1

BHARAT HEAVY ELECTRICALS LIMITED – HARIDWAR

TURNKEY PROJECT ON AUXILIARY COOLING WATER
SYSTEM FOR 800 / 1000 MW TG
________SPECIFICATION NO. : HEEP/TEST-BED/800/CWS,REV.01_____

BHARAT HEAVY ELECTRICALS LIMITED – HARDWAR

Electrical Machines Test-bed

SPECIFICATION

for

AUXILARY COOLING WATER SYSTEM

FOR 800 / 1000 MW TG

CONTENTS

SLNO DESCRIPTION

01 INTRODUCTION
02 SCOPE OF WORK
03 SCOPE OF SUPPLIES & SERVICES
04 TECHNICAL SPECIFICATION
05 DRAWINGS/DATA SHEET/ DOCUMENTS
06 GUARANTTEE
07 PROJECT SCHEDULE
08 GENERAL TERMS & CONDITIONS
09 REFERENCE DRAWINGS / SKETCHES

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 BHARAT HEAVY ELECTRICALS LIMITED – HARIDWAR
TURNKEY PROJECT ON AUXILIARY COOLING WATER
SYSTEM FOR 800 / 1000 MW TG
________SPECIFICATION NO. : HEEP/TEST-BED/800/CWS,REV.01_____

1.0 INTRODUCTION

Turbo-generators and Motors are tested in fully assembled condition at

Test-bed, Block-1 as per IEC and IS Standards. The existing Oil & Water
Pump-house is capable of meeting the requirement of cooling water to test
Turbo-generator upto 500 MW only.

Maximum capacity of existing water services 1800 cu m/hr. Stand-by

Pump capacity is 900 cu m/hr. Cooling tower is rated for uninterrupted
cooling of warm water by 7ºC at consumption of 1800 cu m/hr. Inlet
temperature of cold water is maintained below 36ºC in the summer. Pump
section consists of 6 Nos. Pumps, each rated for 900 cu m/hr,
Head 32 MWC Speed 1450 RPM. Three pumps (two active + one standby)
are used for cold water pumping.

1.1 PURPOSE

A new Cooling Water Service System has been envisaged to test Turbo-
generator up to 800 MW / 1000 MW. It is proposed to provide Vertical
Turbine Pumps for pumping cold water from cold water sump up to the
various cooler inlets and return water from the coolers to the cooling tower
along with necessary control & Instrumentation, Measurement & protection
and Mimic panels to test 800/1000 MW Turbo-generator.

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 BHARAT HEAVY ELECTRICALS LIMITED – HARIDWAR
TURNKEY PROJECT ON AUXILIARY COOLING WATER
SYSTEM FOR 800 / 1000 MW TG
________SPECIFICATION NO. : HEEP/TEST-BED/800/CWS,REV.01_____

2.0 SCOPE OF WORK

2.1 General

The scope of work under this Bid Enquiry would include setting up of new
cooling water service system on Turnkey basis as per battery limits shown
in the Drawings/and detailed in the Specifications herewith.

2.2 Engineering Services

The scope of engineering services shall include, but not limited to the
following:

a) Detailed engineering for all Civil, Structural, Hydro-Mech and

Electrical works for cooling water service system with pumps, piping,
valves, controls & accessories.

b) Calculations for Total Head requirement.

c) Calculations for Cold Water sump capacity/sizing.

d) Calculation of cooling tower sizing

e) Architectural & Structural designs and layout for construction of Pump

house, Cold Water Sump, Electrical Sub Station Building and
associated Structures/Units.

f) Detailed Engineering for Electrical works Single Line diagrams and

Layout arrangement for all Electrical equipments, lighting etc.

g) Erection & Commissioning of the Plant and proving of the system by

Trial Runs.

h) Training of Purchasers’ (BHEL, HEEP) personnel at site during

commissioning of the Plant.

i) Any other item as per requirement on the basis of Turnkey project

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 BHARAT HEAVY ELECTRICALS LIMITED – HARIDWAR
TURNKEY PROJECT ON AUXILIARY COOLING WATER
SYSTEM FOR 800 / 1000 MW TG
________SPECIFICATION NO. : HEEP/TEST-BED/800/CWS,REV.01_____

2.3 Plant & Equipment

The equipment to be provided is detailed in the Clause 3 in the following

sheets.

Along with above, all the Hydro-Mech-Elect equipments required for the
Job shall be provided. Any item not specifically written in the
specifications but required for completing the works shall be deemed to be
included in the scope of supply by the Contractor.

2.4 Civil & Structural Works

a) Complete civil work including design and construction required for
completion of the project such as Construction of Cold Water Sump, Pump
house, Electrical Sub Station building, Cooling Towers, Trenches, Supports
and other associated structures as required for the Cooling Water Service
System.
b) All civil work shall be carried out as per latest technical
specifications.

2.5 Scope of Civil Work

Engineering, civil work including building construction, awarding &
execution of works contract for civil work and E&C of equipment (This
shall include procurement of misc. items required for civil work) for
following:
 Cooling Tower
 Cold well sump
 Pump house building to accommodate water-pump sets,
valves, pipings, local control & instrumentation panels for
all the Electricals with proper ventilation and illumination
 Foundation for motor and pump sets, pipe supports, main
header valve chamber etc.
 Electrical building to accommodate 11 KV/415 volts,
Transformer and 415 volts MCC panel which will include
the Incomer, outgoing feeders for pump-motor, cooling
tower motor, Valve-motors, control supply etc.
 Required cable trenches for laying of cable within
/outside the buildings shall be included in the civil work.


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 BHARAT HEAVY ELECTRICALS LIMITED – HARIDWAR
TURNKEY PROJECT ON AUXILIARY COOLING WATER
SYSTEM FOR 800 / 1000 MW TG
________SPECIFICATION NO. : HEEP/TEST-BED/800/CWS,REV.01_____

 Any other item as per requirement on the basis of Turnkey

project

2.6 Scope of Electrical Work

 Engineering, procurement, awarding & execution of

works contract, E&C of equipment ( This shall include
procurement of misc. items required for erection &
commissioning ) , supervision of erection &
commissioning and proving of All Electricals which
includes 11 KV/415 volts Transformer and 415 volts MCC
panel i.e. Incomer, outgoing feeders for pump-motor,
cooling tower motor, Valve-motors , control supply etc
 Preparation of cable schedule and its layout scheme
 Fan & Lighting work of buildings
 Any other item as per requirement on the basis of Turn-
key project

2.7 Scope of Motor- Pump sets, Piping Work & their accessories

a) Engineering, procurement, awarding & execution of works

contract, E&C (This shall include procurement of misc. items
required for erection & commissioning), supervision of erection
& commissioning and proving of motor-pump-sets, piping work
& all the accessories as per drawings.

b) Layout drawings for motor- pump sets

c) Layout drawings for piping to connect cooling tower, cold well

sump, pump-house building, and 800/1000 MW test bed.

d) Layout for all the accessories like valves, supports etc

e) Any other item as per requirement on the basis of Turnkey

project

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 BHARAT HEAVY ELECTRICALS LIMITED – HARIDWAR
TURNKEY PROJECT ON AUXILIARY COOLING WATER
SYSTEM FOR 800 / 1000 MW TG
________SPECIFICATION NO. : HEEP/TEST-BED/800/CWS,REV.01_____

2.8 Scope of Erection, Commissioning & Proving

a) Competent staff to be deputed full time during execution of

the Project staring from beginning of the project till its proving.
b) Awarding & execution of the works contract (This shall
include procurement of misc. items required for erection &
commissioning).
c) Supervision of Erection & commissioning of all equipments
supplied by supplier.
d) To train the purchaser's (BHEL, HEEP) personnel at site
during commissioning of the equipment.
e) First trial testing shall be performed during testing of 800/1000
MW TG.
f) Any other item as per requirement on the basis of Turnkey
project

2.9 Reference Drawings

(i) ACW System 1-139-01012

(Only Part-I covering cooling tower & pump House)

(ii) Proposed location of New Pump House and piping routing upto
basement for Auxiliaries TGE-2466

(iii) MCC Single Line Diagram for Pumps& Electrics for 800 MW Test
Bed in Block-1 TGE-2467

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 BHARAT HEAVY ELECTRICALS LIMITED – HARIDWAR
TURNKEY PROJECT ON AUXILIARY COOLING WATER
SYSTEM FOR 800 / 1000 MW TG
________SPECIFICATION NO. : HEEP/TEST-BED/800/CWS,REV.01_____

3.0 SCOPE OF SUPPLY & SERVICES

SL.NO. EQUIPMENT QUANTITY

1 Vertical Turbine Pumps with Accessories Capacity 4 Sets
1000 m3 /hr at 50 MWC ( Refer clause 2.2 b)as per
Technical Specifications
2 Vertical Solid Shaft Squirrel Cage Induction Motors 4 Nos.
200 KW 1500 rpm (Syn.) for above Pumps as per
Technical Specifications
3 450 mm dia Cast Iron Double Flanged Butterfly Valves 4 Nos.
PN 1.0 for Pump delivery line with Electrical Actuator as
per Technical Specifications
3a 450 mm dia Cast Iron Double Flanged Butterfly Valves PN 1 No.
1.0 for Pump delivery line Manually operated as per
Technical Specifications
4 450 mm dia Cast Iron Double Flanged Non Return 4 Nos.
Valves PN 1.0 for Pump delivery line as per Technical
Specifications
5 600 mm dia Cast Iron Double Flanged Butterfly Valves 7 Nos.
PN 1.0 with Electrical Actuator for Pipeline System as
per Technical Specifications
6 200 mm dia Cast Iron Sluice Valves PN 1.0 for Cooling 12 Nos.
Towers with Hand-wheel (2 Valves per CT cell) as per
Technical Specifications
7 Self Cleaning Strainers capacity 2000 cu.m/hr 2 Nos.
8 FRP Induced Draft Cooling Tower with 6 Cells as per 1 Set
Technical Specifications.
9 Instrumentation:
9.1 Flow meter Electromagnetic On-line type suitable for 1 No.
flow rate of 2000 m3/hr as per Technical Specifications

9.2 Capacitance/Ultrasonic type Level Measurement System 1 Set

for Cold Water Sump with High/Low alarms

9.3 Pressure gauges/Pressure Transmitters (Pressure gauges 1 Set

at each Pump delivery and PG&PT at Common outlet)
One Pressure gauge & PT on the Common Return Line

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9.4 Electronic Tempt. measurement system for Cold Water 1 Set
Sump with High/Low Alarms

9.5 Signal & Control Cables with accessories from field 1 Lot
instruments to control panel including Cable Trays and
conduits as required
10 Control Panel for Remote Control/Operation with 1 Set
Indications including for Level, Flow, Tempt, Pressure
complete with accessories
11 EOT Crane 5.0 T capacity with gantry rails and 1 Set
accessories/controls as per Technical Specifications
12 1.5T Air Conditioner in Control Room with Wiring/ 1 Set
Controls
13 450 mm dia. Exhaust Fans with Accessories 900 RPM 6 Nos.
14 Portable Dewatering Pump set Submersible type capacity 4 Sets
10 m3/hr each Total Head 15 mts with flexible pipe and
submersible cable
15 11 KV/415V 1000 KVA ONAN Dyn.11 Indoor Dry type 1 No.
Transformers as per Technical Specifications
16 Power cum Motor Control Centre (Main LV 1 Set
Switchboard) comprising of Incomer feeders Bus coupler
& Outgoing feeders with protections relays, metering &
indications as per Technical Specifications and Single
Line Diagram
17 Sub Distribution Board comprising of Incomer & 1 Set
Outgoing Feeders with metering & indications for
Lighting & Small power requirements as per Technical
Specifications and Single Line Diagram
18 Capacitor Bank with APFC Panel for improvement of 1 Set
System Power factor to 0.98 with protections, metering
& indications
19 11 KV grade 3C x 70 sq. mm Aluminium Conductor 1200 mts
XLPE insulated Armoured Cables
20 1.1 KV grade 6 (3½C x 300 sq.mm) Aluminium 1500 m
Conductor PVC insulated Armoured Cables
21 Bus duct with Copper Bus bars for Inter-connections 1 Lot
between LV of 1000 KVA Transformer & Incomer from
LT Power Distribution
22 1.1 KV Grade PVC insulated armoured Cables for:

22.1 Inter-connection between Main Pump Motors & PMCC 1 Lot

size 3C x 150 Sq. mm (Copper Conductor)

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22.2 Inter-connection between PMCC & Cooling Tower 1 Lot
Motors Size 3C x 10 Sq. mm (Copper Conductor)

22.3 Inter-connection between PMCC & APFC Panel 1 Lot

Size 3C x 300 Sq. mm ( 2 runs) (Aluminium Conductor)
22.4 Inter-connections between PMCC & Sub Distribution 1 Lot
Board (SDB) 3C x 240 Sq. mm (Aluminium Conductor)
23 1.1 KV Grade Copper Conductor PVC Insulated Cables
for:
23.1 Inter-Connections Between SDB & Valve Actuator 1 Lot
Motors Size 3 C x 4 Sq. Mm

23.2 Inter-Connections Between SDB & Exhaust Fans Size 1 Lot

3C x 4 Sq. Mm

23.3 Inter-Connections Between SDB & EOT Size 4C x 6 Sq. 1 Lot

mm

23.4 Inter-Connections Between SDB & Battery Charger Size 1 Lot

4C x 6 Sq. mm

23.5 Inter-connections between SDB & Lighting DB 1 Lot

Size 4C x 6 Sq. mm
24 1.1 KV Grade Copper Conductor PVC Insulated 1 Lot
armoured Control Cables
25 100 AH 24V DC Lead Acid Batteries including Battery 1 Set
Stand, Couplers/Connectors and accessories as per
Technical Specifications
26 Battery Charger for 100 AH 24V DC Batteries including 1 Set
metering & indication as per Technical Specifications
27 Industrial Luminaries in CRCA Sheet Steel Housing with 1 Lot
Reflector for 2 x 36W and 1 x 36 W FL for the entire
Building complete with accessories Control-gear,
Conduits, Wiring and Switches with Spare plugs
28 GI Earth Strips & earth pits ( 02 for Transformer neutral 1 Lot
and 02 for Equipment body) for earthing of all
Electricals as per IE Rules
29 Safety equipment comprising First Aid Box, Shock 1 Lot
Treatment Chart, Rubber Mats etc.
30 900 cu meter/hour, 32 MWC Motor-Pump set for existing 2 Nos.
system to be quoted as an optional

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31 Spare-parts for 2 years normal maintenance (List to be 1 Lot
furnished)

The Scope of Supply/Works for Cabling would include necessary Termination

Kits for 11 KV Cables; Lugs, Glands & other accessories for LV Cables.

For underground/buried cables; sand & bricks shall be provided for protection.

For Cables to be carried in the Trenches ladder type Cable Trays and supports
shall be provided.
The trenches shall be provided with chequered plate covers.

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 BHARAT HEAVY ELECTRICALS LIMITED – HARIDWAR
TURNKEY PROJECT ON AUXILIARY COOLING WATER
SYSTEM FOR 800 / 1000 MW TG
________SPECIFICATION NO. : HEEP/TEST-BED/800/CWS,REV.01_____

4.0 TECHNICAL SPECIFICATIONS:

4.1 SITE CONDITIONS

4.1.1 Environmental Conditions

 Maximum Ambient temperature: 45-50 deg C

 Reference temperature for : 50 deg C
Electricals design
 Altitude : < 300 mts above Mean Sea Level
 Max Temperature of outlet water from test bed :42-460 C (assumed)
 Temperature of inlet water to the test bed: less than 10 0C from the test
bed outlet temperature.

 Cooling Tower to be designed with dry bulb and wet bulb temperature
of Haridwar in consideration
 Contactor shall take care of environmental regulation as per guidelines
by State Pollution Control Board and Central Pollution Control Board.
 Contractor shall take care of safety requirements also

4.1.2 Water quality at inlet to the system:

BODs at 27ºC : 1 mg/L

COD at 27ºC : 4 mg/L
Total suspended solids : 17 mg/L

4.1.3 Power Supply

Supply System : 11000 Volts 3 Phase 50 C/s AC

Voltage Variation : (±) 10%
Frequency Variation : (±) 5%
Combined Voltage & Frequency : (±) 10%
Variation

4.1.4 Site location & space requirement for new cooling water service plant

Contactor shall examine & decide in consultation with BHEL the exact
location of site for its optimum use in testing of 800/1000 MW TG as per

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 BHARAT HEAVY ELECTRICALS LIMITED – HARIDWAR
TURNKEY PROJECT ON AUXILIARY COOLING WATER
SYSTEM FOR 800 / 1000 MW TG
________SPECIFICATION NO. : HEEP/TEST-BED/800/CWS,REV.01_____

space requirements for new cooling water service plant keeping in view of
the following:

 The water head & flow requirements are met for testing of 1000 MW
TG at new location situated approximately at 150 meters away from
New Pump House.

4.1.4 Conformance with National And International Standards

 Supplier shall take care of loading requirements of civil structures

equipments etc and submit the layout drawing.

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 BHARAT HEAVY ELECTRICALS LIMITED – HARIDWAR
TURNKEY PROJECT ON AUXILIARY COOLING WATER
SYSTEM FOR 800 / 1000 MW TG
________SPECIFICATION NO. : HEEP/TEST-BED/800/CWS,REV.01_____

4.2 TECHNICAL DETAILS/SPECIFICATIONS

4.2.1 PUMPS

Make Mather & Platt/equivalent

Quantity 4 Nos. (2W + 2 SB)
Type Vertical Turbine
Total Bowl Assembly Head 50 MWC ( refer clause 2.2 b)
Rated Output 1000 cu.m / Hr. (each pump)
Liquid handled Cold clear Water
Bowl Efficiency 88%
Power absorbed 154.73 KW plus transmission losses
Recommended drive 200 KW
Column length To suit Cold Water Sump depth
Lubrication Self Water
Speed (Nom.) 1480 RPM
Material Construction
Bowl C I FG 260
Impeller SS CF 8 M
Pump Sleeve SS CF 8 M
Pump/Head/line shaft SS AISI 410
Line Shaft bearing THORDON
Discharge Head CI FG 260
Column pipes MS fabricated
Motor Stool MS fabricated
Packing Graphite Asbestos
Shaft Sealing Gland packing

4.2.2 MOTORS

Make Crompton/ABB/Kirloskar/Alstom
Type Squirrel Cage Induction Solid Shaft
Type of Mounting Vertical Flange mounted
Motor Output 200 KW
Quantity 4 Nos.
Supply Voltage 415V (±) 10%
Supply Frequency 50 Hz (±) 5%

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Combined Voltage & Frequency (±) 10%
Variation
Duty Continuous S1
Type of Enclosure TEFC
Degree of Protection IP-55
Syn. Speed 1500 RPM
Full load Current (Nom.) 325 A
Insulation Class/Temp. rise allowed Class F/Class B with reference Tempt
as 50ºC

4.2.3 VALVES

Cold well Pump Delivery line Butterfly 450 mm, PN-1.0 rated,
Valve C I Body & disc with
SS trims, Motor operated
as per BS:5155/IS:13095
Cold well Pump Non return valve single 450 mm, PN-1.0 rated,
door swing check type on C I Body & disc with
pump delivery line SS trims, Motor operated
as per IS:5312 Part-1
Valve Chambers Butterfly valves 600 mm PN-1.0 rated,
C I Body & disc with
SS trims, Motor operated
as per BS:5155/IS:13095
Cooling tower inlet to Gate valve/Sluice valve 200 mm PN-1.0 rated,
cells C I Body & disc with
SS trims, Manually
operated as per IS:14846

4.2.4 COOLING TOWERS

Type of Cooling Tower Induced Draft

Overall Dimensions (L*W*W) mm 4000*12000*4550 2 Nos.
Height of Air Inlet mm 800
Material of Louvers FRP
Material of Tower Structure RIGID PVC
Type Honey Comb
Colour Transparent Blue/Black
Cooling Tower No. of Cells 6
Auxiliary Equipments
1. Fan type Axial Flow
No. of Fan 6

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 Dia of Fan 2440
Fan RPM 470
No. of Blades/Fan 6
Material of Blades FRP
Material of Hud Cast Aluminium
Fan Shaft SS 304
Type of Balancing Dynamic
2. Motor
No of Motor 6
Motor HP 15
Seed (Nom.) 1440 RPM
Drive Reduction Gear Box
Make (Motor) Hindustan or other reputed
Make (Gear Box) MM Gears/Deekay or other reputed
3. Distribution Piping
Type Fixed Nozzle
Material PVC, Non-clog
4. Design Performance
Spray Loss Max. % 0.1
Evaporation Loss Max. % 0.59
5. Inlet Pipe “10” NB
Outlet Pipe “10” NB
6. Hardware
Material of Bolt, Nut and Washer SS
Weight of Tower without Water-KG 2000/Tower)
Weight of Tower with Water-KG 3600/Tower) App. Reference Values
7. Contact Surface Area 30000/Tower)

4.2.5 TRANSFORMER

 One No. 1000 KVA 11 KV/415V 3 Phase 50 Hz Dry type Power

Transformer shall be provided.

 Indoor installation for Connections with 11 KV XLPE Cables on

HV and Bus ducting for LV

 Impedance 5%

 ONAN Cooling

 Vector Group Dyn.11

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 BHARAT HEAVY ELECTRICALS LIMITED – HARIDWAR
TURNKEY PROJECT ON AUXILIARY COOLING WATER
SYSTEM FOR 800 / 1000 MW TG
________SPECIFICATION NO. : HEEP/TEST-BED/800/CWS,REV.01_____

 LV Neutral solidly earthed

 Design Ambient Temp 50ºC

 Double Wound with Copper windings

 Windings Temp Rise measured by resistance method 45ºC

 Full capacity Off-load type Tap Changer on HV Side for Dry type Tr.
with Pad locking facility for (+) 5% to (-) 10% range; Tap Set 2½%

 Rated Voltage HV 12 KV (HV Side) and 1100V (LV Side). Nominal

system voltage 11 KV (HV) & 415V (LV)

 One Minute Power Frequency withstand voltage (day & wet)

28 KV (HV) & 3 KV (LV) rms values

 1.2/50 micro second full wave impulse withstand voltage 75 KV (Peak)

 Minimum creepage distance 372 mm (HV) and 34 mm (LV)

 Governing Standards IS:2026, IEC 60076, 60214 and 60296

 Accessories – all standard accessories like WTI and Tripping

For door opening

 Wheels – Bidirectional, plain

4.2.6 415V POWER CUM MOTOR CONTROL CENTRE

 415V PMCC Panels shall be of single front, non-draw out, freestanding,

floor mounting type. This shall be compartmentalized design and made
of CRCS sheets.

 Totally enclosed, dust & vermin proof enclosure with IP-52 degree of
protection.

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 BHARAT HEAVY ELECTRICALS LIMITED – HARIDWAR
TURNKEY PROJECT ON AUXILIARY COOLING WATER
SYSTEM FOR 800 / 1000 MW TG
________SPECIFICATION NO. : HEEP/TEST-BED/800/CWS,REV.01_____

 It shall have copper bus bars.

 The Sheet Steel thickness shall be min. 2.0 mm for front/base/side and
3.16 mm for load bearing pads.

 This Panel shall have two 415V, 1600A, 50 KA (1 sec) TPN bus
sections coupled by a 415V, 1600A, 50 KA (1 sec) bus coupler, with
Manual transfer interlock.

 The Incomer shall have 1600 Amp ACB (motorized and fully withdraw
able) and have Voltmeter, Ammeter with CTs, Selector Switches and
Indicating lamps etc.

 The Outgoing Pump Motor Feeders shall be provided with 415V,

630A MCCB Star/Delta Motor Starter modules with necessary
protection and indications.

 The Outgoing Cooling Tower Motor Feeders shall be provided with

415V, 63A SFU’s & Star/Delta Starter shall have necessary protection
and Indication.

 Suitable terminals for terminating 1600 Amp, 3 Phase, 4 W supply shall

be provided in the MCC.

4.2.7 BATTERIES & BATTERY CHARGER

 24V/100 AH Battery Lead Acid type, low maintenance type.

 Positive plates either of Plant or Tubular type.

 Negative plates box type

 Containers transparent made of toughened glass or plastic provided with

Acid Level Indicator.

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 BHARAT HEAVY ELECTRICALS LIMITED – HARIDWAR
TURNKEY PROJECT ON AUXILIARY COOLING WATER
SYSTEM FOR 800 / 1000 MW TG
________SPECIFICATION NO. : HEEP/TEST-BED/800/CWS,REV.01_____

 Rated on 2 Hour basis; maximum recharge time of 8 hours.

 Shall conform to IEC Standards

 Electrolyte Sulphuric Acid

 Battery Racks shall be provided

 Porcelain insulators, Rubber pads & Set of inter-cell, inter tier and inter-
bank connectors provided as required for complete installation.

 Accessories for testing & maintenance:

- DC Voltmeter : (One)

- Hydrometer : (One)

- Filler hole thermometer with Plug & Cap : (One)

- Pocket Thermometers : (Three)

- Acid Resisting Funnels : (Three)

- Acid Resisting Jugs of adequate capacity : (Two)

- Rubber Aprons : (Two)

- Rubber Gloves : (Four)

- Cell Lifting Straps

 Float cum Boost type Battery Charger shall be provided comprising of

Silicon controlled Rectifiers connected in a full wave bridge circuit with
ripple control devices and transient suppression network. The Rectifier
shall consist of two branches, one for Supplying the battery and other
for Feeding external loads.

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 BHARAT HEAVY ELECTRICALS LIMITED – HARIDWAR
TURNKEY PROJECT ON AUXILIARY COOLING WATER
SYSTEM FOR 800 / 1000 MW TG
________SPECIFICATION NO. : HEEP/TEST-BED/800/CWS,REV.01_____

 The 415V AC Input to Battery Charger shall be through suitably rated

MCCB. On output side, a 2 pole MCCB of suitable rating shall be
provided.

 Battery Charger shall be suitable for float charging. The battery under
normal conditions and boost charging the battery when it has discharged
during service conditions. The changeover from float to boost mode
and vice-versa shall be automatic.

 Battery charger shall be designed for Voltage regulation of 1% and

ripple content in the rectified DC supply of less than 2%. Boost
charging time not to exceed 8 Hours. DC Output voltage during float
charging stabilized within ± 1%. Voltage regulation by constant voltage
regulator having fast response SCR Control. Ripple Content within 1%
of DC Output nominal voltage with battery disconnected.

 Battery Charger equipment complete with all accessories housed in a

free standing Sheet Steel cubicle.

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 BHARAT HEAVY ELECTRICALS LIMITED – HARIDWAR
TURNKEY PROJECT ON AUXILIARY COOLING WATER
SYSTEM FOR 800 / 1000 MW TG
________SPECIFICATION NO. : HEEP/TEST-BED/800/CWS,REV.01_____

4.2.9 INSTRUMENTATION:

(a) Level Measurement:

Consisting of level transducer, level transmitter digital level indicator to

indicate the water level in the Cold Water Sump.
- Overall Accuracy of System ± 0.5% of full scale
- Type Ultrasonic/Capacitance
- Level Transmitter Microprocessor based with backlet/LCD
display with 4-20 mA output
- High/Low Level Alarms Contacts shall be provided

(b) Pressure Measurement:

Besides Pressure gauges on the individual pump delivery branches;

electronic type pressure measurement system shall be provided on the
common manifold/header of Pumps.

The Pressure transmitter shall have accuracy of ± 0.25% and of

capacitive type. The range shall be 0-60 mwc and output signal 4-20
mA for indication in LCD type.

On each of the Pump delivery-line common manifold & return line,

a pressure gauge of 150 mm dial shall be provided. Accuracy ± 1% of
full scale; Range 0-60 mwc. Pressure gauge shall be equipped with
shatter proof glass. The Body shall be in Die cast Aluminium; Sensor &
other wetted parts in SS; Dial of Aluminium with white background &
black writing.

(c) Flow Measurement:

The Flow meter shall be provided in the Common manifold.
The Flow meter shall be In-line full bore electromagnetic type.
The Overall accuracy shall be ± 1%. Range 0-2000 m3/hr. The
materials for Electrode: SS 316, Coil Housing SS 316; Liner Hard
Rubber. Flow Transmitter, microprocessor based with 4-20 mA output,
type of display 4 digit of segment backlit LCD/LCD with flow rate in
cu.m/hour. Totaliser shall be provided with 8 digit of segment backlit
LED/LCD

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 BHARAT HEAVY ELECTRICALS LIMITED – HARIDWAR
TURNKEY PROJECT ON AUXILIARY COOLING WATER
SYSTEM FOR 800 / 1000 MW TG
________SPECIFICATION NO. : HEEP/TEST-BED/800/CWS,REV.01_____

4.2.10 CONTROL PANEL:

The Instrument Control Panel shall be provided separately in the Control

Room. Control Panel shall be free standing floor mounting pattern;
made out of Cold Rolled Steel Sheets in minimum 2 mm thickness;
incorporating:
- Flow indicator/Integrator
- Level Indicator
- Pressure Indicator
- Tempt Indicator
- Start/Stop Control & Indication of Main Cold Water Pumps
- Start/Stop Control & Indication of Cooling Tower Motors
- Start/Stop Control & Indication of Pump delivery B.F. Valves
- Start/Stop Control & Indication of CT fan motors
- Annunciation Alarm for abnormal conditions for Water Level, Water
Pressure & Water Tempt.

4.2.11 CAPACITORS:
Capacitors shall be provided for improvement of Power factor at all
working loads to min. 0.98 lagging. LV Capacitors with APFC Relay and a
Panel shall be provided for connection to PMCC bus as shown in SLD.
Capacitors shall comply with IEC 60871, IS 13585, IS 13925. The rating
of the Capacitors shall be suitable to achieve the above referred
improvement. Estimated Rating 300 KVAr. However the rating as per
actual requirement depending upon uncorrected PF of Motors to be
provided.
 Type of Insulation : APP/MD
 Rated Voltage : 415V
 Supply System : 50 Hz 3 Ph AC
 Capacitor Bank Connection : Delta
 Mounting & Location : Floor mounted Indoor
 Design/Reference Tempt : 50ºC
 Arrangement : Automatic power factor connection
 Type of Switching : Automatic
 Degree of Protection of Enclosure: IP-52
 Type of APFC Relay : Microprocessor based automatic
Power factor corrections
relay (max setting 0.99)

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 BHARAT HEAVY ELECTRICALS LIMITED – HARIDWAR
TURNKEY PROJECT ON AUXILIARY COOLING WATER
SYSTEM FOR 800 / 1000 MW TG
________SPECIFICATION NO. : HEEP/TEST-BED/800/CWS,REV.01_____

APFC Relay shall automatically Switch ON/OFF the Capacitor banks to

attain value of PF close to the set value. A minimum power factor of 0.98
at any and all time shall be maintained. Switching shall follow first in first
out method to ensure uniform use of all Capacitor Banks.

The cubicle shall be fabricated out of 2 mm thick cold rolled sheets. The
Panel shall consist of the following:

- Isolating MCCB
- Contactors with overload element
- Relays responsive to current/voltage/KVAR/PF for automatic Switching
- Sequencing devices, timers & auxiliary relays for automatic Sequential
Switching of Capacitor units/banks
- Auto/Manual Selector Switch
- APFC Relay
- Indicating lamps

4.2.12 EOT CRANE:

 Capacity : 5 MT (SWL)

 Class : II/IS:3177

 Lift : 6 mts

 Span : 5.5 mts

 Bay Length : 15 mts

 Electrically operated bridge type with down shop conductor, rails and
other accessories.
 Pendant type push button station sheet steel enclosed consisting of Push
Buttons & Indicating Lamps for Start/Stop, Long Travel (Right/Left),
Cross Travel (To/Fro) Hook (Hoist/Lower) and Supply ‘ON’ indication.

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 BHARAT HEAVY ELECTRICALS LIMITED – HARIDWAR
TURNKEY PROJECT ON AUXILIARY COOLING WATER
SYSTEM FOR 800 / 1000 MW TG
________SPECIFICATION NO. : HEEP/TEST-BED/800/CWS,REV.01_____

 Pendant controls shall be supported independently of electrical cable

and shall be earthed separately. Automatic reset type Limit Switches
shall be provided to prevent Over travel for –
- UP/DOWN motions of Hook
- Long Travel motion
- Cross Travel motion

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 BHARAT HEAVY ELECTRICALS LIMITED – HARIDWAR
TURNKEY PROJECT ON AUXILIARY COOLING WATER
SYSTEM FOR 800 / 1000 MW TG
________SPECIFICATION NO. : HEEP/TEST-BED/800/CWS,REV.01_____

4.2.13 900 cu meter/hour Motor –Pump Set

Split casing, single stage, horizontal shaft, centrifugal pump suitable
for Circulation of clear water in Electrical machines for cooling
purpose.

PUMP

1. Discharge rate - 900 m3/hr

2. Total head - 32 mts.
3. Suction x Delivery-300x250 mm
4. Efficiency- 87%
5. Temp. – 75 0 C
6. RPM - 1450
7. BKW – 90.15 KW
8. Motor – 150hp/110Kw
9. DOR – CW from DE, suction on right and delivery on left side*
10. Compliance with standard safety norms.
* Direction of rotation of Pump and Suction/Delivery as viewed
from DE

Material of Construction
1. Casing-CI IS 210 GR FG 200
2. Impeller - Bronze IS 318
3. Shaft- C-40 IS 157
4. Shaft Sleeve- CI IS 210 GR FG 200
5. Casing Wear ring- Bronze IS 318
6. Stuffing Box Bush- CI IS 210 GR 200

MOTOR
1. Make- Alstom/ Crompton
2. Specification – 110 KW TEFC, Squirrel Cage Induction Motor
3. Supply- 3 phase, 415 volts, 50 Hz
4. Insulation- Class F
5. Enclosure- Conforming to protection IP-55
6. Operating altitude- upto 1000mts.

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 BHARAT HEAVY ELECTRICALS LIMITED – HARIDWAR
TURNKEY PROJECT ON AUXILIARY COOLING WATER
SYSTEM FOR 800 / 1000 MW TG
________SPECIFICATION NO. : HEEP/TEST-BED/800/CWS,REV.01_____

4.3 ENGINEERING CONSIDERATIONS

 Cooling Tower for uninterrupted cooling of warm water by 10ºC at

consumption rate of 2000 m3/hr maintaining cold water temperature
below 36ºC when ambient is in the range of 45-50ºC.

 Max. Pressure drop in TG Coolers will be approx 8 MWC (Meter Water

Column). Location of inlet to the Hydrogen cooler top is 6 meter from
ground level.

4.4 PIPE WORK

 Piping upto & including 150 NB shall be carbon steel (ERW IS:1239)

 Piping 200 NB and above shall be carbon steel (IS:2062) rolled and
welded conforming to IS:3589.

 All pressure tappings and root valves shall be NB 15

 All Pipelines to be supplied shall be of minimum working pressure 10

kg/cm2, test pressure 15 kg/cm2. Test certificate for pressure test to be
furnished.

 Thickness of the Pipelines shall be as per table below:

NB OD Thickness NB OD Thickness
15 21.8 3.2 150 166.5 5.4
25 34.2 4.0 200 219.1 6.0
40 48.8 4.0 250 273.0 6.0
50 60.8 4.5 300 323.9 6.0
65 76.6 4.5 350 355.6 6.0
80 89.5 4.8 400 406.4 6.0
100 115.0 5.4 450 457.0 6.0
125 140.8 5.4
500 508 7.0
600 610.0 7.0

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 BHARAT HEAVY ELECTRICALS LIMITED – HARIDWAR
TURNKEY PROJECT ON AUXILIARY COOLING WATER
SYSTEM FOR 800 / 1000 MW TG
________SPECIFICATION NO. : HEEP/TEST-BED/800/CWS,REV.01_____

 Buried piping shall be protected as per IS:10221

- Surface cleaning by wire brush

- Apply one coat of Coal tar/Primer/Enamel confirming to AWWA C-

203/ IS 10221

- Apply one layer of Tape comprising Coal tar. Application of Tape shall
conform to AWWA C-203/IS 10221 (Appendix – B) with minimum
thickness of tape as 4 mm ± 10%.

 External surface of the over ground piping shall be protected by

- Surface cleaning by wire brush

- Application of one coat of Red lead primer followed by adequate no of

finish coats of synthetic enamel to achieve total dry film thickness of
125 microns

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 BHARAT HEAVY ELECTRICALS LIMITED – HARIDWAR
TURNKEY PROJECT ON AUXILIARY COOLING WATER
SYSTEM FOR 800 / 1000 MW TG
________SPECIFICATION NO. : HEEP/TEST-BED/800/CWS,REV.01_____

5.0 DRAWINGS/DATA SHEETS/DOCUMENTS

Following Engineering data and documents shall be prepared by Contractor

for the Cooling Water System of Test-bed, Block-I to complete the entire
project, which includes Engineering, Civil work, Supply, Erection,
Installation & Commissioning and providing on full load condition of
Cooling Water System on Turnkey basis.

5.1 Detailed Civil Structure drawing/layout drawing and certified dimensioned

drawing with civil assignment for

 Cooling Tower
 Cold Well Sump
 Pump House
 Electrical Building for 11 KV/433 Volts Transformer, MCC Panel etc

5.2 Detailed Layout drawing and certified dimensioned drawing with civil
assignment for

 Water Pump sets

 Valves
 Piping Scheme etc

5.3 Detailed Single-line diagram of Cooling Water System with Specification

of major components

5.4 Layout/Schematic/Control drawing of Electricals as per following:

 Single-line diagram of Mains Supply 11 KV Transformer

 Single line diagram of MCC Panel (Power Scheme)

 Annunciation& Protection Panel
 Control Schemes of Motor Pump set, Fan Motor and Valves Motor etc
 Cable Schedule for all above
 Layout drawing of all Electrical of MCC Panel including Incomer
transformer 11 KV/415 Volts
 Layout diagram for control & instrumentation panel

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 BHARAT HEAVY ELECTRICALS LIMITED – HARIDWAR
TURNKEY PROJECT ON AUXILIARY COOLING WATER
SYSTEM FOR 800 / 1000 MW TG
________SPECIFICATION NO. : HEEP/TEST-BED/800/CWS,REV.01_____

5.5 List of vendors with details addresses (postal addresses, e-mail, fax number
& telephone number etc) for approval for all bought out items & spares.

5.6 Operation & Maintenance manual with catalog and test certificates of
equipments

5.7 Approved Scheme of cooling water system for 800/1000 MW TG for our
approval

5.8 5 Sets of each of above documents shall be furnished by the Contractor

5.9 All catalogues & technical details given by Vendor shall be furnished.

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 BHARAT HEAVY ELECTRICALS LIMITED – HARIDWAR
TURNKEY PROJECT ON AUXILIARY COOLING WATER
SYSTEM FOR 800 / 1000 MW TG
________SPECIFICATION NO. : HEEP/TEST-BED/800/CWS,REV.01_____

6.0 GUARANTEE

a) Guarantee for healthy functioning of the Cooling Water System for

800/1000 MW TG Project shall be provided for a period of
24 months after commissioning & providing of complete system.
In this period, Supplier to provide all the necessary services
(including deputation of Supplier expert) & spares free of cost for
any kind of trouble-shooting during operation of the offered system.

b) Supplier shall furnish test and guarantee certificates of all bought out
items to HEEP, BHEL.

c) During guarantee period, as and when there is requirement of

Contractors’ experts against any irregularities reported in the system,
persons shall reach HEEP Work place within 3 days. Contractor
shall organize for the Vendor’s visit, if needed, during their stay at
HEEP.

d) Contractor shall pay at least 8 visits for a minimum 1 week period

free of cost for their services (including deputation of experts) as and
when required during guarantee period.

7.0 PROJECT SCHEDULE

Project completion schedule to be furnished by Contractor along with the

offer and shall be got approved by HEEP. The Project is to be completed
by December, 2007.

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 BHARAT HEAVY ELECTRICALS LIMITED – HARIDWAR
TURNKEY PROJECT ON AUXILIARY COOLING WATER
SYSTEM FOR 800 / 1000 MW TG
________SPECIFICATION NO. : HEEP/TEST-BED/800/CWS,REV.01_____

8.0 GENERAL TERMS & CONDITIONS

8.1 Before quote, Supplier along with other Tenderer is requested to visit the
site, understand the technical requirements in detail, site conditions, space
availability and other requirements. Contractor is required to ensure
complete understanding of technical requirements and site conditions.

8.2 Contractor shall complete the entire job for the cooling water system of
Test-bed, Block-I, as per this specification on turnkey basis.

8.3 Contractor shall obtain approval for scheme for complete cooling water
system to test 800/1000 MW TG.

8.4 Supplier shall obtain final approval for each item before issue of
Purchase order/awarding of works contract by them.

8.5 Any material/or component not foreseen till the stage (completion &
approval of Technical Specifications by BHEL for Cooling Water System
800/1000 MW TG), but which are necessary for the implementation,
satisfactory & trouble free operation of the system and its accessories
shall be responsibility of the Contractor to fulfill them as per Project
schedule without any extra cost.

8.6 Contractor shall train Testing staff at site during commissioning of the
Project. Contractor shall arrange training of testing staff at Contractor
works for operation & maintenance aspects of water pump, cooling tower
and accessories.

8.7 Contractor shall carry out inspection of all bought out items at
manufacturers’ works as well as on receipt at HEEP, HARIDWAR.

8.8 Contractor shall quote for comprehensive Annual Maintenance Contract

(AMC) for complete Auxiliary Cooling Water System for three years.

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