1.0 Specification of Ash Handling System:

2.0.0                 Intent of Specification

This specification is intended to cover the following activities and services in respect of all the equipment of Ash Handling Plant for (2 x 500 MW) units.

2.1.0                 Scheme of Ash Handling System:

2.1.1 Bottom Ash Handling System

The Bottom Ash handling system shall be of Wet type with water impounded hopper and jet pumps for intermittent removal.

The bottom ash resulting from the combustion of coal in the boiler shall fall into a W-type water impounded (water filled) ash storage hopper provided under the furnace bottom. The bottom ash hopper discharge gates shall be opened twice in a shift of eight (8) hrs. and the stored ash shall be removed by means of jet pumps and transported in slurry pipe lines to the ash slurry sump, integral in the ash slurry pump house for its further disposal to the dump area by means of ash slurry disposal pumps. Each section of the bottom ash hopper shall be provided with two (2) nos. ash gates, two (2) nos. clinker grinders and two (2) nos. jet pumps complete with feed gate housings. Only one set of equipment under each section shall be in operation during the ash removal operation, with the other set as standby.

2.1.2                 Economiser and Air Preheater Ash Removal System

Ash collected in economiser, economiser bypass duct, primary air heater and secondary air heater hoppers will drop continuously through suitable vertical pipe connections to the flushing connections provided beneath each of the hoppers.  The flushing equipment serves to mix the ash with the water and discharge the ash in the form of slurry.  The slurry from flushing equipments shall be led to economiser & air preheater slurry trench, which in turn shall be connected to ESP fly ash slurry trench.  The economiser and air preheater ash slurry alongwith ESP fly ash slurry shall be conveyed to the sump of combined ash slurry pump house through ESP fly ash slurry trench.

2.1.3                 Dry Fly Ash Extraction and Transportation System :

The dry fly ash handling system consist of ESP and duct hopper ash removal systems.  A two stage conveying system shall be provided.  The first stage shall include extraction of dry fly ash from under the various ESP / duct hoppers to the intermediate surge/buffer hoppers / collector tanks located near the ESPs. In the second stage ash shall be conveyed/transported from under these buffer hoppers to the storage silos located outside plant boundary. A vacuum system shall be provided for extraction of dry fly ash in the first stage, for second stage, viz., transportation of dry fly ash to the main storage silos, located outside plant boundary shall be necessarily by the pressure conveying system only.

2.1.4                 Fly Ash Extraction System

The first stage vacuum extraction system shall include extraction by vacuum of ash from various ESP and duct hoppers to the intermediate surge/buffer hoppers/collector tanks located near the ESPs.

First stage vacuum extraction shall have the feature of segregation of ash from various fields of ESP and duct hoppers.

The scheme envisages extraction of dry fly ash from under the ESP and duct hoppers by four (4) nos. of normal working vacuum pumps with 100% standby for each unit i.e. a total of eight (8) nos. for each unit. However, interconnection between the dedicated standby vacuum pumps of adjacent streams is envisaged to improve the availability & flexibility in operation of the streams. Each vacuum pump dedicated to a stream, shall extract both the coarse and fine fly ash.  The vacuum extraction shall operate so as to allow sequential ash discharge from ESP and duct hoppers into the conveying system which shall be in continuous operation. On completion of ash removal from all the ESP and duct hoppers connected to a vacuum pump stream, the deashing shall be reinitiated automatically.

For each ash extraction stream one number surge/buffer hopper is envisaged. Fly ash can be either collected in buffer hoppers and conveyed to storage silos or fed to wetting head and collector tank units provided through the tap off upstream of respective buffer hoppers. In the wetting head and collector tank unit the fly ash is mixed with water and resultant slurry is discharged for further conveying it to the combined ash slurry disposal pump house sump via pipelines and slurry trenches. Water for wetting head and collector tank units shall be drawn from discharge of fly ash HP water pump. One working and one standby wetting head and collector tank unit shall be provided for each ash extraction stream.

The surge/buffer hoppers shall be equipped with primary collectors/ secondary collectors/target box alongwith bag filter as applicable to vacuum  extraction system. Air blowers for each unit shall be provided to aerate ash inside the buffer hoppers to facilitate free flow of ash.

Instrument air compressor, for each unit shall also be provided to meet the complete instrument air requirements i.e. valve actuation, bag filter cleaning etc. of the ash handling system.

2.1.5                 Dry Fly Ash transportation System

For second stage conveying each surge/buffer hopper shall be provided with locks/pumps tank/ash transporters of adequate number and capacity. Three (3) nos. pressure conveying pipe lines for one unit shall be provided, two (2) working and the third line as standby, to continuously transport the dry fly ash (both coarse and fine) from surge/buffer hoppers to storage silos. Transport of fly ash from each unit surge/buffer hoppers to the storage silos, located outside plant boundary, shall be with the help of 3×50% transport air compressors suitably sized and designed to cater to the ash evacuation requirements of one unit. However, the same set of 3×50% transport air compressors shall be used for catering to the ash evacuation requirements of the second unit also. Adequate space provisions shall be kept within the dry fly ash transportation pipe trestle, compressor house & the associated MCC room for further extension, if required.

2.1.6                 Dry Fly Ash Storage

For dry ash storage two (2) silos are envisaged. Each silo shall have the minimum effective capacity to store 1000M³ of dry fly ash. Provisions in the feed system shall be kept to facilitate inter change. In case of increased demand of fly ash Purchaser proposes to add additional silos of same or higher capacity. Bidder shall keep the provisions in Ash Handling Plant for future addition of silos such that additional silos can be added without affecting the existing system operation.

For each of the main storage silos four (4) outlets at the bottom shall be provided. One outlet shall be fitted with Ash conditioner for loading the ash into open trucks. Second outlet shall be provided with telescopic chute and rotary feeder for loading the ash into closed tankers, third and fourth connection at present shall be blanked connection and shall be provided with isolation valve.  One of the blanked connection will be used in future for adding pneumatic equipment for transportation of fly ash to third party. Other connection shall be used in future for wetting head with suitable pumping arrangement to bring the ash slurry from silo area to the combined slurry disposal pump house. Layout provision for above facilities shall be kept in silo area. The storage silos shall be fitted with bag filters and fans for cleaning the vent air before discharging to the atmosphere. Each storage silo shall be provided with a dedicated aeration system.

2.1.7                 Ash Disposal System

For both the units, bottom ash from discharge of jet pumps, economiser and air preheater slurry from discharge of flushing apparatus and fly ash slurry from wetting head, collector tanks and airwasher units provided upstream of buffer hoppers shall be led to a common slurry sump of combined ash slurry disposal pump house which will have two (2) compartments each serving for two (2) streams of slurry disposal pumps. From the sump, the slurry shall be continuously pumped to the disposal area by means of slurry pump sets and disposal pipes. The ash slurry disposal system envisages four (4) identical streams (series) of ash slurry pumps connected to four (4) nos. disposal pipe lines. Of the four (4) pump streams and associated disposal pipe lines provided, two (2) nos. will be working continuously and out of the remaining two streams, and associated disposal pipelines one will always be available as standby even when the other is under maintenance. No interconnection between the slurry discharge lines are to be provided.

Provision shall be kept to supply water at each of the slurry disposal pump stream suction for flushing the disposal line by running the slurry disposal pumps stream (series) prior to shut down of a pump stream. For supplying the raw water at the suction of slurry disposal pumps stream, flushing water pumps shall be provided and the water connection shall be made on down stream of the suction valve of the slurry pump series alongwith necessary piping and valves.

2.1.8                 Water Facilities

It is proposed to operate the ash water system in a closed circuit. The ash water from the ash dyke shall be re-used after treating a part of the same in a side stream lime softening plant.  During recirculation mode the make up to ash water system (to compensate for the ash water blow down and evaporation loss) shall be supplied from the CW system blow down water.

For the purpose of water supply to the ash handling system, water pumps taking suction from overground RCC sump shall be installed in the ash water pump house envisaged. Water supply to ash water pump house shall be tapped from following sources :

(a)        Recirculated ash water from ash pond area as the normal water supply, whenever available.

(b)        CW System Blowdown :

This water shall be used for the purpose of supplying make up to the normal water supply, i.e. when the ash handling system is operating on recirculation mode. CW blow down alongwith raw water shall be used during once through mode i.e. when recirculated ash water from ash pond is not available.

(c)        Raw Water make up :

The raw water alongwith CW blow down water shall be used for initial period or during emergency period when recirculated ash water from ash pond area is not available.

(d)        The fly ash slurry disposal water requirements for disposal of fly ash in slurry form, from the wetting head and collector tank is to be met from fly ash water pumps to be located in the ash water pump house. 2×100% fly ash water pumps for each unit are envisaged for the purpose. The bottom ash hopper overflow water shall be led to an overflow tank in case of water impounded hopper system.  Bottom ash over flow water pumps shall take suction from over flow tank/sump and pump the water to the required treatment facilities where the water shall be treated so that outlet water quality is having TSS < 100 ppm. This treated water shall be led to sump of ash water pump house, through gravity flow.

(f)        Sealing Water

Sealing water for ash slurry pumps, vacuum pumps, clinker grinder etc. shall be from CW system blow down.  The maximum temperature of seal water shall be 36oC.  No seal water shall be wasted.  After sealing, the seal water shall be led to sump of slurry pump house, to be used as make up.

(g)        Cooling Water

Demineralised water (DM) shall be provided to meet cooling water requirements of various heat exchangers, intercoolers, after coolers etc. The inlet temperature of 39oC and outlet temperature of 43oC of DM water, for sizing various heater exchanger shall be considered. PH of DM water shall be 9.5.  Inlet pressure of DM water shall be 10 kg/cm2(g).  Heat exchangers etc. shall be sized for 10 kg/cm2(g) inlet pressure of DM water and 3.5 kg/cm2(g) pressure drop in the system. All valves, piping, fittings and equipments handling DM Water shall be of suitable construction material.

2.1.9                 Ash Dyke Water Recirculation and Side Stream Filtration System

Ash dyke decanted water shall be recirculated back from ash dyke to plant for treatment and reuse in ash handling system. The decanted ash water from ash dyke shall be recirculated in the ash handling system after treatment.

Decanted water shall be pumped to the sump of ash water pump house through a single pipeline. A tapping shall be taken from this header to the side stream treatment plant.

VENDERS- worldwide

www.ashhandling.com

www.khi.co.jp

www.metsominerals.com

www.flsmidth.com

www.nol-tec.com

www.ebu.hu

www.tltbabcock.com

www.unitedconvereyor.com

Venders INDIA

www.uccindia.net

www.dcpis.com

www.mcnallybharat.com

www.desein.com

www.driplexwater.com

www.bgrcorp.com

www.tata.com

www.rel.com

www.mahindra.com

VENDERS-VACCUM PUMPS

1.www.vooner.com

2.nash elmo industries china ltd co.

AIR COMPRESSORS

1.Atlas copco air compressor www.atlascopco.com

2.kirloskar pnenumatic co ltd

FLUIDISING BLOWER

1. KAY INTERNATIONAL

2. SWAM PNEUMATIC

3. USHA COMPRESSORS

STANDARD

BS  EN  45510-4-7

ISO 8573

www.pumps.org

specification of coal handling plant-www.specchp.wordpress.com

specification of mill reject -www.specmillreject.wordpress.com

www.specinstrumentation.wordpress.com

CHART

.ANSI Pipe Schedule Chart

• Sheet Metal Gauges and Tolerances
• Standard Drill Sizes
• Fly Ash Utilisation http://flyashindia.tifac.org.in/
• www.flyash.com
• www.iflyash.com

INDEX

1.0 Scheme of Ash Handling System:

2.2.1 AHP -Mechanical Equipment

2.2.2 AHP – Electrical Works

2.2.3 AHP :Control and Instrumentation

2.3.0 System Capacity & AHP DESIGN DATA

2.4.0 Site Tests

2.5.Performance and Guarantee Tests (AHP)

2.6.0 Spares(AHP)

2.8.0 Equipment Specification

2.8.2 .Jet Pumps

8.3 Slurry Line Valves

2.8.4. Clinker Grinders

2.8.5 Flushing Apparatus

2.8.6 Expansion Joints for Economiser Hoppers

2.8.7 Expansion Joints for Fly Ash Handling System

2.8.8 Vacuum Pumps for Fly Ash Extraction

2.8.9 Fly ash branch feed valves and segregation valves

2.8.10 Air Intake Valves

2.8.11 Fluidising Pads/ Air Activated Gravity Conveyors

2.8.12 Fluidizing Air Blower

2.8.13 Pneumatic Ash Conveying Pipe Line

2.8.14 Fittings & PIPES

2.8.15 Surge/ Buffer Hoppers

2.8.16 Air Compressors for Pneumatic Conveying of Ash

2.8.17 AHP- Fluidising Air Blowers

2.8.18 Instrument Air Compressors and Drives

2.8.21 Bag Filters

2.8.22 Dry Fly Ash Storage Silos

2.8.23 Water and Air Piping, Fitting and Accessories

2.8.24 Water and Air Line Valves and Special

2.8.25 Ash Slurry Disposal Pipes and Valves

2.8.27 Horizontal Centrifugal Pump

2.8.27               Horizontal Centrifugal Pumps

 

                        The ash slurry pumps for combined B.A. and F.A. disposal, B.A. Cooling water over flow pumps, BAHP pumps, BALP pumps, flushing water pumps seal water pumps, for ash slurry pumps, dust suppression, ash conditioning and seal water pumps in main storage silo area and cooling water pumps for cooling various equipments of ash handling plant shall essentially be horizontal and centrifugal type.

 

                        The equipment shall be capable of developing the required head at rated capacity for continuous operation.

 

                        All centrifugal pumps shall have a drooping characteristics curve, with the head continuously increasing with decreasing flow to maximum head at zero flow and the pumps shall preferably be non-overloading type beyond rated duty point.

 

                        The characteristics curves of each set of pumps shall match each other for equal load sharing in case of parallel operation and such pumps shall be identical and all parts shall be fully interchangeable.

 

                        Standard type pumps with a proven record of reliability shall only be provided.

 

                        Specific Design Requirements for Slurry Pumps

 

                        The ash slurry sump geometry and configuration shall be such as to minimise ash settlement, formation of vortices and air entrainment in the slurry as this may affect the operation of the slurry disposal pumps.  To minimise the ash settlement adequate number of high velocity water jetting nozzles shall be provided in the slurry sumps.

 

                        The rating of the ash disposal pumps shall be based on the stipulations con­tained herein as given under:

 

                        A)        F.A. and B.A. Handling

 

                                    The maximum velocities in slurry transformation lines for both F.A. and B.A. shall be limited to 2.8 m/sec.

 

                                    The maximum concentration of B.A. and F.A. slurries when being

                                    handled independently or combined shall be as under:-

 

                                    i)          B.A.                                         -           25% (W/W)

 

                                    ii)         F.A.                                          -           30% (W/W)

 

                                    iii)        Combined B.A. & F.A.              -           25% (W/W)

 

                        B)        Combined Ash Slurry Disposal System

 

                                    The combined ash slurry disposal system shall meet the following mandatory requirements :

 

a)                Not more than (2) pump streams shall be employed for handling the total bottom and fly ash slurry generated from the two units when the bottom ash is extracted either intermittently and fly ash is extracted at the specified  removal rates.

 

                                    b)         Minimum make up water should be required at the slurry sump during the operating condition when only one unit is operating or during the periods in a shift of 8 hours when fly ash slurry is being received continuously and the bottom ash slurry is being received intermittently since these operating modes are also considered as normal operating modes.

 

                                    c)         The concentration of the ash (combined bottom and fly ash in the sump) in the slurry handled by the ash slurry disposal pumps shall not exceed 25% (W/W) and the flow velocity in the ash slurry disposal pipeline shall not exceed 2.8 m/sec. during any operational mode of the system.  The bottom ash and fly ash slurry concentration under any mode of operation shall be decided considering the rated capacity of respective extraction systems.

 

                                    d)         The ash slurry disposal system should also be designed to cater to the operating conditions as when only the F.A. handling system for both the units is working (i.e. when B.A. and economizer ash evacuation is over), the slurry concentrations under such condition shall not exceed 30% (W/W) and the flow velocity in ash disposal pipe line shall not exceed 2.8 m/sec.

 

                                                            The fly ash slurry concentrations under this mode of operation, shall be decided, considering the rated capacity of the extraction system.

 

To maintain the concentration limit and to run the ash slurry disposal pumps effi­ciently a provision shall be made for make-up water pipe connections complete with motor operated gate valves and manual gate valves.

 

                        Minimum 10% margin shall be considered for ash slurry pump sizing over and above the total slurry disposal head requirement comprising the straight pipe line frictional loss and bends loss.  The value of the constant ‘C’ in William-Hazen equation, shall be considered as 140 for calculating the system head.

 

                        An additional flow of 100 m³/hr (continuous) shall be considered on ash slurry pump capacity to take into account sludge disposal from clarifier units to be pumped by ash slurry disposal pumps to the disposal area.  Bidder may take advantage of this additional quantity of sludge (the density of solids in sludge may be taken as 1.1 and the concentration as 5%) while arriving at ash slurry concentration for the combined ash disposal pumps.  Apart from the working streams one standby and one maintenance standby shall be provided for the ash slurry disposal system.

 

                        The slurry pumps shall essentially be slow rpm pumps. The rotational speed of the impeller at design point shall not exceed 1000 rpm.

 

                        The first stage of slurry disposal and transportation pumps shall be provided with variable speed hydraulic coupling of robust design for setting the optimum operating speed of the pumps based on actual site requirements after the system is installed.  Minimum (+) 10% and (-) 45% speed variation with respect to speed at rated  design point shall be provided in the first stage of combined ash slurry disposal pumps and ± 20% for bottom ash transportation and BA overflow water pumps. The slurry pump motor speed shall not exceed 1500 rpm.

 

                        To minimise the drive losses in the first stage of slurry disposal and transportation pumps, a constant speed reduction gear box shall be provided.  The gear boxes to be employed shall be suitable for heavy duty application and of such reputed make which have proven established record of trouble free service under heavy load transmission duties.

 

                        For the subsequent slurry disposal and transportation pump stages, the drive shall be transmitted through belt drive arrangement.  If in future, the operating speed of these pumps is also required to be changed, the Owner intends to carry out this change by replac­ing the existing belt-pulley with a pulley of different diameter to allow a future variation of ± 10%.  Pump and motor layouts in the pump house shall be accordingly decided to take care of this requirement.

 

                        Continuous motor rating (name plate rating) at 50°C for ash slurry pumps shall have atleast 20% margin above the maximum load demand of the driven equipment at the rated duty point. The maximum load demand shall be calculated considering slurry density, efficiency of pump when handling slurry and the complete drive losses in the transmission (fluid coupling, gear box, etc.). For selecting the motor, the maximum pump efficiency to be considered shall be 70%. To ensure interchangeability, all the pumps & motors of the pumping streams shall be of similar rating and the pumps shall be designed for + 10% and – 45% speed variation.

 

                        Pumps shall be single stage, end suction design provided with heavy duty impellers suitable for highly abrasive duty application.

 

                        All the wear parts of pumps, impellers and liners etc. shall have a minimum guaranteed life of 8000 hrs. of operation.

 

                        Provision shall be made for adjustment to take up wear by axial movement of the shaft.

 

                        The seals shall be water flushed packed glands, fed from an external clean water supply source.

 

                        The impeller tip speed at the rated parameters shall not be more than 1676 metres/min.  Bidders shall make selection of the pump size such as to limit the tip speeds to above specified limits.

 

                        The passages and clearances in pump components shall be properly designed, considering the size of ash and clinker to be handled.

 

                        The pumps shall have flooded suction inlet and shall be located indoors.  Howev­er, pumps shall be suitable for operating with upto 2 metres suction lift.

 

                        The glands of the pumps should be suitably designed to prevent clogging of ash particles.

 

2.8.27.1            Specific Requirements for Seal Water and other Horizontal Water Pumps

 

                        (a)        Seal water system, taking suction from water supply terminal points, shall be provided to supply gland sealing water for ash slurry disposal pumps, bottom ash slurry transportation pumps, BA overflow water pump, sludge pump, sump drainage pumps, clinker grinders, submerged scraper conveyors and cooling water for air compressors, blowers, vacuum pumps, fluid couplings, etc. Any other cooling/seal water requirement for the plant shall also be included in this seal water system.

 

                        (b)        To meet the gland sealing requirement in combined ash disposal pump house and bottom ash transportation pump house (if applicable). The pumps will take suction from  clarified water storage.  Separate pump sets shall be provided for meeting the sealing water requirements in each of the above mentioned buildings and 100% standby pumps shall be provided for each of these duties.

 

                                    For sealing requirement of clinker grinders, SSC’s (if applicable) in the boiler area and sump drainage pumps in bottom ash transportation pump house the water shall be tapped from the  clarified water storage.

 

                                    All the necessary piping and valving shall be in the scope of supply.

 

                        (c)        Additionally One (1) no. tank shall be provided in the ash storage silo area for meeting the water requirements of ash conditioning, dust suppression, cooling water for silo aeration blowers (if any) and seal water for sump drainage pumps.  Necessary pumps (as specified and as required) shall be provided to meet these requirements which will take suction from this tank.  Bidder may combine the requirements of dust suppression, cooling water for blowers and seal water for sump drainage pumps (depending upon the pressure/flow requirements) in which case the cooling water requirement for silo aeration blowers (if any) and water requirement for dust suppression shall be considered as simultaneous requirement.  The pumps shall be suitably designed to take care of the varied water requirements.

 

                        (d)        The design of the seal water system for supplying water to gland sealing to various ash slurry pumps shall be such as to have the gland sealing water system for maximum of two (2) stages of the working streams supplied from one seal water pump and shall have its own 100% standby pump.  For the balance stage (stages) of the working streams separate seal water pump shall be provided with its own 100% standby facility.  The seal water pump shall be sized for meeting the seal water requirements of pumps in working streams and one (1) no. additional stream which will be in flushing mode.

 

                        At least 15% margin shall be provided in the pump capacity over and above the maximum seal water/cooling water and other flow requirements. For calculating the system head, the value of constant ‘C’ in William Hazen equation shall be considered as 100.

 

                        Continuous motor rating (name palte rating) at 50°C for seal/cooling water pumps and other horizontal water pumps shall have at least 15% margin above the maximum load demand of the driven equip­ment in the complete operating range to take care of the system frequency varia­tion.

 

                        Seal water/cooling water and other horizontal water pumps shall be direct driven with speed not exceeding 1500 rpm.

 

2.8.27.2            Construction Features

 

            ●          Casing

 

                        i)          The casing shall be structurally sound to provide housing for the pump assembly and shall be designed hydraulically to minimise radial loads at part load operations.         

 

                        ii)         With the exception of the slurry pumps, pump casings shall preferably be horizontal split type, with the top casing and internals being removable without disturbing the main pipework connections.  In general all pumps shall be designed such that the rotating assembly can be withdrawn without removing the motor. The casing shall be finished to smooth surfaces as far as possible.  Casing drain and vent connection with plugs and valves shall be provided where required. Casing shall withstand without expansion joints, the usual moment and thrusts.

 

                        iii)        In case of ash slurry pumps, these shall be of either twin casing construc­tion or single casing with metal lining construction or single volute casing construction. The pressure casing (or outer casing) shall be generally in accordance with the stipulation of API-610. The thickness of inner casing in case of single casing with metal lining pumps and the wear margin in case of single volute casing pumps shall not be less than 35 mm.

 

            ●          Impeller

 

                        i)          The complete rotor assembly shall be statically and dynamically balanced and designed with critical speed substantially abvoe the operating speed.

 

                        ii)         Impellers shall be made in one piece and securely fixed to the shaft.  Means shall be provided to prevent loosening during operation including rotation in reverse direction.

 

                        iii)        Impeller fastening nuts (if provided)shall be of cap type and shall tighten in direction of normal rotation.

 

                        iv)        For ash slurry pumps, the minimum impeller thickness shall not be less than 30 mm and shroud cover thickness shall not be less than 35 mm.

 

            ●          Impeller/Casing Wearing Rings (Where applicable)

 

                        Replaceable type wearing rings shall be provided at suitable locations for each pump. The rings shall be so fitted as to prevent turning while the pump is in opera­tion.

 

            ●          Shaft

 

                        i)          The shaft shall be finished to close tolerance at the impeller, coupling, pulley and bearing diameters. The impeller, pulley and shaft sleeves shall be firmly secured to the shaft by key and/or nuts.  Slurry pump impellers may be screwed on the shaft (threads to tighten during normal pump rota­tion).         

 

                        ii)         The shaft shall be adequately sized to withstand all stresses from rotor weight and hydraulic loads etc. and ground and polished to final dimen­sions.

 

                        iii)        The design of the shaft shall also take into consdieration the critical speed of the shaft which shall be at least 20 percent above the maximum operating speed or about 60 to 75 percent of the lowest operating speed.

 

            ●          Shaft Sleeve

 

                        Pumps shafts shall be protected by renewable type shaft sleeves which shall extend well beyond the pump glands. The sleeves shall be highly  polished and shall be securely fastened to the shaft to prevent any loosening.

 

            ●          Bearings

 

                        i)          Heavy duty ball, roller (tapper roller wherever required)or sleeve bearings, adequately designed for the type of service specified and for long and trouble free operation, shall be furnished. Sleeve type bearing shall not be supplied for slurry handling liquids.

 

                        ii)         The design of oil lubricated bearings shall be such that the bearing lubricat­ing oil does not contaminate the liquid being pumped.

 

                        iii)        Grease lubricated ball bearings are acceptable, if the pumps is specifically designed for grease lubrication and if shaft speed is less than the speed limit recommended by the bearing manufacturer and the fluid temperature does not exceed 65.5 deg.C (150 deg.F).

 

                        iv)        Each bearing housing shall have drain plug.

 

            ●          Thrust Bearings

 

                        Adequately designed thrust bearings to absorb pump end thrust or other unbal­anced forces, if any, shall be provided wherever required. Suitable arrangement for adjusting clearances shall be provided.

 

            ●          Stuffing Boxes & Sealing

 

                        i)          Stuffing boxes of packed ring construction or of mechanical seal type as applicable shall be provided. Packed ring stuffing boxes shall be properly lubricated and sealed as per service requirement and manufacturer’s stand­ard.

 

                                    If lantern rings are provided between the packages, these shall be complete with inlet and outlet piping connections.  Lantern rings shall be axially split type.

 

                        ii)         For pumps handling clear cool water if external gland sealing is required, it shall be done from the pump discharge or from any intermediate stage.

 

                        iii)        For pumps handling sandy/muddy water or slurry, external clear water sealing shall be provided. The design should also provide for flushing of the clearance between pump rotation and stationary parts continuously by trickle clear water flow.

 

                        iv)        The Bidder shall provide the necessary piping, valves, boosters, fittings, etc. for the gland sealing connection.

 

                        v)         For mechanical seals, the mating surfaces shall be suitably hard faced to ensure long life.

 

            ●          Couplings

 

                        i)          The pump & motor shaft shall be connected with a suitably designed flexi­ble coupling of approved design preferably with a spacer to facilitate dismantling of the pump without disturbing the motor.  Necessary expand­ed metal coupling guards for the coupling shall also be furnished.

 

i)                 Other arrangements for coupling the pump with prime mover may be employed only in case the same is categorically specified.

 

ii)                For pumps handling abrasive slurry or where fast wearing of pumps is likely due to the particular service conditions, variable speed drive shall be employed, thus enabling operation of pumps within specified ranges of speed with respect to pump speed at rated operating point. Pumps shall be suitable for operation at such higher speeds. The variable speed drive shall be the variable speed hydraulic coupling as specified.

 

            ●          Base Plates

 

                        i)          The base plates shall be of fabricated steel and of rigid construction, proper­ly ribbed as required.  Driplip with drain tap based on type of service speci­fied shall be furnished.

 

                        ii)         All directly coupled pump motor sets shall be supplied with common base plates.

 

                        iii)        For pumps coupled with motor through the variable speed drive transmission system, separate base plates for pumps and motors are acceptable.

 

                        iv)        The common base plate together with all foundation bolts and nuts shall be supplied by the Contractor.

 

            ●          Connections/Nozzles

 

                        Cast iron flanges shall be flat faced. Flanges shall be full or spot faced on the back side also.

 

                        All accessories required for proper and safe operation of the complete pump motor set shall be furnished.

 

                        Each pump shall be provided with drain, vent and a priming connection at suitable location, wherever applicable.

 

                        Pumps are required to operate for some period with discharge valve closed. The pumps shall be suitable for zero-flow operation for a reasonable period.

 

            ●          Accessories

 

                        The following accessories shall be supplied for all pump motor sets:

 

                        i)          Foundation bolts and nuts for pumps.

 

                        ii)         Foundation bolts and nuts for motors.

 

                        iii)        Foundation bolts and nuts for base plates.

 

                        iv)        Foundation bolts and nuts for slide rails, if slide rails are provided.

 

                        v)         Base plate for all pump-amotor sets.

 

                        vi)        Transmission guard for flexible coupling/vee belt transmission etc. as ap­plicable.

 

                        vii)       Slide rails for motors if variable pitch, set of vee belts or flexible coupling as applicable.

 

                        viii)       Suitable connection for sealing/cooling/flushing water supply, if applicable.

 

                        ix)        Lubrication fittings as necessary for proper and easy lubrication of the equipment.

 

                        x)         Drain and vent cocks as required.

 

                        xi)        Priming funnel or overhead tank, as required.

 

                        xii)        Foundation bolts for hydraulic coupling.

 

                        xiii)       Suitable adopter for pumps suction and discharge, if required.

 

                        xiv)       Anchor Bolts, Sleeves, Inserts, Lifting Lugs, Eye Bolts etc.

 

                                    The Bidder shall supply all anchor bolts, foundation plates, sleeves, nuts inserts etc. to be embedded in concrete for the equipment to be supplied.  The length of foundation bolts shall be liberally sized to reach below the reinforcement level.

 

                        xv)       Any other accessories mentioned elsewhere in this specification.

 

2.8.28 Slurry Disposal Line Valves

2.8.28               Slurry Disposal Line Valves

 

                        All valves shall be suitable for the service conditions i.e. flow, temperature and pressure under which these are required to operate and those performing similar duties shall be interchangeable, with one another unless, otherwise approved. All valves end connections shall be suitably protected to prevent damage and entry of dirt, till erected and commissioned.

 

                        Valves shall be provided with gear operator of proven quali­ty, reputed make and conforming to some internationally accepted standard, if the effort required to operate the valve exceeds 25 kgf.

 

                        All valves shall be fitted with indicators so that the valves opening can be readily determined.

 

                        The size of all valves shall be the same as that of parent pipe.

 

Material of construction shall be as follows:

a)         Body                Cast steel/Spheroidal ductile iron ASTM A 536

b)         Plate                 Alloy Cast iron/Hardened SS (400BHN)

 

2.8.29 Vertical Sump Drainage Pumps

2.8.29               Vertical Sump Drainage Pumps:

 

                        The equipment shall be vertical centrifugal type with separate discharge pipe and shall be capable of developing the required head at rated capacity for continuous operation.

 

                        Individual components of the identical pumps shall be interchangeable.

 

                        Head-capacity curve of the pump shall be rising type upto the shut-off condition.

 

                        The characteristics curves of each of pumps shall match each other for equal load sharing in case of parallel operation.

 

                        Standard type pumps with a proven record of reliability shall only be provided.

 

                        The pump shall be capable of handling equipment/floor drain water which will be contaminated with all kinds of suspended impurities and abrasive ash particles.  The pump shall be designed and equipped for indoor/outdoor operation, as specified.

 

                        Continuous motor rating (name plate rating) at 50°C for vertical sump drainage pump shall have at least 10% margin above the maximum load demand of driven equipment in the entire operating range (including run out condition of pumps in case of parallel operation) to take care of system frequency variation.  The maximum load demand shall include the drive losses in the transmission system.

 

2.8.29.1            Construction Features

 

            ●          Column Pipe

 

                        The column pipe shall serve as a housing for the line shaft and bearing and support for bowl (casing).  The line shaft bearing shall be supported from the pump column pipe.  Individual sections of column pipe shall be coupled by flanged joints.  The flange outside diameter shall not exceed the bowl outside diameter.

 

            ●          Casing

 

                        (i)         In addition to housing the impellers properly, the casing shall provide a smooth path to water passages and shall be hydraulically designed to minimise radial thrust.

 

                        (ii)        Suitable sealing arrangement shall be provided to prevent the leakage of pumped liquid into the column pipe.

 

            ●          Impeller

 

                        (i)         The impeller shall be semi open or open (non clogging) as per standard design of the Manufacturer.  All rotating parts including the impeller shall be statically and dynamically balanced.  The critical speed of all the rotating parts shall be substantially above the design speed.

 

                        (ii)        Impellers shall be securely fastened to the impeller shaft with keys, taper bushings or locknuts.

 

                        (iii)       The impeller shall be specifically designed to pass large solids or unscreened liquids.  The clearances between stationary and moving parts shall be such as to allow sustained performance without excessive maintenance.

 

            ●          Pump Shaft-Motor Shaft Coupling

 

                        (i)         The pump shaft shall be connected to motor shaft by a heavy duty rigid/flexible coupling or the pump shall be V belt driven.

 

                        (ii)        In the case of shafts with rigid couplings the maximum permissible error in the axial alignment of the pump shaft with the axis of the motor shaft shall be limited to maximum of 1.00 mm.

 

            ●          Discharge Pipe

 

                        (i)         The discharge pipe should be terminated above the base plate or mounting channel.  Type of end connection shall be as specified in data sheets.

 

                        (ii)        No support shall be provided for the bottom elbow (near pump bowl) to facilitate easy removal of the pump from top without the necessity to go down to the sump for removal of bottom support, if provided.

 

            ●          Base Plate

 

                        The base plate shall accommodate the column pipe level switches, oil lubricator and discharge pipe so that the whole pump unit can be dismantled from the top by removing the base plate.  The base plate size shall be such as to cover the full opening on top of the sump with adequate clearance between the sump edge and foundation bolts.  In case the size of base plate becomes too large either to cover the sump or to accommodate the discharge pipe, then smaller base plate with mounting channels may be provided. The channel length shall be adequate to span the opening in the sump and the spacing between the channels should be adequate to facilitate removal of pump without disturbing the channels.  Also the discharge pipe shall be supported from the channel by removable clamps.

 

            ●          Shaft

 

                        (i)         The design of the shaft shall also take into consideration the critical speed of the shaft which shall be minimum 20% higher than any operating or run away speed.

 

                        (ii)        Individual sections of the shaft shall be interchangeable.

 

 

            ●          Line Shaft Coupling

 

                        The type of couplings shall be such to prevent loosening during reserve rotation.

 

            ●          Line Shaft Bearing

 

                        Bearings shall be oil/water lubricated. Line shaft bearings shall be spaced not more than 1.5 meters apart.  Suitable oil lubricators (mounted on top of the base plate) with lubricating pipe to each bearing shall be provided for supplying the lubricating water to the bearings.  For lubrication purpose clarified water shall be available at a head specified elsewhere.  If the clarified water is required at a higher pressure than specified above, the same may be boosted up by separate set of pumping system.

 

            ●          Thrust Bearing

 

                        Suitable thrust bearing shall be provided to take the axial thrust.

 

            ●          Shaft Sleeves

 

                        Replaceable shaft sleeves shall be furnished.  The shaft sleeve shall be securely locked to shaft to prevent loosening while in operation.

 

            ●          Suction Bell

 

                        The pump shall be complete with adequately dimensioned suction bell, to guide and streamline intake fluid.

 

            ●          Impeller Adjustment

 

                        The pump shaft shall have suitable arrangement for vertical adjustment of impeller position from an accessible point.  The impeller adjustment shall be such that the impellers run free in any installed condition in spite of the extension of line shaft caused by hydraulic down thrust, the weight of the shafting and impellers.

 

            ●          Wearing Rings

 

                        Replaceable type wear rings shall be provided for casing and/or impellers wherever applicable.

 

            ●          Accessories

 

                        All accessories as required for efficient and safe operation of the pump motor sets shall be furnished by the Bidder, and these shall include but may not be limited to the following :

 

                        (i)         Base plates together with foundation bolts and nuts.  The base plate shall accommodate the discharge pipe, which is to be terminated above the floor level.

 

                            (ii)        Motor Stool.

                       

(iii)       Non-return valves and gate valves on pump discharge lines

           

(iv)       Lifting lugs, eye bolts etc.

 

                        (v)        Pre-lubricating tank with accessories (if necessary).

 

                        (vi)       Sleeves and inserts to be embedded in concrete.

 

                        (vii)      Coupling guard, if necessary.

 

2.8.29.2            The sump drain pumps shall be provided as follows:

 

S. No.	Description	Sump Drainage Pumps for Ash Slurry Pump House	Sump drainage Pumps for B.A. Slurry transportation pump house (if applicable)		Sump drain age pumps for silo area
1.	Type	Vertical, Centrifugal, single stage, semi-open or (open non-clogging) type impeller.
2.	Duty	Intermittent, However, to be designed for continuous operation.
3.	Fluid to be pumped	Slurry pump house floor suspended solids drain and sump drain with(30% ash particles by weight) Pump shall be able to handle 60 mm lump size of ash		B.A. slurry pump pit drain with suspended solids(30% ash particles by weight).		Silo area drains (with 30% particles by weight)
4.	Capacity and total dynamic head (Guaranteed)	80M3/Hr, 15MWC		80M3/Hr,15MWC		80M³/ Hr @ required head to pump the drain back to combined ash disposal pump house
5.	Suction Condition	…………………Submerged……
6.	Number of pumps	Two (1W+1S)		Two (1W+1S) For each unit		Two (1W+1S)
7.	Pump speed (Max.)	………………. 1000 rpm …………………………………………….
8.	Type of coupling between pump & Motor	…………….. Directly driven through flexible or rigid coupling/V-belt driven
9.	Location of pump thrust bearing	…………….. in Motor Stool ……………………………………..
10.	Material of Construction
	(i) Casing	……………Alloy cast iron (350 BHN) (Min 2.7% Ni; 1% Cr.)…………………………………………….
	(ii) Impeller	………………alloy cast iron (350 BHN          (Min 2.7%, Ni, 1% Cr.)……………………………………………
		……………….. Stainless Steel …………………………………..
	(iii) Impeller shaft
	(iv) Line shaft	……………. EN – 8 to BS:970 ………………………………..
	(v) Column pipe and discharge pipe	Fabricated steel to pipe           IS:226 (Minimum 6 mm Thk) …………. ……………………
	(vi) Shaft sleeve	Hardened stainless steel to 400 BHN
	(vii) Base plate	Steel to IS:226 upto 20 MM thickness and IS:2062 over 20 mm thickness

 

 

2.8.30 Codes and Standards

2.8.30               Codes and Standards

 

The design, manufacture, inspection and testing of all equipments  shall comply with all the currently applicable statutory regulations and safety codes in the locality where the equipment are to be installed.  The equipment shall also conform to the latest applicable Indian/British/American standards.  Other internation­ally acceptable standards, which ensure equal or higher performance than those specified, shall also be accept­ed.  Nothing in this specification shall be construed to relieve the Contractor of the required statutory responsibility.  A list of standards is given  below for reference:

 

                        IS:1239                         :           Mild steel tubes, tubular and other

                        (Part I & II)                              wrought steel fittings

 

                        IS:1367                         :           Technical supply condition for threaded steel fastener introduction and general information.

 

                        IS:3589                         :           Electrically welded steel pipes for water gas and sewage (200 to 2000 nomi­nal dia).

 

                        IS:4736                         :           Hot dip zinc coating on steel tubes.

 

                        IS::6392                        :           Steel pipe flanges.

 

                        IS:1363                         :           Black Hexagonal bolts, nuts and lock

                        (Part I & II)                              nuts

 

                        IS:1364                         :           Precision and semi-precision hexagonal screws, nuts and locks nuts (dia 6 to 39 mm).

 

                        IS:2016                         :           Plain washers.

 

                        IS:2062                         :           Structural steel fusion-welding quality.

 

                        IS:2712                         :           Compressor asbestos Fire Jointing Gaskets.

 

                        IS:3138                         :           Hexagonal bolts and nuts(M-42 to M-150).

 

                        IS:5822                         :           Code of Practice for laying steel pipes.

                        IS:9404                         :           Colour code for identification of pipe lines used in thermal power plants.

 

                        BS:534                         :           Black bolts, screws and nuts.

 

                        BS:916                         :           Black bolts, screws and nuts.

 

                        BS:2633                        :           Specification for Class-I Arc welding of terrific steel for pipework carrying fluids.

 

                        BS:4504                        :           Flanges and bolting for pipes, valves and fittings metric series.

 

                        ANSI B 2.1                   :           Dimensions of American Taper pipe threads.

 

                        ANSIB16.5                   :           Steel pipe flanges, flanged valves and fittings.

 

                        ANSI B16.9                  :           Factory made wrought steel butt welded fittings.

 

                        ANSI B16.11                :           Forged steel fittings (Socket-welding and threads).

 

                        ANSI B16.21                :           Non-metallic gaskets for pipe flanges.

 

                        ANSI B16.25                :           Butt welding Ends.

 

                        ANSI B.16.28               :           Steel short Radius fittings.

 

                        ANSI B31.1                  :           Power piping code.

 

                        ANSI 36.10                   :           Welded and seamless wrought steel pipe.

 

                        ANSI A-234:                             Carbon and Ferritic alloy steel fit­tings.

 

                        ASTM-A-53                  :           Pipe, steel black and hot dipped, zinc coated, welded and seamless.

                       

                                                                        BS-1571(Part I&II)       Acceptance test for positive displacement compressors and exhaust­ers.

 

                        IS:6206                                     Guide for selection, installation and mainte­nance of air compressors plants with operating pressures upto 10 bars.

 

                        IS:5727                                     Glossary of terms relat­ing to compressors ex­hausters

 

                        ASME Power Test Code            Displacement compressors, vacuum pumps and

                        PTC-9                                      blowers.

 

                        IS:5456                                     Code of practice for testing of positive displacement type air compressors and exhausters.

 

                        ISO : 1217                                Displacement Compressors-Acceptance tests

 

                        BS-1571 (Part I&II)                  Acceptance test for positive displacement compressors and exhausters.

 

                        IS : 6206                                   Guide for selection, installation and maintenance of air compressors, plants with operating pressures upto 10 bars.

 

                        IS : 5727                                   Glossary of terms relating to compressors and exhausters.

 

                        ASME Power Test                    Displacement compressors, vacuum pumps

                        Code PTC-9                             and blowers.

 

                        IS : 5456                                   Code of practice for testing of positive displacement type air compressors and exhausters.

 

                        BS : 726                                   Compressor performance test.

 

                        IS : 3401                                   Silica Gel

 

                        ISO : 1217                                Displacement Compressors-Acceptance tests

 

                                                                        IS:778   Gun Metal Gate, Globe and check valves for general purpose.

 

                        IS:780                                       Sluice valves for water works purpose 150 to 300 mm size.

 

                        IS:1703                                     Ball valves (Horizontal plunger type) includ­ing floats for water supply.

 

                        IS:2685                                     Code of practice for selection, installation and maintenance of sluice valves.

 

                        IS:2906                                     Sluice valves for water works purposes (350 to 1200 mm size).

 

                        IS:5312                                     Swing check type reflex (Non-return) valves.

 

                        BS:1868                                    Specification for steel check valve (Flange & Butt welding ends).

 

                        BS:1873                                    Steel globe and globe stop and check valves (flanged and butt welding ends).

 

                        BS:5152                                    Specification for Cl. Globe, stop and check valves for general purpose.

 

                        BS:5353                                    Carbon and Alloy steel plug valves.

 

                        BS:5153                                    Cl. check valves for general purpose.

 

                        BS:5154                                    Copper alloy globe stop and check and gate valves for general purpose.

 

                        BS:5158                                    C.l. and carbon steel plug valves for general purpose.

 

                        ANSI b16.10                             Face to face and End to End dimensions of Ferrous valve.

 

                        ANSI b16.34                             Steel valves flanged and butt welding ends.

 

                        ANSI B-21                                Dimensions of American tape pipe threads.

 

                        API-598                                    Valve inspection and test.

 

                        API-600                                    Steel gate valves.

 

API-602                                    Compact design carbon steel gate valves for refinery.

 

                        Standards for  Ash Slurry Pipes and  Valves

                       

                        API-5L Gr.B                   -         Line Pipe

 

                        IS:3589                           -         Line Pipe

 

                        ERW steel pipes to          -         Line Pipe

                        SAIL commercial quality

                                   

                        i)          IS:1520             -           Horizontal centrifugal pumps for clear, cold fresh water.

 

                        ii)         IS:5120             -           Technical requirements for rotody­namic special purpose pumps.

 

                        iii)        IS:5639             -           Pumps handling chemicals & corro­sive liquids.

 

                        iv)        IS:5659             -           Pumps for process water.

 

                        v)         IS:6536             -           Pumps for handling volatile liquids.

 

                        vi)        API:610            -           Centrifugal pumps for general refin­ery services.

 

                        vii)       Standards of Hydraulic Institute of U.S.A.  

 

                                   

2.9.0 Inspection and Testing

2.9.0                 Inspection and Testing

 

The bidder shall submit a quality control plan for the approval of the purchaser. The plan shall additionally include the following inspection and testing.

 

                        All material shall be tested as per relevant governing standards.

 

                        UT & DP on shaft material shall be conducted.

 

                        The feed gate housing shall be performance tested under no load condition and cycle test shall be conducted for 10 cycles of ON/OFF operation alongwith the actuating cylinder.

 

                        All actuators cylinders shall be tested as per relevant governing standard.

 

                        Jet pumps shall be visually inspected and checked for dimensional accuracies at manufacturer’s works.

 

                        The performance and guarantee test shall be carried out for all jet pumps at site after erection to verify the rated capacity of jet pumps.  For this purpose the bidder shall supply a set of additional jet pumps, minimum two (2) numbers, with same material of construction, having 25 mm larger throat diameter than the designed throat diameter.  The dimensions (including the nozzle diameter) of other parts of these jet pumps like inlet section, discharge and tail piece shall be the same as the design jet pumps.

 

                        All materials shall be tested/inspected as per governing Code/Standard and test certificates/reports shall be furnished for Owner’s approval.

 

                        Jet pump assemblies shall be subjected to Hydraulic pressure test at shop.

 

                        All materials of valve components shall be tested/inspected as per governing stand­ard/code for its chemical and mechanical properties.

 

                        The valves shall be hydraulically tested for body and seat leakage test at shop.

 

                        All valves shall be subjected to cycle test for 10 cycles  for ON-OFF operation before hydraulic test.

 

                        All pneumatically operated valves shall be tested alongwith the actuators.  However all actuators shall be tested as per relevant standard at manufacturer’s shop

 

2.9.1                 Clinker Grinder

 

                        All raw materials of grinder shall be of tested quality and test certificates shall be furnished for review.

 

                        Clinker grinders shall be visually inspected and checked for dimensional accuracies at manufacturer’s works

 

                        No load run test for 6 hours continuous operation of clinker grinder shall be done to ensure trouble free operation.

 

                        UT/MPI/DP test shall be carried out on shaft material.

 

                        MPI/DP test shall be carried out on welding.

 

                        Welding procedure and welder qualification shall be done prior to welding.

 

2.9.2                 Fluid Coupling

 

                        Static and dynamic balancing shall be carried out for all rotating parts.

 

                        Check for leak tightness of the coupling shall be carried out.

 

                        Functional test on fusible plug for each type of coupling shall be conducted at shop.

 

Check for temperature rise, torque speed, torque slip characteristics and overspeed test on coupling of each size and type during load test (preferably at full load at shop).

 

2.9.3                 Flushing Boxes

 

                        All material of flushing boxes shall be of tested/inspected as per relevant code standard requirements for chemical and mechanical properties.

                        Welding procedure/welder qualification shall be carried out prior to welding.

 

                        MPI/DPI tests as applicable shall be done on weldments to ensure freedom from defects.

 

                        Fill test on assembly shall be carried out.

 

2.9.4                 Gear Boxes

 

                        Gear boxes shall be visually inspected and checked for dimensional accuracy at manufacturer’s works.

 

                        Gear tooth hardness shall be checked and case hardness depth shall be measured.

 

                        UT/MPI/DP test shall be carried out on shaft material

 

                        Non load run test shall be carried out on assembled gear boxes for one (1) hour duration.

 

                        Noise and vibration test shall be conducted at shop and site.         

 

2.9.5                 Expansion Joint for Eco Hopper

 

                        All material shall be tested for chemical, mechanical properties and all other tests as per relevant standards.

 

                        Leak test shall be carried out at 1.1 times design pressure.

 

                        DPT shall be carried out on expanded portion to check cracks.

 

                        Proof of design test/cycle test shall be carried out on one of the expansion joint as per relevant standards. In case the bidder has already carried out the same on the expansion joint of the type and rating being offered, then the test certificate shall be submitted for Engineer’s approval.

 

2.9.6                 Expansion joints for Fly Ash Handling System

 

                        All material shall be tested for chemical, mechanical properties and all other tests as per relevant standards.

 

                        Leak test shall be carried out at 1.1 times design pressure.

 

                        DPT shall be carried out on expanded portion to check cracks.

 

Proof of design test/cycle test shall be carried out on one of the expansion joint as per relevant standards.  In case the bidder has already carried out the same on the expansion joint of the type and rating being offered, then the test certificate shall be submitted for Engineer’s approval.

 

2.9.7                 Vacuum Pumps

 

                        All materials shall be tested for chemical & mechanical properties as per the relevant governing standard.

 

                        Performance test shall be done for capacity & power consumption at rated condition as per pneurop/equivalent standard.

 

               Noise & vibration level shall be measured.

 

2.9.8                 Valves on Fly Ash Branch Segregation

 

                        All material component of valves shall be tested/inspected for its chemical and mechanical properties as per relevant governing standards.

 

                        All valves shall be subjected to cycle test for at least 10 cycles ON-OFF operation to ensure smooth operation.

 

Pneumatic cylinder operated valves shall be tested alongwith pneumatic cylinders.  However, all pneumatic cylinders shall be tested at manufacturer’s works as per relevant standard.

 

2.9.9                 Vacuum Breaker

 

                        All material of vacuum breaker components shall be tested for its chemical and mechanical properties as per relevant governing standard.

 

                        All vacuum breakers shall be subjected to cycle test for atleast 10-cycles ON-OFF operation to ensure smooth operation.

 

Pneumatic cylinder operated vacuum breakers shall be tested alongwith pneumatic cylinders.  However, all pneumatic cylinders shall be tested at manufacturer’s works as per relevant std.

 

2.9.10               Air Intake Valves

 

                        The valves materials shall be tested for chemical and mechanical properties as per relevant governing standard.

 

                        All valves shall be subjected to cycle test for at least 10 cycles ON-OFF operation.

 

2.9.11               Air  Ejector

 

                        Air Ejectors materials shall be tested for chemical and mechanical properties as per relevant standard.

 

                        Hydraulic/pneumatic pressure test at 1.5 times the design pressure or two times the operating pressure, whichever is higher, shall be carried out at manufac­turer’s works.

 

2.9.12               Centrifugal Fans for  Fluidising Pads

 

                        i)          One fan of each type will be type tested as per corresponding IS code.  BS 848 shall supplement the IS code.

 

                        ii)         Acceptance test and routine test shall be carried out as per corresponding IS code.  BS 848 shall supplement the IS code.

 

                        iii)        Dynamic balancing shall be carried out for all fans.

 

                        iv)        Vibration and noise level test shall be carried out for all fans.

 

                        v)         Welding shall be carried out by qualified welders.

 

2.9.13               Air Locks/Pump Tank

 

                        Air locks/pump tanks materials shall be tested for chemical and mechanical properties as per relevant standard.

 

                        Air locks/pump tanks shall be tested hydraulically for 1.5 times the design pressure at manufacturer’s works.

 

                        Welding procedure and welder qualification shall be approved prior to welding.  NDT shall be conducted on welding.

 

                        Inlet and outlet valves shall be tested for its performance to ensure smooth operation.

 

2.9.14               Pneumatic Ash Conveying Pipe Line

 

                        Pipes & fittings shall be tested for chemical, mechanical & dimensional check as per relevant standards.

 

                        Pipes shall be hydraulically tested as per relevant standard.

 

                        Fittings shall be hydraulically tested at twice the operating pressure or 1.5 times the design pressure whichever is higher.

 

                        In case of cast basalt-lined fittings, basalt-liners shall be tested for chemical and mechanical properties.  Basalt liners shall be examined visually for detection of cracks and defects.

 

Cast Basalt lined fittings shall be hydro tested at twice the operating pressure or 1.5 times the design pressure whichever is higher.

 

2.9.15               Surge/Buffer Hoppers

 

                        Welding procedure/welder qualification shall be done as per ASME Sec-IX.

 

                        DP/MPI test shall be done on weldments suitably.

 

2.9.16               Air Compressors and Receivers

 

                        All material shall be tested for chemical and mechanical properties as per relevant standard.

 

                        All pressure parts shall be subjected to hydraulic testing at a pressure of 200% of working pressure for a period of not less than one (1) hour.

 

                        The Bidder shall include for performance testing of each compressor in accordance with BS:1571 / IS:5456 / ISO:1217.  Each test will be witnessed by the Engineer. The tender must include a testing proposal by the Bidder.

 

                        UT and MPI/DP test shall be carried out all forgings and shafts.

 

                        Rotating elements of compressor components shall be statically and dynamically balanced. 

 

                        Compressor noise and vibration shall be measured at shop and site.

 

                        Type testing as per IS:5456/ISO:1217 shall be carried out in presence of the Owner, if not carried out earlier.  The testing procedure shall be mutually discussed and finalised before commencement of the test.  In case type testing is already carried out, a test certificate with details of test results shall be submitted to the Owner for review and approval.  Also, calculation for volumetric efficiency shall be furnished to Owner.

 

                        Welding procedure and welder qualification shall be carried out as per ASME Sec. IX prior to welding.

 

                        All welding shall be tested as per IS:2825.

 

Air receiver shall be hydraulically tested at twice the operating pressure or 1.5 times the design pressure whichever is higher for 30 minutes

 

2.9.17               Air Blowers

 

                        All materials shall be tested for chemical and mechanical properties as per governing Code/Standard.

 

                        NDT shall be conducted on shaft and impeller.

 

                        Rotating elements shall be subjected to static and dynamic balancing.

 

                        Performance testing of blowers shall be carried out as per BS:1571 at manufacturer’s shop.

 

                        Noise and vibration level shall be measured.

 

2.9.18               Instrument Air Compressors

 

                        All material shall be tested for chemical and mechanical properties as per relevant standard.

 

                        UT and MPI/DPT shall be done on all forgings and shafts.

 

                        Rotating elements shall be statically and dynamically balanced.

 

                        Performance/routine test shall be carried out as per BS-1571/IS:5456.

 

2.9.19               Air Receivers

 

                        All material shall be tested for chemical and mechanical properties as per relevant standard.

 

                        Welding procedure and welder qualification shall be carried out as per ASME Sec-IX prior to welding. All welding shall be tested as per IS:2825.

 

                        Air receivers shall be tested hydraulically at twice the operating presure or 1.5 times the design pressure whichever is higher for 30 minutes.

 

2.9.20               Air Drying Plant

 

                        All material shall be tested for chemical and mechanical properties as per relevant standard.

 

                        Welding procedure and welder qualification shall be carried out as per ASME Sec.IX prior to welding. All welding shall be tested as per IS:2825.

 

                        Pressure vessels shall be tested for hydraulic pressure at twice the working pressure or 1.5 times the design pressure whichever is higher.

 

                        Sequence test shall be carried out.

 

                        Type testing as per IS:5456/ISO:1217 shall be carried out in presence of the Owner, if not carried out earlier.  The testing procedure shall be mutually discussed and finalised before commencement of the test.  In case type testing is already carried out, a test certificate with details of test results shall be submitted to the Owner for review and approval.  Also calculation for volumetric efficiency shall be furnished to Owner.

 

2.9.21               Wetting Head

 

                        Wetting head shall be visually inspected and checked for dimensional accuracies at manufacturer’s works.

                        Hydraulic/pressure test shall be carried out on assem­bled wetting heads.

 

All materials shall be tested for chemical and mechanical properties as per relevant standard.

 

2.9.22               Collector Tanks

 

                        All materials shall be tested/inspected as per govern­ing code/standard for chemical and mechanical proper­ties.

 

                        Welding procedure/welder qualification shall be carried out prior to welding.

 

                        MPI/DP test on welding shall be carried out.

 

                        Fill test on assembled tank shall be carried out.

 

2.9.23               Bag Filters

 

                        All material shall be tested for chemical and mechanical properties as per relevant standard.

 

                        Welding procedure and welder qualification shall  be carried out prior to welding.

 

                        NDT shall be done on weldments.

 

                        Leakage test shall be carried out for casing.

 

Pulsing and sequential test on bag filter cases shall be done at shop.

 

2.9.24               Ash Storage Silo

 

                        All material shall be tested for its mechanical and chemical properties as per relevant standard.

 

                        NDT shall be carried out on weldments.

 

                        Welding procedure & welder qualification shall be carried out as per ASME Sec. IX prior to welding.

 

Fit up assembly checks shall be carried out at shop for all despatchable segments of silo.

 

2.9.25               Piping Valves and Fittings

 

                        Pipe & fittings material shall be tested for chemical, Mechanical properties and dimensional check as per relevant governing standard.

 

                        Hydraulic test shall be done on ERW pipes as per relevant standard.

 

Fittings shall be hydraulically tested at twice the operating pressure or 1.5 times the design pressure whichever is higher.

 

                        Valve materials shall be tested for chemical and mechanical properties as per relevant governing standard.

 

                        All valves shall be tested hydraulically for body and seat as per governing API/BS/IS standards.

 

Air seat test shall also be carried out at 7kg/cm2 pressure in case of air duty valves and wherever applicable as per relevant standard.

 

2.9.26               Inspection and Testing – Ash Slurry Disposal Pipes and Fittings

 

                        Pipes and fittings shall be tested for chemical, mechanical and dimensional check as per relevant std.

 

                        Pipes shall be hydraulically tested as per relevant std.

 

                        Fittings shall be hydraulically tested at twice the operating pressure or 1.5 times the design pressure whichever is higher.

 

                        In case of Cast Basalt lined fittings, Basalt liners shall be tested for chemical & mechanical properties.  Basalt liners be examined visually for detection of cracks & defects.

 

                        Cast Basalt lined fittings shall be hydro-tested at twice the operating pressure or 1.5 times the design pressure whichever is higher.

 

2.9.27               Horizontal Centrifugal Pumps

 

2.9.27.1            Testing and Inspection at Manufacturer’s Works

 

                        All materials shall be tested for chemical and mechanical properties as per relevant governing standard.

 

                        a)         The pump casing shall be hydraulically tested at 200% of pump rated head or at 150% of shut-off-head, whichever is higher.  The test pressure shall be maintained for at least half an hour.

 

                        b)         For each ash slurry disposal pump the rated pressure corresponds to design pressure.  Rated/Shut off head for each slurry pump shall be taken after adding the rated/shut off head for all the pumps coming in a series. The testing for each pump shall be done corresponding to these pressure and as defined at (a) above.

 

                        The pump rotating parts shall be subjected to static and dynamic balancing tests.

 

                        UT shall be done on shaft forgings and MPI/DP shall be done on shafts and impeller.

 

                        All pumps shall be tested for performance test for capacity head, efficiency and brake horse power at rated speed as per HIS and IS as applicable.

 

                        Noise & Vibration shall be measured during the performance testing at shop.

 

                        Fluid Coupling

 

                        All material shall be tested for chemical & mechanical properties as per relevant standard.

 

                        (i)         Static & dynamic balancing shall be carried out for all rotating parts.

 

                        (ii)        Check for leak tightness of the coupling shall be carried out.

 

                        (iii)       Functional test on fusible plug for each type of coupling shall be conducted at shop.

 

                        (iv)       Check for temperature rise, torque speed, torque slip characteristics and overspeed test on one coupling of each size and type during load test (preferably at full load at shop).

 

                        BS:5353            :           Carbon and Alloy steel plug valves.

 

                        ANSI B:16.10   :           Face to face and end to end dimensions of Ferrous valves.

 

                        API-598            :           Valve inspection and test.

 

2.9.27.2            Slurry Disposal Line Valves

 

                        All materials of valves components shall be tested/inspected as per governing std./code for its chemical & mechanical properties.

 

                        All valves shall be hydraulically tested for body and seat leakage test at shop.

 

 

                        (i)         IS : 1710                       Vertical Turbine pump for clear, cold, fresh water.

 

                        (ii)        IS : 5639                       Pumps handling chemicals and corro­sive liquids.

 

                        (iii)       IS : 5120                       Rotodynamic Special Purpose Pump.

 

                        (iv)       IS : 5659                       Pumps for process water

 

                        (v)        IS : 5600                       Specification for sewage and drainage pumps.

 

                        (vi)       Standards of Hydraulic Institute, U.S.A.

 

2.9.27.3            Vertical Sump Drainage Pumps

 

                        Testing & Inspection at Manufacturer’s Works

 

                        All material shall be tested for chemical & mechanical properties as per relevant governing std. Shaft forgings shall be subjected to UT MPI/DP test shall be carried out on impeller and shaft to ensure freedom from defects.

 

                        The pump casing shall be hydraulically tested at 200% of pump rated head or at 150% of shut-off head, whichever is higher. The test pressure shall be maintained for at least half an hour.

 

                        The pump rotating parts shall be subjected to static and dynamic balancing.

 

                        All pumps shall be tested at the shop for capacity, head, efficiency & brake horse power at rated speed as per HIS/IS as applicable.

 

                        The pump accessories e.g. the thrust bearing, the motor pump shaft coupling etc. will be subjected to tests as per Manufacturer’s standard.

 

 

                        Noise & vibration shall be measured during the performance testing at shop.

 

                        Test reports and certificates of the above mentioned test to ensure satisfactory operation of the system shall be submitted to the owner before despatch.

 

                        Tests at Site

 

                        After erection at site, pumps as detailed under different groups shall be operated to prove satisfactory performance as individual equipment as well as a system.

 

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