Product Standard: Pumps FP60300

Rev No.
5
PRODUCT STANDARD FP60300
TD-106-1
Form No. PUMPS Rev No. 07

HYDERABAD PAGE 1 of 17
TECHNICAL SPECIFICATION FOR BOILER FEED PUMP RECIRCULATION
(HIGH PRESSURE DROP) MODULATING CONTROL VALVE FOR SUPER-
CRITICAL POWER PLANTS
1.0.0 INTENT OF SPECIFICATION:
The intent of specification is to procure High-pressure drop control valve for use in the
recirculation system of Boiler feed pump of thermal power plant, to ensure minimum
quantity of flow through the pump. The valve shall be capable of throttling from
discharge pressure of Boiler feed pump to the deaerator pressure for both hot and cold
The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED,
conditions of operation as given at CL. 3.1.0.

It must not be used directly or indirectly in any way detrimental to the interest of the company.
2.0.0 SCOPE OF SUPPLY:

Scope of supply shall include Modulating control valve with the following accessories.
a) Pneumatic actuator.
b) Solenoid valve.
c) Limit switches.
d) Air filter regulator with output gauge.
e) Hand wheel for manual operation.
COPYRIGHT AND CONFIDENTIAL
f) Stem travel indicator.

g) Pneumatic tubing.
h) Terminal box for limit switches.
i) One set of soft goods for each valve (Soft goods shall include
total number of gaskets,” O” rings, backup rings, seals, gland packing’s and
any other seating items required for one valve assembly) supplier shall
indicate quantities of each type of packing in the enquiry.
j) Smart Positioner.
k) Booster relay / volume booster shall be provided wherever required.
l) Volume tank & associated accessories.
m) Orifice Plate in Downstream line (RO) along with Flanges, Gaskets.
n) Universal HART calibrator 1 No. per project.
3.0.0 TECHNICAL PARAMETERS:
Boiler feed pump is variable speed type and the valve shall be suitable for the following
conditions corresponding to maximum & minimum speed and temperature.
3.1.0 OPERATNG CONDITIONS:

System pipe at
System Valve
Orifice Plate
Inlet & body
Flange Inlet &
Feed Orifice Plate Outlet Design
Inlet Outlet
Var water Flow Downstream Pipe OD & pressure
Operation Pressure Pipe OD & thk.
No. Temp. (m3/hr) Pressure thk. (mm) (kg/cm2)/
kg/cm2 (mm)
(ºC) (kg/cm2) Temp (ºC)
PipeDesign PipeDesign
Pr(kg/cm2)/ Pr(kg/cm2)/
Temp (ºC) Temp (ºC)
/
323.9 x 56 273 x 6.35 BW
01 Hot 188.5 367 650 14.3 BW ends ends
& ANSIB16.25 ANSI B16.25 460/200
04
Cold 110 48 196 3.4 450/200 35/200
Revisions : Prepared By : Approved By : Date :

Ref. Doc
Refer to record of revisions.

ROHIT P. P. SRINIVAS 10.02.2017
Mar Tue 10 13:41 2020 This Drawing is printed from Engineering Digital Archive System (EDAS).
Therefore signatures are not essentially required.
Rev No. 5
TD-106-2

System pipe at
System Inlet Orifice Plate Valve
Orifice & Outlet Flanges Inlet & body
Feed Plate Pipe OD & Outlet Design
Inlet
Var water Flow Downstre thk. (mm) Pipe OD & thk. pressure
Operation Pressure
No. Temp. (m3/hr) am (mm) (kg/cm2)/
kg/cm2
(ºC) Pressure Pipe Design Pr Temp (ºC)
Pipe Design
(kg/cm2) (kg/cm2)/
Pr (kg/cm2)/
Temp (ºC) Temp (ºC)
301x 53 BW 323.9 x 9.53 BW

The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED .
Hot 190 412.8 583 15.8 ends ends ANSI

02 ANSI B16.25 B16.25 542/200
Cold 110 37.6 164 4 542/200 40/200
232 x 41 BW 219.1 x 8.18 BW

Hot 190 416.1 359 15.8 ends ANSI ends ANSI
03 B16.25 B16.25 542/200
Cold 110 51.5 94.5 4 542/200 40/200
273 x 50 BW 273 x 9.27 BW

Hot 190 415.9 450 15.7 ends ANSI ends ANSI

05 B16.25 B16.25 542/200
Cold 110 52.9 121.2 4 490/200 40/200
3 273 x 50 BW 273 x 9.27 BW

. Hot 190 421 448 15.8 ends ANSI ends ANSI
06 B16.25 B16.25 510/200
2
.Cold 110 53 120 4.3 490/200 40/200
3.2.0 Pressure drop across orifice plate at cold condition shall be designed for 1 kg/cm2
3.3.0 Valve shall go to full open condition with supply air failure to actuator and supply
voltage failure to solenoid valve.
4.0.0 DESIGN FEATURES & GENERAL REQUIREMENTS:
4.1.0 Valve shall be pneumatically operated modulating type.

4.1.1 Valve shall be DRAG design type (Applicable only for Var-04).
4.2.0 The multiple stages shall be such that the controlled pressure drop across each stage
shall ensure that the valve doesn’t cavitate in any of the stages.
4.3.0 Bidder shall offer multistage trims valves. Trim shall be of multistage and multipath
design with number of discrete pressure drop stages to eliminate the chances of
erosion, cavitation, noise and vibration throughout the control range of the valve.
4.4.0 Balanced trim valves shall be offered for high shut-off pressure or high pressure drop
condition to reduce the size of the actuators.
4.5.0 Quick replacement type trim shall be considered for easy maintenance.
4.6.0 The control valves and accessories equipment furnished by the Bidder shall be
designed, constructed and tested in accordance with the latest applicable
requirements of code for pressure piping ANSI B 31.1, the ASME Boiler & pressure
vessel code, Indian Boiler Regulation (IBR-IIIC), ISA, and other standards specified
Ref. Doc
elsewhere as well as in accordance with all applicable requirements of the “Federal

Occupational Safety and Health Standards, USA” or acceptable equal standard.
Bidder shall provide the IBR certificates for all the Control valves coming on piping
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TD-106-2

system under IBR scope. Inspection agency for IBR tests & certificates shall be an
approved agency of IBR.
4.7.0 The design of valve body shall confirm to the requirements of ANSI B-16.34 and other
applicable standards for dimensions, material thickness and material specification for
their respective pressure classes.
5.0.0 CONTROL VALVE SIZING & CONSTRUCTION:
5.1.0 Control valve body shall be selected as per the ISA Guideline. The valve body shall be
of forged steel.
5.2.0 The control valve sizing (Cv / Kv) shall be based on following guidelines:
a) The valves shall pass normal flow (MCR condition) with 60 to 70 percent opening
for linear characterised valves and between 70 to 80 percent opening for equal
percentage characterised valves.
b) The valves shall have adequate range ability to pass the minimum and maximum
flows at 10% and 85% of the valve opening respectively. Valve stem travel range from
minimum to maximum flow condition shall not be less than 50% of the total valve stem
travel.
c) Valve Cv shall be selected in such a way that the valve shall be capable of handling
at least 120% of required maximum flow.
d) The valve selection shall be based on the highest size dictated by the above
considerations unless noise, flashing or other factors dictate the final selection.
e) Trim exit outlet velocity as defined in ISA handbook does not exceed 8 m/sec for
liquid services, 150 m/sec for steam services and 50/% of sonic velocity for flashing
services The sizing procedure followed shall be as per latest edition of ANSI/ISA or
equivalent standard.
5.3.0 Each recirculation line will be routed independently to deaerator storage tank. An
orifice, with a small pressure drop, shall be fitted in each line near the deaerator to
prevent any flashing in the pipeline. This Orifice plate along with counter flanges and
fasteners to be supplied along with RC Valve.
5.4.0 Bidder to furnish detailed calculation for trim exit velocity and valve outlet velocity in
technical proposal stage.
5.5.0 Bidder to furnish detailed noise calculation for all valves. Which will be subject to
Employer’s approval during detailed engineering.
5.6.0 Control valves for steam and water applications shall be designed to prevent
cavitation, wire drawing, flashing on the downstream side of valve and downstream
piping. Thus for cavitation/flashing service, only valve with anti-cavitation trim shall be
provided. Bidder shall furnish in his proposal detailed calculations to establish whether
cavitation will occur or not under any operating condition for a particular application.
These calculations clearly indicating shall be subject to BHEL review and approval and
in case it is established at any stage of the contract that cavitation will occur, the
Bidder shall provide anti-cavitation trim for the same at no extra price. Further the
Bidder shall furnish in his proposal the detailed write up, technical literature etc. clearly
indicating as to how the occurrence of cavitation shall be prevented by the design of
this offered anti-cavitation trim. The valve design which only shifts the occurrence of
cavitation for minimizing the erosion will not be acceptable.
Ref. Doc
5.7.0 Control valves shall have leakage class equal or better than class-VI with metal-to-
metal seating (For Var-04) and Class-V for all other variants.
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TD-106-2

5.8.0 The control valve induced noise shall be limited to 85 dBA at 1 meter from the valve
surface under actual operating conditions. The noise abatement shall be achieved by
valve body and trim design and not by use of silencers.
5.9.0 Bidder shall furnish the Control valve manufacturer’s data sheets and sizing
calculations including the inlet/outlet velocity calculations with the proposal, which will
be subjected to BHEL approval during detailed engineering stage.
5.10.0 The exact characteristic (i.e. Linear/equal percentage/quick-opening type) for each of
the control valves shall be selected to match the process requirements and shall be
subjected to BHEL approval during detailed engineering stage.

6.0.0 VALVE CONSTRUCTION:
6.1.0 All valves shall be of globe body design.

6.2.0 a) Valves with high lift cage guided plugs & quick-change trims shall be supplied. The
quick change trim shall consist of a cage and a seating clamped in the valve body by
the valve bonnet and sealed with a spiral wound stainless steel asbestos gasket. The
trim shall be removable through the top after bonnet removal without any cutting or
welding of the valve. Where applicable, plugs shall be designed to include pressure
balancing for cage guided valves.

b) The valve offered shall have pressure reduction through multi-stage, multi-path,
axial flow/radial flow anti-cavitation design. The trim / stack shall be provided with
parallel sets of multiple axial/radial holes. The flow path through the holes shall be
staggered and shall be determined by the valve plug. Pressure reduction through
contours or steps formed on the valve stem/spindle is not acceptable.
6.3.0 Cast Iron valves are not acceptable.
6.4.0 Bonnet joints for all control valves shall be of the flanged and bolted type or other
construction acceptable to the Employer. Bonnet joints of the internal threaded or
union type will not be acceptable.
6.5.0 Plug shall be of one-piece construction cast, forged or machined from solid bar stock.
Plug shall be screwed and pinned to valve stems or shall be integral with the valve
stems.
6.6.0 All valves connected to vacuum on downstream side shall be provided with packing
suitable for vacuum applications (e.g. double vee type chevron packing)
6.7.0 Valve characteristic shall match with the process characteristics.
6.8.0 Extension bonnets shall be provided when the maximum temperature of flowing fluid is
greater than 280 deg. C.
6.9.0 Flanged valves shall be rated at no less then ANSI press class of 300 lbs.
6.10.0 The gland material shall be chosen to suit the operating temperature. However
Asbestos is not to be used.
6.11.0 All control valves shall have stems, guide bushings, plugs, seat rings, stem lock pin,
stuffing box parts and other trim parts made of stainless steel. Valve guide posts and
bushings shall be stellited faces for applications involving high pressure drop as well
as for flashing and cavitation applications.
6.12.0 Stem travel indicators shall be provided on all valves.
Ref. Doc
6.13.0 Each valve shall have an arrow fixed permanently on the valve body to indicate the
correct direction of flow.
Rev No. 5
TD-106-2

6.14.0 Each valve shall have a stainless steel name plate permanently fastened to the yoke
which shall be visible when the valves are in service. The name plate shall indicate
valve serial no., body material, size, pressure rating, trim material & type, action in air
failure, steam travel, Rated Cv etc.
6.15.0 Suitable lugs shall be provided on the valve body/Assembly for lifting/handling and to
assist placement of the valve assembly in the desired position.
6.16.0 Valve orientation (inlet/outlet) shall be as per Annexure-1.
7.0.0 VALVE MATERIALS:
I. Body : As per ASTM-A217 Gr. WC9

II. Trim : SS 440 C
However, Bidder may offer valves with body and trim materials better than specified
materials and in such cases Bidder shall furnish the comparison of properties including
cavitation resistance, hardness, tensile strength, strain energy, corrosion resistance
and erosion resistance etc. of the offered material vis-a-vis the specified
Material for BHEL consideration and approval.
8.0.0 END PREPARATION:
Valve body ends shall be butt welded type as per ANSI B 16.34 for control valves of
sizes 65 mm and above. Valve inlet and outlet pipe size details are given at Cl. No.
3.1.0. Required valve edge preparation details will be furnished during contract
execution stage. Bidder shall offer valve body such that it is directly weldable to pipe
size without any cost implication to BHEL.
Orifice plate flanges to ends shall be butt welded type as per ANSI B 16.34.
Recirculation line size details are given at Cl. No. 3.1.0. Required Flange edge
preparation details will be furnished during contract execution stage. Bidder shall offer
Flanges such that it is directly weld able to pipe size without any cost implication to
BHEL.
9.0.0 VALVE ACTUATORS:
The control valves shall be furnished with pneumatic actuators. Spring-diaphragm

type actuators shall generally be used. Piston type actuators shall be offered in case of
high shut-off pressure & quick response requirement. The Bidder shall be responsible
for proper selection and sizing of valve actuators in accordance with the Pressure drop
and maximum shut off pressure and leakage class requirements. The Valve actuators
shall be capable of operating at 80 deg C continuously.
The actuator shall be designed for 150% thrust required for the valve (at shut-off
pressure) at an air line supply pressure of 5.5 Kg/Sq.cm.
Diaphragms shall be designed for 200% maximum operating pressure. Nylon
reinforced neoprene is preferred as diaphragm material.
Air connection size shall be 1/4” NPT (F) unless otherwise dictated by process
response time. Integral tubing shall be stainless steel.
All actuators shall be of fail safe design signifying that the spring direction will tend to
move the valve to open in case of air failure. “Failure to Open” shall be marked on the
actuator.
Actuators shall be supplied with name plates which indicate the diaphragm air
Ref. Doc
pressure at full open and full closed positions. For single seated valves the pressure
shall be listed for maximum differential and for zero differential across the valve.
Opening and Closing time of the valve shall be less than 10 seconds.
Rev No. 5
TD-106-2

10.0.0 CONTROL VALVE ACCESSORY DEVICES:
10.1.0 All pneumatic actuated control valve accessories such as air locks, hand wheels/hand-
jacks, limit switches, microprocessor based electronic Positioner, diffusers, external
volume chambers, position transmitters (capacitance or resistance type only),
reversible pilot for Positioner, tubing and air sets, solenoid valves and junction boxes
etc. shall be provided as per the requirements.
10.2.0 Limit Switches:
Limit Switches shall have not less than two normally open and two normally closed
contacts in both open and closed conditions. Electrical rating of the limit switch
contacts shall be 240V AC, 5.0 amps or 220V DC, 0.5 Amps. The enclosure of the limit
switches shall be as per IP-65. Each limit switch shall be supplied with cable glands.
10.3.0 Solenoid Valves:
1. Operating Principle : Electromagnetic (noiseless).
2. Coil voltage rating : 240 V AC /24 V DC (as required).
3. Ways : 2/3/4 way.
4. Port size : 1/4" NPT all ports.
5. Body : SS bar stock Trim : SS-316.

6. Duty : Suitable for continuous energization.
7. Sealing : Airtight and leak proof.
8. Ambient Temperature : 0 - 50 OC.
9. Fluid Temperature : 0-200 OC (approx.).
10. Coil Enclosure : Stainless Steel.
11. Insulation : Class-H.
12. Coil Casing : IP-65 (Explosion proof for NEC Class- 1, Division-1 area).
13. Mounting : On pipe or on panel.
14. Cable Connection : ½” NPT.
15. Air filter regulator shall have sintered bronze filter element with maximum 5
microns filter size & 2 inch dial size pressure gauges.
16. Accessories : Terminals and Cable gland for connecting power supply, SS Tag
plate.
10.4.0 Tubing & Air Sets:
The tubing required to interconnect devices assembled together shall be fully annealed
soft copper conforming to ASTM-B.68 or B.75 (USA). Swaged type flare less tubing
fittings shall be used for tubing connections.
Control valves shall be provided with a combination of filter regulator and shall be
mounted on the valve itself. Filter regulator shall be suitable for a maximum inlet
pressure of 10 kg/cm2.Filter regulator shall have built-in housing blow down valves and
a 2” pressure gage. Filter shall be made of sintered bronze and size shall not be more
than five microns.
10.5.0 Smart Positioner:
i) The valve shall be offered with HART protocol based Smart Electro Pneumatic
Positioners to ensure accuracy and repeatability of response.
ii) Positioners shall have integral non contact type position transmitter, input and output
gauges, local keypad & display and 4-20 mA DC output to DDCMIS in CCR.
iii) Positioners shall be capable of functioning under hot, humid and vibrating
conditions.
Ref. Doc
iv) Positioner casings shall be dust tight, corrosion resistant and weatherproof to IP 65
and explosion proof in hazardous areas.
Rev No. 5
TD-106-2

v) In general, positioner shall operate at signal range 4 – 20 mA DC for the full travel of
the valve. Split range operation in few cases may be required.
vi) Remote calibration from control room shall be possible through HART management
station.
vii) Universal HART calibrator to be provided- 1 no. per project.
10.6.0 JUNCTION BOX:

1. Type of Enclosure: Dust tight & weatherproof conforming to IP 65
2. Material: 3 mm sheet steel / fiberglass reinforced polyester (UV stabilized)

3. Type of Cover: Solid unhinged with retention chain / Screwed at all four corners
4. Paint: RAL 7032-Siemens Grey
5. Mounting: Surface / Two (2) inch Pipe stanchion (At a dry compartment at one
side of the enclosure / rack with front opening type door)
6. Cable Entry: 3 mm (min) Bottom / side Gland plate
7. Gasket: Neoprene
8. Grounding: Brass earth lug with green screw head External-2 no’s, Internal-1no.
(M6)
9. Number of Drain Holes: Two at bottom capped
10. Identification: Label for JB and Tags for cable
11. Accessories: a) Rail mounted cage clamp type screwless terminals (suitable for
conductor size up to 2. 5sq.mm of suitable voltage grade) with markers and 20%
spare terminals
b) Cable gland (Brass) & raceways
c) Ferrules & lugs (Brass)
d) Aluminum back panel
e) Canopy at top
f) Mounting brackets
g) bolts and nuts made of brass etc.
10.7.0 Bidder to provide Cast Steel (CS) yokes. Cast Iron (CI) yokes are Not Acceptable.
11.0.0 QUALITY ASSURANCE & TESTS:
All valves including actuators shall be tested in accordance with the quality assurance
program agreed between the Employer and Contractor, which shall meet the
requirements of IBR and other applicable codes mentioned elsewhere in the
specifications.
The quality control plans and reference documents shall be furnished for BHEL
approval. If required supplier shall depute their representative for discussions and
finalization of quality plan and reference documents with BHEL.
The tests shall include but not be limited to the following:
11.1.0 Non Destructive Test as per ANSI B-16.34.
11.2.0 Valve closure test and seat leakage test in accordance with ANSI/FCI 70.2 and as per
the leakage class indicated above.
11.3.0 Functional Test: The fully assembled valves including actuators control devices and
accessories shall be functionally tested to demonstrate times from open to close
Ref. Doc
position.
11.4.0 Properties of materials shall be determined from the test pieces fully representative of
the material and its condition. Detailed results of the test conducted to determine the
Rev No. 5
TD-106-2

mechanical properties, chemical analysis and details of heat treatment procedure shall
be recorded on certificates.
11.5.0 Hardness check shall be carried out on all hard faced/stellited surfaces, if any.
11.6.0 Bar stock for valves stem shall be subjected to UT. Finish machined valve stem shall
be subjected to magnetic particle examination/dye penetration test.
11.7.0 Wall thickness measurement by ultrasonic for critical and highly stressed zones of the
castings / forging shall be carried out.
11.9.0 Hydrostatic shell test:

11.9.1 Valves shall be subjected to hydrostatic shell test in accordance with ANSI-B 16.34
prior to seat leakage test. If the valves are reworked on the pressure parts for any
reason after hydrostatic test, they must be retested.
11.9.2 Valves shall be hydrostatically tested in manufacturer’s works in accordance with code
requirements. All hydrostatic testing and inspection shall be completed before any
paint is applied to valve body. Certificates of inspection shall be executed in
accordance with the latest and required codes and shall be forwarded to the Engineer.
11.9.3 All gaskets used for test shall be of the same material and designs as specified for the
finished product. Where mechanical gasket joints and broken following tests, new
gasket shall be furnished with the equipment and the joints shall be re-tested.
11.10.0 Leakage Test:
11.10.1 Valve closure test and seat leakage tests shall be performed in accordance with
ANSI/FCI 70.2 and as per applicable leakage class. Seat leakage test shall be carried
out by closing the valve with the help of job actuator. Actuator body shall be subjected
to pneumatic test and no leakage is permitted.
11.10.2 If valves are disassembled after the completion of the valve closure and seat leakage
tests for any rectification, these tests shall be repeated.
11.11.0 Functional Tests:
The fully assembled or completed valves including the actuators control devices and
accessories shall be functionally tested to demonstrate the operability and response
time of the valve and the actuator. This may be done by cycling the valves 3 or 4 times
from open to close position. The same controller can be used to test each valve.
These tests shall also include the verification of control valve operation features such
as stay put operation, fail to open, fail to close on air failure, control signal failure etc.
in line with the specification requirement.
11.12.0 Life Cycle Test (Type test):
Type test certificate carried out earlier by the vendor on similar design size and the
type of valve and actuator shall be furnished. The certificate shall contain the model
no. /size of the valve and actuator. The actuators of the valves shall be tested for
compliance with the life cycle data in line with the relevant standards. The voltage,
current rating and insulation class of solenoid operated valve shall be tested for
compliance with specification requirement.
11.13.0 Cv Test:
Cv test shall be carried out as per approved test procedure on each size, type and
design of the each Purchase Order. As per ISA-75.02 standard from 0 to 100% of the
valve travel in steps of 20% and test values shall meet published catalogue
Ref. Doc
requirements taking into consideration the allowable tolerances as per ISA-75.11 and
test report shall be furnished for BHEL approval. Before commencing the test, Cv type
test procedure shall be submitted for BHEL review and approval.
Rev No. 5
TD-106-2

11.14.0 WITNESSING OF TESTS BY BHEL/END USER/TPIA:

The following tests shall be offered for Witness by BHEL/End User/TPIA
a) Physical Dimensions of the Valve
b) Hydro Test
c) Performance Test
d) Seat leakage Test
e) Cv Type Test (one valve of each type, size & design of each purchase order)
* Tests indicated at d) & e) above, shall be witnessed by BHEL.

12.0.0 PACKAGE :
12.1.0 Guidelines for Packing
 After inspection of control valves assembly. Smart Positioner along with Pressure Gauge
shall be disassembled & packed separately.
 Threaded connection of Smart Positioner & Pressure Gauge shall be shipped with the
end caps fitted to avoid any damage.
 Instructions with sketch for mounting the Smart Positioner & Pressure Gauge shall be
sent along with the aforesaid accessories.

 Packing of the control valves and Smart Positioner along with Pressure Gauge shall be
done in separate wooden boxes/cases in order to avoid damage during transit and also
during storage at site in tropical climatic conditions for a period of 18-24 months.
 The Vendor shall be responsible for any loss or damage during transportation, handling
and storage due to improper packing. The Packing shall be Sea-worthy.
 All valves & smart positioner along with pressure gauges shall be packed properly with
quality wooden planks with proper wooden frame support. Moreover the valves are
internally covered with polythene sheets to protect from the water and moisture entry.
 Stronger shock absorbing cover material like expanded Polyurethane which can take
any direct impact on it shall be used for packing.
 Proper reaper support to be provided in the packing and Valve assembly to be aligned
properly to avoid the damage of accessories during transit due to vibration effect.
 Marking for Fragile & Condensing environment shall be done on the packing box.
Ref. Doc
Rev No. 5
TD-106-2

The Following Details are to be marked on the Packing Cases
 Address of consignee
 Purchase order no.
 Description of items or title of packing list
 Weight
 Dimension of the Box
 Marking showing upright position
 Marking showing sling position
 Marking showing umbrella

(i.e. for machines/components to be stored under covered storage).
12.3.0 PROTECTION
All coated surface shall be protected against abrasion, impact, discoloration and any
other damages. All exposed threaded portions shall be suitably protected with either a
metallic or a non-metallic protecting device. All ends of all valves and piping and
conduit equipment connections shall be properly sealed with parts which are likely to
get rusted, due exposure to weather should also be properly treated and protected in a
suitable manner. EMI/static charge proof packaging should be used for PLC/Electronic
hardware.
13.0.0 PRESERVATIVE SHOP COATING:

13.1.0 All exposed metallic surface to corrosion shall be protected by shop application of
suitable coatings. All surfaces which will not be easily accessible after the shop
assembly, shall before hand be treated and protected for the life of the equipment. All
surfaces shall be thoroughly cleaned of all mill scale oxide and other coatings are
Prepared in the shop, the surfaces that are to be finish painted after installation or
require corrosion protection until installation, shall be shop painted with at least two
coats of primer. Transformers and other electrical equipment, if included shall be shop
finished with one or more coats of primer and two coats of high grade resistance
enamel. The finished colours shall be as per manufacturer’s standards to be selected
and specified by the Engineer at a later stage.
13.2.0 Shop primer for all steel surface which will be exposed to operating temperature below
95C shall be selected by the Contractor. Special high temperature primer shall be
used on surface exposed to temperature higher than 95C.
13.3.0 All other steel surfaces which are not to be painted shall be coated with suitable dust
preventive compound subject to the approval of the Contractor.
14.0.0 RATING PLATES, NAME PLATES AND LABELS:
14.1.0 Each main and auxiliary item of plant is to have permanently attached to it in a
conspicuous position rating plates of non-corrosive material upon which is to be
engraved manufacturer name, equipment, type or serial number together with details
of the loading conditions under which the item of plant in question has been designed
to operate and such diagram plates as may be required by the Engineer.
Ref. Doc
14.2.0 Each item of plant is to be provided with nameplate or label designing the service of
the particular equipment. The inscriptions are to be approved by the Engineer or as
detailed in the appropriate sections of the Technical Specifications.
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14.3.0 Such nameplates or labels are to be of white non-hygroscopic materials with engraved
back lettering or alternatively in the case of indoor circuit breakers, starters, etc. of
transparent plastic material with suitably colored lettering engraved on the back.
14.4.0 Terms of plant such as valves and dampers, which are subject to handling, are to be
provided with engraved chromium plated or label with engraving filled with enamel. The
nameplates for valves shall be marked in accordance with MSS standard Sp-25 and
ANSI B 16.34 as minimum.
15.0.0 DOCUMENTS TO BE FURNISHED ALONG WITH OFFER:

a) GA drawing (shall include weld end details, outline dimensions and other
terminal details) for BHEL review and approval.
b) Sectional drawing (including Part list with Material of construction)
c) Data sheet for BHEL review and approval.
d) CV & anti-cavitation calculations along with outlet velocity calculation.

e) Detailed velocity calculation across each discrete stage for BHEL review and
approval.
f) Catalogue for valve, actuator and accessories. Model nos. chosen shall be
marked on the catalogues.
g) Quality plans and reference documents (if other than international standards
are referred)
h) Test Procedure for the following tests to be submitted for BHEL review and
approval.
1. Performance Test
2. Seat leakage Test
3. Cv Type Test
16.0.0 DOCUMENTS TO BE FURNISHED AFTER PLACEMENT OF ORDER:
a) GA drawing (shall include weld end details , outline dimensions and other
terminal details) for BHEL review and approval.
b) Sectional drawing (including part list with Material of construction) & Data
Sheet for BHEL review and approval.
c) Hook-up diagram of Control Valve with Actuator & Accessories.
d) Valve Edge preparation details.
e) All calculations like CV & anti-cavitation calculations, Noise Level, Trim Exit
Velocity, Valve Outlet Velocity, Actuator sizing etc.
f) All relevant catalogues for the models of the valves as well as accessories
finalized.
g) O & M instructions.
h) Preservations and storage instruction write up for valve and its accessories.
i) Detailed velocity calculation across each discrete stage for BHEL review and
approval.
j) Quality plans shall be in BHEL format
Ref. Doc
k) Documentation package (Quality file)
Rev No. 5
TD-106-2

l) Test Procedure for the following tests to be submitted for BHEL review and
approval.
1. Performance Test
2. Seat leakage Test
3. Cv Type Test
For (a) & (b) as listed above reproducible shall be furnished. Final approved drawings
shall be furnished in CD-ROM.
16.1.0 Guarantee shall be as specified in the enquiry.

17.0.0 Quality Assurance plan of Control valve & actuators shall be as per BHEL
format.
18.0.0 VARIANT NOS & MATERIAL CODES:

VAR. BHEL
DESCRIPTION
No Material Code
01 RC VALVE MODULATING TYPE FOR 800MW FP9760300010
02 RC VALVE MODULATING 50% 800MW PATRATU FP9760300028
03 RC VALVE MODULATING 30% 800MW PATRATU FP9760300036
04 RC VALVE MODULATING TYPE 800MW (YADADRI) FP9760300044
05 RC VALVE MODULATING TYPE 50% 660MW(PANKI) FP9760300052
06 RCVALVE MODULATING TYP 50% 660MW (UDANGUDI) FP9760300060
19.0.0 SPARES
(A) Mandatory spares to be considered as separate package. Mandatory spares to be
packed in different color & shipped separately. Marking on mandatory spares must be
in different color from main supply so that these are easily identifiable at site.
(B) Recommended Spares:
In addition to the Mandatory spares mentioned, the bidder shall also furnish a List of
Recommended spares for 3 years of normal operation of the Control valves/
Accessories. BHEL/Customer reserves the right to buy any or all of the recommended
spares. The prices of these spares will remain valid for a period of minimum 6 months
after the placement of order.
(C) Start-up & Commissioning Spares:
Start-up and Commissioning spares are those spares, which may be required during
the start-up and commissioning of the Control Valves. All start-up spares, which are
supplied under this contract, shall be strictly interchangeable with the parts for which
they are intended for replacements. The format for price schedule to be filled-up by the
bidder is enclosed in Volume-III.
The Start-up and commissioning spares indicated by the bidder shall be a part of the
main Control valves supply. However bidder to indicate prices separately. The list of
these spares required is enclosed in the section-D of this specification.
Bidder to indicate the service life expectancy period for the spare parts under
Ref. Doc
normal working conditions. The spares shall be treated and packed for long storage,
under climatic conditions prevailing at site. Small items shall be packed in sealed
transparent plastic bags with desiccators’ packs as necessary.
Rev No. 5
TD-106-2

(D) For Spare Variant Table:
Spares for Var-01

S.No Description Material Code Remark/Applicable
1 LIMIT SWITCH FOR MOD RC VALVE FP9760300516 Applicable for Var- 01
2 POSITIONERS FP9760300524 Applicable for Var- 01
3 ACTUATOR PISTON SEAL KIT FP9760300532 Applicable for Var- 01
4 COMPLETE SOFT SEAL FOR FP9760300540 Applicable for Var- 01

5 VALVE DISC & VALVE SPINDLE FP9760300559 Applicable for Var- 01

6 VALVE SEAT FOR FP9760300567 Applicable for Var- 01
7 ACTUATOR SUB ASSEMBLY FP9760300575 Applicable for Var- 01
8 GUIDE FP9760300583 Applicable for Var- 01
9 COUPLING NUT FP9760300591 Applicable for Var- 01
10 ACTUATOR PISTON WITH ROD& SEAL FP9760300605 Applicable for Var- 01
11 VALVE TRIM FP9760300613 Applicable for Var- 01
12 SOLENOID VALVE FP9760300621 Applicable for Var- 01

13 *****NOT USED***** FP9760300630 ---
14 *****NOT USED***** FP9760300656 ---
15 FEEDBACK LINKAGES FP9760300664 Applicable for Var- 01
Spares for Var-02

1 SMART POSITIONERS & ACCESSORIES FP9760300672 Applicable for Var- 02
2 COMPLETE SOFT SEAL KIT FP9760300680 Applicable for Var- 02
3 VALVE STEM WITH PLUG ASSEMBLY FP9760300699 Applicable for Var- 02
4 ACTUATOR ASSEMBLY FP9760300710 Applicable for Var- 02
5 SEAT RING / VALVE SEAT FP9760300702 Applicable for Var- 02
6 DIAPHRAM/PISTON,ORINGS,SEALS ETC FP9760300729 Applicable for Var- 02
7 STACK / CAGE ASSEMBLY FP9760300737 Applicable for Var- 02
8 SOLENOID VALVES FP9760300745 Applicable for Var- 02
9 E/P CONVERTERS FP9760300753 Applicable for Var- 02
10 FILTER REGULATORS FP9760300761 Applicable for Var- 02
11 PRESSURE GUAGES OF ALL TYPES FP9760300770 Applicable for Var- 02
Ref. Doc
Rev No. 5
TD-106-2

Spares for Var-03

1 SMART POSITIONERS & ACCESSORIES FP9760300788 Applicable for Var- 03
2 COMPLETE SOFT SEAL KIT FP9760300796 Applicable for Var- 03
3 VALVE STEM WITH PLUG ASSEMBLY FP9760300800 Applicable for Var- 03
4 Applicable for Var- 03

ACTUATOR ASSEMBLY FP9760300826

5 SEAT RING / VALVE SEAT FP9760300818 Applicable for Var- 03
6 DIAPHRAM/PISTON,ORINGS,SEALS ETC FP9760300834 Applicable for Var- 03
7 STACK / CAGE ASSEMBLY FP9760300842 Applicable for Var- 03
9 E/P CONVERTERS FP9760300869 Applicable for Var- 03
10 FILTER REGULATORS FP9760300877 Applicable for Var- 03
11 PRESSURE GUAGES OF ALL TYPES FP9760300885 Applicable for Var- 03
Spares for Var-04

1 LIMIT SWITCH FOR MOD RC VALVE FP9760300893 Applicable for Var- 04
2 POSITIONERS FP9760300907 Applicable for Var- 04
3 ACTUATOR PISTON SEAL KIT FP9760300915 Applicable for Var- 04
4 COMPLETE SOFT SEAL FP9760300923 Applicable for Var- 04
5 VALVE DISC & VALVE SPINDLE FP9760300931 Applicable for Var- 04
6 VALVE SEAT FP9760300940 Applicable for Var- 04
7 ACTUATOR SUB ASSEMBLY FP9760300958 Applicable for Var- 04
8 GUIDE FP9760300966 Applicable for Var- 04
9 COUPLING NUT FP9760300974 Applicable for Var- 04
10 ACTUATOR PISTON WITH ROD& SEAL FP9760300982 Applicable for Var- 04
11 VALVE TRIM FP9760300990 Applicable for Var- 04
12 SOLENOID VALVE FP9760300508 Applicable for Var- 04
13 FEEDBACK LINKAGES FP9760300494 Applicable for Var- 04
Ref. Doc
Rev No. 5
TD-106-2

Spares for Var-05

1 RC VALVE STEM PACKING FP9760300486 Applicable for Var- 05
2 MOULDED RUBBER DIAPHRAGMS FP9760300478 Applicable for Var- 05
LUBRICANTS FOR GASKETS-1YR FP9760300460
3 Applicable for Var- 05
CONSUMPTION
4 RC VALVE LIMIT SWITCHES FP9760300451 Applicable for Var- 05
5 RC VALVE POSITIONER FP9760300443 Applicable for Var- 05

6 RC VALVE POSITIONER TRANS FP9760300435 Applicable for Var- 05

7 COMPLETE VALVE TRIM ASSY FP9760300427 Applicable for Var- 05
8 RC VALVE ACTUATOR ASSY FP9760300419 Applicable for Var- 05
10 AIR LOCK RELAYS FP9760300397 Applicable for Var- 05
11 SOFT GOODS KIT FOR RC VALVE FP9760300389 Applicable for Var- 05
12 METAL SEAT SET FP9760300370 Applicable for Var- 05
13 SEAT RING SET FP9760300362 Applicable for Var- 05
14 SPINDLE ASSY FP9760300354 Applicable for Var- 05

15 ACTUATOR SOFT GOODS KIT FP9760300346 Applicable for Var- 05
16 AIR FILTER REGULATORS FP9760300338 Applicable for Var- 05
Spares for Var-06

1 RC VALVE ACTUATOR ASSY VAR-06 FP9760300311 Applicable for Var- 06
2 COMPLETE VALVE TRIM ASSY FOR VAR-06 FP9760300303 Applicable for Var- 06
3 COMPLETE DIAPHRAGM ASSY FOR VAR-06 FP9760300249 Applicable for Var- 06
4 SOLENOID VALVES ASSY FOR VAR-06 FP9760300281 Applicable for Var- 06
PNEUMATIC AIR-FILTER/REGULATR FOR FP9760300273 Applicable for Var- 06
5
VAR06
POSITION FEEDBACK TRANSMITTER FOR FP9760300265 Applicable for Var- 06
6
VAR06
7 AIR LOCK RELAYS FOR VAR-06 FP9760300257 Applicable for Var- 06
Ref. Doc
Rev No. 5
TD-106-2

FIGURE-1
(OUTLINE DIM. OF RC VALVE)
Note: Dimension (in mm) to be furnished by vendor along with technical Offer.
Ref. Doc
Rev No. 5
TD-106-3
Form No.
PUMPS Rev No. 07
RECORD OF REVISIONS
Rev.
Date Revision Details Revised By Approved By
No.
00 10.02.2017 First Issue - -

The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED,
Cl.no. 4.0.0, 5.0.0, 7.0.0, 9.0.0, 11.10.0,

01 22.11.2018 11.13.0, 11.14.0, 15.0.0, 16.0.0 Rajesh Ch KHRK
updated.
Var02, 03, 04 added. Var02, 03, 04
02 14.12.2018 Rajesh Ch KHRK
spares list added.
Clause no 3.1.0, 4.4.0, 6.2.0 b), 2.0.0 i)
updated. Clause no 3.2.0 added.
03 02.05.2019 K.Sangeetha. KHRK
Clause no 4.5.0 deleted. Pt “n” added in
clause no 2.0.0.
Var 05 and spares list for Var 05 added.
04 19.09.2019 K.Sangeetha. KHRK
Spec generally revised.
Parameters at 3.1.0 are updated for

05 06.03.2020 RAJESH CH KHRK
var-02, 03 & 05.
Cl.no. 4.1.1 added.

06 06.03.2020 RAJESH CH KHRK
Cl.no. 5.7.0 revised.
07 09.03.2020 Parameters at 3.1.0, updated for var-06. ROHIT.P KHRK

Ref. Doc.

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Rev No.

Form No. PUMPS Rev No. 07

conditions of operation as given at CL. 3.1.0.

2.0.0 SCOPE OF SUPPLY:

f) Stem travel indicator.

3.0.0 TECHNICAL PARAMETERS:

3.1.0 OPERATNG CONDITIONS:

Revisions : Prepared By : Approved By : Date :

Refer to record of revisions.

Form No. PUMPS Rev No. 07

301x 53 BW 323.9 x 9.53 BW

Hot 190 412.8 583 15.8 ends ends ANSI

02 ANSI B16.25 B16.25 542/200

Cold 110 37.6 164 4 542/200 40/200

232 x 41 BW 219.1 x 8.18 BW

Cold 110 51.5 94.5 4 542/200 40/200

273 x 50 BW 273 x 9.27 BW

Hot 190 415.9 450 15.7 ends ANSI ends ANSI

Cold 110 52.9 121.2 4 490/200 40/200

3 273 x 50 BW 273 x 9.27 BW

4.0.0 DESIGN FEATURES & GENERAL REQUIREMENTS:

4.1.0 Valve shall be pneumatically operated modulating type.

elsewhere as well as in accordance with all applicable requirements of the “Federal

Form No. PUMPS Rev No. 07

5.0.0 CONTROL VALVE SIZING & CONSTRUCTION:

Form No. PUMPS Rev No. 07

subjected to BHEL approval during detailed engineering stage.

6.0.0 VALVE CONSTRUCTION:

6.1.0 All valves shall be of globe body design.

balancing for cage guided valves.

Form No. PUMPS Rev No. 07

I. Body : As per ASTM-A217 Gr. WC9

The control valves shall be furnished with pneumatic actuators. Spring-diaphragm

Form No. PUMPS Rev No. 07

5. Body : SS bar stock Trim : SS-316.

Form No. PUMPS Rev No. 07

10.6.0 JUNCTION BOX:

2. Material: 3 mm sheet steel / fiberglass reinforced polyester (UV stabilized)

11.0.0 QUALITY ASSURANCE & TESTS:

Form No. PUMPS Rev No. 07

11.9.0 Hydrostatic shell test:

Form No. PUMPS Rev No. 07

11.14.0 WITNESSING OF TESTS BY BHEL/END USER/TPIA:

* Tests indicated at d) & e) above, shall be witnessed by BHEL.

sent along with the aforesaid accessories.

Form No. PUMPS Rev No. 07

 Marking showing umbrella

(i.e. for machines/components to be stored under covered storage).

13.0.0 PRESERVATIVE SHOP COATING:

14.0.0 RATING PLATES, NAME PLATES AND LABELS:

Form No. PUMPS Rev No. 07

15.0.0 DOCUMENTS TO BE FURNISHED ALONG WITH OFFER:

b) Sectional drawing (including Part list with Material of construction)

c) Data sheet for BHEL review and approval.

d) CV & anti-cavitation calculations along with outlet velocity calculation.

16.0.0 DOCUMENTS TO BE FURNISHED AFTER PLACEMENT OF ORDER:

k) Documentation package (Quality file)

Form No. PUMPS Rev No. 07

16.1.0 Guarantee shall be as specified in the enquiry.