Automation_final Send By Mr

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR

BEMBALA RIVER PROJECT Tal. Babhulgaon

Dist. Yavatmal

Construction, Operation and Maintenance of Dehani Lift (Drip) Irrigation Scheme under Bembla River Project.

SPECIFICATIONS SECTION - 1 1.0

CONTROL PHILOSOPHY The concept of this project is to supply irrigation water to 2500 fields for seven types of crops / field in two stages. Initially the irrigation water will be pumped from the Bembla River submergence through eight pumps where four are of 900HP and the balance four are of 300 HP at Stage I pumping station. These two sets of pumps are connected to two different headers which further carry the irrigation water to the main distribution chamber 1(MDC 1). On each header we have a pressure transmitter whose high signal is taken into the logics for tripping of pumps. This MDC 1 has four outlets, out of which three carry water to 34 Sub Distribution chambers (SDC) and the forth carries water to the Stage II pumping station through gravity. Again each SDC’s have 1 number of 80HP / 100 HP pump which pump water to various fields (Appx 16 TO 50 No’s). Here the first stream ends. The second stream starts from the MDC 1 which feeds the irrigation water to the Stage II pumping station. Here again we have eight pumps where four are of 325HP and the balance four are of 150HP. These two sets of pumps are connected to two different headers which further carry the irrigation water to the main distribution chamber II (MDC II). On each header we have a pressure transmitter whose high signal will be taken into the logics for tripping of pumps. This MDC II has three outlets which carry water to three Distribution chambers through gravity. Again each SDC’s have 1 number of VFD driven 80HP /100HP pump which pump water to various fields (Appx 16 TO 50 No’s). Here the second stream ends.

Contractor

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Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR

At each SDC there is a dedicated micro PLC and a communication tower which enables the operator at that particular location to view and control the water at fields under the said SDC and communicate to the main PLC’s which are placed at Stage I & II Pumping stations. 2.0

OPERATION OF PUMPS: The pumps at the stage 1 pumping station run on the philosophy such as to manage the 100% of load which is as follows. Initially the two pumps of 900HP and two pumps of 300HP will be powered ON either from PLC or from LPBS which feed water to MDC 1 as said above. At the MDC 1 we have an ultrasonic level transmitter which measures the water level and the same signal is used in the logics as interlocks and permissives. At the discharge of every pump we have a motor operated ON/OFF valve which will remain close when its respective pump is OFF and the same opens after its respective pump is powered ON. Also there is a pressure switch a pressure gauge at the outlet of every pump. The pressure switch is a low pressure switch which will trip its respective pump after a time delay of 5 sec. The level transmitter mounted on the MDC 1 will enable the PLC to take over the load change over with respect to time. Here as the level varies with respect to time the number of pumps will be powering ON/OFF. From the MDC 1 which has four outlets carrying water out of which 3 outlets carry water to 34 SDC and the balance 1 will carries water to the stage 2 pumping station. Here at every SDC we have 1 number of Verticle Turbine pumps which takes water from its sump, which gets water from MDC 1 through gravity. At the inlet of these sumps we have a motor operated control valve which will control the level of water which is monitored by an ultrasonic level transmitter. Similarly at the discharge of each pump we have a motor operated ON/OFF Valve, a Pressure Switch and a Pressure Gauge. The Valve at the discharge will be closed initially when the pump is OFF and the same will open automatically once the pump goes ON. The Pressure Switch Low is used to trip the pump if the discharge of the pump is low which will be sensed with a time delay of 5 sec. The discharge of these pumps which are VFD driven carry water to the fields where we have a Pressure transmitter on the main header to maintain the header pressure whose signal is fed to the VFD Panel in order to vary the speed of the SDC pump. The tappings are taken from the main header

Contractor

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Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR which takes water into the field through a flow transmitter and motor operated control valve. There is also a pressure gauge provided at every tapping. This similar operation philosophy is applicable for Stage II pumping station but from the MDC II, 23 SDC ‘s will be fed with irrigation water where each SDC will control All field.

3.0

INSTRUMENTATION AND CONTROLS

3.1

SCOPE OF Work The scope of work covers the design, manufacture, inspection and testing at works, packing, transportation from place of manufacture to site, unloading and storing at site, complete erection, field calibration, testing, start-up, commissioning and performance testing at site of the I&C equipment for the Intake well and pump house – stage I consisting of Eight (8) nos. VT Pump sets, Intake well and pump house – stage II consisting of Eight (8) nos. pump sets, discharge valves, Two (2) nos. Main Distribution Chambers (MDC), Fifty Seven (57) nos. of Sub Distribution Chambers (SDC) and other equipment included in the scope of supply of this package. The I&C system for the intake Well Pump House Stage I & II, MDC I & II and SDC 1 to SDC 57 is implemented in set of PLCs which are interconnected to perform as a single lift irrigation system. There are five junction points for the system. They are further described below. The following are the minimum system requirements:

3.2

Intake Well and Pump House Stage - 1 a) Telemetry Transmitter and Receiver ( to cover all the analog and digital signals of intake pumping system, MDC’s and SDC’s status of all the control SWGR etc.,) b) Redundant PLC based control system with two numbers OES and A4 Laser printer c) Local Control panel with annunciator, Power supply, I/O’s, Utility Sockets, Light, Exhaust Fan etc. as applicable housing the PLC mentioned above. d) All instruments as per P& IDs and as required by the system, along with mounting accessories, erection hardware etc., e) Battery and UPS

Contractor

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Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR f) Vibration Monitoring System for all pumps and motors in pump House I & II.

3.3

Main Distribution Chamber -1 Below the MDC 1, the following shall be mounted. a) All instruments as per P & IDs and as required by the system, along with mounting accessories, erection hardware etc. shall be provided.

3.4

Intake Well and Pump House Stage - 2 The following are envisaged at this Pump house: a) Telemetry Transmitter and Receiver ( to cover all the analog and digital signals of intake pumping system, MDC’s and SDC’s status of all the control SWGR etc.,) b) Redundant PLC based control system with one number OES and A4 Laser printer c) Local Control panel with Annunciator, Power supply, I/O’s, Utility Sockets, Light, Exhaust Fan etc. as applicable housing the PLC mentioned above. d) All instruments as per P& IDs and as required by the system, along with mounting accessories, erection hardware etc., e) Battery and UPS f) Vibration Monitoring System for all pumps and motors.

3.5

Main Distribution Chamber -2 Below the MDC 2, the following shall be mounted. a) All instruments as per P & IDs and as required by the system, along with mounting accessories, erection hardware etc. shall be provided.

3.6

Sub Distribution Chambers 1 to 57. a) Telemetry Transmitter and Receiver ( to cover all the analog and digital signals of intake pumping system, MDC’s and SDC’s status of all the control SWGR etc.,) b) Micro PLC based control system with one number OES and A4 ink jet printer. c) Local Control panel with Power supply, I/O’s, Utility Sockets, Light,

Contractor

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Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR Exhaust Fan etc. as applicable housing the PLC mentioned above. d) All instruments as per P& IDs and as required by the system, along with mounting accessories, erection hardware etc.,Battery and UPS 4.0

SCOPE OF WORK

4.1 The following field instruments are to be envisaged 4.1.1 One no. Pressure indicator and Pressure switch at discharge of each pump. 4.1.2 Two numbers Ultrasonic type Level Transmitters for each sump of pump houses . 4.1.3 One number Pressure Transmitter for each Group pump discharge header. 4.1.4 All the field instruments as per the requirement and erection hardware for all the above. 4.1.5 One number of level transmitter in each Main Distribution Chamber. 4.1.6 Instruments for each Pump and Bearing in the two Sump well pump houses follows: 4.1.6.1

Monitoring the signals received from Minimum 1 no. simplex / duplex RTDs for HT motor winding of each pumps.

4.1.6.2

Monitoring the signal received from the Duplex thermocouple for each bearing of pumps and its motors.

4.1.6.3

One number of Flow switch in each Thrust Bearing cooling water line per pump House.

4.1.6.4

Vibration Monitoring system for all the 8 pumps

4.1.7 Instruments for 57 SDC Pump houses follows: 4.1.7.1

One number of Level Transmitter for each SDC sump.

4.1.7.2

One number of pressure gauge, pressure switch, pressure transmitter and flow transmitter at discharge of each pump.

4.1.7.3

Contractor

All the pumps housed in the SDC have to operate with VFD.

N0 of Corrections

Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR 4.1.7.4

All the necessary junction boxes required as per the configuration.

4.2

Erection hardware as required for all I&C equipment in the scope, including junction boxes as required . Marshalling / Termination Cabinet For interface with Purchaser’s SCADA system, Telemetry cabinet in Switchyard control room shall be provided with terminals and interface hardware as required. The number of Inputs/Outputs envisaged for SCADA is as per the P&I Bidder shall terminate all the signals (both analog and binary including the drive related signals) for SCADA interface. For all the equipment included in the package, the complete I&C cabling shall be included in the scope from instrument to junction box, from JB to Marshalling / Termination cabinets / Local panel, from actuator to PMCC / Local panel, from LPB to PMCC, from Actuator to Marshalling/Termination cabinet/Local panel, etc., Instrumentation & Control Cable (0.5 sq. mm, armoured, 600V) between sensor to Junction Boxes and junction boxes to the Marshalling / Termination cabinet of lengths as required. All instrumentation that are necessary for control /monitoring of the pump lubrication / seal system shall be supplied as required. Contractor shall be responsible for engineering and implementation of the controls and monitoring of all the drives supplied. Control desk with CRTs and all other specified hardware Redundant PLC based system with cabinets, processor cards, complete with I/O cards, Conditioning cards, power supply modules and other associated hardware for the Intake Well Pumps Stage I & II, MDC I & II, as specified which shall provide for complete CRT Operation, Control & monitoring of the respective plants and Annunciation system. PLC based system with cabinets, processor cards, complete with I/O cards, Conditioning cards, power supply modules and other associated hardware for SDC 1 to 57 as specified which shall provide for complete CRT Operation, Control & monitoring of the respective plants and Annunciation system PLC based local control panels as specified.

Contractor

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Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR

Power supply distribution including cabinets. UPS power supply distribution Software Timers Control Desk and System Cabinets, Relay Cabinets as applicable. Engineering and implementation of the control & monitoring in Bidders PLC for all the Drives included as part of this package All the drives (Intake Well & Pump Hose Stage I &II , MDC I & II, SDC 1 to 57, discharge valves, etc.,) supplied by Bidder will be operated through the PLC system supplied by Bidder. The Bidder is responsible to do the engineering / implementation for the equipment supplied by him, in the PLC system. Bidder shall do the necessary Engineering /implementation for all his drives. The engineering / implementation of Control and Monitoring for all Bidder’s supplied drives in the PLC shall be by the Bidder. Bidder shall be fully responsible for the successful commissioning of all his Drives. The responsibility of the Bidder shall include the following in minimum: i)

Furnish the following design inputs, as per the Contract schedule requirements during detailed engineering stage, (in both soft and hard copies), as per Purchaser’s Format.

(a)

“Schedule of Instruments with Settings” to be furnished by Bidder in Purchaser’s format, during detailed engineering in soft and hard copies with all information and set points duly filled up. This schedule shall cover all instruments required for lift irrigation system sequence operation, protection and logic including all instruments required for the safe and trouble-free operation of raw water system.

(b)

Termination details of Marshalling / Termination Cabinets of Telemetry system in Switchyard control room.

(c)

Detailed system control write-up.

Contractor

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Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR (d)

Control schemes and logic diagrams including Raw water system protection and controls as deemed necessary for the lift irrigation system to be implemented in Bidder’s PLC shall be furnished by Bidder. All the set points, characteristics curves, graphs, equations, etc., shall be furnished.

(e)

List of alarms shall be furnished along with set points.

(f )

Junction box groupings.

(g)

Drive List

(h)

Detailed P& ID including functional descriptions .

(i )

Bidder shall do the commissioning of the Drives supplied by him and be responsible for successful and timely completion of commissioning of the same.

Design inputs indicated at (b) and (e) for SCADA engineering are required within three months from the LOI date. Bidder is accountable for any delays in SCADA engineering due to non-availability of the engineering inputs. 5.0

SPECIFIC REQUIREMENTS

5.1

Bidder shall terminate all his field signals in the terminal blocks of the Bidder’s Marshalling/Termination cabinet of Telemetry system. The signal grouping / termination shall be subject to Purchaser’s approval.

5.2

Instrument for all shall makes prescribed in the schedule ‘B’ tagging shall as per Purchaser’s tagging philosophy.

5.3

Ultrasonic Level Transmitters with required mounting arrangements, structure, access etc. as required

5.3.1 Training on O&M of Ultrasonic Level Transmitters shall be included. 5.3.2 Commissioning of the Ultrasonic Level Transmitter shall be by Bidder. 5.4

Supply of all construction and erection drawings including detailed layout drawings, instrument Hook up drawings etc., with all details as per Purchaser’s requirement in soft and hard copies is included in Bidder’s scope.

5.5

Bidders terminal Point for signal termination

Bidders terminal point for signal termination is Marshalling / Termination cabinet of Telemetry cabinet in switchyard control room. Contractor N0 of Corrections Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR

5.6

All field instrument enclosures, Local control Boxes shall conform to IP-67 Degree of Protection.

6.0

LOCAL OPERATION

Local Stop push button station shall be provided for all pumps and Local open / close push Buttons shall be provided for all motorized valves. Push Button –Stop signal shall be directly wired to respective PMCCs. For all HT Drives and Critical Drives One number Emergency Stop Push buttons shall be provided. 7.0

PMCC INTERFACE TO PLC PMCCs supplied by Bidder shall accept commands-open / close and provide feedbacks for control & monitoring in PLC. The feedbacks shall also cover all the numerical relay information. Bidder shall confirm to the following minimum requirements: The number of signals to be exchanged shall include individual PMCC commands, feedbacks, voltage and current, relay parameters etc., A detailed configuration drawing indicating looping of PMCC relays and hooking up to PLC shall be furnished in the bid. The Bidder is responsible for ensuring the compatibility of his Telemetry system with Purchaser’s SCADA system.

8.0

VALVES / ACTUATOR / PLC / PMCC INTERFACE For valves, one set of limit and torque switch ‘NC’ contacts and Actuator thermal, overload ‘NC’ contact shall be wired to the PMCC. Bidder shall ensure that the valve limit and torque switch status feed backs shall also be made available in PLC by wiring the second set (“NO” contacts) of limit and Torque switch contacts to the Bidder’s PLC. The actuator motors shall be designed for short time duty (S2) in accordance with IEC 34-1 Hand wheel operation shall be provided in addition to motor drive. The actuator shall be provided with accessories viz., Torque limit switch, end of travel switch, adjustable limit switch, hand wheel motor, thermostat,

Contractor

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Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR integral starter, etc.. Complete actuator shall be tested at factory as per IS 9334. Two normally open and two normally closed or two changeover potential free contacts corresponding to open and close positions of the valve shall be provided. Degree of protection for actuator motor enclosure shall be IP-55 and IP-67 for indoor and outdoor respectively.

1.

Notes:The valve shall be designed considering the larger of the following torque requirements for which calculations shall be submitted: (a) Calculated as per AWWA-C504-80 (b)

Calculated as per the Standard to which valve is designed.

2. Motor operated valve actuator shall be rated to provide an output torque of at least 150% of torque required as per Note-1 above. 3. The actuator shall be capable of operating in any mounting angle. 4. The transmission unit shall be designed to transmit twice the valve design torque. 5. The actuator shall provide an unseating torque of at least 50% in excess of valve seating torque at the specified voltage. 6. Seat leakage tests shall be conducted for duration of not less than 5 minutes at specified design pressure. 7. Hydrostatic test of body and disc shall be conducted separately for a duration of not less than 10 minutes at twice the maximum operating pressure or one and half times the design pressure whichever is higher. 8. The valve flanges shall have mating surfaces machined to tolerances within 10 microns and the back face to within 25 microns. 9. Segmental welded carbon steel flange plates above 20 mm thickness shall be subjected to preheating before welding and stress relieving after welding as per IS 2825. 10. One coat of zinc rich primer and two coats of enamel shall be applied to all steel and cast iron exposed surfaces.

Contractor

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Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR 11. Fabricated steel valves shall meet the following requirements. 11.1 Butt welded joints are of fill penetration welds

9.0

ERECTION, FIELD CALIBRATION, TESTING AND COMMISSIONING Bidder shall envisage erection, testing, field calibration and commissioning of all Instrumentation and Control Equipment supplied under this contract to the complete satisfaction of the Purchaser / Purchaser’s representative.

10.0

INSPECTION Bidder shall conduct functional test at manufacturer’s works and offer for Purchaser’s inspection for the following instruments: Ultrasonic Level Transmitters and Pressure Transmitters. PLC, Battery and Battery Charger , Flow Transmitter, etc.

11.0

JUNCTION BOXES Junction Boxes shall be provided for a) Termination of all field sensors and transmitters located area wise. b) c)

Termination of transmitters mounted on the transmitter racks. Termination of both the contacts of switches and duplex elements of temperature measurement.

d) The arrangement of terminals in the field junction boxes shall match 1:1 with the terminals in the Bidder’s PLC termination cabinet supplied, to avoid any criss-crossing of wires. 12.0

PLC Requirements

Please Refer Page No. 30 make as per detailed Annexure – I of section 6 1.1.3 PART 2 OF 2 13.0

SPECIFICATION FOR INSTRUMENTS The specification as applicable for the field instruments are as follows:

Contractor

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Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR

13.1

Pressure Indicators/Guage Direct reading, pipe mounted pressure gauges of aluminium casing with six (6) inch dial; 316 SS Bourdon tube and nylon movements and an accuracy of +0.5% of span including accessories like snobberies for pump discharge applications and chemical diaphragm for corrosive and oil services. Material of accessories will be SS. IP65 or equivalent degree of protection for enclosure. Over range protection will be 25% above maximum pressure.

13.2

Pressure Switches Non indicating type, field mounted pressure switches of aluminium casing (epoxy coated) and 316 SS element and accuracy of +1% of span, including accessories like snobberies for pump discharge applications and chemical diaphragm for corrosive and oil services. Material of accessories will be SS. Auto reset micro switch with adjustable range with 2 SPDT contacts rated for 0.2 A at 220 V DC. IP 65 or equivalent degree of protection for enclosure. Over range protection 50% above maximum pressure.

. 13.3

Pressure Transmitters Micro-processor based; rack mounted with accuracy of +0.2% of span; field zero and span adjustment; self diagnostics, temperature sensor for compensation. Power supply 24 V DC; output signal of 4-20 mA DC. IP 65 or equivalent degree of protection; aluminum housing with epoxy coating; 316 SS sensing element. Accessories like snubbers for pump discharge applications and chemical diaphragm with 15 m capillary for corrosive and oil services. Material for accessories will be SS.

13.4

Thermometers with contact Indicating type, field mounted, filled system of adequate length of capillary and six (6) inch dial housed in aluminium casing (epoxy coated) with an accuracy of +1% of span; response time of 2-4 seconds; linear calibration over the range and 316 SS thermowell having a process connection of M33 x 2 thread. Material of accessories will be SS. IP 65 or equivalent degree of protection for enclosure. Bar stock assembly type of thermowell.

Contractor

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Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR Adjustable high and very high contacts of rating 5 amps at 240 V AC or 0.2 Amps at 220 V DC shall be provided. 13.5

Thermowells Pipe/equipment mounted temperature test wells of 316 SS with a process connection of M33x2 thread. Material of accessories will be SS. Bar stock assembly type of thermowell.

13.6

Temperature Switch Non-indicating type, field mounted, filled system with adequate length capillary housed in aluminium casing (epoxy coated) with an accuracy of +1% span; linear calibration over the range and 316 SS thermowell having a process connection of M33x2 thread. Micro switch with reset type with adjustable range with 2 SPDT contacts rated for 0.2 A, 220V DC. IP 65 or equivalent degree of protection for enclosure. Bar stock assembly type of thermowell. Material of accessories will be SS.

13.7

Thermocouple Assembly Duplex type with accuracy of +0.5% of span, response time of 2 to 6 sec; Spring loaded; mineral insulated, thermocouple assembly housed in aluminium casing (epoxy coated) having a process connection of M33 x 2 thread with 316 SS thermowell. Material of accessories will be SS. IP 65 or equivalent degree of protection for enclosure. Bar stock assembly type of thermowell..

13.8

Resistance Temperature Detectors (RTD) Duplex type with accuracy of +0.5% of span; response time 1-2 seconds; Spring loaded, mineral insulated, three (3) wire RTD assembly housed in aluminium casing (epoxy coated) having a process connection of M33 x 2 thread with 316 SS thermowell. IP 65 or equivalent degree of protection for enclosure. Material of accessories will be SS.

13.9(a) Ultrasonic Type Level Transmitters Ultrasonic type level transmitters of long range type to cover the entire RAW WATER sump depth (minimum 6 meters), with field temperature compensation, repeatability of 0.10% or better , with a response time better than 150 milliseconds, linearity of 1 % , with LCD indicator , Contractor

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Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR suitable for specified atmospheric conditions, IP-65 protection, stainless steel housing , with an accuracy of +0.5% of span, 4-20 mA DC output (2 wire system), +24 V DC supply, isolated and ungrounded electrical circuits, Auto tuning, connector cable of required length, the material of accessories will be SS. 13.9(b) Flow Transmitters The Flow Transmitter shall be of Ultrasonic type having the following specifications, For all Flow Transmitters, the Local Indication shall be provided. The instruments shall meet the following requirements. Accuracy: Output Signal Range Load Impedance Housing Operating Temp Power supply Accessories 13.10

: +/- 0.5% of calibrated span for Flow : +/- 4-20 Ma : 500 Ohms (Impedance) : Weather proof IP 55 with durable corrosion resistant Coating. : 0 to 60 deg C : As per Contractor Standard practice : Local Indication, Span Adjustment, 6 Digit totaliser

Flow Glasses Online flow glasses for pipe size up to 80 mm with a rotary wheel (not a flapper type) suitable for installation on vertical or horizontal pipe lines having pyrex tempered glass. The material of accessories will be SS.

13.11

Flow Switches Indicating, differential pressure, flapper type, on line flow switches for line sizes up to 80 mm with an accuracy of +2% of span and dial size of min. 50 mm having 316 SS flapper housed in die cast aluminium. Micro switch with adjustable range with 2 SPDT contacts rated for 0.2 A, 220 V DC. IP 65 or equivalent degree of protection for enclosure. The material of accessories will be SS.

13.12

Variable Frequency Drive The VFD shall include the following protective circuits and features: i) ii) iii) iv)

Contractor

Output phase-to-phase short circuit condition. Total ground fault under any operating condition. High input line voltage. Low input line voltage. N0 of Corrections

Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR v) Loss of input or output phase. vi) External fault. (This protective circuit shall permit wiring of remote N.C. safety contact to shut down the drive). User supplied end switches, thermal switches, fire-stats, freeze-stats inputs will be connected to this VFD supplied circuit. vii) Metal oxide varistors for surge suppression shall be provided at the VFD input terminals.

13.13

Pressure - Transmitter Racks Closed type transmitter racks to mount all pressure, differential pressure and flow transmitters with vibration damper (Keldur); air supply lines and header will be provided with bulk head fittings to receive impulse lines; also provided with blow down/drain header. The material of accessories will be SS.

13.14

Junction Boxes Wall/column mounted junction boxes having 32 terminals and cable entry only at the bottom and sealed with fire proof compound; screwed terminal type; material of accessories will be SS. IP 65 or equivalent degree of protection for enclosure. Separate terminal blocks shall be used for analog and digital signal and also for signals with different voltages.

13.15

Marshalling /Termination Cabinets Indoor located, free standing vertical type marshalling cabinets with IP-32 enclosure and with 2 mm thick sheet metal of cold rolled steel; single door with neoprene gaskets; anti vibration pads of 15 mm thick; fluorescent lighting; blower & louver in each cabinet with brass mesh; fire detection for each cabinet; fire proof compound (50 mm thick) for sealing cable entry (bottom, front, rear). The colour of the cabinets shall be indicated at detailed engineering stage. The type of terminal shall be Phoenix / Weid muller / WAGO. The terminal blocks shall be cage clamp type. Fused terminal blocks hinged at one end to facilitate easy isolation shall be provided wherever necessary. All cabinets shall be provided with 20% spare terminals. The type of terminals for terminations from cabinets/panels shall match with the pre fabricated cables and pins supplied. The terminals for field cables shall be arranged in a logical order of equipment/system wise and shall be worked out by Bidder, subject to approval by

Contractor

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Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR Purchaser/ Consultant. Door shall have concealed type hinges and swing of 180 Degree & lockable. The doors shall be provided both on the front and rear. Channels, bolts & nuts shall be zinc plated and passivated. Two coats of premier paint and black colour paint shall be applied. The marshalling / termination cabinets, the terminal blocks, the terminals and the electronic hardware if any, shall have identification numbers. Each cabinet shall be provided with one each 3 pin receptacles for 240 V AC, 1Ph, 50 c/s and receptacles for +24V DC. A system cabinet and associated cabinets shall be supplied on a skid to avoid outside interconnecting cables. Cabinet shall be delivered totally wired. Preparation of interconnection schedule (ICS) between Termination / marshalling cabinets/PLC in Bidder’s scope & JBs in Bidder scope etc. is in Bidder’s scope. The format of Interconnection Cable Schedule (ICS) shall be given to the Bidder during detailed engineering stage. Quantity shall be as required. All cabinets shall have common key for the locks . All the terminals shall have no screws and the cables shall be gripped by spring. All the cabinets shall have universal type of lock and key arrangement. Each terminal shall have LED indication with fuses to indicate and isolate earth faults. 13.16

Wireless Telemetry System The Wireless System should be capable of connecting upto a distance of 30km without any additional repeaters. The System should support various network such as 10 base-T, V.35 , 4 & 12 BRI , E1. The System should also support Voice and Data simultaneously. The wireless system should handle atleast 1 MB data /sec. The complete response time thru the Wireless Telemetry system should not be more than 4 secs. Diagnostics functions related to Packet Loss, Network down should be available. Necessary Lightening and Surge Protection related to the Wireless Tower is in the scope of the Bidder

14.0

Impulse Pipes and Fittings Impulse pipes, tubes, fittings, piping / tubing shall be supplied for all the instruments under the scope of this specification. Impulse piping shall be provided for all instruments and the material of the piping shall

Contractor

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Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR be the same as the parent pipe material. For transmitters, SS 316 tubing shall be used within the transmitter rack for connecting from the manifold upto the transmitter. T joints provided shall be suitable for connecting impulse pipe at one end, and impulse tube at the other end. Length of impulse piping from tapping point to rack shall be limited to 10 metres. Size and thickness of piping/tubing shall be suitable for the design pressure and temperature conditions as per ANSI 16.11. Impulse tubing shall be complete with union connections and end fittings at supply and receiving ends. All fittings with SS tubing shall be stainless steel compression type fittings. Impulse pipe/tube fittings & accessories Nipple shall be provided for root valve size more than ½ inch and the nipple size shall be same as the root valve size. Reducer/adapter shall be provided to suit instrument connection, where nipple, root valve size is more than ½ inch. Bulkhead fitting socket welded type to be provided at instrument rack/enclosure. Fittings All fittings except the last fitting connecting to the instrument shall be socket welded. The size of the fittings shall be same as the impulse line size. The fitting connecting to the instrument shall have a size and thread to suit the instrument connection Drain Drain shall be provided for all water and non-inflammable/noncorrosive fluids only. Drain valve One number globe drain valve shall be provided for process conditions of less than 425oc and 62 bar. The valve size shall be same as impulse piping/tubing size. Drain pot with plug shall be provided in place of drain valves. Funnel with drain header

Contractor

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Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR This shall be provided in the racks for blowing/draining out the process fluid in the impulse tubing. The size of the drain header shall be 1”. When instruments are mounted local to the tapping point and are not mounted in the rack, or panel or enclosure, the drains shall be connected to the nearest floor level or plant drain. After the installation of Instruments, before taking in to service, all impulse lines, shall be blown with adequate line pressure and temperature conditions to keep the lines thoroughly clean to the satisfaction of PURCHASER / Engineer. Blow-out of these lines & commissioning of the Instruments shall be repeated many times till all the lines are taken for continuous operation. Once the Instruments are taken to service, Bidder shall physically inspect the various points & pipes for leakages and take-up repair work to verify the faults. 15.0

Selection of Ranges for Instruments The ranges of the instruments shall be selected based on the philosophy indicated below:

16.0

Contractor

(a)

For pressure measurements, the maximum operating pressure shall be within 70 to 80% of the maximum scale range. The operating range for transmitters shall be 30 - 80% of the specified range of the instrument.

(b)

For temperature measurement, the maximum operating temperature shall be within 80 to 90% of the maximum scale range.

(c)

For pressure switches and temperature switches, the set points shall fall within 40% to 70% of the scale range selected.

(d)

For level measurement, the maximum of the range shall cover the very high point and the minimum of the range shall be stacked with overlap to cover permissive, alarm and trip levels.

Performance Test Points (a)

Pressure, temperature and flow test points shall be provided in line with performance test requirements.

(b)

Pressure test points shall be complete with root valves and shall terminate with a nipple. N0 of Corrections

Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR

(c)

Temperature test points shall be provided with thermowell.

(d)

All instruments required for performance testing to prove the performance of the pump shall be provided by the Bidder for the duration of the performance test. These test instruments shall have test certificates traceable to International standards and shall be valid for the duration of the performance test.

17.0

Tests and Inspection

17.1

After Manufacturing, all instruments shall be tested and calibrated at Factory. Bidder shall be responsible in obtaining test certificates related to calibration of all the Instruments and submit for Purchaser/Consultant’s approval. Bidder shall only allow despatch of these instruments after test certificates are approved by Purchaser/Consultant. The details of the tests to be carried out for the field instruments shall be as indicated in the subsequent sections and any other tests as required by the Standards and Codes.

17.2

Tests to be Performed for Field Instruments 1. 2.

3.

4.

Contractor

Pressure indicators Calibration Hydro tests (1.5 times max. pr.) Pressure switches Calibration test / Hydro test / Contact rating test / Accuracy test / Repeatability Thermometers with contacts Calibration / Material test / Accuracy test / Bore concentricity: + 5% of wall thickness / Hydrostatic test for TW (1.5 times max. pr.), functional test Resistance temperature detector assembly. Calibration / Material test / Bore concentricity test / Insulation test (< 500 MΩ at 500V DC) as per ISA, Hydro test for TW. Bore concentricity: + 5% of wall thickness, Accuracy test.

5.

Thermocouple assembly

6.

Calibration / Material test, Insulation test (> 500 Ω at 500 V, DC) as per ISA, Hydro static tests (1.5 times max. pr.), Bore concentricity: + 5% of wall thickness. Thermowells N0 of Corrections

Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR

7. 8 9. 10.

11.

Thermocouple extension cable Thermo-emf characteristic / Continuity test / Measurement on capacitance, inductance and loop resistance / Insulation resistance / High voltage test as per latest IS / Tensile and elongation test / Oxygen index test / Any other test applicable.

12.

Transmitter Racks Hydro test, air leak test for piping / tubing and fittings. certification as required for tubing / piping and fittings.

13

Contractor

Material test / Bore concentricity : + 5% of wall thickness / Hydrostatic test for TW (1.5 times max. pr.) Flow Switch Material test / Hydrostatic test (1.5 times max. pr.) / function test. Solenoid valves Hydrotest / Seat leakage test / CV test / Coil insulation test Junction Boxes Test for degree of protection / Material test Tests for terminal blocks Test for moulding for flame resistant, Non-hygroscopic and Decarbonised / Insulation test between terminals / Insulation between terminal block and frame.

IBR

Field instruments ( Local Instruments, Local Gauges, Transmitters, Switch Elements, Temperature Elements, Level Instruments, Thermowells) Calibration test, Hydro test (1.5 times max. Pr.), contact rating test for switches, over range test, accuracy test, leak test, Bore concentricity test: +/-5% of wall thickness & material test for temperature instruments, Insulation test (<=500Mohm at 500v, dc) as per ISA for RTD / Thermocouple, seat leakage test & ball check for level gauges, hysterisis test.

N0 of Corrections

Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR 17.3

Instrument & Control cables Power frequency Test Voltage withstanding Test a) Dry –2KV for 1 min b) Wet – 2 kV for 1 min Conductor resistance Test as per IS-1554. High Voltage test as per IS-1554 Humidity Test. For FRLS Cables Flammability test a) IEEE 383 b) IEC 332 (Part – I) – FRLS c) IEC 332 (Part – III) – FRLS d) IEC 331 – FS Swedish Chimney Test SS 4241475 Apart from the above mentioned the following are also applicable for Control cables: a) Temperature rise tests on Power circuits. b) Short time current tests on Power circuits.

17. 4

Local Instrument Panels Verification of Degree of protection, Electrical tests, Type tests & Routine tests as per relevant Indian standards. Note: Bidder to submit all test certificates for Purchaser review & record.

17.5

Marshalling / Termination Rack Verification of Degree of protection, Electrical tests, Type tests & Routine tests as per relevant Indian standards.

18.0 CODES AND STANDARDS All equipment and services covered under this specification shall comply with all currently applicable statutes, regulations and safety codes in the locality where the equipment shall be installed. All codes and standards Contractor

N0 of Corrections

Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR refer to in this specification shall be understood to be the latest version on the date of offer made by Bidder unless otherwise specified. If such standards are not existing for any equipment or system, the same shall comply with the applicable recommendations of the following professional institutes:

18.1

(a)

National Electricity Manufacturers Association (NEMA)

(b)

The Institute of Electrical and Electronic Engineers (IEEE).

(c)

Instrumentation, Systems and Automation society (ISA).

(d)

American National Standards Institute (ANSI).

(e)

Deutsche Industries Norman (DIN).

(f)

International Electrochemical Commission (IEC).

(g)

Verin Deutschar Eisecnhuttenleutte (VDE)

(h)

Indian Standard Institute (ISI).

Standards not indicated in the specification are acceptable subject to approval by the Owner/Engineer if they are established to be equal or superior to the standards indicated in the specification.

18.2 the

The Bidder shall furnish English translation of all standards to which equipment and systems offered conform to.

18.3

The following specific codes and standards are applicable: Instrumentation Symbols and identification Binary logic diagrams for process operation Graphic symbols for inst. Logic and comp. System Environmental conditions Bearing Temperature Monitoring Systems Valves Seat Leakage Thermocouples Measurement & Control, Electrical sensors, Elec. Position sensors & Sig. Converters for IS two wire DC systems. Industrial Pt. RTD

Measurement of Fluid Flow by Meter Run Contractor N0 of Corrections

ISA S 5.1 ISA S 5.2 ISA S 5.3 ISA S 71.04 API 670 ANSI B 16.104 ANSI MC 96.1 DIN 19243 DIN 43760/ IEC 751 ISO 5167 Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR Temperature Measurement

ANSI MC 96.1 / IEC 751 IEC 529

Degree of Protection by Enclosure Notes : All other relevant codes, as applicable, are to be used along with the above basic codes and of latest version. The codes and standards specified above are indicative but not exhaustive.

Contractor

N0 of Corrections

Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR

SECTION - 2 1.0

INSTRUMENTATION AND CONTROL ( I & C ) SYSTEM FOR LIFT IRRIGATION SYSTEM

1.1

DESIGN PHILOSOPHY The instrumentation and control (I&C) system called for in the specification shall be designed for safe, reliable, efficient and easy operation of Lift Irrigation System and its associated auxiliaries. The I&C system shall permit automatic operation of Lift Irrigation System. The system shall be capable of being monitored remotely from control room SCADA system. The I & C system shall be designed based on the latest state of the art technology. The controls shall be designed to provide automatic sequencing of start up, running and shutdown of the system along with protection and interlocks as required. The offered I&C system shall be designed to have a fully automated control for Lift Irrigation System using Sequence control concept. The Instrumentation and Control equipment system called for in this specification shall consist of PLC based system for carrying out the functions of measurement system, control system, protection and interlock system, and Annunciation system, operating system and communication system. The PLC system offered shall be compatible with the telemetry based communication system being supplied and shall include all Hardware, Software, Module, etc., as part of each of the sixty numbers PLC cabinets as required to interface with the telemetry system for the both transmitting and receiving i.e bi directional. Bidder to furnish substantiating documents to establish that the offered PLC based system is interfaced with the proposed telemetry based communication system and is in operation in similar capacity for similar distances. The system shall be complete with hardware and software along with the Man Machine Interface (MMI) capable of operating together as an integrated system along with panels, cables, unit control desk, cabinets, field instruments and erection hardware, control elements and devices to perform the various functions of the above system as specified.

Contractor

N0 of Corrections

Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR

The system shall be upgradable, evolutionary in both hardware and software. Manufacturers shall provide evidence on such upgrades in similar plants, along with the bid. The hardware and software used shall be of the Latest version. The instrumentation and control system envisaged for Lift Irrigation System has to include the following and all other required items :

1.1.1

a)

Open Loop control system.

b)

Control desk .

c)

Annunciation system.

d)

Power supply system (UPS with 1 hour battery backup).

e)

Cables (Instrument and control cables, prefabricated cables).

f)

System cabinets, marshalling cabinets etc.

Open Loop Control The controls shall be realised in microprocessor based Programmable Logic Controllers. A 1:1 redundancy has to be provided for the processors used in the PLCs and they shall be designed to have hot standby back up facility. The system has to provide for sequencing of automatic start up , shut down and emergency take over by standby equipment and automatic switch over for manual intervention. The system shall also comprise of data acquisition and historian functions of binary and important Analog parameters. The PLC shall be provided with a Operating cum Engineering Station for performing software changes.

1.1.2

The system shall include the following features for efficient operation from MMI. a)

Individual overview, plant group displays, plant control displays for Drives and all Electrical breakers , unfulfilled criteria display.

b)

Plant dynamic schematics (mimic diagrams), bar graph display, Electrical Single Line Diagram, Switchgear status, All breaker On-Off conditions, Equipment status etc.,

c)

Alarm displays

d)

Trend plots.

e)

Logs and reports.

Contractor

N0 of Corrections

Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR

f)

Operation guidance for start up and shut down.

g)

Interface with Telemetry system as required.

PLC Based Control System General Contractor shall provide complete and independent Control and instrumentation System with all accessories, auxiliaries and associated equipments and cables for the safe, efficient and reliable operation of the Makeup water system Bidder to refer configuration diagram for PLC based off-site control system The Control room shall be in in Air-conditioned area and necessary Airconditioning shall be provided by the Contractor

PROGRAMMABLE LOGIC BASED CONTROL SYSTEM :PLC Controller / Processor The Controller / processor unit shall be capable of executing the following functions:a) Receiving binary and analog signals from the field and operator initiated Commands from Operator Station. b) Implementing all logic functions for control, protection and annunciation of the equipment and systems. c) Implementing modulating control function for certain application as Specified elsewhere in the specification d) Issuing control commands e) Providing supervisory information for alarm, various types of displays, Status information, trending, historical storage of data etc. f) Performing self-monitoring and diagnostic functions. The Contractor in his bid shall submit full details regarding various functions along with expansion capability. The programmable system shall delivery successful operation of the plant. Contractor

N0 of Corrections

complete programme for the

Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR

PLC for Intake Pump house 1&2 The Main PLC for Intake Pumphouse PH-1 and PH-2 shall be provided with two processors(Main processing unit and memories) one of normal operation in one as hot standby. In case of failure of working processor, there shall be an appropriate alarm and simultaneously the hot standby processor shall take over the complete plant Operation automatically. The transfer from main processor to standby processor shall be totally bump less and shall not cause any plant disturbance whatsoever. In the event of both processors failing , the system shall revert to fail safe mode. It shall be possible to keep any of the processor as master and other as standby. The standby processor shall be updated in line with the changes made in working processor. The memory shall be field expandable. The memory capacity shall be sufficient for the complete system operation and have a capability for at least 20% expansion in future. Programme operating sequences and criteria shall be stored in non volatile semi conductor memories like EPROM. All dynamic memories shall be provided with buffer battery back up which shall be for at least 8 hours. The batteries shall be lithium or Ni-Cd type. The PLC system shall be provided with necessary interface hardware and Software for radio communication or fibre optic connectivity for two – way transfer of signals for the purpose of control & operation. The exact number of points to be transferred through above communication link and the format of the data shall be finalized during detailed engineering. Latest version of Graphical Interface Unit (GIU)/PC based Operator Station any Keyboards shall be provided for control & monitoring and programming function. Operator Station shall perform control, monitoring and operation of all Auxiliaries / drives interacting with PLC based control system. It shall be possible to use the same as programming station of the PLC. It shall basically perform the following functions. a) Operator interface for PLC based control system. Operator functions shall as minimum include local/remote selection, A/M selection, open/ close operation, sequence auto, start/stop selection, ON/OFF, bypassing criteria etc. b) Supervisory functions like:Mimic displays, which shall depict the process in graphical form and shall Cover all the process areas being monitored. Alarm monitoring/reporting, generation of logs, calculations, printing of logs & reports etc. Contractor

N0 of Corrections

Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR c) Suitable Interface with station wide LAN ( In Employer’s Scope) for two-way transfer of data. In case the Operator Station cannot be used as programming station of the PLC, then a separate programming shall be provided. Programming Station shall have access to the processor of the control system for programming. Program shall not require special computer skills. On the programming console, it shall be possible to do the programming, selfdiagnostics, testing of sequence, simulation and any sequence modification. Programming shall be possible in any of the following format:a) Flow-chart or block logic representing the instructions graphically. b) Ladder diagrams. A forcing facility shall be provided for changing the states of inputs and outputs, timers and flags to facilitate fault finding and other testing requirements. It shall be possible to display the signal flow during operation of the program. Programming shall be possible OFF line. A NORMAL / TEST / PROGRAM / OFF lockable selector switch shall be provided. In case of test mode of operation, all outputs shall be blocked. Provision shall be made of erasing and duplicating the user program and term storage facilities shall be provided with the help of optical type. Priority of different commands shall be as follows: Manual intervention shall be possible at any stage of operation. Protection commands shall have priority over manual commands and manual commands shall prevail over auto commands. In PLC controller, memory should exist as to where the sequence was aborted due to power supply failure so that further operation from that point can restart after power supply restoration. This restart after recovery of the power supply shall be through operator intervention so as to enable verification of readiness of other related equipments. All necessary software required for implementation of control logic, operator station displays / logs, storage & retrieval and other functional requirement shall be provided. The programs shall include high level languages as far as possible. The contractor shall provide sufficient documentation and program listing so that it is possible for Employer to carry out modification at a later date. Contractor

N0 of Corrections

Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR The Contractor shall provide all software required by the system for meeting the intent and functional/ parametric requirements of the Specification. Industry standard operating system like UNIX/WINDOWS NT etc. to ensure openness and connectivity with other system in industry standard protocols (TCP-IP/OPC etc.) shall be provided. The system shall have user oriented programming language & graphic user interface. All system related software including Real Time Operating System, File management software, screen editor, database management software. On line diagnostics/debug software, peripheral drivers software and latest version of standard PC-based software and latest WINDOWS based packages etc. and any other standard language offered shall be furnished as a minimum. All application software for PLC system functioning like input scanning, acquisition, conditioning processing, control and communication and Software for operator interface of monitors, displays, trends, curves, bar charts etc. Historical storage and retrieval utility, and alarm functions shall be provided. The Contractor shall provide software locks and passwords to Employer’s Engineers at site for all operating & application software so that Employer’s engineers can take backup of these software and are able to do Modifications at site. INPUT / OUTPUT MODULES Input / Output modules, as required in the Control System for all type of field input signals (4-20 mA,. RTD, non change over/change over type of contact inputs etc.) and outputs from the control system (non change over/ change over type of contact, 24/48 VDC output signals for energizing interface relays, 4-20 mA output etc) are to be provided by the Contractor, Contractor to refer relevant drawing for interface/ termination requirements of Field Instruments/Drives. Electrical isolation of 1.5KV with optical couplers between the plant input/output and controller shall be provided on the I/O cards. The isolation shall ensure that any inadvertent voltage or voltage spikes(as may be encountered in a plant of this nature) shall not damage or mal-operate the internal processing equipment. The Input/Output system shall facilitate modular expansion in fixed stages. The individual input/output cards shall incorporate indications on the module front panels for displaying individual signal status. Individually fused output circuits with the blower fuse indicator shall be provided. All input/output points shall be provided with status indicator. Input circuits shall Contractor

N0 of Corrections

Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR be provided with fuses preferably for each input, alternatively suitable combination of inputs shall be done and provided with fuses such that for any fault , fuse failure shall affect the particular Drive system only without affecting other systems. All input/output cards shall have quick disconnect terminations allowing for card replacement without disconnection of external wiring and without switching of power supply. The Contractor shall provide the following monitoring features:A) B) C) D)

Power supply monitoring. Contact bounce filtering. Optical isolation between input and output signals with the internal circuits In case of power supply failure or hardware fault, the critical outputs shall be automatically switched to the fail-safe mode. The fail-safe mode shall be intimated to the successful contractor during detailed engineering.

Further, keying-in of individual wire connectors shall be provided to ensure that only the correct card is plugged on the I/O module. It shall be possible to remove I/O module without disconnecting wiring from field inputs or outputs. There shall be at least 20% spare capacity available on input ,output and memory module ,over and above the system requirement. Binary output module shall be rated to switch ON/OFF coupling relays of approx.3VA at 24 VDC .Analog output modules shall be able to load impedance of 500 Ohms minimum. Output module shall be capable of switching ON/OFF inductive loads like solenoid valves, auxiliary relays etc. without any extra hardware. Only one changeover contact shall be provided in MCC for control and Interlock requirement. Further multiplication, if required, shall be done by the Contractor in PLC system. All input field interrogation voltage shall be 24V DC or48 VDC. In Case of loss of I/O communication link with the main processing unit, the I/O shall be able to go to predetermined fail safe mode (to be decided during detailed engineering) with proper annunciation. Contractor shall provide Input/Output modules housed in free- standing cabinets/racks (with suitable redundant data link to PLC system) as specified and as may be required (to be finalized during detailed engineering). These Contractor

N0 of Corrections

Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR Input /Output modules shall meet the technical requirements as mentioned in the above clauses. Further these Input/Output modules shall be designed to continuously work under the environment expected to be encountered in assigned areas without any air-conditioning support. MICRO PLC For all SDC’ s Micro PLC’s to be used with necessary Panels, SCADA Systems and Telemetry systems, the Micro PLC should have the following Specs, a) b) c)

The PLC should support 1024 DI/DO’s, 256AI/AO’s The PLC shall support Minimum 100Khz high speed counter inputs The PLC shall support serial port and Ethernet Port at 100MBPS speed Mode of Measurements :- Measurements shall be on the basis of “Per No.” Mode of Payment :- Mode of payment will be “per No.

PRINTER One number A3 size inkjet printer per PLC shall be provided as a part of the supervisory system. It shall print out all alarm/trip conditions and event changes in plant status along with date along with date and time occurrence. The time least count for event recording shall not be more than 100 milliseconds. SYSTEM REACTION TIME. The reaction time of the programmable control system from input signals at the input cards to output of the associated signals or commands of the output card inclusive of programmed logic processing, comprising a mixture of logic gates, arithmetic operations and other internal operations shall be less than 250 milliseconds under the most arduous control system operating conditions.

1.15

PUMP HOUSE CONTROL ROOM LAYOUT FOR EACH OF THE INTAKE WELL PUMP HOUSE STAGE 1 & 2, MDC 1 & 2, SDC 1 to 57 MCC CONTROL ROOM.

1.15.1

The control room layout shall house the following equipment: a)

Contractor

Unit Control Desk (UCD) to house MMI.(Printer shall be located in N0 of Corrections

Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR a separate side table.) b)

The PLC Panels, Marshalling cabinets, Relay cabinets & Electrical auxiliary cabinets as applicable.

c)

Uninterrupted power supply system (UPS)

Items referred above shall be mounted in an air conditioned Control Room

2.0

TECHNICAL FEATURES FOR I & C EQUIPMENT Scanning rate of analog signals

:

Maximum 250 m sec

Scanning rate of digital signals

:

100 msecs

Scanning rate of pulse signal

:

Maximum 100 m sec

Updating rate of Analog signal Parameter display in MMI

:

Max. 2 second (for measurement)

Time for display in MMI screen Updating rate of pulse signal

: :

Less than 2 seconds on operator's request max 2 sec

Keyboard command to field equipment to be executed in less than 2 sec. Notes :1.

Bidder shall furnish in his proposal the test facility and details of the simulation test available in their factory including their previous experience.

2.

All these tests shall be witnessed by Purchaser or his representatives.

3.

These tests shall be conducted based on approved FAT procedure witnessed and certified by Purchaser / Consultant.

Contractor

N0 of Corrections

Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR

Section 3 SPECIFICATION FOR INSTRUMENTS The specification as applicable for the field instruments are as follows: 1

Pressure Indicators/Guage Direct reading, pipe mounted pressure gauges of aluminium casing with six (6) inch dial; 316 SS Bourdon tube and nylon movements and an accuracy of +0.5% of span including accessories like snobberies for pump discharge applications and chemical diaphragm for corrosive and oil services. Material of accessories will be SS. IP65 or equivalent degree of protection for enclosure. Over range protection will be 25% above maximum pressure.

1.1

METHOD OF CONSTRUCTION Method of construction will be as per the drawings shown in the book published for construction method approved by the electrical Engineer to Govt. by letter No. 31/15190 of 1965 – 66 ED 11-12-1965.

1.2 MODE OF MEASUREMENT AND PAYMENT The measurement of the item described shall be taken as per unit as No. of the components / materials actually received at site. Payment of the item shall be made “per No.”

.2

Pressure Transmitters Micro-processor based; rack mounted with accuracy of +0.2% of span; field zero and span adjustment; self diagnostics, temperature sensor for compensation. Power supply 24 V DC; output signal of 4-20 mA DC. IP 65 or equivalent degree of protection; aluminum housing with epoxy coating; 316 SS sensing element. Accessories like snubbers for pump discharge applications and chemical diaphragm with 15 m capillary for corrosive and oil services. Material for accessories will be SS.

2.1

METHOD OF CONSTRUCTION

Contractor

N0 of Corrections

Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR Method of construction will be as per the drawings shown in the book published for construction method approved by the electrical Engineer to Govt. by letter No. 31/15190 of 1965 – 66 ED 11-12-1965. 2.2 MODE OF MEASUREMENT AND PAYMENT The measurement of the item described shall be taken as per unit as No. of the components / materials actually received at site. Payment of the item shall be made “per No.”

3

Ultrasonic Type Level Transmitters Ultrasonic type level transmitters of long range type to cover the entire RAW WATER sump depth (minimum 6 meters), with field temperature compensation, repeatability of 0.10% or better , with a response time better than 150 milliseconds, linearity of 1 % , with LCD indicator , suitable for specified atmospheric conditions, IP-65 protection, stainless steel housing , with an accuracy of +0.5% of span, 4-20 mA DC output (2 wire system), +24 V DC supply, isolated and ungrounded electrical circuits, Auto tuning, connector cable of required length, the material of accessories will be SS.

3.1

METHOD OF CONSTRUCTION Method of construction will be as per the drawings shown in the book published for construction method approved by the electrical Engineer to Govt. by letter No. 31/15190 of 1965 – 66 ED 11-12-1965.

3.2

MODE OF MEASUREMENT AND PAYMENT The measurement of the item described shall be taken as per unit as No. of the components / materials actually received at site. Payment of the item shall be made “per No.”

4

Flow Transmitters The Flow Transmitter shall be of Ultrasonic type having the following specifications, For all Flow Transmitters, the Local Indication shall be provided. The instruments shall meet the following requirements. Accuracy: Output Signal Range Load Impedance

Contractor

: +/- 0.5% of calibrated span for Flow : +/- 4-20 Ma : 500 Ohms (Impedance) N0 of Corrections

Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR Housing Operating Temp Power supply Accessories 4.1

: Weather proof IP 55 with durable corrosion resistant Coating. : 0 to 60 deg C : As per Contractor Standard practice : Local Indication, Span Adjustment, 6 Digit totaliser

METHOD OF CONSTRUCTION Method of construction will be as per the drawings shown in the book published for construction method approved by the electrical Engineer to Govt. by letter No. 31/15190 of 1965 – 66 ED 11-12-1965.

4.2 MODE OF MEASUREMENT AND PAYMENT The measurement of the item described shall be taken as per unit as No. of the components / materials actually received at site. Payment of the item shall be made “per No.”

5.1

PLC for Intake Pump house 1&2

The Main PLC for Intake Pumphouse PH-1 and PH-2 shall be provided with two processors(Main processing unit and memories) one of normal operation in one as hot standby. In case of failure of working processor, there shall be an appropriate alarm and simultaneously the hot standby processor shall take over the complete plant Operation automatically. The transfer from main processor to standby processor shall be totally bump less and shall not cause any plant disturbance whatsoever. In the event of both processors failing , the system shall revert to fail safe mode. It shall be possible to keep any of the processor as master and other as standby. The standby processor shall be updated in line with the changes made in working processor. The memory shall be field expandable. The memory capacity shall be sufficient for the complete system operation and have a capability for at least 20% expansion in future. Programme operating sequences and criteria shall be stored in non volatile semi conductor memories like EPROM. All dynamic memories shall be provided with buffer battery back up which shall be for at least 8 hours. The batteries shall be lithium or Ni-Cd type. The PLC system shall be provided with necessary interface hardware and Software for radio communication or fibre optic connectivity for two – way transfer of signals for the purpose of control & operation. The exact number of points to be transferred through above communication link and the format of the data shall be finalized during detailed engineering. Contractor

N0 of Corrections

Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR Latest version of Graphical Interface Unit (GIU)/PC based Operator Station any Keyboards shall be provided for control & monitoring and programming function. Operator Station shall perform control, monitoring and operation of all Auxiliaries / drives interacting with PLC based control system. It shall be possible to use the same as programming station of the PLC. It shall basically perform the following functions. d) Operator interface for PLC based control system. Operator functions shall as minimum include local/remote selection, A/M selection, open/ close operation, sequence auto, start/stop selection, ON/OFF, bypassing criteria etc. e) Supervisory functions like:Mimic displays, which shall depict the process in graphical form and shall Cover all the process areas being monitored. Alarm monitoring/reporting, generation of logs, calculations, printing of logs & reports etc. f) Suitable Interface with station wide LAN ( In Employer’s Scope) for two-way transfer of data. In case the Operator Station cannot be used as programming station of the PLC, then a separate programming shall be provided. Programming Station shall have access to the processor of the control system for programming. Program shall not require special computer skills. On the programming console, it shall be possible to do the programming, selfdiagnostics, testing of sequence, simulation and any sequence modification. Programming shall be possible in any of the following format:c) Flow-chart or block logic representing the instructions graphically. d) Ladder diagrams. A forcing facility shall be provided for changing the states of inputs and outputs, timers and flags to facilitate fault finding and other testing requirements. It shall be possible to display the signal flow during operation of the program. Programming shall be possible OFF line. A NORMAL / TEST / PROGRAM / OFF lockable selector switch shall be provided. In case of test mode of operation, all outputs shall be blocked. Provision shall be made of erasing and duplicating the user program and term storage facilities shall be provided with the help of optical type. Contractor

N0 of Corrections

Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR Priority of different commands shall be as follows: Manual intervention shall be possible at any stage of operation. Protection commands shall have priority over manual commands and manual commands shall prevail over auto commands. In PLC controller, memory should exist as to where the sequence was aborted due to power supply failure so that further operation from that point can restart after power supply restoration. This restart after recovery of the power supply shall be through operator intervention so as to enable verification of readiness of other related equipments. All necessary software required for implementation of control logic, operator station displays / logs, storage & retrieval and other functional requirement shall be provided. The programs shall include high level languages as far as possible. The contractor shall provide sufficient documentation and program listing so that it is possible for Employer to carry out modification at a later date. The Contractor shall provide all software required by the system for meeting the intent and functional/ parametric requirements of the Specification. Industry standard operating system like UNIX/WINDOWS NT etc. to ensure openness and connectivity with other system in industry standard protocols (TCP-IP/OPC etc.) shall be provided. The system shall have user oriented programming language & graphic user interface. All system related software including Real Time Operating System, File management software, screen editor, database management software. On line diagnostics/debug software, peripheral drivers software and latest version of standard PC-based software and latest WINDOWS based packages etc. and any other standard language offered shall be furnished as a minimum. All application software for PLC system functioning like input scanning, acquisition, conditioning processing, control and communication and Software for operator interface of monitors, displays, trends, curves, bar charts etc. Historical storage and retrieval utility, and alarm functions shall be provided. The Contractor shall provide software locks and passwords to Employer’s Engineers at site for all operating & application software so that Employer’s engineers can take backup of these software and are able to do Modifications at site. INPUT / OUTPUT MODULES

Contractor

N0 of Corrections

Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR Input / Output modules, as required in the Control System for all type of field input signals (4-20 mA,. RTD, non change over/change over type of contact inputs etc.) and outputs from the control system (non change over/ change over type of contact, 24/48 VDC output signals for energizing interface relays, 4-20 mA output etc) are to be provided by the Contractor, Contractor to refer relevant drawing for interface/ termination requirements of Field Instruments/Drives. Electrical isolation of 1.5KV with optical couplers between the plant input/output and controller shall be provided on the I/O cards. The isolation shall ensure that any inadvertent voltage or voltage spikes(as may be encountered in a plant of this nature) shall not damage or mal-operate the internal processing equipment. The Input/Output system shall facilitate modular expansion in fixed stages. The individual input/output cards shall incorporate indications on the module front panels for displaying individual signal status. Individually fused output circuits with the blower fuse indicator shall be provided. All input/output points shall be provided with status indicator. Input circuits shall be provided with fuses preferably for each input, alternatively suitable combination of inputs shall be done and provided with fuses such that for any fault , fuse failure shall affect the particular Drive system only without affecting other systems. All input/output cards shall have quick disconnect terminations allowing for card replacement without disconnection of external wiring and without switching of power supply. The Contractor shall provide the following monitoring features:E) F) G) H)

Power supply monitoring. Contact bounce filtering. Optical isolation between input and output signals with the internal circuits In case of power supply failure or hardware fault, the critical outputs shall be automatically switched to the fail-safe mode. The fail-safe mode shall be intimated to the successful contractor during detailed engineering.

Further, keying-in of individual wire connectors shall be provided to ensure that only the correct card is plugged on the I/O module. It shall be possible to remove I/O module without disconnecting wiring from field inputs or outputs. There shall be at least 20% spare capacity available on input ,output and memory module ,over and above the system requirement.

Contractor

N0 of Corrections

Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR Binary output module shall be rated to switch ON/OFF coupling relays of approx.3VA at 24 VDC .Analog output modules shall be able to load impedance of 500 Ohms minimum. Output module shall be capable of switching ON/OFF inductive loads like solenoid valves, auxiliary relays etc. without any extra hardware. Only one changeover contact shall be provided in MCC for control and Interlock requirement. Further multiplication, if required, shall be done by the Contractor in PLC system. All input field interrogation voltage shall be 24V DC or48 VDC. In Case of loss of I/O communication link with the main processing unit, the I/O shall be able to go to predetermined fail safe mode (to be decided during detailed engineering) with proper annunciation. Contractor shall provide Input/Output modules housed in free- standing cabinets/racks (with suitable redundant data link to PLC system) as specified and as may be required (to be finalized during detailed engineering). These Input /Output modules shall meet the technical requirements as mentioned in the above clauses. Further these Input/Output modules shall be designed to continuously work under the environment expected to be encountered in assigned areas without any air-conditioning support. 5.1.1

METHOD OF CONSTRUCTION Method of construction will be as per the drawings shown in the book published for construction method approved by the electrical Engineer to Govt. by letter No. 31/15190 of 1965 – 66 ED 11-12-1965.

5.1.2MODE OF MEASUREMENT AND PAYMENT The measurement of the item described shall be taken as per unit as No. of the components / materials actually received at site. Payment of the item shall be made “per No.”

MICRO PLC FOR MDC’s At MDC’s Micro PLC’s to be used with necessary Panels, SCADA Systems, the Micro PLC should have the following Specs, d)

The PLC should support 1024 DI/DO’s, 256AI/AO’s

Contractor

N0 of Corrections

Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR e) f)

5.2.1

The PLC shall support Minimum 100Khz high speed counter inputs The PLC shall support serial port and Ethernet Port at 100MBPS speed METHOD OF CONSTRUCTION

Method of construction will be as per the drawings shown in the book published for construction method approved by the electrical Engineer to Govt. by letter No. 31/15190 of 1965 – 66 ED 11-12-1965. 5.2.2

MODE OF MEASUREMENT AND PAYMENT The measurement of the item described shall be taken as per unit as No. of the components / materials actually received at site. Payment of the item shall be made “per No.”

5.3 MICRO PLC FOR SDC’s For all SDC’ s Micro PLC’s to be used with necessary Panels, SCADA Systems, the Micro PLC should have the following Specs, g) h) i)

5.3.1

The PLC should support 1024 DI/DO’s, 256AI/AO’s The PLC shall support Minimum 100Khz high speed counter inputs The PLC shall support serial port and Ethernet Port at 100MBPS speed METHOD OF CONSTRUCTION Method of construction will be as per the drawings shown in the book published for construction method approved by the electrical Engineer to Govt. by letter No. 31/15190 of 1965 – 66 ED 11-12-1965.

5.3.2

MODE OF MEASUREMENT AND PAYMENT The measurement of the item described shall be taken as per unit as No. of the components / materials actually received at site. Payment of the item shall be made “per No.”

6

Wireless Telemetry System

Contractor

N0 of Corrections

Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR The Wireless System should be capable of connecting upto a distance of 30km without any additional repeaters. The System should support various network such as 10 base-T, V.35 , 4 & 12 BRI , E1. The System should also support Voice and Data simultaneously. The wireless system should handle atleast 1 MB data /sec. The complete response time thru the Wireless Telemetry system should not be more than 4 secs. Diagnostics functions related to Packet Loss, Network down should be available. Necessary Lightening and Surge Protection related to the Wireless Tower is in the scope of the Bidder 6.1

METHOD OF CONSTRUCTION Method of construction will be as per the drawings shown in the book published for construction method approved by the electrical Engineer to Govt. by letter No. 31/15190 of 1965 – 66 ED 11-12-1965.

6.2MODE OF MEASUREMENT AND PAYMENT The measurement of the item described shall be taken as per unit as No. of the components / materials actually received at site. Payment of the item shall be made “per No.”

7

Pressure Switches Non indicating type, field mounted pressure switches of aluminium casing (epoxy coated) and 316 SS element and accuracy of +1% of span, including accessories like snobberies for pump discharge applications and chemical diaphragm for corrosive and oil services. Material of accessories will be SS. Auto reset micro switch with adjustable range with 2 SPDT contacts rated for 0.2 A at 220 V DC. IP 65 or equivalent degree of protection for enclosure. Over range protection 50% above maximum pressure.

7.1

METHOD OF CONSTRUCTION

Contractor

N0 of Corrections

Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR

Method of construction will be as per the drawings shown in the book published for construction method approved by the electrical Engineer to Govt. by letter No. 31/15190 of 1965 – 66 ED 11-12-1965. 7.2 MODE OF MEASUREMENT AND PAYMENT The measurement of the item described shall be taken as per unit as No. of the components / materials actually received at site. Payment of the item shall be made “per No.”

8

Thermometers with contact Indicating type, field mounted, filled system of adequate length of capillary and six (6) inch dial housed in aluminium casing (epoxy coated) with an accuracy of +1% of span; response time of 2-4 seconds; linear calibration over the range and 316 SS thermowell having a process connection of M33 x 2 thread. Material of accessories will be SS. IP 65 or equivalent degree of protection for enclosure. Bar stock assembly type of thermowell. Adjustable high and very high contacts of rating 5 amps at 240 V AC or 0.2 Amps at 220 V DC shall be provided.

8.1

METHOD OF CONSTRUCTION Method of construction will be as per the drawings shown in the book published for construction method approved by the electrical Engineer to Govt. by letter No. 31/15190 of 1965 – 66 ED 11-12-1965.

8.2 MODE OF MEASUREMENT AND PAYMENT The measurement of the item described shall be taken as per unit as No. of the components / materials actually received at site. Payment of the item shall be made “per No.”

9

Variable Frequency Drive The VFD shall include the following protective circuits and features: Output phase-to-phase short circuit condition. i. Total ground fault under any operating condition. ii. High input line voltage. Contractor

N0 of Corrections

Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR iii. Low input line voltage. iv. Loss of input or output phase. v. External fault. (This protective circuit shall permit wiring of remote N.C. safety contact to shut down the drive). User supplied end switches, thermal switches, fire-stats, freezestats inputs will be connected to this VFD supplied circuit. vi. Metal oxide varistors for surge suppression shall be provided at the VFD input terminals. 9.1

METHOD OF CONSTRUCTION Method of construction will be as per the drawings shown in the book published for construction method approved by the electrical Engineer to Govt. by letter No. 31/15190 of 1965 – 66 ED 11-12-1965.

9.2 MODE OF MEASUREMENT AND PAYMENT The measurement of the item described shall be taken as per unit as No. of the components / materials actually received at site. Payment of the item shall be made “per No.”

10

Providing & Intallation of Cables & Cable Tray For all the equipment included in the package, the complete I&C cabling shall be included in the scope from instrument to junction box, from JB to Marshalling / Termination cabinets / Local panel, from actuator to PMCC / Local panel, from LPB to PMCC, from Actuator to Marshalling/Termination cabinet/Local panel, etc., Instrumentation & Control Cable (0.5 sq. mm, armoured, 600V) between sensor to Junction Boxes and junction boxes to the Marshalling / Termination cabinet of lengths as required.

9.1

METHOD OF CONSTRUCTION Method of construction will be as per the drawings shown in the book published for construction method approved by the electrical Engineer to Govt. by letter No. 31/15190 of 1965 – 66 ED 11-12-1965.

9.3 MODE OF MEASUREMENT AND PAYMENT The measurement of the item described shall be taken as per unit as No. of the components / materials actually received at site. Payment of the item shall be made “per Lot/Set.”

Contractor

N0 of Corrections

Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR

SECTION – 4 TECHNICAL SPECIFICATION FOR 6.6 KV SOFT STARTER 1.0

SCOPE :This specification covers the Design, manufacture testing at works and supply of 6.6KV SOFT STARTER for the following Motors

2.0

a)

66KV 660KW Motor

4Nos.

b)

66KV 220KW Motor

4Nos

c)

66KV 220KW Motor

4Nos.

CLIMATIC CONDITIONS : The Vaccum Circuit Breaker are required for mounting on outdoors structures for protection of transformers and tapping points where the climatic conditions will be as follows :

3.0

i)

Temp. variation : 3 deg. C to 50 Deg. C.

ii)

Relative humidity upto 100%

iii)

Altitude : 0 to 1000 meters.

SPECIFICATIONS FOR NEUTRAL SOFT STARTER (HIGH VOLTAGE) i)

The High Voltage Soft Starter for HT induction motor will be based on Flux Compensated Magnetic Amplifier principle and shall be installed on the Neutral side of HT induction Motor

ii)

The Flux Compensated Magnetic Amplifier (FCMA) Soft Starter shall be suitable for operation on specified Voltage at 3 Ph, 50 Hz A.C. supply and suitable for connection to the phase segregated Neutral Terminal Box of the HT induction motor for Neutral Soft Starter.

iii)

The Soft Starter shall be rated equivalent to the HT induction motor rated power and shall be capable of operating satisfactorily with the HT induction motor under the specified starting conditions of the induction motor. The Soft Starter rating offered shall not be less than the rated

KW of the HT induction motor. Contractor N0 of Corrections

Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR iv)

The Soft Starter shall reduce the starting current of the HT induction motor at least to 80% of the direct on line starting current of the motor. The Soft Starter shall have a facility to further reduce the current, if the motor & load torque speed curves permit so. The Soft Starter shall control the starting torque in such a manner so as to effect smooth starting of the HT induction motor drive. The Soft Starter shall be provided with suitably rated ammeter to indicate the motor current during starting.

v)

The Flux Compensated Magnetic Amplifier (FCMA) shall work on the principle of unsaturated core in the working zone and shall not lead to generation of harmonics. The Soft Starter shall have Silicon steel core. Air core will not be acceptable. The windings of the Soft Starters shall be with insulation class H Max. Temperature of winding shall be limited to that of class B. The FCMA unit should be Air Cooled, and dust & vermin proof. The FCMA Soft Starters should be suitable for indoor mounting.

vi)

The Soft Starter shall be so rated as to allow at least two consecutive starts from cold or four hot start per hour.

vii)

The Soft Starter shall be designed for supply voltage variation of ± 6% and frequency variation of +/- 3%.

viii)

The Soft Starter should be suitable for working at control supply voltage on 110V DC.

ix)

The FCMA Soft Starter shall be housed in a sheet steel enclosure of thickness not less than 14 gauge and painted with corrosion resistive paint such as Epoxy or Polyurethane. The degree of protection shall be IP-4 or equivalent.

x)

FCMA Soft Starter unit shall have anti condensation heater, complete with switch and thermostat. The heater shall have interlocking in such a way that it is switched 'OFF' when motor is in run mode.

xi)

FCMA Soft Starter shall not contain any active electronic components.

Contractor

N0 of Corrections

Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR xii)

FCMA Soft Starter shall have a built in facility for run mode bypass so that the incoming voltage to the HT induction motor is equal to the supply voltage.

xiii)

The breaker shall confirm to the specific technical requirements mentioned below:

4.0

TESTING :

Routine Test a) Physical inspection for dimensional check. b) Control circuit operation check . c) High voltage test. d) Insulation resistance test before & after high voltage test. e) Temperature rise test for bypass device at rated HT induction motor current for 1 hour.

Site Test a) Insulation resistance check. b) Control circuit test. c) Test to demonstrate achievement of starting current as per specifications and as finalised during detail engineering. 5.0

Guarantee of Performance :

The equipment should be almost maintenance free and should not produce any harmonics. The tenderer should give guarantee of performance of at least 1 year from the date of commissioning. 6.0

METHOD OF CONSTRUCTION Method of construction will be as per the drawings shown in the book published for construction method approved by the electrical Engineer to Govt. by letter No. 31/15190 of 1965 – 66 ED 11-12-1965.

Contractor

N0 of Corrections

Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR

7

MODE OF MEASUREMENT AND PAYMENT The measurement of the item described shall be taken as per unit as No. of the components / materials actually received at site. Payment of the item shall be made “per No.”

Contractor

N0 of Corrections

Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR

SECTION - 5 TECHINICAL SPECIFICATION FOR ELECTRICALLY OPERATED BUTTERFLY VALVES 1.0

SCOPE :-

This specification covers the Design, manufacture testing at works and supply of Electrically operated Butterfly Valves 2.0

CLIMATIC CONDITIONS : The Electrically operated Butterfly Valves are to be used where the climatic conditions will be as follows : a)

Temp. variation : 3 deg. C to 50 Deg. C.

b)

Relative humidity upto 100%

c)

Altitude : 0 to 1000 meters.

3.0 SPECIFICATIONS FOR ELECTRICALLY OPERATED BUTTERFLY VALVES General Each pump shall be provided with a butterfly valve in the delivery pipe.

The butterfly valve shall be flanged water works pattern,

eccentrically pivoted and shall be electrically actuated.

The

actuators shall be suitable for opening and closing against the maximum head realized under operation conditions and any necessary spur or other gearing and links etc shall be incorporated. The actuator motors shall be complete with limit switches, interlock switches for remote control and also contacts for close, open, in operation and percentage opening position indications.

The

actuators shall be suitable for operation with DOL starting on 415 V, 3 phase, 50 Hz A.C. power supply. Necessary arrangement with hand wheels shall be provided for emergency manual operation with suitable interlocking mechanism to prevent the actuator operation when the valve is being operated manually and vice Contractor

N0 of Corrections

Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR versa. The actuator shall be located at motor floor and so also the manual operation of valve shall be from motor floor. The valves shall generally conform to BS 5155. The closing time for electrical actuator shall be from 2 to 3 minutes. The actuator shall incorporate Backlash hammer blow feature. Horse power of motor shall be adequate with atleast 50% margin over maximum power required for unseating the valve against line pressure equivalent to valve rating specified in Schedule ‘B’ or normal operation whichever is higher. Construction Butterfly valve suitable for flange bolting individually to flanges of pipe and pump with the disc, to form a section cut through a sphere, working in conjunction with a cone shaped seating in body and suitable seal ring fitted to the disc, with the help of retaining ring and stainless steel screws shall be conforming to BS 5155, the disc shaft bearings shall be off set along the pipe axis from the plane of the seating so as to get an unbroken position in full closed position. The head stock, where actuators operating hand wheels will be located, shall be of C.I. construction with proper aesthetic appearance. Hand wheels or the actuators shall be chrome plated. Design Duty Working Pressure As per design Maximum working pressure As per design Maximum differential pressure across As per design disc under which valve shall be operated Maximum rate of flow through valve As per design Nature and condition of fluid Raw river Contractor

N0 of Corrections

Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR water

with

–

upto

50

mm.

suspended material Type of actuator

Electrical

and

Manual Materials of Construction Body

Close grained homogeneous grey C.I. conforming to IS 210

GR FG 200 Disc / Door Same as body End housing & cover gear box Grey cast iron conforming to housing for manual operation

grade 20 of IS 210 or cast

Bearings

steel P.T.F.E.

(Glass

Carbon friction

filled

filed) coefficient

or

having 0.04

(Note water itself acts as a lubricant

for

PTFE

bearings) OR Gun metal conforming to IS Stub Shaft Rubber seal ring

318 grade II Stainless Steel AISI 304 Precision molded nitrile rubber

Hardware used inside Retaining Ring

ring (shore hardness 55 to 65) Stainless steel Grey cast iron or cast steel,

nickel plated. Inside portion of the valve shall be painted by black paint confirming to IS 158. Local Operation Switch: Local Operation Switches near the valves should invariably be provided for operation of the valves. Testing The valve shall be subjected to seat and body test in accordance Contractor

with BS 5155 at the manufacturers works vide table below. This N0 of Corrections Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR test shall be carried out in presence of engineer or his representative before delivery test certificates shall be furnished in triplicate. Valve

Seat Test Pressure

Body Test Pressure

Rating PN-0.6 PN-1.0 PN – 1.6

6.0 Kg / Cm2 10.0 Kg / Cm2 16.0 Kg / Cm2

9.0 Kg / Cm2 15.0 Kg / Cm2 24.0 Kg / Cm2

4.0SHOP TESTS The following shop tests shall be conducted on all the valves. They shall be carried out, before painting, in the presence of the engineer and/or his authorized representatives unless waived in writing.

a)

PERFORMANCE TEST

After assembly, each valve with the respective operating mechanism shall be shop operated over the full range of movement in both the directions, with the valve body subjected to the full hydro static pressure conditions to demonstrate that the units are in working order without any leakage through the joints. Performance test shall be conducted for three successive open close cycle with the valve shaft both in vertical and horizontal planes.

PRESSURE TESTS Body hydrostatic Test With the valve disc in slightly open position, the entire valve shall be subjected to hydrostatic pressure. The test pressure shall be equal to twice the maximum operating pressure. Under this pressure, there shall be no leakage through the body or its bonnet joints and no part shall be deformed. The duration of test shall be 30 minutes.

c)

Disc Hydrostatic test

With one end of the valve open to atmosphere and the disc in the closed position, the valve shall be subjected to the specified hydrostatic test pressure on Contractor

N0 of Corrections

Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR the other end. This test shall be conducted on both sides of the disc. After this testing no part of the valve or disc shall be permanently damaged. The test pressure shall be one half times the working pressure and the duration 30 minutes.

d)

Visual Inspection

Valves shall be offered for the engineer’s visual inspection, before shipment, for checking the conformity of the final product with respect to the approved drawings/specifications. Necessary test certificates for all the above tests shall be furnished for the engineer’s approval. f) VALVE TAG NO. Each valve shall have a permanent brass or stainless steel metal tag attached to the valve. Each valve shall bear the name plate details listed below : a) Sl. No. of valve. b) Valve size (Normal size) DN c) Nominal pressure (PN) d) Hydrostatic test pressure e) Seat test pressure f) Maximum flow g) Weight of valve actuator h) Manufacturer’s name and valve number i) Year of manufacture j) Body of material designation k) Arrow to indicate direction of flow.

5

METHOD OF CONSTRUCTION Method of construction will be as per the drawings shown in the book published for construction method approved by the electrical Engineer to Govt. by letter No. 31/15190 of 1965 – 66 ED 11-12-1965.

6

MODE OF MEASUREMENT AND PAYMENT The measurement of the item described shall be taken as per unit as No. of the components / materials actually received at site. Payment of the item shall be made “per No.”

Contractor

N0 of Corrections

Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR

Section - 6 Vibration Monitoring System 1.0 a) Microprocessor Based Vibration Monitoring System shall be provided for all water pumps. The number of locations to be monitored on each pump shall be two. b) 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-amplifiers/electronics mounted in local weather proof boxes, vibration monitors mounting racks and cabinets. The vibration monitoring system shall include all power supplies, interconnecting Contractor

N0 of Corrections

Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR cabling, indicators, integrating units, signal conditioning devices and all other accessories required for monitoring of vibration at each point. The equipment supplier shall provide the vibration pads. c) Contractor shall offer vibration monitors for each measurement location as required. Offered vibration monitors shall be modular in construction, plug in type. d) Inductance type velocity transducers shall be used, however the finally selected sensor type shall also depend on recommendation of the equipment manufacturer and suitable for application requirement which shall be finalized during detail engineering and without any extra price. e) Transducers shall be furnished in weatherproof housing suitable for field conditions. Cables/cabling from transducers to local JB and local JB to vibration Monitoring system in pump house shall to be provided by the vibration monitoring system suppliers. f) Vibration monitoring system shall give an output of 4-20 mA DC for each point to be monitored. The signal shall be suitable for use as an input to PLC based control system, 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 points. g) The vibration monitor racks with power supplies shall be located in pump house control room. 2

METHOD OF CONSTRUCTION Method of construction will be as per the drawings shown in the book published for construction method approved by the electrical Engineer to Govt. by letter No. 31/15190 of 1965 – 66 ED 11-12-1965.

3

MODE OF MEASUREMENT AND PAYMENT The measurement of the item described shall be taken as per unit as No. of the components / materials actually received at site

.

Contractor

N0 of Corrections

Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR

SECTION – 7 ANNEXURE – I VENDOR LIST Name Of Equipment

Contractor

Approved Make Approved Make No.1 No.2

N0 of Corrections

Approved Make No.3

Approved Make No.4

Approved Make No.5

Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR

PRESSURE GAUGES

TEMP GAUGES

AN INSTRUMENT

AN INSTRUMENT

DIFFERENTIAL AN PRESSURE INSTRUMENT GAUGES CHEMICAL SEAL AN DIAPHRAGM INSTRUMENT PRESSURE GAUGE CHEMICAL SEAL AN DIAPHRAGM INSTRUMENT DIFF.PRESSUR E GAUGE INSTRUMENTA ROTAMETER/F TION LOW ENGINEERS INDICATORS PVT.LTD PRESSURE/DP /FLANGED YOKOGAWA LEVEL TRANSMITTER TEMP.TRASMI TTERS

TEMPERATUR E ELEMENT Name Of Equipment

Contractor

FORBES MARSHALL

GENERAL INSTRUMEN TS H GURU CONSORTI UM

FORBES MARSHALL

GENERAL INSTRUMEN TS H GURU CONSORTI UM

FORBES MARSHALL

FORBES MARSHALL

FORBES MARSHALL

GENERAL INSTRUMEN TS H GURU CONSORTI UM GENERAL INSTRUMEN TS H GURU CONSORTIU M GENERAL INSTRUMEN TS H GURU CONSORTIU M

FIE BAG

FIE BAG MANOMETER S

FIE BAG MANOMETER S FIE BAG MANOMETER S FIE BAG MANOMETER S

FORBES MARSHALL

EUREKA

AI FLOW

YOKOGAWA

EMERSON

ABB

HONEY WELL

WIKA/SIEMEN S

MASIBUSINOR

YOKOGAWA

EMERSON

ABB

HONEY WELL

WIKA

VED SREE

VED SREE

NAGMAN

Approved Make Approved Make No.1 No.2

N0 of Corrections

GLOBAL ELECTRONI NAGMAN CS GLOBAL ELECTRONI MASIBUS CS Approved Make No.3

Approved Make No.4

Approved Make No.5

Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR

ELECTROMAG NETIC FLOW METER

FORBES MARSHALL

YOKOGAWA

EMERSON

ELECTROMAG NETIC FLOW TOSHNIWAL METER

ISOIL-ORBIT

EUREKA

SIGMA-ORBIT

THERMOPO LISONICORBIT

LEVCON

VT AUTOMET

ULTRASONIC FLOW METER

ORBITRITTMAYER

MULTIPATH ORBITULTASONIC RITTMAYER FM LEVEL GAUGE,TUBUL CHEMTROL AR/REFLEX/TR ANSPERENT LEVEL GAUGE,FLOAT & SBEM BOARD/FLOAT & TAPE PRESSURE/DP SWITZER SWITCHES TEMPERATUR SWITZER E SWITCHES FLOW SWITCH

Name Of Equipment PROCESS INDICATORS

Contractor

INDFOSS

PULSER-ORBIT

PH /CONDUCTIVIT Y/TURBIDITY/R HACH-ORBIT ESIDUAL CHLORINE

PH /CONDUCTIVIT Y/TURBIDITY/R ESIDUAL CHLORINE SIGNAL ISOLATORS

INDFOSS

SWITZER

E+H

ABB

PULSERORBIT

YOKOGAWA

ABB

SIEMENS SIEMENS INST.ENGIN EERS PVT LTD

ABB EUREKA

EMERSON

YOKOGAWA

ABB

LECTOTRACK

MTL

PEPER&FI SHER

Approved Make No.3

Approved Make No.4

GENCO-ORBIT

SAVANTDWAYER MASIBUS

Approved Make Approved Make No.1 No.2 MASIBUS

ASCON

N0 of Corrections

EUROTHER YOKOGAW A M

Approved Make No.5 ABB

Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR

PLC AND SCADA PLC AND SCADA

ROCK WELL

MICROCONFORBES HONEYWELL MARSHALL

SCHNEIDER

BATTERY

EXIDE

AMAR RAJA

CONTROL PANEL

MASIBUS

AUTOMATION SOLUTIONS

UPS

TATA-LIEBNT

APC

ACTUATORS

AUMA

ROTORK

CABLES

RELIANCE INDIA LTD FINOLEX

CABLE TRAYS

DOLPHIN

LOCAL PUSH BUTTON STATIONS

SWITCHING CIRCUITS

CABLES

MTL

SIEMENS

MICROVERS E

ROBOT SS INSTRUMENT SYSTEMS S ARUN HI-REL ENGINEERI ELECTRONI NG&CONT CS ROLS DB power LIMIT TORQUE UNIVERSAL PARAMOU POLYCAB CABLES NT RITAL

FINE CAB SP ENGG.INDUST AMTEK RIES Pune AUTOMATI PEC CONTROL & ON ELECTRICA SWITCH GEAR SOLUTION LS S

MASIBUS HENSEL SYSTEMS

ELPRO

FORBES MARSHALL

PACE

RAOVELA

APLAB

BANTIA

SIEMENS

PROCON

Approved Make Approved Make No.1 No.2

Approved Make No.3

VIBRATION MONITORING

ROCK WELL

SHINKAWA/FOR BES MARSHALL

BENTLY NEVEDA

TELEMETRY SYSTEM

ELPRO(FORBE S MARSHALL)

D-LINK.

TELENET

Contractor

ABB

HBL-NIFE AMCO

DELTON

LOCAL PUSH BUTTON STATIONS WIRE LESS TECHNOLOGY D-LINK /TELEMETRY FURNITURE TUMBI DC/AC POWER DIGITRONICS, SUPLY PUNE ANNOUNCIATI MASIBUS ON

Name Of Equipment

GE FANUC

YOKOGAWA

N0 of Corrections

Approved Make No.4

Approved Make No.5

SHEETAL WIRELESS

VLINK.

Executive Engineer

VIDARBHA IRRIGATION DEVELOPMENT CORPORATION, NAGPUR GEMINI TELEMETRY COMMUNICATI SYSTEM ON JUNCTION BOXES

SUCHITRA INDUSTRIES

Honey well KS PROBOT MANISHA INSTRUMENTS INSTRUMEN ABB PUNE ENTERPRISES PVT LTD TS

CHLORINE LEAK CAPITAL WALLACE&TIE DETECTOR CONTROL RNAN PENSTOCK LEVEL CHEMTRO SWITCH SWITZER TECHTROL LEVCON L LOSS OF HEAD INDICATORS SBEM PRIMARY GENERAL FLOW ENGINEERI INSTRUME ELEMENTS(FL MICRO INSTRUMENTA NG NTS OW PRECESSION TION LTD SPECIALITI CONSORTI NOZZILE,ORIFI ES UM CE ETC)

Contractor

N0 of Corrections

SBEM

Executive Engineer