Part/Item Specification

Intake : Intake gate and Scour gate with hoisting arrangements (manual & electrical), Trashrack, Flushing pipe, Flushing valve,
Air vent pipe for flushing intake, Welded mesh covering, Cat ladder
WCS : Pipe with bends and expansion joints, Bellmouth pieces
Surge : Dewatering pipe, Dewatering valve, Water level sensor pipe, Stainless steel staircase, Cat ladder, Welded mesh
Scope covering, Valve house superstructure
Penstock : Pipe with bends, expansion joints etc. and Manhole (1 No), Bellmouth piece at the intake, Butterfly valve, Air vent
pipe
Powerhouse : Draft tube gate (Manual& Electrically operated)

Material for pipes, gates and MS IS 2062 Class B

trashrack
 The gate shall have sufficiently sized air vent for all the dynamic flow conditions.

All welding shall be done by the electric arc welding.

All gate parts shall be sand blasted and protected with a corrosion resistant primer and paint as specified in the tender
specification. All embedded parts shall be painted with cement latex milk consisting of 10 parts (by weight) cement, 5 parts
water and 1 part latex additive.

Materials:
• The skin plate stiffeners, wheel track base, arms bracings, tie members girders, guides, guide rollers, seal base, bearing
plates
Flushing and Intake Gates and anchor bolts shall be made of structural steel confirming to IS - 2062.
• The wheel track seal seat, wheel pins and axles shall be made of stainless steel.

Inspection and testing:

• After the complete erection of the gate structures the contactor shall carry out the following tests:
i. Operational tests in dry conditions - Two full operations of the gate from completely closed to fully open position and vice
versa. The movement shall be free and without vibration. The gate moving parts shall keep the correct tolerance and gap
with the embedded parts.
ii. Operational tests with reservoir at full reservoir level/maximum water level or at any other water levels as directed. The
gates shall be checked on the same points as above but for wet conditions with water level at FRL/MWL.

SOQ: cleaning (sand blasting) and painting of the whole gate with water proof (epoxy) paint two coats
 One coat of red lead paint shall be done to the panels of trash rack.

The trash rack metal works and other embedded parts shall be painted with suitable anti-corrosive paints (both primer
&finishing
Intake Trashrack coats.

SOQ: cleaning (sand blasting) and painting of the whole portion with water proof (epoxy)/ marine paint of two coats over
priming coat
 The plates are tested (Ultrasonic test) and confirm that there are no discontinuities or any flaw in the sheet. The results of the
test have to be handed over to the site Engineer for verification before the plates are fabricated.

Inspection and testing of plates before fabrication:

a) Visual inspection: The plates shall be visually examined to ensure that no distortion has occurred during transport and
handling. The contractor shall produce the Mill Test Certificate of the steel plates to the Engineer in Charge before
fabrication.
b) Ultrasonic Inspection: The contractor shall perform ultra sonic examination of the plates. The Ultrasonic test shall be in
accordance with the testing procedure.

Plate preparation, forming and assembly:

The two sides of the plate shall be cut simultaneously and the edges one after the other. The method of preparing grooves
WCS , Penstock for welding, as well as the dimension and shape of welding groove shall be as approved by the Engineer in Charge. Grooves
shall be inspected for edge laminations and cracks as well as for uniformity of contour. If found unsatisfactory the entire plate
will be rejected.
The plates shall first be shaped by edge pressing and then by rolling in a rolling machine. No heating of the plates shall be
permitted during the entire forming process.
Plates shall be assembled and secured held in place prior to welding. Once single pipe sections are welded and inspected,
two sections shall be shop assembled and welded such that the resulting pipe will not exceed 5m in length.
The number of welded joints shall be minimized. Longitudinal welding joints shall be staggered by at least 30 cm in adjoining
sections. Assembly rings/ suitable clamping devices shall be used to align the joints and no force or hammering shall be
permitted after the joints have been welded.
 Erection method:
The end of the pipe/pen stock elements shall be aligned within the specified tolerance. After the sections are properly
spaced and aligned, the tolerances and the uniformity of the root gap are checked, the pipe & penstock elements shall be
held in position by use of any approved form of temporary bar or clamp. The alignment shall be got approved from the
Engineer before welding.

The erection is expected to proceed on the following sequence of operation.

WCS , Penstock (contd..) a. Place and align in position each pipe and assemble with the
adjoining pipe.
b. Weld the circumferential joints.
Dye penetration inspection shall be done during erection for the entire welds. Defects in the weld, if any, shall be rectified
and reexamined by radiography, at the cost of the contractor, to the satisfaction of the Engineer in Charge.

Tolerances
The contractor shall fabricate, assemble, and install pipe/penstock within the tolerance specified under or as per approved
standards.
The contractor will have to attend the rectifications, for deviations if any noted, at no extra cost to the company.
• The tolerance permissible for joint alignment will be - 3mm.
• Diameter: The outside circumference measured shall be within 10mm of the nominal circumference calculated from the
theoretical
WCS , Penstock (contd..) outside diameter.
• Out of roundness: The difference between the maximum diameter and minimum diameter shall not exceed 12mm,at any
cross section along the pipe/penstock, after erection and before concreting. Only a smooth oval out –of –roundness that can
be corrected in the fields shall be acceptable.
• Flatness or peaking at the longitudinal joints shall be limited to 4.5mm from the correct shape as determined by a circular
template.
• Overall length and straightness: The permissible variation from the nominal length shall be 6mm for a 5m long section.
• The maximum deviation of the cut edge of a pipe from a plane normal to the axis of pipe /penstock shall not exceed 3 mm.
 Welding:
Welding operation shall be under the supervision of the competent and experienced personnel who hold a supervisory
welder’s certificate as defined under the latest ASME boiler and pressure vessel code.

Radiographic Inspection:
The contractor shall carry out the radiographic examination of the shop welds and field welds in accordance with the relevant
standards
Radiographic examination shall cover the following amounts of welds.
a.100% of the longitudinal welds and 100% of the joints in Y piece.
WCS , Penstock (contd..) b.100% of the circumferential welds of penstock sections designed to transmit pull of the valves and closing joints
c. coverage of special items or accessories wherever applicable and wherever required by the Engineer such as manhole etc.
d.100% of T-junctions between circumferential and longitudinal welds in addition to spot checks for a total of 25% of
circumferential welds (same section)

The Radiographs shall be made available as the tests proceed for examination and approval by the Engineer in charge. The
Contractor shall properly store and preserve all the radiographs, whether the welding is accepted or rejected. He shall also
maintain a numbering system with identification drawings.
On completion of the inspection, one complete set of radiographs labeled, packed and accompanied by a description of the
numbering system and identification drawings shall be transmitted to the Engineer in charge.

Bracing and protection:

When a pipe/penstock has satisfactorily gone through all the shop tests, adequate spiders shall be provided to avoid
WCS , Penstock (contd..) deformations of the pipe section during handling and transport and shall be welded to the internal face of the pipe. If the
pipe is stiff enough for the transport, this bracing may be omitted subject to the approval of the Engineer in charge.
 Protective coating:
All paint shall be delivered to the shop/ field in the original sealed containers and shall be clearly marked with the
manufacture’s name and identifying brand number or name. The paint shall be mixed and applied in strict conformity with
the manufacturer’s direction. Use of thinners is prohibited, unless specified by the manufacturer.

Prior to any other surface preparation, all grease and oil shall be removed from the surface of the pipes by using suitable
solvent and wiping with clean rags until it is clean. Welds, edges and sharp corners shall be ground to a curve and all weld
splatter removed prior to blast cleaning. The surface of pipe elements shall be sand blasted to “white metal” in accordance
WCS , Penstock (contd..) with specification SSPC-SP-5-63 or equivalent.

After dry blast cleaning, all surfaces shall be dusted off with compressed air free of detrimental oil or water, and shall be
protected from and maintained free of oil, grease and dirt. The surface preparation shall be approved by the Engineer in
charge, before applying the protective coatings. The primer coat must be applied as soon as possible, but not later than 3
hours after blast cleaning. In no instance shall the blastcleaned surface be left uncoated overnight. No coating shall be
applied at shop closer than 10cm from the edges, which will be field welded. This remaining exposed steel shall be protected
during storage by a rust preventive compound, which will not interfere with
the field welding.
 The application of protective coatings to the steel pipes at the site shall be carried out in steps as follows:

a. Immediately after each consecutive welding, as well as the inspection and stress relieving of weld (wherever it is required)
are completed, the surface of the pipe not covered with the shop primer shall be protected by a rust preventive compound.

b. When the steel pipe is completed in full length, areas of field weld or where the shop priming has been damaged in the
face shall be cleaned and prepared for painting. Work under this item shall be started from one end of the pipe to ensure
that the surfaces to be painted area clean and not soiled by dust or residue from sand blasting and cleaning operations.
WCS , Penstock (contd..) c. The primer coats and the finishing coat for the surfaces as pecified shall then be applied in portions referred to in (2)
above. Proper curing time shall be given for the primer and subsequent cleaning of the surface as decided by the Engineer in
charge shall be carried out before applying the finishing coat.

The surfaces to be coated shall be completely dry, clean and free from moisture. Do not paint if the steel and/or air
temperature is below the manufacturer’s recommendation or if the relative humidity of air is above 85 percent, The dry film
thickness of primer shall be 2.5 microns. If mud cracking does occur, the affected areas shall be blast cleaned to “white
metal” and recoated, to the satisfaction of the Engineer in
charge.

Cleaning operations:
After the erection of the Pipe (WCS pipe or Penstock pipe) including the concreting is completed, all interior bracing and
temporary supports which were used in order to facilitate the erection shall be removed. If the welded attachments are to be
removed by burning, a 12 mm stub shall be kept for chipping and grinding. All field welds exposed to flowing water shall be
WCS , Penstock (contd..) finished by grinding flush with the inside face of the pipe. Under no circumstances shall the joints be ground below the inside
face of the steel liner. However a maximum difference in level of 1.5 mm will be allowed. Prior to surface preparation for
protective coating, the interior of the steel liner shall be cleaned and freed from any foreign bodies, which may be found in it
(wood, rags, electrode waste, cement, grout spill etc). All internal cleaning operation shall be done with great care to
minimize damage to the shop primer coating.
 Inspection
a. General: The Contractor shall take every precaution during inspections to prevent damage to the pipes and protective
coating. Inside the pipe the personnel shall wear shoes with rubber soles and heels. The equipment where it will be in
contact with the steel pipe shall have rubber wheels, and padding shall be used under under the supports of temporary
structures.
c. Field Inspection:
The whole interior of the erected penstock line shall be inspected to ascertain that the work is properly executed in
accordance with the contract, the requirement of the specifications has been met, and the specified tolerances are
WCS , Penstock (contd..) maintained.
d. Acceptance:
After inspection a report on the observations made shall be prepared by the Inspector/Engineer. The report shall state the
dimensions as checked at the selected sections and any defect or deficiencies observed. Each repair, if performed shall be
mentioned, together with the result of the after repair-inspection. If requested by the Contractor, Engineer may issue a
provisional Acceptance Certificate, noting any defects, which shall be rectified by the Contractor within a prescribed time
limit at his cost. The final acceptance of the work shall be made after the expiry of the warranty period, if the Contractor has
fulfilled all obligations of this contract.
 Hydrostatic Pressure test

a. General:

All the fabricated sections, straight pipes, bends, Y- piece etc shall be subjected to hydrostatic testing at shop.
During each testing, each piece shall be subjected to a test pressure of 1.5 times design pressure or to a pressure which will
develop a stress equal to 0.8 times yield point whichever is more.
Each individual section shall be completely filled with water and the pressure is gradually raised to test pressure. The
pressure shall be applied three times successively increasing and decreasing at uniform rate. The test pressure shall be held
stationary for such a time as is considered sufficient forinspection of all plates, joints and connections to detect leakage and
WCS , Penstock (contd..) signs of failure.If the test discloses any defects such as leakage or local strains, these shall be rectified.

On completion of the erection and dry inspection, Both Pipes shall be subjected to pressure test. The hydrostatic pressure
test consists of the controlled filling up of the pipe maintaining it for a specified length of time, and discharging the water. It is
expected that the turbine inlet valves in the Power House will be operational.The turbine inlet valves constitute an integral
part of the testing set-up without which the test shall not be made. The Contractor shall submit to the Engineer in charge for
approval a detailed procedure of testing and inspection as well as the required equipment and mode of recording test
observations.
The Contractor shall obtain the written authorization from the Engineer in charge prior to proceeding with the hydrostatic
pressure test.
 b. Preparation for testing:
At the bottom of penstock, upstream of the turbine inlet valves,at least two pressure gauges, properly calibrated for the
ranges of the test pressures are required. The gauges shall be installed by the Contractor at his cost.
c. Pressure testing:
After completing the test in water conductor pipe then the test in penstock starts. When the penstock and testing equipment
WCS , Penstock (contd..) are ready for the test, the penstock shall be filled slowly continuously checking for leakage or sign of faults. Constant
communication shall be maintained during the testing between the supervising staff at the strategic points. The maximum
testing pressure of maximum static head available at the time of test shall be maintained at least for one hour. The pressure
gauge, preferably at least one recording type, enables these operations to be controlled. During the test, the penstock shall
be full of water. The Contractor shall obtain the advice of the Engineer in charge to operate the turbine inlet valves for
discharging water through the turbines.

Weights:
The payment will be made for the actual weight of the finished product as recorded by the weighment at shop or any other
nearest weigh bridge, after deducting the weight of the spiders if any. However as mentioned elsewhere for the purpose of
making payments, for transport as well as installation of dresser couplings, dresser expansion joints and other finished goods
which are to be transported to the site directly from shop. The weighbridges shall be checked and certified by the inspector
WCS , Penstock (contd..) of
Weights and Measures of the concerned State Governments. All the weighment of the steel plate for fabricated items shall
be in the presence of the Engineer in charge or his authorized representative and proper records, duly attested by the above
authorization shall be maintained by the Contractor. The weights as per the actual weighment mentioned above shall be
reckoned for making payment for different items involving measurement of weight as per the “Schedule of items.”
 c. Insurance:
The Contractor shall insure with any insurance company approved by the Company in a manner satisfied by the Company.
The insurance shall cover the entire steel/fabricated steel for pipes as well as penstock shells, specials and accessories against
WCS , Penstock (contd..) /loss/destruction/damage/fire accidents, flood, exposure to weather or through theft, riot, civil commotion, war, earth quake
or rebellion, during their entire transportation and handling (including handling at the delivery point). The insurance policies
shall be drawn in favor of the Agreement authority and shall be made payable to him. The cost of insurance, premium etc.
shall be paid by the Contractor and such charges deemed to be included in the unit rates agreed to in the Schedule of items

Ultrasonic inspection of steel plates:

a. Scope:
If the test certificates are available for each plate from the manufacturer then Ultrasonic test at shop can be avoided.
Otherwise we have to perform full ultrasonic test at fabrication shop before the start of Fabrication.
b. Test Procedure:
Surfaces of metal shall be clean, free of dirt and loose scale. The scanning may be either manual or mechanical. The scanning
WCS , Penstock (contd..) over the surface of the plates made as follows.
- Complete coverage of the plates edges by covering a path of 7.5cm in width.
- Intermittent coverage of the plate by covering a 2.5 cm square path for every 60 cm square over the surface of plates
c. Test results
i. Laminar Type Defects; .A complete elimination of the basic ultrasonic thickness pattern and substitution of a new pattern
or reading and indicating a defective area of at least 7.5 cm square at the edge of the plate shall be cause for rejection of the
plate or part of the plate, if the latter can be cut without jeopardizing the overall dimensions of the plate during fabrication of
the penstock sections.
ii. Transverse Type Defects: Rejection of plate due to a transverse defect shall be based on comparison of magnitude of the
indication shown on the screen. Tracks or deep surface defects shall be reported to the Engineer in order to determine the
salvage of the plate.
 d. Report
All data required for the complete report and record of the ultrasonic testing technique shall be agreed upon by the Engineer
and the Contractor. The Report shall give the following information:
WCS , Penstock (contd..) i. Surface finish on the surface under test.
ii. Internal structure of the steel.
iii. Location and extent of areas to be tested.
iv. Size of transducer and type of search unit.
v. Test frequency to be used.
vi. Couplant type and grade.
vii. Method of calibration
viii. Size, location and concentration of indications which are to be considered acceptable or questionable.
 RADIOGRAPHIC INSPECTION
1. Scope
Radiographic inspection covered by this procedure applies to all items requiring in accordance with the specifications and the
drawings, and shall include the use of the following radiation sources:
a) X-Ray Machine
b) Iridium 192-Gamma Ray Equipment
3. General requirements
a) Process Approval
Radiographic process is required before any activity will be permitted to perform after inspections by Engineer. Process
approval is required for each source of radiation used. Separate tests are required for each material classification
and thickness range. A full description of the radiographic technique used for each radiograph shall be submitted and
WCS , Penstock (contd..) shall include the following information:
i. Radiation source and capacity
ii. Film type and brand
iii. Type and thickness of intensifying screens
iv. Blocking and masking technique
v. Source to film distance
vi. Thickness and type of material radio graphed
vii. Exposure Conditions
viii. Processing technique
Developing solution - Type, time, temperature
Fixing solution -Type, time, temperature
 b) Technique - Requirements
i. Direction of Radiation: Central Beam Perpendicular to the surface of film.
ii. Sensitivity: Radiography shall be performed with a technique which will distinguish the smallest hole of the applicable
penetrameter.
iii. Image quality: The radiographic image shall be free of blemishes which interfere with its interpretations.
iv. Source-Film Distance: Any distance will be satisfactorily provided that the required radiographic sensitivity and sharpness
is attained and distortion is not excessive.
c) Penetrameter
The quality of radiography shall be determined by a Penetrameter.
i. Fabrication: Penetrameters shall be fabricated of radiographically similar material as the object being inspected shall
conform to the design described in the ASME Code section VIII.
WCS , Penstock (contd..) ii. Identification: The rectangular Penetrameter shall be identified with an internal number made of lead which is
attached to the Penetrameter. The thickness of the Penetrameter shall be 2% of the thickness of the total thickness
penetrated by radiation.
iii. Film Density: When more than one film is exposed, a minimum of one penetrameter shall be required for each film. The
density of the film shall vary plus or minus 15% within the density of 2.
d) Identification of a Radiograph
A minimum of positive identification of the film, shall be provided. The following information shall appear.
1. Date
2. Part number
3. Seam identification number
4. Welder symbol
5. Welder original or subsequent exposure.
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