(6X200MW) TEESTA STAGE III HE PROJECT BID DOCUMENT SECTION - 4 MAIN INLET VALVE AND ACCESSORIES (SPHERICAL VALVE)

) 4.1. Scope of Work This section of the specification covers the provision of all labour, plant and material and performance of all work necessary for the design, manufacture, testing, delivery, erection, testing & commissioning, handing over and guarantee for two years for the main inlet valve and accessories for all six units. 4.1.1. Detail Scope of Supply Six (6) sets of hydraulically operated turbine main inlet valves of the spherical type for shutting-off pressure water supply from the penstock to the turbine distributor shall be provided, complete with necessary piping, control and gauge cabinet, up-stream connecting and down-stream connecting pipes with companion flanges, dismantling joint, bypass, drain and air bleeder valves, operating mechanism and necessary auxiliaries including gaskets, anchor bolts, sole plates, and other items necessary for a complete installation. Depending upon operating requirements, the valve shall be either fully open or fully closed and no partial opening of the valve is envisaged. In the closed position, the valve shall be leak tight. The valve shall consist of following principal parts: Valve body Valve rotor/plug Upstream seal (Maintenance seal) Downstream seal (service seal) Hydraulic cylinder with operating mechanism Counter weight Two motor driven oil pumps mounted on a sump tank Oil pressure tank Oil Piping Control and gauge cabinet with controls Dismantling joint 4-1

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(6X200MW) TEESTA STAGE III HE PROJECT BID DOCUMENT Upstream companion flange (for penstock) Bypass valve, control and drain piping Water and oil pipelines Air Bleeding Valve Drain valve along with guard valve.

Matching piece with penstock and turbine distributor including suitable Taper piece Oil for first filling with 10% extra quantity, in nonreturnable drums, for all four units. 4.2. Other items necessary for completeness

Special Design and Layout Conditions The Main Inlet Valves shall be used as a Turbine Shut-Off Valves. Each MIV shall be a spherical type valve complete with separate OPU system, service & maintenance seals, by pass valve system and counter weights for closing. The design of the valve shall be such as to resist the hydraulic forces acting directly on the body and when fully open, shall provide minimum obstruction to flow of water. In the closed position, the valve shall be leak tight. MIV shall be capable of opening under full differential pressure so that in case of heavy erosions in the jets, units are operable. The valves shall be capable of closing by the use of counter weights against maximum head, including water hammer, starting from an initial discharge up to maximum turbine discharge or run away conditions at maximum head with normal working stress on all parts. The inlet valves shall be suitable to be handled by the main powerhouse EOT cranes and the design & dimensioning of the valves shall be such that each valve can be handled (lifting & lowering) by EOT crane through hatches of suitable size with adequate clearances.

4.3. 4.3.1.

Basic Dimensions and Ratings Technical Data and Description of Proposed Equipment Number of valves Type 6 Spherical 4-2

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(6X200MW) TEESTA STAGE III HE PROJECT BID DOCUMENT Nominal diameter Elevation of valve centreline Rated head Maximum static water pressure 1.8 m 780 m 778 m 80.5 Kg/cm2

Maximum water pressure (including water hammer) 92.5 Kg/cm2 Hydrostatic Test pressure (on valve body) Opening time Closing time 4.3.2. General Description Double sealed spherical valve with splitted body and two drives. The closing of the valve at maximal flow rate and full one side pressure is affected by closing weights. Opening of spherical valve at nearly equilibrated pressure, by oil pressure from turbine governor. Drive (2 linear servomotor) fixed on the valve body The axial forces are transmitted over the upstream pipe into the concrete. Own weight and mass of water are to be transmitted by the valve feet into the ground. Valve shall meet the requirements as per IS-7332 or equivalent International Standards as applicable. A broad list of preferred materials of construction and manufacturing method of components is given in table-1. 4.4. Performance Criteria & Guarantee The equipment covered under this contract shall be capable of performing all intended duties and it is the responsibility of contractor to supply the equipments as per guaranteed technical particulars. 135 Kg/cm2 60 s, adjustable 60 s, adjustable

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(6X200MW) TEESTA STAGE III HE PROJECT BID DOCUMENT 4.5. 4.5.1. Design And Construction Valve Body The valve body shall be made in two pieces of cast steel to facilitate assembly and transport. It shall be provided with integrated flanges for making watertight connections to the upstream and downstream extension pieces. The body shall be provided with two bearings to receive the plug trunnions and to support the plug inside the body. High-pressure grease lines for lubrication of bearings shall be provided and connected to centralized grease lubrication system of the unit. Alternatively, selflubricated bearings may be provided. The valve body shall have a base or feet for mounting and supporting the valve on a concrete foundation. 4.5.2. Valve Rotor and Trunions The valve rotor shall be of cast steel, or fabricated steel, and supported in its body by forged steel trunions rigidly attached by screw and keys. The valve rotor and trunnion assembly shall be placed horizontally in the halves of the valve body. Those portions of the main shafts that pass through stuffing boxes and operate in packing or bearing areas shall be protected by removable and renewable stainless steel sleeves. Trunnion packing (multiple V type) shall be provided at the outside end and designed to be replaced without dewatering the penstocks. Table 1 SN o. Component Service seal (Sliding part) Manufacturi ng Method Material S.St. 13-4 or better Material Standard ASTM A-743 GR/CA-3NM or similar/ equivalent Surface Hardne ss (BHN) 200 275

1. (i)

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(6X200MW) TEESTA STAGE III HE PROJECT BID DOCUMENT ii) 2. (i) ii ) Service seal (stationery part) Maintenance seal (sliding part) Maintenance seal (stationery part) Casting/Fab. Forging/Cast Casting/Fab. --do---do---do--

--do--

--do--

--do--

--do--

--do--

--do-275 max.230 max. 275 max --do-275 max -

3. Valve Rotor a) b Rotor ) trunnion c) Valve Body 4. 5.

C.St. -do-do--do-S.St. 13-4 or better BS 1456 Gr.A S.St 13-4 or better Syn.Rubb er --do-BS Gr A or equivalent ASTM A148 Grade 80-50 or equivalent

Bypass valve Casting body Bypass valve Needle and Forging seat surface Sealing Valve Body Sealing Valve needle and seal Trunnion gland seal Casting

6.

7.

ASTM A743 CR/CA-6NM

275 max

8.

--do--

--do--

4.5.3.

Valve Seats and Seals The downstream seats shall be designed for normal operation and the upstream seats shall be designed to be used when the downstream seats require adjustment or removal. The upstream body seat ring shall be oil operated with provision of mechanical locking arrangement.

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(6X200MW) TEESTA STAGE III HE PROJECT BID DOCUMENT Removable type seats of stainless steel Cr-13% and Ni-4% shall be provided on the valve body and valve plug, both upstream and downstream of the valve centerline for working seals. Both sets of body seat rings shall be retractable by control system. However, control system shall be arranged such that the upstream seats are normally disengaged. The guide surface of the retractable seat rings shall be of stainless steel to eliminate the possibility of contact corrosion or electrolytic action occurring with the seat rings. The retractable seat rings shall be operated by water pressure and fitted with O rings to prevent leakage of water past the seat rings. Upstream maintenance seal must have high degree of watertight reliability to ensure replacement of downstream service seal without dewatering penstocks. Application of protective coating of valve seals on valve body and valve Rotor shall be considered to increase reliability in service and prevention of corrosion damage. The cost coating shall be quoted optional extra. 4.5.4. Dismantling Joint, Upstream and Downstream Connecting Pipes The spherical valve shall be furnished with upstream and downstream companion flanges of the full face bearing type, made of annealed cast steel or fabricated from steel plate along with necessary connecting pipe (valve inlet pipe) to match with the corresponding penstock at upstream and suitable pipe for connecting with the turbine distributor at downstream of the valve. Necessary coordination in this regard shall be made by contractor with the penstock contractor and turbine manufacturer. The valve inlet pipe shall be fabricated from high strength steel plates conforming to ASTM-537, class-2. The following connections shall be provided on the valve inlet pipe: One for bypass valve One for spherical valve control One for emptying the penstock MAIN INLET VALVE 4-6

(6X200MW) TEESTA STAGE III HE PROJECT BID DOCUMENT Tapping for discharge/ flow measurements, and pressure gauges/transducers, etc. 4.5.5. Valve Servomotor The servomotor mechanism shall be furnished complete with trunnion mounted operating cylinder, piston, piston rod, connecting linkage, locking device and appurtenant parts. The servomotor shall be equipped with a hand operated mechanical locking device arranged to hold the spherical valve in the closed position against the full force of the hydraulic operating cylinder. Provision shall be made for padlocking this device in the closed position. The servomotor shall have sufficient capacity to open or close the spherical valve completely in about one minute each. Means shall be provided to positively lock and shield the adjustment device. Suitable counterweights shall be provided for self-closure of the valve in the shortest possible time without the aid of servomotor. All parts of the servomotor mechanism and spherical valve components shall be designed to withstand the full force of the hydraulic operating cylinder in the event the valve becomes stalled in any position. The servomotor mechanism shall also overcome any friction in the valve seats due to body distortion. Servomotors shall be capable of opening of MIV against full differential pressure. Proximity switches shall be provided for control and indication on the unit control board to indicate the valve open and close position. 4.5.6. Valve Operation and Control System The Oil pressure unit (OPU) shall supply oil for spherical valve. A local control switch and all necessary solenoid devices, limit switches, etc. shall be furnished to accomplish the following sequence of operations: Upon receiving an opening electrical impulse from the local control switch or DACS, the spherical valve shall open if required conditions are fulfilled. Upon MAIN INLET VALVE 4-7

(6X200MW) TEESTA STAGE III HE PROJECT BID DOCUMENT receiving a closing electrical impulse from the local control switch, remote push button, DACS or unit protective devices, the spherical valve shall close. Sequence of closing of valve shall be followed by application of service seal. In addition, service seal shall disengage before valve rotor/plug starts rotating. The spherical valve shall close automatically without electrical signal when the mechanical over speed trip device provides a mechanical or hydraulic impulse to the valve control. A control valve suitable for remote electric (220 V DC) and local manual operation shall be provided to operate and hold the valve in either the close or open position. 4.5.7. Control and Gauge Cabinet All control equipment, insofar as practicable, shall be housed in a metal cabinet with front control and instrument panel and hinged access doors. The following instruments and devices shall be incorporated in the unit gauge panel: Penstock pressure gauge (0 to 150 kg/sq. cm.) Distributor pressure gauge (0 to 150 kg/sq. cm.) Control switch for local control of valve and service/ maintenance seal Valve rotor/plug position indicator Valve operating seal position indicator Indicating lights to indicate valve fully open, valve plug moving, and valve fully closed positions. Pressure switch-interlock in control circuit Control valves and necessary piping Pressure gauge for oil pressure tank Other instruments/devices as felt necessary. 4.5.8. Bypass Valve and Piping A bypass line with necessary bypass valve and guard valve of suitable diameter shall be provided for filling the turbine MAIN INLET VALVE 4-8

(6X200MW) TEESTA STAGE III HE PROJECT BID DOCUMENT distributor and for equalizing the pressure on both sides of the valve plug before opening the main valve. The bypass valve shall be of needle or plug type, arranged for automatic operation, and suitable for throttling service at all openings, with a minimum of cavitation and vibration. The bypass valve shall be provided with a hand-operated stop, which may be adjusted to limit the amount of valve opening to any position from closed to fully open. An indicator shall be provided to show the operating position of the bypass valve. Needle and seat of bypass valve shall be of stainless steel. A hand operated high-pressure gate valve (guard valve) with solid disc shall be furnished, for installation on the by pass tap-off on the upstream inlet pipe, for shutting off penstock pressure from the bypass valve for maintenance purposes. A blow off connection for removing sediment from the valve body to the runner pit shall be provided at the bottom of the spherical valve. The connection shall be equipped with a hand operated gate valve and blow off valve in tandem. A blow off connection for the purpose of removing sediments from the valve body to the runner pit shall be provided at the bottom of spherical valve. The connection shall be equipped with an energy absorbing fitting on the discharge side of the blow off valve. 4.5.9. Air Relief Valve The necessary air relief valve shall be provided to admit air while draining the distributor, and to vent the distributor when filling from the by-pass line of the main inlet valve. 4.5.10. Pressure Oil System for Spherical Valve

4.5.10.1. General Each unit shall be provided with an oil system serving the main inlet valve operation for the operating mechanism, servomotor and controls. The pressure oil system shall consist of a sump tank, two (2) A.C. motor driven screw pumps of suitable capacity, oil pressure accumulator, pipes, fittings etc. (This may be common with Turbine Governing system)

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(6X200MW) TEESTA STAGE III HE PROJECT BID DOCUMENT 4.5.10.2. Oil Pressure System Each oil pump for the oil pressure supply system shall be independently driven by a 3-phase 415V a.c. electric motor and each shall have a capacity sufficient to operate the complete governor oil pressure system. A complete pump logic control system shall be provided that will permit the selection of either pump, as the main unit with the other pump acting as a standby, which will cut in automatically to supply the oil and close a set of alarm contacts. 4.5.10.3. Oil Pump Each oil pump shall be of the screw type, with a capacity (l/minute) of not less than the total servomotor volume per minute or higher according to DIN 3421-1987 when operating under the pumping pressure recommended by the manufacturer. Each pump shall be self-priming under maximum oil pressure and furnished complete with: Direct connected 3 phase AC motor, 415 volts 10%, 50 Hz completely enclosed frame, squirrel cage rotor type with class F insulation. Combination motor starter and contactors instruments and indicators. with

Unloader valve, check valve, pilot valve, safety valve, and required number of other automatic and hand operated valves for the complete scheme. Coupling and drive guards. Pumps shall be suitable for continuous operation even when the required pressure in oil pressure tank has been built up. Automatic control system with adjustable pressure switches, contactors and relays to ensure start up of standby pump in case of pump failure or pressure falling from preset value as per logic scheme approved by the Engineer. 4.5.10.4. Connections The connections to each pump shall be arranged so that either pump may be removed for repair or replacement without interfering with the continuous operation of the other. MAIN INLET VALVE 4-10

(6X200MW) TEESTA STAGE III HE PROJECT BID DOCUMENT 4.5.10.5. Oil Sump Tank The sump tank shall have adequate capacity to drain the entire oil system including servomotors. The two pumps starting equipment and related auxiliaries shall be mounted on the tank and wired complete with leads labelled and brought to terminal blocks in a suitable terminal box. The tank shall be provided with: Manhole Oil return strains readily removable for cleaning. Oil level sight gauge with guard and shut off valves Oil fill centrifuging and drain connections Low oil level alarm float switch.

4.5.10.6. Oil Pressure Tank 4.5.10.6.1. Capacity

The capacity of the pressure tank shall be sufficient to operate the servomotors of the spherical valve, with minimum pressure of normal operating range and under other normal operating conditions, through four complete servomotor strokes (4 x sum of servomotor volumes) with the oil pumps and air compressor not operating, and at the remaining pressure the operating mechanism can still operate with a safe margin. One complete servomotor volume shall be considered to be equivalent to the volume of oil required for one complete opening and closing stroke of spherical valve servomotor/s. Design calculation of capacity of oil pressure system shall be furnished. Alternatively This can be designed to operate with Nitrogen Bottle Battery Oil Pressure accumulators pipes, valves, fittings, instrumentation and switchgear and controls for manual, electrical and automatic operation and sustenance supplied for Turbine Governors for three consecutive Operations(CloseOpen Close) in case of non availability of OPU Pumps. (as detailed in Turbine Specifications)

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(6X200MW) TEESTA STAGE III HE PROJECT BID DOCUMENT 4.5.10.6.2. Construction

The pressure tank shall be constructed in accordance with part UW of the ASME Code for Unfired Pressure Vessels, Section VIII, for the maximum working pressure of the system. 4.5.10.6.3. Oil Pressure Tank Protection and Safety Features

Following safety/ control features shall be provided: Air pressure relief device, mounted on or near the top of the tank. Two low oil level devices with independent, adjustable, circuit closing alarm contacts. One low level device shall be set to operate an alarm when there is sufficient oil under pressure to provide only two full strokes of servomotor/s. The other low level device shall be set to shutdown the unit when there is sufficient oil under pressure for approximately 1- strokes. The pipe connections for these devices shall be independent of the oil supply lines to the servomotors. Two oil level devices with independent adjustable contacts for air compressor control. Pressure switch for air compressor control/solenoid valve pressure line. Sight oil level gauge with guard, shut off valves and automatic shutoff device. Automatic means to prevent entry of air into the oil piping system (float valve). Connection for air compressor line with shutoff valve and check valve. Air blow-off valve, pressure gauge, manhole, drain connection, lifting lugs, control devices for compressor, anchor bolts, and all necessary equipment for a complete assembly. 4.5.10.7. Oil Pressure Piping All piping shall be seamless steel. The entire piping system shall be welded, insofar as practicable, leaving only such flanged connections as may be necessary for erection or possible subsequent dismantling for repair. Whenever straight pipes are provided, tapered flanged connections shall be introduced to ensure leak-proof connection. MAIN INLET VALVE 4-12

(6X200MW) TEESTA STAGE III HE PROJECT BID DOCUMENT Long radius pipe bends shall be used in lieu of standard pipe elbows, wherever feasible. Gate valves shall be provided in the pressure line between the pressure tank and the actuator tank. The valves shall be located near the tank. Valves shall be cast or forged steel valve with rising spindle type and having flanged ends. 4.5.10.8. Cleaning and Painting The interior surfaces of tanks and piping shall be cleaned thoroughly to remove all mill scale and dirt. After cleaning, the interior of the sump and pressure tank shall be painted. All openings in tanks and ends of pipe shall be sealed to exclude foreign material during shipment and before installation. 4.6. Quality Control and Assurance The contractor has to supply the equipments of main inlet valve and accessories (spherical valve) of the best quality. The contractor has to maintain quality control during manufacturing, installing, testing& commissioning of equipment as per the approved quality assurance plan. 4.7. 4.7.1. Drawings, Documents and Design Calculations Drawings and Documents The Contractor shall submit the all the drawings and documents as per clause no.1.7.1.3 of GTS. These drawing should include at least the following: General arrangement, plan and section of valve, servomotor, etc. G.A. and assembly drawing of valves, control valves, other bypass, air bleeder Control schematic showing all devices, controls illustrating functioning of opening and closing sequences. Instructions for erection, operation and maintenance including replacement procedure for seals.

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(6X200MW) TEESTA STAGE III HE PROJECT BID DOCUMENT Other drawings specifications. 4.7.2. Design Calculation The Contractor is required to submit the design calculation for following to the Engineer for approval during detail engineering. Structural analysis of different parts of spherical valve Head loss calculation Torque calculation Oil pressure system 4.8. Shop Tests Major components of valve shall be match-marked and doweled to ensure correct assembly and alignment. The spherical valve shall be given complete and thorough hydrostatic test to demonstrate the strength of the valve body, valve plug and to determine leakage through the valve seats. Tests also shall apply to all the valve auxiliary equipment, which will be subjected to the penstock pressure, such as the bypass valve, control valve, servomotor cylinder, etc. The tests on the spherical valve shall be conducted as follows: The ends shall be closed with flanged bulkheads and the valve plug turned to the open position so that a hydrostatic pressure can be applied to the body of the valve by a suitable connection in the upstream bulkhead. The hydrostatic pressure shall be held for a period of 30 minutes at a pressure not less than 135 kg/cm2. After completion of the first test, the valve shall be closed, the downstream bulkhead removed, and the same hydrostatic pressure applied as before. After a period of 15 minutes, the pressure shall be reduced to maximum static pressure of 77.8 kg/cm2. The leakage through the closed valve shall then be accurately measured to determine whether the valve meets Contractors leakage guarantee. Leakage through each MAIN INLET VALVE as per provision of technical

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(6X200MW) TEESTA STAGE III HE PROJECT BID DOCUMENT seat shall be determined independently after a number of engage/disengage operations. All other tests including performance tests shall be carried out on each valve in accordance with IS: 7332. Insulation resistance measurement and dielectric tests on solenoids, control wiring and limit switches, etc. as per relevant IS/IEEE standards. Water tightness test on limit switches. Operational tests to check hydraulic interlocks for valve seat and plug operations. Hydraulic testing of valve servomotors, pressure accumulator and all water pipelines at two times the normal working pressure. Leakage test of valve servomotors. Functional check of all limit switches, control valve and pressure gauges. Operational check of assembled valve and servomotors for free movement for closing and opening. Hydrostatic and leakage tests on bypass drain air release and other valves. A list of shop assembly and tests required to be carried out as per approved 'QAP'. 4.9. Installation and Commissioning The contractor shall furnish all labour, tools, supplies, strings and supports and all other provisions or materials necessary to assemble, erect, install, test and commission the equipments in a thorough workmanlike manner following the best modern practices. The equipment and all their components shall be placed with great care and shall be aligned correctly to provide an installation consistent with the close tolerances used in the erection of modern equipment. The proper elevations and centerlines to which equipment is to be set shall be established by the contractor. All necessary materials and labour for performing all the site tests shall be provided by the contractor. All test equipment and instruments shall be furnished by the contractor and will remain the contractors property after the fulfillment of all field tests. MAIN INLET VALVE 4-15

(6X200MW) TEESTA STAGE III HE PROJECT BID DOCUMENT All civil work required for foundation shall be carried by other contractors. The contractor is required to submit all foundation drawings well in advance. 4.10. Field Tests All field tests including operational, precommissioning and commissioning tests shall be conducted by the Contractor to ensure proper performance for guarantee considerations. Following field tests shall be performed to ensure that the valve meets specification provisions and manufacturers guarantee: Leakage test after site assembly, before installation to be performed on valves. Tests domes for the pressure test to be supplied. Tests to determine opening/closing time during normal and emergency shutdown conditions. Tests to check penstock pressure rise under 110% load throw-off conditions with respect to maximum turbine discharge condition for all the six machines. Tests to determine leakage from each valve seals under specified head conditions with penstock filled with water including operation test to check maintenance & operation leakages after repeated applications (10-15 times). Testing and setting of all relays, limit switches and electrical control. Dielectric and insulation measurement tests on all electrical items i.e. solenoids, limit switches, wiring, etc. as per relevant standards. Operation Test to check sequence of operation and interlocks of bypass valve, air bleeder valve, valve plug and valve seats as per approved logic diagram. Any other tests as recommended by Manufacturer or are necessary as per the provision of specifications and applicable IS/IEEE standards.

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(6X200MW) TEESTA STAGE III HE PROJECT BID DOCUMENT 4.11. 4.11.1. Spare Parts General spare parts The Contractor shall supply the general spare parts as per clause no. 1.7.24 of GTS. The supply of this spares shall be as per the approved list of spares for each component / equipment / item during detail engineering. 4.11.2. Recommended spare parts The Contractor shall furnish the list of recommended spare parts as per clause no 1.7.24 of GTS The following specified spare parts, as defined in GTS. which shall comprise the total requirement for Main inlet valve and accessories under this Contract, shall be supplied. Complete downstream moveable seat ring assembly 2 sets including O rings Plug seat ring 1 Set Sets of all O ring seals and all gaskets

for one valve including valve servo-motor and necessary equipment Upstream Seals Sets Coil for each type of solenoid, incorporated 1 set Number of each size of valve used 1 set All types of indicating lamps 6 sets Bypass Valve Assembly 1 set Air release valve assembly 1 set Set of 5% piping/fittings 1 set into the control 4 Sets 2

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(6X200MW) TEESTA STAGE III HE PROJECT BID DOCUMENT Motor of each type 1 set Oil pump for spherical valve pressure supply 1 set Complete set of gaskets, O rings and packing

used in spherical valve pumping set. 1 set Level switches and relays 1 set Pressure switches and relays, limit switches 1 set Sight glass gauges for pressure and sump tanks 1 set Trunnion bearing 1 set

Note: One set is defined as the total number required for one unit. 4.12. Special Tools The Contractor shall provide one set of all necessary special tools and maintenance equipment for repair and maintenance as recommended by the manufacturer. A list of such tools shall be approved during detail engineering However, it shall include at least following maintenance equipment for repairs and maintenance with descriptions and quantities of the following: Special erection tools, instruments and devices Maintenance hand tools, wrenches, instruments etc. Cranes, hoists, winches, etc. required for erection.

4.13.

Schedule of Requirements I) Six (6) nos, 1800 mm dia spherical valves complete with piping valves, controls, control and gauge cabinet and associated equipment as specified. Tools and plants maintenance. for assembly, disassembly and

II)

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(6X200MW) TEESTA STAGE III HE PROJECT BID DOCUMENT III) IV) Spares One (1) set of templates for site repair/ replacement of service/ maintenance valve seals.

4.14

Guaranteed And Other Technical Particulars The guaranteed and other technical particulars shall be as per annexure.

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