURE IN °C

SURFACE PREPARATION

PAINT SYSTEM

TOTAL DFT IN MICRONS (MIN.)

REMARKS

7.1.1 -90 TO 4000 SSPC-SP-10 1 COAT OF F-9

65-75 No over coating is to be done

7.1.2 401 To 500 SSPC-SP-10 1 COAT OF F-12

40-50 FINISH COAT AT SITE

TABLE 7.2: REPAIR OF PRE-ERECTION/ PRE- FABRICATION AND SHOP

PRIMING AFTER ERECTION/ WELDING FOR CARBON STEEL LOW TEMPERATURE CARBON STEEL & LOW ALLOY STEEL, ITEMS IN ALL ENVIRONMENT.

S.

No. DESIGN

TEMPERATURE IN °C

SURFACE PREPARATION

PAINT SYSTEM

TOTAL DFT IN MICRONS

(MIN.)

REMARKS

7.2.1

-90 TO 400 SSPC-SP-3 (FOR REPAIR ONLY) SSPC-SP-10

1 COAT OF F-9

65-75 FOR DAMAGED AREA OF MORE THAN 5X5 CM.

7.2.2

40 TO 500 SSPC-SP-3 (FOR REPAIR ONLY) SSPC-SP-10

2 COATS OF F-12

40-50 FOR DAMAGED AREA OF MORE THAN 5X5 CM.



TABLE 8.0: FIELD PAINT SYSTEM FOR NORMAL CORROSIVE ENVIRONMENT (FOR CARBON STEEL, LOW TEMPERATURE CARBON STEEL & LOW ALLOY STEEL)

ALL NORMAL CORROSIVE AREAS SUCH AS OFF SITES EXTERNAL SURFACE OF UNINSULATED COLUMNS, VESSELS, HEAT EXCHANGERS, BLOWERS, PIPING, PUMPS, TOWERS, COMPRESSORS, STRUCTURAL STEEL WORKS, RCC CHIMNEY WITH OR WITHOUT REFRACTORY LINE INSIDE CHIMNEY (ALL ENVIRONMENTS), EXCLUDING TANK TOPS, FLARE LINES, D.M. PLANTS, INTERIOR OF TANKS ETC. FLARE LINES FOR NORMAL CORROSIVE ENVIRONMENT ALSO TO NE PAINTED AS PER TABLE 9.0

PAINT SYSTEM S. NO

.

DESIGN TEMPERATURE IN

C

SURFACE

PREPARATION

FIELD PRIMER FINISH PAINT

TOTAL DFT IN MICRO

NS (MIN.)

REMARKS

8.1 -90 TO –15

SSPC-SP-10

REPAIR OF PRE-FABRICATION PRIMER 1 COAT OF F-9 @65-75μ DFT/ COAT

NONE 65-75 No over coating to be done follow repair procedure only on damaged areas of pre-erection/ pre-fabrication primer/ coating F-9

8.2 -14 TO 60 SSPC-SP-10

REPAIR OF PRE-FABRICATION PRIMER 1 COAT OF F-9 @ 65-75μ DFT/ COAT + 2 COATS OF P-2 @ 40μ DFT/ COAT 2 X 40 = 80

2 COATS OF F-3 @ 40 μ DFT/ COAT 2 X 40 = 80

225

8.3 61 TO 80 SSPC-SP-10

REPAIR OF PRE-FABRICATION PRIMER 1 COAT OF F-9 @ 65-75μ DFT/ COAT + 2 COATS OF P-6 @ 40μ DFT/ COAT 2 X 40 = 80

1 COATS OF F-6 @ 100 μ DFT/ COAT

245



8.4 81 TO 250 SSPC-SP-10

REPAIR OF PRE-FABRICATION PRIMER 1 COAT OF F-9 @ 65-75μ DFT/ COAT


125

8.5 251 TO 400

SSPC-SP-10



105

8.6 401 TO 500

SSPC-SP-10

REPAIR AS PER 7.2.2 2 COATS OF F-12 @ 20 μ DFT/ COAT 2 X 20 = 40

80

NOTE 1 : FOR MS CHIMNEY OR WITHOUT REFRACTORY LINING 8.3, 8.4 AND 8.5 SHALL BE FOLOWED.

NOTE 2 : FOR EXTENAL SURFACE OF RCC CHMNEY: 2 COATS OF F-6 @ 100 μ DFT/ COAT TO OBBTAIN 2 X 100=200μ SHALL BE APPLIED AFTER MAKING SURFACE PREPARATION AS PER GUIDELINES IN 1.5

NOTE 3 : WHEREVER REQUIRED S.NO. 8.3 SHALL BE USED FOR 14°C TO 80°C AND S.NO. 8.2 WILL BE DELETED.



TABLE 9.0: FIELD PAINT SYSTEM FOR CORROSIVE ENVIRONMENT (FOR CARBON STEEL, LOW TEMPERATURE CARBON STEEL & LOW ALLOY STEEL)

FOR ALL CORROSIVE AREAS ABOVE GROUND WHERE H2S, SO2 FUMES OR SPILLAGE’S

OF ACID/ ALKALI/ SALT ARE LIKELY TO COME IN CONTACT WITH SURFACE SUCH AS EXTERNAL SURFACE OF

UNINSULATED COLUMNS, VESSELS, HEAT EXCHANGERS, BLOWERS, PIPING, PUMPS, TOWERS, COMPRESSORS, FLARE LINES,

STRUCTURAL STEEL ETC.

PAINT SYSTEM S. NO

.


°C

SURFACE PREPARATION


TOTAL DFT IN

MICRONS (MIN.)

REMARKS

9.1 -90 TO –15

SSPC-SP-10


NONE 65-75 Repair of pre-erection/ pre fabrication primer shall be done wherever damage is observed.

9.2 -14 TO 80 SSPC-SP-10

REPAIR OF PRE-FABRICATION PRIMER 1 COAT OF F-9 @ 65-75μ DFT/ COAT + 1 COATS OF P-6 @40 μ DFT/ COAT

1 COATS OF F-6 @ 100μ DFT/ COAT + 1 COAT OF F-2 @ 40μ DFT/ COAT

225 Surface preparation is required only for repairing of damaged pre-erection/ fabrication primer

9.3 81 TO 400 SSPC-SP-10



105



9.4 401 TO 500

SSPC-SP-10

REPAIR 2S PER 7.2.2

2 COATS OF F-12 @ 20 μ DFT/ COAT

80



TABLE 10.0: FIELD PAINT SYSTEM FOR HIGHLY CORROSIVE (FOR CARBON STEEL, LOW TEMPERATURE CARBON STEEL & LOW ALLOY STEEL) EXTERNAL SURFACES OF UNINSULATED COLUMNS, VESSELS, HEAT EXCHANGERS, BLOWERS, PIPING PUMPS, TOWERS, COMPRESSORS, FLARE LINES, STRUCTURE STEEL ETC.

EXPOSED TO SPILLAGE OR FUMES OF HCL H2S04, SALTY WATER IMPINGEMENT,

CHLORIDE ETC.

PAINT SYSTEM S. NO

.


°C

SURFACE PREPARATION


TOTAL DFT IN MICRO

NS (MIN.)

REMARKS

10.1

-90 TO –15

SSPC-SP-10

REPAIR OF PRE-FABRICATION PRIMER 1 COAT OF F-9 65-75μ DFT/ COAT

NONE 65-75 Repair of pre-erection/ fabrication primer shall be followed. No over coating is allowed

10.2

-14 TO 80 SSPC-SP-10

REPAIR OF PRE-FABRICATION PRIMER 1 COAT OF F-9 @ 65-75μ DFT/ COAT + 1 COATS OF P-6 @40 μ DFT/ COAT

2 COATS OF F-6 @ 100μ DFT/ COAT = 2 X 100= 200 + 1 COAT OF F-2 @ 40μ DFT/ COAT

345 Surface preparation is required only for repairing of damaged pre-erection/ fabrication primer.

10.3

81 TO 400 SSPC-SP-10



105

10.4

401 TO 500

SSPC-SP-10

REPAIR AS PER 7.2.2


80



TABLE 11.0 : FIELD PAINT SYSTEM FOR CARBON STEEL STORAGE TANKS (EXTERNAL) FOR ALL ENVIRONMENTS.

PAINT SYSTEM S.

NO. DESIGN

TEMPERATURE IN °C

SURFACE PREPARATION FILED

PRIMER FINISH PAINT

TOTAL DFT IN

MICRONS (MIN.)

REMARKS

1.1 EXTERNAL SHELL. WIND GIRDERS APPARATUSES, ROOF TOPS OF ALL GROUND TANK INCLUDING TOP SIDE OF FLOATING ROOF OF OPEN TANK AS WELL AS COVERED FLOATING ROOF AND ASSOCIATED STRUCTURAL WORK ROLLING AND STATIONARY LADDERS, SPIRAL STAIRWAYS, HAND TAILS FOR ALL ENVIRONMENTS FOR GRUDE OIL, LDO, HSD, ATF KEROSENE, GASOLINE, MOTOR SPIRIT, DM WATER, FIREWATER, RAW WATER, POTABLE WATER, ACIDS, ALKALIS SOLVENTS AND CHEMICALS ETC. 11.1.1

-14 TO 80 SSPC-SP-10 1 COAT OF F-9 @ 65-75μ DFT/ COAT + 1 COATS OF P-6 @40 μ DFT/ COAT 65 X 40 = 105

1 COATS OF F-6 @ 100μ DFT/ COAT + 2 COATS OF F-2 @ 40μ DFT/ COAT 2 X 40 = 80

285

11.1.2

81 TO 500 SSPC-SP-10 1 COAT OF F-9 @ 65-75μ DFT/ COAT


105

F-6 should be suitable for occasional water immersion

11.2 EXTERNAL SURFACE OF BOTTOM PLATE (SOIL SIDE) FOR ALL STORAGE TANKS. 11.2 -14 TO 80 SSPC-SP-10 1 COAT OF

F-9 @ 65-75μ DFT/ COAT

3 COATS OF F - 7 @ 100 μ DFT/ COAT 3 X 100 = 300

365 F7 should be suitable for immersion service of the products given.



TABLE 12.0 : FIELD PAINT SYSTEM FOR CARBON STEEL AND ALLOY STORAGE TANK: (INTERNAL)

PAINT SYSTEM S. NO.

DESIGN TEMPERATUR

E IN °C


PRIMER FINISH PAINT

TOTAL DFT IN

MICRONS (MIN.)

REMARKS

INTERNAL SURFACE OF UNDERSIDE OF FLOATING ROOF, INTERNAL STRUCTURAL OF CONE ROOF, BOTTOM PLATE, ROOF STRUCTURE, STEEL, LADDERS SUPPORTS FOR STORING GRUIDE OIL, LDO AND HSD (EXCLUDING WHITE OIL PRODUCTS) 12.1 -14 TO 80 SSPC-SP-10 1 COAT OF


3 COATS OF F-7 @ 100μ DFT/ COAT 3 X 100 = 300

365 F7 should be suitable for immersion service of the products given.

12.2 BARE SHEEL OF INSIDE FLOATING ROOF TANK AND CONE ROOF TANK FOR PRODUCTS MENTIONED IN 12.1 12.2.1

-14 TO 80 SSPC-SP-10 PHOSPHATING TREATMENT WITH PHOSPHATING CHEMICALS (2 COATS)

2 COATS OF @10 μ 2 X 10 = 20

20

12.3 FLOATING CONE ROOF TANKS FOR PETROLEUM PRODUCTS SUCH AS ATF, GASOLINE, NAPHTHA, KEROSENE, MOTOR SPIRIT, INSIDE OF BOTTOM PLATE, UNDERSIDE OF FLOATING ROOF AND SHELL ABOVE MAXIMUM LIQUID LEVEL AND STRUCTURAL STEEL , LADDERS ETC.



12.3.1

-14 TO 80 SSPC-SP-10 1 COAT OF F-9 @ 65-75μ DFT/ COAT


365 F-6 should be suitable for immersion service of petroleum produce like ATF, Kerosene, petrol etc.

12.4 BARE SHELL OF INSIDE OF FLOATING CONE ROOF TANKS FOR PRODUCTS MENTIONED IN 12.3 12.4.1

-14 TO 80 SSPC-SP-10 1 COAT OF F-9 @ 65-75μ DFT/ COAT

NONE 65-75 No over coating is allowed same as per pre-erection primer, if any

12.5 INTERNAL PROTECTION IF FIXED ROOF TYPE STORAGE TANKS FOR POTABLE WATER: INSIDE OF SHELL, UNDER SIDE OF ROOF AND ROOF STRUCTURE INSIDE SURFACE BOTTOM PLATE AND STRURAL STEEL WORKS, LADDERS, WALKWAYS, PLATFORMS ETC. 12.5.1

-14 TO 80 SSPC-SP-10 2 COAT OF F-6 @ 40μ DFT/ COAT 2 X 40 = 80


280 F-6 shall be suitable for immersion service.

12.6 D. M. (DEMINERALISED WATER) AND HYDROCHLORIC ACID (HCL): INTERNAL SHELL, BOTTOM PLATE AND ALL ACCESSORIES 12.6.1

-14 TO 80 SSPC-SP-10 EBONITE RUBBER LINING AS PER SMMS SPECIFICATION 6-06-204

12.7 EG TANKS (INTERNAL SHELL, BOTTOM PLATE ROOF AND ALL ACCESSORIES) 12.7.1

ALL SSPC-SP-10 3 COATS VINYL CHLORIDE CO-POLYMER AMERCOAT 23 @ 75μ / COAT

225

12.8 INSIDE PONTOON AND INSIDE OF DOUBLE DECK OF ALL FLOATING ROOFS.



12.8.1

-14 TO 80 SSPC-SP-3 1 COAT OF F-8 @ 100μ DFT/ COAT


200

12.9 INTERNAL SURFACE OF AMINE & SOUR WATER STORAGE TANKS 12.9.1

-14 TO 80 SSPC-SP-10 1 COAT OF F-9 @ 65-75μ DFT/ COAT 2 X 40 = 80


215-225



TABLE 13.0 : COATING SYSTEM FOR EXTERNAL SIDE OF UNDERGROUND CARBON STEEL PLANT PIPING AND TANKS

PAINT SYSTEM S. NO.

DESIGN TEMPERATUR

E IN °C

SURFACE PREPARATION PRIMER FINISH

PAINT

TOTAL DFT IN

MICRONS (MIN.)

REMARKS

13.1 CARBON STEEL PLANT PIPING (UNDERGROUND) 13.1.1 YARD COATING 13.1.1.1

25 TO 60 SSPC-SP-10 1 COAT OF SYNTHETIC FAST DRYING PRIMER TYPE-B AS PER AWWA-C-203 (1991)

4mm THICK COALTAR COATING WRAPPING AS PER AWWA-C-203 IN 2 LAYER OF EACH 2mm THICKNESS

4mm CTE coating shall confirm to 120/ 5 as per BS: 4164

13.1.2 OVER THE DITCH COATING 13.1.2.1

25 Tto 60 SSPC-SP-10 1 COAT OF SYNTHETIC FAST DRYING PRIMER TYPE-B AS PER AWWA-C-203 (1991)

2 LAYERS OF COALTAR BASED TAPE COATING AS PER AWWA-C-203 & AS PER SMMS EIL SPEC. 6-06-203-REV.2

4 mm

13.2 CARBON STEEL PLANT PIPING (UNDERGROUND) 13.2.1 61 TO 400 SSPC-SP-10 1 COAT OF


NONE 65-75

13.3 EXTERNAL SIDE OF UNINSULATED UNDERGROUND STORAGE TANKS:



13.3.1 40 TO 80 SSPC-SP-10 1 COAT OF F-9 @ 65-75μ DFT/ COAT


365

13.3.2 -90 TO –41 81 TO 400° c

SSPC-SP-10 1 COAT OF F-9 @ 65-75μ DFT/ COAT 1 COAT OF AMERCOAT 738 @ 250μ DFT/ COAT

NONE NONE

65-75 250



TABLE 14.0 : PAINTING UNDER INSULATION FOR INSULATED (HOT COLD SAFETY CARBON STEEEL, LOW ALLOY STEEL, LOW TEMPERATURE CARBON STEEL & STAINLESS STEEL PIPING, STORAGE TANKS EQUIPMENTS IN ALL ENVIRONMENT

PAINT SYSTEM S. NO.

DESIGN TEMPERATUR

E IN °C


PINTS

TOTAL DFT IN

MICRONS (MIN.)

REMARKS

14.1 INSULATED CARBON STEEL, LOW ALLOY STEEL AND LTCS PIPING AND EQUIPMENT & TANKS 14.1.1

-4 TO 125 SSPC-SP-10 REPAIR OF PRE-FABRICATION PRIMER F-9 @ 65-75μ DFT

2 COATS OF F-14 @ 125μ DFT/ COAT 2 X 125 = 250 OR 3 COATS OF F-15= 3 X 80=240

315 For other temprature ranges no painting is required under insulation.

14.1.2

OPERATING TEMPERATURE –45 TO 125° C BUT DESIGN TEMPERATURE 126-400° C

SSPC-SP-10 REPAIR OF PRE-FABRICATION PRIMER F-9 @ 65-75μ DFT


105-115

14.2 INSULATED STAINLESS STEEL INCLUDING ALLOY-20- PIPING 14.2.1

BELOW 0° C TO ALL MINUS TEMPRATURE

ALUMINUM SHEETING WITH ALUMINUM FOIL AND CHLORIDE FREE MINERAL SEALANT CONTAINING BARIUM CHROMATE SHALL BE APPLIED

If the piping & equipments



14.2.2

0 TO 120 SSPC-SP-10 ( 15-25μ SURFACE PROFILE)

NONE 2 COATS OF F-14 @ 125μ DFT/ COAT 2 X 125 = 250 OR 3 COATS OF F-15= 3 X 80 = 240

250 are already erected then surface shall be prepared by cleaning with emery paper and wash/ flush with chloride free DM water followed by wiping with organic solvent

14.2.3

121 TO 500 SSPC-SP-10 NONE 3 COATS OF F-12 @ 20μ DFT/ COAT 3 X 20 = 60

60 No pre erection primer to be applied

14.2.4

501 TO 1000 SSPC-SP-10 NONE 1 COAT OF AMERCOAT 738 @ 150μ DFT/ COAT

150 Only Amorcoat 738 from Amoron is available for this temperature range.

14.2.5

CYCLIC SERVICE-196 TO 480 EXCEPTING –45 TO 120

SSPC-SP-10 NONE 1 COAT OF AMERCOAT 738 @ 150μ DFT/ COAT

150

14.3 NO PAINTING REQUIRED FOR INSULATED MONEL, IN COLOY AND NICKEL LINES



TABLE 15.0 : INTERNAL PROTECTION OF CARBON STEEL WATER BOXES AND TUBE SHEETS OF COOLERS/ CONDENSERS WATER BOXES, CHANNELS, PARTITION PLATES, END COVERS AND TUBE SHEETS ETC.

PAINT SYSTEM S. NO. DESIGN

TEMPERATURE IN °C


PAINT

TOTAL DFT IN

MICRONS (MIN.)

REMARKS

15.1 Upto 65 SSPC-SP-10 1 COATS OF F-6 @ 40μ DFT/ COAT

2 COATS OF F-7 @ 125μ DFT/ COAT 2 x 125 = 250

290 For C. S.

15.2 Upto 65 NON FERROUS AND BRASS TUBE SHEETS

SSPC-SP-10 1 COATS OF P-4 @ 8μ DFT/ COAT 1 COATS OF P-6 @ 40μ DFT/ COAT


300 FOR NON FERROUS SURFACE

TABLE 16.0 FIELD PAINTING SYSTEM FOR GI TOWERS/ NON-FERROUS

TUBE SHEET

PAINT SYSTEM S. NO. DESIGN TEMPERATURE IN °C


PAINT FINISH PAINT

TOTAL DFT IN

MICRONS (MIN.)

REMARKS

16.1 Upto 65 SSPC-SP-10 1 COATS OF P-4 @ 8-10μ DFT/ COAT + 1 COAT OF P-6 @ 4μ DFT/ COAT


130 SHADE AS PER DEFENCE REQUIREMENTS



16.2 Upto 65 NON FERROUS AND BRASS TUBE SHEETS

SSPC-SP-10 1 COATS OF P-4 @ 8μ DFT/ COAT 1 COATS OF P-6 @ 40μ DFT/ COAT


300



17.0 STORAGE 17.1 All paints and painting materials shall be stored only in rooms to be arranged by

contractor and approved by Purchaser/Consultant for the purpose. All necessary precautions shall be taken to prevent fire. The storage building shall preferably be separate from adjacent building. A signboard bearing the words “ PAINT STORAGE NO NAKED LIGHT- HIGHLY INFLAMMABLE” shall be clearly displayed outside.

18.0 COLOUR CODE FOR PIPING For identification of pipeline, the colour code as per Table 18.1 shall be used.

Paint material for color-coding shall be as specified in this standard in clause- 6.0.

18.1 Colour coding scheme for pipe, equipment, machinery & structure:

SR. NO.

DESCRIPTION GROUND COLOUR

FIRST COLOUR

BAND

SECOND COLOUR

BAND 18.1.1 ALL KINDS OF WATER

DRINKING WATER DE-MINERALISED WATER COOLING WATER BOILER FEED WATER CONDENSATE QUENCH WATER WASH WATER PROCESS WATER PROCESS WATER FIRE WATER SEA WATER

Sea Gree -do- -do- -do- -do- -do- -do- -do- -do- Fire red Sea Green

French Blue Gulf Red French Blue Gulf Red Light Brown Dark Grey Ganary Yellow Oxide Red Crimson Red White

Signal Red - - - Signal Red - - - - - -

18.1.2 STEAM VERY HIGH PRESSURE STEAM (VHP) HIGH PRESSURE STEAM (SH) MEDIUM PRESSURE STEAM (SH) LOW PRESSURE STEAM (SL)

Aluminiumto IS2339 -do- -do- -do- -do-

Signal Red French Blue Gulf Red Canary Yellow Grey

- - Canary Yellow



DILUTION STEAM/ PURGE STEAM

18.1.3 COMPRESSED AIR PLANT AIR INSTRUMENT AIR NITROGEN OXYGEN CO2

Sky Blue -do- -do- Canary Yello -do- -do-

Signal Red Silver Grey French Blue Black White Light Grey

- - - - - -

SR. NO.

DESCRIPTION GROUND COLOUR

FIRST COLOUR

BAND

SECOND COLOUR

BAND 18.1.4 GASES

FUEL GAS AND SOUR GAS CHARGE GAS RESIDUE GAS, LPG ACETYLENE SWEET GAS

Canary Yellow -do- -do- -do- -do-

Grey Signal Red Oxide Red Service Brown Grey

Dark Violet French Blue White - -

18.1.5 ACIDS AND CHEMICALS SULFURIC ACID NITRIC ACID HYDROCHLORIC ACID ACETIC ACID CAUSTIC CHLORINE

DARK Violet -do- -do- -do- smoke Grey Canary Yellow

Brilliant Green French Blue Signal Red Silver Grey Light Orange Dark Violet

Light Orange -do- -do- -do- - -do-

18.1.6 HYDRO CARBONS NAPTHAS PROPYLENE PROPYLENE C.G. (LIQ) ETHYLENE GLYCOL ETHYLENE DICHLORIDE BENZENE BUTADIENE ETHANE(LIQ) PROPYLENE(LIQ) ETHYLENE(LIQ) TAR AROMATIC GASOLINE METHANOL (LIQ)

Dark Admiralty Grey -do- -do- -do- -do- -do- -do- Dark Admiralty Grey -do- -do- -do-

Brilliant Green -do- -do- -do- Gulf Red Canary Yellow Black Light Grey Signal Red Light Grey Signal Grey Brilliant Green

Black Smoke Grey Gulf Red - - - French Blue Black Black Brilliant Green Canary YellowGulf Red



PYROLYSIS GASOLINE MIXED C4(LIQ) LPG(LIQ) KEROSENE DIESEL OIL (WHITE) DIESEL OIL (BLACK)

-do- -do- -do- -do- -do- Light Brown -do- -do-

White Brilliant Green Signal Green Brilliant Gren -do- -do- -

Black Light Brown Dark Violet - -

18.2 The colour code scheme is intended for identification of the individual group of

the pipeline. The system of colour coding of a ground colour and colour bands superimposed on it.

18.3 Ground colours as given in Table 18.1 shall be applied throughout the entire

length for uninsulated pipes, on the metal cladding & on surfaces covered by Clause 2.2.2, ground colour coating of minimum 2m length or of adequate length not to be mistaken as colour band shall be applied at places requiring colour bands. Colour band(s) shall be applied at the following location.

a. At battery limit points b. Intersection points & change of direction points in piping ways.

c. Other points, such as midway of each piping way, near valves, junction

joints of services appliances, walls, on either side of pipe culverts.

d. For zong stretch/ xard piping at 50M interval.

e. At start and terminating points. 18.4 Identification Sign 18.4.1 Flow direction shall be indicated by an arrow in the location stated in Para a,b,c &

d and as directed by Purchaser/Consultant. 18.4.2 Colours of arrows shall be black or white and in contrast to the colour on which

they are superimposed. 18.4.3 Product names shall be marked at pump inlet, outlet and battery limit in a

suitable size as approved by Purchaser/Consultant.



18.4.4 Size of arrow shall be either of those given in 18.5. 18.5 Colour Bands 18.5.1 As a rule minimum width of colour band shall conform to the following table:

Nominal Pipe Size Width : L(mm) 3” NB and below 25mm

Above 3” NB upto 6” NB 50mm Above 8” NB upto 12” OD 75mm

Above 12” OD 100mm

Note: For insulated pipes, nominal pipe size means the outside diameter of insulation.

Nominal pipe size figures are to be inches. 18.5.2 Colour band(s) shall be arranged in the sequence shown in Table 18.1 and the

sequence follows the direction of flow. The relative proportional width of the first colour band to the subsequent bands shall be 4:1, minimum width of any band shall be as per Clause 18.5.1.

18.5.3 Whenever it is required by the Purchaser/Consultant to indicate that a pipeline

carries a hazardous material, a hazard marking of diagonal strips of black and golden yellow as epr IS:2379 shall be painted on the ground colour.

18.6 Wherever it is required by the Purchaser/Consultant to indicate that a pipeline

carries a hazardous material, a hazard marking of diagonal strips of black and golden yellow as per IS:2379 shall be painted on the ground colour.

19.0 IDENTIFICATION OF VESSELS, PIPING ETC. 19.1 Equipment number shall be stencilled in black or white on each vessel, column,

equipment & machinery (insulated or uninsulated) after painting. Line number n black or white shall be stencilled on all the pipelines of more than one location as directed by Purchaser/Consultant, size of letters printed shall be as below :

Column & Vessels - 150mm(high) Pump, Compressor and other machinery - 50mm (high) Piping - 40-150mm

19.2 Identification of storage tanks



The storage tanks shall be marked as detailed in the drawing.

20.0 PAINTING FOR CIVIL DEFENCE REQUIREMENTS 20.1 Following items shall be painted for camouflaging if required by the client.

a. All columns b. All tanks in offsite c. Large vessels d. Spheres

20.2 Two coats of selected finishing paint as per defence requirement shall be applied

in a particular pattern as per 20.3 and as per the instructions of Purchaser/Consultant.

20.3 Method of Camouflaging 20.3.1 Disruptive painting for camouflaging shall be done in three colours in the ratio of

5:3:2 (all matt finish).

Dark Green Light Green Dark Medium Brown 5: 3: 2

20.3.2 The patches should be asymmetrical and irregular. 20.3.3 The patches should be inclined at 30 degree to 60 degree to the horizontal. 20.3.4 The patches should be continuous where two surfaces meet at an angle. 20.3.5 The patches should not coincide with corners. 20.3.6 Slits and holes shall be painted and dark shades. 20.3.7 Width of patches should be 1 to 2 meters. 21.0 INSPECTION AND TESTING 21.1 All painting materials including primers and thinners brought to site by contractor

for application shall be procured directly from manufacturers as per specifications



and shall be accompanied by manufacturer’s test certificates. Paint formulations without certificates are not acceptable.

21.2 Purchaser/Consultant at his discretion, may call for tests for paint formulations.

Contractor shall arrange to have such tests performed including batch wise test of wet paints for physical & chemical analysis. All costs there shall be borne by the contractor.

21.3 The painting work shall be subject to inspection by Purchaser/Consultant at all

times. In particular, following stage wise inspection will be performed and contractor shall offer the work for inspection and approval of every stage before proceeding with the next stage. The record of inspection shall ne maintained in the registers. Stages of inspection are as follows:

a. Surface preparation b. Primer application c. Each coat of paint In addition to above, record should include type of shop primer already applied on equipment e. g. Red oxide zinc chromate or zinc chromate or Red lead primer etc.

Any defect noticed during the various stages of inspection shall be rectified by the contractor to the entire satisfaction of Purchaser/Consultant before proceeding further. Irrespective of the inspection, repair and approval at intermediate stages of work. Contractor shall be responsible for making good any defects found during final inspection/ guarantee period/ defect liability period as defined in general condition of contract. Dry film thickness (DFT) shall be checked and recorded after application of each coat and extra coat of paint should be applied to make-up the DFT specified without any extra cost to owner, the extra cost should have prior approval of Purchaser/Consultant.

21.4 Primer Application After surface preparation the primer should be applied to cover the crevices,

corners, sharp edges etc. in the presence of inspector nominated by Purchaser/Consultant.

21.5 The shades of successive coats should be slightly different in colour in order to

ensure application of individual coats, the thickness of each coat and complete



coverage should be checked as per provision of this specification. This should be approved by Purchaser/Consultant before application of successive coats.

21.6 The contractor shall provide standard thickness measurement instrument with

appropriate ranges(s) for measuring.

Dry film thickness of each coat, surface profile gauge for checking of surface profile in case of blast cleaning. Holiday directors and pinhole detector and positector whenever required for checking in case of immersion conditions.

21.7 Prior to application of paints on surface of chimneys the thickness of the

individual coat shall be checked by application of each coat of same paint on M. S test panel. The thickness of paint on test panel shall be determined by using gauge such as ‘Elkomere’. This thickness of each coat shall be checked as per provision of this specification. This shall be approved by Purchaser/Consultant before application of paints on surface of chimney.

21.8 At the discretion of Purchaser/Consultant, the paint manufacturer must provide

the expert technical service at site as and when required. This service should be free of cost and without any obligation to the owner, as it would be in the interest of the manufacturer to ensure that both surface preparation and application are carried out as per their recommendations.

21.9 Final inspection shall include measurement of paint dry film thickness. Adhesion

Holiday detection check of finish and workmanship. The thickness should be measured at as many points/ locations as decided by Purchaser/Consultant and shall be within + 10% of the dry thickness, specified in the specifications.

21.10 The contractor shall arrange for spot checking of paint materials for Sp. Gr., flow

time (ford cup) and spreading rate. 22.0 GUARANTEE 22.1 The contractor shall guarantee that the chemical and physical properties of paint

materials used are in accordance with the specifications contained herein/ to be provided during execution of work.

22.2 The contractor shall produce test report from manufacturer regarding the quality

of the particular batch of paint supplied. The Purchaser/Consultant shall have the right the test wet samples of paint at random, for quality of same as stipulated in



clause 11 above. Batch test report of manufacturer’s for each batch paint supplied shall be made available by the contractor.

23.0 QUALIFICATION CRITERIA OF PAINTING CONTRACTOR

Painting contractor who is awarded any job for EIL, projects under this standard must have necessary equipments, machinery, tool and tackles for surface preparation, paint application and inspection. The contractor must have qualified trained and experienced surface preparation, paint applicator, inspector, and supervisors. The contractor supervisor, inspector surface perpetrator and paint applicator must be conversant with the standards referred in this specification .The contractors capacity, capability and competency requirements for the job shall be quantified in the contract document and shall be assessed by an EIL team before awarding any job.

24.0 PROCEDURE FOR APPROVAL OF NEW COATING MATERIALS AND

MANUFACTURER’S

Following procedure is recommended to be followed for approval of new manufacturers.

24.1 The manufacturer should arrange testing of the inorganic zinc silicate coating

materials as per the list of tests given in para 24.5 below from one of the reputed Government laboratories.

24.2 Samples of coating should be submitted to the Govt. laboratory in sealed

containers with batch no. and test certificate on regular format of manufacturer’s testing laboratory. The sampling shall be certificate and sealed by a citifying agency.

24.3 All test panels should be prepared by govt. testing agency coloured photographs

of test panels should be taken before and after the test should be enclosed alongwith test report.

Sample batch. No. and manufacturer’s test certificate should ne enclosed alongwith the report. Test reports contain details of observation and rusting if any, as per the testing code. Suggested government laboratories are:

RRL, Hayderabad HBTI, Kanpur DMSRDE, Kanpur



IIT, Mumbai BIS Laboratory UDCT, Mumbai RITES, Calcutta PDIL

24.4 Manufacturers should intimate the company, details of sample submitted for

testing name of Govt. testing agency, date, contact personnel of the Govt. testing agency. At the end of the test the manufacturer should submit the test report to the company for approval. The manufacturer(s) shall be qualified based on the result of these tests and other assessment and the Company’s decision in this regard shall be final and binding on the manufacturer.

24.5 Tests required for evaluation of acceptance of coating materials for offshore

application.

Test ASTM Test Method

Density D 1475 Dipping properties D 823

Film Characteristics Drying time D 1640 Flexibility D 1737/ D 522 Hardness D 3363

Adhesion D 2197 Abrasion resistance D 968/ D 1044 DFT/ Coat AS PER SSPC GUIDELINES Storage Stability D 1849

Resistance to Humidity for 2000 hrs. D 2247 Salt Spray for 2000 hrs. B 117 Accelerated Weathering D 822 % Zn in DFT G 53

24.6 Coating system for panel test shall be decided after discussion with MECON.



ANNEXURE-I

LIST OF RECOMMENDED MANUFACTURERS

Indian Vendors 1.0 Asian Paints(I) Ltd. 2.0 Berger Paints Ltd. 3.0 Goodlass Nerlolac Paints Ltd. 4.0 Jenson And Nicholson Paint Ltd & chokuGu Jenson & Nicholson Ltd. 5.0 Shalimar Paints Ltd. 6.0 Sigma Coating, Mumabai 7.0 CDC Carboline Ltd. 8.0 Premier Products Ltd. 9.0 Coromandel Paints & Chemicals Ltd. 10.0 Anupam Enterprises 11.0 Grand Polycoats 12.0 Bombay Paints Ltd. 13.0 Vanaprabha Esters & Glycer, Mumbai 14.0 Sunil Paints and Varnishes Pvt. Ltd. 15.0 Courtaulds Coating & Sealants India (Pvt.) Ltd. 16.0 Mark-chem Incorporated, Mumbai (for phosphating chemicals only) 17.0 VCM Polyurethane Paint (for polyurethane Paint only) FOREIGN VENDORS FOR OVERSEAS PRODUCTS 1.0 Sigma Coating, Singapore 2.0 Ameron, USA 3.0 Kansai Paint, Japan 4.0 Hempel Paint, USA 5.0 Valspar Corporation, USA 6.0 Courtaulds Coating, UK. Note: This list subjected to revision based fresh approval which will be intimated to PDD/

Vendor Cell.



ANNEXURE-II

LIST OF RECOMMENDED MANUFACTURER’S PRODUCTS

S. No.

MANUFACTURER

NAME

P2 CHLORINATED

RUBBER Zp PRIMER

P4 ETCH PRIMER/ WASH PRIMER

P6 EPOXY ZINC PH. PRIMER

F9 INORGANIC

ZINC SILICATE PRIMER/ COATING

1. ASIAN PAINTS (I) LTD.

ASIOCHL OR HB. ZN.PH PRIMER RO PC 168

APCONYL WP 636 (PC 335)

APCODUR HB. RO.ZP-PC433

APCOCIL 605

2. BARGER PAINT LTD.

LINSOL HIGH BUILD ZP PRIMER

BISON WASH PRIMER

EPILUX 610 ZINC ANODE 304

3. AMERON/ GODDLASS NEROLAC PAINTS LTD.

- AMERCOAT 187 AMERCOAT 71

DIMET COTE-9

4. JENSON & NICHOSON PAINTS LTD. AND CHOKUGU JENSON NICHOLSON

JENSOLAC CHLORINATED RUBBER HB ZN.PH. PRIMER

J & N ETCH PRIMER

EPILAC ZINC PHOSPHATE PRIMER

-

5. SHALIMAR PAINTS LTD.

CHIOROKOTE ZINC PHOSPHATE PRIMER GREY

TUFFKOTE ETC PRIMER

EPIGUARD 4 ZINC PHOSPHATE PRIMER GREY

TUFFKOTE ZILICATE TL

6. SIGMA COATING

SIGMA NUCOL UNICOAT 7321

SIGMA COVER PRIMER (7413)

COLTURE CM PRIMER 7412

SIGMASIL MC (7568)

7. CDC CARBOLINE LTD.

- - CARBOLINE 893

CARBOZINC 11

8. PRIMER PRODUCTS LTD.

- - P-15/3A U-16/92

U17/ 92 ETHYL SILICATE INORGANIC ZINC

9. CORAMANDEL COROCLORE CR CPC WASH COROPEX -



PAINTS CHEMICALS LTD.

HB. ZN. PH. PRIMER

PRIMER EPOXY ZH. PH. HIGH BILD PRIMER

10. ANUPAM ENTERPRISES

ANUCHLOR ZP PRIMER

ANUPRIME 291 ANUPAM ANILICOR A-EZP-500

-

LIST OF RECOMMENDED MANUFACTURER’S PRODUCTS (Contd…)

S.

NO.

MANUFACTURER’S NAME

P2 P4 P6 F9

11. GRAND POLYCOATS

GP CHILOROPRIME 601

GP PPRIME 401 - -

12. BOMBAY PAINTS LTD. THEMPEL MAKINE PAINTS

HEMPA TEX HIGHBUILD 4633

PENTOLITE WASH PRIMER 8520

HEMPEL’S SHOP PRIMER E-1530

GALVASOL 1570

13. VANAPRABHA ESTERS & GLYCERIDES,

VEGCHLOR HB PRIMER 1143

VEG WASH PRIMER 1181

VEGPOX 1241 Z/ P

-

14. SUNIL PAINTS AND VARNISHED PVT. LTD.

SUNCHLOR HB ZINC PHOSPHATE PRIMER

SUN WASH SUNPOXY ZINC PHOSPHATE PRIMER

-

15. COURTAULDS COATING LTD.

- - INTERGARD 251

INTERZINC

16. MARK-CHEM INCOPORATED, (FOR PHOSPHATING CHEMICAL ONLY)

RUST PREVENTIVE LIQUID DRSAIO

17. VCM POLYURETHANE PAINTS (FOR POLY EURETHANE PAINTS ONLY)

18. JOTUN PAINTS EPOXY CQ JOTACOTE – 2



SPECIAL ZINC PHOSPHATE PRIMER

19. KCC PRODUCTS (KOREA)

EZ 180(N)

LIST OF RECOMMENDED MANUFACTURER’S PRODUCTS (Contd….)

S.

No. MANUFACTUR

ER NAME

F2 ACRYLIC-POLY

YURETHANE FINISH PAINT

F3 CHLORINATED

RUBBER FINISH PAINT

F6 HIGH BUILD

FINISH PAINT

F7 HIGH BUILD COAL TAR

EPOXY COATING


APCOTHANE CF76 (PC 1109)

ASIOCHLOR CF 621 (PC 161)

APCODUR HB COATING 9466

APCODUR CF 300

2. BARGER PAINT LTD.

BARGER THANE ENAMEL (81)

LINOSOL CHLORINATED RUBBER HB COATING

EPILUX 04 AND 78 HB EPOXY COATING

EPILUX 555


AMERCOAT 450GL

AMERCOAT 515 AMER COAT 383 HS

AMERCOAT 78 HB


J & N 993 HB POLYURETHANE FINISH PAINT.

JENSON HB CHLORINATED RUBBER FINISH PAINT

EPILAC 981 ENAMEL

EPILAC SOLVENTLESS COAT TAR EPOXY COATING


SHALITHANE FINISH

CHLORKOTE FINISH

EPIGARD KL FINISH

BIPIGARD’S BLACK HB COAL TAR EPOXY COATING

6. SIGMA COATING

SIGMADOUR HS SEMIGLOSS 7530

SIGMA NUCOL FINISH 7308

SIGMA COVER CM 7456

COLTURIET TCN 300

7. CDC CARBOLINE 132 - CARBOLINE CARBOMASTIC-



CARBOLINE LTD.

191 14


U3/ 92 POLYURETHANE

CR-71 FINISH PAINT

42B/ 4A HIGH BUILD EPOXY

350B/ 3A, COAL TAR EPOXY COATING

9. CORAMANDEL PAINTS CHEMICALS

- COROCLORE CR FINISHING

COROPEX EPOXY HB COATING

COROPEX EPOXY COAL TAR COATING


ANUTHANE ENAMEL

ANUCHLOR HB ENAMEL

DURACOAT-6000

COROGUARD

11. GRAND POLYCOATS

GP COAT 131, 132 GP BOND 141

GP CHILOROGAURD 631

GP GUARD HP 234

POLYGUARD GE

LIST OF RECOMMENDED MANUFACTURER’S PRODUCTS S. NO.

MANUFACTURER’SNAME

F2 F3 F6 F7

12. BOMBAY PAINTS LTD./ PAINTS

PENTATHANE FP 4510

HEMPATEX HIBUILD 4633

HEMPADUR HIGH BUILD 5520

HEMPADUR 1510


VEGTHANE FP 3641

VEGCHLOR FP 3140

VEGPOX- 3265 VEGPOX 3562

VEGPOX 4265


SUNTHANE (ALIPHATIC)

SUNCHLOR HB CR COATING

LPOXY HB ‘PS 901’

LPOXY BLACK P. S. 551


INTERTHANE - INTEGARD EM SERIES

INTERTUF JXA 006/ 007/ 010

16. MARK-CHEM INCOPORATED, (FOR PHOSPHATE PAINTS ONLY)


PIPCOTHANE ALIPHATIC POLYURETHANE FINISH PAINT



18. JOTUN PAINTS HARDTOP AS PENGUARD JOTAGUARD 85 19. KCC

PRODUCTS (KOREA)

KOPOX TOPCOAT HB ET 5740

EH 173

LIST OF RECOMMENDED MANUFACTURER’S PRODUCTS S. NO.

MANUFACTURER’S NAME

F-8 EPOXY MASTIC

COATING SURFACE

TOLERANT

F-11 HEAT

RESISTANCE SYNTHETIC

MEDIUM ALUMINUM

PAINT

F-12 HEAT RESISTANCE SILICON AL. PAINT


APCODOR CF 640 ASIAN HR ALUMINUM PAINT (PC 300)

HR SILICON ALUMINUM PAINT (PC 189)

2. BARGER PAINT LTD. PROTECTOMASTIC

FERROLOT HR ALUMINUM PANT

BARGER HEAT RISISTANT SILICON ALUMINUM PAINT


AMERLOCK 400 AMERCOAT 878


- FERROTECT SYNTHETIC RUBBER H/R ALUMINUM PAINT 4000

FERRLOTECT SILICON HEAT RESISTANCE 1000


EPIPLUS 56 HEAT RESISTING LUSTROL ALUMINUM

LUSTOTHERM HIGH TEMP ALUMINUM PAINT

6. SIGMA COATING SIGMA ETPC ALUMINUM

HIGH TEMPERATURE RESISTANT EPOXY SUSTEM UPTO 200° C 4062

AROSTA FINISH HR

7. CDC CARBOLINE LTD.

CARBOMASTIC-15 CARBOLINE 1248 CARBOLINE 4674


HB EPOXY MATIC 150B/ 150A

9. CORAMANDEL PAINTS CHEMICALS

- SILVOTOL HR ALUMINUM PAINT

CPC SILICONE HR ALUMINUM PAINT




ANUMASTIC-102 - ANUPAM HEAT GUARD

LIST OF RECOMMENDED MANUFACTURER’S PRODUCTS S.

NO. MANUFACTURER’S

NAME F8 F11 F12

11. GRAND POLYCOATS

GP PRIME GUARD 235

-

12. BOMBAY PAINTS LTD./ HEMPEL MARINE PAINTS

HEMPADUR 1708

KANGAROO HHR ALUMINUM 4950

HEMPADUR HIGH BUILD 5520


VEGEPOX MASTIC 2255

VEG HR AL PAINT TO IS211339

VEG HHR AL PAINT TO 600°C


LPOXY HIGHBUILD P.S.901

- -


INTERPLUX - INTERTHERM 50

16. MARK-CHEM INCOPORATED, (FOR PHOSPHATE PAINTS ONLY)


-

18. JOTUN PAINTS JOTUMATIC 87 SOLVELITT HEAT RESISTANT SILICON PAINT

19. KCC PRODUCTS (KOREA)

EH 4158H QT 606




FOR

INTERNAL LINING PIPES ,TANKS & VESSELS



CONTENT

SL.NO. DESCRIPTION PAGE NO. 1.0 Coating/Internal lining of piping -General 1-13 2.0 Specification for solvent free epoxy internal lining 13-15 3.0 Specification for glass flake reinforced ambient cure polyester

acrylic polymer internal coating 15-17

4.0 Specification for rubber lining 17-28 5.0 Technical specification for FRP (B) & FRP (I) lining 28-32



1.00 COATING / INTERNAL LINING OF PIPING

(Polyurethane / Epoxy / Glass Flake Polyester Acrylic Polymer/Rubber lining/FRP lining)

01.01 GENERAL

(a) The internal surfaces of carbon steel pipes and fitting to be used for sea water application shall be protected with coating that have high resistance to corrosion, abrasion, and erosion and be able to withstand flow of sea-water at a temperature of 50 deg. C maximum at water velocities of 2 to4 m/s. The coatings shall be proven products for their suitability in linings of steel piping for seawater duty in similar applications. Contractor shall furnish list of installations where such coating have been used in the past and performance feedback from such users.

(b) The coating material shall be 100% solids poly-urethane, or, 100% solvent

free epoxy coating, or, glass flake polyester acrylic polymer. Test certificates of coating material conforming physical properties as per the following standards shall be furnished from internationally reputed testing agencies.

- British standards (BS) - International Standard Organization (ISO) - American Society of Testing Materials (ASTM) - Steel Structure Painting Council, USA (SSPC)

- National Association of Corrosion Engineers, USA (NACE)

(c) The storage, mixing, surface preparation and application of the

lining/coating shall be strictly in accordance with the manufacturer’s instructions & approval data sheets. The coating / lining process shall be carried out at shop in an in-line process except for field joints or site-fabricated fittings & specialties.

(d) The minimum nominal dry film thickness (DFT) of coating after application

shall be 2mm/1.5mm / 1mm or better for 100% solids polyurethane/100% solvent free epoxy/ glass flake polyester acrylic polymer respectively.



(e) Described below are detailed specifications for each of the lining materials that have been indicated as alternatives.

(f) It may be noted by the contractor that they may choose & select any of the

three (3) options given above regarding the choice of the lining/coating material.

(g) Lining material supplied for the PROJECT shall be marked with the

following information:

- The manufacturer’s name - The material identification number - The batch number - Date of manufacture - The shelf life and storage temperature limits - Identification of parts and mixing ratio by volume

- Health and Safety markings along with any markings required by current

legislation.

Lining material shall be stored and handled in accordance with the coating manufacturer’s recommendations.

01.02 SPECIFICATION FOR ELASTOMERIC POLYURETHANE INTERNAL LINING

01.02.1 Scope 01.02.02 This specification governs the minimum requirements for materials, equipment,

application, inspection repair and handling aspects associated with the coating of 100% Solids (Solvent less) Two Component, Fast Curing Elastomeric Polyurethane Coating classified under ASTM D-16, Type-V. The coating process of straight pipes/fittings shall be carried out at shop with necessary cut-back areas at both ends of pipe and fittings for field jointing. Lining/coating of internal surface of field joints shall be done at site. Similarly Tailor-made fittings can also be site coated.



01.02.03 It is envisaged that the Polyurethane on the steel surface will provide a hard yet flexible, impermeable barrier with outstanding adhesion, impact and abrasion resistance to protect the surface from corrosion in the operating conditions.

01.02.04 The steel surface preparation, prior to actual commencement of coating, to

conform to SSPC-SP 10/NACe No. 2 (Joint surface Preparation Standard From, Society For Protective Coatings, USA and NACE International, USA dated September 15, 1994) near white blast cleaning, included in the scope of cleaning.

Supplier or his licensed applicator shall obtain prior written approval from the

Employer for any deviations from the requirements of this specification and/or the standard referred herein.

The work shall conform to the following documents (latest revision or as specified)

are referred in this specification:

(a) SSPC SP-1 Nov. 1, 1982 : Solvent cleaning (b) SSPC SP-10 /NACE No.2 : Near-White Blast Cleaning Sept. 15, 1994 (c) SSPC-SP COM July 1, 1995: Surface Preparation Commentary (d) SSPC PA2 Measurement of Dry Paint Thickness With Magnetic Gauges (e) ASTM D 4541 : Method for Pull Off Strength of Coatings Using Portable

Adhesion Testers (f) RP 0188-90 : Holiday Testing (g) RP 0169-94 : NACE International; Control of External corrosion On

Underground or Submerged Metallic Piping systems (h) RP 0675-88 : NACE International ; Control of External corrosion on

Offshore Steel Pipelines. (i) ANSI/AWWA C222 : Polyurethane Coating For the Interior& Exterior of

Steel Water Pipe Fittings.

01.03 General Requirement Contractor shall perform all work in accordance with this specification and other

requirements noted herein. Contractor shall submit a detailed written description in



the form of a manual covering coating equipment, procedure, materials, inspection, tests and repair etc, for Employer’s approval.

The contractor shall also supply copies of test reports conducted by internationally

reputed test agencies evidencing that materials conform to minimum performance requirements. The contractor shall also supply certificates from coating manufacturer as under.

- That the materials (with batch numbers, dates of manufacturer and shelf

life) are free from all manufacturing defects. - That the materials will meet performance criteria as given below when

applied. - That the contractor or his applicator possesses the necessary technical

skills and equipment to apply these materials and is authorized by the manufacturer for this purpose.

100% Solids, Two component Polyurethane are specialized coatings characterized by very short pot lives. The coating shall be applied either by the coating material manufacturer himself or by his authorized applicator. The authorized applicator should have been trained and certified by the coating manufacturer and shall posses the necessary specialized equipment, trained crew and experience in spraying fast setting plural component polyurethane coatings. Contractor shall provide, for the Employer’s approval, details of coating manufacturer’s authorized applicator including details of equipment, experience in spraying fast setting 100% Solids Polyurethane coatings and client references for verification. In no case shall coating application be undertaken by coating contractors without prior track record of applying these materials. In addition, contractor shall provide certificate from coating materials manufacturers that the applicator possesses the necessary technical skills and equipment to apply these materials and is authorized by the manufacturer for this purpose.

Applied coating will be tested for dry film thickness, holidays and adhesion. All coating operations shall be performed under the supervision of, and performed by, personnel skilled in the application of the coating system. It is axiomatic in protective coatings that the performance of even the highest quality coating will depend largely on the quality of the surface preparation. A high grade of surface preparation ensues high adhesion and a long service life. As such strict adherence to surface preparation standards as well as confirmatory adhesion tests shall be made.



The contractor shall provide access, during all phases of work, to the Employer and their representatives.

All cleaning, priming and coating machines shall be equipped with rubber or wheels overlaid with hard fiber to prevent damaging the concrete surface. The materials shall be applied by Airless Spray System, as per the standards specified by the material manufacturer. Blast cleaning and coating operations will be carried out using automated internal blast cleaning and coating equipment with longitudinal traveling, rotating blast nozzle/spray tips. Rotation and transverse speeds shall be set by variable speed drives. 100% Solids Polyurethane systems are solvent free eliminating solvent health hazards and flammability concerns. All safety precautions warranted by good industrial hygiene practices and regulated by local, state or central laws must be taken into consideration while applying these coatings.

01.04 Material Specification Elastomeric Polyurethane Coating:

Spray applied, Impermeable, 100% Solids, Elastomeric Aromatic Polyurethane Coating (Non Tar Extended), as per ASTM D-16, Type-V (Two component, Chemical Cure). Shall meet following criteria. All tests at ambient (25C) unless otherwise specified.

a) Nominal Thickness SSPC PA2 : 2,000 Microns (Elcometer Pull Off) b) Adhesion ASTM D-4541 : 10 N/mm2 (minimum) c) Recoverable elongation ASTM D-638 : 10% Minimum d) Tensile Strength : 17 N/mm2 (ASTM D-638) e) Surface Hardness ASTM D 2240 : 60 Min. (Cured Film-Shore D) f) Water Vapour Permeability : 0.3 gms./24 Hour/M2 Max. ASTM E-96/F-

1249-90 g) Operating Temperatures : 0OC to 60OC h) Salt Spray Test 6,000 Hour. : No Effect ASTM B 117-73



i) Impact Resistance ASTM G-14 : 0.23 X 106 gm–cm or 200 Inch Lb (Minimum).

j) Abrasion Resistance ASTM D 4060/ : Weight Loss 0.05 gms. Max FTMS

141 Taber Abraser H-10 Wheel 1,000 gms., 1,000 cycles k) Flexibility as per ASTM D 1737 : No effect bending through Pass over 12

mm Mandrel 180O Bend0.5 in thick plate coated with 0.05 thick coating. l) Cathodic Disbondment (ASTM G-8) : Pass < 5 mm (28 days @ 25OC) m) Chemical Resistance, ASTM D 543 Immersion of 30 days in sea water

followed by: i) (%) Weight Change : < 1.0% ii) (%) Hardness (Shore D) Change: < 5.0% iii) (%) Tensile Strength Change : < 5.0% n) Accelerated Weathering ASTM G-154/ : No effect except some BS-3800,

2000 hours discoloration

Primer The type of primer used shall be as per coating manufactures recommendations provided the applied coating system shall meet specifications. Typically a two (2) component chemical cured Polyurethane Primer is to be applied.

01.05 Surface Preparation

(i) The steel surface shall be blast cleaned to SSPC SP-10/NACe No. 2 Near White Blast Cleaning.

(ii) A near-white blast cleaned surface, when viewed without magnification,

shall be free of all visible oil, grease, dust, dirt, mill scale, rust, coating, oxides, corrosion products and other foreign matter, except for staining as noted below

(iii) Random staining shall be limited to no more than 5 percent of each unit

area of surface as defined in section D(vi) and may consist of light shadows, slight streaks, or minor discolorations caused by stains of rust, stains of mill scale or stains of previously applied coating.



(iv) Acceptable variations in appearance that do not affect surface cleanliness

as defined in section D(ii) include variations caused by type of steel, original surface condition, thickness of the steel, weld metal, mi or fabrication marks, heat treating, heat effected zones, blasting abrasive, and differences in the blast pattern.

(v) Anchor profile obtained by blast cleaning will be > 75 Microns when

measured with a surface profile gauge such as Elcometer 123. The average reading from five (5) randomly selected areas shall constitute the height of the profile. The profile measurement is to be done on flat (without curvature) areas only.

(vi) Unit area for determining staining shall be approximately 6400 mm2. (vii) The contractor shall immediately bring to the Employer/consultants

attention any unacceptable metal defects detected at the time of surface preparation and hold the steel piece till such time as cleared for further action.

(viii) Compressed air used for blast cleaning shall be dean, dry and free of

moisture and oil. Moisture separators, oil separators, traps or other equipment may be necessary to achieve dean, dry air.

(ix) Blast cleaning operations shall be done in such a manner that no damage

is done to partially or entirely completed portions of the work. (x) Dry blast cleaning shall not be conducted during times when the surface

will become wet after blast cleaning or when ambient conditions are such that visible rusting occurs before coating. If any rust forms after blast cleaning, the surface shall be re-blasted before coating.

(xi) Before blast cleaning, visible deposits of oil and grease shall be removed in

accordance with SSPC SP-1. (xii) Before blast cleaning, any surface, imperfections remaining (after fabrication) such as sharp fins, weld spatter, or burning, slag shall be removed from the surface. Chlorides are also to be removed before blast cleaning. The surface shall be thoroughly checked for surface chloride contamination using a SCM 400, or other Inspector’s approved meter. Where contamination by soluble salt is detected, the surface shall be cleaned by high-pressure water jetting with fresh water and the chloride contamination rechecked to ensure complete removal.



The maximum level of contamination shall not exceed5 microgram per sq cm.

(xii) Any of the following methods of surface preparation may be used to

achieve a near white blast cleaned surface: (a) Air Abrasive Blast/Disposable Abrasive : Dry abrasive blasting using

compressed air, blast nozzles and disposable abrasive. (b) Air Abrasive Blast/Recycled Abrasive : Dry abrasive blasting using a dosed

cycle, re-circulating abrasive system with compressed air, blast nozzle, and abrasive, with or without vacuum for dust and abrasive recovery.

(c) Centrifugal wheel Blast : Dry abrasive blasting using a dosed cycle, re-

circulating abrasive system with centrifugal wheels and abrasive. (xiii) Wet abrasive blasting shall not be permitted by this specification. (xiv) Selection of abrasive media for the blasting operation will depend upon the

type of system employed (xiii) above. Abrasives used shall be as under:

For air Abrasive Blast D(xiii) Granulated Copper slag is to be used. For Air Abrasive Blast/Recycled Abrasive and Centrifugal Wheel Blast Steel grit (not shot) or non-metallic mineral abrasive-Garnet are to be used. No other abrasive media shall be used by the contractor without prior approval. Contractor shall adopt good blasting practices such as those recommended in SSPC SP-COM.

(xv) The cleanliness and size of recycled abrasive shall be maintained to

ensure compliance with this standard. (xvi) The blast cleaning abrasive shall be dry and free of oil, grease and other

contaminants. (xvii) Contractor shall use abrasive media of size that will ensure the necessary

anchor profile height specified. (xviii) Visible deposits of oil, grease or other contaminants shall be removed

according to SSPC SP-1. (xix) Dust and residues shall be removed from prepared surface by brushing,

blowing off with dean, dry air or vacuum cleaning. Moisture separators, oil



separators, traps or other equipment may be necessary to achieve dean, dry air.

01.06 Priming

(i) Priming shall not be done when ambient conditions are dusty or conducive to condensate formation on the steel substrate.

(ii) Before beginning priming and coating, measure the humidity using a digital

psychromotor or a sling psychromotor and calculate the dew point. Measure surface temperature using an Infra Red non contact thermometer. Temperature of steel surface must be at least 3OC higher than the dew point. Under controlled conditions, it is possible to heat the steel surface to eliminate condensation problems.

(iii) The type of primer used shall be as described in the coating specification

C(ii). Primer shall be applied with conventional spray equipment or airless spray depending upon type of primer used.

(iv) The blast cleaned steel shall be primed preferably within2 hours after blast

cleaning but not more than 24 hours and under no circumstances shall be primer be applied to a surface where corrosion has occurred.

(v) Primer shall be sprayed onto the cleaned surface in a fog coat as thinly as

possible (approx. 50 Microns Wet Film thickness WFT) so as to tint but not mask the colour of the substrate. The primer on application shall be free from runs or drips or areas of excessive thickness. In view of the inaccuracy of measuring DFT of primer applied at 25-50 microns on a blast cleaned surface with an anchor Profile of >75 microns; no DFT checks of the primer shall be made, rather primer thickness shall be verified by volumetric/coverage calculations. Due to the same reason, fog coat applied primer may have a mottled appearance.

(vi) The primed surface shall be protected so that it will not come into contact

with rain, dust or other substances until completely hardened and coated with the Elastomeric Polyurethane Top coat.

(vii) Primed surface should be over coated only when it is hard and not tacky.

Overcoat window period of the primer depends upon brand/make of primer and is normally between 1-48 hours. Applicator must ensure that the Polyurethane Coating is applied within this overcoat window period. In the event that the overcoat window period of primed surface is exceeded



without top coating with the Polyurethane, the surface may be re-primed and coated. For overcoat intervals exceeding 5 days from original priming date, the surface must be re-blasted, primed and coated.

01.07 Coating

(i) Nominal thickness of the Elastomeric Polyurethane shall be 2,000 Microns when measured in accordance with SSPC PA 2. The finished coating shall be generally smooth and free of sharp protuberances. A minor amount of sags, dimpling and “curtaining” which otherwise meets specification requirements shall not be considered cause for rejection. Before beginning coating, measure the humidity using a digital psychrometer or sling psychrometer and calculate the dew point. Measure primed surface temperature using an Infra Red non contact thermometer. Temperature of primed surface must be at least 3OC higher than the dew point.

(ii) Equipment for the spray application shall be Airless Spray equipment with

system specification meeting minimum specified by the coating manufacturer. Equipment shall consist of Material Feed Pumps, Purge Pump, Proportioning Pump, Mix Manifold, Static Mixer, Interconnecting Hoses etc. System shall normally be capable of 1500-3000 Psi fluid pressure (at tip) and a material supply rate of 4-10 Litres/Minute.

(iii) Applicator must follow standard written instruction from coating

manufacturer on material storage, handling and spray. (iv) Partially used and unused material drums must be tightly sealed and

contain a blanket of nitrogen to prevent moisture contamination when not in use.

(v) Before application on the substrate apply a test patch for runs or drips and

gel time as well as tack free time. (vi) The proportioning pump shall be fitted with a numeric counter to keep track

of the volume (the proportioning pump delivers a precise volume of materials per stroke) of materials being used while spraying. The applicator shall calculate the steel ‘unit’ area, material volume and counter numbers required, approximate speed (Liters/Minute) based on spray tip size as well as number of passes and spray coating materials according to these criteria.



(vii) Entire thickness shall be built up in a single applications (with one number pass). If the surface is large enough to require more than one day for the coating, the edges of the coated areas shall be feathered and roughened with a grinding tool prior to beginning priming and coating.

(viii) Areas not to be coated shall be masked with disposable plastic sheets,

cardboard etc. (ix) Any holidays or skips shall be repaired with Elastomeric Polyurethane hand

mix kit with slower pot life after roughening the edges.

1.08 Field Joint (i) Standard Holdbacks When the pipe sections are joined together by field

welding, a holdback that is free of interior or exterior coating shall be left uncoated. This holdback shall be of sufficient width, as required by the constructor, to permit the making of field joints without damage to the interior or exterior coating.

(ii) Protection During Welding During the welding process the coating shall be

protected from welding sparks and spatter using a nonflammable protective barrier. Any coating damaged by the welding process shall be repaired as per Clause F of this sub-section. This repair may be made at the same time the welded joint is being coated.

(iii) Surface Preparation After welding, the joint shall be cleaned so as to be

free from mud, oil, water, grease, welding flux, weld spatter, dust, and loose residues. The cleaned metal surfaces of the joint shall then be abrasive blast cleaned to provide a surface that complies with Clause D. Other methods of surface preparation shall be permitted as long as they provide the same surface as defined in Clause D. The existing coating shall be abraded approximately 1 to 2 in (2.5 to5 cm) from the edge of holdback so that a surface profile in the existing coating meets the manufacturer’s recommendations. The entire area to be coated shall be clean, dry, and uncontaminated

(iv) Coating Application The coating system shall be applied to the welded

joint in accordance with Clause F. The joint material may be the originally applied coating or another material designed specifically for joint coatings as approved by the manufacturer. Apply joint materials to the same thickness or greater as originally specified for the main coating system.



(v) Material selection at the option of the purchaser, weld areas may be protected with materials and methods conforming to ANSI/AWWA C217, and ANSI/AWWA C222 that are compatible with the originally applied coating material.

1.09 Inspection & Testing

In addition to requirements stipulated in chapter titled Quality Assurance & Plan the following shall also apply:

(i) All work under this specification shall be subject to inspection by the owner

or his representative. All parts of work shall be accessible. The contractor shall correct such work as is found defective under the specification

. (ii) The following tests shall be made by the applicator prior to, during and

after priming and coating application: (iii) Blast surface profile using Elcometer 123 or equivalent surface profile

gauge. The average of readings from five randomly selected areas shall constitute the average surface profile. Test area to be flat (without curvature).

(iv) The dry film thickness shall be checked with a Magnetic Mil Gauge

(Positest by DeFelsko or equivalent) in accordance with SSPC PA2. The average of readings from five randomly selected areas shall constitute the film thickness. No single spot measurement shall be less than 80% of specified thickness. Frequency shall be as per SSPC PA 2.

(v) Holidays testing using high voltage holiday detector (Tinker Rasor or

equivalent) as per NACE International RP 0188-90 “Holiday Testing”. Coating to have cured at least 24 Hours prior to holiday test. Due care should be taken not to use voltage exceeding the dielectric strength of the coating. The location of the holidays shall be noted on the coated surface for repair.

(vi) Pull off Adhesion to steel shall be measured using Elcometer / Positest/

equivalent adhesion tester as per ASTM D 4541. Average reading from three (3) randomly selected spots shall constitute one test and shall be at least 10 (Ten) N/mm2. Adhesion test shall be carried out on fully cured coating (7 days at 25OC)& on flat (without curvature) test area.



Minimum 5 nos. tests shall be carried out in one (1) km at locations desired by Engineer in charge/site engineer/Project Manager, on behalf of Employer. If the adhesion in not satisfactory, a systematic inspection (adhesion test) of all pipe shall be carried out and all pipes not meeting this adhesion requirement shall be rejected. Damaged test areas of acceptable pipe shall be repaired as indicated in clause above. The rejected pipes shall be cleaned by blasting and re-coated.

(vii) All previously carried out test-certificates on material shall be furnished for

Employer’s scrutiny that have done already by manufacturer.

(iii) Maximum Substrate temperature 60OC (iv) Spray technique Air less spray recommended (v) VOC NIL (calculated), UK-PG 6/23(92) Appendix-3 USA-EPA Method 24 (vi) Relative Humidity during application of lining. < 85% (vii) Specific gravity of material (average) 1.52 + 0.05 (viii) Adhesion ISO 4624 “Pull-off test for adhesion” using portable adhesion tester or Equivalent international standard. Not less than 63Kg/cm2 (approx. 900 psi) when using a PAT Model GM01 hydraulic adhesion tester on5 mm thick steel (1x500 micron applied directly to SA 2.5 blasted steel). (ix) Hardness-ASTM D 2240, or, Hardness ASTM D 2583-via Barcol Impression Minimum 85 shore D, or, typically 75-80 using Barcol Impressor (x) Tensile strength– ASTMD 2370 An average of 10 MPa (1450 psi) is required to achieve fracture of the coating (for 1x500 micron “free film”) (xI) Elongation Break An average of 2% on 1x500 micron free film. Surface Preparation All surfaces to be coated should be clean, dry and free from contamination. Prior to paint application all surfaces should be assessed and treated in accordance with ISO 8504: 1992. Wherever necessary, the weld spalters are to be removed and wherever required weld seams and sharp edges are to be smoothened. Oil and grease shall be removed in accordance with SSPC SP 1 Solvent cleaning. The lining shall only be applied to surfaces prepared by abrasive blast cleaning to SA 2½ (ISO 8501-1:1988) or SSPC-SP-10. A sharp, angular surface profile of 75100 microns (3-4 mils) shall be achieved. The lining shall be applied before oxidation of the steel occurs. If oxidation does occur the entire oxidized areas should be re blasted to the standard specified above. Surface defects revealed by blast cleaning process, should be ground, filled, or, treated in the appropriate manner. Surfaces must be primed with suitable primer before oxidation occurs. Chlorides are also to be removed before blast cleaning, following the same guide lines as for that for Polyurethane coating specified above

2.0 SPECIFICATION FOR SOLVENT FREE EPOXY INTERNAL LINING 2.01 Scope



This specification covers the technical details of the two component solvent free epoxy having 100% solid content, its method of application, surface preparation requirements, testing requirement and QA/inspection criteria. The epoxy lining process shall be carried out at lining applicator’s works before the internally lined pipes & components are dispatched to site, where only field joints are to be carried out at the previously planned cut-back portion of the pipes & components. In exceptional cases large diameter fittings & specialties may be allowed to be internally lined at site-fabrication yard/in-situ through automatic/semi-automatic means to achieve same level of finish done at shop.

2.02 Product Specification

The product (coating material) shall be high build, fast cure anti-corrosive coating meant for application in aggressive corrosion environment like sea-water application in the internal surfaces of pipes. The recommended working “Volume Solids” is 85% or it should be as recommended by manufacturer. Method of application of this coating material by Airless spray technique and in exceptional cases of unforeseen encounter with “pits” in metal, through brush to ensure proper treatment. The following recommended test data may be adhered to for the coating material. However, if manufacturer furnished test data are different from the following, based on his recommendation and practice then the same is also acceptable. In such case necessary certificates for tests already carried out & verified may please be furnished for Employer’s scrutiny of test results. Coating thickness shall be 1000 micron (nominal DFT) with at least 90% of the nominal DFT to be obtained at any spot measurement of DFT during testing.

2.03 Test Type Test Method Specification Details Typical Results

Cathodic Disbondment ASTM G8“Cathodic Disbonding of Pipeline Coatings”, Method A 2 x 600 micron DFT applied directly to SA 2.5 blasted steel. Typically less than1 mm disbondment following 30 days exposure. Immersion ISO 2812 Part 2“Resistance to water immersion@ 40OC.” 1 x 500 micron DFT applied directly to SA 2.5 blasted steel. No film defects following 8000 hours exposure Immersion IS 2812 Part2 (Modified)“ Resistance to sea water immersion@ 40OC. 1 x 500 micron DFT applied directly to SA 2.5 blasted steel. No film defects following 8000 hours exposure Salt Spray ISO 7253“Resistance to neutral salt spray (fog) @ 35OC. 2 x 600 micron DFT applied directly to SA 2.5 blasted steel. No film defects, and no rust creep at the scribe following 6000 hours exposure. Abrasion ASTM D 4060 “Abrasion Resistance of Coatings via the Taber Abraser ” 1 x 500 micron DFT applied directly to SA 2.5 blasted steel. Average of 224 mg weight loss per 1000 cycles using H18 wheels and a 1 Kg loading.



2.04 Priming

Priming shall be done with a priming material suitable for the coating/lining material being applied and usually should be between 15-50 micron DFT (0.6-2 mils), or as recommended by manufacturer. Surface preparation shall be same as clause 1.05 above and priming shall be done before oxidation of blasted surface starts to set in. Coating/lining material shall be applied on primed surface within the time frame recommended strictly by the coating/lining material manufacturer.

2.05 Coating

The coating material shall be applied in requisite thickness in accordance with Recommended Working procedure for application by manufacturer and shall be done by airless spray technique except heavily pitted areas which shall be stripe coated by brush to ensure good “wetting” of surfaces.

2.06 Field Jointing

Field jointing shall be undertaken by the applicator agency strictly as per the recommended instruction of the manufacturer with stipulated “cut-back”/”hold-back” dimensions earmarked for such jointing and abrasion procedure and dimension for the edge of coating done at shop dictated. Manufacturer’s proven practices shall also be taken into consideration.


In addition to requirements stipulated in chapter titled Quality Assurance plan , the requirements of inspection & testing as applicable for Polyurethane lining material as specified under clause 1.09 above shall also apply. However, for adhesion test the manufacturer’s recommended testing standard & practice is acceptable. Cathodic disbonding test results shall also be furnished.

3.0 SPECIFICATION FOR GLASS FLAKE REINFORCED AMBIENT CURE POLYESTER ACRYLIC POLYMER INTERNAL COATING

3.01 Scope

This specification covers the technical details of the two-component (or, as per manufacturer’s practice), glass flake reinforced ambient cured polyester coating, its method of application, surface preparation requirements, testing requirement



and QA/inspection criteria. The glass-flake reinforced polyester coating material lining process shall be carried out at lining applicator’s works before the internally lined pipes and components are dispatched to site, where only field joints are to be carried out at the previously planned cut-back portion of the pipes and components. In exceptional cases large diameter fittings and specialties may be allowed to be internally lined at site-fabrication yard/in-situ through automatic/semi-automatic or manufacturer recommend means to achieve same level of finish and quality as done in shop.

3.02 Product Specification

The product (coating material) shall be high build, fast cure anti-corrosive coating meant for application in aggressive corrosion environment like sea-water application in the internal surfaces of pipes. The recommended working “Volume Solids” is 85% or it should be as recommended by manufacturer. Method of application of this coating material by Airless spray technique and in exceptional cases of unforeseen encounter with “pits” in metal, through brush to ensure proper treatment. The following recommended test data may be adhered to for the coating material. However, if manufacturer furnished test data are different from the following, based on his recommendation and practice then the same is also acceptable. In such case necessary certificates for tests already carried out & verified may please be furnished for Employer’s scrutiny of test results. Coating thickness shall be 1000 micron (nominal DFT) with atleast 90% of the nominal DFT to be obtained at any spot measurement of DFT during testing.


Cathodic Disbondment ASTM G8 “Cathodic Disbonding of Pipeline Coatings”, Method A 2 x 600 micron DFT applied directly to SA 2.5 blasted steel. Typically less than1 mm disbondment following 30 days exposure. Immersion ISO 2812 Part 2 “Resistance to water immersion@ 40OC”. 1 x 500 micron DFT applied directly to SA 2.5 blasted steel. No film defects following 8000 hours exposure Immersion IS 2812 Part2 (Modified)“Resistance to sea water immersion@ 40OC. 1 x 500 micron DFT applied directly to SA 2.5 blasted steel. No film defects following 8000 hours exposure Salt Spray ISO 7253“Resistance to neutral salt spray (fog) @ 35OC. 2 x 600 micron DFT applied directly to SA 2.5 blasted steel. No film defects and no rust creep at the scribe following 6000 hours exposure. Abrasion ASTM D 4060“Abrasion Resistance of Coatings via the Taber Abraser ” 1 x 500 micron DFT applied directly to SA 2.5 blasted steel. Average of 224 mg weight loss per 1000 cycles using H18 wheels and a 1 Kg loading.




Adhesion ISO 4624-“Pull-off test for adhesion” using portable adhesion testers 2 x 500 micron DFT applied directly to SA 2.5 blasted steel. Not less than7 MPa (1015 psi) when using a PAT Model GM 01 hydraulic adhesion tester on 5mm thick steel. Elongation@ Break BS 6319 Part7 1 x 500 micron DFT “free film” Elongation 0.61% Impact BS 3900 Part E3 1 x 500 micron DFT applied directly to SA 2.5 blasted steel. Direct Impact Resistance-6.5 Joules Tensile Strength BS 6319 Part7 1 x 500 micron DFT “free film” An average of 210 Kg/cm2 is required to achieve fracture of the coating.


Surface preparation shall be same as that given for solvent free epoxy coating material under clause 1.05 above. All chlorides shall be removed as detailed in case of Epoxy coating material/Polyurethane material.

3.06 Priming

It shall be done with a compatible primer material which is suitable to coating material. Method of application shall be same as that followed for Epoxy lining material under clause 2.04

3.07 Coating The coating material shall be applied in requisite thickness in accordance with recommended working procedure for application by manufacturer and shall be done by Airless spay technique within the recommended temperature and humidity range.

3.07 Field Jointing

Procedure shall be same as that for Epoxy coating material or as recommended by manufacturer based on proven practices.


The inspection and testing shall be same as that indicated in clause 1.09 above Specification for polyurethane Coating/lining material intended for carbon steel piping external & internal surface and other steel structure surface (in the vicinity of Sea-Surface experiencing wave-splash off and on).

4.0 SPECIFICATION FOR RUBBER LINING



4.1 SCOPE

4.1.1 This specification covers the requirements for design, supply of materials, surface preparation, application of rubber lining, curing, inspection, testing and repairs of lining with rubber for vessels, tanks, piping etc.

4.1.2 Rubber lining shall be provided to the equipment on all portions indicated in the

respective data sheet / drg. of the equipment.

4.1.3 The items shall be rubber lined at site or at the vendor’s shop as per the order.

4.2 GENERAL

4.2.1 CODES AND STANDARDS

4.2.1.1 The applicable codes, standards and legal regulations shall be as indicated in the approved drawings, data sheets and specifications. Such codes and standards shall be of latest editions, unless otherwise specified.

4.2.1.2 The Vessel to be rubber lined shall in general confirm to the requirements of Part I

of Indian Standards 4682-1968 “Code of practice for lining of vessels and equipments for chemical processes Part I – Rubber lining”.

4.2.1.3 Vessels and Tanks to be rubber lined shall be fabricated in such a manner that it

complies with the requirements of IS 4682 – Part – I.

4.2.1.4 The lining shall be as per this specification and confirm to the requirements of IS 4682 Part-I.

4.2.2 SPECIAL REQUIREMENTS

4.2.2.1 Special requirements pertaining to specific application when issued along with this

specification shall be adhered to strictly.

4.2.2.2 It shall be the responsibility of the vendor to ensure that all aspects of design, fabrication, inspection and testing conform to the requirements of the specified codes, standards and legal requirements.

4.2.2.3 Conflicts, if any, between the equipment data sheet/drawing/this

specification/codes and other enquiry/purchase order specifications shall be referred to PURCHASER/CONSULTANT for clarification, prior to the work.



Changes in price and delivery due to such clarification shall be resolved and settled immediately. In any case the vendor is bound to accept the stringent of the conflicting clauses without any price/delivery change.

4.2.3 STATUTORY APPROVAL

4.2.3.1 Vendor shall obtain approval from the statutory bodies for equipment falling under

such categories.

4.2.4 DRAWINGS AND SPECIFICATIONS

4.2.4.1 Drawings of equipment to be rubber lined will be provided to the vendor which will contain information such as the shape, dimensions, design conditions and material of construction, etc. for preparation of application drawings.

4.3 DESIGN OF LINING

4.3.1 The selection of lining and its method of application shall be based on the following information :

1. Constituents including traces of operating medium. 2. Maximum, minimum and normal operating temperatures and pressure

conditions including cycle of variation. 3. Cycle of operation, whether batch or continuous process. 4. Details of the amount, particle size and physical characteristics of the

suspended matter, if any, together with rates of flow. 5. Probable anticipated mechanical damage, if any, during construction or

operation. 4.4 MATERIAL

4.4.1 The quality of the rubber shall be such that it should withstand the chemical and

physical condition specified during its service life. It shall withstand deterioration by prolonged contact with the contents of the vessel.

4.4.2 Thickness and hardness of the lining specified by PURCHASER/CONSULTANT is

the minimum requirements and for general guidelines only. The vendor is at liberty to change the thickness and also the hardness to suit the service condition specified. Such changes shall be explained in the offer with the reasons for the changes.



4.4.3 Linings shall be designed taking into account the proposed vulcanising method (autoclave vulcanization/site vulcanization/ and with pressure steam or open steam),

4.4.4 The rubber sheet should be free from blisters and other imperfections which would

affect the performance of the lining. The thickness tolerance of the lining shall not exceed plus or minus 10%

4.4.5 The lining shall be done with natural rubber which shall be vulcanized thereafter or

with pre-vulcanised rubber of suitable grade and hardness for the service mentioned in the enquiry/order.

4.4.6 Only virgin rubber shall be used for the lining and the vendor shall provide an

identification number for the approved mix and supply samples of vulcanized sheets for tests and reference in case of any dispute which may arise in future.

4.4.7 Alternate materials such as synthetic rubber equal or superior in quality maybe

offered as an alternative when called for in the enquiry and the properties and suitability of such materials shall be established by the vendor. Such materials shall be used only with the prior approval of PURCHASER/CONSULTANT.

4.4.8 Care should be taken in the manufacture of the sheets to ensure minimum of

stress in the material which could cause shrinkage during vulcanization.

4.4.9 Care should be taken to see that the rubber sheets used on the job are not semi-vulcanised due to exposure to outside temperatures/long storage.

4.4.10 VULCANISATION

(1) Generally vulcanization of the lining shall be done by steam curing. This

shall be achieved by keeping the lined equipment in autoclaves for the desired duration and temperature.

(2) The equipment itself shall be used as the autoclave by admitting steam

directly into the vessel, provided that all parts of the equipment is designed to withstand the applied steam pressure. Vendor shall submit calculations to establish this aspect along with such offer. However, this method shall be adopted only with prior approval from PURCHASER/CONSULTANT.

(3) When the above two alternatives are impractical and the equipment is

larger than 2 meter diameter pre-vulcanised (pre-cured) rubber sheets shall be mutually agreed upon before placement of order/application.



(4) In any case curing the lining by compartments or in parts is not acceptable

as the resultant vulcanization will not be uniform (5) Alternate vulcanization methods shall be employed when called for by the

design and overall dimensions of the equipment and depending on the facilities available at site, without risking the performance of the lining to the required service with mutual agreement of vendor and PURCHASER/CONSULTANT.

(6) If the edges of flanges are blanked off, a satisfactory method shall be

resorted to, to avoid under vulcanization of the flange faces. (7) During vulcanization abrupt increase and decrease of pressure and

temperature shall be strictly avoided. (8) The temperature difference between the inside and outside of the shall be

limited to less than 10 deg. C during vulcanization by providing suitable insulation.

4.5 SURFACE PREPARATION

4.5.1 All surfaces to be rubber lined shall be thoroughly cleaned using a solvent or with

live steam.

4.5.2 The cleaned surface is then sandblasted to SA 2½ to remove rust and scale. The sand/grit used for the job shall be 30-40 mesh size. 5 to 60 Kgs/cm2g air pressure shall be used for blasting to prepare the surface fit for lining. The sand used for the job shall have sharp edges and shall be preferably mountain sand, sand used once shall not be reused. After each days sandblasting is over the surface blasted is cleaned and first coat of primer applied immediately to prevent rust formation.

4.5.3 Sharp changes in contours in the surface to be covered shall be avoided wherever

possible. Edges formed by the junctions of plates, etc. in different planes and external angles including misalignment should be welded and finished by grinding to a suitable radius. Internal angles should be fillet welded and ground concave so as to provide adequate radius. The radius should be as great as possible. The minimum radius shall be equal to the thickness of lining. Lining vendor shall ensure that all the surface/contour/welds etc. are prepared to his satisfaction before taking over the equipment for lining work.



4.5.4 All surfaces which are to be covered with rubber shall be free from pit holes and other physical imperfections. Pittings, corrosion, cavities, depressions, laminations, etc shall be filled by welding and ground to a smooth curvature.

4.5.5 All weld spatters should be removed from surface to be rubber lined.

4.5.6 Any projections that are objectionable to soundness of lining, shall be removed by

grinding.

4.5.7 An initial sandblasting may be resorted to, if necessary to assess the repairs to be done for the vessel to make it fit for rubber lining.

4.5.8 Only after complete repairs have been carried out and vessel made fir for rubber

lining, final sandblasting as mentioned above shall be done and first coat primer applied.

4.6 APPLICATION

4.6.1 GENERAL

(1) All the surface of the vessel shall be lined as shown in the data sheets/drawings with rubber sheets of specified thickness securely bonded to the metal surface.

(2) Before applying the second coat of Rubber solution in the surface on which the

first prime coat has been given after sand blasting shall be cleaned with cloth moistened with petrol or other suitable cleaning agent to remove the possible dust accumulation due to blasting. The surface shall be thoroughly checked for any rust formation also. After cleaning with petrol/suitable cleaning agent sufficient time lag shall be given for the vapours to evaporate and to get a dry surface. Subsequent coats of rubber solution shall be applied after the solvent has evaporated from the previous layer. The rubber coatings shall be applied in a thin uniform continuous layer using brush. Care shall be taken not to form air bubbles while applying the coating. Drips or clots if any, shall be carefully rubbed into the metal with a brush. The coating – film shall be protected against contamination by dust, fibers and hairs from the brush.

(3) The calendared rubber sheets shall be made to fit the surface to be lined. The

edges of the rubber sheets shall be chamfered with the maximum inclination of the knife to get a proper overlapping joint. That side of the sheet which will be in contact with the adhesive shall be wiped with the rubber solvent to clean its



surface and increase its tack. As soon as the solvent evaporates and the surface still retains its tack the sheet shall be applied to the metal.

(4) Any preshrinking of the rubber sheet shall be done at shop/site before hand

tailoring the sheet to fit the surface to be lined.

(5) The air trapped between the rubber sheets and the metal surface shall then be thoroughly and carefully forced out by using suitable rollers.

(6) Extreme care shall be taken during rolling to avoid air entrapping. In

unvulcanised sheets if air bubbles are noticed, the same shall be punctured at a suitable inclination, with a needle/knife dipped in rubber solution and the air pressed out through the hole formed and the puncture/cut rolled with the roller.

4.6.2 JOINING OF SHEETS

(1) Unvulcanised sheets shall be joined by using overlap bevel joints and

vulcanized sheets by strapped joints as detailed in IS 4682-Part I. (2) The staggering of the joints of the first and second layer rubber lining shall

not be less than 100mm. (3) Overlap joints shall be made in such a way that the overlap flow the

direction of liquid flow. (4) Joints at corners and at the edge of rings shall be strictly avoided.

4.6.3 SAFETY AND PRECAUTIONARY ASPECTS

(1) All safety precautions as per the Factories Act shall be strictly followed

while working inside the vessels. (2) All naked light shall be avoided. 24 Volts safety lamps shall be used. (3) While applying solution, frequent checks shall be conducted with a gas

tester to ensue that no inflammable or explosive gases exist within the limit. (4) The following precautions shall be adhered to while testing for continuity of

lining with a spark tester.

a. Remove moisture from inside the tank or other object being tested and form the surface of the rubber so as to prevent electric shock.



b. Remove oil, dust, wood, metal, etc. from the rubber lining surface. c. For vessels, tanks, ducts, pipe lines in open areas spark test shall not be

conducted while it is raining. d. Inflammable objects shall be kept away from the test area. e. Confirmation shall be obtained from the Owner that no flammable or

explosive gases or other materials exist in the test area

(5) Smoking inside or near the rubber lining area or near the area where the compound, adhesive, etc. and stored shall be strictly forbidden.

(6) Workers of inside of the vessel shall be instructed to wear only rubber

shoes. There shall not be any nail or other sharp objects in the shoes which can damage the rubber lining.

(7) Metal scaffolding shall be avoided inside the vessel. (8) Bamboo or wooden scaffolding/platforms used shall be sufficiently strong

and shall not have sharp edges which may damage the rubber lining. (9) Ladders used for the job shall have the bottom covered with rubber shoe to

prevent any possible damage to the lining. (10) Knives or sharp objects shall not be allowed inside the vessel except for

any repairs of the rubber lining being done. (11) Care shall be taken to ensure that semi-vulcanised rubber sheets are not

used on the job.

4.6.4 SPECIAL REQUIREMENTS FOR LINING OF VACUUM VESSELS

(1) The vendor shall decide the lining material and application procedure only after complete study of the working conditions.

(2) Triplex rubber lining with soft-hard-soft layer is preferred for vacuum

service rubber lining. (3) For Vessels which operate under vacuum, pre-vulcanised rubber sheets

shall not be used since it has less bond strength. (4) Since Peeling of rubber from metal surface can be due to improper metal

surface, surface preparation is one of the most important factors in lining of vacuum vessels.



(5) Wherever possible, the rubber lining of vessels under vacuum should be

done in the vendor’s shop so that special attention can be given during application, vulcanization etc. Equipment shall be vulcanised in an autoclave.

(6) Wherever the rubber lining of vessels under vacuum are done at site the

vessel shall be vulcanised by pressure vulcanization method by using the equipment as an autoclave by sealing openings with blind flanges and taking all design/application precautions. Adequacy of strength of the equipment against the steam pressure and temperature shall be ensured before proceeding this method.

(7) The equipment shall be provided with outside insulation to limit the

temperature difference between inside and outside within 10 deg. C. (8) Each rubber sheet shall be spark tested to detect defects / pin holes before

application. Spark testing should be done before and after vulcanization. (9) Peel test shall be conducted for each batch of material and only after

ensuring that the bond strength is as per IS 4682 Part I of the lining job shall be carried out.

(10) Wherever the lining thickness is more than 3mm, lining shall be done in

different layers with the maximum thickness of the single layer being 2.5mm. All vertical and horizontal joints should be staggered and should have proper overlaps.

(11) After completion of the lining, before vulcanization the lining shall be

subjected to positive air pressure (as limited by the design of the equipment) which ensures even bondage between metal surface and rubber.

(12) After completion of the rubber lining, the vessel shall be kept for a period of

minimum 2 days for natural drying before being vulcanised. (13) Sample rubber pieces shall be put inside the vessel during vulcanization

and checks shall be made on the sample pieces at the end of vulcanization to ensure that uniform proposed hardness has been obtained.



(14) Care shall be taken to see that the pressure and temperature inside the vessel is raised/lowered slowly at a uniform rate and any abrupt increase/decrease shall be strictly avoided.

(15) Steam traps and drain holes shall be provided at the lowest point of the

vessel to drain the condensed water to prevent under vulcanisation of the rubber in those areas.

(16) A hammer test shall be conducted with a wooden mallet to detect any

separation of rubber from metal surface (17) During testing, if the rubber lined surface shows defects in more than 10%

area, the vessel shall be completely relined and retested at free of cost. 4.7 TESTING

4.7.1 Inspection and testing of rubber lining shall be carried out at all stages.

4.7.2 The physical properties/composition of the rubber lining shall be tested when

specified by PURCHASER/CONSULTANT as per the requirements of IS 3400.

4.7.3 Peel test shall be conducted on samples of each batch of compound and adhesive and the values obtained shall be as per IS 4682 – Part I.

4.7.4 The vendor shall give test results conducted on samples of hard rubber for bond

strength as per ASTM-429 and the values shall be as per IS Standards.

4.7.5 Continuity of the lining shall be ensured by visual inspection and high frequency spark test as per IS 4682 – Part I. Spark test shall be conducted before and after vulcanisation. The voltage used shall be as per IS 4682-Part I.

4.7.6 Hammer test with wooden hammer shall be conducted before and after

vulcanisation to detect any possible air gaps/separation of sheets from metal surface.

4.7.7 Hardness test shall be conducted on completion of vulcanisation as specified in IS

4682 – part I

4.7.8 The thickness of the lining shall be checked by direct measurement or by using a thickness metre as the case may be.



4.7.9 A hydraulic test, wherever required at an agreed pressure and for an agreed duration of time shall be conducted in a manner specified by PURCHASER/CONSULTANT and there shall be no leakage past in lining.

4.7.10 A vacuum test shall be carried out maintaining the specified vacuum for a period of

8 hours and by an agreed method wherever specified by PURCHASER/CONSULTANT.

4.7.11 Wherever contamination of the contents of the equipment by the lining material in

detrimental, check shall be conducted on samples of the compound.

4.8 REPAIRS

4.8.1 Any minor defects noticed on testing and inspection shall be rectified by the vendor in a manner mutually agreed by the vendor and purchase. The repair shall be done as per good engineering practice and to the entire satisfaction of PURCHASER/CONSULTANT site engineer.

4.8.2 After the repairs, the vendor shall conduct further tests and satisfy

PURCHASER/CONSULTANT regarding the suitability of the lining.

4.8.3 After conducting tests, if the lining again shows major defects, the vendor shall replace the complete lining to the satisfaction of PURCHASER/CONSULTANT representative.

4.8.4 In case of any dispute regarding the degree of the defect as to major defect or

minor defect and the areas to be replaced, the decision of PURCHASER/CONSULTANT shall be final.

4.9 STORAGE

4.9.1 STORAGE OF LINING MATERIALS

(1) The rubber sheets and adhesives shall be transported from the works of the vendor and stored at site stores at the required temperatures.

(2) The air conditioned/cold storage facilities provision required at site and

during transportation shall be mutually discussed and arranged between the vendor and PURCHASER prior to placement of order. However, it shall be the responsibility of the vendor to arrange all facilities for the safe transport and storage of the sheets and adhesives at his own cost.



(3) The vendor shall ensure that the work area is properly protected against

unfavourable weather conditions such as rain, wind, dust, etc.

4.9.2 STORAGE OF LINED VESSELS

(1) The lined vessels shall be kept preferably in cool and dark places. In case of large equipment the outside of the vessel shall be covered to protect from direct sunlight.

(2) The rubber lined vessels may be filled with water until it is commissioned. (3) The rubber lined equipment shall be kept away from fire.

5.0 TECHNICAL SPECIFICATION FOR FRP (B) & FRP (I) LININIG

5.1 Introduction

FRP (B) (Fiberglass Reinforced Plastic with Bisphenol-A resin) & FRP (I)(Fiberglass Reinforced Plastic with Isopthalic resin) linings are widely used to protect the steel and concrete structures exposed in the chemical and outdoor environment. These are suitable for corrosive service. Following are some of the important features of the lining work:

(1) Surface preparation shall conform to SA 21/2 must be of prime quality

(2) Avoid using the service temperature beyond 60°C as well as a sudden

change in the service temperature for a good long-term performance of FRP (B) lining.

(3) Use flexible resin with about 3-4% elongation rather than brittle resin with

1-2% elongation to avoid chalking, crazing, cracking which might occur due to differences in the thermal expansion between liner and the substrate

(4) Must use a primer coat of high elongation resin to ensure the bonding

between liner and the substrate 5.2 Hand Lay-up Lining



5.2.1 Hand Lay-up method of lining consists of 2-3 layers of 450 gsm chopped strand mat (CSM), preferably powder bonded, laid over a sand blasted, subsequently primed substrate and followed by a layer of C-glass or synthetic surfacing mat and a resin-rich top coat. Typically, the lining is 3.5 - 5 mm thick and averages 20-25% glass and 75-80% resin. Because of the high resin content, this type of lining possesses a high degree of chemical resistance.

5.2.2 The FRP lining need to have a resin-rich surface reinforced with surfacing mat. It would improve the appearance of lining as well as its resistance to corrosion and abrasion. In the absence of surface mat, the liner is covered with only a thin layer of resin, which may wear away in the course of normal use exposing the glass fibers. This is extremely undesirable as these exposed glass fibres would pick up dirt, absorb as well as act as a wick resulting in a rapid failure of the lining.

5.2.3 The resin topcoat must not be allowed to cure in presence of air, since the resin

surface that is exposed to air does not cure completely. An incompletely cured resin surface means reduced weather and chemical resistance, which can lead to premature failure of the liner. This can be overcome by mixing MECHWAX SOLUTION with the topcoat resin and the topcoat should be allowed to cure within 10-15 minutes. The MECHWAX SOLUTION is soluble in liquid resin but insoluble in the cured resin and hence it exudes to the surface as the resin cures, protecting it from air. The oxygen present in the air would inhibit the complete cure of unsaturated polyester resin and in addition, sometimes may leave a tacky surface.

5.2.4 The resin applied to a vertical surface will have a tendency to flow or run

downwards before it has time to gel. A proper care has to be taken in this regard by selecting the gel time of the resin and the lining area to be covered at a time.


It is the most important parameter in the process of lining.

(1) For Steel Surfaces

Weld preparation a. Fillets and edge welds shall be smooth and to a 1/8 inch rounded radius b. All welds to be lined need to have a smooth continuous weld with weld

splatters and crevices removed by grinding c. All edges and corners need to be ground smooth



d. A rippled surface needs to be corrected to a smooth surface by suitable means

e. All corners and edges to be lined need to be round to a radius of 1/8 inches minimum

Cleaning The surface should be cleaned by wiping with cloth wet with solvent to remove oil, grease and loosely adhering deposits

Sandblasting a. It is the most preferred method for cleaning the steel surfaces b. The surface of the metal to be lined shall be blasted to a white metal finish

using 20-40 mesh sand. The compressed air must be clean and oil free. Profiles should be primed on the same day, within 6-8 hours.

(2) For Concrete Surfaces

a. Fill and patch all the holes with putty made by mixing silica powder and resin.

b. If the concrete is old or has set for a period of time, blast to a fresh surface. c. Sand blasting is the preferred method of surface preparation. d. If cleaning is done by acid etching, then thoroughly flush the surface with

water until all traces of acids are removed. e. Do not let acid dry on the surface. f. The sand blasted surface should be primed on the same day, within 6-8

hours.

(3) Application of Primer Coat

a. The primer coat shall consist of 50 parts by weight of resin and 50 parts by weight of silica powder

b. The catalysed primer shall be applied by spraying, brushing or rolling to a minimum dry film thickness of 25-50 micron. All runs, drips and sags of wet film need to be removed.

5.4 Lining

(1) The primer coat need to be totally tack-free dry, but at the same time, it

should be set less than 14 days, prior to lining. Otherwise check the primer



coat for styrene sensitivity. If it is sensitive to styrene, then good inter-coat adhesion will exist.

(2) Minimum of two layers of 450 gsm chopped strand mat, preferably powder

bonded, shall be applied. If the application of the second layer is delayed for more than 8 hours, the first layer need to be styrene wiped before applying the second layer to ensure proper interlayer adhesion. The lined surface needs to be then tested for pinholes by spark test method as described below.

(3) A Layer of surfacing mat needs to be applied on the top of the lined

surface, which has passed the spark test. (4) The resin top-coat need to be prepared by mixing 2-3% of MECHWAX

SOLUTION with bisphenol resin and then the resin is initiated with normal catalyst system. For application on vertical surfaces, use thixotropic grade of resin. This resin needs to be applied when the layer of surfacing mat becomes tack free.

(5) While lining, the complete wetting of the glass fibres with resin and removal

of entrapped air in the lining needs to be ensured. (6) No pigment paste be mixed either with resin and/or topcoat at the time of

lining. 5.5 Inspection of Lining

The finished lining needs to be inspected by:

(1) Spark Testing The linings inspected for pinholes with a high voltage Holiday Detector at 10 KV (100 V/mil). The pinholes shall be marked for repairs. (2) Styrene Sensitivity This test ensures complete curing of FRP lining. A small area (50 mm2) is wiped with cloth dampened in styrene. This area is rubbed with a finger after wiping and if it is softened or becomes tacky, the surface is considered styrene sensitivity, if the surface does not soften or become tacky, it is deemed styrene insensitive (3) Acetone Resistance Test



It is more stringent test for the complete curing of the resin. Apply a small amount of acetone on the cured resin surface and rub it around slightly with your finger until the acetone evaporates. If the surface feels soft or tacky, it is inferred that the surface is not properly cured. (4) Hardness Test It is one of ht most important tests to confirm the complete curing of the resin. The hardness of the cured surface can be measured using a portable Barcoal Hardness Tester as per the procedure described in the ASTM D2583. If the FRP (B) lined surface achieves a minimum of 90% value of Barcol Hardness assured by the resin manufacturer, then only the lined surface can be put into the actual service. The value of Barcol Hardness can be improved by heating the lined surface to a maximum temperature of 60°C for 8-10 hours by means of hot air.



PREFERRED MAKES



CONTENTS

Sl. NO. Description Page No.

A Prepared Vendor List 1-1

1. Technological Equipment 1-3

2. Air-Conditioning & Ventilation 3-4

3. Electrical Power Distribution 4-5

4. Shop Electrics 6-6

5. Illumination 6-8

6. Instrumentation 8-12

7. Material Handling 13-15

8. Lab equipment 15-16

9. Fire Protection & Safety 16-16

10. Fire Fighting 16-17

11. Mechanical Repair Shop 17-17

12. Air compressors & Repair shop 17-17

13. Sewerage treatment plant 18-18



A. PREFERRED VENDOR LIST A suggested vendor list of major items of plant and equipment is given

below. Vendors have been selected based on their previous experience and reliability of equipment supplied by them for similar applications.

1. Technological Equipment

S.No. ITEM VENDORS 1. Process centrifugal pumps Termomeccanica,

Ingersoll Rand, KSB, Gould, Dresser, Flowserve, Sulzer. Beacon weir limited.

2 Vertical centrifugal turbine pumps, Horizontal centrifugal & High pressure centrifugal pumps

Calder, Sulzer, KSB, Ingersoll , Union Pumps, Termomeccanica, Flowserve., Beacon weir limited, Robuschi, Kirloskar

3. Dosing pumps Swelore Engineering Pvt Ltd, LMI, Pulsa Feeder, Dosapro M-Roy, Prominent.

4. Energy Recovery Pressure Exchangers

ERI Note- Only 1 vendor (ERI, USA) has been considered, as they have supplied most of the operating units and credentials of other parties with PX have not yet been established for large plants

5. Root blower Swam Pneumatics Pvt Ltd, Robuschi, Hibon Int.

6. Fans & blowers Patels airflow limited, FLAKT WOOD, DUST VENT, TLT, C DOCTOR, RIECO

7. Submergible pumps Flyght, Fisher Xomox, BDK, ABS, KSB, Lovara.

8. Ball valves KSB, BDK, Virgo, Hawa, Fisher Xomax, Fouress,



Grove, Bremer, Alfa Valvole.

9. Butterfly valves Flow serve,Keystone, Shipham valves ,Fisher Xomox, BDK, KSB, Grove, Saunders.

10. Gate ,globe and Check valves

Flow serve ,Titanium tantalum products limited , Hawa valves, Shipham valves,UK, Alliance Valves & Piping Supplies Ltd.

11. Agitators Ceecons, Remi 12 Cartridge filters Fluxa, Filteration engineers India

pvt.Ltd,Mumbai, 3M ENCI pvt.Ltd, Bea Filtri, Grand Prix, FAI, Delta Engineering, Osmonics, HYDAC INTERNATIONALS, GEOFLUID PROCESSORS PVT. LTD

13. Static mixers Sulzer Keene Pittaluga Alfa-Laval

14. Expansion joints Angst+Pfister Idrosapiens KSB

15 R.O. skids RO skid structural supply, fabrication including assembly of membranes and pressure tubes from the prefered makes (RO membranes & pressure tubes & its associated components) can be carried out by the contractor.

16. R.O. membrane HYDRANAUTICS FILMTECH (Dow) TORAY KOCH (Osmonics) GE

17. Disk filters Arag Azud Osmo Asia Akral Amiad

18. UF Membranes and systems

Inge Ag-PP Norit-PP Hydranautics-PP DOW-PP

19 Recarbonation & Re-mineralisation

WTD Fichtner



20. Pipes flanges & fittings (SS

And Duplex).

SWASTIK LLOYDS ENGINEERING PVT LTD, Alliance Valves & Piping Supplies Ltd, Titanium tantalum products limited , SIMON STEEL (INDIA), D SIM Ltd P.A Inc. CTA Tubisteel Sumitomo Zhejiang Steel Pipe

21 Fiberglass & Plastic Pipes & Fittings

Hobas Tubi Fiberplast Idrogest Icp Pvt Ltd Jain irrigation, Reliance.

22 HDPE pipes & fittings JAIN IRRIGATION SYSTEMS LTD, Godavari Polymers Pvt Ltd, NOCIL/Reliance, KWH PIPES .

23 Pressure vessels Codeline pentair water, BEL COMPOSIT LTD., BEKAERT PROGRESSIVE COMPOSIT CORPORATION.

24 Carbon dioxide storage vessel

Universal Industrial Gases, Inc,USA, Trinity Containers LLC, SICGIL INDIA LIMITED, SS Foundry Chemical Industries Pvt. Ltd.

25 Carbon steel pipes & fittings

Jindal pipes ltd. SAIL, Suryaroshni ltd., Saw pipes ltd, Tata iron & steel company- tube division, Indian seamless metal tubes ltd, Kalyani steels ltd, Maharashtra seamless ltd.

2. Air-Conditioning & Ventilation SL. No Description Make

1 Central Chilled Water Plant system

Blue Star / Carrier / Voltas / Daikin / Western Air Ducts/ Rola Star

2 Split type Air-conditioners Voltas / LG / Carrier / Samsung / Hitachi/ Blue Star

3 Tube Axial Fans HPS / TCF-NADI / Dustven / Khaitan

4 Centrifugal Fans HPS / TCF-NADI / Dustven

5 Exhaust Ventilation GEC / Almonard / Khaitan / Radiant / Ventura / Crompton



6 Wind Turbine Ventilators Golden engineering co. Pvt. Ltd, Real metals & systems Pvt. Ltd, Encon envirotech engineering.

7 Ducting ROLASTAR / WESTERN AIR DUCTS 8 Man-coolers Almonard / Khaitan / Humidin 9 Duct / Underdeck Insulation Paramount / Thermaflex / Armacell

10 Acoustic Insulation UP TWIGA / LLOYD / Rock wool

11 Cooling Tower Shri Ram / Voltas / Advance / Mihir / Paharpur

3. Electrical power distribution:

Sl.No Item name Make

1. 121 kV outdoor SF6 breaker ALSTOM/ ABB /BHEL / CGL / TELK 2. 123 kV outdoor Disconnecting

switch Elpro/S&S

3. Current / Potential Transformer CGL / TELK / ALSTOM / BHEL/ABB 4. Lightning Arrestors ABB/OBLUM / CGL /ELPRO / AREVA

/LAMCO/JAYASHREE INSULATORS 5. Relay and control Panel SIEMENS/ALSTOM/ ABB/ Easun Reyrolle 6. Relays (Conventional) Alstom / Easun Reyrolle/ABB 7. Relays (Numerical) Alstom / ABB / Siemens / Easun Reyrolle 8. Microprocessor based Metering Enercon / Alacrity / SEMS 9. Indicating meter AE / IMP / MECO 10. Control and selector Switch Kaycee / Salzer / Alstom

11. Insulator Jayashree/WS

12. Insulator BHEL/WS/JAYSHREE/Modern

13. Battery AMCO / HBLNIFE / EXIDE / AMARARAJA

14. Battery Charger Amar Raja / Caldyne / Universal / AE / Chhabi Electricals /HBL Nife

15. L.T. Switchgear, MCC & PDB SIEMENS / CONTROL & SWITCHGEAR / GEPC / SCHNEIDER / L&T

16. L. T. Air Circuit Breaker L & T/ SIEMENS/ SCHNEIDER / CONTROL & SWITCHGEAR / GEPC

17. Power Transformer Distribution & Converter duty transformers

BHARAT BIJILEE / KEC / AREVA / CGL/EMCO BHARAT BIJILEE / KEC / AREVA / CGL/EMCO / Voltamp / PS Electricals / Indcoil

18. HT switchboard ABB / SIEMENS / AREVA

19. HRC Fuses AREVA / D & P / SIEMENS / L & T /



STANDARD / HAVELLS ( for LT) AREVA / SIEMENS /ABB/CGL ( HT)

20. Capacitor (L. T) Capacitor (H. T)

UNISTAR / KHATAU / CGL / ASIAN /MEHER /SIEMENS UNISTAR / ASIAN / ABB /CGL

21. HT Reactors PS Electricals / Shrihans Electricals / Trench electrics / Western Hivolt / Quality power Electrical equipment (P) Ltd.

22. Numerical Relays SIEMENS / AREVA / ABB

23. Vacuum Contactors BHEL / AREVA / SIEMENS / CGL/ABB

24. Cable Termination Kits (heat shrink type)

Raychem / MECP /Densons

25. Micro processor based meters ENERCON / SWIFT / NEPTUNE / ABB / SIEMENS

26. V.C.B. (Indoor & outdoor) SIEMENS / AREVA/ ABB

27. Insulators JAYASHREE/ASSOCIATED POECELAIN/WS INDUSTRIES

28. Neutral Grounding Resistor S R Narkhede/PEFCO/Resitech Electricals/Ohmark Controls

29. Protection and auxiliary Relays (Electromechanical)

ABB / AREVA/ EASUN REYROLLE

30. HT Cables UNIVERSAL / NICCO / POLYCAB / RPG CABLES (ASIAN) / CCI

31. LT power and control Cable UNIVERSAL / NICCO / CCI / RPG CABLES (ASIAN) / POLYCAB / FINOLEX / LAPP

32. Cable Lugs DOWELLS / JAINSON

33. Terminal Block ESSEN / ELMEX / CONNECTWELL / S & S / PHOENIX / WAGO

34. Battery AMCO / HBLNIFE / EXIDE / AMARARAJA

35. Cable Glands COMET / HMI

36. HT & LT bus duct 1) M/s. Stardrive 2) M/s.C & S 3) M/s. Bright engineers.



4. Shop Electrics:

S.No.

Item name Make

1. Micro processor based meters Enercon/Swift/Neptune/ABB/Siemens 2. Indicating meters AE/IMP/MECO/Rishabh 3. CTs/PTs Pragati/Kappa/Precise/AE 4. Control/Selector switches Kaycee / Salzer 5. LT MCCs & PDB Schneider/L & T / Siemens 6. VFD ABB / L & T / Siemens 7. LT motor KEC/Siemens/Bharat Bijilee/Alstom/ABB/CGL 8. ACBs Schneider/Siemens/L & T 9. MCCBs Merlin Gerin/L & T/Siemens/ABB 10. MPCBs Siemens / Telemechanique / Sprecher and

Schuh 11. Contactors, O / L relays with SPP Telemecanique/L & T / Siemens 12. SFU, Load break switches, Fuses, , SIEMENS / L & T / GEPC / Schneider/ ABB 13. Control voltage Transformer Southern Electric / KAPPA / Automatic Electric

/ Kalpa / Pragathi Electrics 14. MCB / ELCB MDS/Hager/Siemens 15. Motor protection relays L & T (MM-30) / Schneider (SEPAM)/Multilin

(239) 16. Cables NICCO/Polycab)/Fort Gloster/Universal/RPG

(LT power & control)/Delton (control) 17. Push buttons Vaishno / Siemens / L & T / BCH / GEPC 18. Indicating lamps (LED type) Siemens/Raas Controls/L&T 19. Industrial Plugs & Sockets Best & Crompton/Schneider Electrics/ Bharatia

Industries 20. Local push button station BLEP/Flexpro/Flameproof Equipment/Pushtron 21. GRP cable Trays ERCON/General composites/Densons 22. Pulse Tacho EFKTOR-IFM (I) (EFKTOR-Germany) /

TLMKNQ –Arihant Electrical (Telemechanique-France) / Allen Bradley (I) Ltd./ STROTER (MIG)

5. Illumination:

S.No. Item name Make

1. MCC/MLDB.MELDB/Feeder pillar /LT Swich gear

Siemens/L&T/GE-pc/Schnieder/Areva

2. Indicating meters AE/IMP/MECO/Rishabh 3. CT’s/PT’s Pragati/Kappa/Precise/AE 4. Control/Selector switches Kaycee / Salzer



5. MCCB’s, ACB L & T/Siemens/ABB 6. MCB / ELCB MDS/ Havells/ IndoAsian/Standard 7. LT Power Cables NICCO/Polycab/FortGloster/Universal/RPG 8. Indicating lamps (LED type) Siemens/Raas Controls/L&T 9. Industrial Plugs & Sockets Best & Crompton/Schneider Electrics/ Bharatia

Industries 10. TPN Switches / Switch Fuse Units

/ FSUs / HRC fuses and DP & TPN Switches with Sheet Steel Enclosure

Siemens / Larson & Turbo / Controls and Switchgears Company Ltd./ Schnieder Electrics

11. Light Fixtures & Lamps

Philips / Crompton Greaves / Bajaj / GE lighting/ Havells

12. MCBs & Lighting Distribution Board with MCBs

Indo Asian Fusegear Ltd./(INDO – KOPP) MDS-Legrand/Havells/ Standard Electricals S & S Power Switchgear Ltd

13. Copper Wires / Flexible Cables

Polycab / Finolex / Ravicab / Rajanigandha

14. 5 /15 A Piano Switches And Socket Out Lets

Anchor Electricals / Lisha / MK Electric India

Ltd / MDS-Legrand.

15. Industrial Switches & Socket Outlets

Best & Cromption Engg. Ltd. / Bharatia – Cutler Hamer Ltd. / Essen Engineering Company P.Ltd. / Ajmera / Cyclo / Crompton Greaves Ltd.

16. Ceiling Fan / Exhaust Fan Crompton Greaves Ltd., / Bajaj Electricals Ltd., / GEC / Khaitan Electricals Ltd.,

17. Energy Meter BHEL / Havells/L&T 18. Timer & Contactor Bharatia Cutler Hamer Ltd., / GEC Alsthom

India Ltd. / L & T Ltd. / Siemens Ltd.. 19. Call Bell & Bell Pusher

Home / Lisha / Anchor

20. Street Light Poles Rajan / KL Industries / Shubham / Ridhi. 21. PVC Pipes

Avon Plast / Modi / Universal Precision

22. GI Pipes TATA / Jindal / Apollo / Zenith

23. High Mast Philips/CGL/Bajaj/GE/BPProjects P Ltd.

24. DG set-Alternator AVK-SEK/Crompton Greaves/Kerala Electrical & Allied Engg

25. DG set-Engine Caterpillar/Cummins/Detroit/Greaves Cotton/Kirloskar



6. Instrumentation ,Control & Automation

S.N. ITEM DESCRIPTION PREFERRED MAKES

A Field Instruments:

1. Pressure / Differential Pressure gauge

WIKA, Manometer India, AN Instruments, General

Instruments, Waaree instruments, Walchandnagar (Tiwac), H. Guru.

2. Pressure / Differential Pressure switches Switzer, Indfoss, Vasutech

3. Pressure / Differential Pressure Transmitters

Emerson (Rosemount), Chemtrols (Fuji), Honeywell, Yokogawa, ABB, Siemens, Emerson , E & H

4. Temperature gauges WIKA, Manometer India, AN Instruments, Generalinstruments, Waaree instruments, H. Guru

5. Thermocouple & RTD / thermowell

General Instruments, Nagman Instruments, Toshniwal Industries, Tempsens, Pyro-electric Instruments, Industrial Instrumentation.

6. Temperature Switch WIKA, Manometer India, AN Instruments, General Instruments, Indfoss, Switzer, Vasutech

7. Temperature transmitter Emerson (Rosemount), Yokogawa, ABB, Honeywell, Siemens

8. Rotameters Krohne-Marshall, Instrumentation engineers, Trac, Eureka instruments. Chemtrols

9. Orifice Plate & flanges Assembly/ Venturi , Flow nozzle

Engineering Specialities, Micro-precision, Hydro-pneumatics, Chemtrols-Samil, Instrumentation ltd,

10. DP type Flow / Level Transmitters

Emerson (Rosemount), Chemtrols (Fuji), Honeywell, Yokogawa, ABB, Siemens

11. Flow Switch Switzer, Levcon, Krohne-Marshall, D.K. Instruments,

12. Electromagnetic flow meter Emerson (Rosemount), Krohne -Marshall, Yokogawa, ABB, Endress & Hauser.

13. Level gauge (magnetic & reflex type)

Levcon Instruments, Techtrol, Sigma, Pratolina Instruments, Waaree Instruments




14. Level Switch (Conductivity type) Nivo Controls, Level-Tech, Endress & Hauser,

Switzer Instruments, Chemtrols (Vega), SBEM.

15. Level Switch (Capacitance/RF type)

Nivo Controls, Level-Tech, Endress & Hauser,

Switzer Instruments, Chemtrols ( Vega), SBEM.

16. Level Switch (Float type) Trac, D K Instruments, Levcon Instruments, Techtrol , Forbes Marshall, Emerson(Mobrey)

17. Level (Ultrasonic type) Transmitter

Krohne Marshall, Endress & Hauser, Chemtrols (Vega ), Emerson.

18. Control valve

Instrumentation Ltd, Fisher-Xomox , Dresser Industries (Masoneilan) , Samson Controls, MIL Controls, Forbes Marshall ( Arca ), ABB, Dembla, Fouress, Keystone( Tyco valves).

19. Electrical Actuator Auma, Limitorque, Marsh, IL(Vaas Bernard), Beacon Rotork, Keystone,

20. Pneumatic Actuator Instrumentation Ltd. (Palghat), Fisher-Xomox , Dresser Industries (Masoneilan), ABB, Samson Controls, MIL Controls, Forbes Marshall ( Arca).

21. Electro-hydraulic actuator Reineke, Askania

22. Self regulating pressure control valve

Samson Controls, Nirmal Industries, Forbes Marshall, Instrumentation Ltd.

23. I/P converters Shreyas-Barton, Forbes Marshall (Moore products), MIL controls, ABB, Fisher –Xomox.

24. Pneumatic Positioner Instrumentation Ltd. (Palghat), Fisher-Xomox , Dresser Industries (Masoneilan), Samson Controls, Forbes Marshall ( Arca) , ABB

25. Electro- pneumatic positioner Siemens, Dresser Industries (Masoneilan), Samson Controls.

26. Solenoid Valve Asco, Herion, Rotex, Schrader-Schovill, Jucomatic, Avcon

27. Air filter regulator Shavo-Norgren, Placka , Schrader-Schovill




B Control room Instrumentation

1. Distributed Control System (DCS) Yokogawa, Honeywell, ABB, Emerson (Rosemount).

2. Master station Limitorque, Rotork

3. UPS APC, Emersion Process Management, Siemens, Hirel Electronics Ltd, DB Power Electronics

4. Battery AMCO batteries, Amara Raja batteries Ltd., Punjab Power packs Ltd., SAB NIFE power system Ltd, Hyderabad

5. Computer IBM, HP, Compaq, Dell

6. Large Video Screen Display Sharp, Barco, Viewsonic

7. Printer WIPRO, TVSE, HP

8. Consoles Chemin, Lotus, Pyrotech Control India, Instrumentation Limited, Siemens Limited, Rittal

9. Ethernet switch & Terminal server IBM, Nortel Networks, Cisco, Extreme

10. Passive components including FO cable AMP, KRONE, MOLEX, SYSTIMAX

11. Network rack NETRACK, APW, PRESIDENT

12. Panels/ Auxiliary Panels/ Control Desk Rittal, Pyrotech, Siemens, BCH, HOFFMANN

13. Plugs & sockets Anchor

14. Relays & Contactors Omron, Siemens, Abb, Jvs Electricals

15. Limit switches

Telemechanique , L & T, siemens, BCH, Honeywell Automation (I) Ltd, Jayashree Electronics, Electronic & Power control company Bhilai, Electromag devices pvt Ltd, Speed O Controls Pvt Ltd

16. Hand held Calibartor YIL, Emerson, Honeywell

17. Digital Indicator Pyrotech Instruments, lectrotek, Chino-Laxsons, Micro systems, Master Electronics

18. Microprocessor based controller Yokogawa, Siemens, Honeywell, Eurotherm,




(one / two loop) Chemtrols(Fuji).

19. DC Power Supply Unit Aplab, Elnova,Siemens,Phoenix, Schneider

20. Signal isolators Pepperl & Fuchs, MTL, Stahl, Yokogawa, Forbes Marshall (Protech), Chino

21. Annunciation system Instrumentation Ltd, lectrotek, Minilec,IIC

22. Instrument Panels Rittal, Instrumentation Ltd, Pyrotech, Radha Krishna Controls,

23. Instrumentation Cable Delton Cables Ltd., Finolex, Thermo Cables, Lapp India Pvt. Limited. Universal cable Ltd, KEI industries Ltd.m Special cables Pvt Ltd

24. Power cable Havell’s India Ltd. Universal cable Ltd.,KEI industries, Polycab, Uniflex cables, Delton cables

25. Control Cable Udey Pyrocables Pvt. Ltd.LAPP, Delton, Universal cable, RPG, CMI, KEI Industries, Havell

26. Thermocouple Compensating Cable

Toshniwal Cables, General Instruments, Paramount Cables, Thermcables, Udey pyrocables

27. Fiber Optic cables Amp, Krone, Molex

C. Analytical Instruments

1. ORP/ pH/ Conductivity/ TOC measurement

Emerson (Analytical), Forbes Marshall (Polymetron), Yokogawa, ABB, Honeywell, Foxbro, Ametek, Servomax, Hertman & Brown, Ion Exchange, HACH, Teledyne.

2. Turbidity measurement E&H, ABB, YIL, GE Instrumentation, HACH

3. Chlorine measurement Chemtrac, E&H, ABB, YIL, HACH

4 online SDI meter: M/s. MABAT, M/s. APPLIED MEMBRANES.

D. Others:

1. Junction Boxes, Transmitter Protection Boxes

Baliga, Ex Protecta, Flame Proof Equipment (P) Ltd, Sudhir Switch Gears (P) Ltd, Flamepack

2. Cable Trays Indiana, Premeir, Elcon, Sumip

3. Cable Glands Dowell's Elektro Werke, Comet, Gland Mech Industries, Sunil And Company




4. Surge Protection Device MTL, Obo Betermann (Cape Elect. Corpn)

5. Barrier P&F, MTL, Obo Betermann (Cape Elect. Corpn)

6. Auxiliary Relays Siemens, OEN

7. Terminals Elmex, Wago, Phoenix

8. Circuit breaker/Miniature circuit breaker Siemens, MDS, Krupp

9. Ball Valve/ Needle Valve

Audco, Samson, Fouress Engg. AKAY Industries Ltd., Leaders valves ltd., Hawa Engineering Ltd., Tyco valves & controls, Flowchem Inductries, BDK engineering industries ltd., Expert engineering enterprises

10. Check Valve Steel Strong, Niton, PEC, Neco – Schubert & Salzer Pvt. Ltd., BDK Engg

11. Pressure Relief Valve Instrumentation Ltd., Keystone valves Ltd., Sebim valves, Tyco Sanmar

12. Pipes Jindal pipes, Suryaroshni, Ratnamani, Indian Seamless, Maharashtra Seamless, BHEL, Saw Pipes

13. Pipe fittings & flanges Gujarat Infra pipes, Tube products, Kwality, Venus, Parveen Ind., Stewarts & Lloyds

14. Impulse pipe & fittings Swagelok, Parker Hannifin Corporation

15. Instrument tubing Apex Tubes Pvt Ltd , Choksy Tube Co Ltd., Maharashtra Seamless Ltd , Ratnamani Metal & Tubes Ltd , Saw Pipes Ltd , Zenith Ltd, Swagelock

16. Instrument Transformer Indcoil Manufacturing Company, National Engineering Corporation, Automatic Electric Ltd

17. Fire Detection & alarm system GE/ EST, Notifier, Monely / AS, Honeywell

18. Public Address system & associated euipments Philips/ BOSCH, Neumann

19. Wireless Data Communication system Motorola, Radwin, Lotus wireless

20. Vibration Monitoring System Bentley Nevada, Schenk Avery corporation, SPM Instruments - Hyderabad,

21. Instrumentation erection contractors

Jasubhai engrs, Instrumentation ltd., ADS Corporation, Chemin



7. MATERIAL HANDLING:

SL. NO.

DESCRIPTION VENDOR LIST

1. Cranes & Hoists

i. Tuobro Ferguson (I) Pvt. Ltd., Kolkata ii. Shivpra Cranes Pvt. Ltd., Hyderabad iii. Eddycranes Engineers Pvt. Ltd., Mumbai iv. Armsel MHE Pvt., Ltd, Bangalore v. Elite Steels Pvt. Ltd, Faridabad

2. Mechanical & Electrical items in Cranes & Hoists: a. Wire rope Mumbai wire rope/ United Wire Rope/ Usha Martin/

Fort William/ J.K. Steels b. DCEM brakes BCH

c. DC Disc Brakes Pethe / EMCO Lenz

d. Crane duty Motors KEC / MARATHON / CGL / ABB

e. VFD ABB / L&T / Siemens f. Moulded Case

Circuit Breakers (MCCBs)

Areva / L &T / GE power / Siemens / ABB

g. Isolators, Switch Fuse Units

Siemens / L&T / BCH / Areva / ABB / Control & Switcgear Co. Ltd.

h. AC Power Contactors

Siemens / L&T / Schneider / BCH / Siemens / ABB

i. Protective Relays Areva / ABB / Easun Reyrolle Relays & Devices

Ltd.

j. Thermal Overload Relays Siemens / L&T / BCH / Schneider / ABB

k. Timers, Auxiliary Contactors, Relays

Siemens / BCH / Schneider / GE power

l. Control Transformers

Siemens / Indcoil / National Engg. Corporation / Automatic Electric Ltd. /BCH / Gyro Laboratories (P) Ltd.

m. Miniature Circuit Breakers (MCBS)

MDS Switchgear Ltd. / Indo Asian Switchgear Ltd. (Indo-Kopp)/ Versatrip CKT. Breakers / Havell’s India Pvt. Ltd. / S&S Power Switchgear Ltd. /



Siemens

n. Indicating Meters

Automatic Electric Ltd. / Meco Instruments Pvt. Ltd. / Industrial Meters Ltd. (IMP) / GE power

o. Control/ Selector Switches

Siemens / L&T / BCH / GE power / Kaycee Industries Ltd. / Salzer Electronics Ltd.

p. Push Buttons

Siemens / L& T / BCH / GE power / Schneider / Salzer Electronics Ltd.

q. Indicating Cluster LEDs Lamps

Siemens / L&T / BCH / GE power / Binay Electronics & Electricals

r. Hooters/ Bells

Kheraj Electricals Industries / Electronic & Power Control Co. / British Electrical Manufacturing Co. Ltd.

s. Terminal Blocks

Elmex Controls Pvt. Ltd. / Connectwell /Essen Engg. Company Pvt. Ltd. /Controls & Switchgear Co. Ltd.

t. LT Air Circuit Breaker Panels

GE power / L&T/ Siemens Ltd. / ABB

u. Rotary Cam Limited Switches (MECH.)

Technocrats / AG Engineering Enterprises / AG Mechanical / Electronic & Power Control Co./ Strom - Kraft Controls

v. Track Type Limit Switches

Technocrats / Electronic & Power Control Co. / Strom - Kraft Controls / Union Engineering / Electromag Devices /Jaibalaji / Industries Syndicate / R.K. Electricals

w. Lighting Fixtures

Philips Idia Ltd. / Crompton Greaves Ltd. /Bajaj Electricals Ltd /Apar Limited

x. Switches/ Switch Socket Outlets (Industrial)

GE power /Essen Engg. Company Pvt. Ltd. /Best & Crompton Engg. Ltd. / Crompton Greaves Ltd. /Bhartia Cutler Hammer Ltd.

y. LT Power, Control & Flexible Cables

Cable Corporation of India Ltd. /The National Insulated Cable Company of India Ltd. /Universal Cables Ltd. /Fort Gloster Industries Ltd. /Asian Cables Ltd. /Industrial Cables

z. Screened/ Signal Cables

Cable Corporation of India Ltd. /Universal Cables Ltd. / Fort Gloster Industries Ltd. / Asian Cables



Ltd./ Industrial Cables / Finolex Cables Ltd. /Delton Cables Ltd.

3. Limestone Recharging System

i. Vinar Systems Pvt. Ltd., Kolkata ii. Shree Conveyor Systems Pvt. Ltd., New

Delhi iii. Tecpro Systems, Chennai iv. Masyc Projects Pvt. Ltd, New Delhi

4. Capsule Elevator

i. Otis Elevator Co. (I) Ltd. ii. Kone Elevator (I) Pvt. Ltd iii. Thyssenkrupp Elevator (I) Pvt. Ltd. iv. Omega Elevators

8. LAB EQUIPEMENT: Suggested list of vendors :

1. CHEMICALS & INSTRUMENTS CORPORATION

2. CHEMITO INSTRUMENTS PVT. LTD.

3. M/S. SYSTRONICS

4. M/S. ADAIR DUTT & CO.

5. NON DESTRUCTIVE TEST APPLIANCES PVT. LTD.

6. ELECTRONIC & ENGINEERING CO. (I) P. LTD.

7. BLUE STAR LIMITED.

8. GORDAN DAS DESAI PVT. LTD ( FOR LABORATORY

FURNITURE )

9. MODERN LAB SERVICES CHANNEL ( FOR LABORATORY

FURNITURE)

10. SRI RUDRAN INSTRUMENTS COMPANY

11. BELLSTONE HI-TECH INTERNATIONAL

12. BALANCING INSTRUMENTS & EQUIPMENTS (MIRAJ) PVT.LTD

13. TECHSCIENCE SERVICES PVT LTD

14. M/s LOVIBOND



15. M/s EUTECH,SINGAPORE

16. M/s SHIMADU

17. M/s TOSHINIWAL INSTRUMENTS MFD.PVT.LTD.AJMER

18. M/s CITIZEN

19. M/s SPRECISA INSTRUMENTS AG,SWITZERLAND

20. M/s OLYMPUS

21. M/s. ELICO

22. M/s. Dantech Engineers pvt. Ltd,

23. M/s. Innovative Scientific solutions.

24. M/s. Aimil limited

25. M/s. Bellstone, New Delhi. 9. FIRE PROTECTION & SAFETY EQUIPEMENTS

1. M/s. STEELAGE INDUSTRIES LTD. 2. M/s. AGNICE FIRE PROTECTION LTD. 3. M/s. VIJAY INDUSTRIES & PROJECTS LTD. 4 M/s. NEW FIRE ENGINEERS PVT. LTD. 5. M/s. MATHER & PLATT (INDIA) LTD.

6. M/s. RELIANCE FIRE PROTECTION SYSTEMS

7. M/s. AGNI CONTROLS 8. M/s. ZENITH FIRE SERVICES 10. FIRE FIGHTING:

SL. NO.

DESCRIPTION VENDOR LIST

1. PIPES INDUS, JINDAL, SURYA ROSHNI, AJANTA TUBES, ZENITH, SAIL, MAN INDUSTRIES, SAW PIPES

2. BALL VALVE FLOW CHEM, AUDCO, LEADER VALVES LTD., VASS , FISHER-XOMOX , REYNOLD , ALFA LAVAL , VIRGO ENGINEERS LTD

3. SLUICE / GATE VALVE INDIAN VALVES, STEAM AND MINING, H. SARKER, VENUS PUMPS & ENGINEERING

4. DUAL PLATE CHECK VALVE ADVANCE VALVES , R& D MULTIPLES 5. BUTTERFLY VALVE STEAM AND MINING, JASH,KIRLOSKER ,

MATHER AND PLATT, AUDCO, ALFA



LAVAL, LEADER, TYCO, INTERVALVE, FOURESS ENGINEERS

6. PUMPS

FLOWSERVE, KIRLOSKAR, SULZER, MATHER & PLATT, BEACON WEIR

7. FIRE FIGHTING EQUIPMENT HDFIRE, NEWAGE, NEW FIRE, STEELAGE, TYCO, VIMAL, ZENITH, MATHER AND PLATT

11. MECHANICAL REPAIR SHOP

Suggested list of Vendors:

HMT Ltd, BFW Ltd, PMT Ltd, SAGAR, EIFCO Ltd, BATLIBOI Ltd, Thakoor Ltd, SWAGATH, TOOL CRAFT, ESAB, ADVANI ORLIKON, MMT, GODREJ, ITL, LAXON, MITUTUYO, EVEREST, ENERPACK ADDISION, WIDIA, SANDVIK, TAPARIA, EASTMAN, HITACHI, BOSCH RALLI WOLF, ELGI, IEC AIR TOOLS, CHICAGO PNEUMATICS, BLACK & DECKER, EUREKA FORBES, NILFISK, ROOTS MULTICLEAN Ltd

12. Air compressors & work shop

Sl. No

Description Name of vendors

1 Air compressors Chicago Pneumatics, ELGI Equipments, Ingersoll-Rand, Kirloskar Pneumatics.

2 Air dryers Del Air, Gem equipment, Lloyds Steel Industries, Sanpar Air dryers, Chemech engineers. Mellcon,K.G.Khosla

3 Pipes TATA, Jindal, Lloyds Metals & Engineers, BHEL, SteelTube Company, Maharastra Seam less Ltd., The Indian Seam less, Metal Tubes Company Ltd.,

4 Ball valves Audco India Ltd, KSB Pumps, Virgo Engineers, Micro finish.

5 Non-return valves

Audco India Ltd., KSB Pumps

6 Fine filters Ultra Filters, Dominic Hunter,Elgi equipment 7 Motors SIEMENS / Bharat Bijlee / ABB / Kirloskar /

Alstom / Crompton Greaves



13. SEWAGE TREATMENT PLANT (STP)

Sl. No

Item Preferred Make

1. DICL pipes & fittings Electro Steel Castings/Jindal Saw Pipes.

2. Submersible sewage pump Kirloskar/Kishor Pump/KSB Pumps

3. Chemical dosing pumps/ Metering pumps

Alwyn/ ASIA-LMI/ Shapotools/ Swelore / Anticorrosive eqpt / Microfiners

4. Screens Jash/ EIMCO – KCP/ Triveni/ AVC Engineering Co.

5. Ball valves Audco/ Alfa Laval/ Fishers/ Keystone/ Virgo.

6. Butterfly valves Alfa Laval/ Audco/ BDK/ Fouress/ Intervalve/ Keystone/ Jash.

7. Wafer type Dual plate check valve

AVC/ BDK/ Intervalve/ Advance.

VOL.IIA

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Transcript of VOL.IIA