ANNEXURE TO TENDER NO:DPS/ MRPU/KNRPC/FAB/2151/PT-2455

TECHNICAL
SPECIFICATION
Design, Fabrication, Supply, Testing and
commissioning of D.M water plant
 CONTENTS
SPECIFICATION FOR DEMINERALISED WATER PLANT.................................................. 3
1. SCOPE ....................................................................................................................................... 3
2. DESIGN BASIS ......................................................................................................................... 3
3. SCOPE OF SUPPLY ................................................................................................................. 5
4. MATERIAL OF CONSTRUCTION ......................................................................................... 7
5. LAYOUT CONSIDERATIONS ................................................................................................ 7
6. DRAWINGS .............................................................................................................................. 7
7. SCHEDULES ............................................................................................................................. 7
8. APPROVAL OF FABRICATION DRAWINGS: ..................................................................... 7
9. APPLICABLE CODES AND STANDARDS ........................................................................... 8
10. INSTRUMENTATION ........................................................................................................... 13
11. CLEANING OF EQUIPMENT & PIPING ............................................................................. 14
12. DOCUMENTATION............................................................................................................... 14
13. SHIPMENT .............................................................................................................................. 14
14. GUARANTEE ......................................................................................................................... 15
15. INFORMATION TO ACCOMPANY THE OFFER:.............................................................. 15
16. VENDOR EVALUATION CRITERIA ................................................................................... 16
17. THE ENCLOSED FIGURES .................................................................................................. 16
18. SCOPE OF THE PURCHASER .............................................................................................. 16
19. SPECIFIC REQUIREMENT & INSTRUCTION TO THE CONTRACTOR ........................ 16
Annexure – I...................................................................................................................................... 17
TECHNICAL DATA PROFORMA ................................................................................................. 17
Annexure-II ....................................................................................................................................... 23
(Commercial Part) ............................................................................................................................. 23
Break-up of the total cost for 1 Nos of D.M plants ........................................................................... 23
Break-up of the total Installation and commissioning ...................................................................... 25
Annexure III ...................................................................................................................................... 28
Annexure IV ...................................................................................................................................... 29
 SPECIFICATION FOR DEMINERALISED WATER PLANT

1. SCOPE
This specification covers
a) Design, layout preparation, approval of drawing, fabrication, shop inspection and testing at
manufactures work, delivery at site (INRP-Kalpakkam).
b) Erection, testing, commissioning with performance guarantee and relevant documentation
for safe, trouble free and continuous operation of one DMW plant.
The DMW plant shall comprise of the following hardware components and the initial charge of
filtering media and resin:
• Raw water pumping system comprising of centrifugal pump, drive- motor & starter to
maximum flow required by the system
• Mixed Media Sand Filter with internals and piping
• Activated Carbon Filter with internals and piping
• Strong Acid Cation (SAC) Exchange Column with internals and piping
• Strong Base Anion (SBA) Exchange Column with internals and piping
• Mixed Bed Polisher Column with internals and piping
• Degasser tower with internals
• Regeneration system with mode of acid and alkali injection and associates storage tanks for
acid and alkali required for regeneration
• Instrumentation and control system
• Initial charge of resin and filter media.

2. DESIGN BASIS
The design basis for the DM water plant will be based on the following:

2.1 Plant capacity:

The table below shows details for the DMW Plant

Maximum flow rate 10 m3/h

DMW output per regeneration of Cation exchange and Anion

200 m3
exchange column

DMW output per regeneration of Mixed Bed Unit column

600 m3
(200 m3 X 3 =)

2.2 Raw water to be treated:

Pallar water / MAPS Reservoir
 WATER ANALYSIS

RAW WATER ANALYSIS

PALLAR MAPS
SL NO. PARAMETER
WATER RESERVOIR
<10% change
1. Colour *
euphotic depth
2. Odour * *
3. pH 8.1 8.6
Electrical Conductivity at 200 C
4. µS/cm 389 295

5. Turbidity NTU * 2.0 – 5.0

6. Total dissolved solids mg/lit 256 198
7. Total suspended solids mg/lit 0.9 3.5
8. Total hardness (as CaCO3) mg/lit 108 94
9. Calcium hardness (as CaCO3) mg/lit 58 54
a) Magnesium hardness (as
10. CaCO3)mg/lit * *

11. b) Chlorides (as Cl) mg/lit 48 52

12. c) Sulphates (as SO4) mg/lit 6.7 10.6
d) Total alkalinity (as
13. CaCO3) mg/lit 130 124
e) m-alkalinity (as CaCO3)
14. mg/lit 130 116
f) p-alkalinity (as CaCO3)
15. mg/lit 0 8.0

16. g) Nitrate (as NO3) mg/lit 0.181 0.046

17. h) Nitrite (as NO2) mg/lit 0.0065 0.0084
18. Biological oxygen demand mg/lit 2.1 3.5
19. Chemical oxygen demand mg/lit 1.1 3.0
20. Silica dissolved mg/lit 3.9 4.1
21. Iron dissolved (as Fe) mg/lit * 0.1 –0.4
22. Dissolved oxygen mg/lit 3.4 6.4 – 9.2
23. Coliforms organisms/100ml * 150
24. Plankton count cells/ml * *
25. Phosphate mg/lit 0.048 0.025
26. Chlorine demand mg/lit 0.8 1.0
27. α - emitters µ/ml (4mBq)/l NIL <1.08x10-4
28. β - emitters µ/ml (14mBq)/l NIL <3.78x10-4
The above Raw water analysis is indicative and Supplier has to get the actual raw water
 analysis for design purpose.

2.3 Required output water quality:

1 Electrical Conductivity at 200 C <1

µS/cm

2 Silica as SiO2 (mg/l) < 0.05

3 pH Neutral (6.8 to 7.2)

4 Total Dissolve Solids (mg/l) <1

5 Turbidity (ppb) < 50

2.4 Services available at Site:

Oil free compressed air at 6.0 kg/cm2. Power supply at 3φ, 440 V, Civil building for locating
the plant: Refer Figure-2: Area layout available for locating DMW unit.

2.5 Regeneration chemicals:

DMW plant shall be designed for the regeneration of Cation/Anion resin by the following
chemicals.
HNO3 for Strong Acid Cation Exchanger
NaOH for Strong Base Anion Exchanger

2.6 Mode of operation:

The DMW plant shall be designed for manual operation.

2.7 Description of the system:

The DMW plant of maximum generation rate of 10m3/h is provided for preparation of various
chemicals required for the continuous operation of Uranium Oxide Facility (UOF) and for
process cooling. Raw water required for the plant shall be supplied from over head raw water
storage tank. Treated water from MBU will be stored in DMW storage tank (01 nos) of capacity
12 m3 located in the same area as shown in the area layout. The effluent (regenerant chemicals,
rinse and back water etc.) will be collected in the Effluent storage area.

3. SCOPE OF SUPPLY
The scope of supply shall cover following hardware components and the initial charge of
filtering media and resin for the DMW plant.
The table below list the hardware required for the DMW plant

S No ITEM Quantity
3.1 Raw water pumping system comprising of centrifugal pump, drive- 2 (one working + one
motor & starter to provide maximum flow required by the system. stand- by)
 Preferred Make
Pump: Kirloskar Brothers / Johnson/ Grundfos equivalent
Motor: Kirloskar/Siemens/Crompton/Johnson/Grundfos equivalent
3.2 Multigrade sand filter with internals, associated piping, valves and 1
initial charge of media.
3.3 Activated Carbon Filter with internals, frontal piping, valves and 1
initial charge of filtering media (Granular Activated Carbon)
3.4 Strong Acid Cation (SAC) Exchange Column with internals 1
associated piping, valves.
First charge of SAC resin. 1 Charge
3.5 Degasser Tower (Air Blower, Packing material and DG water transfer 1
Pump)
3.5 Strong Base Anion (SBA) Exchange Column with internals 1
associated piping, valves.
First charge of SBA resin. 1 Charge
3.6 Mixed bed polished column with internals, associated piping, valves. 1
First charge of Cation resin
First charge of Anion resin 1 Charge
1 Charge
3.7 Regeneration system
Acid measuring tank for SAC Exchange Column 1
Mixed bed polishing system 1
Acid Ejectors 2
Caustic measuring tank for SBA Exchange Column 1
Mixed Bed polishing Column 1
Caustic Ejectors 2
3.8 Maintenance tool kit 1 Set
3.9 Interconnecting piping, fittings, valves, accessories, structural pipe, 1 Set
supports etc.
3.10 Any other equipment or accessories which the supplier feels necessary
for the satisfactory performance of the system
Instrumentation and Controls * (Refer Figure – 1)
3.11 Pressure gauge 9 Nos.
3.12 Differential pressure transmitter 2 nos.
3.13 Flow Totalizer (magnetic and vortex type) 1 each
3.14 Flow Meter with local display 2 Nos
3.15 On line pH meter with transmitter (4 – 20 mA) having 2 Sets
local display
3.16 Online Conductivity meter with transmitter (4 – 20 mA) 2 Sets
 having local display.
3.17 Level gauges 5 Nos.
3.18 Differential Pressure Gauges 2 Nos.
3.19 Fully enclosed epoxy painted Instrument panel (floor 1 Nos.
standing) to house all the above instruments.
3.20 Any additional instrumentation required which the
supplier feels necessary for the satisfactory performance of
the system.
3.21 MCC panel (3 starter and power for instruments) 1 Nos.

4. MATERIAL OF CONSTRUCTION
Material of Construction for SAC, SBA, MB, piping, accessories etc. shall be made of MS pipe
lined with Rubber. The material of construction for Sand bed filter and activated charcoal filter shall
be made of MSEP.

5. LAYOUT CONSIDERATIONS
The plant is proposed to be located indoors in an area of 33.5 m x 8.5 m (approx.). Bidder has
to prepare the layout to fit in the available space .

6. DRAWINGS
After placement of Purchase Order the supplier has to submit detailed flow sheet (with stream
flow rates, pressure etc.), P&ID (showing all equipment, pipe sizes, MOC details,
instrumentation and controls and interlocks), and fabrication drawings indicating Equipment
details, BOQ, which when approved in writing by the purchaser shall form a part of this
specification.

7. SCHEDULES
The supplier shall clearly indicate a firm time schedule immediately after receiving the purchase
order giving the break-up of different activities (as mentioned below) for the job execution from the
date of receipt of purchase order.
- Preparation of GA, equipment & piping drawings.
- Submission of these drawings for approval at different stages of fabrication and inspection
of equipment / vessel.
- Procurement of raw material / resins, valves, instruments etc.
- Assembly of equipment at supplier place.
- Delivery at site and commissioning.

8. APPROVAL OF FABRICATION DRAWINGS:

Within 30 days from the receipt of order and before proceeding with fabrication, supplier shall
submit 3 (Three) copies of fully dimensioned drawings and bill of materials with the following
 information:
8.1 Specified standards for the construction from among the tender specification or equivalent
8.2 Specific materials specification from among the tender specification or equivalent.
8.3 The welding procedure indicating details of base metal, welding electrodes, joint penetration
with dimensions, cleaning methods, number of plates, welding current etc. shall be submitted
for purchaser approval.
8.4 Hydrostatic Test pressure based on the design pressure and the specific codes of construction of
tank.
8.5 Dimensions and fix up tolerances.
8.6 A design pressure and major structural loading.
These drawings when approved in writing shall form part of this specification. No fabrication shall
commence until the drawings are approved. Any deviation from specification shall be
communicated to the purchaser for acceptance / clearance before incorporation of the same in the
equipment during the manufacture.

9. APPLICABLE CODES AND STANDARDS

Design, fabrication & installation of the equipment and piping shall be done in accordance with the
latest versions of the relevant standards including the following codes:
Deviation from specifications/ applicable standards:
If the manufacturer intends to make any deviations from the specification or in the applicable
standards, the same shall be clearly set forth in the quotation giving reasons/ justification for such
deviations.
If the deviations are found acceptable they shall be included in the order specifications.
No deviations from the specifications or in the applicable standards shall be allowed after placing
the purchase order.

9.1 Pressure vessels and storage tanks:

• Design, fabrication and testing of metallic pressure vessels shall confirm to IS- 2825/
ASME Boiler & Pressure Vessel Code Section VIII Div.1, Section IX and Section V.
• Pressure vessels shall be designed for at least at pressure equal to the maximum shut-off
head of preceding pump plus total suction head of the same pump. Pressure vessels shall
also be designed for full vacuum. Test pressure shall be as per applicable design code.
• Corrosion allowance shall be 3 mm for unlined vessels and vessels with internal painting.
• Minimum nominal thickness of shell, bottom and roof including corrosion allowance shall be
6 mm. Minimum nominal thickness of vessel dished end after forming and including corrosion allowance
shall be 6 mm.
• Vessels and equipment of inside diameter less than 1 metre shall be provided with girth flanges
designed as per code.
• All storage tanks shall be provided with drain valve and piping and overflow piping and the
same shall be led to the nearest drain sump.
• Vessels, tanks and equipment of inside diameter larger than 2 metres or height more than 2
metres shall be provided with approach ladder to reach the top, handrail at the top and
suitable operating platforms for access to manholes, inspection openings and operations
and maintenance of valves, instruments etc.
• Overflow nozzle size shall be at least one size larger than that of the inlet nozzle.
• All equipment shall be skid mounted.

9.2 Centrifugal pump and motor:

• Raw water feed pump shall be of centrifugal type and shall conform to the requirements of
IS-5120.
• The pump shall be capable of developing the required total head at rated capacity for
continuous operation. The pumps shall operate satisfactorily at any point on the H-Q
characteristic curve over a range of 50% to 130% capacity or capacity corresponding to
75% of the total head whichever is lower.
• The total head capacity curve shall preferably be continuously rising towards the shut off.
In case of unstable (drooping) characteristic the duty point shall be well away from the
unstable region. The shut off head shall be at least 110% of the total head.
• Pumps shall run smooth without undue noise and vibration. The velocity of vibration shall
be within 4.5 mm / sec. The noise level shall be limited to 85 dBA at a distance of 1.8 M.
• Impeller shall be made in one piece and securely keyed to the shaft. Means shall be
provided to prevent loosening during operation including rotation in reverse direction.
• The first critical speed of the pump motor shall be at least 30 percent above the operating
speed.
• Replaceable shaft sleeves shall be provided to protect the shaft where it passes through
stuffing boxes.
• Stuffing boxes shall be of such design that they can be repacked without removing any part
other than the gland and lantern ring.
• Pump shall be furnished complete with flexible coupling. Back-pull out pump shall be
provided with spacer type coupling.
• All incidental piping (including valves) required for sealing, lubrication and cooling for
stuffing box packing and / or bearing of pump shall be furnished.
• A directly coupled 3-phase induction motor conforming to the requirements of IS-325 shall
drive the pump. The motor shall have suitable degree of protection as IS-4691.
• Motor shall be sized with motor rating at least 15% higher than the maximum input rating
of the driven equipment.
• Drive motors shall be continuously rated and suitable for working under humid and
gaseous conditions.
• Pump and motor shall be mounted on a common base plate.

9.3 Piping:
• The piping design shall satisfy the requirements of applicable section of ASME-ANSI B
 31.3.
• Structural steel for pipe supports and other requirements shall conform to IS 2062.
• Flanges shall be of 150 # pressure rating as per ANSI B-16.5. Pipe threads shall generally
be to ANSI B 2.1 / IS-554. Threading of pipes shall be done after any bending operations.
• Pipe lines shall be of MS with corrosive protective coating either with Rubber/ FRP lined
as per BS 6374 part V.
• Where both the internal and external surfaces of the pipe comes in contact with corrosive
fluid the piping shall be of MS rubber lined.
• Velocities in pressurised lines shall not exceed 2.4 metres/second. In pump suction line
velocities shall not exceed 1 metre/second.
• Piping shall be routed to avoid interferences. If interferences are noticed at site, piping shall
be suitably modified and rectified by the contractor at no extra cost to the purchaser.
Layout shall follow good engineering practice.
• Effective precautions such as capping or sealing shall be taken to protect ends of all pipes,
fittings, valves against ingress of dirt and damage during transit or storage. Flange gasket
contact surfaces shall be suitably protected against damage.
• All piping shall be cleaned and purged with air blast or flushed with water to remove all
rust, mill scale etc from inner surface. Rotary wire brush may be used for cleaning of
unlined pipes of sizes above 300 mm. The method of cleaning shall be such that no
material is left on the inner surface, which may affect the serviceability of the pipe.
• Piping shall be routed in a manner so as to avoid hindrance of movement of men and
materials.
• Pipeline shall be routed in a manner that it is short and with minimum bends, in plumb
when vertical or parallel to walls when horizontal; with necessary slope (1:100 minimum)
to avoid any hold up of liquid, as well as to avoid any interference with other piping,
equipment and structure.
• All valves and on-line indicator type instruments shall be located at a height so that they
can be conveniently operated or observed. In case the same is not feasible necessary
platforms with ladders shall be fabricated and installed by the contractor.

9.4 Welding:
• All SS plates, piping & structural members shall be welded using full Shielded Metal arc
welding (SMAW) process.
• All welding procedures shall be approved by the Engineer prior to start of any welding
activity (prefabrication or installation) covered under those procedures. The information
contained in each welding procedure specification (WPS) and procedure qualification
record (PQR) shall include, but not be limited to, the information contained in Section IX
of ASME Boiler and Pressure Vessel Code. WPS and PQR shall be performed both at the
works of the contractor and at plant site.
• The cost of performing the procedure and performance qualifications shall be borne by the
 contractor including materials, consumables and required testing. The welder’s deployed
by the contractor should have adequate experience on similar type of welding works.
• A weld map with weld descriptions and a table or fabrication drawing (sketch) that
specifies where each procedure will be used , shall be submitted to the Engineer along with
the WPS and PQR documents for each equipment and piping system.
• All welding including tack, temporary and repair welds shall be carried out only by
qualified welders.
• The test records of all welders and welding operators shall be available at all times at the
work location for review by the Engineer. Engineer shall have the right to retest of any
welder at any time.
• All intersecting and abutting parts to be welded shall be joined by full penetration groove
welds.
• Welding shall not be done when surfaces are wet or damp exposed to rain or snow or when
the welders are exposed to inclement conditions. Any wet damp surfaces shall be dried by
heating and shall be warm to the hand before welding.
• Weld faces shall be cleaned by acetone prior to root pass and after every pass.
• All joints and faying surfaces shall be seal welded by a continuous fillet weld, unless
specified otherwise.
• Pressure-retaining welds shall be separated from other ( pressure or no pressure) welds by
no less than 20 mm or three times the joint thickness, whichever is greater. This
requirement is intended specifically for nozzles and other attachments that are added onto
or adjacent to an existing joint.
• When the inside surfaces of items are inaccessible for welding or fairing any offset within
the tolerances provided shall be faired to at least 3: 1 taper by grinding. For circumferential
joint, the inside diameter shall match each other within 1.6mm. When the items are aligned
concentrically, a uniform mismatch of 0.8 mm all around the joint.
• All grinding wheels used shall be free from iron oxide, zinc and other harmful impurities
and should not be based on carbide materials and shall be subject to the approval of the
Engineer before being put to use.
• The filler wire and welding electrodes shall be as per the following specifications:
a) For welding MS materials: Filler wire: E 7018 (AWS/ASME A 5.1)
• Electrodes which have been exposed to rain or which have been otherwise exposed to
water however shall be discarded. Re-baking of such contaminated electrode shall not be
permitted.

9.5 Inspection & Testing:

• The contractor shall provide all the testing and inspection services and facilities except
where otherwise specified, for the inspection and testing requirements covered under the
scope of this specification. Minimum inspection requirements shall be met as per code and
these specifications.
• Proforma for test and inspection on all materials and fabrication, erection shall be got
approved by the engineer and all the records shall be maintained properly.
• Inspection, testing and repair procedures, shall be got approved by the engineer. Inspection
by the engineer or his authorized representative shall not relieve the contractor of
inspection and conformity to this specification. Engineer reserves the right to waive off,
any inspection requirements.
• All the materials procured by the contractor including weld materials, liquid penetrant
material, etc., shall be tested as required by material designate standards and this
specification. Proof in the form of manufacturer’s certificate is acceptable but if these are
not available, the test shall be performed by the contractor at his cost.
• Straightness of the pipes shall not deviate more than 3.0 mm in a length of 3 meter at any
section of pipes.
• All welds shall be LP examined after root and final pass as per ASTM E 165 (Standard
Method for Liquid Penetrant Examination).
• For the weld joints of size 50 mm NB and below no relevant indications of any size are
permitted. The LPE materials shall be tested, as per ASTM for sulphur and halogen content
and manufacturers test certificate shall be provided co-relating both. The sulphur content
shall not exceed 1% by weight and halogen content shall be limited to 25 ppm.
• All butt welds shall be subject to 10% radiography as per ASTM – E – 94 (Standard Guide
for Radiographic Testing) and ASTM – E – 142 (Standard Method for Controlling Quality
of Radiographic Testing). The Engineer shall have right to reject any radiographic
examinations not conforming with proper technique or processing.
• Where 10% radiography is called for, this shall be spread uniformly over all diameters in a
particular system. In diameters upto and including 400mm NB shall mean 10% of the
joints in each pipe diameter encountered. In diameters above 400mm NB the 10% shall
mean cumulative linear centimeters of all pipe circumferential joints. Selection of the
joints or location shall be at the discretion of the Engineer.
• Weld acceptance standards shall be as per ASME Section VIII Division 1. Radiographic
film interpretation shall be done by personnel certified to ASNT level II, film interpreter or
approved equivalent.
• All vessels and equipment shall be tested hydrostatically at the shops where manufactured,
to the approved test pressures as per code. All piping systems shall be tested
hydrostatically after erection to the approved test pressures as per code. The test duration
shall be two (2) hours or until all joints are examined, whichever is longer. In case of
leakages, re-test shall be carried out for the same duration after rectification of defects.
• Any deviations from the specifications / approved procedure shall be immediately reported
to the Engineer and his decision obtained prior to proceeding with the next stage of the
work.
9.6 Pressure Filters & Activated Carbon Filters:
• Filter bed shall withstand the maximum pressure drop encountered during the operation,
without breakdown of filter media.
• Filter media shall be non-toxic and shall not impart colour, odour or taste to the water.
• Unit shall normally be backwashed once a day only.
• The inlet distribution system shall be designed to give uniform distribution of water over
filter bed. The under-drain collection system shall be designed for uniform collection of
filtered water and distribution of backwash water.
• Provision shall be made for access to the internal surface of the bottom dished end i.e.
below the bed supporting plate.
9.7 Ion Exchange Units:
• Due consideration shall be given to minimum and maximum bed depths, minimum rising
space for resins and surface flow rates while sizing the units.
• One hand hole of 150 mm NB size shall be provided on the shell of the ion- exchange
vessels.
• One viewing port at normal bed depth level and another at expanded level during backwash
shall be provided for all the units except the mixed bed unit.
• For mixed bed units, three viewing ports, one at the resin interface after separation, the
second at the normal bed depth and the third at the expanded level during backwash shall be
provided.
• Gross output of an exchanger unit shall be calculated as the sum of the productive output of
the unit and the regeneration water requirement for self and/or downstream or upstream
units.
• Published catalogue and literature shall cover all design parameters without any need to
extrapolate.
• Mechanical de-rating factor on resin exchange capacity shall be considered as 10% of
exchange capacity derived from published catalogue and literature.

10. INSTRUMENTATION
• The contractor shall supply the instrumentation and other accessories (Refer fig-1) as
specified in 3.13 of this section, which is the minimum essential instrumentation for the
plant. Over and above this, if the bidder provides additional items, it shall be assumed that
these extra items are necessary for the satisfactory operation and maintenance of the plant
and no credit shall be given for these items at the time of bid evaluation.
• All instruments shall have permanent stainless steel tag plates, fixed on the body,
indicating service.
• Supplier shall provide technical specifications of different sensors & instruments to be used in
this plant before the Supply of the plant.
11. CLEANING OF EQUIPMENT & PIPING
• Equipment, pipes, fittings etc. shall be cleaned off mill scale, dirt, grease, foreign matter,
paints etc. prior to fabrication and installation by using suitable chemical reagents/ metal
brushes. Local passivation of stainless pipes/ components shall be carried out whenever
these are mechanically worked or welded. Use of halogen free detergents could also be
made for cleaning operations. Oil-free compressed air shall be employed for cleaning of
pipes.
• Edge preparation shall be carried out in a manner so as to avoid filings falling inside the
equipment.
• Marking tape/crayon, and paint marks shall be cleared from surface. Acetone, diethyl ether
or methyl alcohol are some of the solvents which could be used for this purpose.
• All areas of installation as well as all equipment and piping shall be kept dust free.
Pipelines shall be flushed of all of filings, dirt & dust etc. by using a dry and clean cotton
liner.
• As far as possible, all openings in equipment and piping shall be kept suitably closed by
blind flanges or plugs.
• The procedure for cleaning shall be submitted by the contractor for approval.

12. DOCUMENTATION
Each System shall be supplied complete with two sets of full documentation covering:
• The detailed plant piping layout including PFD and P&ID and their reproducible
tracings.
• The equipment drawing approved by the purchaser.
• The installation, maintenance and operation manuals for the system with sufficient
details.
• Test report on the DP, hydrostatic, weld and spark tests carried out.
• Material test certifications.
• Test certificates and maintenance schedule for pumps, instrumentation etc.
• Performance characteristics for pumps and motors.
• Manufacturer’s literature on the operation and maintenance instructions for the bought
out items.
Note: The supplier shall provide the AutoCAD drawings also on Re-writable / non rewritable
Compact discs.

13. SHIPMENT
The water treatment units will be shipped to WIP stores, Kalpakkam only after obtaining a
shipping release from the purchaser or his authorized representatives. The supplier shall be
fully responsible for protective measures to ensure the safe delivery of the equipment and
associated components.
 14. GUARANTEE
The supplier shall guarantee that the goods furnished by him are in full accordance with the
requirement of these specifications.
The supplier shall provide the warrantee that the goods are new and of quality meeting the
standards / codes and constructional requirements are free from defects in design, material of
workmanship or materials, the supplier shall at his own cost, take steps to carry out the repair
or replacement of such goods or parts thereof after obtaining due approval of the purchaser.

15. INFORMATION TO ACCOMPANY THE OFFER:

The following information shall essentially be furnished along with the quotation to evaluate
the offer. Failure to supply full information as asked for or supplying only part information will
result in rejection of the offer without any further reference to bidder.
15.1 PFD, P&ID and equipment /piping layout drawings identifying all the major
components offered under the scope of supply against each system.
15.2 Equipment drawing indicating diameter, height, thickness of the shell, lining and the
dished ends, pressure rating for the vessels.
15.3 Material of Construction proposed for each component in the system. The MOC and
equipment lining must be compatible with chemicals used during regeneration.
15.4 The standards / codes for design, fabrication, MOC and performance testing as
applicable.
15.5 Guarantee performance of the system regarding the water quality at the inlet and exit
of each exchanger units.
15.6 The type, manufacturer, model and other technical specification and details for all
the items under the scope of supply and bought out items.
15.7 Resin proposed to be utilized for each system with following information:
• Type
• Trade name & alternate source of availability
• Technical literature on performance, capacity etc.
• Quality used for each bed.
• Time for regeneration
15.8 Following details regarding schemes for each exchanger in a system.
• Type of regeneration
• Chemicals used, their quantities and concentrations
• Means of injecting chemicals into the beds.
• Regeneration levels achieved.
• Time taken for regeneration of each bed
• Total regeneration cycle time.
• Flow rates required.
15.9 Calculation /design basis details for the resin quantities used for each bed.
15.10 Total waste volumes generated per bed regeneration and their average compositions.
15.11 PRICE:
The price quoted shall be separately for items (a) & (b)
a. Item (a): Design, layout preparation, approval of drawing, fabrication and supply at site of
DMW Plant as a single item.
b. Item (b): Installation of all equipments, centralized wired instrument panel, piping,
tubing, power, control and signal cabling, testing, commissioning and handing over with
performance guarantee and relevant documentation of the DMW plant.

15.12 PERFORMANCE GUARANTEE:

The unit shall be guaranteed to give trouble free performance for one year from the date of
commissioning.

15.13 TIME SCHEDULE:

The offer shall include the detailed time schedule giving the break-up of different activities
(like Design, Layout preparation, approval of drawing, fabrication, installation, testing and
commissioning of DMW plant etc.) to be followed during execution of the purchase order as
mentioned in Point No. – 7.

15.14 QUALITY ASSURANCE PLAN:

The offer shall include the detailed quality assurance plan to be followed during execution of
the purchase order as mentioned in Point No. – 9.

16. VENDOR EVALUATION CRITERIA

16.1 The bidder shall be reputed & regular manufacturer of DMW Plants of similar nature
and he shall shall have experience in supply of DMW plants of comparable capacity
to reputed firms.
16.2 The bidder shall have separate departments for design, drafting, procurement,
manufacture, QA, erection and commissioning.

17. THE ENCLOSED FIGURES

Fig No: 1 & 2 shall provide the general guidelines for designing the DMW plant. Kindly note
that these drawings are indicative only.
Figure 1: P&ID- DMW Plant.
Figure 2: Area layout plan – DMW plant

18. SCOPE OF THE PURCHASER

18.1 Provision of the Civil building.

19. SPECIFIC REQUIREMENT & INSTRUCTION TO THE CONTRACTOR

19.1 Capacities of all equipment should meet guarantee requirements and should be
substantiated by calculations.
19.2 Effluents generated shall be discharged into the storm water drain designated by BARC.
19.3 Power Cabling supply and erection from the MCC panel up to the individual points,
supply and erection for instrumentation are in the contractor’s scope.

Annexure – I

TECHNICAL DATA PROFORMA

(To be filled in and submitted along with the offer)

Table: 1
Description As Specified
Design Basis
Water Source PALLAR WATER/MAPS
RESERVOIR
3
Normal Flow 10.0 m /h
3
Maximum Flow 12 m /h
3
Capacity per regeneration for 200 m
Cation / Anion Exchanger
3
Capacity per regeneration for 600 m
Mixed Bed Exchanger
DM Water Quality
pH 6.8 – 7.2
TDS < 1.0 ppm
Dissolved Silica ≤ 0.05 ppm
Electrical Conductivity at ≤ 1 µs / cm
o
20 C
Applicable Codes & Standards
Design & Fabrication BS- 6374 PART V
ASME Section VIII
Div.1, Section IX and
Section V.
MOC for equipment. MS (Rubber lined/FRP)
MOC for Strainer MS (Rubber lined/FRP)
MOC pipeline MS (Rubber lined/FRP)
MOC flange MS (Rubber lined/FRP)
Valve, MOC / type MS (Rubber lined/FRP)
Pumps & Motors MS (Rubber lined/FRP)
Feed Pumps
Nos. 2
Preferred Make Kirloskar / Mather &
Patt/Johnson
Type Centrifugal
MOC ---
Flow Rate ---
Discharge Head ---
Motor HP / RPM ---
Starter, Motor included Yes
Sand Filter
Media ---
Capacity: Normal / Max. ---
Pressure: Normal / Max./ ---
Design
Media Volume ---
Shell: dia. / height / thickness ---
Dish thickness ---
MOC ---
Piping and valves size ---
Service cycle ---
Backwash Flow Rate ---
Back wash frequency ---
Backwash time ---
Activated Carbon Filter
Media Granular Activated
Carbon
Capacity: Normal / Max. ---
Pressure: Normal / Max. / ---
Design
Media Volume ---
Shell: dia. / height / thickness ---
Dish thickness ---
MOC ---
Piping and valves size ---
Service cycle ---
Backwash Flow Rate ---
Back wash frequency ---
Backwash time ---
Cation Exchanger
Capacity: Normal / Max/ Min ---
Regeneration Capacity 200 m3
Pressure: Normal / Max./ ---
 Design
Material of construction ---
Shell: dia / height/ thickness ---
Dish Thickness ---
Piping and valves size ---
Resin type ---
Make ---
Trade Name ---
Resin Quantity ---
Regeneration Chemical HNO3
Regeneration Flow Rate ---
Regeneration Frequency ---
Regeneration time ---
Regeneration tank: ---
Capacity/MOC/Make
Degasser Tower
Size
MOC
Packing Material
Flowrate 10m3
Air Blower
Water Column
Air Temperature
Air Flowrate
Dg Water Transfer Pump
(special type for Low pH
handling
Quantity 01 No.
Capacity
Head
MOC
Anion Exchanger
Capacity: Normal / Max/ Min ---
Regeneration Capacity 200 m3
Pressure: Normal / Max./ ---
Design
Material of construction ---
Lining thickness ---
Shell dia / height/ thickness ---
Dish Thickness ---
Piping and valves size ---
Resin type ---
Make ---
Trade Name ---
Resin Quantity ---
Regeneration Chemical NaOH
Regeneration Flow Rate ---
Regeneration Frequency ---
Regeneration time ---
Regeneration tank: ---
Capacity/MOC/Make
Mixed Bed Exchanger
Capacity: Normal / Max/ Min ---
Regeneration Capacity 600 m3
Pressure: Normal / Max./ ---
Design
Material of construction ---
Lining thickness ---
Shell dia / height/ thickness ---
Dish Thickness ---
Piping and valves size ---
Resin type: Cation ---
Make ---
Trade Name ---
Quantity ---
Regeneration Chemical HNO3
Resin type: Anion ---
Make ---
Trade Name ---
Quantity ---
Regeneration Chemical NaOH
Regeneration Flow Rate ---
Regeneration Frequency ---
Regeneration time ---
Regeneration tank: 1 No.
Capacity/MOC/Make
Regeneration
Cation Bed
Type ---
Resin Quantity ---
 Chemical Used ---
Ch Quantity (100%) ---
Regenerant Tank ---
Material ---
Anion Bed
Type ---
Resin Quantity ---
Chemical Used ---
Ch Quantity (100%) ---
Regenerant Tank ---
Material ---
Mixed Bed Unit
Type ---
CX: Resin Quantity ---
Chemical Used ---
Ch Quantity ---
Regenerant Tank Volume ---
Material ---
AX: Resin Quantity ---
Chemical Used ---
Ch Quantity ---
Regenerant Tank Volume ---
Material ---
Instrumentation
Pressure gauge 9 Nos.
Differential pressure transmitter 2 nos. Forbes Marshall /
J.N. Marshall/ Equivalent
Flow Totalizer (magnetic and 1 each. Rosemount / ABB
vortex type) Kent Taylor / Forbes
Marshall / J.N. Marshall/
Equivalent
Flow Meter with local display 2 Nos. Rosemount / ABB
Kent Taylor / Forbes
Marshall / J.N. Marshall/
Equivalent
On line pH meter with 2 Sets. Rosemount / ABB
transmitter (4 – 20 mA) having Kent Taylor / Forbes
local display Marshall / J.N. Marshall/
Equivalent
Online Conductivity meter with 2 Sets. Rosemount / ABB
transmitter (4 – 20 mA) having Kent Taylor / Forbes
local display. Marshall / J.N. Marshall/
Equivalent
Level gauges 5 Nos.
Differential Pressure Gauges 2 Nos.
Fully enclosed epoxy painted 1 Nos.
Instrument panel (floor standing)
to house all the above
instruments.
MCC panel (3 starter and power 1 Nos.
for instruments)
Any additional instrumentation
required which the supplier feels
necessary for the satisfactory
performance of the system (list
the items).
 Annexure-II

(Commercial Part)

Break-up of the total cost for 1 Nos of D.M plants (To be Uploaded as a document)

S No. ITEM Specification Quantity Cost

& make
1 Raw water pumping system comprising of 2
centrifugal pump, drive motor & starter to provide
maximum flow required by the system

2 Mixed media sand filter with internals, frontal 1

piping, valves and initial charge of media.
3 Activated Carbon filter with internals, frontal 1
piping, valves and initial charge of filtering media
(Granular Activated Carbon)
4 Strong Acid Cation (SAC) Exchange Column with 1
internals, frontal piping and valves.
First charge of SAC Resin
5 Degasser Tower (Air Blower, Packing material and 1
DG water transfer Pump)
6 Strong Base Anion (SBA) Exchange Column with 1
internals, frontal piping and valves.
First charge of SBA Resin
7 Mixed bed polisher column with internals, frontal 1
piping, valves.
First charge of Cation resin
First charge of Anion resin
8 Regeneration system
Acid measuring tanks for SAC Exchange Column As
Mixed bed polishing system applica
Acid Ejectors ble in
Caustic measuring tanks for SBA Exchange flow
Column sheet
Mixed Bed polishing Column
Caustic Ejectors
9 Maintenance tool kit 1
10 Interconnecting piping, fittings, valves, accessories, 1 lot
structural pipe supports etc.
11 Any other equipment or accessories which the
supplier feels necessary for the satisfactory
performance of the system (list the item)
Instrumentation and Controls * (Refer Figure – 1)
12 Pressure gauge 9 Nos.
13 Differential pressure transmitter (Forbes Marshall 2
/ J.N. Marshall/ Equivalent)
14 Flow Meter with digital display and transmitter 1
(Rosemount / ABB Kent Taylor / Forbes
Marshall / J.N. Marshall/ Equivalent)
15 Flow Meter with local diaplay (Rosemount / ABB 1
Kent Taylor / Forbes Marshall / J.N. Marshall/
Equivalent)
16 On line pH meter with transmitter (4 – 20 mA) 2
having local display (Rosemount / ABB Kent
Taylor / Forbes Marshall / J.N. Marshall/
Equivalent)
17 Online Conductivity meter with transmitter (4 – 2
20 mA) having local display. (Rosemount / ABB
Kent Taylor / Forbes Marshall / J.N. Marshall/
Equivalent)
18 Level gauges 5 Nos.
19 Differential Pressure Gauges 2 Nos.
20 Fully enclosed epoxy painted Instrument panel 1 Nos.
(floor standing) to house all the above
instruments.
21 MCC panel (3 starter and power for instruments) 1 Nos.
22 Any additional instrumentation required which
the supplier feels necessary for the satisfactory
performance of the system (list the items).
 Break-up of the total Installation and commissioning

S No. ITEM Specification Quantity Cost

& make
1 Installation of all equipment, pumps,
instruments.
2 Installation of piping, pipe supports, pipe
rack
3 Installation of electrical Power cabling,
earthing control and signal cabling
4 Installation of instrumentation control &
signal cabling and panel
5 Testing and commissioning of all systems.
 Annexure III

Figure1: DM plant Schematic

 Annexure IV

Figure-2: Area Layout for DM water Plant