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TECHNICAL SPECIFICATION FOR 600 TR VAPOUR ABSORBTION CHILLER FOR MAPS.

1.0 General

1.1 This specification is intended to design, manufacture and supply of 600 TR Vapor

Absorption Chiller (VAM) which includes erection, commissioning, performance testing and

providing performance guarantee at Madras Atomic Power Station, Kalpakkam, located at

about 65 kilometers from Chennai, in the coast of Bay of Bengal.

1.2 The climate at Kalpakkam is tropical with high humidity and is conducive for corrosion and

fungus growth.

1.3 The Power station consists of two identical power generating plants, each rated for 220

MWe and chilled water is used for various process cooling requirements.

1.4 Satisfactory operation of the power station will depend upon reliable and uninterrupted

supply of chilled water and hence the chiller being supplied shall be of proven and rugged

design.

1.5 The system supplied shall complete in all respects, ready for operation with all auxiliaries,

safety features, electrical, instrumentation, etc. Any item not specifically mentioned in this

specification but nevertheless required for satisfactory operation, maintenance and safety

of the equipment / personnel shall be deemed to have been specified by the purchaser and

shall be included in the scope of supply of the vendor.

1.6 The requirements specified in the technical specification are minimum requirements and it

is the responsibility of the bidder to provide a system that can perform satisfactorily at the

maximum specified conditions and at the rated capacity.

1.7 Scope of supply shall include the following:

1.7.1 Factory assembled and leak tested, packaged, water-cooled absorption water chillers,

consisting of absorber / evaporator assembly, condenser / low temperature generator

assembly, high temperature generator, Absorbent heat exchangers, filters, absorbent and

refrigerant pumps and motor, purge system, control panel with machine status, diagnostic

display and safeties, interconnecting piping, absorbent, inhibitor and refrigerant, auxiliary

components and accessories.

1.7.2 Supply of Steam Pressure Reducing Valve (PRV) and steam control valves (CV). Steam PRV

should match to the inlet steam which is dry saturate at a pressure of 40 kg/cm2 (g) &

250OC suited to maximum of 3 inch NB carbon steel pipe (ASTM A-106 Gr-B).

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1.7.3 All accessories like control, instrumentation, electrical cabling, pumps, valves, refrigerant,

absorbent and all other items that are required for the satisfactory operation of the chiller

shall be under the scope of contractor.

1.7.4 Inspection and testing at contractors works as well as at MAPS

1.7.5 Packing, delivery of items to MAPS, receipt and unloading at MAPS.

1.7.6 Site erection of the equipment, piping, wiring and control system installation and

commissioning.

1.7.7 Performance test at site.

1.7.8 Training of MAPS personnel at contractor’s training center and operation and maintenance

training at MAPS to O&M personnel

1.7.9 Chiller Operation and Maintenance Manual which shall include starting, performance

assessment, operational aids, trouble shooting, etc.

1.7.10 Test reports and test certificates of Chiller unit and its components.

1.7.11 All the as built drawings

1.7.12 One set of special tools and tackles

1.8 Vendors are advised to carry out site survey to familiarize with the existing systems, site

conditions and the quantum of work involved at site prior to bidding in their own interest.

1.9 All the equipments shall be heavy duty type suitable for industrial installations and capable

of providing trouble free performance for a long period of time.

2.0 Pre-Qualification Criteria for Suppliers

2.1 Vendor should have successfully supplied and commissioned similar system of similar

capacity or more in any of the Power Plants in India.

2.2 Vendor should have supplied at least 200 machines of similar vapour absorption type with a

minimum capacity of 300TR or more in India in the last 5 years.

2.3 Vendor should have design capability and the product shall be designed and manufactured

in India.

2.4 Vendor should have manufacturing set up in India and structured sales and service network

in Chennai.

2.5 Vendor shall be able to supply spare parts and shall have established after sles service

team network in India.

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2.6 Vendor should have minimum 20 years of experience in design and manufacture of Vapor

Absorption Machines (VAM).

2.7 Company’s yearly turnover should be more than Rs 150 crores on a continuous basis for

the past three years.

2.8 Bidder shall enclose the details of the vapour absorption machines already supplied by

them along with the utilities contact details in the bid for review by NPCIL.

3.0 Specification for 600 TR Vapor Absorption Chiller

Description Unit Cooling Mode

Capacity ( + 3 %) : TR 600.0

A Chilled Water Circuit :

1. Chilled water flow m³/hr 360.0 (available)

2. Pressure drop across the machine kg/cm2 0.8 max

3. Chilled water inlet temperature °C 11.0

4. Chilled water outlet temperature °C 6.0 (required)

5. Chilled water Connection diameter DN 250mm (existing)

6. Chilled water fouling factor m² hr°C/kcal Standard

7. Maximum working pressure kg/cm²(g) 8

B Cooling Water Circuit:

1. Cooling water flow m³/hr 600.0 (available)

2. Pressure drop across the machine kg/cm2 0.8 max

3. Cooling water inlet temperature °C 34.0

4. Cooling water outlet temperature °C 39.5 max

5. Cooling water connection diameter DN 250mm (existing)

6. Cooling water fouling factor m² hr°C/kcal Standard

7. Maximum working pressure kg/cm²(g) 8

C Steam Circuit :

1. Steam pressure kg/cm²(g) 40.0 (available)

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2. Steam consumption ( + 3 %) kg/hr To be specified

3. Condensate drain temperature °C 70 – 100 (required)

4. Condensate drain pressure kg/cm²(g) 1.0 (required)

5. Connection - Inlet diameter DN To be specified

6. Connection - Drain diameter DN To be specified

7. Design Pressure kg/cm²(g) 10.5

D Electrical Data :

1. Power supply 415 V( ±10%), 50 Hz (±5%), 3

Phase, 3 wire system

2. Power consumption kVA 20 max

3. Absorbent pump rating kW (A) To be specified

4. Refrigerant pump rating kW (A) To be specified

5. Vacuum pump rating kW (A) To be specified

6. Starting methodology for the above

pumps

To be specified

E Physical Data :

1. Length mm 5900 max

2. Width mm 2500 max

3. Height mm 3500 max

4. Operating weight ton To be specified

5. Flooded weight ton To be specified

6. Dry weight ton To be specified

7. Shipping Weight ton To be specified

8. Tube cleaning space mm To be specified

F Tube Metallurgy :

1. Evaporator tube material Copper based

2. Absorber tube material Copper based

3. Condenser tube material Copper based

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G Low Temperature Heat

exchanger Type Standard

4.0 Standards to be followed

The design, manufacture and performance of the equipment shall comply with all currently

applicable standards, regulation and safety codes applicable. Nothing in this specification

shall be construed to relieve the contractor of this responsibility.

4.1 JIS Standard 8622B for Vapor Absorber Machine.

4.2 ASME codes for unfired pressure vessels Section-VIII Div.-1

4.3 Relevant IS standards for motors, switch gears and control devices.

4.4 TEMA standards for class-C heat exchangers, wherever applicable.

4.5 IS-660 Safety code for mechanical refrigeration

4.6 All other relevant specifications as indicated by manufacturer.

5.0 Details of the existing systems :

5.1 Chiller unit, being procured through this tender, is for installation in a chiller plant, already

provided with other chiller machines.

5.2 Cooling water is derived from a closed loop process water system that caters for many

loads in addition to the chillers. Similarly, the chilled water is a closed loop system and has

four centrifugal pumps. These pumps supply chilled water to all the four existing chiller unit

and will also supply chilled water to the unit being procured as a fifth machine in the chiller

plant.

5.3 Both the process water and the chilled water are treated water with stringent chemistry

control.

5.4 Chemistry parameters of Chilled Water available at MAPS:

a. Specific Gravity : 1.0

b. pH value : 8.5 to 9.5

c. Suspended solids : 5 ppm

d. Silica : 0.1 ppm max

e. Chemical added : LiOH

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5.5 Chemistry parameters of Cooling Water available at MAPS:

a. Specific Gravity : 1.0

b. pH value : 8.5 to 9.5

c. Total dissolved solids : 250 ppm

d. Total suspended solids : 100 ppm max

e. Calcium as CaCO3 : 100 ppm max

f. Total hardness : 200 ppm max

g. MO alkalinity : 200 ppm as CaCO3

h. Silica : 0.1 ppm max

6.0 Requirement of the new chiller unit:

6.1 The chiller unit will be installed in the existing chiller plant. Hence the boundary dimensions

of the proposed chiller unit shall be such that it can be accommodated within the maximum

dimensions specified in Section-E of 3.0 (Specifications for the chiller). Detail of the floor

space available is indicated in the attached schematic.

6.2 Foundation details, load details and dimensions shall be indicated by the supplier in his bid

along with overall dimensions of the chiller unit to verify adequacy of existing space to

place the new chiller machine.

6.3 Process steam is available at 40kg/cm2 pressure and at 250OC temperature. The chiller

being procured shall be designed to derive its steam requirements from this source.

6.4 Refrigerant: De-ionized or distilled water.

6.5 Absorbent: Lithium bromide solution with corrosion inhibitor.

6.6 Performance enhancer: Octyl Alcohol.

6.7 To minimize corrosion, the chiller shall be designed in compliance with advanced series flow

technology to avoid simultaneous occurrence of high temperature and high concentration.

Two stage evaporation technology shall be utilized to minimize specific steam consumption

and to maximize the performance.

6.8 The chiller unit shall be designed in such a way that it would be possible to operate the

machine at various loads i.e from full load to part load of 10% minimum for long durations

without any problems on a continuous duty cycle.

6.9 Units shall be designed to operate without crystallizing even with cooling water-entering

temperature of 10o C minimum. For the rated condition, the crystallization temperature

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should be at least 12o C below the operating temperatures to avoid crystallization during

varying loads.

6.10 Real time on-line concentration monitoring shall be incorporated in the machine and

concentration of the strong solution shall be continuously displayed in the control panel.

The PLC shall have programme to compare the real time concentration with the

crystallization temperature and shall initiate corrective action.

6.11 The chiller unit shall be designed with split absorber to improve the absorption rate of

Lithium Bromide and for improved efficiency.

6.12 The chiller unit shall be provided with multi stage level sensing provisions in High

Temperature Generator, Absorber and Evaporator in order to ensure precise control of

Lithium Bromide and refrigerant during fluctuating part load conditions, to avoid dry

running of absorbent and refrigerant pumps and thus increase the life of Absorbent pumps.

The level measurement system shall be passive and shall not have any moving

components.

6.13 Chiller unit shall have provision for auto shut off on low pressure in the steam inlet to

chiller.

6.14 Condensate from the unit shall be collected in a condensate storage tank and this

condensate shall be taken back to the main system. The capacity of the condensate tank

shall be such that it shall be possible to operate the machine at maximum capacity for at

least 30 minutes without the condensate tank overflowing in the event of failure of the

condensate transfer pump.

6.15 Condensate transfer pump shall be of steam pressure powered pump.

7.0 Heat exchangers

7.1 High temperature generator (HTG) shall be a shell and tube type heat exchanger. Steam

shall pass inside the tubes and the absorbent solution shall flow outside these tubes. The

tube sheets shall be of boiler quality carbon steel and tubes shall be of titanium stabilized

Ferritic stainless steel SS-430 Ti, with plain or enhanced surface.

7.2 Low temperature generator (LTG) shall be shell and tube type heat exchanger. The

refrigerant Vapour from high temperature generator shall pass through the tubes and the

absorbent solution shall flow outside the tubes. The tube sheets shall be of boiler quality

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carbon steel and tubes shall be of titanium stabilized Ferritic stainless steel SS-430 Ti, with

plain or enhanced surface.

7.3 A low temperature absorbent heat exchanger (LTHE) shall be an integral part of the

machine to increase the COP by pre-heating the weak solution with strong solution. This

shall be copper brazed stainless steel plate type heat exchanger.

7.4 A high temperature absorbent heat exchanger (HTHE) shall be an integral part of the

machine to increase the COP by pre-heating the weak solution with intermediate solution

from HTG. This shall be copper brazed stainless steel plate type heat exchanger.

7.5 A drain heat exchanger (DHE) shall be integral part of the machine to increase efficiency by

pre-heating weak solution with condensed refrigerant from low temperature generator. This

shall be copper brazed stainless steel plate type heat exchanger.

7.6 A heat Re-claimer (HR) shall be integral part of the machine to pre-heat weak solution with

steam condensate from high temperature generator. This can be a shell and tube type or a

plate type heat exchanger with stainless steel plates.

7.7 Tubes in evaporator, absorber and condenser shall be of seamless DLP (De-oxidised Low

residual Phosphorous) copper, with plain or enhanced surface.

7.8 Stainless steel Eliminators shall be provided to separate absorber from evaporator, low

temperature generator from high temperature generator and condenser from low

temperature generator.

7.9 Helium shroud and spray leak test shall be performed to ensure leak tightness of the unit.

The leak rate should be less than 5 x 10-7 std cc/sec.

8.0 Absorbent and refrigerant distribution:

8.1 Gravity feed distribution technology shall be utilised to spray refrigerant in evaporator and

lithium bromide solution in absorber. Absorbent in spraying tubes shall spray downward to

ensure good film thickness and better heat transfer.

8.2 The system shall be of non-clogging design specifically designed for the intended duty,

providing consistent spray throughout the life of the machine.

8.3 The spray trays should be of stainless steel.

9.0 Water boxes:

9.1 Unit shall have marine type water boxes on at least one side of condenser and absorber

bundles, and bonnet type water boxes on the evaporator bundles.

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9.2 The water boxes shall be designed for a maximum allowable working pressure of 8.0

kg/cm2(g). All water boxes shall have ANSI #150 raised face flanges for nozzle

connections.

9.3 All water boxes shall be provided with drains and vent connections.

10.0 Canned motor pumps:

10.1 Solution and Refrigerant pumps shall be solution cooled, centrifugal type canned motor

pumps.

10.2 Isolation valves should be welded at inlet and outlet to enable easy maintenance of the

pumps.

10.3 Pumps shall be so designed to facilitate removal / replacement of bearings and filters for

maintenance.

10.4 Bearings shall be designed for a minimum trouble free operation of 20000 hours of

operation.

10.5 Bearing monitor shall be provided to indicate degradation in pump bearing.

10.6 The motor power rating shall be such that at least 10% margin exists on maximum load

demand in the entire operating range of the pumps.

10.7 Ambient temperature of 50OC shall be considered in designing the motors for pumps.

11.0 Valves:

11.1 All valves used for adjusting the solution flow shall be of fully welded design to prevent

leakage of air into the unit.

11.2 All isolation and service valves shall have double seal arrangement with one seal having no

moving parts.

11.3 The steam control valve shall be pneumatic operated, with air failure to close, globe type

valve.

11.4 Diaphragm valves, shall be used only in the purge system to isolate chiller and provide

access to the vacuum pump. A non-return valve shall be provided for vacuum pump.

11.5 Scope of supply shall include steam PRV / steam pressure control valve, relief valve, steam

line CV, condensate transfer pump with head capacity of 10 mWC, condensate collection

tank of capacity of about 600 liters, etc.

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12.0 Sight glasses:

12.1 Unit shall be equipped with at least one sight glass in the evaporator, absorber and high

temperature generator each to permit exact adjustment of absorbent and refrigerant levels

for tuning and troubleshooting.

12.2 Sight glass should be non-fused, removable type to permit maintenance.

13.0 Thermal Insulation:

13.1 Insulation of hot and cold surface areas shall be carried out at the manufacturer’s factory.

13.2 However, for multi-sectional shipment this shall be provided, after installation of the

machine at MAPS, according to appropriate standards, installation and material type as

required to meet the codes.

13.3 Detailed technical document on the insulation shall be provided by supplier.

13.4 Non-combustible insulation material of closed cell elastomeric rubber foam / thermocool

shall be used for cold surfaces and hot surfaces.

13.5 Insulation for evaporator header, HTG header, instruments on chilled water circuit shall be

removable.

14.0 Purge system:

14.1 System shall be designed to automatically remove non-condensable gas from chiller to

purge tank during machine operation.

14.2 The removal of non-condensable gas from the purge tank shall be automatic or manual.

14.3 An absolute pressure transmitter with a range of 0-100 mm Hg shall be used to measure

the vacuum. The purge system should be equipped with a absorbent cooler for improved

purging efficiency.

14.4 Vacuum pump shall be oil sealed rotary vane type, skid mounted and factory installed. Anti-

suck back arrangement shall be provided to prevent air leakage.

15.0 Piping requirements:

15.1 Piping and instrumentation for the chilled water, cooling water, and steam supply and

condensate return shall be supplied and installed by the contractor.

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15.2 The supply and installation of the absorber to condenser piping shall be furnished by the

chiller manufacturer.

15.3 Chilled water flow switch and DP switch shall be factory supplied and factory installed on

the chilled water nozzles.

15.4 All chilled water, condenser water, steam and condensate connections are to be provided

with factory welded ANSI flanges.

16.0 Lithium Bromide and refrigerant charge:

16.1 Lithium Bromide should be packed separately outside the chiller main body so that during

transportation it will not cause heavy movements to avoid shifting of center of gravity

causing possibility of toppling. If the machine is tested at factory maximum possible

absorbent should be taken out and charged with Nitrogen

16.2 Lithium bromide solution shall contain a corrosion inhibitor, to minimize the rate of copper

and ferrous metal corrosion on the solution side of the unit.

16.3 The corrosion inhibitor used shall be non-toxic and shall not generate ammonia in order to

protect copper tubes in the chiller.

16.4 Lithium bromide solutions containing chromates or arsenites as corrosion inhibitors shall

not be acceptable.

17.0 Electrical requirements:

17.1 Power supply to the unit shall be as specified on the equipment schedule.

17.2 Electrical power requirements and the power scheme of the equipment shall be provided

along with the offer for detailed review by MAPS.

17.3 Contractor shall supply and install all auxiliary electrical protection devices as per codal

requirements and as felt necessary by the chiller manufacturer.

17.4 Contractor shall supply and install all electrical wiring (both low voltage and line voltage)

and devices required to interface the chiller controls with the power plant control system.

17.5 Each electrical device shall have two grounding terminals and shall be connected to station

ground bus.

17.6 All the interconnection cables, within the panel and between the panel to equipments, shall

be FRLS copper cables.

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17.7 All cable terminations shall be through tinned copper lugs.

18.0 Controls:

18.1 The chiller shall be controlled by a skid mounted, stand-alone, branded, Programmable

Logic Control (PLC) based control system.

18.2 The operator interface shall have touch screen type colour display, providing easy access to

various performance parameters of the chiller.

18.3 The chiller control panel shall be located in the Chiller control room, away from the chiller

unit, and shall monitor & control chiller operation by means of steam control valve,

temperature sensors, flow instruments, level probes, various relays and switches.

18.4 PLCs shall be equipped with self diagnostic capability.

18.5 The Control Panel enclosure shall be of IP42 protection class and shall house the following

components:

a. Single point wiring connection for incoming power supply.

b. Non fused disconnect switch.

c. Motor starters, complete with current overload protection, for absorbent pump(s),

refrigerant pump, and purge pump (current overloads).

d. Multi-tap transformer to suit 3 phase, 415 V, 50 Hz input power to the panel and

secondary tap to give Control Power supply.

e. Step down Transformer should be located outside the control panel.

18.6 Capacity control shall be achieved by means of PID control in PLC, thereby controlling the

steam control valve opening based on chilled water inlet temperature. During cold start, the

steam control valve shall be opened in a controlled manner to eliminate thermal shock.

18.7 The chiller control panel shall incorporate advanced motor protection to safeguard the

motor throughout the starting and running cycles from the adverse effects of Motor

overload.

18.8 A Variable frequency drive shall be provided for absorbent pump to regulate the absorbent

flow rate during part loads, thereby reducing power consumption and specific steam

consumption.

18.9 PT-100 type RTDs should be used to measure the required process temperatures. The

thermo-wells shall be of stainless steel. All thermo-wells on the vacuum side should be

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directly welded to the piping to avoid leakages. Flanged or threaded connections are not

acceptable on vacuum side.

18.10 Since chilled water flow safety is extremely important to prevent ice formation, more than

one device should be provided to sense low chilled water flow. An independent flow

transmitter and a flow switch shall be provided to ensure redundancy and diversity.

18.11 Safety (Total) shutdowns – Panel shall be pre-programmed to shut the unit down and close

“safety shutdown” contacts under any of the following conditions:

a. Low / loss of chilled water flow.

b. Leaving chilled water temperature sensor error.

c. Low leaving chilled water temperature / anti-freeze trip.

d. Absorbent pump trip / not responding.

18.12 All safety shutdowns shall require unit to be manually restarted.

18.13 Watch dog contact facility to indicate healthiness of control power supply

18.14 Control Panel terminals shall preferably be screw-less type.

18.15 Whenever a safety shutdown occurs, except power failure, logging of last six alarms should

take place in PLC. After any alarm, operator has to manually acknowledge the alarm and

reset the alarm to start the machine again.

18.16 Warning Conditions – PLC Panel shall close warning contacts and generate a unique

warning message whenever one of the following operating conditions is detected:

a. Purge pump current overload.

b. Faulty chilled water inlet temperature sensor.

18.17 Cycling (Dilution) Shutdowns – The Panel shall be pre-programmed to shut unit down

whenever one of the following conditions is detected:

a. High temperature generator temperature high.

b. High temperature generator vapour temperature high

c. Faulty temperature sensor (in case of cooling water inlet, cooling water outlet, high

temperature generator temperature, low temperature generator, spray solution or

refrigerant U-tube sensor error).

d. Low entering cooling water temperature.

e. Refrigerant pump trip / not responding.

f. Power failure.

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18.18 Last six alarms will be logged in Operator Panel with date & time. After each normal as well

as abnormal shutdown, only manual start is required.

18.19 The chiller control panel shall be capable of displaying system data in the following formats:

a. English as well as Metric units.

b. Display numerical as whole numbers or one digit right of decimal.

18.20 The front of the chiller control panel shall be capable of displaying the following in clear

language, without the use of codes, look-up tables, or gauges:

a. Entering chilled water temperature.

b. Leaving chilled water temperature.

c. Entering cooling water temperature.

d. Leaving cooling water temperature.

e. Intermediate absorbent temperature leaving high temperature generator.

f. High temperature generator refrigerant temperature.

g. Strong absorbent temperature leaving low temperature generator.

h. Strong absorbent temperature leaving low temperature heat exchanger

i. Condensed refrigerant temperature leaving condenser

j. Strong absorbent concentration

k. Percentage opening of steam control valve.

l. Chiller running hours.

m. Purge pump-out time last or current cycle.

n. Total purge pump-out time.

o. Time / date of last purge pump-out.

p. Chilled water set point.

q. Chiller status.

r. Pump and instrument status

19.0 Low temperature safety

19.1 If chilled water temperature goes low, refrigerant pump and the steam supply should be

stopped to avoid chilled water temperature reaching anti-freeze setting thereby avoiding

the tripping of the chiller.

19.2 When chilled water temperature goes above set point value, refrigerant pump and steam

supply should commence automatically.

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19.3 The chiller control panel shall take run / trip feedback from chilled water and cooling water

flow to generate alarm / take adequate safety action in case of low flow.

20.0 Crystallisation prevention

20.1 Crystallization prevention shall be carried out based on the actual strong absorbent

concentration.

20.2 The heat input to the chiller should be limited as a preemptive action based on the strong

absorbent concentration.

20.3 To prevent crystallization, the level of LiBr in absorber should be measured and refrigerant

blow down should be automatically given when the level drops.

21.0 BMS / DCS connectivity

21.1 Third party connectivity shall be through read-only MODBUS RTU protocol through an RS

485 port available on the PLC.

21.2 The operating parameters, alarms and status of chiller mounted instruments shall be

available for monitoring from the central control room.

21.3 All necessary hardware and software required to connect chiller PLC to BMS/DCS system

shall be supplied and installed by the contractor.

22.0 Quality Control and Inspection:

22.1 On placement of PO, supplier shall provide detailed QA plan indicating the various

inspections and testing of the chiller components.

22.2 The QA plan shall include all the testing, right from raw material identification to the tests

done after complete assembly. Leak tests, vacuum test, performance tests, test reports of

LiBr and other chemicals, physical properties of materials, logic checks, etc shall form the

minimum requirements of the QA plan.

22.3 Test reports for motors

22.4 Drawings of the chiller unit shall be submitted by the supplier indicating details of all the

sub components, dimensions, ratings, etc.

22.5 Details of welding procedures, welder qualification, NDT procedures, shall be submitted.

Welder qualification will be certified by NPCIL QA or its authorized agencies. All the weld

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joints shall be inspected by the appropriate NDT methods and details of the same shall be

provided in the QA plan.

22.6 Ultrasonic test shall be performed on all castings and forgings. Procedure and acceptance

standards with areas subject to NDT shall be clearly indicated in QA plan.

22.7 Details of all the bought out items shall be clearly indicated with the make, technical details

and shall be submitted along with the QA plan and the drawings.

22.8 All the above documents will be reviewed and approved by NPCIL. Only after such

approval, manufacturing can commence.

22.9 Review and approval of documents by NPCIL would be only to verify the compatibility with

basic designs and concepts and in no way absolve the contractor of his responsibility /

contractual obligation to comply with the tender / contract requirements, applicable codes,

specification and statutory rules and relations. Any error / deficiency noticed during any

stage of manufacturing / execution / installation shall be promptly corrected by the

contractor without any extra cost or time, whether or not comments on the same were

received from NPCIL during the review stage.

22.10 NPCIL QA will carry out stage wise inspection as per the specifications, drawings and the

approved QA plan. Supplier shall organize for all the test facility during such inspections. All

the inspection documents shall be compiled and the entire reports shall be handed over to

NPCIL in soft copy as well as two hard copies for reference and records.

22.11 Performance test, including determination of capacity, efficiency and characteristics, etc

shall be clearly indicated in the inspection plan. Performance data shall be clearly ndicated

in the drawing /data sheet submitted for approval.

22.12 Material can be dispatched only after final inspection and issue of shipping release by

NPCIL QA.

22.13 Sample QA plan is attached for reference

23.0 Performance guarantee:

23.1 The tenderer shall guarantee the performance of the equipment supplied under this

specification, when working under the normal operating condition / design conditions as

specified in the data specification sheet for at least 2 years from the date of commissioning.

23.2 The machine will be available for commissioning within 6 months from the date of receipt

of the machine at site.

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23.3 The guaranteed performance parameters furnished by the bidder in his offer, shall be

without any unspecified tolerance values and all margins required for instrument

inaccuracies and other uncertainties shall be deemed to have been included in the

guaranteed figures.

23.4 If the shop performance tests indicate failure of equipment to meet the specified

requirements, it would be tenderer’s responsibility to carry out required modifications at no

extra cost to purchaser. Tests shall be repeated after carrying out the modification to

demonstrate satisfactory performance.

23.5 Supplier shall make routine visits (at least once in three months) for assessing the health of

the machine and for tune up for at least 2 years period after successful commissioning.

23.6 A group of four personnel from NPCIL shall be trained at the manufacturers factory on the

operation and maintenance aspects of the chiller, free of cost.

23.7 In addition, supplier shall provide the detailed training for the operation and maintenance

staff of NPCIL at the purchaser’s premises, free of cost. Training and transfer of knowledge

for operation and maintenance of the chiller unit shall form part of contract and a part of

supplier’s scope.

24.0 Special cleaning and painting:

24.1 All equipment surfaces shall be smooth and free from burrs and shall be protected against

corrosion and mechanical damage.

24.2 Low temperature equipments and pipe’s external surface to be coated with two coats of red

lead primer.

24.3 High temperature equipments and pipe’s external surface to be coated with two coats of

heat resistant (HR) paint as per Annexure -1 for painting specification.

24.4 Since the environment is highly corrosive, detailed corrosion resistant painting specification

shall be submitted for review and approval by NPCIL.

25.0 Drawings:

Supplier shall submit the following drawings with the proposal and when approved by the

purchaser shall be considered as part of the specification.

25.1 Dimensional outline drawing of 600 TR VAM on A3 size paper.

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25.2 In this drawing various components (bill of materials) of the VAM and its materials of

construction shall be tabulated.

25.3 Drawings of the various heat exchangers deployed in the unit.

25.4 Dimensioned outline drawings of foundation on A3 size paper.

25.5 Dimensioned drawing of companion flanges – In this drawing ID, OD, thickness, PCD,

Number and size of bolt holes shall be given. Material of construction of the flanges shall

be clearly indicated.

25.6 Complete Electrical and control schematic of the chiller.

25.7 Technical data and drawings of associated components like steam PRV, CV, relief valve,

controllers, relays, etc.

25.8 After approval, all the drawings like Equipment datasheet, GA drawing, Foundation

drawing, Insulation drawing, Steam CV datasheet, PRDSH data sheet, E&I panel drawings,

Control panel GA, Instrument datasheets, QAP, Painting procedure, etc shall be submitted.

Drawings shall be submitted in AUTOCAD, in soft copy as well as hard copy, for reference

and records of NPCIL.

26.0 Documents to be submitted:

Supplier shall submit three hard copies and soft copies of the following documents to the

purchaser for reference and retention:

26.1 Design manual

26.2 Inspection and operation manual indicating operating parameters, limits, trip values and

troubleshooting guide

26.3 Maintenance manual detailing the preventive maintenance requirements

26.4 Manual for method of testing and calibration of all instruments and controls

26.5 System interlocks and interlock block diagram

26.6 Schematic piping diagrams with details of equipments

26.7 Test reports of all the components properly indexed

26.8 Performance test report

26.9 Manuals for all the bought out items

26.10 Data sheet for all the equipments including heat exchangers

26.11 Details of spare parts with part number and description

19

27.0 Spare parts:

27.1 The supplier shall indicate item wise prices of all spare parts and consumables

recommended by him for five years of satisfactory operation of the equipment being

supplied by him in addition to the items referred below.

a. Absorber Pump.

b. Refrigerant circulating Pump.

c. Purge pump with motor

d. One steam Pressure Reducing Valve (PRV)

e. One Steam Control Valve (CV)

f. One set of sight glasses of various sizes

g. One set of hoses of various sizes

h. One set of elastomers of various sizes

i. One set of diaphragms of various sizes

j. One set of angle valves of various sizes

k. PLC- PLC CPU, digital input and output cord, analog input / output cord and RTD

cord.

l. Starter units.

27.2 Contractor shall supply adequate quantity of commissioning and start up spares so as to

ensure commissioning of the system is not hampered for want of spares. Supply of

commissioning and start up spares in included in the scope of contract and no extra

payment will be made.

27.3 Any spares required during commissioning shall be supplied by the contractor without any

time and price implication.

27.4 Supplier shall provide an undertaking for supply of spares for smooth operation of the

chiller in future.

28.0 Packing and shipment:

28.1 All parts shall be properly packed, boxed, crated or otherwise protected for preventing any

possible damage during transportation.

28.2 Flanges shall be drilled as per the specified standard and all exposed surface shall be

protected by fitting suitable wooden / metal / PVC blank flanges so that they are not

damaged during transportation.

20

28.3 No shipment shall be made unless shipping release is issued by purchaser in writing and for

shipment.

28.4 Lifting lugs to be provided for lifting / shifting / erection of the equipment and capacity of

each lifting lug shall be clearly marked.

28.5 Stainless steel name plate shall be provided for the equipment with all the specifications

mentioned in Clause 3.0.

28.6 Before the equipments are packed, they shall be carefully checked to ensure all extraneous

matters such as rage, tools, rubbish foreign matters, loose scale and dirt, welding rod,

studs, bolts etc. have been removed. After the interior is cleaned and dried, all opening

shall be closed with blank flanges, caps etc., to prevent damage, entry of water, dirt or any

other foreign material.

29.0 Erection and commissioning at MAPS:

29.1 Working at MAPS premises requires security passes to be made for all the persons

involved.

29.2 Personnel to be engaged in work shall undergo mandatory industrial safety training for a

period of one day.

29.3 The persons to be engaged in the erection and commissioning works shall undergo Orange

qualification programme conducted by MAPS.

29.4 Contractor shall arrange for all the formalities to get the security passes, safety training

and Orange qualification for the employees to be engaged for work.

29.5 Working at MAPS would require contractor to follow all the industrial safety rules and other

statutory requirements applicable to MAPS employees from time to time.

29.6 Any violation of the rules and regulations will attract penalty.

29.7 Contractor shall ensure a high degree of housekeeping during and after completion of

work. Housekeeping shall be done on a continuous basis during the job to keep the area

neat and tidy.

29.8 Contractor shall arrange for transportation of the equipment and other items from O&M

stores to chiller plant for erection of the same.

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30.0 NPCIL scope:

30.1 Foundation for the machine will be constructed by NPCIL. However, detailed foundation

drawing of the machine and the details of foundation shall be provided by supplier.

30.2 Terminal connection of piping to the chiller will be provided to the chiller unit and will be

terminated with a flange joint at the chiller machine.

30.3 The terminal points for the chiller unit, provided by supplier, shall include the steam PRV,

RV, CV and water lines will include the flow switches. Piping from downstream of these

points will be fabricated and erected by NPCIL. A detailed scheme of the terminations shall

be provided in a drawing by supplier.

30.4 Power supply of 415V AC, 50 Hz, 3 phase, 3 wire will be extended to the chiller panel by

NPCIL. All the field control and power cabling from panel to the individual elements

including pumps, etc shall be in the scope of supplier.

30.5 Instrument air at a pressure of 4 kg/cm2 will be provided at chiller plant for steam control

valve operation. Contractor shall clearly specify and submit the drawing, along with detailed

bill of materials, of the airline for fabrication and erection by purchaser. Air header will be

extended to the point indicated by the contractor. Subsequent tubing and connections will

be in the scope of contractor.

30.6 Any other requirement, not specifically referred to in this specification and required for

successful erection and commissioning of the new chiller, shall form part of supplier’s

scope.

31.0 Preferred Make:

31.1 Preferred make for some of the components is indicated below. However supplier shall

indicate the make of all the components for review and approval by NPCIL:

Sl. No. Item Description Preferred Make

1 PLC Siemens / Schneider / Omron

2 Operator Panel (HMI) Siemens / Schneider / Omron

3 AC drive ABB/ L&T / Siemens / Schneider

4 Switch Gear L&T / Siemens / Schneider

6 Power Cables Finolex / Polycab / RR Kabel /

Universal

22

7 Control Cables Finolex / Polycab / RR Kabel / Universal / LAPP

8 Plate type HX Alfa Lavel / SWEP

9 Absorbent & Refrigerant canned motor pumps Teikoku Electric

10 Vacuum Pump Indo Woosung / Hind HiVac

11 Pneumatic steam control valve Samson / Tecnik, Forbes Marshall

13 Flow Switch Saginomiya

14 DP switch Switzer

15 Pressure Gauges Micro process controls

16 Diaphragm valves Saunders

17 RTD sensor Nutech / Temtech / Temson

18 Vacuum manometer Fitzer / Technoflow

19 Condensate solenoid valve Jefferson / Rotex

20 Condensate transfer pump Forbes Marshall

32.0 Technical Details to be submitted along with the bid:

Bidder shall fill in all the details in the following table and submit the same along with the

technical bid.

Sl.

No. Item Description Unit Value

A Cooling Capacity TR

B Chilled Water Circuit

a Chilled water inlet temperature OC

b Chilled water outlet temperature OC

c Chilled water flow rate m3/hr

d Passes in evaporator Nos

e Chilled water circuit friction loss m WC

f Terminal connection size mm

23

g Fouling factor considered hr-ft2 OF /BTU

h Maximum working pressure kg/cm2 (g)

C Cooling Water Circuit

a Heat rejected kCal/hr

b Cooling water inlet temperature OC

c Cooling water outlet temperature OC

d Cooling water flow rate m3/hr

e Passes in absorber / condenser Nos

f Cooling water circuit friction loss m WC

g Fouling factor considered hr-ft2 OF /BTU

h Terminal connection size mm

i Maximum working pressure kg/cm2 (g)

D Steam Circuit

a Heat input kCal/hr

b Steam pressure kg/cm2 (g)

c Steam consumption kg/hr

d Drain outlet temperature OC

e Condensate drain pressure kg/cm2 (g)

f Condensate flow rate kg/hr

g Condensate temperature OC

h Steam inlet connection size mm

i Drain connection size mm

E Electrical data

a Power supply V, Hz

b Absorbent pump kW

c Refrigerant pump kW

24

d Vacuum pump kW

e Power consumption kVA

F Physical Data

a Length m

b Width m

c Height m

d Dry weight Ton

e Operating weight Ton

G Tube metallurgy

a Evaporator

b Absorber

c Condenser

1 Refrigerant

2 Absorbent

3 Range of load operation

4 Duty

5 Temperature and concentration of

Lithium Bromide solution

a Entering high temperature generator OC

b Solution leaving high temp generator OC

c Solution leaving low temp generator OC

d Solution leaving high temp heat exchanger OC

e Solution leaving low temp heat exchanger OC

f Solution leaving absorber OC

25

6 Pressure

a Evaporator section mm of Hg

b Absorber section mm of Hg

c Condenser mm of Hg

d Generator mm of Hg

7 Steam consumption

a 100% kg/hr

b 80% kg/hr

c 60% kg/hr

d 40% kg/hr

e 20% kg/hr

f 10% kg/hr

8 Corrosion inhibitor

a Type

b Charge liters

9 Refrigerant

a Composition

b Charge liters

10 Absorbent

a Composition

b Charge kg

11 Type of lube oil if any

26

12 Refrigerant Pump

a Flow rate m3/hr

b Suction pressure m

c Discharge pressure m

Power Consumption

d Motor rating kW

e Motor rated voltage V

f Type of pump

13 Absorbent Solution Pump

a Flow rate m3/hr

b Suction pressure m

c Discharge pressure m

d Motor Rating kW

e Motor rated voltage (3 phase)

f Type of pump

g Power Consumption kW

14 Vacuum pump

a Capacity lpm

Power Consumption

b Motor rating kW

15 Materials for construction with

standards conforming

a Upper and Lower shell

b HTG Shell

c HT HX Shell

d LT HX Shell

27

e Heat reclaimer HX Shell

f Tube sheets

g Channel covers

h Supports

i Flanges

j Baffles

k Eleminators

l Trays

m Spray Nozzles

16 Tube Materials

a HTG

b Condenser

c LTG

d Absorber

e Evaporator

f HT HX

g LT LX

h Heat reclaimer HX

17 Material of Bolts and Material of nuts

18 Material of external frame work

19 Material of nozzles for water service

20 Material of nozzles for refrigerant and steam

service

21 Automatic decrystallisation circuit provided

22 Steam pressure reducing valve

a Make

28

b Type

c Capacity

d Upstream pressure

e Downstream pressure

f Range of adjustment

23 Inlet Steam Control Valve

a Make

b Type

c Accessories

d Air supply pressure requirement kg/cm2

24 Steam Relief Valves

a Make

b Type

c Set Pressure kg/cm2

25 Process Water (Cooling Water) shut

off valve

a Type

b Actuator

c Other Accessories

d Air supply pressure requirement

26 Starters / Contactors for motors

a Type

b Rating

c Make

d Model No.

29

e Protection for motors

f Class of insulation

27 Control Panel

a Type of construction

b Dimensions

c Type of mounting

d Thickness and material shell

e Type of relays used make and model No.

f Control cable type

g Control cable make

h Control cable size

i Hand switches / PBs / Indication lamps - Numbers

j Hand switches / PBs / Indication lamps - Type

k Hand switches / PBs / Indication lamps - Manufacturer

l List of indicators provided

28 Annunciation system

a No. of windows

b Manufacturer

c Details of PLC control

29 Power Equipment

a Total KW required for VAM (415V, 50 Hz, 3

phase)

b Control power supply arrangement

30 List of tests to be done at works

30

31 List of tests to be done at site after

installing

32 QA plan for manufacture including welding

33 Erection

a Confirmation of Feasibility of erection in the

place indicated in the sketch

34 Delivery and erection schedule from

the date of receipt of order

a Submission of fabrication drawings for

approval

b Start of fabrication

c Complete fabrication

d Despatch equipment

e Arrival at site

f Time required for erection and

commissioning

35 Drawings

a Schematic process and instrumentation

diagram indicating scope of supply

b GA and layout drawings giving nozzle sizes

and orientation

c Control panel sketch

d Overall dimensions and VAM sectional

drawings

36 Information

a Description literature with materials of

31

construction for equipment and instruments

bringing out scheme of working, list of

similar equipments supplied with

commissioning date.

b Any other pertinent data

37 Schedule for submission of drawing

data, instruction manual, TC etc.

a Final Schematic P&I diagram

b Load and Foundation data

c Detailed equipment drawings with

dimensions and materials

d Valve schedule

e Instrument schedule

f Electrical wiring diagram

g Control panel drawings

h Pump details

i Material TC

j Shop test results

k Instructions for erection, operation and

maintenance

l Report on site tests

38 COP of the machine

32

Annexure -1 Painting Specification for Chiller Unit:

Fundamentally any internal surface of chiller coming in contact with LiBr / D.M. Water should be

strictly paint-free. As an implication of above, a portion of external area e.g. shell cut outs which

come in contact with LiBr / D.M. water because of fitting of external box during assembly, shall be

painted after completion of the sub assemblies.

1.0 Washing

1.1 Do washing of complete machine using power jet pump cleaner.

1.2 Specifically tube sheet within header should be cleaned thoroughly for soap solution

removal.

1.0 Tube plate (within header) and inside header painting

Stage: After completion of Nitrogen and Helium leak testing of assembled machine.

2.1 Since the tube plate and headers are already blasted, do manual (hand tool) surface

preparation to remove all soap and rust.

2.2 Additionally hand wire brush may be used to clean tube plate ligaments and header corners

near tube plate.

2.3 During this stage only minimum paint should enter in tubes mouths.

2.4 Add minimum / no thinner to get maximum DFT per coat, i.e. 80 to 100 microns.

2.5 Ensure minimum specified DFT of 80 – 100 microns.

2.6 Inlet / outlet piping / nozzle connections need to be similarly cleaned, prepared and painted

to the extent of accessibility.

2.7 Applicability : Tube Plate Area within Headers & Headers Inside

2.8 Process Steps : Painting – First Coat

2.9 Paint Description : GP Guard 275 Epoxy Coating Semi Glossy or equivalent

2.10 Paint Shade : RAL 7037

2.11 Thinner /description : GP-002 (5–10%) or equivalent

2.12 Viscosity : 70-80 seconds by Ford Cup No-4 @ 30°C

2.13 DFT : 80 – 100 microns

2.14 Application : Brush or better

2.15 Over coat interval : 6 hours

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3.0 Surface Preparation

3.1 Pre-condition of a Blasting surface preparation:

3.1.1 All welding work should have been completed and no welding work shall remain pending.

3.1.2 Helium leak, Hydro / pneumatic tests of Chiller should have been completed satisfactorily.

3.1.3 Headers have been opened after hydro test, dried completely, gaskets have been replaced

and pneumatic test has been completed.

3.1.4 Performance test has been satisfactorily completed.

3.1.5 All sharp edges have been rounded before shot blasting to 1R or minimally the edges have

been broken to avoid paint chipping and injury.

3.2 Blasting preparation:

3.2.1 Remove the delicate items Control panel, rupture disk, manometer assembly, pressure

gauge, etc., before blasting.

3.2.2 Do rubber wrapping of items where blasting is undesirable e.g. Service valve, Damper

valve, Angle valve, Level electrode assembly, Manometer assembly, Pressure gauge,

canned pump.

3.2.3 Mask of SS components of chiller e.g. SS headers, SS exhaust duct, SS auto purge system,

etc.

3.2.4 Ensure masking of clad (CuNi, Ti, SS, etc) surfaces, e.g. clad tube plates, clad headers, SS

ducts etc.

3.2.5 Blank / plug the openings: Cooling water in & out, Chilled water in & out, Steam in & out,

steam drains, threaded couplings.

3.3 Blasting:

3.3.1 Do blasting to Grade: Sa 2.5

3.3.2 First coat is to be done within maximum 3 hours after completion of blasting.

3.3.3 Inaccessible areas for shot blasting shall be cleaned by use of mechanical power tool /

Emery paper / Emery wheel etc.

3.3.4 Cleaning: Do cleaning of machine after blasting, to blow off any residue, with dry air.

3.3.5 Mask the sight glass and name plates to avoid painting of the same.

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4.0 Painting of First Coat

4.1 Applicability : All Prepared External Surfaces

4.2 Process Steps : Painting – First Coat

4.3 Paint Description : Epoxy High Build Primer, Matt Finish - GP Prime 216 HSBS or

equivalent

4.4 Paint Shade : ABB Grey

4.5 Thinner /description : GP-002 (5–10%) or equivalent

4.6 Viscosity : 40-45 seconds by Ford Cup No-4 @ 30°C

4.7 DFT : 80 – 100 microns

4.8 Application : Brush / Airless spray

4.9 Volume solids : 63 ± 3%

5.0 Putty filling and first coat dress up

Putty filling shall be done after complete drying of paint.

5.1 NC Cellocat Putty or equivalent shall be used after drying of first coat, maintaining a drying

time of 2-3 hours after application of putty.

5.2 Dupont putty 749 R or equivalent shall be used in the following areas after first coat:

Structural Areas only (Not to be used on pressure parts)

Upper shell tube plate & lower shell tube plate gap on resting thickness, Saddle, skid,

Angle, channel brackets, supports for vacuum pump, Instruments brackets, base frame

of chiller etc.

5.3 Orbital sander, emery paper 180-220 grit size may be used for dressing up of first coat

followed by air cleaning.

5.4 Applicability : External surfaces painted with first coat of GP 216

5.5 Process Steps : Painting – 2nd Coat

5.6 Paint Description : Acrylic Apliphatic Polyurethane, GP BOND 141 AS or equivalent

5.7 Paint Shade : RAL 5024 – Pastel Blue

5.8 Thinner /description : GP-002 (5–10%) or equivalent

5.9 Viscosity : 23-25 seconds by Ford Cup No-4 @ 30°C

5.10 DFT : 40 – 50 microns

5.11 Application : Brush / Air / Airless spray

5.12 Pressure at nozzle : 30 psi

35

5.13 Volume solids : 48 ± 3%

6.0 Finishing stage

6.1 Ensure there is no run down of paint, no dry spray and full coverage of areas.

6.2 Check hard to reach areas like: below headers, below heat exchangers and in between

shells.

6.3 Carry out touch up and cleaning of the chiller assembly. Paint splash / stains removal from

electrical conduit, control panel, insulation glue removal, etc.

6.4 Ensure no marking / stencilling /marker writing, on any of the components.

6.5 SS tubing of instruments shall be cleaned / polished.

6.6 SS components like fabricated duct, etc., shall be polished to even surface finish.

6.7 Removal of greasing and wrapping.

6.8 Ensure no painting is done on SS components, e.g. thermowell sensor fitted in header /

sensor mounted on piping.

6.9 Ensure total DFT of Paint between 120 – 150 microns

7.0 Black synthetic enamel paint:

7.1 Chiller valves cap shall be shot blasted, primer painted with GP 216 or equivalent and top

coated with Black synthetic enamel paint.

7.2 Black line indication on top and bottom of the center line punch on tube plates shall be

made.

7.3 Unit Number shall be Stencilled and CG shall be marked.

8.0 Golden yellow synthetic enamel paint:

8.1 All temporary blanks and Lifting Hooks shall be shot blasted, primer painted and top coated

with synthetic enamel golden yellow painted.

8.2 Rupture disc assembly blank’s hardware shall be finish painted with RAL 5024 shade of GP

141 paint or equivalent.

8.3 Steam fired HTG tube plate to lower shell tube plate tack welds (for transit protection) shall

be yellow painted.

8.4 Direct fired HTG & Lower shell transit supports shall be yellow painted

36

8.5 Painted machine shall not be transported or handled before the paint is sufficiently dry,

hardened and damage during transport shall be avoided.

8.6 Packing frame of the chiller assembly shall be single coat of epoxy primer painted.

8.7 In case the painting gets damaged at any part during transit, supplier shall arrange for re-

painting at site.