4.00.00 MEASURING INSTRUMENTS (PRIMARY AND SECONDARY)

4.00.00  MEASURING INSTRUMENTS (PRIMARY AND SECONDARY)

 

4.00.01  Measuring instruments/equipment and sub-systems  offered

 

         by   the  bidder  shall  be  from  reputed   experienced

 

         manufacturers of specified type and range of  equipment,

 

         whose  guaranteed  and trouble free operation  has  been

 

         proven in not less than two coal fired power station  of

 

         similar  capacity  for a period of  at least  two  years. 

 

         Further all instruments shall be  of proven reliability,

 

         accuracy,   repeatability   requiring   a   minimum   of

 

         maintenance.   They  shall comply  with  the  acceptable

 

         international standards and shall be subject to MPPGCL’s

 

         approval.    

 

         All instrumentation equipment and accessories under this

 

         specification  shall  be   furnished  as  per  technical

 

         specifications,  ranges makes/ Nos. as approved  by  the

 

         MPPGCL during detailed Engg.

 

4.00.02  Every  panel mounted instrument requiring  power  supply

 

         shall  be  provided with a pair  of  easily  replaceable

 

         glass   cartridge  fuses  of  suitable  rating.    Every

 

         instrument shall be  provided with a grounding  terminal

 

         and shall be  suitably connected to the panel  grounding

 

         bus.

 

4.00.03  (a)  All local gauges as well as  transmitters,  sensors

 

         and  switches for parameters like pressure temp.,  level

 

         flow  etc.  as  required  for  the  safe  and  efficient

 

         operation  and  maintenance  as well  as   provision  of

 

         operator   and  management  information  including   all

 

         computation   of   equipment   under   the    scope   of

 

         specification  shall be  provided.  The  necessary  root

 

         valves,  impulse  piping,  drain  cocks,   gauge-zeroing

 

         cocks,  valve  manifolds and all the  other  accessories

 

         required   for   mounting/  erection  of   these   local

 

         instruments   shall   be    furnished   even   if    not 

 

         specifically  asked  for.   The  contacts  of  equipment

 

         mounted instruments, sensors switches etc. for  external

 

         connection  including spare contacts shall be wired  out

 

         in  flexible/ rigid conduits, independently to  suitably

 

         located  common  junction  boxes.   The  proposal  shall

 

         include   the  necessary  cables,   flexible   conduits,

 

         junction  boxes and accessories for the  above  purpose. 

 

         Double  root valves shall be provided for  all  pressure

 

         tapings where the pressure exceeds 40 Kg/Sq.Cm.

 

     (b) All  field mounted primary instrument shall be IP-65  or

         better.

 

     (c) All primary instruments used for measurement of Hydrogen

 

         shall be intrinsically safe and explosion proof as  NEC,

 

         Article 500, Class-I, Division-I.

 

     (d) All primary instrument used for measurement of HFO,  LDO

 

         and Turbine Lub oil System shall be flame proof(IEC-79.1

 

         Part-I).

 

     (e) All  primary  instrument installed at ” Minus  level  or

 

         floor” shall be protection level IP-68.

 

     (f) All Thermocouple/ RTD shall be duplex.

 

     (g) Following instrument cable termination shall be plug  in

 

         connection type.

 

         i) Valve, Dampers/Drive(Internal  Junction Box)

         ii)Transmitter, E/P converter process actuated switches.

         iii)RTD, Thermocouple

 

     (h) All   field   instrument  used  in  acid   or   alkaline

 

         atmosphere,  shall  be  with  standard  Anti   corrosion

 

         coating i.e. the combination of polyurethane and   epoxy

 

         resin baked coating(ANSI/ ISA-71.04).

 

     (i) Where  the process fluids are corrosive, viscous,  solid

 

         bearing or slurry type diaphragm seal shall be  provided

 

         for   transmitters,   Local  gauges,  process   actuated

 

         switches. Points below the diaphragm shall be  removable

 

         for  cleaning.  The entire volume  above  the  diaphragm

 

         shall be completely filled with an inner liquid suitable

 

         for application.

 

4.00.04       HART Management System

 

         Centralized  configuration, maintenance,  diagnostics  &

 

         record keeping facility for Electronic Transmitters.

 

         The  bidder shall provide a dedicated and standalone  PC

 

         based  system  with suitable software for  each  of  the

 

         generating   units   for   centralized    configuration,

 

         maintenance,  diagnostics  &  record  keeping  for   all

 

         electronic transmitters.  

 

         For this system, suitable HART interface modules,  power

 

         supply modules etc.shall be provided suitably mounted in

 

         cabinets for heating up to a dedicated 21” TFT PC & Laser 

 

         Printer (B/W, Size A 4) to be provided by the Bidder.

 

         The processor, power supply, communication port shall be 

 

         redundant. The configuration of PC shall be fault tolerant     

 

         and time synchronized from master clock.

 

         Each   of  the  transmitters  shall  be  terminated   in

 

         marshalling cabinets through maxi terminal connections on

 

         special  twin  terminal  blocks to be  provided  by  the

 

         bidder.   The  transmitter  signals  from  each  of  the

 

         transmitters  shall  be  wired in  parallel  to  Control

 

         System  and  to  HART interface  modules.   The  control

 

         system  will necessarily use 4-20 mA analog signals  and

 

         superimposed  digital  signal  shall  be  used  in  HART

 

         interface modules.

 

         The multiplexed signal from HART interface modules shall

 

         be   hooked  up to  a  PC   station  through   associated

 

         communication    modules,    converters    etc.      The

 

         communication  module shall provide data on RS-485  link

 

         at  a  minimum speed of 19.2 K baud.   If  the  bidder’s

 

         standard    HART   interface   module    has    integral

 

         communication  module to provide RS-485 link,  the  same

 

         shall  also  be  acceptable.   In  all  HART   interface

 

         modules,  provision  for connecting  at least  20%  extra

 

         transmitters shall be kept.

 

         A  RS-485  to  RS-232 Converter shall  be  provided  for

 

         interfacing HART data of transmitters to a P C  station.

 

         This  converter shall also provide proper  isolation  to

 

         ensure data integrity.

 

         Any  failure/ short/ open circuit and/or removal of  any

 

         of  the  cards/  devices/  cables  in  this  centralized

 

         configuration,   maintenance  diagnostics   and   record

 

         keeping  system,  including  failure  removal  of   HART

 

         interface modules, communication modules, converter etc.

 

         shall in no way affect the 4-20 mA analog signals  being

 

         used in control systems.

 

         Suitable  redundant 24 V DC power  supply  packs/modules

 

         and  redundant  feeders shall be provided  to  feed  all

 

         modules/  devices.   These power supply  packs/  modules

 

         shall  be  fed from redundant feeders  of  Bidder’s  UPS

 

         system.

 

         All  modules/ cards/ power supplies shall be mounted  in

 

         cabinets to be located in control equipment room.   The

 

         PC  and printer shall be located in  programmer’s  room. 

 

         Communication  protocol  converter  shall  be   suitably

 

 

         mounted  in  proper  enclosure  either  at  CER  or   in

 

         programmer’s room.

 

         All cables/ links for connecting system described  above

 

         shall  be  provided by the bidder on as  required  basis

 

         within quoted price.   

 

         The bidder shall also provide following facilities  shall

 

         be  available as a minimum through software.

 

     (a) Constant  scanning  to  monitor  faults  of  changes  to

 

         instrument configuration.

 

     (b) MPPGCL    defined   and   standard    calibration    and

 

         configuration procedures for all transmitters.

 

     (c) Constant  signal data collection facilities to  maintain

 

         continuously updated records in accordance with ISO 9000

 

         quality standards.

 

     (d) Automatic tracking of configuration changes made in  the

 

         field,   such   as  may  be  introduced   by   hand-held

 

         communicator.   All  configuration  function  associated

 

         with  hand-held communicators shall be available in  the

         system.

 

     (e) Event and log reports on screen as well as on printer.

 

     (f) Any  addition/ deletion of transmitter will be  reported

 

         on printer and logged in hard disk.

 

4.01.00  Specification for  Electronic Transmitters for Pressure,

         DP, Flow, Level

 

      i) Type of Transmitter – Microprocessor based 2 wire  type,

                               HART protocol compatible.

     

     ii) Accuracy            - +/- 0.1 % of span

    iii) Output Signal Range – 4-20 mA DC(Analog)superimposed

                               digital on HART protocol

     iv) Turn Down Ratio     - 100:1

      v) Stability           - +/-0.1% of calibrated span for six

                               months up to 70 Kg/Sq.Cm  and

                               +/-  0.25% for range more than  70

                               Kg/Sq.Cm(g).

     vi) Zero and span drift – +/- 0.015% per Deg.C at max.  span

                               and 0.11% per Deg.C at min. span

 

    vii) Load Impedance      - 500 ohm (Min)

 

   viii) Housing             - Weather  proof as per  IP-65  with

                               durable corrosion resistant coating

 

     ix) Over Pressure       - 150 % of Max. operating pressure

      x) Connection(Electrical- Plug and socket type

     xi) Process Connection  - 1/2 inch NPT (F)

 

    xii) Span and Zero       - Continuous, tamper proof,  Remote

         Adjustability         as well as manual from  instrument

                               with     zero   suppression    and

                               elevation facility.

 

   xiii) Accessories        i) Diaphragm seal, pulsation dampeners

                               syphon etc. as required by service

                               and operating condition.

       

                           ii) 2/3/5 Valve manifold as applicable

 

    xiv) Diagnostics         - Self Indicating Feature

     xv) Power Supply        - 24 V DC +/- 10%

    xvi) Adjustment/         - Centralized PC based system as per

         Calibration           Clause 4.00.04. In addition total

         Maintenance           ten(10) Nos. of    hand     hold

                               calibrators for two units shall be

                               provided.

  

   Note:- (1)Displacer type or guided Radar type Level Transmitter 

             shall be provided for level measurement of condenser

             hotwell level, LP  Heater I,II,III and Vacuum services. 

         (2) Guided wave Radar Transmitter shall be  provided for

             Level measurement of  Turbine oil tank.

         (3) LVDT Type transmitter is not acceptable.

         (4) Where the process fluids are corrosive, viscous, solid

             bearing or slurry type, diaphragm seals shall be provided.

             Parts below the diaphragm shall be removable for cleaning.

             The entire volume above the  diaphragm shall be completely

             Filled with an inert liquid suitable for the application.

 

4.02.00  Temp. Sensing Elements & CJC Boxes

 

(A) a) i) Type of Thermocouple -16  AWG  wire  of  chromel-Alumel

                               (Type K)or 24 AWG wire  Pt-Rhodium

                               Pt   (Type  R),  ungrounded   type

                               depending   on   operating   temp.

                               range.

     ii) Type of RTD         - 4 wire- Pt RTD 100 ohm(as per DIN-

                               43760)

 

   b)    No.of Element       - Duplex

 

   c) Housing/ Head       - IP-65/Diecast Alu.(Where applicable)

   d) i) Sheathing  of       - Swaged  type  magnesium  oxide

         Thermocouple          insulation 

     ii) Sheathing  of       - Metal sheathed, ceramic backed

         R T D

   e)    Calibration and     - As per IEC-751/ANSI-C-96,1

         accuracy              +/-0.5% of range for R T D

 

   f)    Characteristic      - Linear with  respect  to  temp.

                               within +/- 1/2 % of top range value 

   g)    Accessories         - Thermowell   of 316  SS  tapered,

                               solid bore, Temp.stub, compensating

                               cable upto CJC box.

                               plug in connectors.(Ref.Note)        

 

         Note:-   For  Fans/AH/Mill Bearing  Temp.&  Metal  Temp.

         measurement  the screwed termination can be accepted  if

         plug  in  connection are not standard  practice  of  the

         bidder.

 

   h)    Standard            - ANSI C 96.1 for Thermocouple and

                               ASME PTC- 19.3 for thermowell

 

   i)    CJC Box Ref.Temp.   - 60 Deg.C +/-0.5 Deg.C for type K

                               Thermocouple

                               60 Deg.C +/-2 Deg.C for type R

                               Thermocouple

   j)    Effect of ambient   - +/- 0.1% per 10 Deg.C

         Temp.variation for

         CJC boxes

   k)    Material of C J C   - 2 mm thick sheet steel

         boxes

   l)    Protection Class of – IP-65 

         CJC boxes

   m)    Cable entry         - Bottom with gland plates suitable

                               for cables used

   n)    Temp.Control of CJC – Automatic with remote Temp.

         boxes                 Monitoring

o)              CJC Box power supply – 240 V AC 50 Hz

 

   p)    Thermowell            General

 

                            i) One piece 316 SS, tapered, drilled

                               from bar stock (As per  ASME  PTC

                               19.3-1974).

 

                           ii) For  Mill classifier outlet  long

                               life solidsintered tungsten carbide

                               material    of    high    abrasion

                               resistance.

 

                          iii) For   Air  &  Flue  gas   316   SS

                               protecting tube with welded cap.

 

                           iv) For   furnace   zone,   impervious

                               ceramic protecting tube  along with

                               incoloy   supporting   tubes   and

                               adjustable flanges.

 

         Bidder shall provide calculation for thermowell

         As per ASME- PTC-19.3.

   

(B)      For  detection of leakage of various drain  valve  drain

 

         pipe and Turbine  metal temp. thermocouples shall be

 

         provided as per the following specification to meet ASME-

 

         TDP-1 Standard.

 

         1. Measuring Medium              - Metal Temperature

         2. Metal of Thermocouple Element – Chromel Alumel Type K

         3. Tyoe of Thermocouple          - Duplex with separate

                                            hot junctions,

                                            ungrounded type.

         4. Insulation                    - Mineral Insulation

                                            Magnesium Oxide

         5. Thermocouple wire gauges      - 16 AWG

         6. Protective sheath             - SS 321

         7. Protective sheath dia         - 8 mm O.D.

         8. Characteristics of Thermocouple- Special  limits  of

                                            error  as in ANSI  MC

                                            96.01.1975

         9. Mounting Accessories          - 1/2″  BSP SS  sliding

                                            end  connector,  weld

                                            pad,  weld on  clamps

                                            of   heat   resistant

                                            steel SS 310.

        10. Cold  end sealing             - SS   pot  seal   with

                                            colour   coded   PTFE

                                            headed sleeve insulated   

                                            flexible tails. Sealing

                                            Compound- Epoxy resin.

        11. Minimum bending radius        - 30 mm

        12. Length of T/C                 - 30 Mtr.(Min)as per

  requirement

                                       

4.03.00  Flue Gas Analyser

 

         Bidder shall supply flue gas analyser instruments   with

 

         following common requirements :-

 

      a) Output signals analog       - 4-20 mA DC

         Binary                      - 2NO + 2NC for high alarm

 

      b) Zero & span adjustment      - Available

      c) Ambient Temp.               - 60 Deg.C

      d) Indication                  - Digital

      e) Enclosure Type/Material     - Weather & Dust proof

                                       IP 65Die cast Alu./SS

      f) Type of Electronics         - Microprocessor Based

      g) Digital Signal transmission – RS 232

         protocol

      h) Calibration                 - Auto & Manual(from Remote)

      i) Error Diagnostic            - To be provided

      j) Others                      - It analyzer provides super-

                                       imposed HART signal on 

                                       4-20 mA DC output, it

                                       shall also be connected to

                                       PC based station specified

                                       under Clause 4.00.04.                     

 

4.03.01  SO2 Analyzer/Monitor shall be sampling type and based on

 

         principle of measurement radiation absorption (UV) type.

 

     a)  Accuracy        - +/- 1% of F.S.

     b)  Linearity       - +/- 1% of F.S.

     c)  Response time   - 10 Sec for 90% of FS

     d)  Drift           - +/- 1% / 10 Deg.C

     e)  Sensor Type     - Luminescence/ IR

     f)  Operating Range – 0-300 Deg.C

     g)  Filter          - Sintered Bronze

                           5 Micron

     h)  Sampling System – With dual sampling through heavy  duty

                           pumps,    solenoids,   filters    etc.

                           along with  coolers and flow meter  and

                           level  switch in gas coolers for  auto

                           draining purpose.

     i) Accessories      - Yes

        Purging System

     j) Compensation for – Yes to be provided

        Temp. moisture for

        oxygen including

        cables up to JB

     k) Automatic zero   - Yes

        and span adjustment

 

4.03.02  NOX Analyzer/Monitor shall be sampling type and based on

 

         principle of measurement  radiation (UV/ IR) type.

 

     a)  Accuracy        - +/- 1% of F.S.

     b)  Linearity       - +/- 1% of F.S.

     c)  Response time   - 10 Sec 90% of FS

     d)  Drift           - +/- 1% / 10 Deg.C

     e)  Sensor Type     - Luminescence/ IR/UV

     f)  Operating Range – 0-300 Deg.C

     g)  Filter          - Sintered Bronze

                           5 Micron

     h)  Sampling System – With dual sampling through heavy  duty

                           pumps,    solenoids,   filters    etc.

                           along with  coolers and flow meter  and

                           level  switch in gas coolers for  auto

                           draining purpose.

     i) Accessories      - Yes

        Purging System

     j) Compensation for – Yes to be provided

        Temp. moisture for

        oxygen including

        cables up to JB

     k) Automatic zero   - Yes

        and span adjustment

 

4.03.03 Oxygen  Analyzer/Monitor shall be non heated INSITU  dry

 

        type  and  based  on principle  partial  pressure  using

 

        Zirconium oxide cell.

 

     a)  Accuracy        - +/- 0.5% of F.S.

     b)  Linearity       - +/- 1% of F.S.

     c)  Response time   - 10 Sec for 90% FS

     d)  Drift           - +/- 0.005%, 2 Deg.C

     e)  Sensor Type     - High Temp.zirconium

                           oxide cell

     f)  Operating Range – 0-700 DEG C

     g)  Filter          - Sintered Bronze

                           5 Micron

     h) Accessories      - Yes

        Purging System

     i) Compensation for – Yes to be provided

        Temp. moisture for

        oxygen including

        cables up to JB

     j) Automatic zero   - Yes

        and span adjustment

     k) Filter Protection – Abrasive Shield

        and Probe

 

4.03.04       CO Analyser/Monitor shall be INSITU  type , based  on    

        principle  of  measurement IR absorption type.

 

     a)  Accuracy        - +/- 2% of F.S.

     b)  Linearity       - +/- 1% of F.S.

     c)  Response time   - 5 Sec for 90% of FS

     d)  Drift           - +/- 1% / 10 Deg.C

     e)  Sensor Type     - IR

     f)  Operating Range – 0-300 Deg.C

     g)  Filter          - Sintered Bronze

                           5 Micron

     h)  Sampling System – as per requirement

     i) Accessories      - Yes

        Purging System

     j) Compensation for – Yes to be provided

        Temp. moisture for

        oxygen including

        cables up to JB

     k) Automatic zero   - Yes

        and span adjustment

 

4.03.05  Dust  density  Monitoring system shall  be  INSITU  type 

 

         visible light type (through LED) and based on  principle

 

         of measurement transmission and absorption type.

 

     a)  Accuracy        - +/- 2% of F.S.

     b)  Linearity       - +/- 1% of F.S.

     c)  Response time   - 5 Sec. or less

     d)  Drift           - +/- 1% in 24 Hrs.

     e)  Sensor Type     - Luminescence

     f)  Operating Range – 0-300 Deg.C

     g)  Filter          - Sintered Bronze

                           5 Micron

     h) Accessories      - Yes

        Purging System

     i) Compensation for – Yes to be provided

        Temp. moisture for

        oxygen including

        cables up to JB

     j) Automatic zero   - Yes

        and span adjustment

     k) Shutter solenoid for isolating lens during unit trip and

        purge air failure automatically to be provided.

 

4.03.06  Following   flue  gas  Analyzer  measurement  shall   be 

 

         provided by bidder :-

 

 

 

      i) Opacity Meter  (Total 5 Nos.)

 

         a) On Chimney         - 1 No.

         b) FG at ESP outlets  - 4 Nos.

 

     ii)  CO Analyzer   (Total 3 Nos.)

      

         a) On Chimney         - 1 No.

         b) FG after ID Fan Discharge – 2 Nos.

          

    iii) SOX/ NOX/CO2 Analyzer

 

         a) On Chimney         - 1 No.

 

    iv)  Oxygen Analyzer

 

         a) Oxygen in FG at ECO – 2 Nos.

.

         b) Oxygen in FG after APH     - 2 Nos.

        

     v)  Oxygen Analyzer (HT Type)Total- 2 Nos.

 

         a) Oxygen in FG after Platen SH (L) – 1 No.

         b) Oxygen in FG after Platen SH (R) – 1 No.

 

     vi) Velocity of Flue Gas at Chimney     - 1 No.

 

4.03.07 a)Bidder shall provide calibration gas in cylinder for one

 

          year for flue gas analyzers.

 

        b)Any other Analyzer recommended by Boiler manufacture or

 

          pollution board.

 

4.04.00  Vibration Monitoring System

 

         Microprocessor  based vibration monitoring system  shall

 

         be  provided for ID, FD, PA Fans, CEP’s, BFPs,  CW  pumps

 

         and  all other pumps/ motors operating on 6.6 KV.

 

         The  No. of  bearing locations to be  monitored  on  each

 

         fan/pump  shall be as per requirement  finalised  during

 

         detail engineering but not less than 2 bearing locations

 

         for  each fan/pump(except for vertical pumps  for  which

 

         one  bearing  location  may  be  sufficient).  Vibration

 

         measurement  shall  be  carried out  in  2  points,  the

 

         horizontal  and  vertical planes for  each  location  of

 

         measurement.   The  system shall be  designed   in

 

         accordance to recommendation of API-670(Latest Edition).

 

         The Vibration Monitoring System shall be furnished on  a

 

         system  basis including vibration transducers  with  low

 

         noise flexible cables in flexible conduit, terminated in

 

         local    terminal   boxes,   necessary    pre-amplifier/

 

         electronics  mounted in local weatherproof boxes(IP-65)

 

         vibration  monitors  &  mounting  racks/cabinets.    The

 

         Vibration-monitoring  system shall  include  all  power

 

         supplies,    inter-connecting    cabling,    calibration

 

         equipment,   indicators,   integrating   units,   signal

 

         conditioning devices and all other accessories  required

 

         for monitoring of Vibration at each point.

 

         Bidder shall offer 2 channel vibration monitors for each

 

         measurement location catering for horizontal and vertical

 

         measurements.   Offered  vibration  monitors  shall   be

 

         modular  in construction, plug in type and suitable  for

 

         19″ rack mounting.

 

         Eddy current type proximity transducers shall be   used. 

 

         However,  the  finally selected sensor type  shall  also

 

         depend on recommendation of the equipment manufacturer &

 

         suitable for application requirement.  Transducers shall

 

         be furnished in weatherproof housing suitable for  field

 

         conditions.

 

         Vibration  monitoring system shall give buffered  output

 

         of  4-20  mA DC for each point  monitored.   The  signal

 

         shall be suitable for use as an input to DDCMIS as  well

 

         as for analog recording & analysis, linear in proportion

 

         to  vibration velocity as well as  displacement.  Monitor

 

         shall   provide  vibration  indication   calibrated   in

 

         velocity  units  along with  provisions  of  changing  to

 

         displacement    unit   (field   programmable)for    each

 

         measurement point in both horizontal & vertical planes.

         The vibration monitor racks with power supplies shall be

 

         mounted in unit control panel.  However, for CW Pump the

 

         rack cabinet shall be located in CW pump house on the CW

 

         pump  local  control  panel.  The No.of  racks  &  power

 

         supplies shall be such that on failure of a single power

 

         supply/  module,  not more than four monitors  shall  be

 

         affected.

 

         The  functional  requirement  for  vibration  monitoring

 

         system   shall  include  but  not  be  limited  to   the

 

         following:-

 

     (a) Vibration monitor front face status indications shall be

 

         available fr indications of healthy conditions of  pick-

 

         up circuit, monitor circuit and power supply.  Also  set

 

         point  indication with set point adjustment facility  for

 

         setting alarm & trip levels shall be provided.

 

     (b) The  facility shall be available from front of  mounting

 

         rack for functional checking of monitors with inhibition

 

         of alarm of alarm and trip contact outputs during test.

 

     (c) All    vibration   monitoring   equipment    shall    be 

 

         functionally  tested for circuit continuity  and  output

 

         response. All the  components & inter-connection  cables

 

         shall   be   tested  to  ensure  compliance   with   the

 

         specification requirements & all other applicable  codes

 

         and standards.

 

         In  case it is the proven standard practice  to  monitor

 

         the vibration parameters from control/ monitoring  CRTs

 

         instead   of   dedicated  monitors   with   the   signal 

 

         conditioning  equipment  in control equipment  room  the

 

         same  shall also be acceptable.  However,  all  relevant

 

         functional requirements detailed above shall be met  and

 

         the system shall be subject to MPPGCL approval.

 

(d)       The Temp.range of sensor shall be 0 to 121 Deg.C.

 

    (e)  The  system  shall  be designed  in  accordance  to  the

         recommendation of API-670.

  

4.05.00  Specification for Flow Elements

 

S. No.	Features	Essential / Minimum Requirements      Orifice                    Flow  Nozzle
1         2   3           4   5     6       7         8     9     10     11     12     13	Type         Material   Thickness         Beta Ratio   Tappings     Assembly Drg.& flow Vs DP curve   Beta Ratio Calculation to be submi- tted   Material of Branch pipe   Accessories     Root valve Type   Root valve Material   Root valve Size   Impulse pipe    of same       material  upto root valve	Concentric as per ASME PTC-19.5(Part-II),ISA RP-3.2, 1060 or BS-1042           316 SS   3mm for main pipe diameter up to 300 mm and 6 mm for main pipe dia above 300 mm          0.34 to 0.7   Flanged weld neck 3 Nos.of     316 tappings           YES               YES           Same as main pipe     Root valves,flanges,vent/ Drain hole (As required)         Globe           316 SS           Half inch                Required	Long radius, welded type  as per ASME PTC-19.5 (Part-III)or BS-1042         316 SS   Suitable for intended application          Around  0.7       D and D/2 (3 Nos. of  Tappings)           YES               YES          Same as main pipe     Root valves, vent and Drain hole        Globe               316 SS         Half inch           Required

 

   (a)  IMPACT HEAD TYPE FLOW ELEMENT

 

 

          The  impact head  type element (annubar) shall be tubular  insert type with four impact ports facing upstream direction, located precisely for determination of average flow velocity and shall be  of 316  SS.

 

           Accuracy shall be +/- 1.0 % of actual value or better.  Repeatability shall be  +/- 0.01 % of actual value or  better.

 

          The elements shall be  supplied  complete with mounting hardware, end support plugs and CS valve manifold (1/2” NPT connection) for instrument connections.  All pertinent data including MPPGCL’s instrument Tag No. for the flow element shall be punched on a stainless steel plate and affixed to the element.

 

          Bidder shall submitted certified flow calculation and  differential pressure Vs. flow curves for each element for MPPGCL’s approval.  Sizing calculation, precise flow calculation for all the  flow elements, fabrication and assembly drawings and installation drawings shall be  submitted for MPPGCL’s approval.

 

          On line retracting facility and flushing arrangement shall be  provided.

          

          Anubar Type flow element  shall be  used for measurement  

          of C W flow.

 

          Bidder shall submit all sizing calculations, precise flow calculations, fabrication and assembly drawings, installation drawings for all the flow elements for MPPGCL’s review and approval.

 

          

 

 

 

 

 

 

 

(b)   Coriolis Type Mass Flow Meter

 

 

   (i) Accuracy      -  0.2% of F S

 

   (ii)Repeatability -  0.1%

 

  (iii)Output        -  4-20 mA

 

  (iv) Protection    -  IP-65

      

   (v) Hazardous Area-  Flame proof

 

       Classification  

 

 

   Bidder shall provide Coriolis type Mass Flow Meter for flow measurement of HFO (Main & Return) and LDO.

 

(c)Bidder shall submit all sizing calculation, precise flow calculation fabrication and assembly drawing, installation  drawing  for all the  flow elements for MPPGCL’s review  and approval.

 

(d)Bidder shall provide three Tappings per flow elements.  Bidder shall provide three Flow Transmitters for M S Flow and Feed water flow, for all other services, bidder shall provide two flow transmitters. 

 

(e) Testing  Flow  Element

 

     (i)  Factory Acceptance Test

 

·        Tag No./ Type

·        Dimension, surface finish

·        Hydraulic test as per IBR

 

     (ii) Type Test Report (Document Review)

 

·        IBR Certificate

 

·        Sizing Calculation

 

·        Material Test certificates

 

·        Wet calibration shall be carried out as per type test 

on each size and design of  flow element as per ASME

PTC or BS 1042.

 

 

 

 

 

4.06.00  Specification for Pr.Gauge, D P Gauge, Temp.Gauge  and

         Level Gauge

 

         Temp./Pressure/ Level Gauges shall be provided for local

 

         supervision wherever required.

 

S. No.	Features	Essential   / Minimum Requirements  Pr.Gauge / D P Gauge          Temp. Gauge
1           2     3     4     5   6     7     8     9     10   11         12           13       14	Sensing Element & material       Body Material   Dial Size    End Connection    Accuracy   Scale     Range Selection   Over Range test   Housing     Zero/span   Identification         Accessories           Material of Bourdon Movement   Standard	Bourdon for high Pr., Diaphragm /bellow for low Pr. of 316 SS        Die-cast Aluminium       150 mm     Half inch NPT(F)       +/- 1% of span   Linear, 270 Deg. Arc Graduated in metric units   Cover 125 % of Max. of scale          YES      Weather and dust proof     As  Per  IP-65       Adjustment   Engraved with service legend or engraved phenolic laminated tag Plate   BBlow out disc, syphon, snubber, pulsation dampener, chemical seal (if required by process) gauge isolation valve      316 SS / 304 SS          ASME B 40.1	Mercury in steel below 450 Deg.C and insert gas Actuated for above 450 Deg.C of SS bulb  and Capillary    Die-cast Aluminum       150 mm     3/4″  NPT (F)       +/- 1% of span   Linear, 270 Deg. Arc Graduated in Deg.C   Cover 125 % of Max. of scale           YES      Weather and dust proof as  Per  IP-65      Provided   Engraved with service legend or laminated phenolic  nameplate        SS Thermowell            316 SS / 304 SS

 

 

 

    LEVEL GAUGES

 

(a)     The tempered toughened borosilicate gauge glass steel armoured reflex / transparent or float type arrow type level gauges  shall  be equipped  with  gauge  valves including a  safety  ball check. Length of gauge glass shall not be  more than 1400 mm.  If the  vessel is higher, multiple gauge glasses with 50 mm over lapping shall be provided.

(b)Bidder shall  provide roller type  Bi- colour level  gauges for 

   drum.

 

(c)Bidder shall provide magnetic level gauges for Hotwell,

   flash tank, LP & HP Heaters, Deaerator, Turbine oil tanks,  

       Cond surge tank ,gland cooler .

 

4.07.00  Process Actuated Switches

 

S. No.	Features            Essential / Minimum Requirements            Pr.Switch DP  Temp.Switch   Level Switch    Limit Switch
1               2	Sensing Element             Material	Piston Actuated for High Pr.and Diaphragm or Bellows for Low Pr.vacuum    316 SS	Vapour Pr. Sensing, Liquid  filled bellow type with bulb and capillary      316 SS/304 SS	Float  type orAs per note              316 SS	Micro- Switch           Silver Plated     high Conductivity non-corrosive
3       4     5     6       7           8       9     10       11               12	Repeata-bility     End Connection   Over Range Proof Pr.   No. of Contacts     Rating of Contacts (Hermati-  cally  sealed)   Enclosure       Elect. Connection   Set Point/ Dead     Accessories               Mounting	+/- 0.5% for full range   Half inch NPT(F)   150% of Max. design Pr.   2NO+2NC,SPDT snapaction dry contact   5A,240 V AC or 0.25 A, 220 V DC       Weather and dust proof as per IP-65    Plug in socket    Provided       Syphon,  Snubber, Chemical Seal pulsation Dampener, as required by process)   Suitable for Enclosure/ Rack mounting	+/- 0.5% for full range     Half inch NPT(F)     –     2NO+2NC,SPDT snapaction dry contact   5A,240 V AC or 0.25 A, 220 V DC       Weather and dust proof as per IP-65   Plug in socket    Provided       Thermowell of 316 SS & packing glands         Suitable for Rack mounting vertically	+/- 0.5% for full range     Manufacturer Standard   150% of Max. design Pr.   2NO+2NC,SPDT snapaction dry contact   5A,240 V AC or 0.25 A, 220 V DC       Weather and dust proof as per IP-65   Plug in socket    Provided       All mounting Accessories               –	+/- 0.5%            –         –     2NO+2NC,SPDT       5A,240 V AC or 0.25 A, 220 V DC       Weather and dust proof as per IP-65   Plug in socket    Provided        –               Direct factory Mounting on Valves, equip-  ment with pro- vision for adjusting at site

 

Note for Level Switches –

 

(a) Capacitance types for turbine oil and dirty medium,    

    application.

(b) Capacitance/ Conductivity/ Ultrasonic type for acid and  alkali

    application.

(c) Radio-frequency/Ultrasonic type for ash hopper, ash-slurry

    application.

 

4.08.00  Indicators, Recorders

 

     a)  All   remote    receiver   indicators   for    pressure,

 

         Diff.pressure,  level, temp. and flow  indicators  shall

 

         have  accuracy  of  +/- 0.1% to +/- 1%  digit   of  full

 

         scale. All analog indicators shall be 4-20 mA input type

 

         and  all  Digital Indicators shall  be  universal  input

 

         type.

 

     b)  All  Recorders shall be Microprocessor Based  Chartless,

 

   shall be universal  input type. Accuracy shall be +/-0.3%

 

   or better. All recorder shall be with 2 GB flash memory

 

   card.

 

     c)  The  Indicators,  Recorders,  Ammeters  etc.  shall  be

 

         mounted on vertical portion of unit control desk. 

 

4.09.00  INTEGRATORS

 

         Integrators shall have totalizer display of six  digits,

 

         4  mm  high.   Totalizer  mechanism  shall  be  as   per

 

         manufacturer’s  standard.  It shall have an accuracy  of

 

         +/- 0.5% of span.  Input shall be 4-20 mA DC.

 

4.10.00  ELECTRICAL METERING INSTRUMENTS/ TRANSDUCERS

 

         Electrical  metering  instruments  Ammeters,   voltmeter

 

         etc./  transducers  shall  be  provided  by  bidder  for

 

         mounting   on  UCD/  UCP.   Application   standard   for

 

         electrical metering instruments shall be as per IS:1248-

 

         1968  (Revised).  Suitable magnetic shielding and  other

 

         protections etc.(wherever required)for these instruments

 

         shall be provided by the bidder. Ammeter shall be provided on UCD for DDCMIS control. HT/LT drives it will cover all HT drives, critical LT Motors, including DC operated motor.

         The transducers having 4-20 mA dual isolated outputs for current measurement shall be provided and located in respective SWGR/MCC.

4.11.00  Solenoid Valve

All solenoid valve coils shall be class 4 high temperature

Or class `F’ insulation temp rise class B , construction as application and shall be

Designed for continuous duty and endures shall IP-65 or better.

4.12.00  Relays

 

         All the relays shall be  suitable for control supply of 24 V DC. Each relay shall have 4 changeover type hermitically sealed contacts. Rating of contacts shall be  5 Amp. at  220 V AC & 0.2 Amp. at 220 V DC.  All relay contacts shall be  wired up to terminal blocks.

 

4.13.00  Rotameter

 

The Rotameter shall be variable area linear scale  type, with

+/-2% accuracy and magnetic float indication. Flange; orifice

in case bypass Rotameter(for line size above 50 mm).

4.14.00  Electric to Pneumatic (E/P) Converters

 

E/P converters and associated accessories shall be furnished in accordance with the  specifications given below :-

 

         Air Supply : 1.5 Kg/Cm.Sq. Input signal 4-20 mA DC (as required by the design of control system), output signal 0.2 to 1.0 Kg/Cm.Sq, Linearity 0.5% of span or better, Hysteresis 0.1% Of span or better, Ambient Temp. effect less than 0.02% of span per Deg.C between –20 to +60 Deg.C.  Mounting: Close to actuator (but not on the actuator), output capacity to suit the actuator, protection class IP-65.

 

On loss of control signal, the last set point pressure shall be maintained so that the associated control valve remains in stayput position without using any solenoid valve.  The allowable drift rate shall be  +/- 2% of set point/ hour maximum.