TENDER DOCUMENTS FOR FREE ISSUE ITEMS FOR. PROPOSED 800 MTPD exp. upto 1600 MTPD CATTLE FEED PLANT ON 20 HRS OPERATION BASIS.

Transcription

1 TENDER DOCUMENTS FOR FREE ISSUE ITEMS FOR PROPOSED 800 MTPD exp. upto 1600 MTPD CATTLE FEED PLANT ON 20 HRS OPERATION BASIS. AT Kapdivav, P.O. Chikhload, Taluka - Kapadwanj, Dist. - Kheda, Gujarat 1. Design, manufacture, supply, erection, testing and commissioning of Raw Material (grains) Bulk Storage GI Silos MT x 8 Nos. 2. Design, manufacture, supply, erection, testing and commissioning of 4 TPH Solid Fuel Fire Boiler Plant. 1 No. 3. Design, manufacture, supply, erection, testing and commissioning of Mild Steel Molasses Storage Tanks for Liquid Molasses MT x 2 Nos. 4. Design, supply, installation and commissioning of 500 CFM Air Compressor and Accessories. 2 Nos. 5. Design, Manufacture, supply, erection, testing and commissioning of SDF Dry Transformer KVA x 2 Nos. 6. Design, manufacture, supply, erection, testing and commissioning of 80 MT capacity Electronic Road Weigh Bridge. 2 Nos. BID REFERENCE NO: AMUL/CFF- 1/KAPDIVAV/2013 KAIRA DISTRICT CO-OPERATIVE MILK PRODUCERS UNION LIMITED AMUL DAIRY, ANAND, GUJARAT

2 CONTENTS SR NO SECTION DESCRIPTION Page No. 01 Section I Invitation for Bids 4 02 Section II Instructions to Bidders 7 03 Section III General Conditions of Contract Section IV Part I Special Conditions of Contract Section IV Part II Special Conditions of Contract for Erection & Commissioning Section IV Part III Special Conditions of Contract for Mechanical Works Section V Technical Specifications Sub Section 1 Introduction Sub Section 2 Instructions to Bidders Sub Section 3 Responsibilities Sub Section 4 Project Management Sub Section 5 Technical Specification Sub Section 6 Deviations from Technical Requirement Sub Section 7 Optional Items Sub Section 8 Drawings Data & Documentation Sub Section 9 Technical Evaluation of Bid Sub Section 10 Performance Guarantee Sub Section 11 Bidders Meeting Section VI Bidding Terms Deviation Section VII Bid Form & Price schedule Performa Section VIII Qualification Application Section IX Collaborators' Authorization Form 282 2

3 SR NO SECTION DESCRIPTION Page No. 23 Appendices a) Form of BG for Performance Security 286 b) Form of BG Against Advance Payment 289 c) Contract Form 291 d) Proforma of Completion Certificate 292 e) Form of BG for Bid Security (EMD) 294 f) List of acceptable Banks for Bank Guarantees From Foreign / 296 Nationalized / Scheduled Banks 24 Appendices a) Site Layout Drawings 299 b) Spares Philosophy 301 c) Documentation Philosophy 304 3

4 SECTION I INVITATION FOR BID 4

5 Kaira District Co-operative Milk Producers Union Limited. Amul Dairy, Anand , Gujarat (India) Phone: , Fax: Invitation For Bid (IFB) Bid Reference AMUL/CFF-1/KAPDIVAV/2013 Name of Project CATTLE FEED FACTORY SN Description Design, manufacture, supply, erection, testing and commissioning of Raw Material (grains) Bulk Storage GI Silos MT x 8 Nos. Design, manufacture, supply, erection, testing and commissioning of 4 TPH Boiler Plant. 1 No. Design, manufacture, supply, erection, testing and commissioning of Mild Steel Molasses Storage Tanks for Liquid Molasses 6000 MT x 2 Nos. Design, supply, installation and commissioning of 500 CFM Air Compressor and Accessories 2 Nos. Design, Manufacture, supply, erection, testing and commissioning of SDF Dry Transformer 1500 KVA x 2 Nos. Design, manufacture, supply, erection, testing and commissioning of 80 MT capacity Electronic Road Weigh Bridge 2 Nos. Estimated Cost (Rs) EMD (Rs.) 100 Lacs 1 Lac 100 Lacs 1 Lac 1.7 Crore 1.7 Lacs 40 Lacs Nil 25 Lacs Nil 30 Lacs Nil Duration (months) Bidding Document Sale. Last Date & Time of Bid. Start Stop Submission Tender Opening 4 Months , Thursday , Monday at Hrs., Monday at Hrs., Wednesday Date of Pre Bid Meeting. Place of Pre-Bid Meeting and Tender Opening at Hrs., Tuesday Office of: General Manager (Projects & Engineering) Amul Dairy Road, Anand Phone: (02692)

6 1. Eligibility Criteria 1.1 The Bidder/Bidder shall have turnover, in each of the last three years, at least equal to the estimated cost of the job and must have executed, in the last ten years at least a contract of similar nature and of value not less than 50% of the estimated cost of the job. Apart from this the sole criteria will be the original key equipments manufacturer and technical competence to execute the job of this kind. Total value will be considered in the project including the imported machinery directly imported by the client for the project. 2. Purchase of Bidding Document 2.1 Interested bidders may download the Tender documents free of cost from the Website 3. Submission of Bid 3.1 The bidder who purchase the bidding document, are eligible for submission of bids in their name only. 4. Bid Security 4.1 All bid must be accompanied by bid security (Earnest Money Deposit EMD) in the form specified in the bidding document. The bids not accompanied with EMD shall be summarily rejected. The bid security shall be denominated in Indian Rupees of value as specified and shall be in the form of Bank Guarantee from Nationalized or Scheduled Banks or Demand draft in favour of Kaira District Co-operative Milk Producers Union Ltd., payable at Anand. The Bid security may be forfeited if A bidder or bidder withdraw its bid during the period of bid validity specified by the bidder/ bidder on the bid form or In case of successful bidder/ bidder, if the bidder/ bidder fails to sign the contract. 5. Rights Reserved by KDCMPU Ltd. 5.1 KDCMPU Ltd, at its sole discretion and without assigning any reason thereof, reserves the right to accept and / or reject the whole or part of any or all the bids received. 6. Validity The offer should be valid for 90 days from the date of tender opening Managing Director 6

7 SECTION II INSTRUCTION TO BIDDERS 7

8 CONTENTS 1. COST OF BIDDING 2. CONTENTS OF BIDDING DOCUMENT 3. CLARIFICATION OF BIDDING DOCUMENT 4. AMENDMENT OF BIDDING DOCUMENT 5. PRE BID MEETING 6. LANGUAGE OF BID 7. DOCUMENTS COMPRISING THE BID 8. BID FORM 9. BID PRICES 10. PRICE ADJUSTMENT 11. BID CURRENCY 12. DOCUMENTS ESTABLISHING BIDDER S EXPERIENCE AND QUALIFICATIONS 13. DOCUMENTS ESTABLISHING GOODS CONFIRMITY TO BIDDING DOCUMENT 14. BID SECURITY (EARNEST MONEY DEPOSIT) 15. PERIOD OF VALIDITY OF BIDS 16. FORMAT AND SIGNING OF BID 17. SEALING AND MARKING OF BIDS 18. DEADLINE FOR SUBMISSION OF BIDS 19. LATE BIDS 20. MODIFICATION AND WITHDRAWAL OF BIDS 21. OPENING OF BIDS BY PURCHASER 22. CLARIFICATION OF BIDS 23. PRELIMINARY EXAMINATION 24. EVALUATION AND COMPARISION OF BIDS 8

9 25. CONTACTING THE PURCHASER 26. POST QUALIFICATION 27. RIGHT TO VARY QUANTITIES AT THE TIME OF AWARD 28. RIGHT TO ACCEPT ANY BID AND TO REJECT ANY OR ALL BIDS. 29. NOTIFICATION OF AWARD 30. SIGNING OF CONTRACT 31. PERFORMANCE SECURITY 32. IMPORT LICENSE 33. TURN KEY CONTRACT 34. BREAK UP PRICES 35. DELIVERY SCHEDULE OF ITEMS 36. TABLE 1 CHECK LIST OF BID SUBMISSION 9

10 1. Cost of Bidding 1.1 The Bidder shall bear all costs associated with the preparation and submission of its bid, and the Kaira District Co-operative Milk Producers Union Ltd. hereinafter referred to as "the Purchaser", will in no case be responsible or liable for those costs, regardless of the conduct or outcome of the bidding process. 2. Contents of Bidding Document 2.1 The goods required, bidding procedures and contract terms are prescribed in the Bidding Document. The contents of the Bidding Document are organized in sections as given in the Table Contents at the beginning of this document. 2.2 The Bidder is expected to examine all instructions, forms, terms and specifications in the Bidding Document. Failure to furnish all information required as per the Bidding Document or submission of a bid not substantially responsive to the Bidding Document in every respect will be at the Bidder's risk and may result in the rejection of its bid. 3. Clarification of Bidding Document 3.1 A prospective Bidder requiring any clarification on the Bidding Document may notify the Purchaser in writing by fax/ telex/ cable at the Purchaser's mailing address indicated in the Invitation for Bids. The Purchaser will respond in writing to any request for clarification on the Bidding Document, which it receives not later than 7 days prior to the deadline for the submission of bids prescribed by the Purchaser. Written copies of the Purchaser's response (including an explanation of the query but without identifying the source of inquiry) will be sent to all prospective Bidders, which have received the Bidding Documents. However, the Bidders cannot consider delay in receipt of clarifications, as a cause for requesting extension in the due date of submission of the bids. 4. Amendment of Bidding Document 4.1 At any time prior to the deadline for submission of bids, the Purchaser may, for any reason, whether at its own initiative or in response to a clarification requested by a prospective Bidder, modify the Bidding Document by amendment. 4.2 The amendment will be notified in writing or by or by fax or cable to all prospective Bidders, which have received the Bidding Documents and will be binding on them. The amendment will be attached to the bidding document sold subsequently. 4.3 In order to afford prospective Bidders reasonable time, in which to take the Amendment into account in preparing their bids, the Purchaser may, at its discretion, extend the deadline for the submission of bids. 10

11 5. Pre Bid Meeting The bidder or his official representative is advised to attend a pre bid meeting which will be convened at the office of General Manager (Projects & Engineering), Amul Dairy, Anand. Venue of the Meeting : Office of General Manager (P&E), Amul Dairy, Anand , Gujarat Date of Pre Bid Meeting : Clarifications shall be submitted to the bidders on the same day. 6. Language of Bid 6.1 The Bid prepared by the Bidder and all correspondence and documents relating to the bid exchanged by the Bidder and the Purchaser shall be written in the English language. Any printed literature furnished by the Bidder may be written in another language so long as accompanied by an English translation of its pertinent passages in which case, for the purposes of interpretation of the bid, the English translation shall govern. 7. Documents comprising the Bid 7.1 The bid prepared by the Bidder shall comprise the following Components: A Bid Form and a Price Schedule completed in accordance with Clauses 7, 8 & Documentary evidence established in accordance with Clause 10 that the Bidder is qualified to perform the contract if its bid is accepted Documentary evidence established in accordance with Clause 11 that the goods and ancillary services to be supplied by the Bidder conform to the Bidding Document Bid security (Earnest Money Deposit) furnished in accordance with Clause 12 along with the bid security details form A statement of deviation and exception to the provision of bidding documents. 8. Bid Form 8.1 The Bidder shall complete the Bid Form and appropriate Price Schedule furnished in the Bidding Document, indicating for the goods to be supplied, a brief description of the goods, their country of origin, quantity and prices. 9. Bid Prices 9.1 The Bidder shall indicate on the appropriate Price Schedule attached to this document the total bid prices of the goods it proposes to supply, install and commission under the contract. To this end, the Bidders are allowed the option 11

12 to submit bids for anyone or more packs specified in the "Schedule of Requirement" and to offer discounts for combined packs. However, Bidders must submit a bid for the complete requirement of goods and services specified under each pack, failing which, such bids will not be taken into account for evaluation& comparison and will not be considered for award. 9.2 Prices indicated on the Price Schedule shall be entered separately in the following manner: The total price is to be given for the total scope considering and without considering EPCG benefit The price of the goods, quoted exfactory, exshowroom, exwarehouse or off theshelf, as applicable, including all customs duties and other duties, sales and other taxes already paid or payable on the components and raw material used in the manufacture or assembly of goods quoted exfactory or on the previously imported goods of foreign origin quoted exshowroom, exwarehouse or offthe shelf Any excise duty (Customs Duty, Countervailing Duty etc. for import) applicable and payable on the goods along with tariff numbers and the details of classification of the goods, if this contract is awarded AS A PERCENTAGE OF EXWORKS PRICE or otherwise indicating clearly in the price schedule format given Any sales and other taxes applicable, which will be payable on the goods if this Contract is awarded AS A PERCENTAGE OF EXWORKS, packed including ED PRICE or otherwise indicating clearly in the price, schedule format given Charges for packing and forwarding, inland transportation, insurance and other local costs incidental to delivery of the goods to their destination; AS A PERCENTAGE OF EX-WORKS PRICE or otherwise indicating clearly in the price schedule format given The cost of installation and commissioning as described in the technical specifications and in accordance with Special conditions of Contract with regard to erection, testing and putting the equipment into satisfactory operations, including successful completion of performance and guarantee tests to be performed at the destination by Bidder and AS A PERCENTAGE OF EXWORKS PRICE or otherwise indicating clearly in the price schedule format given The cost of incidental services listed in Clause 7 of Special Conditions of Contract AS PERCENTAGE OF EXWORKS PRICE or otherwise indicating clearly in the price schedule format given. 9.3 The Bidder's separation of price components in accordance with above will be solely for the purpose of facilitating the comparison of bids by the Purchaser and will not in any way limit the Purchaser's right to contract on any of the terms offered. 12

13 9.4 Price of spare parts All the Bidders are required to submit the following details about the spare parts, along with their bids: Spare parts required for the items quoted by the Bidders, for 2 years normal operation. The price should be part of contract Item wise prices of all the spare parts valid, for acceptance by the Purchaser and placement of orders, for one year from the date of bid opening. 10. Price Adjustment 10.1 Price quoted by the Bidder shall be subject to adjustment during the performance of the contract to reflect changes in the cost of labour and material components in accordance with the procedure specified in the special conditions of the contract. A bid submitted with a fixed price quotation will not be rejected but the price adjustment shall be treated as zero. 11. Bid Currency 11.1 Prices shall be quoted in Indian Rupees only for the goods and services, which the Bidder will supply if a contract is awarded against this invitation for bid. For import, ceiling amount in respective currencies should be mentioned along with exchange rates considered. The price adjustment shall be allowed on account of any changes in the landed cost due to variation in the Exchange rates and / or Customs Duty (combined effect). For arriving at the variation in landed cost, the actual invoice value (from the foreign bidder) with bank certificate for Exchange Rates & bill of entry for Customs Duty paid has to be submitted as supporting documents. However, such changes shall be allowed only within the ceiling amount quoted and within the period of the contract. The variation will be worked out on the difference between Customs Duty rate / exchange rate mentioned in the Bid and the actual respective rates levied during the time of actual imports multiplied by the actual CIF value and not the ceiling value. The purchaser may opt for importing the key machinery direct in case it is deemed fit. But this will be as per the quoted price in the bid All claims shall be against the supporting documents. 12. Documents Establishing Bidder's Experience and Qualifications 12.1 Pursuant to Clause 7 the Bidder shall furnish, as part of its bid, documents establishing the Bidder's qualifications to perform the Contract if its bid is accepted. The Bidder should also give information in the format attached to the Bidding Document The documentary evidence of the Bidder's qualifications to perform Contract if its bid is accepted, shall establish to the Purchaser's satisfaction That in the case of a Bidder offering to supply goods and services under the Contract which the Bidder did not manufacture or otherwise produce, 13

14 The Bidder has been duly authorised by the goods' manufacturer or producer to supply the goods. The bid shall include manufacturer s authorisation Form given in the bidding documents That the Bidder has the financial, technical and production capability necessary to perform the Contract. To ascertain this, all bids submitted shall include the information as per the pro forma along with qualification application (Table 1, 2 & 3) in Appendices II Copies of original documents defining the constitution or legal status, place of registration and principal place of business of the company or firm partnership, etc; Details of experience and past performance of the Bidder on equipment offered and those of similar nature and those of similar nature within the past 5 years and details of current contracts in hand and other commitments Major items of plant and equipment available/ installed in the Bidder's factory premises Qualification and experience of key personnel for successful execution of the contract Reports on financial standing of the Bidder such as profit and loss statements, balance sheets and, auditor's report of the past three years, bankers certificates etc Information regarding any current litigation in which the Bidder is involved 12.2 Bidders who meet the criteria given above are subject to be disqualified if they have made untrue or false representations in the forms, statements and attachments submitted in proof of the qualification requirements or have record of poor performance such as abandoning the work, not properly completing the contract, inordinate delays in completion or financial failures etc 13. Documents Establishing Goods' Conformity to Bidding Document 13.1 Pursuant to Clause 6 the Bidder shall furnish, as part of its bid, documents establishing the conformity to the Bidding Document of all goods and services, which the Bidder proposes to supply under the Contract The documentary evidence of the goods' and services' conformity to the Bidding Document may be in the form of literature, drawings and data, and shall furnish: A detailed description of the goods' essential technical and performance characteristics A list giving full particulars, including available sources and current prices, of all spare parts, special tools, etc. necessary for the proper and 14

15 continuing functioning of the goods for a period of two years, following commencement of the goods' use by the Purchaser; and A clause by clause commentary on the Purchaser's Technical Specifications demonstrating the goods and services' substantial responsiveness to those specifications or a statement of deviations and exceptions to the provisions of the Technical Specifications The purposes of the commentary to be furnished pursuant to above, the Bidder shall note that standards for workmanship, material and equipment, and references to brand names or catalogue numbers designated by the Purchaser in its Technical Specifications are intended to be descriptive only and not restrictive. The Bidder may substitute alternative standards, brand names and/or catalogue numbers in its bid, provided that it demonstrates to the Purchaser's satisfaction that the substitutions are substantially equivalent or superior to those designated in the Technical Specifications. 14 Bid Security (Earnest Money Deposit) 14.1 Pursuant to Clause 6 the Bidder shall furnish, as part of its bid, bid security (Earnest Money Deposit) as specified in the NIT (Notice Inviting Tender) The bid security is required to protect the Purchaser against the risk of Bidder's conduct, which would warrant the security forfeiture The bid security shall be denominated in Indian Rupees of value as specified and shall be in the form of BG or a Demand draft in favour of Kaira District Co-operative Milk Producers Union Ltd., payable at Anand Any bid not accompanied with bid security in accordance with clause 14.1 and 14.3 above will be rejected by the purchaser as nonresponsive Unsuccessful Bidders' bid security will be discharged/ returned as promptly as possible but not later than 30 days after the expiration of the period of bid validity prescribed by the Purchaser. The successful Bidder's bid security will be discharged upon the Bidder's executing the Contract agreement on acceptance of the order & furnishing the performance security, pursuant to Clause The bid security may be forfeited: If a Bidder withdraws its bid during the period of bid validity specified by the Bidder on the Bid Form; or In the case of the successful Bidder, if the Bidder fails: To sign the Contract in accordance with Clause To furnish performance security in accordance with Clause 29 15

16 15 Period of Validity of Bids 15.1 Bids shall remain valid for 90 days after the last date of submission of the bids prescribed by the Purchaser, pursuant to Clause 16. A bid valid for a shorter period may be rejected by the purchaser as non-responsive In exceptional circumstance, the Purchaser may prior to expiry of the initial validity period, solicit the Bidders' consent to an extension of the period of validity. The request and the responses thereto shall be made in writing (or by cable or telex/fax). The bid security provided under Clause 12 shall also be suitably extended. A Bidder may refuse the request without forfeiting its bid security. A Bidder granting the request will not be required nor permitted to modify its bid. 16. Format and Signing of Bid 16.1 The Bidder shall prepare two copies of the bid, clearly marking each "Original" and "Copy" as appropriate. In the event of any discrepancy between them, the original shall govern The original and all copies of the bid shall be typed or written in indelible ink and shall be signed by the Bidder or a person or persons duly authorized to bind the Bidder to the Contract. Written power-of-attorney must accompany the Bid to indicate the authorization. The person or persons signing the bid shall initial all pages of the bid, except for laminated printed literature The bid shall contain no interlineations, erasures or overwriting except as necessary to correct errors made by the Bidder, in which case, the person or persons signing the bid shall initial corrections. 17. Sealing and Marking of Bids 17.1 The Bidders shall seal the original and each copy of the bid in an outer envelope, duly marking the envelopes as "original" and "copy." 17.2 All the inner and outer envelopes shall be addressed to the Purchaser and must bear the Invitation for Bids (IFB) reference number All the envelopes should bear the word "DO NOT OPEN BEFORE (The time and date of opening as specified) The inner envelopes shall indicate the name and address of the Bidder to enable the bid to be returned unopened in case it is declared "late." 17.5 If the outer envelope is not sealed and marked as required, the Purchaser will assume no responsibility for the bid's misplacement or premature opening. A bid opened prematurely for this cause will be rejected by the Purchaser and returned to the Bidder. 16

17 18. Deadline for Submission of Bids 18.1 The Purchaser at the address specified must receive bids not later than the time specified for receipt of the bids The Purchaser may, at its discretion, extend this deadline for the submission of bids by amending the Bidding Document in accordance with Clause 4 above in which case all rights and obligations of the Purchaser and Bidders previously subject to the deadline will thereafter be subject to the deadline as extended No telegraphic/ telephonic/ fax bids shall be considered. However, any amendment sent by a telegram or a telex or fax to the bid already submitted/received shall be considered provided it is received before the due date and time of opening of the bids and it is confirmed in writing by post. 19. Late Bids 19.1 Any bid received by the Purchaser after the deadline for submission of bids prescribed by the Purchaser, pursuant of Clause 16 will be rejected and returned unopened to the Bidder. 20. Modification and Withdrawal of Bids 20.1 The Bidder may modify or withdraw its bid after the bid's submission, provided that written notice of the modification or withdrawal is received by the Purchaser prior to the deadline prescribed for submission of bids The Bidder's modification or withdrawal notice shall be prepared, sealed, marked and dispatched in accordance with the provisions of Clause15. A withdrawal notice may also be sent by fax or cable but followed by a signed confirmation copy, post marked not later than the deadline for submission of bids No bid may be modified subsequent to the deadline for submission of bids No bid may be withdrawn in the interval between the deadline for submission of bids and the expiration of the period of bid validity specified by the Bidder on the Bid Form. Withdrawal of a bid during this interval may result in the forfeiture of the Bidder's bid security, pursuant to Clause Opening of Bids by Purchaser 21.1 The Purchaser will open the bids, in the presence of the Bidders' representatives who choose to attend, at the time and date specified in the Invitation for bids, at the office of the Amul Dairy, Anand, Gujarat 17

18 India. The Bidders representatives who are present shall sign a register/ form evidencing their attendance The Bidders' names, bid prices, modifications, bid withdrawals and the presence or absence of the requisite bid security and such other details as the purchaser, at its discretion, may consider appropriate will be announce during the opening of the bids. 22 Clarification of Bids 22.1 To assist in the examination, evaluation and comparison of bids the Purchaser may, at its discretion, ask the Bidders for a clarification of its bid. The request for clarification and the response shall be in writing and no change in the price or substance of the bid shall be sought, offered or permitted. 23 Preliminary Examination 23.1 The Purchaser will examine the bids to determine: Whether they are complete, Whether any computational errors have been made, Whether required sureties have been furnished, Whether the documents have been properly signed, Whether the bids are generally in order Arithmetical errors will be rectified on the following basis: If there is a discrepancy between the unit price and the total price that is obtained by multiplying the unit price and quantity, the unit price shall prevail and the total price shall be corrected. If the Bidder does not accept the correction of the errors, its bid will be rejected. If there is a discrepancy between words and figures, the amount in words will prevail Prior to the detailed evaluation, pursuant to Clause22, the Purchaser will determine the substantial responsiveness of each bid to the Bidding Document. For purposes of these clauses, a substantially responsive bid is one, which conforms to all the terms and conditions of the Bidding Document without material deviations. The Purchaser's determination of a bid's responsiveness isto be based on the contents of the bid itself without recourse to extrinsic evidence If the prices of certain components/sub assemblies/spare parts are not included, the Purchaser will load the offer with the cost of these in evaluation if goods/equipment/plant is functional. If the Purchaser considers that without these the goods/equipment is not functional, then the bid will be treated as incomplete and non responsive To facilitate loading incomplete bids, the highest cost of such components offered by other Bidders or the estimated cost of such components in the 18

19 opinion of the Purchaser or other Purchases similarly made based on past experience shall be considered for loading incomplete bids Since the bid is invited for the complete job of design, supply, installation and commissioning of the equipment/plant, the incomplete or part bids submitted by any Bidder may not be considered for evaluation and may be liable for rejection A bid determined as not substantially responsive will be rejected by the Purchaser and may not subsequently be made responsive by the Bidder by correction of the nonconformity The Purchaser may waive any minor informality or nonconformity or irregularity in a bid, which does not constitute a material deviation, provided such waiver, does not prejudice or affect the relative ranking of the Bidder. 24 Evaluation and Comparison of Bids 24.1 The Purchaser will evaluate and compare the bids previously determined to be substantially responsive, pursuant to Clause 21. No bid will be considered if the complete requirement covered under this work is not included in the bid. However, the discounts offered by the Bidders, if any, will be taken into account in the evaluation of bids so as to determine the bid offering the lowest evaluated cost for the Purchaser in deciding award of contract/s The Purchaser's evaluation of a bid will include and take into account, in the caseof goods manufactured in India or goods of foreign origin already located inindia, sales and other similar taxes, which will be payable on the goods if acontract is awarded to the Bidder. Also, applicable excise duty payable by thepurchaser will be added to the bid price for evaluation The comparison shall be of free delivery at site basis including unloading and inclusive of all taxes (sales, works contract etc.) and duties (customs, counter vailing, excise etc.) of the goods offered from within India, such price to include all costs as well as duties and taxes paid or payable on components &raw material incorporated in the goods as well as taxes & duties payable on finished goods and the installation and commissioning costs as per the provisions in the technical specification The Purchaser's evaluation of a bid will take into account, in addition to the bid price and the price of incidental services, the following factors, in the manner and to the extent indicated in this Clause 22 and in the Technical Specifications: Cost of inland transportation, insurance and other costs within India incidental to delivery of the goods to their final destination and applicable excise duty payable by the Purchaser; Delivery schedule offered in the bid The cost of components and service; 19

20 The availability of spare parts and after sales services for the equipment offered in the bid Deviation in payment schedule from that specified in the Special Conditions of Contract The quality and adaptability of the equipment offered The performance and productivity of the equipment offered 24.5 Pursuant to above of Clause 22, the following evaluation methods will be followed: Inland Transportation, ex-factory/ Insurance and Incidentals: For the goods offered, the Bidders must quote separately for inland transportation, insurance and other incidentals for delivery of goods to the project site as stated in Clause Delivery Schedule: The Purchaser desires to have delivery of the goods covered under the invitation, at the time specified in the Schedule of Requirements. The estimated time of arrival of the goods at the project site/ destination should be calculated for each bid after allowing for reasonable transportation time Bidders shall state their bid price for the payment schedule outlined in the Special Conditions of Contract. Bids will be evaluated on the basis of this base price The goods/ plant offered shall have the guaranteed performance with regard to the rated capacity and operating parameters specified in the technical specifications related to Process performance and consumption guarantees If it is found that any Bidder for any reason indicates impractical or impossible data to arrive performance guarantees, such data shall be corrected and all the calculations shall be based on the data furnished by the highest Bidder for the purpose of comparison. 25 Contacting the Purchaser 25.1 Subject to Clause 21, no Bidder shall contact the Purchaser on any matter relating to its bid, from the time of the bid opening to the time the Contract is awarded Any effort by a Bidder to influence the Purchaser in the Purchaser's bid evaluation, bid comparison or contract award decisions may result in the rejection of the Bidder's bid. 26 Post Qualification 26.1 In the absence of prequalification, the Purchaser will determine to its satisfaction whether the Bidder selected as having submitted the lowest evaluated responsive bid is qualified to satisfactorily perform the Contract. 20

21 26.2 The determination will take into account the Bidder's financial, technical and production capabilities. It will be based upon an examination of thedocumentary evidence of the Bidder's qualifications submitted by the Bidder,pursuant to Clause 10 as well as such other information as the Purchaser deemsnecessary and appropriate including details of experience and records of pastperformance An affirmative determination will be a prerequisite for award of the Contract to the Bidder. A negative determination will result in rejection of the Bidder's bid, in which event; the Purchaser will proceed to the next lowest evaluated bid to make a similar determination of that Bidder's capabilities to performsatisfactorily Subject to Clause 26, the Purchaser will award the contract to the successful Bidder whose bid has been determined to be substantially responsive and has been determined as the lowest evaluated bid provided further that the Bidder is determined to be qualified to perform the contract satisfactorily as per Clause 22 and Right to Vary Quantities at the Time of Award 27.1 The Purchaser reserves the right at the time of award of Contract to increase or decrease by up to 15% (Fifteen percent) the quantity of goods and services specified in the Schedule of Requirements without any change in unit rates as specified in the price break.up or other terms and conditions. 28 Right to Accept any Bid and to Reject Any or All Bids 28.1 The Purchaser reserves the right to accept or reject any bid, and to annul the bidding process and reject all bids at any time prior to award of Contract, without thereby incurring any liability to the affected Bidder or Bidders or any obligation to inform the affected Bidder or Bidders of the grounds for the Purchaser's action. 29 Notification of Award 29.1 Prior to expiration of the period of bid validity, the Purchaser may notify the successful Bidder in writing by registered letter or by cable or fax to be confirmed in writing by registered letter, that its bid has been accepted The notification of award will constitute the formation of the Contract Upon the successful Bidder's acceptance of the Purchase Order and signing of the contract agreement, the Purchaser will promptly notify each unsuccessful Bidder and will discharge its bid security. 21

22 30 Signing of Contract 30.1 At the same time as the Purchaser notifies the successful Bidder that its bid has been accepted, the Purchaser will send the Bidder the Contract Form /Purchase Order in corporating all agreements between the parties Within 30 days of receipt of the Contract, the successful Bidder shall return the duplicate copy of the Order duly signed and sealed in token of acceptance of the order to the Purchaser. 31 Performance Security 31.1 Within 30 of the receipt of the notification of award, the successful Bidder shall furnish the performance security in accordance with the Conditions of Contract, in the Performance Security Form provided in the Bidding Document or another form acceptable to the Purchaser Failure of the successful Bidder to comply with requirement of Clause 28 or Clause 29 shall constitute sufficient grounds for the annulment of the award and forfeiture of the bid security, in which event the Purchaser may make the award to the next lowest evaluated Bidder or call for new bids. 32 Import License 32.1 For the goods of foreign origin, if any, offered on CIF Mumbai Port basis, the import license shall have to be arranged by the Purchaser and the details of such license shall be notified to the successful bidder. In case of goods offered from within India and for which a contact is awarded, if any import is required the license shall be arranged by bidders themselves. 33 Turnkey Contract 33.1 All the Bidders should quote for the design, supply, installation, testing and commissioning of equipment as detailed in this bidding document on turnkey basis within the scope specified in the technical specification. The Purchaser shall, however, be at liberty to award the contract for the part or whole of the work. 34 Breakup prices 34.1 All the Bidders shall furnish the cost separately for the supply and installation/commissioning along with detailed cost breakup (itemwise), which will be applicable for progressive payments. Items and works for which no breakup price is furnished by the Bidder will not be paid for by the Purchaser when supplied/executed and shall be deemed covered by other breakup prices. Such break up cost should be based on exworks cost and percentage of exworks cost should be indicated separately for packing and forwarding, sea/air freight & Inland 22

23 transportation, insurance, taxes & custom duties and other incidental charges, erection, and commissioning on percentage basis for each item. 35 Delivery Schedule of items 35.1 Bidders should submit a detailed item wise delivery schedule keeping in view the completion period of the contract. Such items shall be grouped under monthly Delivery schedule with total value of such items. This will facilitate for ensuring the cash flow requirement for the project Material should be supplied strictly as per the time schedule mentioned in Purchase Order. Amul has right to deduct the lump sum amount from the final bills if delay in material supply found. 23

24 TABLE 1 CHECK LIST OF BID SUBMISSION SR NO REQUIREMENT TICK (E) 1 Bid Form on your Letterhead 2 Qualification Application and Supporting 3 Price Schedule summary sheet and item wise break-up sheet 4 Manufacturer s Authorisation Form 5 Technical Deviation Statement Form 6 Commercial Deviation Statement Form 7 Bid Security (Earnest Money Deposit) 8 Power-of-attorney for authorised Signatory 24

25 SECTION - III GENERAL CONDITIONS OF THE CONTRACT 25

26 Contents 1. Definitions 2. Application 3. Definition of Country of origin 4. Standards 5. Use of Contract Documents and Information 6. Patent Rights 7. Performance Security 8. Inspection and Tests 9. Packing and Marking 10. Delivery and Documents 11. Insurance 12. Transportation 13. Incidental Services 14. Spare Parts 15. Warranty/Guarantee 16. Payment 17. Prices 18. Change Orders 19. Contract Amendment 20. Assignment 21. Subcontracts 22. Delays in the Bidder's Performance 23. Price Reduction Clause 24. Termination for Default 25. Force Majeure 26. Termination for Insolvency 27. Termination for Convenience 28. Resolution of Disputes 29. Governing Language 30. Applicable Law 31. Notices 32. Taxes and Duties 33. Right to use defective equipment 34. Income Tax and Other Taxes 35. Jurisdiction 26

27 1. Definitions 1.1 In this Contract, the following terms shall be interpreted as indicated: 1.2 "The Contract" means the agreement entered into between the Purchaser and the Bidder, including all attachments and appendices thereto and all documents incorporated by reference therein. 1.3 "The Contract Price" means the price payable to the Bidder under the Contract for the full and proper performance of its contractual obligations. 1.4 "The Goods" means all of the equipment, machinery, and/or other materials, which the Bidder is required to supply to the Purchaser under the Contract. 1.5 "Services" means services ancillary to the supply of the Goods, such as transportation and insurance, and any other incidental services, such as installation, commissioning, provision of technical assistance, training and other such obligations of the Bidder covered under the Contract. 1.6 "The Purchaser" means the Organization purchasing the Goods and services and would include the term "Owner". 1.7 "The Bidder" means the individual or firm supplying the Goods and services under this Contract would include also the terms contractor or Bidder. 1.8 Engineer-in-charge means the Engineer designated as such or other Engineer appointed from time to time by the Purchaser and notified in writing to the Bidder to act as Engineer-in-charge for the purposes of contract. 2. Application 2.1 These General Conditions shall apply to the extent that provisions in other parts of the Contract do not supersede them. 3. Definition of Country of origin 3.1 For purpose of this Clause "origin" means the place where the Goods were mined, grown or produced, or from which the Services are supplied. Goods are produced when, through manufacturing, processing or substantial and major assembling of components, a commercially recognized new product results that is substantially different in basic characteristics or in purpose or utility from its components. The origin of Goods and Services is distinct from the nationality of the Bidder. 4 Standards 4.1 The Goods supplied under this Contract shall conform to the standards mentioned in the Technical Specifications, and, when no applicable standard is mentioned, to the latest Indian Standards. 27

28 5 Use of Contract Documents and Information 5.1 The Bidder shall not, without the Purchaser's prior written consent, disclose the Contract, or any provision thereof, or any specification, plan, drawing, pattern, sample or information furnished by or on behalf of the Purchaser in connection therewith, to any person other than a person employed by the Bidder in the performance of the Contract. Disclosure to any such employed person shall be made in confidence and shall extend only so far as may be necessary for purposes of such performance. 5.2 The Bidder shall not, without the Purchaser's prior written consent, make use of any document or information except for purposes of performing the Contract. 5.3 Any document, other than the Contract itself, shall remain the property of the Purchaser and shall be returned (in all copies) to the Purchaser on completion of the Bidder's performance under the Contract if so required by the Purchaser. 6 Patent Rights 6.1 The Bidder shall indemnify the Purchaser against all thirdparty claims of infringement of patent, trademark or industrial design rights arising from use of the Goods or any part thereof. 7 Performance Security 7.1 The Bidder shall furnish performance security to the Purchaser in the amount specified in the Special Conditions of Contract. 7.2 The proceeds of the performance security shall be payable to the Purchaser as compensation for any loss resulting from the Bidder's failure to complete its obligations under the Contract. 7.3 The Performance Security shall be denominated in Indian Rupees and shall be in one of the following forms: A bank guarantee issued by a Nationalized Bank in India and in the form provided in the Bidding Document. Such bank guarantee shall be valid till the expiry of the warranty period Demand Draft from a Nationalised Bank in favour of Kaira District Co Operative Milk Producers Union Ltd. payable at Anand. No interest shall be paid on the security deposit, which shall be retained till the completion of the warranty period. 7.4 The performance security will be discharged by the Purchaser and returned to the Bidder not later than 30 days following the date of completion of the Bidder's performance obligations, including any warranty obligations, under the Contract. 28

29 8. Inspection and Tests 8.1 The Purchaser or its representative shall have the right to inspect and/or test the Goods to confirm their conformity to the Contract. The Special Conditions of Contract and/or the Technical Specifications shall specify what inspections and tests the Purchaser requires and where they are to be conducted. The Purchaser shall notify the Bidder in writing of the identity of any representatives, if retained for these purposes. Bidders must carry out test as per guideline of purchaser at their own cost. 8.2 The inspections and tests may be conducted on the date of delivery and/or at the Good's final destination. Where conducted on the premises of the Bidder or its subcontractors(s), all reasonable facilities and assistance including access to drawings and production data shall be furnished to the inspectors at no charge to the Purchaser. In case of any defects or deficiency notified by the Purchaser's inspection authority, the Bidder will rectify and make good the same without delay and not proceed with further processing of such item(s) of Goods without obtaining approval from the inspection authority. 8.3 Should any inspected or tested Goods fail to conform to the Specifications, the Purchaser may reject them and the Bidder shall either replace the rejected Goods or make all alterations necessary to meet specification requirements free of cost to the Purchaser upto the satisfaction of Purchaser. 8.4 The Purchaser's right to inspect, test and, where necessary, reject the Goods after the Goods' arrival at the destination shall in no way be limited or waived by reason of the Goods having previously been inspected, tested and passed by the Purchaser or its representative prior to the Goods shipment from the country of origin. 8.5 Nothing in this clause shall in any way release the Bidder from any warranty or other obligations under this Contract. 9. Packing and Marking 9.1 The Bidder shall provide such packing of the Goods as is required to prevent their damage or deterioration during transit to their final destination as indicated in the Contract. The packing shall be sufficient to withstand, without limitation, rough handling during transit and exposure to temperature, salt and precipitation during transit and open storage. Packing case size and weights shall take into consideration, where appropriate, the remoteness of the Goods' final destination and the absence of heavy handling facilities at all points in transit. 9.2 The packing, marking and documents within and outside the packages shall comply strictly with such special requirements as shall be expressly provided for in the Contract and, subject to Clause 18, in any subsequent instructions ordered by the Purchaser. 29

30 9.3 Each package shall be marked to indicate a) Name of the Bidder, b) Details of items in the package, c) Name of the Consignee, d) Purchase Order Number, e) Gross, net and tare weights of the item, f) Destination. 10. Delivery and Documents 10.1 Delivery of the goods shall be made by the Bidder in accordance with the terms specified by the Purchaser in its Schedule of Requirements and the Special Conditions of Contract. For the purpose of the Contract, "FOB", "C&F", "CIF", "FOR Destination", "Free delivery at site" and other trade terms used to describe the obligations of the parties shall have the meanings as per the common trade practices DRAWINGS AND QAP: Drawings & QAP to be submitted within 15 days from date of LOI / P.O in prescribed format of Purchaser. Necessary type test reports shall also be submitted along with the drawings in line with requirement. All drawings and documents shall be submitted in the name of KDCMPUL(AMUL)& PO reference shall appear in all drawings/documents/qap/test report. Any delay in the submission of drawings & QAP will reduce the agreed delivery period by equal time. Bidder has to give Weight & Volume details of the packed equipment for his scope of supply along with drawings to enable purchaser to arrange for suitable storage at site. All drawings/ documents shall be submitted in 3 sets (hard copy) for further submission to client. All the drawings and documents shall also be submitted in editable soft format RISK PURCHASE: In the event of any failure in supplying the equipment by stipulated delivery date or in the event of non-performance of ordered equipment after commissioning due to design and/or manufacturing defects, purchaser reserves the right and option to cancel the order in part or full and purchase such cancelled equipment from elsewhere on account of and at the risk of bidder without prejudice to other terms, conditions of this purchase order. 11. Insurance 11.1 The goods supplied under the Contract shall be fully insured in Indian Rupees against loss or damage incidental to manufacture or acquisition, transportation, storage and delivery in the manner specified in the Special Conditions of Contract. Where the Purchaser requires delivery of the Goods on free delivery at site basis; the Bidder shall arrange and pay for marine insurance naming the Purchaser as the beneficiary. The Bidder shall provide a copy of the insurance policy along with invoice to the Purchaser who will make arrangements to extend the validity of the policy, if necessary. The Bidder shall initiate and pursue claim till settlement and promptly make arrangements for repair and/or replacement of any damaged item/s irrespective of settlement of claim by the underwriters. 30

31 12. Transportation 12.1 The Bidder is required under the Contract to deliver the Goods FOR destination, specified in the Schedule of Requirement. Transport of the Goods, up to the destination shall be arranged and paid for by the Bidder and the cost thereof shall be included in the Contract Price. Where the Bidder is required to effect delivery under any other terms, for example, by post or to another address in the source country, the Bidder shall be required to meet all transport and storage expenses until delivery. In all the above cases, transportation of the Goods after delivery shall be the responsibility of the Purchaser. 13. Incidental Services 13.1 As specified in the Special Conditions of Contract, the Bidder shall be required to provide any or all of the following services: Performance or supervision of onsite assembly and/ or startup of the supplied Goods; Furnishing of a detailed operations and maintenance manual for each appropriate unit of the supplied Goods; and manuals covering the operation and maintenance of automation software and control systems Furnishing of tools required for assembly and/or maintenance of the supplied goods Performance or supervision or maintenance and/or repair of the supplied Goods, for a period of time agreed by the parties, provided that this service shall not relieve the Bidder of any warranty obligations under this Contract an Conduct of training of the Purchaser's personnel, at the Bidder's plant and/or onsite, in assembly, startup operation, maintenance and/or repair of the supplied Goods. 14. Spare Parts 14.1 As specified in the Special Conditions of contract, the Bidder may be required to provide any or all of the following materials and notifications pertaining to spare parts manufactured or distributed by the Bidder: Such spare parts as the Purchaser may decide to purchase from the Bidder, provided that this decision shall not relieve the Bidder of any warranty obligations under the Contract; and In the event of termination of production of the spare parts: Advance notification to the Purchaser of the pending termination, in sufficient time to permit the Purchaser to procure its needed requirements; and Following such termination, furnishing at no cost to the Purchaser, the softcopies, the blueprints, drawings and specifications of the spare parts, if and when requested. 31

32 The spares & consumables required till successful commissioning shall be in the scope of bidder Bidder confirms the availability of spare parts required for O&M of the equipment for a period of 10 years from the date of LOI/PO Necessary commissioning spares to be considered in bidder s scope which may be required during erection & commissioning of the equipment, without any extra cost implication to purchaser. The same shall be supplied to site within 2 days notice from purchaser Bidder has to submit spares price list, indicating complete technical specification, Part No. / Ordering no. of OEM. 15. Warranty/Guarantee 15.1 The Bidder warrants that the Goods and equipment supplied, installed and commissioned under the Contract are new, unused, of the most recent or current models and incorporate all recent improvements in design and materials unless provided otherwise in the Contract. The Bidder further warrants that the Goods supplied under this Contract shall have no defect arising from design, materials or workmanship (except in so far as the design or material is required by the Purchaser's Specifications) or from any act or omission of the Bidder, that may develop under normal use of the supplied Goods in the conditions obtaining in the country of final destination. The Bidder also guarantees that the Goods supplied shall perform satisfactorily as per the designed/rated/installed capacity as provided for in the Contract. The warranty will not cover normal wear and tear of consumables and minor spares This warranty/guarantee shall remain valid for not less than 12 months after the goods or any portion thereof as the case may be, have been commissioned, or for not less than 18 months after the date of shipment / dispatch, whichever period concludes later. Bidder to submit the price for additional warranty of 18 months after expiry of above warranty period at the time of order finalization. Any rectification/replacement of any defective material supplied or works done during warranty period shall be made good without any time and cost implication to purchaser. Any repaired / modified or replaced part shall be subject to defect free guarantee for a further period of 12 months from the date of rectification /replacement The Purchaser shall promptly notify the Bidder in writing of any claims arising under this warranty Upon receipt of such notice, the Bidder shall, with all reasonable speed, repair or replace the defective Goods or parts thereof, without costs to the Purchaser other than, where applicable, the cost of inland delivery of the 32

33 repaired or replaced Goods or parts from the port of entry to the final destination If the Bidder, having been notified, fails to remedy the defect(s) within a reasonable period, the Purchaser may proceed to take such remedial action as may be necessary, at the Bidder's risk and expense and without prejudice to any other rights which the Purchaser may have against the Bidder under the Contract This warranty/guarantee shall not cover any damage/s resulting from normal wear and tear or improper handling by the Purchaser or his authorized representatives The Bidder shall guarantee the complete installation for satisfactory performance for a minimum period of twelve months from the date of commissioning. The Bidder at his own cost shall rectify any defect arising out of faulty installation or use of substandard material or workmanship. 16. Payment 16.1 The method and conditions of payment to be made to the Bidder under the Contract shall be specified in the Special Conditions of Contract The Bidder's request(s) for payment shall be made to the Purchaser in writing, accompanied by an invoice describing, as appropriate, the Goods delivered and Services performed, and by shipping documents, submitted pursuant to Clause 10, and fulfilments of other obligations stipulated in the Contract Payments shall be made promptly by the Purchaser within forty five (45) days of submission of an invoice/claim by the Bidder and shall be in Indian Rupees only. 17. Prices 17.1 Prices charged by the Bidder for Goods delivered and Services performed under the Contract shall not, with the exception of price adjustments authorized by the special conditions of the contract, vary from the prices quoted by the Bidder in its bid and the Contract shall be on fixed price basis. Variation due to changes in statutory levies and exchange rates (for imported items if quoted with foreign currencies multiplied by the exchange rates limited to the foreign currencies ceiling quoted) shall be acceptable within the contact period. 18. Change Orders 18.1 The Purchaser may, at any time, by a written order given to the Bidder make changes within the general scope of the Contract in any one or more of the following: Drawings, designs or specifications, where Goods to be furnished under the Contract are to be specifically manufactured for the Purchaser 33

34 The method of shipment or packing The place of delivery or The Services to be provided by the Bidder If any such change causes an increase or decrease in the cost of, or the time required for, the Bidder's performance of any part of the work under the Contract, whether changed or not changed by the order, an equitable adjustment shall be made in the Contract Price or delivery schedule, or both, and the Contract shall accordingly be amended. Any claims by the Bidder for adjustment under this clause must be asserted within thirty (30) days from the date of the Bidder's receipt of the Purchaser's change order. 19. Contract Amendment 19.1 No variation in or modification of the terms of the Contract shall be made except by written amendment signed by the parties. 20. Assignment 20.1 The Bidder shall not assign, in whole or in part, its obligations to perform under the Contract, except with the Purchaser's prior written consent. 21. Subcontracts 21.1 The Bidder shall notify the Purchaser in writing of all subcontracts awarded under the Contract if not already specified in his bid. Such notification, in his original bid or later, shall not relieve the Bidder from any liability or obligation under the Contract Subcontracts must comply with the provisions of Clause Delays in the Bidder's Performance 22.1 Delivery of the Goods and performance of Services shall be made by the Bidder in accordance with the time schedule specified by the Purchaser in its Schedule of Requirements An unexcused delay by the Bidder in the performance of its delivery obligations shall render the Bidder liable to any or all of the following sanctions: Forfeiture of its performance security, Imposition of liquidated damages, and/or Termination of the Contract for default 22.3 If at any time during performance of the Contract, the Bidder or its subcontractor(s) should encounter conditions impeding timely delivery of the Goods and performance of Services, the Bidder shall promptly notify the Purchaser in writing of the fact of the delay, its likely duration and its cause(s). As soon as practicable after receipt of the Bidder's notice, the 34

35 Purchaser shall evaluate the situation and may at its discretion extend the Bidder's time for performance, in which case the extension shall be ratified by the parties by amendment of the Contract. 23. PRICE REDUCTION CLAUSES 23.1 Subject to Clause 25, if the Bidder fails to deliver any or all of the Goods or perform the Services within the time period(s) specified in the Contract, the Purchaser shall, without prejudice to its other remedies under the Contract, deduct from the Contract Price, as liquidated damages as under: For the Supply Component: A sum equivalent to 0.5% of the contract value for each week of delay or part thereof For the Erection and Commissioning Component: A sum equivalent to 0.5% of the contract value for each week of delay or part thereof beyond the time specified in the contract for the successful completion of the plant. The total amount so deducted as per above, shall not exceed 10 % of the Contract value. Once the maximum is reached, the Purchaser may consider termination of the Contract For the Supply Component : Any delay beyond the agreed date of delivery, PRICE will be reduced at the rate of 1% per week of total contract value, subject to maximum of 5% of the order value, without prejudice to any other terms/ conditions of this purchase order Any incremental taxes and levies on account of delay in performance of the Contract by the Bidder shall be to the Bidder's account. 24. Termination for Default 24.1 The Purchaser may, without prejudice to any other remedy for breach of contract, by written notice of default sent to the Bidder, terminate the Contract in whole or in part: If the Bidder fails to perform any other obligation(s) under the Contract or If the Bidder fails to deliver any or all of the Goods within the time period(s) specified in the Contract, or any extension thereof granted by the Purchaser pursuant to Clause In the event the Purchaser terminates the Contract in whole or in part, pursuant to Clause 24, the Purchaser may procure, upon such terms and in such manner, as it deems appropriate, Goods similar to those undelivered, and the Bidder shall be liable to the Purchaser for any excess costs for such similar Goods. However, the Bidder shall continue performance of the Contract to the extent not terminated Consequent to such termination of Contract, the Purchaser shall recover the advance paid, if any, to the Bidder along with 18% per 35

36 annum compounded quarterly on the last day of March, June, September and December on the advance paid for the entire period for which the advance was retained by the Bidder. 25. Force Majeure 25.1 Not withstanding the provisions of Clauses 22, 23 and 24, the Bidder shall not be liable for forfeiture of its performance security, liquidated damages or termination for default, if and to the extent that, its delay in performance or other failure to perform its obligations under the Contract is the result of an event of Force Majeure For purposes of this clause, "Force Majeure" means an event beyond the control of the Bidder and not involving the Bidder's fault or negligence and not foreseeable. Such events may include, but are not restricted to, acts of the Purchaser either in its sovereign or contractual capacity, wars or revolutions, fires, floods, epidemics, quarantine restrictions and freight embargoes If a Force Majeure situation arises, the Bidder shall promptly notify the Purchaser in writing of such condition and the cause thereof. Unless otherwise directed by the Purchaser in writing, the Bidder shall continue to perform its obligations under the Contract as far as is reasonably practical, and shall seek all reasonable alternative means for performance not prevented by the Force Majeure event. 26. Termination for Insolvency 26.1 The Purchaser may at any time terminate the Contract by giving written notice to the Bidder, without compensation to the Bidder, if: The Bidder becomes bankrupt or otherwise insolvent, The Bidder being a Company is wound up voluntarily by the order of a Court receiver, liquidator or Manager appointed on behalf of the debenture holders or circumstances shall have arisen which entitle the court or debenture holders to appoint a receiver, liquidator or a Manager, provided that such termination will not prejudice or affect any right of action or remedy which has accrued or will accrue thereafter to the Purchaser. 27. Termination for Convenience 27.1 The Purchaser, may by written notice sent to the Bidder, terminate the Contract, in whole or in part, at any time for its convenience. The notice of termination shall specify that termination be for the Purchaser's convenience, the extent to which performance of work under the Contract is terminated, and the date upon which such termination becomes effective. 36

37 27.2 The Purchaser shall purchase the Goods that are complete and ready for dispatch within 30 days after the Bidder s receipt of notice of termination at the Contract terms and prices. For the remaining Goods, the Purchaser may decide: To have any portion completed and delivered at the Contract terms and prices and/or To cancel the remainder and pay to the Bidder an agreed amount for partially completed Goods and for materials and parts previously procured by the Bidder. Both Purchaser and Bidder shall mutually settle all terminations as per clause 24, 25, 26 and Resolution of Disputes 28.1 The Purchaser and the Bidder shall make every effort to resolve amicably by direct informal negotiation any disagreement or dispute arising between them under or in connection with the Contract If, after thirty (30) days from the commencement of such informal negotiations, the Purchaser and the Bidder have been unable to resolve amicably a Contract dispute, either party may require that the dispute be referred for resolution to the formal mechanisms specified in the Special Conditions of Contract. These mechanisms may include, but are not restricted to, conciliation mediated by a third party, adjudication in an agreed national or international forum, and/or international arbitration. The mechanism shall be specified in the Special Conditions of Contract. 29. Governing Language 29.1 The Contract shall be written in the language of the bid, as specified by the Purchaser in the Instructions to Bidders. Subject to Clause 30, that language version of the Contract shall govern its interpretation. All correspondence and other documents pertaining to the Contract, which are exchanged by the parties, shall be written in that same language. 30. Applicable Law 30.1 The Contract shall be interpreted in accordance with the laws of the Union of India. 31. Notices 31.1 Any notice given by one party to the other pursuant to the Contract shall be sent in writing or by fax / and confirmed in writing to the address specified for that purpose in the Special Conditions of Contract A notice shall be effective when delivered or on the notice's effective date, whichever is later. 37

38 32. Taxes and Duties 32.1 The Bidder shall be entirely responsible for all taxes, duties, license fees, etc. incurred until delivery of the contracted Goods to and taking over of the works by the Purchaser. The onus of paying all the statutory levies as per the applicable tariff heads and norms shall be on the Bidder. 33. Right to use defective equipment 33.1 If after delivery, acceptance and installation and within the guarantee and warranty period, the operation or use of the equipment proves to be unsatisfactory, the Purchaser shall have the right to continue to operate or use such equipment until rectification of defects, errors or omissions by repair or by partial or complete replacement is made without interfering with the Purchasers' operation. 34. Income Tax and Other Taxes 34.1 The Bidder shall be liable to pay all corporate taxes, income tax and other taxes that shall be levied according to the laws and regulations applicable from time to time and the price bid by the Bidder shall include all such taxes. Wherever the laws and regulations require deduction of such taxes at the source of payment, the Purchaser shall effect such deductions from the payment due to the Bidder. The remittance of amounts so deducted and issuance of certificate for such deductions shall be made by the Purchaser as per the laws and regulations in force. Nothing in the Contract shall relieve the Bidder from his responsibility to pay any tax that may be levied on income and profits made by the Bidder in respect of the Contract. The Bidder's staff, personnel and labour will be liable to pay personal income taxes in respect of such of their salaries and wages as are chargeable under the laws and regulations for the time being in force, and the Bidder shall perform such duties in regard to such deductions thereof as may be imposed on him by such laws and regulations. The Purchaser shall not, in any way, be responsible for such payments by the Bidders' staff. 35 Jurisdiction 35.1 Settlement of any dispute out of the purchase order/ contract against this bid shall be subject to the courts at Anand only. 38

39 SECTION IV - PART I SPECIAL CONDITIONS OF CONTRACT 39

40 Contents 1. Definitions 2. Performance Security 3. Inspection and Tests 4. Delivery and Documents 5. Insurance 6. Incidental services 7. Spare Parts 8. Warranty/Guarantee 9. Payment 10. Price Adjustment 11. Resolution of Disputes 12. Notices 40

41 The following Special Conditions of Contract shall supplement the General Conditions of Contract. Whenever there is a conflict, the provisions herein shall prevail over those in the General Conditions of Contract. The corresponding clause number of the General Conditions is indicated in parentheses: 1. Definitions (Clause 1) 1.1 The Purchaser is Kaira District Co-operative Milk Producers Union Limited and would include the term "Owner" 1.2 The Bidder/Bidder is (Name of Bidder/Bidder). 1.3 Equivalency of Standards and Codes (Clause 4) 1.4 Wherever reference is made in the contract to the respective standards and codes in accordance with which goods and materials are to be furnished, and work is to be performed or tested, the provisions of the latest current edition or revision of the relevant standards and codes in effect shall apply, unless otherwise expressly set forth in the Contract. Where such standards and codes are national in character, or relate to a particular country or region, other authoritative standards which ensure an equal or higher quality than the standards and codes specified will be accepted subject to the Purchaser's prior review and written approval. Differences between the standards specified and the proposed alternative standards must be fully described in writing by the Bidder/Bidder and submitted to the Purchaser at least 30 days prior to the date when the Bidder/Bidder desires the Purchaser's approval. In the event the Purchaser determines that such proposed deviations do not ensure equal or higher quality, the Bidder/Bidder shall comply with the standards set forth in the documents. 2. Performance Security (Clause 7) 2.1 The Performance Security shall be in the amount of 10% of the Contract price up to sixty days after the date of completion of performance obligations including warranty obligations. 3. Inspection and Tests (Clause 8) 3.1 The inspection of the Goods shall be carried out to check whether the Goods are in conformity with the technical specifications attached to the purchase order form and shall be in line with the inspection/test procedures laid down in the Schedule of Specifications and the Contract conditions. 4. Delivery and Documents (Clause 10) For imported goods: Upon shipment, the Bidder/Bidder shall notify the Purchaser and the Insurance Company by fax / the full details of the shipment including purchase order number, description of goods, quantity, the vessel, the bill of lading number and date, port of loading, date of shipment, port of discharge, etc. The Bidder/Bidder shall mail the following documents to the Purchaser, with a copy to the Insurance Company: 41

42 4.1.2 For imported goods: Original and three copies of: The Bidder's invoice showing purchase order no., Goods description, quantity, unit price, total amount; The negotiable, clean, on-board bill of lading marked freight prepaid and three copies of non-negotiable bill of lading; Packing list identifying contents of each package; Insurance certificate; Manufacturer's/Bidder/Bidder's guarantee certificate; Inspection certificate, issued by the nominated inspection agency and the Bidder/Bidder's factory inspection report; and Certificate for Country of origin. The Bidder's certificate certifying that the defects pointed out during inspection have been rectified. 4.2 The Purchaser shall receive the above documents at least one week before arrival of the Goods at the port and, if not received, the Bidder/Bidder will be responsible for any consequent expenses. 4.4 For Domestic Goods: Original and three copies of: The Bidder's invoice showing purchase order no., Goods' description, quantity, unit price, total amount; Delivery note/packing list/lorry receipt; Manufacturer's/Bidder/Bidder's guarantee certificate; Inspection Certificate issued by the nominated inspection agency, and the Bidder/Bidder's factory inspection report; Excise gate pass/ Octroi receipts, wherever applicable, duly sealed indicating payments made; and Any other document evidencing payment of statutory levies. Single MCE insurance policy shall cover the entire project. 4.5 Note: The nomenclature used for the item description in the invoice/s, packing list/s and delivery note/s etc. should be identical to that used in the purchase order/contract. The dispatch particulars including name of transporter, LR Number and date should also be mentioned in the invoice/s. 4.6 Ensure that material supplied are Brand new and defect free and also to be mentioned in Commercial Invoice. 5. Insurance (clause 11) 5.1 The marine/transit insurance shall cover an amount equal to 110% of the FOR destination value of the goods from "warehouse to warehouse" on "All Risks" basis including War Risks and Strike clauses valid for a period not less than 3 months after the date of arrival of Goods at final destination. 42

43 5.2 The Insurance charges shall be paid by successful Bidder/Bidder towards all risks during storage, erection, testing, commissioning and up to acceptance of the plant. 6 Incidental services (Clause 13) 6.1 The incidental services shall be provided as per the requirements outlined in the Schedule of Specifications and as covered under Clause The cost shall be included in the contract price, if provided for in the scope of the Contract. 7 Spare Parts (Clause 14) 7.1 Bidder/Bidders shall carry sufficient inventories to assure ex-stock supply of consumable essential spares considered for the plant All spare parts and components shall be supplied as promptly as possible but in any case within three months of placement of order. 8. Warranty/Guarantee (Clause 15) 8.1 The warranty/guarantee shall be as per provision under Clause 3.15 of General Conditions. 9 Payment (Clause 16) 9.1 Payment for supply, installation and commissioning contracts must be as below: % advance of total contract value (Supply component )on: (i) Acceptance of the order i.e. a. Submission of the Duplicate copy of the order duly signed by the authorised signatory putting stamp of the Organisation. b. Execution of the Contract Form. (ii) Against a bank guarantee for equivalent amount valid for 30 days beyond the stipulated delivery (as per schedule of delivery/supply)/ completion period 20% of the Supply value on first submission of Plant layout, and P&I Diagram for process and services.(supply) 60% progressive payment of supply value against safe receipt of goods at site.(supply) 10% of total contract value (Supply) against submission of bank guarantee valid for 1 year from the date of commissioning % of erection and commissioning value on Pro rata basis. For erection the payment shall be made on progression of erection as per Joint Measurement Sheet within 30 days of submission of JMS (erection and commissioning) 20% Erection & Commissioning value to be pay based on successful erection and Commissioning. 9.2 The Bank Guarantees should be obtained from Nationalized Banks and acceptable Foreign Banks operating in India (please refer to list given in the Appendices I). 43

44 9.3 Notes: All Payments shall be made within 45 days from the date of submission of Invoice. Payment shall be made on complete supply of an item/ group of items specified in the Contract as per the Price Break up. No payment shall be made if supply of an item/ group of items is incomplete. Bank Guarantees for advance payment shall be released not later than 30 days after the date of delivery of all the Goods at their final destination. For items, which do not involve any supply and the Bidder/Bidder/ contractor has to do only the erection and commissioning, 60% payment shall be made on completion of erection of the items as per the break-up prices to be given in the Purchase Order. 9.4 Third party claims, bills and invoices will not be entertained during the contract by AMUL. 10. No rise adjustment during the project period. 11. Resolution of Disputes (Clause 28) 11.1 All disputes or differences in respect of which the decision is not final and conclusive shall, on the initiative of either party, be referred to the adjudication of sole Arbitrator. Within thirty days of receipt of notice from the Bidder/Bidder of his intention to refer the dispute to arbitration, the Purchaser shall finalize a panel of three Arbitrators and intimate the same to the Bidder. The Bidder shall within fifteen days of receipt of this list select and confirm his acceptance to the appointment of one from the panel as Arbitrator. If the Bidder to communicate his selection of name, within the stipulated period, the Purchaser shall without delay select one from the panel and appoint him as the sole Arbitrator. If the Purchaser fails to send such a panel within thirty days, as stipulated, the Bidder/Bidder shall send a similar panel to the Purchaser within fifteen days. The Purchaser shall then select one from the panel and appoint him as the sole Arbitrator within fifteen days. If the Purchaser fails to do so, the Bidder/Bidder shall communicate to the Purchaser the name of one from the panel who shall then be the sole Arbitrator. The appointment of sole Arbitrator so made shall be final and conclusive The Arbitration shall be conducted in accordance with the provisions of the Indian Arbitration Act, 1996 and rules there under or any statutory modifications thereof for the time being in force. The Arbitration proceedings shall be held in Chikhali ONLY at the time as the sole Arbitrator may decide. The decision of the sole Arbitrator shall be final and binding upon the parties and the expenses of the Arbitrator shall be paid as may be determined by the Arbitrator Performance under the Contract shall, if reasonably possible, continue during the Arbitration proceedings and payments due to the Bidder/Bidder by the Purchaser shall not be withheld, unless they are the subjects of the Arbitration proceedings. 44

45 All awards for claims equivalent to Rupees thirty thousand or more shall be in writing and state the reasons for the amounts awarded Neither party is entitled to bring a claim to Arbitration if its Arbitrator has not been appointed within thirty days after expiration of the warranty/ guarantee period. 12. Notices (Clause 31) 12.1 For the purpose of all the notices, the following shall be the address of the Purchaser and Bidder. Purchaser : Kaira District Co- operative Milk Producers Union Limited. Anand , Gujarat,India Phone: , Fax: Bidder: (address will be provided by bidder) 45

46 SECTION IV PART II SPECIAL CONDITIONS OF CONTRACT FOR ERECTION AND COMMISSIONING 46

47 Contents 1. Sufficiency Of Tender 2. Programme Of Installation & Commissioning 3. Preparation of Drawings for Approval 4. Superintendence, Team And Conduct 5. Purchaser's Instructions 6. Right Of The Purchaser 7. Bidder/Bidder s Functions 8. Variations 9. Duties of the Bidder/Bidder Vis-a-Vis the Purchaser 10. Supply Of Tools, Tackles And Materials 11. Protection Of Plant 12. Unloading, Transportation And Inspection 13. Storage Of Equipment 14. Approvals 15. Review & Co-Ordination of Erection Work 16. Extension of Time for Completion 17. Table 1 List of Drawings required Submission 47

48 1. Sufficiency of Tender 1.1 The Bidder/Bidder by bidding shall be deemed to have satisfied himself as to all the conditions and circumstances affecting the Contract Price, as to the possibility of executing the works as shown and described in the Contract, as to the general circumstances at the site of the works, as to the general labour position at site and to have determined the prices accordingly. 2. Programme of Installation & Commissioning 2.1 As soon as practicable after the acceptance of the bid, the Bidder/Bidder shall submit to the Purchaser for his approval a comprehensive programmed in the form of PERT network/ bar chart and any other form as may be required by the Purchaser showing the sequence of order in which the Bidder/Bidder proposes to carry out the works including the design, manufacture, delivery to site, erection and commissioning thereof. After submission to and approval by the Purchaser of such programmed, the Bidder/Bidder shall adhere to the sequence of order and method stated therein. The submission to and approval by the Purchaser of such programmed shall not relieve the Bidder/Bidder of any of his duties or responsibilities under the Contract. The programmed approved by the Purchaser shall form the basis of evaluating the pace of all works to be performed by the Bidder/Bidder. The Bidder/Bidder shall update the PERT Network every month, submit it to the Purchaser and shall inform the Purchaser the progress on all the activities falling on schedule for the next reporting date. 3 Preparation of Drawings for Approval 3.1 The Bidder/Bidder should visit the site to acquaint himself in respect of existing site conditions and to know the details/information required for understanding the nature and type of civil construction works involved in the project. The Bidder/Bidder shall submit to the Purchaser for approval: Within the time given in the specification or in the program, such drawings, samples, patterns and models as may be called for therein, and in numbers therein required. During the progress of works and within such reasonable times as the Purchaser may require such drawings of the general arrangement and details of the works as the Purchaser may require. 3.2 Wherever necessary, the Bidder/Bidder would be provided with a set of architectural drawings for the buildings where the erection works would be carried out and also the equipment details/ drawings of various equipment handed over to the Bidder/Bidder by the Purchaser. 3.3 The specifications/ conditions concerning the submission of drawings by the Bidder/Bidder are detailed as under: 3.4 Within three weeks from the date of receipt of the order, Bidder/Bidder shall furnish a list of all necessary drawings, which the Bidder/Bidder shall submit for approval, identifying each drawing by a serial number and descriptive title and expected date of submission. A brief list of drawings is given in Table 1. This list 48

49 shall be revised and extended if necessary, during the progress of work depending on the nature of the contract also. 3.5 The Purchaser shall signify his approval or disapproval of all drawings or such drawings that would affect progress of the contract as per the agreed programmed. 3.6 The purchaser shall issue, within four weeks of time in all circumstances, any drawing requested by the Bidder/Bidder and required to be provided by us. If the Bidder/Bidder suffers delay and/ or incurs costs due to delay on purchaser s part in this regard, then the Purchaser shall take such delay into account in determining any extension of time to which the Bidder/Bidder is entitled under Clause 15 hereof and the Bidder/Bidder shall be paid the amount of such cost as shall be reasonable. 3.7 P&I Drawings, Plant Layout and GA Drawings submitted for approval shall be signed by responsible representative of Bidder/Bidder and shall be to any one of the following sizes in accordance with Indian Standards: A0, A1, A2, A3 and A All drawings shall show the following particulars in the lower right hand corner in addition to Bidder/Bidder s name: Name of the Purchaser Project Title Title of drawing Scale Date of drawing Drawing number Space for drawing number 3.9 In addition to the information provided on drawings, each drawing shall carry a revision number, date of revision and brief description of revision carried out. Whenever any revision is carried out, correspondingly revision number must be updated All dimensions on drawings shall be in metric units Drawings (three sets) submitted by the Bidder/Bidder for approval will be checked, reviewed by the Purchaser, and comments, if any, on the same will be conveyed to the Bidder/Bidder. It is the responsibility of the Bidder/Bidder to incorporate correctly all the comments conveyed by the Purchaser on the Bidder/Bidder's drawings. The drawings, which are approved with comments, are to be re-submitted to the Purchaser for purpose of records. Such drawings will not be checked/reviewed by the Purchaser to verify whether the Bidder/Bidder has incorporated all the comments. If the Bidder/Bidder is unable to incorporate any comments in the revised drawings, Bidder/Bidder shall clearly state in his forwarding letter such non-compliance along with the valid reasons Drawings prepared by the Bidder/Bidder and approved by the Purchaser shall be considered as a part of the specifications. However, the examination of the drawings by the Purchaser shall not relieve the Bidder/Bidder of his responsibility for engineering design, workmanship, and quality of materials, 49

50 warranty obligations and satisfactory performance on installation covered under the contract If at any time before completion of the work, changes are made necessitating revision of approved drawings, the Bidder/Bidder shall make such revisions and proceed in the same routine as for the original approval Date of submission: In the event, the drawings submitted for approval require many revisions amounting to redrawing of the same, and then the date of submission of the revised drawings would be considered as the date of submission for approval The Bidder/Bidder shall furnish to the Purchaser before the works are taken over, Operating and Maintenance instructions together with Drawings of the works as completed, in sufficient detail to enable the Purchaser to maintain, dismantle, reassemble and adjust all parts of the works. Unless otherwise agreed, the works shall not be considered completed for the purposes of taking over until such instructions and drawings have been supplied to the Purchaser. 4 Superintendence, Team and Conduct 4.1 The Bidder/Bidder shall employ one or more competent representatives, whose name or names shall have previously been communicated in writing to the Purchaser by the Bidder/Bidder, to superintend the carrying out of the works on the site. The said representative or if more than one shall be employed, then one of such representatives shall be present on the site during all times, and any orders or instructions which the Purchaser may give to the said representative of the Bidder/Bidder shall be deemed to have given to the Bidder/Bidder. The said representative shall have full technical capabilities and complete administrative and financial powers to expeditiously and efficiently execute the work under the contract. 4.2 The Bidder/Bidder shall, execute the works with due care and diligence within the time for completion and employ Bidder/Bidder s team comprising qualified and experienced engineers together with adequate skilled, semi-skilled and unskilled workmen in the site for carrying out the works. The Bidder/Bidder shall ensure adequate workforce to keep the required pace at all times as per the schedule of completion. Bidder/Bidder shall also ensure availability of competent engineers during commissioning/start up, trial runs, Operation of the plant/equipment till handing over of the plant. 4.3 The Bidder/Bidder shall furnish the details of qualifications and experience of their senior supervisors and engineers assigned to the work site, including their experience in supervising erection and commissioning of plant and equipment of comparable capacity. 4.4 When the Bidder/Bidder or Bidder/Bidder's representative is not present on any part of the work where it may be desired to give directions in the event of emergencies, orders may be given by the Purchaser and shall be received and observed by the supervisors or foremen who may have charge of the particular part of the work in reference to which orders are given. Any such instructions, 50

51 directions or notices given by the Purchaser shall be deemed given to the Bidder/Bidder. 4.5 The Bidder/Bidder shall furnish to the Purchaser a fortnightly labor force report showing by classifications the number of employees engaged in the work. The Bidder/Bidder's employment records shall include any reasonable information as may be required by the Purchaser. The Bidder/Bidder should also display necessary information as may be required by statutory regulations. 4.6 None of the Bidder/Bidder s supervisors, engineers, or labourers may be withdrawn from the work without notice to the Purchaser and further no such withdrawals shall be made if in the opinion of the Purchaser, it will adversely affect the required pace of progress and/or the successful completion of the work. 4.7 The Purchaser shall be at liberty to object to any representative or person, skilled, semi-skilled or unskilled worker employed by the Bidder/Bidder in the execution of or otherwise about the works who shall, in the opinion of the Purchaser, misconduct himself or be incompetent, or negligent or unsuitable, and the Bidder/Bidder shall remove the person so objected to, upon receipt of notice in writing from the Purchaser and shall provide in that place a competent representative at Bidder/Bidder's own expense within a reasonable time. 4.8 In the execution of the works no persons other than the Bidder/Bidder, sub- Bidder/Bidder and their employees shall be allowed on the site except by the written permission of the Purchaser. 5 Purchaser's Instructions 5.1 The Purchaser may, in his absolute discretion, issue from time to time drawings and/ or instructions, directions and clarifications, which are collectively referred to as Purchaser's instructions in regard to: Any additional drawing and clarifications to exhibit or illustrate details. Variations or modifications of the design, quality or quantity of work or the additions or omissions or substitution of any work. Any discrepancy in the drawings or between the schedule of quantities and/or specifications. Removal from the site of any material brought there by the Bidder/Bidder, which are unacceptable to the Purchaser and the substitution of any other material thereof. Removal and/or re-execution of any work erected by the Bidder/Bidder, which are unacceptable to the Purchaser. Dismissal from the work of any persons employed there upon who shall in the opinion of the Purchaser, misconduct him, or be incompetent or negligent. Opening up for inspection of any work covered up. Amending and making good of any defects. 51

52 6 Right of the Purchaser 6.1 Right to direct works The Purchaser shall have the right to direct the manner in which all works under this contract shall be conducted, in so far as it may be necessary to secure the safe and proper progress and specified quality of the works. All work shall be done and all materials shall be furnished to the satisfaction and approval of the Purchaser. Whenever in the opinion of the Purchaser, the Bidder/Bidder has made marked departures from the schedule of completion or when circumstances or requirement force such a departure from the said schedule, the Purchaser, in order to ensure compliance with the schedule, shall direct the order, pace and method of conducting the work, which shall be adhered to by the Bidder/Bidder. If in the judgment of the Purchaser, it becomes necessary at any time to accelerate the overall pace of the plant erection work, the Bidder/Bidder, when directed by Purchaser, shall cease work at any particular point and transfer Bidder/Bidder s men to such other point or points and execute such works, as may be directed by the Purchaser and at the discretion of the Purchaser. 6.2 Right to order modifications of methods and equipment If at any time the Bidder/Bidder's methods, materials or equipment appear to the Purchaser to be unsafe, inefficient or inadequate for securing the safety of workmen or the public, the quality of work or the rate of progress required, the Purchaser may direct the Bidder/Bidder to ensure safety, and increase their efficiency and adequacy and the Bidder/Bidder shall promptly comply with such directives. If at any time the Bidder/Bidder's working force and equipment are inadequate in the opinion of the Purchaser, for securing the necessary progress as stipulated, the Bidder/Bidder shall if so directed, increase the working force and equipment to such an extent as to give reasonable assurance of compliance with the schedule of completion. The absence of such demands from the Purchaser shall not relieve the Bidder/Bidder of Bidder/Bidder's obligations to secure the quality, the safe conducting of the work and the rate of progress required by the contract. The Bidder/Bidder alone shall be and remain liable and responsible for the safety, efficiency and adequacy of Bidder/Bidder s methods, materials, working force and equipment, irrespective of whether or not the Bidder/Bidder makes any changes as a result of any order or orders received from the Purchaser. 6.3 Right to inspect the work The Purchaser s representative shall be given full assistance in the form of the necessary tools, instruments, equipment and qualified operators to facilitate inspection. The Purchaser reserves the right to call for the original test certificates for all the materials used in the erection work. In the event the Purchaser's inspection reveals poor quality of work/materials, the Purchaser shall be at liberty to specify additional inspection procedures if 52

53 required, to ascertain Bidder/Bidder's compliance with the specifications of erection work. Even though inspection is carried out by the Purchaser or Purchaser's representatives, such inspection shall not, however, relieve the Bidder/Bidder of any or all responsibilities as per the contract, nor prejudice any claim, right or privilege which the Purchaser may have because of the use of defective or unsatisfactory materials or bad workmanship. 7 Bidder/Bidder s Functions 7.1 The Bidder/Bidder shall provide everything necessary for proper execution of the works, according to the drawings, schedule of quantities and specifications taken together whether the same may or may not be particularly shown or described therein, provided that the same can reasonably be inferred there from and if the Bidder/Bidder finds any discrepancy therein, Bidder/Bidder shall immediately refer the same to the Purchaser whose decision shall be final and binding on the Bidder/Bidder. 7.2 The Bidder/Bidder shall proceed with the work to be performed under this contract in the best and workman like manner by engaging qualified and efficient workers and finish the work in strict conformance with the drawings and specifications and any changes/modifications thereof made by the Purchaser. 8 Variations 8.1 The Purchaser shall make any variation of the form, quality or quantity of the Works or any part thereof that may, in his opinion, be necessary and for that purpose, or if for any other reason it shall, in his opinion be desirable, he shall have power to order the Bidder/Bidder to do and the Bidder/Bidder shall do any of the following: Increase or decrease the quantity of any work included in the contract, Omit any such work, Change the character or quality or kind of any such work, Change the levels, lines, position and dimensions of any part of the works Execute additional work of any kind necessary for the completion of the works and no such variation shall in any way vitiate or invalidate the contract, but the value, if any, of all such variations shall be taken into account in ascertaining the amount of the Contract price. 8.2 The Bidder/Bidder shall make no such variations without an order in writing of the Purchaser. Provided that no order in writing shall be required for increase or decrease in the quantity of any work where such increase or decrease is not the result of an order given under this clause, but is the result of the quantities exceeding or being less than those stated in the Contract/Bill of Quantities. Provided also that if for any reason the Purchaser shall consider it desirable to give any such order verbally, the Bidder/Bidder shall comply with such order and any confirmation in writing of such verbal order given by the Purchaser, whether before or after the carrying out of the order, shall be deemed to be an order in 53

54 writing within the meaning of this clause. Provided further that if the Bidder/Bidder shall within seven days confirm in writing to the Purchaser and the Purchaser shall not contradict such confirmation in writing within 14 days, it shall be deemed to be an order in writing by the Purchaser. 8.3 All extra or additional work done or work omitted by order of the Purchaser shall be valued at the rates and prices set out in the contract if in the opinion of the Purchaser, the same shall be applicable. If the contract does not contain any rates or prices applicable to the extra or additional work, then suitable rates or prices shall be agreed upon between the Purchaser and the Bidder/Bidder. Any Extra Work, carried out by the Bidder/Bidder would be at mutually agreed cost 8.4 Provided that if the nature or amount of any omission or addition relative to the nature or amount of the whole of the works or to any part thereof shall be such that, in the opinion of the Purchaser, the rate or price contained in the contract for any item of the works is, by reason of such omission or addition, rendered unreasonable or inapplicable, then a suitable rate or price shall be agreed upon between the Purchaser and the Bidder/Bidder. In the event of disagreement the Purchaser shall fix such other rate or price as shall, in his opinion, be reasonable and proper having regard to the circumstances. 8.5 Provided also that no increase or decrease mentioned above or variation of rate or price shall be made unless, as soon after the date of the order as is practicable and, in the case of extra or additional work, before the commencement of the work or as soon thereafter as is practicable, notice shall have been given in writing: By the Bidder/Bidder to the Purchaser of his intention to claim extra payment or a varied rate or price, or By the Purchaser to the Bidder/Bidder of his intention to vary a rate or price a. No price variation on part of quantity increase or decrease. 8.6 The Bidder/Bidder shall send to the Purchaser s representative once in every month an account giving particulars, as full and detailed as possible, of all claims for any additional payment to which the Bidder/Bidder may consider himself entitled and of all extra or additional work ordered by the Purchaser which he has executed during the preceding month. 8.7 No final or interim claim for payment for any such work or expense will be considered which has not been included in such particulars. Provided always that the Purchaser shall be entitled to authorize payment to be made for any such work or expense, notwithstanding the Bidder/Bidder's failure to comply with this condition, if the Bidder/Bidder has, at the earliest practicable opportunity, notified the Purchaser in writing that he intends to make a claim for such work. 8.8 The work shall be carried out as approved by the Purchaser or his authorized representative/s from time to time, keeping in view the overall schedule of completion of the project. The Bidder/Bidder s job schedule must not disturb or interfere with Purchaser s or the other Bidder/Bidder s schedules of day-to-day work. The Purchaser will provide all reasonable assistance for carrying out the jobs. 54

55 8.9 Night work will be permitted only with prior approval of the Purchaser. The Purchaser may also direct the Bidder/Bidder to operate extra shifts over and above normal day shift to ensure completion of contract as per schedule. Adequate lighting wherever required should be provided by the Bidder/Bidder at no extra cost. The Bidder/Bidder should employ qualified electricians and wiremen for these facilities. In case of Bidder/Bidder s failure to provide these facilities and personnel, the Purchaser has the right to arrange such facilities and personnel and to charge the cost thereof to the Bidder/Bidder In order to enable the Purchaser to arrange for insurance of all items received at the site including the items of supply covered under this contract, the Bidder/Bidder shall furnish necessary details of all the equipment immediately on its receipt at site, to the Purchaser. Any default on the part of the Bidder/Bidder due to which any item does not get covered under the insurance of the Purchaser; the consequential losses shall be charged to the Bidder/Bidder The Purchaser shall not be liable for or in respect of any damages or compensation payable at law in respect or in consequence of any accident or injury to any workman or other person in the employment of the Bidder/Bidder or any sub-bidder/bidder, save and except an accident or injury resulting from any act or default of the Purchaser, his agents, or servants. The Bidder/Bidder shall indemnify and keep indemnified the Purchaser against all such damages and compensation, save and except as aforesaid and against all claims, proceedings, costs, charges and expenses whatsoever in respect thereof or in relation thereto The Bidder/Bidder shall ensure against such liability with an insurer approved by the Purchaser, which approval shall not be unreasonably withheld, and shall continue such insurance during the whole of the time that any persons are employed by him on the works shall, when required, produce to the Purchaser or Purchaser s representative such policy of insurance and the receipt for payment of the current premium. Provided always that, in respect of any persons employed by any sub-bidder/bidder, the Bidder/Bidder's obligations to ensure as aforesaid under this sub-clause shall be satisfied if the sub-bidder/bidder shall have insured against the liability in respect of such persons in such manner that the Purchaser is indemnified under the policy, but the Bidder/Bidder shall require such sub-bidder/bidder to produce to the Purchaser or Purchaser's representative, when required such policy of insurance and the receipt for the payment of the current premium Whenever proper execution of the work under the contract depends on the jobs carried out by some other Bidder/Bidder, the Bidder/Bidder should inspect all such erection and installation jobs and report to the Purchaser regarding any defects or discrepancies. The Bidder/Bidder's failure to do so shall constitute as acceptance of the other Bidder/Bidder's installation/jobs as fit and proper for reception of Bidder/Bidder's works except those defects which may develop after execution. Bidder/Bidder should also report any discrepancy between the executed work and the drawings. The Bidder/Bidder shall extend all necessary help/cooperation to other Bidder/Bidders working at the site in the interest of the work. 55

56 8.14 Bidder/Bidder shall carryout final adjustments of foundations, levelling and dressing of foundation surfaces, bedding and grouting of anchor bolts, bedplates etc. required for seating of equipment in proper position. The Bidder/Bidder shall be responsible for the reference lines and proper alignment of the equipment. However, all civil works like making cut outs in walls, floors and ceilings for pipelines shall be done by the purchaser. Adjustment &levelling are to be carried out by the Bidder/Bidder at no extra cost. The Purchaser shall arrange the necessary refilling/repairs of these cut outs and pockets. The Bidder/Bidder should arrange for laying the supports, cut outs, grouting of bolts, etc., when the civil works are in progress, so as to avoid refilling/repair works. The Purchaser at Bidder/Bidder s costs shall make the damages occurring to civil and other works good. For fixing of piping/equipment supports on wall/beams/roof floor etc., preferably anchor bolts shall be used by the Bidder/Bidder. Drilling of holes for fixing anchor bolts & supply of anchor bolts is in the scope of Bidder/Bidder without any extra cost The Bidder/Bidder shall keep a check on deliveries of the equipment covered in the scope of erection work and shall advise the Purchaser well in advance regarding possible hold-up in Bidder/Bidder's work due to the likely delay in delivery of such equipment/components to enable him to take remedial actions. 9 Duties of the Bidder/Bidder Vis-à-Vis the Purchaser 9.1 The equipment and the items, if any, to be supplied by the Purchaser for erection, testing and commissioning shall be as listed in the contract. 9.2 Besides the utilities/ services as specified in battery limits, Purchaser shall also provide the following assistance/ facilities to the Bidder/Bidder for carrying out the installation work: Plant building ready for installation of equipment/items. Necessary temporary water for carrying out the installation shall be supplied at only one point within the project site by the Purchaser free of charge. All necessary distribution tapings from this point onwards shall be the Bidder/Bidder's responsibility. Necessary temporary power for carrying out the installation shall be arranged by the Bidder/Bidder at Bidder/Bidder's own cost. The Purchaser on written request by the Bidder/Bidder will issue the necessary authorization letter. 9.3 If the power is provided to you, the of total installation charges will be deducted from the erection bill of the Bidder/Bidder. However, the Bidder/Bidder shall supply all the items such as energy meter, switchgear etc. required for getting temporary power. 9.4 The details of temporary water and power requirements shall be furnished one month in advance by the Bidder/Bidder to enable the Purchaser to make timely arrangement. 9.5 If the Bidder/Bidder suffers delay and/or incurs costs from failure on the part of the purchaser to give possession of the civil works in accordance with the mutually agreed schedule, the purchaser shall determine: 56

57 Any extension of time to which the Bidder/Bidder is entitled under clause 22 of GCC (General Conditions of Contract) and The amount of such costs, which shall be added to the contract price, and shall notify the Bidder/Bidder accordingly. 10 Supply of Tools, Tackles And Materials 10.1 The Bidder/Bidder shall, at his own expense, provide all the necessary equipment, tools and tackles, haulage power, consumables necessary for effective execution and completion of the works during erection and commissioning. 11 Protection of Plant 11.1 The Purchaser shall not be responsible or held liable for any damage to person or property consequent upon the use, misuse or failure of any erection tools and equipment used by the Bidder/Bidder or any of Bidder/Bidder's Sub- Bidder/Bidders even though such tools and equipment may be furnished, rented or loaned to the Bidder/Bidder or any of Bidder/Bidder s Sub-Bidder/Bidders. The acceptance and/or use of any such tools and equipment by the Bidder/Bidder or Bidder/Bidder's Sub-Bidder/Bidder shall be construed to mean that the Bidder/Bidder accepts all responsibility for and agrees to indemnify and save the Purchaser from any and all claims for said damages resulting from the said use, misuse or failure of such tools and equipments The Bidder/Bidder and Bidder/Bidder s Sub-Bidder/Bidder shall be responsible, during the works, for protection of work, which has been completed by other Bidder/Bidders. Necessary care must be taken to see that the Bidder/Bidder s men cause no damage to the same during the course of execution of the work All other works completed or in progress as well as machinery and equipment that are liable to be damaged by the Bidder/Bidder's work shall be protected by the Bidder/Bidder and protection shall remain and be maintained until the Purchaser directs its removal The Bidder/Bidder shall effectively protect from the effects of weather and from damages or defacement and shall cover appropriately, wherever required, all the works for their complete protection The Bidder/Bidder shall carry out the work without damage to any work and property adjacent to the area of Bidder/Bidder's work to whomsoever it may belong and without interference with the operation of existing machines or equipment Adequate lighting, guarding and watching at and near all the storage handling, fabrication, pre-assembly and erection sites for properly carrying out the work and for safety and security shall be provided by the Bidder/Bidder at Bidder/Bidder's cost. The Bidder/Bidder should adequately light the work area during night time also. The Bidder/Bidder should also engage adequate electricians/wiremen, helper etc to carry out and maintain these lighting facilities. If the Bidder/Bidder fails in this regard, the Purchaser may provide lighting 57

58 facilities as he may deem necessary and charge the cost thereof to the Bidder/Bidder The Bidder/Bidder shall take full responsibility for the care of the works or any section or portions thereof until the date stated in the taking over certificate issued in respect thereof and in case any damage or loss shall happen to any portion of the works not taken over as aforesaid, from any cause whatsoever, the same shall be made good by and at the sole cost of the Bidder/Bidder and to the satisfaction of the Purchaser. The Bidder/Bidder shall also be liable for any loss of or damage to the works occasioned by the Bidder/Bidder or the Bidder/Bidder s Sub-Bidder/Bidder in the course of any operations carried out by the Bidder/Bidder or by the Bidder/Bidder s Sub-Bidder/Bidders for the purpose of completing any outstanding work or complying with the Bidder/Bidder's obligations. 12 Unloading, Transportation and Inspection 12.1 The Bidder/Bidder shall be required to unload all the materials/equipment from the carriers, those received at site after Bidder/Bidder's team arrives at site. Bidder/Bidder shall be paid extra for unloading of the equipment being supplied by the purchaser whereas no extra payment for unloading of the equipment/piping shall be paid to Bidder/Bidder for the equipment being supplied by the Bidder/Bidder. The Bidder/Bidder shall plan in advance, based on the information received from the Purchaser, Bidder/Bidder's requirement of various tools, tackles, jacks, cranes, sleepers etc. required to unload the material/equipment promptly and efficiently. The Bidder/Bidder shall ensure that adequate and all measures necessary to avoid any damage whatsoever to the equipment at the time of unloading are taken Any demurrage/detention charges incurred due to the delay in unloading the material/equipment and releasing the carriers shall be charged to the Bidder/Bidder's account The Bidder/Bidder shall be responsible for the reception on site of all plant and Bidder/Bidder's equipment delivered for the purposes of the contract The Bidder/Bidder shall safely transport/shift the unloaded materials/equipment by the Bidder/Bidder to the storage area All the materials/equipment received by the Purchaser prior to arrival of the Bidder/Bidder at site shall be handed over to the Bidder/Bidder and there upon the Bidder/Bidder shall inspect the same and furnish the receipt to the Purchaser. The manner in which the inspection shall be carried out is enumerated below: 12.6 The materials/equipment would be carefully unpacked by opening the wooden cases/other modes of pickings as the case may be Detailed inventory of various items would be prepared clearly listing out the shortages, breakage/damages after checking the contents with respect to the Bidder/Bidder's packing list, the Purchaser's purchase order and approved equipment drawings. The Bidder/Bidder shall also check each & every 58

59 equipment for any shortage/shortcoming that may eventually create difficulty at the time of installation or commissioning All the information and observations by the Bidder/Bidder shall be furnished in the form of `INSPECTION REPORT' to the Purchaser with specific mention/suggestions which in the opinion of the Bidder/Bidder should be given due consideration and immediate necessary actions, to enable the Purchaser to arrange repair or replacement well in time and avoid delays due to nonavailability of equipment and parts at the time of their actual need The inspection for all the equipment handed over to the Bidder/Bidder shall be completed within three week's period The protection, safety and security of the materials so taken over from the Purchaser shall be the responsibility of the Bidder/Bidder, until they are handed over to the Purchaser after erection, commissioning and testing as per the terms of the Contract. 13 Storage of Equipment 13.1 The Bidder/Bidder shall be responsible for the proper storage and maintenance of all materials/equipment under Bidder/Bidder's custody. Bidder/Bidder shall take all required steps to carry out frequent inspection of equipment/materials stored as well as erected equipment until the same are taken over by the Purchaser. The following procedure shall apply for the same The Bidder/Bidder s inspector shall check stored and installed equipment/materials to observe signs of corrosion, damage to protective coating to parts, open ends in pipes, vessels and equipment, insulation resistance of electrical equipment etc. The Bidder/Bidder shall immediately arrange a coat of protective painting whenever required. A record of all observations made on equipment, defects noticed shall be promptly communicated to the Purchaser and Purchaser's advice taken regarding the repairs/rectification. The Bidder/Bidder shall there upon carry out such repairs/ rectification at Bidder/Bidder s own cost. In case the Bidder/Bidder is not competent to carry out such repairs/ rectification, the Purchaser reserves the right to get this done by other competent agencies at the Bidder/Bidder's responsibility and risk and the entire cost for the same shall be recovered from the Bidder/Bidder's bills The Bidder/Bidder's inspector shall also inspect and provide lubrication to the assembled equipment. The shafts of such equipment shall be periodically rotated to prevent rusting as well as to check freeness of the same The Inspector shall check for any signs of moisture or rusting in any equipment If the commissioning of equipment is delayed after installation of the equipment, the Bidder/Bidder shall carry out all protective measures suggested by the Purchaser during such period Adequate security measures shall be taken by the Bidder/Bidder to prevent theft and loss of materials handed over to the Bidder/Bidder by the Purchaser. The Bidder/Bidder shall carry out periodical inventory checks of the materials received, stored and installed by the Bidder/Bidder and any loss noticed shall be 59

60 immediately reported to he Purchaser. The Bidder/Bidder shall maintain a proper record of these inventories. The Bidder/Bidder should not sell, assign, mortgage, hypothecate or remove equipment or materials which have been installed or which may be necessary for completion of the work without the written consent of the Purchaser Suitable grease recommended for protection of surfaces against rusting (refined from petroleum oil with lanolin minimum (70 0 C) and water in traces) shall be applied over all equipment as required once in every six months All equipment shall be stored inside a closed shed or in the open depending upon whether they are of indoor or outdoor design. The space heaters where provided into the electrical equipment shall be kept connected with power supply irrespective of their type of storage. Where space heaters are not provided adequate heating with bulb is recommended. For transformers heating of oil shall be done by giving 440 V supply and short-circuiting the LT terminals. Frequent checks on insulation resistance are essential for all electrical equipment and record of the inspection reports and mugger readings shall be maintained equipment wise. Such records shall be presented to the Purchaser whenever demanded All the necessary items/goods required for the Bidder/Bidder as described above shall arrange protection and such cost shall be included in the Contract price If material/ Goods were found damaged during inspection, material should be replaced on TO & FRO basis including Freight and other charges. Material are consider as free replacement. 14 Approvals 14.1 The Bidder/Bidder shall obtain the necessary approvals of the Factory Inspector, Boiler Inspector, Electrical Inspector, Weights & Measures Inspector, Explosive Inspector and any other state and local authorities as may be required and the cost of obtaining such approvals shall be included in the contract price The Bidder/Bidder will furnish all the necessary details, drawings, and submission of application and proofreads to the Purchaser for verification/ signature. The Bidder/Bidder on behalf of the Purchaser shall submit the necessary application duly filled-in, together with the prescribed fees to the appropriate authorities. However all the actual statutory prescribed fees paid by the Bidder/Bidder shall be reimbursed by the Purchaser upon production of the receipt/vouchers Wherever necessary or required, the Bidder/Bidder shall furnish the necessary test and/or inspection certificates etc. from the appropriate authorities as per IBR, IER and other statutory regulations and the cost for obtaining these certificates shall be included in the contract price. 15 Review & Co-Ordination of Erection Work 15.1 The Bidder/Bidder shall depute senior and competent personnel to attend the site co-ordination meetings that would generally be held at the site every 60

61 month. The Bidder/Bidder shall take necessary action to implement the decisions arrived at such meetings and shall also update the erection schedule. 16 Extension of Time for Completion 16.1 Should the amount of extra or additional work of any kind or any cause of delay referred to in these conditions, or exceptional adverse climatic conditions, or other special circumstances of any kind whatsoever which may occur, other than through a default of the Bidder/Bidder, be such as fairly to entitle the Bidder/Bidder to an extension of time for the completion of the works, the Purchaser shall determine the amount of such extension and shall notify the Bidder/Bidder accordingly. Provided that the Purchaser is not bound to take into account any extra or additional work or other special circumstances unless the Bidder/Bidder has within twenty eight days after such work has been commenced, or such circumstances have arisen, or as soon thereafter as is practicable, submitted to the Purchaser full and detailed particulars of any extension of time to which he may consider himself entitled in order that such submission may be investigated at the time. 61

62 Table 1 List of Drawings required Submission SN Drawings 1 Equipment drawings for fabricated & non fabricated items. 2 Equipment layout for production and service blocks. 3 Flow diagrams for PROCESS and various services. 4 Service piping layouts in production and service blocks. 5 Piping & ducting layout in production blocks, WHEREVER REQUIRED. 6 Electrical cable & instrument, conduit/ cable tray layout. 7 Standard Installation Drawings for Equipment. 8 Automation SCADA networking drawings, Cabling drawings etc. 9 Automation logic write-up along with logical flow network. 10 Other miscellaneous drawings as required for erection work. 62

63 SECTION IV PART III SPECIAL CONDITIONS OF CONTRACT FOR MECHANICAL WORK 63

64 Contents 1. Scope 2. General Installation 3. Service Piping Installation 4. Special Instructions And Specifications 5. Insulation of Piping and Equipment 6. Interconnections of Services 7. Guidelines for Expansion Work 8. Cleaning Chemicals and Lubricants 9. Testing, Commissioning and StartUp 10. Trouble shooting during the trial period 11. Painting 12. Training of Personnel 13. Code of Practice for Painting Service Pipe Lines Table 1 Painting of Equipment & Structural Work Table 2 Colour Code For Pipelines as per BIS Table 3 Testing Pressures for Various Pipelines Table 4 Makes of Bought Out Item 64

65 1 Scope 1.1 General installation i.e. positioning and installing all the production, miscellaneous and service equipment as per approved layout drawings and as per the contract. 1.2 Supply and installation of structural platforms and tables cross over etc. 1.3 Supply and installation of all service and product piping including ancillary items. 1.4 Insulation and cladding of piping, equipment including supply of materials. 1.5 Interconnections of services and Electrical with equipment. 1.6 Guide line for expansion work. 1.7 Clean up of work site. 1.8 Supply of all cleaning chemicals and lubricants. 1.9 Testing, commissioning and startup Painting including supply of paints as approved by the Purchaser Training of personnel Detailed specifications are given in the subsequent clauses SCOPE: The bidder s scope shall be to design, engineering, manufacturing, approval, testing, inspection, packing and supply of equipment, components, accessories & spares at site in accordance with the plans, procedures, specifications, drawings, codes & any other documents as specified by the purchaser. Successful Commissioning of equipment at site is in bidder s scope. Any Item(s) not specifically mentioned/listed but are necessary for completion & meeting satisfactory performance as per guaranteed parameters shall be deemed to be part of Scope of Supply of the bidder & shall be supplied by the bidder without any extra cost to bidder. F.O.R. destination, inclusive of Packing, Forwarding and Freight. The price quoted shall remain firm for complete duration of the order & shall not be subject to any escalation whatsoever at any time thereafter. The Billing break-up has to be submitted by the bidder during order finalisation. Price agreed vide this PO shall be valid for a period of 18 months from the date of the PO. 2 General Installation 2.1 Positioning of Equipment The work involves preparation of access for moving of the plant and equipment including their fittings from the work site godown or from the place within the site where they have been unloaded, to the place of erection, decrating and placing on the foundation wherever required. The Purchaser shall arrange all the civil foundations as per the manufacturer/bidder s drawings. The Bidder shall place the equipment and carry out final adjustment of the foundations including alignment and dressing of foundation surface, embedding and grouting of anchor bolts and bedplates. The Bidder shall be responsible for obtaining correct reference lines for the purpose of fixing the alignment of various equipments from master benchmarks provided Tolerances shall be as specified in equipment manufacturer's drawings or as stipulated by the Purchaser's Engineer. No equipment shall be permanently bolted down to foundations or structure until the Bidder has checked the alignment and witnessed by the Purchaser. 65

66 The Bidder shall carry out minor alterations in the anchor bolts, pockets etc. At no extra cost and set the equipment properly as per approved layout, drawings and manufacturer s instructions. The Bidder shall supply all the necessary foundation/anchor bolts and bedplates if required without extra cost if these have not been provided with main equipment The Bidder shall supply, fix and maintain, at his own cost, during the erection work, all the necessary cantering, scaffolding, staging required not only for proper execution and protection of the said work but also for protection of the surrounding plant and equipment. The Bidder shall take out and remove any or all such cantering, scaffolding, staging planking etc., as occasion shall require or when ordered to do so and shall fully reinstate and make good all things disturbed during execution of the work, to the satisfaction of the Purchaser. The Bidder shall be paid no additional amount for the above. 2.2 Structural Platforms and Tables Structural platforms shall be required to access to various equipment. Tables shall be required for handling products. These platforms and tables shall be fabricated keeping stability and other functional as well as aesthetic requirements into consideration as approved by the Purchaser. No payment shall be made for such facility, deemed essential for smooth operation and safety of plant personnel. 3 Service Piping Installation 3.1 General Guidelines All piping systems shall comply with the latest editions of the following regulations wherever applicable: Indian Boiler Regulations Regulations of explosives inspectorate All applicable Indian Standards All applicable State Government/ Central Government Laws/ Acts 3.2 Scope of Supply The Bidder shall supply all piping materials like pipes, fittings, flanges, measuring instruments and all other items as shown in the P&I diagram/specifications and schedule of quantities. All the pipes & fittings and insulation material etc. should be of class and make as approved by the Purchaser. The Bidder, for the class and make of all materials, must obtain prior approval of the Purchaser. The Bidder should furnish the details of makes selected by him, in the pro forma given in Table Scope of Piping Erection The scope of erection for piping, includes all system covered in the flow diagrams and specifications. The Bidder's work commences/ terminates at the pipe connections with valves or flanges as specified in flow diagrams/ battery limits. 66

67 3.3.2 The Bidder shall also install necessary piping and any specialties furnished with or for equipment such as relief valves, builtinbypass, primary elements for flow measurements, control valves and online metering equipment The Bidder shall perform necessary internal machining of pipes for installing orifices, flow nozzles, control valves etc. The Bidder shall install all pipes, valves and specialties being procured from other sources. 3.4 Testing of Piping The Bidder shall test all piping systems including valves and specialties and instruments as per procedure mentioned in Table All piping shall be internally cleaned and flushed by the Bidder after erection in a manner suited to the service and as directed by the Purchaser For hydrostatic testing and water flushing, the Bidder shall furnish necessary pumps, equipment, instruments and piping etc. 3.5 Other Guidelines Colour code shall be used to identify pipe material. The Bidder shall be able to identify on request all random piping prior to field fabrication The Bidder shall be responsible for the quality of welding done by them and shall conduct tests to determine the suitability of the welding procedure by him All piping supports, guides, anchors, hangers, rollers with structural framework shall be supplied and erected by the Bidder. The kinds of pipe supports like CI clamps, wooden saddles, roller supports and support framework shall be as per the design approved by the Purchaser prior to taking up the work All piping shall be suspended, guided and anchored with due regard to general requirements and to avoid interference with other pipes, hangers, electrical conduits and their supports, structural members and equipment and to accommodate insulation and conform to buildings structural limitations. It is the responsibility to the piping Bidder to avoid all interference while locating hangers and supports Anchors and/or guides for pipelines or for other purposes shall be furnished, when specified, for holding the pipeline in position for alignment. Hangers shall be designed fabricated and assembled in such a manner that any movement of the support pipes cannot disengage them All piping shall be wire brushed and purged with air blast to remove all rust, mill scale from inner surface. The method of cleaning shall be such that no material is left on the inner or on outer surfaces, which will affect the serviceability of the pipes Effective precautions such as capping and sealing shall be taken to protect all pipe ends against ingress of dirt and damage during transit or storage. The outside of the steel pipes (black) shall be painted with two coats of red oxide paint/heat resistant paint or as directed by the Purchaser All SHE standerds set by purchaser must be followed stricktly during installation and commissioning of entire plant equipments All Liability arrising due to accident will be born by bidder. 67

68 4 Special Instructions and Specifications 4.1 Steam Piping Steam piping work can be classified into two categories: Highpressure steam piping when the working pressure of steam is more than 1.0 kg/cm2 (15 psi) Lowpressure steam piping when the working pressure of steam is up to 1.0 kg/cm2 (15 psi) All the pipes and fittings used for high pressure steam piping work should conform to IBR and they should be IBR certified and also to be identified with number and mark showing that they are tested by the Boiler Inspector and supported with duly authentic certificates to this effect. ALL HIGH PRESSURE STEAM PIPES SHALL BE SEAMLESS TYPE, SCHEDULE The high pressure steam piping after installation should be hydraulically tested in presence of the Boiler Inspector for his approval The highpressure steam piping work should also include fabrication and installation of pressure reducing stations strictly conforming to IBR. 4.2 Other Piping ALL THE PIPING FOR SOFT AND RAW WATER, H.P. AND L.P. STEAM, AIR AND FURNACE OIL/ LSHS PIPING SHALL GENERALLY BE OF WELDED CONSTRUCTION. Whenever welding is done for pipes of smaller size special care should be exercised to avoid clogging of flow area with the welding material. 5 Insulation of Piping and Equipment 5.1 Hot Insulation of Steam, Condensate & Hot Water and Molasses Pipe Lines All the steam and hot water and molasses pipelines shall be insulated with mineral wool or equivalent of specified thickness. The insulation shall be carried out in the following manner and should be supplied in the form of properly required sizes Clean the surfaces to be insulated. Apply a coat of heat resistant primer and fix glass wool/mineral wool of specified thickness, tightly to the pipes, butting all joints and tie with lacing wire It should then be covered with GI wire netting of 20 mm x 22 SWG In case the insulation does not have the desired insulation properties, the entire insulation will have to be redone at the Bidder's cost to give the desired results In case of condensate return piping all the steps mentioned above shall be executed except that thickness of the insulation shall be 25 mm. 5.2 Aluminium The chilled water, glycol, ammonia, water, steam & hot water molasses lines after insulations may be covered by aluminium. 68

69 5.2.2 Aluminium cladding will be done with 22 gauge aluminium sheet with proper grooves and overlaps and screwed in position with 12 mm self tapping parker screws. 6 Interconnections of Services 6.1 The Bidder shall lay service piping and provide connections with the equipment complying strictly with the equipment manufacturers' instructions. 6.2 The Bidder shall also carry out all the interconnecting service piping with the various items of plant/system. The work shall be complete with capillary piping if required and connections with instruments and controls supplied with the equipment. 6.3 The Bidder shall also carry out electrical connections for equipment with the control panels including equipment lighting as per the wiring diagrams of the equipment Bidders. Connection shall be made for small electrically operated devices on equipment installed as accessories to, or assembled with equipment. Connections regarding instruments, float switches, limit switches, pressure switches, thermostats and other miscellaneous equipment shall be done as per manufacturers' drawings & instructions. 7 Guidelines for Expansion Work 7.1 Clean Up of Works Site All soils, filth or other matters of an offensive nature taken out of any trench, drain or other places shall not be deposited on the surfaces, but shall at once be carted away by the Bidder from the site of work for proper disposal The Bidder shall not store or place the equipment, materials or erection tools on the drive ways and passages and shall take care that his work in no way restricts or impedes traffic or passage of men and materials during erection, the Bidder shall without any additional payment, at all time keep the working and storage area used by him free from accumulation of dust or combustible materials, waste materials rubbish packing, wooden planks to avoid fire hazards and hindrance to other works If the Bidder fails to comply with these requirements in spite of written instructions from the Purchaser, the Purchaser will proceed to clear these areas and the expenses incurred by the Purchaser in this regard shall be payable by the Bidder. Before completion of the work, the Bidder shall remove or dispose off in a satisfactory manner all scaffolding, temporary structures, waste and debris and leave the promises in a condition satisfactory to the Purchaser. Any packing materials received with the equipment shall remain as the property of the Purchaser and may be used by the Bidder on payment of standard charges to the Purchaser and with prior approval of the Purchaser. At the completion of his work and before final payment, the Bidder shall remove and shall restore the site to neat workman like conditions at his cost. 69

70 8 Cleaning Chemicals and Lubricants 8.1 The necessary quantities of cleaning chemicals, lubricants etc., required for the installation, commissioning, testing and startup of all the equipment till handing over are to be supplied the Bidder and nothing extra would be paid for these. 9 Testing, Commissioning and Startup 9.1 The Bidder shall operate, maintain and give satisfactory trial run of the plant, for the design product satisfactorily for a minimum period of 30 days on continuous basis or as mutually agreed by Bidder/purchaser/Purchaser of the plant at the rated output. The Bidder should carry out all rectification of damages/defects and routine troubleshooting during commissioning with the help of purchaser s staff. 9.2 During this period, B idder shall incorporate/execute necessary minor modifications during the trial period for maximizing operational efficiency. The Bidder should also execute minor modifications as may be suggested by the manufacturer/purchaser, if required. The Bidder shall suggest recommended log sheet proofread for recording necessary operating data and pass it on to the Purchaser in proof of satisfactory rated output and performance of the equipment/plant. 9.3 The commissioning shall also include, for all the equipments, the following: Field disassembly and assembly Clean out of lubrication system including chemical cleaning wherever required Circulation of lubricant to check flow Clean out and check out of all the service lines Check out and commissioning of instruments, equipment and plants, filtering of transformer and other oils so that if deteriorated, they shall attain the required properties/standards, specified tests in this regard must be carried out by approved authorities and their satisfactory reports submitted to the Purchaser before startup Recharging or makeup filling of lubricant oil up to the desired level in the lubrication system of individual machine Operation in empty condition to check general operation details wherever required and wherever possible Closed loop dynamic testing with water/product wherever required Operation under load and gradual load increase to attain maximum rated output. 70

71 10. Trouble shooting during the trial period 10.1 The Bidder shall demonstrate proper working of all mechanical and electrical controls; safety and protective device, in presence of the Purchaser's engineer and the same should be duly recorded After conducting testing, in case particular equipment is not working properly or not giving rated output the Bidder will furnish a detailed report to the Purchaser stating therein the detailed account on the performance of the equipment with possible reasons for improper or not working of the same The Purchaser after receipt of report from the Bidder would take up the matter with the manufacturers and if required would invite the representative of original manufacturers. In case the Purchaser considers that the non-performance of equipment is only due to inexperience of the Bidder, then the charges incurred for the manufacturer's representative visit would be debited to the Bidder's account Further, before the commencement of testing or commissioning, the Purchaser reserves the right to invite the original manufacturer's representative at the cost of the Bidder for startup help, assist and guide the Bidder during commissioning in the following cases: The Bidder has no previous experience of commissioning and startup of the similar equipment The Purchaser is of the opinion that the Bidder is not capable to commission and startup of certain specific equipment However, in either of the cases the manufacturer's representatives would be called with prior information to the Bidder and the Bidder will have to extend all cooperation to such representatives in good spirit and in the interest of the work After satisfactory commissioning and startup the Bidder shall keep his representatives under whose supervision the Purchaser's staff shall be operating and maintaining the plant and equipment for a minimum period of two months. The Bidder's representatives should be present at all times during the running and operation of plant and equipment. During this period the Bidder shall ensure proper working of complete plant and equipment and attend any works required to be done and shall also take complete responsibility for proper operation and maintenance of the complete plant and equipment. 11. Painting 11.1 All the equipment/ machineries like motors, pumps, HT/ LT panel, transformer, switch boards, starters, junction boxes, isolators, storage tanks, supporting structures, pipe supports and MS/ GI pipes and all exposed and visible iron parts included in the scope of erection/ commissioning shall be given double coat of paint of approved shade over a double coat of anticorrosive primer wherever necessary irrespective of the condition of original paint of equipment/ machineries/ structures/ supports. Surfaces wherever required must be properly cleaned for scale, dirt and grease prior to painting. Spray painting is preferably be used on all the equipment/ machineries and wherever practicable. Suitable and necessary cleaning/ wiping of sight/ dial glasses, other nonmetallic parts, flooring, walls and other surfaces which have been spoiled by paint during painting must also be carried out by the Bidder. 71

72 11.2 Lettering and other markings, including capacity and flow direction markings, shall also be carried out by the Bidder on the tanks, pipe lines, starters, motors, isolators and wherever else necessary, as directed and as per the standard practice of installation. ISI colour codes and colour charts as mentioned in Table 3 & Table 2 must be adhered to Supply of all paints and all other materials required is included in the scope of supply of the Bidder under this contract/order. 12. Training of Personnel 12.1 The Bidder for operating the plant as may be deputed by the Purchaser shall train necessary staff. The personnel will be associated for the training during the installation; testing, commissioning and startup period and the training tenure shall be extended for a minimum period of one month from the date of commissioning and startup. 13. Code of Practice for Painting Service Pipe Lines 13.1 On Noninsulated Pipe Line & Insulated Pipeline without Aluminium Cladding Ground colour to be applied throughout the length of the pipeline Colour bands to be applied near every valve and branch connection as well as in every room near the entry The 1st band should be 4" wide and the second band should be 1" wide On the 1st band a white arrow to be put to indicate the direction of flow The arrows should be put on the bottom of the pipelines so that the same are visible from below in case of horizontal bank of pipes and on sides in case of vertical bank of pipes The valves should be painted with the same colour as the ground colour of the pipeline On Insulated Pipeline with Aluminium Cladding Ground colour to be applied in a length of 500 mm of the pipe all round near every valve and branch connections as well as in every room near the entry. The complete length of the pipeline should not be painted Colour bands should be applied in the middle of every ground colour strip. The 1st colour band should be 4" wide and the second band should be 1" wide On the 1st band a white arrow is to be put to indicate the direction of flow of the fluid The arrows should be put on the bottom of the pipelines, so that the same are visible from below in case of horizontal bank of pipes and on sides in case of vertical bank of pipes The valves should be painted with the same colour as the ground colour The ground colours and the colours of the 1st and 2nd colour bands have been indicated on the enclosed list for the pipelines carrying various types of fluids and gases. The list also indicates the shade nos. of the colours to be used. In case the exact shade is not available, the nearest possible shade in the same colour may be selected. 72

73 Only synthetic enamel paint should be used for the painting and band markings on the pipelines and it should be ensured that the finish should be glossy Where no colour bands have been recommended, only the ground colour is to be applied as per the above procedure. If only one colour band is recommended the same should be 4" wide and applied on the ground colour. In case of 2 nos. colour bands, the 1st band should be 4" wide and second band 1" wide and should be applied on the ground colour To avoid mixing of colours, it is recommended to apply the bands only after the ground colour paint is dry and subsequently to apply the arrow only after the 1 st band paint is dry. 73

74 Table 1 Painting of Equipment & Structural Work SN Item Painting Shade 1 All Storage silos with outer MS Bright yellow Shade No 632 of ISI 2 All M.S. platforms/pipe supports/ pipe bridges and any other structures Dark Admiral grey shade No.632 of ISI 3 Water Pumps, Geared Motor of vats. Original colour 4 HT & LT panels Original colour 5 LT distribution switchboards Dark admiral grey 6 Coal Handling Equipment Black 7 Boiler Chimney & Generator Exhaust Aluminium Heat Resistant Paint 8 Air Compressor Original colour 9 10 Air Handling Unit in Laboratory including Ducting Mixing units, buffer storage, grinding equipment Aluminium Paint Original colour 11 Sieves, coolers, pellet mill, conditioner Original colour 12 Molasses tanks Bitumen Paint 13 Conveyors and elevators Original colour 74

75 Table 2 Colour Code For Pipelines as per BIS SN Services Ground Colour First Band Second Band 1 Cold Water French Blue Boiler Feed Water Parrot Green - 3 Condensate Light Brown Hot Water Light Brown Sea Green Drinking Water French Blue 166 Signal Red 37 6 Treated Water Light Orange Untreated Water White - Compressed Air 9 Sky Blue Vacuum Black 11 Steam Silver Grey 628 Original colour 12 Diesel Light Brown Brilliant Lubricating Oil 410 Light Grey Drainage Black 15 Fire Hydrant PO Red 75

76 Sr No 1 Name H.P.Steam pipe lines Table 3 Testing Pressures for Various Pipelines Test Pressure kg/cm2 Test medium Duration of Test (Hour) 27 Water 1/2 0 Allowable pressure Drop (kg/cm2) 2 L.P.Steam pipe lines 8 Water 1/2 0 3 Water pipe lines1 8 Water 1/2 0 4 Furnace oil/ LSHS 16 Water ½ 0 5 MS pipes for dairy 6 Water 1/2 0 6 Air 12 Air Ammonia pipe lines 7a Suction N b Discharge 24 N c Vacuum Test of Ammonia Lines Absolute Zero Vacuum 48 NIL 8 Molasses pipe lines 16 Water 1/2 0 Engineerincharge shall provide water at available supply point from which the Bidder shall connect temporary piping for testing water. 76

77 Table 4 Makes of Bought Out Items SN Items Makes 1 Steam piping TATA / JINDAL 1a MS C class pipes (Seamless) TATA / JINDAL 1b Cast steel globe valves Forbes Marshall / AUDCO 1c Bronze globe valves Forbes Marshall / AUDCO 1d Nonreturn valves LEADER 1e Pressure reducing valves, safety valves, expansion joints and other steam fittings. FORBES MARSHALL 1f Pressure & temperature gauges FORBES MARSHALL / E&H 2 Furnace oil piping/ air piping TATA / JINDAL 2a 2b MS C class pipes (seamless/ ERW as approved) Cast steel globe/bronze globe/ Gun metal gate valve TATA / JINDAL Forbes Marshall / AUDCO 2c Pressure gauges FORBES MARSHALL / E&H 3 Water piping TATA / JINDAL 3a GI `B' class pipe TATA / JINDAL 3b CI globe valve KSB/ AUDCO 3c Gun metal gate valve KSB/ AUDCO 3d Gun metal globe valves/ strainers/ non return valves KSB/ AUDCO 3e Water pump GRUNDFOS 4 Insulation materials 4a Expanded polystyrene 4b Glass/ mineral wool LLOYDS/ BEARDSHELL / RINAC LLOYDS/ BEARDSHELL / RINAC LLOYDS/ BEARDSHELL / RINAC Please select reputed established makes only. Actual supply shall be based on makes approved by us. 77

78 SECTION V TECHNICAL SPECIFICATION 78

79 SECTION V SUB SECTION 1 INTRODUCTION 79

80 1 INTRODUCTION 1.1 It is proposed to set up one 800 M Tons/day (expandable to 1600 MTPD) capacity Cattle Feed Plant at KAPADVANJ, GUJARAT for producing concentrate feed in pellet form suitable for milk animals. But the raw material handling capacity till it reaches the hammer mill will have to be designed for 1600 tons of production. 1.2 The project shall be executed on single responsibility Basis and this contract shall be covering design, supply, erection, testing & commissioning of the entire 800 TPD Cattle Feed Plant and related Engineering facilities. 1.3 Foundations, civil works, steam generation, air generation, water generation, and electrical power up to the PCC Area shall be provided by the purchaser, however bidder shall have to specify mechanical load for civil work, required pressure and quantity of steam, Electrical power etc. 1.4 The bidder shall be responsible for developing the conceptual layout and flow diagram to ensure plant with optimum investment to meet all the Quality Standard of feed as well as to fulfil the design data and technical specification specified in the Bidding Document within the battery limits. 1.5 As stated earlier this project will have to be executed on a single responsibility basis and the bidder should consider the complete work in its totality. It should be understood that any minor work which may be necessary to achieve the rated capacity of the plant is included in the scope of work, enough not specifically mentioned. 1.6 It is suggested that the bidder visits the site before pricing the bid. 1.7 The plant shall be designed, supplied and executed in accordance with the prevailing and applicable - Indian Standards - Indian Boiler Regulations. - Indian Electricity Rules - Gujarat State Electricity Board (GEB) - Chief Electrical Inspectorate of Gujarat State - Indian Explosives Act - Indian Factory Act - Indian Pollution Act ( Gujarat Pollution Control Board ) - Indian Weights& Measures Act And any other applicable Indian Act. Wherever Indian Standards are not available/applicable the bidder shall follow International Standards. The bidder shall be responsible for arranging approval from various applicable Indian statutory authorities on behalf of the Purchaser. The statutory fees shall be reimbursed by the Purchaser on production of documentary evidence. All Liaoning expenses will be made by Bidder. 80

81 Site conditions: Average Ambient Temperature (Deg C) : 30 Deg C Maximum Ambient Temperature (Deg C) : 44 Deg C Minimum Ambient Temperature (Deg C) : 18 Deg C Relative Humidity (%): 90% Project Site Address: Kaira District Cooperative Milk Producers Union Ltd. Cattle Feed Factory, Kapadivav, PO Chikhload , Ta. Kapadvanj, Dist. Kheda. India, Gujarat 81

82 SECTION V SUB SECTION 2 INSTRUCTIONS TO BIDDERS 82

83 1. INSTRUCTIONS TO BIDDERS 1.1. This Sub Section of the tender defines the way that bidders are required to structure the presentation of the technical section of their bids All technical data required by the tender is to be provided in the format given in this Sub Section. If no format is given for any specific item the bidder may submit bid in their format Any bidder not following the required bid document structure of presenting technical data that is not in the required format is liable to be deemed nonresponsive. BID STRUCTURE OF TECHNICAL SECTION 1.4. The technical section of the bid is to be structured in the same order as Tender Document. Each statement is to be numbered with the same Subsection and paragraph number as in the Tender Document. Every page of the technical section of the bid is to be numbered. Section number is also indicated in every page. The general structure, therefore, is to be as follows: Sub Section 1 Introduction Subject 2 Instruction to Bidders 3 Design Basis 4 Responsibilities 5 Project Management Scope of Supply and Technical Specification 6 (Tender Packages) 7 Battery Limits 8 Deviations from Technical Requirements 9 Optional & Additional Items 10 Drawings and Documentation 11 Criteria for Technical Evaluation of Bid 12 Process Performance and Consumption Gurantee 13 Requirement for Bidder Meeting 83

84 1.5. The bidder is to cover each requirement of the Tender Document by statements, technical data and descriptive material and, in particular to detail the following: SUB-SECTION: 1: INTRODUCTION The bidder is to describe his technical proposal in details, stating the processes and systems, which he has, applies in designing the plant. Also to highlight any special technical innovations that the bidder proposes to include in the plant that will improve the performance, reduce operating cost or improve product quality. The Preamble should commence at the start of the process and work logically through the process. Any such highlights should be crossreferenced with the Bid sub-section and paragraph number to which they apply. SUB-SECTION: 3: BASIS OF DESIGN The bidder is required to follow the Basic of Design in the tender, and indicate clearly where additional processes or alternative processes of equipment are considered to be necessary or desirable to achieve optimum plant operation efficiency, optimum product quality within the standards specified, and optimum plant operation convenience. Under the utilities sections quantified the peak and daily loads of each utility and crossreference this two service load histogram data to be provided with this bid. All calculation used to determine the capacity / of equipment / system to be attached along with histogram. SUB-SECTION: 4: RESPONSIBILITIES Responsibilities of the Bidder The bidder is required to specifically state his acceptance of nonacceptance of each clause in this subsection. Nonacceptance shall be deemed a deviation from the tender and should be mentioned in deviations, Sub Section 8. Responsibilities of Client The bidder is required to state here any additional responsibilities that he consider are to be borne by Client besides those described in the tender. SUB-SECTION: 5: PROJECT MANAGEMENT Time Schedule The bidder is to state in this subsection the proposed programme of implementation from receipt of order to commencement of product trials, to be provided as per Sub Section

85 Management Team The bidder is to detail the makeup of the management team in terms of designation, accordance with this Sub Section of the tender. Also to quantify the support that will be given by foreign collaborators, with designation and man months of attendance in India and at site. This bidder is to ensure that the following Sub Sections are fully detained and quantify the duration and manpower supplied to each. Commissioning Product trials Training SUB-SECTION: 6: SCOPE OF SUPPLY & TECH. SPECIFICATIONS (TENDER PACKAGE) The bidder is required to follow the sequence of the tender Document and to make a statement on each paragraph. Do not leave any item without a clarify statement. SUB-SECTION: 7: BATTERY LIMITS Battery limits for the plant are mentioned in this subsection. SUB-SECTION: 8: DEVIATIONS All technical deviations are to be stated. This is mandatory, and failures tocomply with make the bid liable to be deemed nonresponsive SUB-SECTION: 9: OPTIONAL ITEMS Items that the bidder includes in this Sub Section that are considered by evaluation team to be essential to the satisfactory operation of the plant, shall be included in the commercial evaluation of the bid. SUB-SECTION: 10: DRAWINGS, DATA & DOC. The list of drawings and technical documents required for technical evaluation is included in Sub Section 10. These include a number of data sheet formats to be completed by the bidder. The completion of this format is mandatory, and failure to comply will make the bid liable to be deemed nonresponsive. 85

86 SECTION V SUB SECTION 3 RESPONSIBILITIES 86

87 3. RESPONSIBILITIES 3.1. BIDDER S RESPONSIBILITIES Developing the process design, complete engineering design and ensuring best performance of individual equipment/system, for which he shall avail the assistance of reputed specialists in their respective fields, wherever required Performance and suitability of the total system Performance tests should be carried out by the bidder in the presence of and to the satisfaction of Purchaser/Client's incharge Execution of the project in accordance with the prevailing Indian Standards, Indian Boiler Regulations, Indian Electricity Rules, Indian Explosives Act, Indian Factories ct, Indian Pollution Act and any other Acts. Wherever Indian Standards are not available the bidder shall follow International Standards Arranging for approvals from various statutory authorities on behalf of the Client / Purchaser. The statutory fees shall be reimbursed by the Client/Purchaser on production of receipts Ensuring satisfactory performance and AfterSales service of 'BoughtOut' items included in the scope of supply First charge of oil, lubricants and consumables. "First charge means that these items shall be replenished whenever and wherever required till the successful completion of product trials and commissioning Test kits required for establishing performance parameters Necessary manpower and tools Performance guarantees with regard to the following: Rated performance of individual equipment and complete system(s) Product quality standards conforming to the prevailing Standards Consumption of utilities for individual equipment and for the complete system Visual safety and operational requirement boards, indicators, markers Bidder has to submit utility consumption date in separate sheet PURCHASER S RESPONSIBILITIES Details of civil design, building layout and drainage and sewage details Documents on local site conditions related to climate, access and communications Temporary water and power supply at one point within the plant premises during erection. Water supply will be free of cost. However for temporary power, the bidder shall pay actual charges against supporting bills, if availed. The bidder shall have option of making arrangements for temporary power on its own. 87

88 Lighting and domestic wiring system and internal telephone system including the switch boards for lighting. Engineering personnel to liaison with the bidder, Project Manager and the execution team Permanent water and power supply at the time of precommissioning of the plant Adequate staff including operators, supervisors and engineers for product trials. However commission trials should be taken by bidders only All civil works including buildings, roads, cable trench, underground condensate piping and drainage Provision of and cost of services, raw products, packaging materials & chemicals Timely provision of personnel for training Provide open storage area only and office space during erection and commissioning of project. The bider need to arrange the office structure Suitable Site fabrication yard Lighting distribution system in RMG and FPG and nonplant areas Telephone and fax on chargeable basis Payment as per agreed terms and conditions Approval of drawing within 10 days from date of submission and decision within a week on any issue which will come up Project manager with team throughout the implementation Lightening protection system & protection against rain Readiness of Civil Building, clear civil fronts in all respects along with necessary utilities within agreed schedule to enable commencement of erection activities to meet the overall completion schedule Availability of required quantity of raw material for the designed product to conduct the first run of product trials at the rated plant capacity. 88

89 SECTION V SUB SECTION 4 PROJECT MANAGEMENT 89

90 4. PROJECT MANAGEMENT 4.1. TIME SCHEDULE The project execution shall be time bound as per the mutually agreed time schedule. A competent execution team shall be deputed at site and shall be headed by a Project Engineer who shall be stationed at site and adequately experienced in Project Management of such magnitude and type. The Project Engineer shall avail of assistance from reputed experts in various fields who shall be directly responsible for satisfactory execution The projectstaffing pattern shall be submitted before commencement of work and should include sufficient personnel to meet the execution time schedule MANAGEMENT TEAM Project Manager who shall be adequately experienced in projects of similar magnitude and type shall head a competent executive team. Reputed experts in various fields who shall be responsible for satisfactory execution of the project shall assist the Project Manager. He shall be responsible for overall implementation of the project, from commencement to final take over of the plant A Project Engineer shall be appointed for day to day operation and coordination, and to ensure successful and satisfactory design, procurement, manufacture, inspection, erection, testing and commissioning of all the equipment/facilities/systems within the time bound schedule The Project Manager and Project Engineer shall attend technical and review meeting between various parties involved in the project, and ensure implementation of all decision taken in the meetings The Project Manager shall also be responsible for detailed material accounting at site and management of project materials and equipment stored at site The Purchaser will nominate a Project Manger with whom the Project Manager of the bidder shall communicate/coordinate For smooth execution of the project, a team of Project Manager and Key Personnel shall remain consistent throughout the execution period The Project Manager shall be fully authorized to take onspot decision with regards to: Modification in layout and execution programme to suit local condition. To purchase essential materials from local market to avoid delays. 90

91 4.3. APPROVAL Purchaser shall give approval on technical documentation within 7 working days after submission. Amendments, which are not in the original scope of work or due to changes in concept, shall be taken up by the bidder as per mutually agreed rates to be decided before execution, and shall be binding on the bidder Bidder shall obtain approval for purchase of specific makes of equipment whose makes are not mentioned in his offer. If two or more makes of equipment are mentioned in the form of alternatives in the approved list, the bidder shall select any one of the particular make from the approved list after mutual discussions with the Purchaser INSPECTION For indigenous items, the bidders shall invite Purchaser for inspection and preliminary testing. Inspection may be required at various stages of manufacture/assembly for some items. The Purchaser will arrange to complete such inspection as maybe necessary along with clearance within a reasonable time (7 days) from the date of intimation by the bidder For imported items, however, the bidder shall do the inspection at his cost and submit the necessary test certificate wherever possible SITE WORK AND INSTALLATION Protection of electronic equipment. It is the responsibility of the bidder to ensure that all electronic equipment and control system shall be fully protected against hostile environment, humidity, heat and dust that will be encountered during storage and installation Temporary power supplies. Power supply at site is normally very stable, but the bidder is responsible to ensure that delicate electronic equipment used during construction, such as welding machine, testing devices etc. are protected against damage from mains supply. In the event of a major power failure in the system, it shall be the responsibility of the bidder to hire a diesel generator if this proves to be necessary COMMISSIONING After satisfactory erection and testing, a competent team shall be deputed to commission the plant and to run product trials and to establish performance parameters. 91

92 4.7. PRODUCT TRIAL AND PERFORMANCE GUARANTEE On completion of the Commissioning period, the plant will be operated at full capacity to the satisfaction of the Project Authority for a period of 30 days on the designed product If shut down occurs due to External Force Majeure reasons after 16 hours of operation in any day, this shall be considered as a full day of testing. If at less than 16 hours of operation, the trials shall be continued for an additional full day Performance Guarantee: Performance and services consumption Guarantees and the relevant penalties for not meeting the rated capacities and efficiencies are covered in the tender TRAINING Training pertaining to the use of the various process equipment in the plant shall form an important component of Project Management Training shall be undertaken by the bidder for a period of six weeks during which the contractor should guide and train the staff of the client in operating the plant equipment to achieve the optimum plant efficiency and product quality Training should commence during the commissioning period and include: Familiarization with major equipment like Grinding, Molassing, Pelleting, bagging etc including the operation of the computer based auto batch weigher Procedure for attaining the rated output and optimum product quality Familiarization with the basic principles of Electronic/Electrical control systems, if any including fault finding Familiarization with startup procedures, regular maintenance and operational procedures including dismantling of machine parts, replacement of spares/ components, preventive maintenance etc Condition monitoring of equipments Training shall be given to all the personnel required to operate the plant, and their immediate Supervisors /Engineers The training schedule should be proposed by the bidder together with the content of training programmes, their duration etc STAND-BY AFTER COMMISSIONING Once the commissioning and warranty runs are over, the bidder shall provide to the plant standby technical supervisory support as follows For one month after warranty runs in which further training of the Purchaser/Client's operating staff if required shall be done and equipment/system still needing finer adjustment/changes shall be carried out. 92

93 For a week each after 4 months, 8 months and 1 year from warranty runs, to have discussions with plant staff, to review the correctness of operations & maintenance procedures These visits of the Bidder other than those covered under guarantee clause, which shall be undertaken whenever required separately SERVICE COVER In order to ensure that the efficiency of the plant is maintained at an optimum level, a proposal to offer a service coverage for a period of two years from the date of plant acceptance shall be given by the bidder for the maintenance of the Auto Batch weigher and Electronic Baggingoff Weigher. The objectives of this coverage shall be: To arrange for regular service visits by the bidder of these equipments to inspect, service and carry out repairs if necessary and whenever there is a breakdown/failure of the system. The frequency and duration of the visits may be clearly specified. 93

94 SECTION V SUB SECTION 5 TECHNICAL SPECIFICATIONS 94

95 DESIGN, MANUFACTURE, SUPPLY, ERECTION, TESTING AND COMM. OF RAW MATERIAL (GRAINS) BULK STORAGE GI SILOS. CAP 500 MT X 8 NOS. 95

96 1.0 INTRODUCTION This section of the documents outlines the technical specifications for the Design, Manufacture, Supply, Erection, Testing and commissioning of raw material (grains) bulk storage silo system required for the 800 MTPD Cattle Feed Plant (expandable up to 1600 MTPD). These technical specifications are for the guidance of the bidders only and not intended to bring out all the details of design and fabrication of the equipment or equipment components. The successful Bidder shall be fully responsible to undertake all the works involved in the design, engineering, manufacture, supplying equipment at site including the erection, testing and commissioning of all the equipment of bulk storage silo system for grains. Bidders are to note that this Raw Material Bulk Storage Silo System being offered in this quote shall be part of the overall project and together with the main feed plant equipment. They shall be fully responsible in the overall timely implementation of the project on Turnkey basis, within the battery limits defined in this slice. The work being carried out shall confirm to high standards of engineering design & workmanship. The equipment offered shall be capable of performing in continuous commercial operation to meet agreed performance standards and acceptable to the purchaser/client. No exclusions of any nature are acceptable, other than those specifically detailed in this quote document. The bidders are required to provide all technical data/information wherever asked for. Any quote not following the quote format structure or provided with insufficient technical data / information / documents is liable to be considered as non-responsive. The Purchaser/Client will interpret the meaning of various equipment specification and drawings submitted by the bidder and shall have the right to reject any material/equipment, which in their opinion is not in full accordance to quote specifications. 2.0 SCOPE OF WORK The scope of the work for this is as follows: 2.1 Design, detailed engineering, manufacturing, inspection at manufacturer s works, packing, forwarding, unloading, erection, testing, commissioning, achieving rated equipment and plant capacities and handing over to purchaser s satisfaction of the following as given section wise in the list below and not limited to : A) Design and supply of: Raw material bulk storage silo system for grains located in project site complete with silos. The total quantity of silo is 8 nos. and each silo capacity is 500 ton. B) Erection, testing and commissioning of: Raw material bulk storage silo system equipment. The scope includes positioning, placement of equipment on foundation, bolting, grouting etc. complete as per requirement. 96

97 Commissioning of the Raw material bulk storage silo system including integrating with the main plant SCADA software and related communication software. 2.2 Bidder s scope of supply also includes supply of wear and spare parts of their equipment for two years trouble free operation. All consumables like Gear oils, lubricants, packing for flanged joints etc. and commissioning spares, required if any, for installation, testing & commissioning till taking over the plant by the purchaser shall be provided by bidder and the same after taking over the plant shall be provided by purchaser / project authority. 2.3 Test runs and commissioning trials including imparting training for operation and maintenance. Important note for Bidder: This is a turnkey job which will have to be executed on a single responsibility basis. Bidder should consider the complete work in its totality. All minor works which may be necessary to achieve the rated capacity of the individual equipment being supplied and in turn to achieve the rated plant capacity, is included in the scope of work, though not specifically mentioned. The unit rates of items / equipment to be quoted by bidder shall include its drive of suitable rating and shall be on FOR site basis inclusive of packing & forwarding, insurance, freight, taxes, duties, octroi etc. The equipment and accessories shall be covered under the warranty/guarantee clauses specified in quote document. 3.0 STATUTORY REQUIREMENTS The Mechanical and Electrical design, performance and function of the main equipment/parts and their accessories, including control and instrumentation panels, shall comply with the latest relevant Indian standards. Safety and other statutory regulations/ requirements shall comply with that being followed in the country. 4.0 BATTERY LIMITS Equipment All raw material bulk storage silo system equipment and machinery to be supplied & erected by the bidder but not limited to the list in SOQ is in the scope of works. All frames, foundation bolts for equipments under this pack are also to be provided by the bidder and their grouting shall be 97

98 arranged by the purchaser under supervision of the bidder. Bidder shall provide equipment details including cut out drawing as per requirement. Silo System Structure: RCC foundation for silos and all other civil works including RCC columns, trenches for hopper / flat bottom silos shall be provided by the Purchaser. 5.0 EXCLUSIONS Civil Works: All civil foundations for flat bottom silos, pits and supporting steel structure of conveyors / elevators of raw material storage silo system shall be provided by purchaser. RAW MATERIALS AND OTHER RESOURCES: All raw materials for production of feed, operating staff for commercial production shall be provided by purchaser/project authority. All consumables like gear oils, lubricants, packing for flanged joints etc. and commissioning spares required if any, for installation, testing & commissioning till taking over the plant by the purchaser shall be provided by bidder and the same after taking over the plant shall be provided by purchaser / project authority. 6.0 TECHNICAL SPECIFICATIONS OF SILO SYSTEM, ACCESSORIES. The silos shall be of galvanized iron corrugated sheet of thickness as per design requirement. The silo height and diameter are to be designed according to ANSI-ASAE based on the raw material grains (like wheat, maize, barley, bajra, jowar etc.). The average bulk density of these raw materials may be considered as 750 kg/cum for grains. Minimum galvanization thickness to be 450 gsm. The silos shall be designed for wind load (highest as per historical records) and for seismic stability as per seismic zone. Flat bottom Silos: Shall be provided with galvanized corrugated steel sheets, outside galvanized stiffeners, bolts, adequate no. of galvanized supporting legs, roof, roof ladder, hand rail for roof ladder, ladders from ground to roof eave with safety cage and one rest platform under cylinder door, inside ladder from access door to ground floor without safety cage. Suitable eaves close between silo cylinders a roof to prevent water entry to be provided. Each silo has to have membrane type high, middle and low level switch, inspection opening on roof and cylinder door. The detailed silo specification for sheets, roof and other accessories shall be as per details given below. 98

99 ROOF: The roof shall be of minimum 0.8 mm thickness and of 30 deg slope for providing optimum strength and providing low peak heights for overhead equipment like conveyors and related equipment. Roof ribs are to be full lapped- double or triple-rib formed for added strength. One pieced roof panel preferred depending on diameter. Steel quality shall conform to S 280 GD according to norm UNE-EN (2004) and having desired tensile strength and yield point Galvanization shall be 450 gm/sq. m according to norm UNE-EN (2004). In case of large diameter silos or wherever required structural roof with beams and purling hot dipped galvanized and designed to support overhead equipment like catwalks and conveyors to be provided. If required provide a vented roof panel, which is pre-punched in order to allow roof vents to be placed in a proper way. Steel quality is S 280 GD according the norm UNE-EN (2004) Overlap detail in the wave of silo roof section to give high strength & stiffness to the roof as well as make it water tight. Eave detail to close gap between roof and cylinder to secure the silo from water penetration. CORRUGATED STEEL BODY SHEET: The vertical body sheets shall be corrugated galvanized sheet of thickness varying from 0.8 mm to 4 mm as per design calculations. The vertical joints shall utilize automatic punching system to assure perfect connection between them. Quality controlled steel coils shall be used for the same of tensile strength not less than 420N/mm2. Galvanization shall be 450gm/sq.m according to norm UNE-EN (2004). Corrugation pitch of 76mm x 14 mm deep preferred with useful length of sheet 1140 mm x 2400 mm. Steel quality shall conform to S 350 GD according to norm UNE-EN (2004). STIFFENERS: Outside positioned stiffeners to carry the vertical load of the silo to the foundation, manufactured from high tensile steel (420 N/mm2) of thickness varying from 1.5 mm to 4mm as per design requirements and galvanization 450gm/sqmt according to norm UNE-EN (2004). Design shall ensure strong joints and best stability. Stiffeners may be C channels /omega shaped of minimum 75 mm and lengths about 1140mm or 2280 mm. Steel quality shall conform to S 350 GD according to norm UNE-EN (2004). Stiffeners same profile section from bottom of silo to eave, as well as overlapping detail in case of double, triple stiffeners, to secure better distribution of loads. SEALANT: These shall be made from butyl rubber compound supplied in strips of 4.5 mm and shall be used to fill vertical joints of body sheets and 99

100 hopper sheet joints. The sealant of bolting holes shall be made with special sealing washer or similar unbeatable weather seal. BOLTING: Each bolt shall have a special sealing washer to act as unbeatable weather seal and shall conform to DIN 933 with steel quality 8.8 or Nuts shall conform to DIN 934 with steel quality 5.6. The bolting shall be electrolytic galvanized and passivated (bi-chromate) having resistance to salt water spray test according to DIN minimum 250 hours without corrosion. CAT WALKS: These shall be formed in two different sections each of 700 mm width including double hand rail (pipe of 32 NB GI A class) of 1 M high. One section shall be used as walkway and the other for installing the conveyor. The structure of the catwalk to be made with profiled beams made from galvanized steel of min. 3 mm thickness. Flooring shall be special grating and not chequered plate. Steel quality shall conform to S 280 GD according to norm UNE-EN (2004) and galvanization 275gm/sqmt according to norm UNE-EN (2004). AERATION SYSTEM: These are for flat bottom silos. For flat bottom silos the aeration system shall be Y type made of special galvanized corrugated and perforated (hole 1.5 mm dia) steel sheets with large area covering the entire flat bottom silo. Centrifugal fan of adequate capacity and required Water Column head shall be fitted to bottom of Y. Special type aeration roof vents are also to be provided. The air blower shall be activated / run automatically when the temperature of raw materials reaches a set temperature above ambient. Dust inside the silos is to be controlled to prevent any dust explosion. SWEEP AUGERS: These shall be used for the grain silos with adequate capacity of MORILLION SPIR0GYRE type or equivalent and shall include one central steel support, electrically operated with suitable KW rating motor, screw flight of suitable size including all supporting structure and planetary advancing system. There should be only one motor per auger and shall not be inside the silo. It shall be outside the silo for easy maintenance and accessible from trench or open area. Industrial sweep auger for heavy duty industrial utilization of every day and to reduce the damaging impact on grain while unloading the silo. Capacity minimum tons/hour One single motor to be located outside and under the floor of the silo to enable it accessible from conveyor trench for maintenance Auger screw to be supported along its length by a square beam to avoid bend under the load of the product even when the silo is full. Water-proof bearings to avoid any damage with the dust. 100

101 Auger screw to be protected by a flat cover. ATEX Conform. TEMPERATURE CONTROL SYSTEM: These shall consist of a temperature control centre made up of a Pentium computer, color screen with provision for indicating the temperature of each probe, activation and deactivation of the probes, activation and deactivation manually the sensors which are in the raw material depending on height of silo fill, graphical representation of temperature charts, RS 232 interface between PC and temp control system and to main plant SCADA system. The temperature control system shall activate the aeration system when set temperature is reached. Supply shall be at 220V with intrinsic safety barrier to feed circuits placed in explosion risk zones (Zone 20 ATEX). Sufficient number of probes with 3 or 4 sensors per probes shall be provided for each silo. The system shall include multiplexation box for the probes, connecting wires/ cables and supports on the silo roof for the cables. Probes should be assembled from outside the silo for easy maintenance. Temperature control system will be automatic and linked to aeration system fans operation Complete automatic management of the temperature developments and aeration fans operation (with sensor of external relative humidity and outside temperature) from control room, historical data in numerical as well as graphical form. Probes to be mounted from outside roof and dismountable also when silo is full. Special support system in silo of probes to reduce load on roof. To minimize the traction effect of the grain on the probe sheath, it should be made up of an inside tube of polypropylene, wrapped/reinforced in steel wires and outside covered with a cape of extruded polyethylene. The sensors to be of Thermistor NTC type ATEX Conform. Important Notes: The foundation location of silos, layout of elevators, trenches, pits including load details on the foundations shall have to be provided to the purchaser to design the foundation. Foundation bolts shall be in the scope of the bidder. The steel supports shall be designed for box type sections or other economical sections, so as to reduce the overall steel requirement, keeping the minimum safety standards as indicated. The silos and the supporting framework shall be designed for wind load (highest as per historical records) and for seismic stability as per seismic zone. Stability certificate for the silos and structure shall be submitted by 101

102 the successful bidder. Design calculations for the silos to be shared with purchaser without any extra cost. Staircase shall be suitably located so that quick approach to working platforms and shall be 1.2 m wide with 32 mm pipe (GI A class) hand railing (double braced). Platforms, railing shall be extended to all working equipment to facilitate inspection, operation and maintenance. Elevation (all sides) drawings for the silo system showing heights of all silos including elevators and conveyors shall be furnished to the purchaser including the conveyor entry direct to plant intake section and pre-weighing sections. 6.6 TECHNICAL SPECIFICATIONS FOR ERECTION, TESTING AND COMMISSIONING Erection, testing and commissioning is inclusive but not limited to the following: - Positioning of all the silo system equipment in the approved locations, including grouting, anchoring etc as per requirement. - Erection/Welding/Grouting into place necessary structural platforms, walkways, hand rails etc., as per requirement. - Name of all important machines to be written on them after final installation but before commissioning by a painter. Necessary aero marks and other identification by painting to be provided on piping as required. - After installation of all equipment and completion of product piping and connection of all utilities including electrical, each major equipment shall be tested at no load after checking all alignments. On completion of satisfactory no load test, section-wise testing at no load shall be carried out. Any defect noticed during no load shall be attended to. After testing of all sections on no load, the plant as a whole shall be tested with raw material for trial run and ultimately commissioning the complete plant to the satisfaction of purchaser/project authority. 6.7 ESTABLISHING PERFORMANCE GUARANTEES On completion of supply, erection, testing and commissioning of the plant / equipment, the same has to be operated at full capacity continuously in 3 shifts of 8 hours basis for four weeks to the satisfaction of the Purchaser/Project Authority, to establish performance guarantees provided by the bidder. However, if purchaser/client is unable to provide 102

103 operating staff for three shifts, number of days can be increased with mutual discussions. 6.8 TRAINING Training in the operation and maintenance of the various equipment of the plant shall form an important component of Project Management. Training shall be undertaken by the bidder for a period of one month during which the contractor should guide and train the staff of the client in operation and maintenance of the plant equipment to achieve the optimum plant efficiency and product quality. Training should commence during the testing/ commissioning period and shall include: 1. Familiarization with all major equipment including the operation of the computer/plc based auto systems. 2. Procedure for attaining the rated output and optimum product quality. 3. Familiarization with the basic principle of Electronic/Electrical control systems, including fault finding. 4. Familiarization with start-up procedures, regular maintenance and operational procedures including dismantling of machine parts, replacement of spares/components, preventive maintenance etc. 5. Condition monitoring of equipments. 6. Generating production and maintenance log sheets of important equipment and systems. Training shall be given to all the personnel required to operate the plant equipment and their immediate Supervisors/ Engineers. The training schedule should be proposed by the bidder together with the content of training programmes, their duration etc. 7.0 TECHNICAL DETAILS AND DRAWINGS TO BE FURNISHED ALONGWITH THE QUOTE Following drawings are enclosed along with the quote: The bidder to provide drawing/data and technical details with their quote as specified. After commissioning and during handing over of the plant by Bidder to Purchaser/Project Authority, the contractor to provide the following: As executed final drawings and technical data of the complete plant for operation, maintenance and permanent record in soft (in AutoCAD) and 3 sets of hard copies. 103

104 The final software and source codes of the systems. A consolidated operation and maintenance manual -3 sets of the complete plant along with operation and maintenance of each key equipment as provided by manufacturer. DRAWINGS Equipment drawing: The general arrangement (GA) drawing of silo and each associated indicating dimensions, tolerances etc., as proposed by the bidder. Layout drawing The machinery and equipment layout drawing of the silo system showing layout of the silos and other equipment. Catalogues The relevant catalogues, technical data sheets, drawings, photographs etc., of each equipment/accessory being offered to be submitted by bidder A) TECHNICAL DATA (to be furnish by bidder) FOR SILOS: SL NO DESCRIPTION UOM I GRAIN STORAGE SILO 1 Model 2 Diameter Mtr 3 Height to Eave Mtr 4 Height to Peak Mtr 5 Volume cum 6 Compacted Capacity with 6% compaction MT 7 Uncompacted Capacity MT 8 Product 9 Bulk Density Kg / m3 10 No of Wall Rings Nos 11 No of sheets /Ring Nos 12 Wall Ring thickness from bottom to Gauge / top mm 13 Wall ring stiffener thickness Gauge / mm 14 Wall Sheet Corrugation mm 15 Columns per wall Sheet Nos 16 Total Stiffener columns Nos 17 Wind Ring Nos 104

105 18 Roof sloop degree 19 Roof Peak Load Capacity Kgs 20 Common bin design wind Velocity Kph 21 Snow Load Psf 22 Seismic Zone IS 23 Galvanizing g/m 2 24 Roof Manhole 25 Side Wall Door on Ring 26 Aeration System 27 Comm. bin roof cap 28 Punched roof sheets, roof vent 29 Total Weight in Kgs 30 Foundation Bolts II BIN ACCESSORIES 1 Internal Ladder 2 External Ladder 3 Base Sealer 4 Roof Hand Rail III Temperature Monitoring System 1 Temperature Cable 2 No of probes 3 No of sensors per probe 4 Plug Box & lead wires 5 Portable Reading instrument 6 Temperature Cable support IV AERATION SYSTEM 1 Number of Fan per Bin Nos 2 Air Flow m 3 / hr 3 Static Pressure mbar 4 Fan Type 5 Power of Fan Motor HP 6 Make of Motor 7 Speed Rpm 8 Floor Type 9 Approx area of FB silo covered by the aeration system 10 Centrifugal fan HP 11 Centrifugal fan capacity in cum/hr and head WC 12 No of special aeration roof vents V BIN SWEEP AUGER 1 Model 105

106 2 Silo Diameter M 3 Capacity Tons/Hr Flight Specifications 4 Diameter of screw mm 5 Tube Diameter mm 6 Length of the Sweep Auger M 7 Electric Motor 1 Main drive HP Electric Motor 2 Traction wheel HP 8 Make of Motor 9 Sheave Pulley mm VI COMMERCIALS 1 500x8 MT Flat Bottom Silo for grains 1 2 SILO ACCESSORIES a Ring internal ladder 1 b Ring External ladder 1 c Base Sealer 1 d Roof ladder Hand rail 1 e High level Indicator 1 f Aeration system 1 g Sweep Auger 1 h Temperature Monitoring System 1 i Floor accessories Inside Silos Like GI perforated grills, etc for trench 1 Automation and PLC Panel Software to communicate all temperature data s with centralized SCADA PLC/PC and required cable length for connection in between Multiplexer Card/Box & Interface card for the Silos. Details of the automation scheme, network diagram, type & model of PLC offered. Technical detail of computer system with a write-up indicating equipment details, process, controls, type of reports which can be printed. Detail of input/output ports and other technical details of the PLC panel & hard ware of computer systems. 8.0 TECHNICAL DETAILS AND DRAWINGS TO BE SUBMITTED AFTER AWARD OF CONTRACT The following shall be provided after award of contract: 106

107 1. The final equipment GA drawing (in both hard -3 sets and soft form) being manufactured as per design and product specifications of purchaser 2. Final services /utilities schematic with sizes of pipe lines, valves, insulation thickness, controls, showing all instruments and accessories 3. Final foundation foot print 4. Final electrical load details in HP/KW 5. Final control schematic of the control panel/automation 9.0 SCHEDULE OF QUANTITIES A SUPPLY RAW MATERIAL STORAGE SILO SYSTEM EQUIPMENT FOR GRAINS. Sr. No. Description Cap Qty FLAT BOTTOM SILO (WITH IMPORTED SHEETS) FLAT BOTTOM SILO ACCESSORY(IMPORTED) ELECTRICALLY OPERATED SWEEP AGUGER (IMPORTED) FOR FLAT BOTTOM SILOS. 500 MT 8 NOS SETS 40 TPH 8 SETS B INSTALLATION, TESTING AND COMMISSIONING 107

108 RAW MATERIAL STORAGE SILO SYSTEM EQUIPMENT FOR GRAINS. Sr. No. Description Cap Qty FLAT BOTTOM SILO (WITH IMPORTED SHEETS) FLAT BOTTOM SILO ACCESSORY(IMPORTED) ELECTRICALLY OPERATED SWEEP AGUGER (IMPORTED) FOR FLAT BOTTOM SILOS. 500 MT 8 NOS SETS 40 TPH 8 SETS 108

109 DESIGN, MANUFACTURE, SUPPLY, ERECTION AND COMMISSIONING OF 4 TPH BOILER PLANT. 109

110 1.0 INTRODUCTION This section of the documents outlines the technical specifications for the Design, Manufacture, Supply, Erection, Testing and Commissioning of the boiler system required for the 800 MTPD Cattle Feed Plant (expandable up to 1600 MTPD). These technical specifications are for the guidance of the bidders only and not intended to bring out all the details of design and fabrication of the equipment or equipment components. The successful bidder shall be fully responsible to undertake all the work involved in the design, engineering, manufacture including the erection, testing and commissioning of the boiler equipment s & associated fuel & service requirements. Bidders are to note that the boiler plant being offered, shall be part of the overall project and together with the main feed plant and other equipment they shall be fully responsible in the overall timely implementation of the project on Turnkey basis, within the battery limits defined in this slice. The work being carried out shall confirm to high standards of engineering design & workmanship. The equipment offered shall be capable of performing in continuous commercial operation to meet agreed performance standards and acceptable to the purchaser/client. No exclusions of any nature are acceptable, other than those specifically detailed in this document. The bidders are required to provide all technical data/information wherever asked for. The Purchaser/Client will interpret the meaning of various equipment specification and drawings submitted by the bidder and shall have the right to reject any material/equipment, which in their opinion is not in full accordance to the specifications. The entire plant should be dust free and suitable aspiration units will be provided at all required points. 2.0 SCOPE OF WORK The scope of the work is as follows: 2.1 Design, detailed engineering, manufacturing, inspection at manufacturer s works, packing, forwarding, unloading, erection, testing, commissioning, achieving rated equipment and plant capacities and handing over to purchaser s satisfaction of the following as given section wise in the list below and not limited to : Part A: Design & Supply of 4 TPH boiler, chimney, ducting, HP steam piping & PRS. High pressure steam generated in the boiler shall be reduced to LP steam in PRS, one located within the Boiler House, other located in the Main plant. Water Piping: Insulated feed water piping drawn out from the outlet ports of the Feed water tank to Boiler, break water tank & its water circulated system to recover heat from the Main blow-down line s operation. 110

111 Fuel Handling System: Fuel dumped into dumping hoppers manually & mechanically conveyed, pulverized (if necessary) before being stored in bunkers for boiler use. The fuel handling & feeding to the Boiler shall be automatic & based on Boiler steam pressure. All electrical & automation works related to the steam generation, fuel handling, pollution control equipment with necessary hardware & software. All structural works like platforms with railing, trench covers, walkways, ladders, for operation & maintenance of the items. The bidder shall supply one no. 4 TPH Multi-fuel (solid) fired Fluidized Bed Combustion (FBC) type Boiler with chimney complete automated fuel storage & handling system, Flue gas ducting, HP steam header, Pressure Reducing Station (PRS), Ash handling system etc. It is to be noted that one boiler shall cater to the steam demand of the entire plant. Connecting the flue gas ducting on chimney and interconnecting the HP steam outlets to a steam header, PRS, water supply to the Boiler etc. is included in the scope of the bidder. Part B: Labour job of installation, testing & commissioning of 4 TPH boiler plant & Utility handling for Cattle Feed Plant. The list given below of equipment is as per preliminary design of the plant by Purchaser. The detail list of equipment & their individual capacity may vary as per design and detailed engineering by the bidder to achieve the minimum steam generation of suitable capacity or as specified in design data & battery limits. If required, the bidder can break-up an item into further detail but wherever purchaser has indicated quantity as one lot, no further detail is required. Bidders may add additional items section wise if these are required as per their detail engineering. These additional / optional / alternatives items offered by the bidder will be considered during technical evaluation of the specifications and would be subjected to acceptance by the purchaser only through addendum of the document. The section wise list of equipment is as follows: BOILER PLANT EQUIPMENT & RELATED WORKS The bidder shall execute the following major works as per the scope; 1. 4 TPH Boiler complete with accessories and mountings, 2. Common chimney (suitable for two boilers operation one planned and one future), independent ducting etc. complete. 3. Common Automatic Fuel handling up to boiler house, independent storage & handling equipment s. 4. Independent Pollution Control & waste heat recovery equipment s. 111

112 5. Utility works including Break water tank, pipes, valves & fittings for water, Compressed air generation & distribution for boiler operation, IMCC & associated electrical works for Boiler & related items in the scope of supply. 6. HP, LP steam, drain etc. piping with insulation, valves, fittings including two PRS complete (10.5 to 3.5 kg/sq.cm (g)), one suitable for 3.0 TPH steam throughput & other 700 kgs/hr. 7. Independent Auto Blow-down with heat recovery systems. 8. Statutory approvals for Boiler & HP steam piping, electrical, weights & measures, Pollution Control equipment s. 9. Complete ash handling system with required statutory approvals. 2.2 Bidder s scope of supply also includes supply of spare parts of their equipment for two year trouble free operation. All consumables like Gear oils, lubricants, packing for flanged joints etc. and commissioning spares, required if any, for installation, testing & commissioning till taking over the plant by the purchaser shall be provided by bidder and the same after taking over the plant shall be provided by purchaser / project authority 2.3 Test runs and commissioning trials including imparting training for operation and maintenance Important note for Bidder The technical specification of equipment is generally based on a particular design but bidders can supply equipment as per their design to meet the functional requirement of equipment specified in these technical specifications. The list of equipment accessories & their capacities may vary as per design and detailed engineering by the bidder to achieve the minimum equipment rated capacity as specified in design data & battery limits. If required, the bidder can break-up an item (or SET) into further detail. This is a turnkey job which will have to be executed on a single responsibility basis. Bidder should consider the complete work in its totality. All minor works which may be necessary to achieve the rated capacity of the equipment being supplied and in turn to achieve the rated plant capacity, is included in the scope of work. The unit rates of items / equipment to be quoted by bidder shall include its drive of suitable rating and shall be on FOR site basis inclusive of packing & forwarding, insurance, freight, taxes, duties, octroi etc. The equipment and accessories shall be covered under the warranty/guarantee clauses specified in document. 112

113 3.0 STATUTORY REQUIREMENTS The Mechanical and Electrical design, performance and function of the main equipment / parts and their accessories, including control and instrumentation panels, shall comply with the latest relevant Indian standards. Safety and other statutory regulations / requirements shall comply with that being followed in the country. The Electrical works shall comply with the latest Indian Electricity Rules and other statutory regulations / requirements of power supply authorities and Chief Electrical Inspectorate. The steam generation plant including HP piping, PRS shall be got approved by the Boiler inspectorate both during stage wise manufacture till despatch and finally after installation and commissioning. Necessary approval for the steam generation and distribution installation and the electrical installation done by the bidder under this shall be obtained by him from the above statutory authorities and any modifications or changes if suggested by the authorities, the same shall be carried out by the bidder without any additional cost. Approval certificate shall have to be handed over to the purchaser. 4.0 BATTERY LIMITS S. No Description Purchaser s scope Bidder s scope 1 Water Up to UG sump Starts from softening water plant outlet to boiler. This includes all required piping, instruments and pumps, electrical panels. 2 Flue Gas _ From the Boiler outlets, across pollution control equipment, ID fans up to the outlet of common self-supported chimney. 3 Steam From the outlet of the PRS to consumption points 4 Blow-down Blow down pit shall be provided. 5 Drains Blow down pit shall be provided. From the outlet of boilers through HP steam piping up to PRS. The steam pipe from safety valves discharge shall be taken outside the boiler house. All necessary pipe fittings & accessories, valves, expansion bends, strainers, PRV controls, trap assembly, steam Flow meter, pressure gauge etc., required is included in the scope of supply. The PRS shall be installed near the consumption points. From Boiler through main blow-down valve, auto-blow-down system up to blow-down pit located outside the boiler house. All other drains from Mobrey water level controllers, level gauges, sample cock, 113

114 6 Fuel Fuel shall be unloaded at a place for day s storage. 7 Electricals Power shall be provided at PCC at the substation. steam trap etc. shall be taken in the trench, outside the boiler house, to blow down pit. From the dump pit up to both Boiler, across automatic handling equipments with conveyors-elevators-hoppers, bunkers etc. From the Outlet of PCC bidder scope will start. MCC, Boiler control panel, required cables and cable trays etc and up to all individual loads for the Boiler and accessories. Cabling for auto blow-down system and all instruments, flow meter, PRVs, probes, sensors etc are covered in the work scope. The junction box and the electrical connection from the box up to the aviation light fittings. The scope includes obtaining approval for electrical installation executed by the bidder from the Electrical Inspectorate. 8 Earthing Earthing grid from the Boiler House IMCC to individual panels, instrument earth, electrical loads in the Boiler house etc. Earthing of the lightening arrestor on the chimney is included in the scope. Earth pit is also included 9 Foundation related & structural works 10 Compresse d Air piping All civil works, indoor trenches. 11 Condensate Condensate from the indirect heat exchangers shall be collected & pumped back to the Feed Necessary steel supports/cable trays etc. for piping/ducting and cabling etc. is in bidder s scope. Supports for piping, ducting, and platform for Feed water Tank, PRS is included in the scope. All necessary foundation bolts/nuts, templates for chimney & machinery etc. are included. All the supports shall be either from rectangular or square hollow sections. All the supports shall be then duly pained in approved shade. Plant layout drawing will be provided by bidder. Suitable size air compressor and required piping with electrical and instrumentation work will be in bidder scope. Condensate from the PRS installed near the Boiler House and plant PRS, shall be taken to the Feed water tank and flash steam recovery from all steam traps. water tank deareator. 12 Flash steam _ Flash steam from the Blow down heat recovery unit shall be taken back to Feed 114

115 13 Raw materials & Consumabl es 14 Ash Collection water tank. All raw materials for All consumables like Gear oils, lubricants, Boiler, operating packing for flanged joints etc. and staff for commercial commissioning spares required if any, for production shall be installation, testing & commissioning till provided by taking over the plant by the purchaser purchaser/ project shall be provided by bidder and the same authority. after taking over the plant shall be provided by purchaser / project authority Generated ash should be transferred to the ash storage area by automatic system. For all machines /equipments in the scope of supply & provision to transmit data to Centralized PLC in Main Control room. Required hardware for communication with central SCADA system should be in bidder scope. 15 Automation Integration of Central PLC with Boiler House 4.1 Standby Services after commissioning: Once the commissioning & warranty runs are completed & plant taken over by purchaser, the bidder shall provide for standby service cover for a period of 1 (one) year. Four visits shall be undertaken by the bidder, once every three month for minimum two days, to assist, fine tune the operations & suggest ways for improvement. Bidder shall suggest solutions to problems occurring during this period. 5.0 EXCLUSIONS Civil Works MCC/Control room shall be provided by the Purchaser. All civil foundations for steam boilers, ash handling, dust extraction, chimney etc., shall be provided by purchaser based on the GA drawing and load/foundation details provided by bidder. Other exclusions: a) Boiler house structure, OH Tank, masonry trenches and blow down pit. b) LP piping after PRS. c) Power & water. d) Fuel & other chemicals. e) Internal lighting electrification, telephone for Boiler House. 115

116 6.0 TECHNICAL SPECIFICATIONS OF BOILER PLANT, FUEL HANDLING SYSTEM & ASSOCIATED UTILITY WORKS: 6.1 FUNCTIONAL REQUIREMENTS General Description: Boiler is required to generate dry saturated steam for feed conditioning & Molasses pre-heating applications in Cattle Feed plant. The boiler shall be with adequate steam space to cater to varying steam load, depending on process requirements. 6.2 DESIGN REQUIREMENTS Boiler: Boiler should be FBC type design, automatically controlled including fuel handling, firing (except ash removal), tested and proven under rigorous conditions and subject to the strictest quality control procedures. Boiler construction shall be in accordance with the latest revision of Indian Boiler Regulations 1950, Act 1923 applicable and in conformity with AOTC requirements for unattended boilers. All materials used shall be approved and tested as per relevant existing codes. All the welded joints shall be as per code requirement. Sr. Parameter Requirement Remarks No. 1 Capacity 4000 kg/hr From and at 100 C of water 2 Net Peak steam demand 3000 kg/hr at 3.5 kg/sq.cm Assuming blow down and condensate recovery 3 Working pressure 10.5 kg/sq.cm 4 Quantity 01 No. 5 Dryness of steam 0.98 minimum 6 Boiler design FBC type suitable for coal, agro based pellets, rice husk, and ground nut shell. 7 Accessories All standard accessories FW pumps, FD, PA, ID fans, O2 trimer with close loop operation to control air fuel ratio. APH pollution control equipment etc Fuel: The boiler should be designed to use solid Fuel (Coal or Agro-based pellets, rice husk, ground nut shell). Ultimate analysis for coal is as under: 116

117 No Parameter Unit Importedcoal IndianCoal Kutch Lignite 1 Carbon % wt Hydrogen % wt Nitrogen % wt Sulphur % wt Oxygen % wt Moisture % wt Mineral Matter (Ash) % wt GCV kcal/kg For specification purpose following GCV is to be considered, Coal Kcal/kg. Agro- based pellets Between Kcal/kg Thermal efficiency: Thermal efficiency with all agro based fuel at 50 % steam load, at deg C ambient temperature & 60 % Relative Humidity, should be maximum but not less than 80% with air pre-heater as per BS: 845 Part 1 indirect abbreviated heat loss method on GCV basis. However, the bidder can offer highest possible efficiency (above 80% with a different technology, considering the fuel as coal or agro based pellets). 6.3 SCOPE OF SUPPLY Boiler: The complete boiler having steam generating arrangement, casing, pumps, controls, instruments, all necessary accessories should be supplied. The Boiler shall be latest design with water-in-tube or water-in-shell. The boiler shall be reliable, rugged & versatile for operation. The boiler shall be complete with all mountings, accessories, controls etc, MOC SA 515/516 Gr 70 for shell, tube plates, pads, bosses etc. The boiler should be of modern & compact design with risers & downcomer headers, with blow-down. Furnace shall comprise of adequate furnace volume & heat transfer surface comprising tubes & connecting strips forming a membrane panel 117

118 to maximize heat transfer area. Equivalent design like swaged water wall design is also acceptable. One pass or two pass smoke tube design acceptable, with up to 50% turn down, without reduction in overall thermal efficiency. The boiler mountings, fittings, accessories shall be as per specified in item The ports for loading of fuel, removal of ash, primary air inlet, and secondary air shall be optimally designed for maximum efficiency & minimum losses. The boiler shall be designed and constructed to generate steam at efficiency of more than 80% on Gross calorific valve (GCV) basis at 50 % steam load. Efficiency shall be demonstrated as per standard BS 845 Part 1 Indirect methods. The insulated cylindrical shell of the boiler shall then be cladded with 22 G aluminium sheets. A movable ladder shall be provided which can be moved as per convenience. Boiler and accessories shall be mounted on a single base frame. Individual systems such as feed water pump etc. may be on separate base plates welded to the boiler base frame. 100 % radiography examination for circumferential & longitudinal seams of shell & stress-relieving shall be executed as per IBR norms The main boiler should be a water tube/fire tube steam boiler type, consists of following major components: A. Furnace B. Radiation part, C. A convection part with horizontal fire tube bundle (Boiler drum) D. Combustion system The water tube radiation part should be connected to the convection part on the waterside with down-comers and with riser tubes on the steam side. A. FURNACE The furnace should be completely integrated in the boiler: the sidewalls and in-bed of the furnace are completely cooled by the membrane walls of the boiler. The furnace should be built of refractory wall construction or the membrane walls of the furnace should be partially covered by refractory wherever exposed to flame directly. The amount of the concrete should be however restricted to a minimum in order to minimize the investment and the maintenance costs and to maximize boiler availability. The design of furnace into the boiler should be such as to control the combustion temperature and furthermore it should reduce excessive slagging of the ashes on the sidewalls of the furnace. The boiler should be extremely efficient for the combustion of fuels with 118

119 varying heating values and fuels characterized by low ash fusion temperatures. A door should be mounted into the rear wall of the furnace and ensure that the boiler is easily accessible. An adequate inspection glass mounted in the rear wall shall give an inside view of the combustion process in the furnace. All working parts of the boiler should be accessible for ease of inspection and maintenance. Insulation & Refractory works: Three layer refractory lining required for the furnace. The bidder shall undertake to execute refractory & lagging works for the furnace & shell at site. All refractory materials shall be castable including refractory bricks; cement firecrete etc shall be executed as per best engineering practices. The fixing arrangement of the membrane panel for the furnace with fire bricks, cement firecrete etc, shall be included in the scope of works. Necessary refractory bricks, fire resistant cement shall be supplied by the bidder. Rock wool/ Mineral wool as per IS 8183 & shall be suitable for ambient temperature of 30 Deg C. Density shall be considered kg/m3. Cladding shall be ribbed Al. Sheet for pressure parts & rest all shall be plain. B. RADIATION PART The radiation part consists of heat transfer surface comprising tubes & connecting strips forming a membrane panel to maximize heat transfer area. The configuration shall incorporate 3 side water walls including the in-bed layer to maximize the absorption of heat of combustion. The ratio of tubes to membrane panel shall be maximum & shall not be below 55 %. The fire tubes in the furnace shall conform to BS 3059 PART 1 ERW or seamless tubes. These tubes in the furnace shall be three side water wall types, to give maximum heat transfer area to enable safe operation & easy maintenance. To maximize combustion efficiency, the furnace temperature shall be maintained between 800 to 850 Deg C. The boiler shall operate in this range to avoid ash fusion & clinker formation. Buck stays to be provided for membrane wall/ furnace walls. C. BOILER DRUM The flue gases needs to be cooled down rapidly in the fire tubes where they pass by convection. The fire tube part should be executed as a multi pass heat-exchanger. The large water content should be provided in the convection drum, with a large evaporation surface along with a modulating feed water control (Single Element Drum Level Controller) which shall ensure in a quick response when the steam production shows a peak load. The voluminous drum should be provided to ensure dry steam without complicated or expensive secondary measures as steam dryers. The flue gas velocities should be optimal chosen to reduce the fouling of the fire tubes. Accessibility should be assured through a door(s) the cleaning doors on the smoke box at the end of the drum. The shell shall consist of adequately sized drum to increase the steam-water 119

120 interface for better steam quality & higher steam release rate. The fire tubes shall be adequately sized (2.5 or 3 OD), to prevent choking. The water-hold-up volume shall be maximum for the rating to meet sudden surges in steam demand. Double hinged Access Doors required in both front & back side for clear access to the tubes for inspection/cleaning. D. COMBUSTION SYSTEM The system shall comprise of spontaneous combustion of the pulverised / palletized fuel within the furnace due to turbulence of particles, through a single bed design. Air from the plenum chamber complete with distribution plate with fluidizing air nozzles shall ensure proper & uniform distribution on air for combustion. For wet or higher size fuels, provision for over-bed feeding shall be included in the scope. Air distributor: Air Distributor shall distribute pre-heated air, to achieve the fluidization velocity, & to evenly spread air in the fluidizing zone. The material of Construction of the distribution plate shall withstand furnace temperature without problems. The number of perforations & the geometric pattern of the perforation shall be suitable for underfeed fuel feeding system of pulverized coal. The distributor plate shall be thermally protected with refractory lining, layer of bed material & in-bed tubes. Bed Materials: Bed materials can be a mixture of silica sand, Coal ash, limestone or pulverized refractory with an average size of 1 mm. The depth of the bed shall ensure optimum pressure drop & effective air velocity for good turbulence. Generally the static bed depth shall be kept between mm. Bed temperature control system shall be provided which shall sense bed temperature shall cut-off or cut in fuel with indicators. ID, FD, Booster Fan: The Boiler shall be supplied with suitable ID, FD, Booster centrifugal fans with air modulating dampers. Vanes of the fans shall be backward inclined / curved. ID Fan shall preferably be installed on the floor level for easier operation & maintenance. These units shall have common baseframe for the fan, gearbox / chain transmission with motor mounted on Anti-Vibration pads. Energy efficient motor (EFF1) of TEFC enclosure with class F insulation and IP 55 protection shall be selected for the motor. The ID fan shall be VFD controlled based on the combustion air requirements, to maintain desired furnace draft. The FD, ID fans should be suitable to create suitable balanced draft for complete combustion of fuel. The ID fan capacity / head shall be selected to compensate the pressure drop across air pre-heater & ducting length and Pollution control equipments. Similarly the FD fan capacity / head 120

121 shall be selected based on pressure drop across APH, ducting length, combustion requirements. The Booster fan shall draw pre-heated air from the FD fan & discharge the air across venturi to draw pulverized/pellet fuel from the Bunkers, for spraying in the combustion zone. The duty shall ensure that sufficient fuel is drawn out from the bunkers for Boiler duty conditions. Secondary Air, if required, shall also be drawn from the pre-heated air from the FD fan AIR PRE-HEATER: An air pre-heater shall be designed to maximize heat recovery from flue gas to improve overall efficiency of boiler. Heat from the Boiler flue gas shall be used to pre-heat the ambient intake air from FD fan, before entering the furnace and shall thus act as a heat recovery unit in the system. The sizing shall be suitable to cater to the total air / flue gas flow of the boiler. The unit shall be insulated, shell & tube design & provided with dampers, necessary pressure & temperature gauges, sensors, controls and all associated accessories etc complete to maximize heat recovery AIR CONTROL The flow of primary air should be automatically regulated by pneumatic dampers. The flow of secondary air should be automatically regulated by pneumatic dampers. The ID fan should be controlled based on Furnace Pressure. The secondary regulation of Primary Air, Secondary Air & ID fan should be done based on feedback on Oxygen feedback in the flue gas. Thus the boiler should have Oxygen Trimming system for Primary, Secondary and ID Fan FUEL CONVEYING & HANDLING SYSTEM Bidder shall design a suitable automatic fuel conveying system and storage hopper as per their design requirement. The entire conveyer will be a closed type with hood arrangement to avoid any dust in the surrounding environment. A suitable dust extraction system shall be supplied. Feeding system shall also be provided for feeding agro-based pellets, & other bigger sized fuels, for above-bed (overfeeding) fuel feeding. The feeder shall be a suitable type / sized feeder with pneumatic spreading arrangement. This feeder shall also be VFD controlled, with online weighing system. The storage bunker for fuel shall be located in the Boiler House, near to the furnace. The dumping area of fuel shall be located outside the Boiler house. Other associated equipments for fuel 121

122 handling system like, Dumping hoppers, Aspiration units for Dumping Hoppers, inclined conveyors, bucket elevators, magnetic drum separator, vibrating screen, crusher, recirculation elevator etc. required for fuels like coal, agro-based pellets shall be included in the scope of the work. Aspiration unit shall be provided for the crusher to avoid dusting and losses. Each Boiler shall have 1 day of fuel storage within set of bunkers provided. The storage shall comprise of two identical bunkers of equal capacity. A hopper below the bunkers shall have necessary stiffeners leading to fuel conveying arrangement to the Boiler. The Bunker storage silos shall be modular in design & suitably stiffened & Floor supported by MS structure. It shall be possible to load any bunker from the dumping Yard by selecting & opening the pneumatic operated gate. The pulverized fuel / pellets feeding from the storage bunker through venturi & the spray nozzles shall be automatic. Nozzles shall be fabricated / machined from high quality SS 310 solid bar or CI with 3 % chromium. The design of individual handling equipments to meet the required handling capacity, dust extraction system & operational requirements shall be the responsibility of the bidder. All structural steel for supporting the handling equipments shall be in the scope of the bidder. Operation & maintenance platforms with hand- railing for the fuel handling system including application of primer & painting of external structures, equipments shall be supplied, as a part of the total work. Purchaser shall only provide for civil works for trenches, elevator pits & pedestals for structures. Note: Bidder shall submit a detailed scheme for the Fuel Feeding system. The feeding system should be of multiple / single designed such that it requires no removal / fittings / alterations while change of fuel. The feeding system should be able to adapt to the various fuels on as it is basis. The change of fuels should be done merely through selection of a switch on the control panel. (Hence the change over should be fully automatic type) WATER HANDLING SYSTEM: Raw water shall be made available in the water sump. Depending on the water requirement for the Boiler House, Raw water shall be pumped by a set of self-priming centrifugal pumps (1 working + 1 standby) to the overhead water tank for storage & use. The Overhead water tank has two 30 KL capacity compartments, one for soft water & other for raw water. The filling of raw water from the sump to the Overhead water Tank (Raw water) shall automatic, based on level sensors on the tank. However, a Push Button Station (PBS) shall be provided in the Boiler House for the filling of Overhead water tank by any of the two raw water pumps on manual mode, if auto-operation fails. 122

123 Control wiring for the PBS shall be drawn from the pump panel up to the Boiler House. A multi-grade filter shall be placed on the pumping line to remove suspended solids from raw water. The multi-grade filter (Simplex) shall be suitable for the pumping capacity (Capacity of the Multi grade filter to be mentioned) Calibrated Water level indicators (SS ball float & counterweight type) shall be provided for each of the overhead tanks & two (Three) for the underground water sump. The overhead water tank shall be located within 30m of the Boiler House. Water shall be drawn from the raw tank compartment of Overhead water tank by the softener pump, which will transfer water across softener to the second compartment of Overhead water tank. Water shall flow by gravity from the soft water compartment of the overhead water tank to the 20 KL insulated Feed water Tank through the atmospheric deareator or additional inlet port. A provision in piping shall be made to directly take soft water from softener to feed water tank in a manual mode, through manually operated valves. A water circulation pump shall continuously circulate Feed water in the feed water tank across the Atmospheric deareator for mixing flash steam with makeup water, condensate etc. Raw Water Pumps Requirement: The pumps for transferring water from underground sump to OH water tank, for water supply for steam generation, shall be supplied. However, the bidder shall propose suitable pumps for these items to match the actual duty requirement. Duty: The pump should be single stage, Horizontal, self-priming, end suction coupled pump. The pump shall be CI casing with Bronze impeller capable of delivering 30,000 L/Hr at 25 MWC (Pressure drop across MGF may also be considered) (min.) with TEFC squirrel cage, degree of protection IP 55 induction motor suitable for 3 phase, 415 V, 50 Hz. AC supply. A common base frame of MS channel (100 x 50 mm) with holding down bolts shall be provided for the motor and pump. A suitable 18 G GI sheet shroud shall be supplied & installed for each pump for protection against external weather conditions. The pump duty is based on approximate site locations, valve, and system resistance and is intended as a guide to facilitate biding. The bidder shall, before execution, verify & decide duty requirements against actual equipment and systems. Successful bidder shall be responsible to ensure that the selection of pumps is based on Best Efficiency Point (BEP) parameter on pump curve, to meet actual duty requirements, for the least connected power. Details of the proposed 123

124 revised pump duties shall be furnished to the Purchaser, and shall be subject to approval. Construction: Pumps for specific services shall meet requirements: The type of pump shall be End suction, base plate type, not close coupled, with C.I. casing, bronze impeller, packed gland, and shaft sleeve. The connections shall be flanged with Casing vent and drain. Gland shall have drainage well. The Shaft shall be supported in deep groove ball bearings. (Vertical pumps of Grundfoss /WILO may be considered) General: The rotating parts of centrifugal pumps shall be dynamically balanced, and pump shall run at 2900 rpm. Unless otherwise specified, drives shall be direct, through flexible couplings of appropriate type and rating. Coupling guards shall be fitted. Motors: Driving motors shall have continuous ratings in TEFC enclosure, F class insulation with IP 55 protection & suitable rated motor for the application. Pumps and motors shall be mounted on common base frame, with alignment locating points factory established to ensure correct positioning of motor when mounted on site. Motor for the pump shall be energy efficiency type, as per IS Eff 1, as per below details INSTALLATION: Motor Power Efficiency (%) KW/ (HP) 2 Pole 4 Pole 5.5 (7.5 hp) (10 hp) General: Pump shall be installed as per manufacturer s installation drawings. The building Contractor employed by the Purchaser will construct pump foundations as per requirements. Bidder shall provide drawings for approval, showing all requirements for arrangement and positioning, including holding down bolt pockets. Suction: To each water pump an isolation valve with suitable pot type strainer with SS304 mesh shall be provided. Each pump shall have an independent suction line complete with a foot valve with strainer. The suction pipes shall be properly supported to enable maintenance of foot valve. Pump gland wells shall be connected drain. 124

125 Discharge: To each water pump a vertical swing check (wafer type), isolation valve (butterfly) shall be provided. The common discharge header shall have 6 Dial type pressure gauge with 65 mm butterfly valve connection for Overhead water tank & 2 nos. 25 mm ball valve connections (spare). Discharge header shall be properly supported Power: Electrical power for the pumps shall be drawn from a power panel located near the sump, provided by the purchaser. Cable from the panel to each pump is included in the scope of work. MULTIGRADE FILTER Multi-grade Filter shall be placed in the raw water pump discharge line to the OH tank. This unit shall be placed adjacent to the Raw water pumps on the UG water sump (Or may be near the sump if not over the sump) & shall be suitable to meet the pump discharge requirements with regards capacity & head. Capacity: 30 KLPH S. No Requirement Qty 1. Vertical in construction MS pressure vessel with inlet, 1 set outlet connection, manhole on top & bottom, media removal port, air release connection. 2. Set of internals for the above comprising raw water 1 set distribution system, strainer plate, strainers, supporting stays etc. 3. Initial charge of Filter media beds 1 Lot 4. 4 Inlet and outlet pressure gauges 1 set 5. Tank shall have MS lifting lugs & be supported on heavy 1 set duty pipe legs welded on MS base plate Note: Tank shall have Torispherical dish ends & joints have to have to be tested for 100 % radiography. Surface preparation of the vessel: Sand blasting followed by epoxy painting internally and synthetic enamel painting externally. 125

126 Vessel shall be pressure tested at Design pressure & tested at 1.5 times Design pressure 7. WATER SOFTENING PLANT FUNCTIONAL REQUIREMENT The water softener up flow type (manual) & should be capable of delivering 200 cu.m. per regeneration of soft water. Brief requirement is indicated below; S. No. Description Requirement 1. Output between regeneration (OBR) 200 cu.m. 2. Minimum flow rate required 15 KLPH 3. Regeneration Manually through brine injection The entire regeneration sequence such as opening and closing of valves, brine injection, beginning of next regeneration etc., shall be with manually operated diaphragm valves. DESIGN REQUIREMENT AND SCOPE OF SUPPLY: S. No Requirement Qty Vertical in construction MS pressure vessel with inlet, outlet 1 set 1. connection Manholes on top & bottom, resin charging and withdrawal connection with supports. Set of internals for the above comprising raw water inlet distribution 1 set 2. system/brine distributor and bottom collecting system 3. Brine tank of HDPE construction to store and measure salt for 1 set regeneration of the softener complete with brine level indicator. 4. Set of mild steel flanged pipe work including regeneration piping 1set 5. Set of manually operated cast iron diaphragm valves for normal 1 set operation and regeneration 6. Manually operated brine injector 1 No Magnetic type Water flow meter with Digital indications of Flow & 1 No 7. totalized flow, with provision for remote display of these parameters. 8. Inlet and outlet sample valves 1 set 9. Raw water pump (Vertical pump may be considered) (1 W +1 S) 2 sets with base frame to suitable to deliver 15 KLPH (the flow should be 126

127 10. sufficient during the back wash cycle of softening plant) at required head. However, the rating of pump shall be decided by the bidder based on site conditions. The pump shall be with MS base frame, TEFC enclosure, IP 55 protected EFF1 motor. The pump casing, gland, stuffing box shall be Cast Iron, shaft of cast steel, shaft sleeve & impeller of bronze. Initial charge of ion exchange resin for the softener vessel 1 Lot Inlet and outlet pressure gauges 1 set 4 Pressure gauge for discharge of softener pump 1 No 13. Hardness test kit 1 set Drains from the softener shall be taken to the drain within or 1 set 14. outside the building. 15. Tank shall have MS lifting lugs & be supported on heavy duty pipe legs welded on MS base plate 1 set Salt dissolving tank of suitable capacity in MS with FRP coating/ Epoxy coating should be provided. Note: The operation of the softener pump (working) shall be automatic based on water level sensors placed in the soft water OH tank. However, Push Button Station shall be available for operation on manual mode through a Auto/manual selector switch. There shall be selector switch for selection of softener pump. Tank shall have Torispherical dish ends & joints have to be have to be tested for 100 % radiography. Surface preparation of the vessel: Sand blasting followed by epoxy painting internally and synthetic enamel painting externally. Vessel shall be pressure tested at Design pressure & tested at 1.5 times Design pressure QUALITY OF RAW WATER: The test results of raw water are furnished as under, but water shall be tested in a Govt. approved lab by the bidder, before finalizing type of softener. 127

128 Raw water Analysis Report Source of Water Total Hardness Calcium Hardness Magnesium Hardness Alkalinity Dissolved soilds Chlorides Sulphates Nitrates Borewell mg/l mg/l mg/l mg/l 953 mg/l mg/l mg/l mg/l QUALITY OF TREATED WATER: S. No. Parameter Value 1. ph Total suspended solids < 5 ppm 3. Total Hardness < 5 ppm FEED WATER TANK (INSULATED) (CAP.: 20,000 L) Functional Requirement: The tank would be used as buffer store for boiler feed water. The tank shall also receive plant condensate, Flash steam, makeup water & have an arrangement to deareate feed water, before it is drawn out for boilers. Design Requirement & Scope of Supply: The tank shall be designed by the successful bidder as below requirements. S. No Description Requirements 1. Overall dimensions Vertical (Horizontal) cylinder with conical top, but not more than 3.5m on any side. 2. Capacity 20,000 L 3. Constructional features Covered, circular cross-section, insulated with welded construction having GI cladding. 4. Finish All welds should be ground smooth. 5. Body The tank shall be fabricated out of MS plate of minimum 5 mm thickness with free standing structure having stiffener & bottom support. 6. Insulation The entire tank shall be insulated with 50 mm thick glass wool of thermal conductivity Kcal/hr.M DEG.CENT. and shall be retained with chicken wire mesh and 2 mm GI sheet as cladding. 7. Manway 600 mm dia circular MS flanged air tight manway at top with 6 mm thick counter flange with minimum no. of quick opening bolts - 1 no. 8. Outlet 80 mm NB flanged with butterfly valve - 2 nos. 128

129 9. Atmospheric deareator Suitably sized head with provision to receive cold make up water, circulated water, condensate return (50mm), Flash steam, automatic air vent connection complete with immersion tube with perforations to enable proper mixing - 1 No. 10. Additional inlet 75 mm at ¾ full level with SS 304 ball float & butterfly isolation valve for quick fill- 1 no. 11. Overflow 80 mm NB flanged with water seal, funnel & connected to drain line - 1 no. 12. Level Indicator Guided SS 304 float connected to counter weight by SS stranded wire. Wire counter weight shall be threaded to gauge board. 13. Air vent 150 mm dia(min) vent head with baffles, SS removable wire mesh - 2 no. 14. Drain Provision with drain cup with 65 mm bend with butterfly valve 1 set. 15. Heating arrangement A suitable sized port with a set of properly selected Steam injectors with flanged inlet with piston 16. Temperature control 17. Makeup water Control isolation valve. Suitable provision for temperature sensor, pn. Operated piston valve with temperature controller for suitable for steam. Connection at deareator head with suitable level probes for pn. Operated makeup water utility valve with level controller suitable for 100 Deg C water 18. Feed Water Suitable sized provision for feed water recirculation circulation 19. Feed water pump Low Water level probe with Alarm & tripping of feed control water pump. 20. Lifting Adequately sized Lifting lugs ( 4 Nos.), approach arrangement & ladder, top railing, internal MS rungs for tank approach inspection/ maintenance shall be provided. 21. Inside painting Sand blasting followed with two coats of heat resistant epoxy primer followed by two coats of heat resistant epoxy paint. 22. Outside paint One coat of heat resistant primer followed with 2 coats of heat resistant synthetic enamel paint. Note: The overflow & drain lines shall be connected & extended to the nearest drain. Bidder shall submit a detailed GA dimensioned drawing along with the bid & shall obtain approval before fabrication Stand-off for all connections on the tank shall be at least 150 mm from cladding. Structural supports, platform, Trench covers, hand railing, staircase etc for the Feed water Tank shall be included in the scope of work & the bidder shall include this in structural item. 129

130 CIRCULATION PUMP: Circulation pump shall be of suitable capacity 3 phase, mono-block centrifugal type with EEF1; TEFC motor with B class insulation suitable for the Feed water conditions. The pump shall have SS body, SS impeller with mechanical seal suitable for the application & shall be mounted on a MS base frame. The circulation line shall have suction isolation ball valve, strainer & NRV, isolation valve, Pressure gauge on the pump discharge. The pipeline shall be properly supported with CI clamps to avoid vibration. (Vertical pump may be considered) WATER PIPES, VALVES & FITTINGS Water piping would be GI B class pipe of suitable sizes for desired flow rate shall be complete with reducers, bends & accessories like isolating valves, pressure gauges, check valves, strainers, water flow meter etc. as required. All pump discharge header shall have a 6 Dial type pressure gauge to read pressure with isolation cock. Pipeline shall be fabricated through manual electric arc welding process after due end preparation. Flanged joints provided at appropriate locations for isolation / maintenance. If the water lines are taken underground, HDPE pipes shall be used after excavation, sand bedding as per best industry practices. The material of the HDPE pipe shall correspond to PE 63 as per ISO & shall meet pressure grade of PN-6. For water line valves for sizes 40 mm & above shall be Butterfly type with handle, MOC of cast iron body, single piece rubber-lined body wafer type, with EPDM/nitrile seat & shall have PN10 rating. For sizes up to 40 mm NB cast steel body Ball valves, in 3-part construction with SS working parts, weldable end type to be used. 9. Non-return shall be wafer type swing check valves with integral hinge pin with rubber O ring seat for ambient water & PTFE seat for hot water and SS working parts shall be selected & shall have PN10 (min) rating. Pot strainer with CI body with SS304 perforated sheet strainer of suitable size shall be provided for each pump. Foot Valves are also to be provided for the pumps to be installed on the sump Specifications to be mentioned The scope of supply also includes all necessary supporting structure required for raw & soft water piping. CI pipe clamps shall be used for supporting water piping. The feed water lines shall be separate for individual boilers & shall be insulated with Glass-wool & cladded with 22 G plain Aluminium sheets. The water flow meter shall have the same specification as steam flow meter. 130

131 Please note: Separate Water flow meter shall be provided in the Feed water pump discharge line for each of the Boiler. Hence 2 Nos water flow meters required. The Flow meter shall have remote display unit mounted on the control panel with open protocol connectivity for data transfer to the central MIS system ASH REMOVAL: Bottom ash removal shall be done from the various ash points in the Boiler & fluidizing box, bag filter, MDC etc. Damper for the fluidizing bed shall be opened manually, depending on increase of plenum air pressure AUTOMATION: All automation required for the automatic operation of the boiler from the Boiler Control panel shall be included in the scope. All controls, safeties for efficient operation of equipments in the scope of supply shall be considered by the bidder. Details of automation may be mentioned. Single element drum level controller. High pressure cut-out High flue gas temperature cut-outs Temperature of boiler feed water Inlet air temperature to APH Outlet air temp from APH Flue gas inlet temp in APH Flue gas outlet temp from APH Draft of furnace Etc The measuring instruments for steam & water flow, temperature, fuel utilization measurement etc., shall have local as well as remote display indicators on Boiler control panel. The indicators on the panel shall be of same make. However, it shall be possible to transfer important plant performance parameters of individual boilers, to the Centralized PLC (located in the Cattle Feed Main plant), through a universal protocol, for totalized & current flow/consumption. These parameters are as under for individual boilers; 1. Steam generation, 2. Water consumption, 3. Fuel consumption, 4. Energy consumption The Boiler Control panels (MCC not the control panel) shall have energy manager to capture, & transmit energy consumptions related to each of the Boilers. All indications on the Boiler panels shall be digital. 131

132 The Power panel (Motor Control Centre) shall be a standard compartmentalized panel construction, instead of Intelligent Motor Control Centre. All switchgears in the scope of supply shall be housed in the MCC. The incomer shall have an Energy monitor (load manager), which would capture overall energy utilization for the entire plant & have the facility to transmit the data. The incomer of the MCC shall be suitable 4 poles MCCB instead of ACB depending on the connected electrical load. Feeders for Raw water, soft water pumps, panel room AC & the other electrical loads in the scope of the tender, shall be considered in the MCC. Automation system shall include all hardware including instruments, panels, network cabling, PLC & associated computer with software. The system shall integrate all information from field & logically control the operations to achieve best performance & efficiency. The PLC shall be integratable to the Main PLC for the entire plant & shall have a universal protocol. Automation consists of the following major requirements; 1. Fuel handling & feeding to the Boiler including VFD for the Rotary feeder controlled by the feedback received from steam pressure transmitter. Fuel rate measurement & display of direct efficiency is included in the scope. 2. Combustion Control system consisting of steam pressure indicator cum controller, pressure Transmitter, PID Controller, Three way manifold, Pneumatic actuators for FD fans, to maintain constant steam pressure & steam quality. 3. Furnace draft control system consisting of pneumatic damper & controller for primary air requirement, furnace draft transmitter, PID controller, VFD for ID fan for accurate control of excess air. 4. Bed temperature control system for fuel cut off or on with controller & temperature indicator. 5. Online indicator & measurement of efficiency through direct method by integrating inputs from feeder i.e. the fuel fed into the Boiler & from steam flow meter for steam generated. 6. Online analyzer shall be installed in the Flue gas line to monitor combustion efficiency & automatically adjust the inlet FD air quantity, PA & ID fans for achieving complete combustion with least amount of excess air. 7. Single element Drum control comprising of pneumatically controlled valve for Feed water regulation into the Boiler, with the help of level transmitter installed on Boiler Drum, including by-pass valve for the control valve, feed water spill back line, three valve manifolds for the transmitter, condensate pot assembly, isolation valves etc. 8. A direct efficiency monitor to record display and print the fuel feeding rate & the steam generation rate, so as to compute the direct efficiency, S/F ratios etc, shall be installed near the boiler. The monitor shall also pick 132

133 critical parameters like feed water temperature, steam pressure, flue gas exit temperatures. CONTROL PANEL, INCLUDING PLC AND TOUCH SCREEN HMI A Programmable Logical Controller (PLC) to control the process. The PLC should be mounted on a durable control panel. The visualization system should give the operator a quick overview of the major process values of the installation. Furthermore, it should allow showing the textbased alarm messages. Before shipment, the control system should be completely tested in order to have a trouble-free start-up on site. The control system shall have the following major functions: Continuous monitoring of the major process values (temperatures, oxygen level, pressures.) Continuous monitoring of the electrical parameters of each boiler. An automated process control for an optimal energy plant operation A continuous safety control of the equipment (and the personnel) Continuous alarm feedback SCADA system for visualization and online efficiency monitoring system and measuring of the following parameters: Stack loss, Enthalpy loss etc. Steam Flow Trends. Water flow trends Compressed Air pressure & flow trends Low pressure steam in Main plant Draft Pressure Air Damper Positions Fuel firing rate & trends Steam to fuel ratios All trends and graphs for all other important parameters. The control panel shall have the following A. Power section: 1 Set Main switches and further for each motor: Incl. a Motor Protection circuit breaker (MPCB) for SC protection Incl. an indicator lamp for ON, OFF and trip status Incl. Intelligent Motor protections relay (IMPR) which should include an automatic thermal overload switch (for protection against abnormally high current) 133

134 B. Regulation and safety equipment: 1 Set the regulation and control of the installation shall be by a Siemens S7-300 series / Equivalent PLC to monitor total electrical parameters Incl. all regulation and safety equipment: Incl. under pressure regulation, including an under pressure detector Incl. Modulating capacity regulation Incl. Water level controller (1 point control) Incl. Continuous oxygen measurement and display on the control panel Network Hardware Ethernet cable / Fibre Optic cable 1 Lot Field run bus / similar bus cable 1 Lot ASI bus cable for valves 1 lot Switches As required Interfacing Units for third party devices / instruments etc. 1 Lot Remote I/Os complete with communication & power unit 1 Lot Hardware based security device 1 Lot The system shall have a redundant I/O panel power supply unit Other hardware as per requirement The hardware units shall be installed inside suitable wall / rack mounted water tight cabinets. All other hardware/software required for communication with plant SCADA and MIS server 1 Lot Accessories All junction boxes / distribution boxes for control / instrumentation system shall be in SS-304 / Cast Aluminium construction. Instrumentation / signal cables / wires shall be laid in separate cable tray so as to avoid any interference. System Software The system software will be based on open architecture / protocol. It shall be latest object oriented software, which result in fully scalable system. Original license version of the latest release of software shall be used. The system shall use Fibre optics as backbone. Software This shall be based on software of open architecture / protocol. Following minimum reports are envisaged from the system. Necessary forms to be developed on the networked PC s for entering the data. All the reports shall be developed after the discussion with the customer. However, following minimum reports are to be considered for development. Fuel storage, feeding reports. Boiler-wise steam generation report 134

135 Water consumption report Boiler-wise efficiency report All equipment hourly log report CONTROL PHILOSOPHY The bidder may propose a brief control philosophy along with the quotation. However, the control philosophy would be actually finalized during detailed engineering. General All equipment, system and accessories furnished shall be from latest proven product range of established / reputed manufacturers and shall conform to applicable national and international standards. The design of various control systems and related equipment shall adhere to the principle of failsafe operation implying that loss of signal, loss of power supply or failure of any component will not lead to hazardous conditions / product losses, while at the same time, prevent occurrence of false and unrelated trips. Climatic Condition The instruments / control system shall be suitable for environmental conditions that are normally encountered in western part of India. All equipment / system / sub-system etc. shall be fully tropicalized accordingly. Ambient Temp. 55 deg. C. Relative humidity 95% at <55 deg. C. System power supply condition For applications requiring AC power, 240 V AC, 50 Hz uninterrupted power supply shall be made available by bidder from UPS (3 phase) complete with a common servo stabilizer. The UPS battery bank may be common. In case of power failure, the UPS (3 phase) should be capable of delivering power for min. 30 minutes to control / instrumentation system including valve actuation power. The UPS shall have a static by-pass switch. Necessary filters should be considered to protect the system from harmonics, which may be generated in the UPS. 12/24 V DC power supply shall be used wherever applicable for Control System and will be derived from the UPS. Any other voltage level required for the system shall also be the responsibility of the Bidder along with all required hardware. DC voltage system for Main CPU & all I/O stations / panels shall be with dual channel & kept separate for different step downs as per requirement. Each filed I/O stations shall have separate voltage step down / standard power converter module system from 220V AC to duel channel 12/24 V DC to meet the requirement. 135

136 Control & Instrument (C&I) equipment furnished shall incorporate necessary techniques for protection against electrostatic discharge and radio frequency interface, as per international codes and standards. Safety earthing and C&I System earthing shall be separate. Safety earth bus shall be connected to main plant earth pit. Separate earth pits shall be provided for system earth bus (electronic earth). Electronic earth shall be cabled directly to the corresponding earth bar. The earthing for automation / C&I system shall be of copper only. All instruments shall have clear access for maintenance, removal, lay-down, calibration etc. The sensors & display units should be separate. All readable instruments shall be clearly visible unassisted. Portable SS access ladder with platform shall be provided for easy access of instruments, valves and actuators. All prefabricated plugged cables, power supply cable for Bidder s System. System Cabinet, Marshalling Cabinet and Power Supply Cabinet to fulfil the system requirement. Power Distribution Cabinet for extension of power supply to field instruments. SINGLE ELEMENT DRUM LEVEL CONTROL SYSTEM The feed water level should be controlled through a proportional signal or process variable (PV) coming from the drum level transmitter. This signal is compared to a set point and the difference is a deviation value. This signal is acted upon by the controller which generates corrective action in the form of a proportional output. The output is then passed to the boiler feed water valve, which then adjusts the level of feed water flow into the boiler drum The single Element Drum Level Control System shall consist of the following: Differential Pressure Transmitter Isolation valve Condensing Pot Control Valve Controller Piston Valves Piping & Hardware AIR POLLUTION CONTROL EQUIPMENTS Pollution control equipments shall be installed to meet the local pollution Control norms (GPCB) which are as under; Parameters Unit Levels 136

137 SPM level mg/nm³ < 150 SOx mg/nm³ 100 NOx ppm 50 However, if there are revisions on the local pollution Control norms, the bidder shall comply with the latest applicable norms. 1) BAG FILTER (PULSE-JET TYPE) The dusty flue gas coming out of the Boiler should be routed through the Bag filter before they pass to the chimney. Bag filter shall separate fly ash from the exhaust flue gases of the Boilers to meet the pollution Control norms. The Bag filter with parallel MDC shall be common for both Boilers (one planned and one future). The entire unit shall be insulated with 75 mm thk mineral wool & cladded with 24 SWG aluminium cladding. The filter material (nomex / ryton bags) shall be able to withstand a temperature of 220 Deg C.The casing of the bag filter shall be fabricated from 3 mm MS sheet. Perforated sheets shall be placed at both sides of the inlet to filter courser particles. Cages for the filter shall be made of special wires to withstand high temperature. Required no. of hoppers shall be provided with 70 deg plate angle with access doors. Hoppers shall end with a rotary airlock valve driven by a geared motor. Venturi for cleaning operation of bags shall be of Cast iron MOC. Air solenoid valves shall be operated for pulsing compressed air for bag cleaning & shall be sequential timer controlled. Supporting structures, hand rails, ladder for the bag filter shall be provided along with the unit. Inlet cum by-pass damper (pneumatically operated) shall be provided to by-pass unit at higher temperatures & during start up. Instrumentation: 1. Hopper with thermostat controlled heater for flowability. 2. Differential pressure switch for on-demand filter bag cleaning. 3. Temperature indicator with controller for by-pass operation. 4. Sequential controller for pulsing bag for cleaning. 5. Limit switches for damper, for indication of Bag filter On-OFF position. 6. Pressure switch for control of air supply. The unit shall come with fittings like Air pressure gauges, air filter with drain valve arrangement, pneumatic cylinder etc. While in operation, the emission limit for Suspended Particulate Matter from stack shall be restricted to 150mg/ Nm3 level or latest GPCB norms. 137

138 In case the flue gas temperatures rise above a pre-set value. The RTD based pneumatically operated control valve will bypass the flue gases through the Mechanical Dust Collector. 2) MECHANICAL DUST COLLECTOR Mechanical dust collector shall comprise of steel structure housing the high efficiency insulated cyclone / multi-cone separator with air-tight rotary air lock with operating handle, for efficient removal of fines from the flue gases. The rotary airlock valve shall be driven by geared motor. The entire unit shall be insulated. This will be installed in parallel to the Bag filter & shall be operated in the by-pass mode of Bag filter. MDC should consist of: Collection Tube Outlet or Discharge tube Inlet Guide Vanes Dust Discharge Boot The dust laden flue gases enter the MDC and then inside the collection tube. At the entry of the collection tubes the inlet guide vanes guide the path of the gases Boiler mountings, accessories, tools: The boiler should have all necessary standard mounting, accessories, and tools for safe and efficient operation of the boiler and in accordance with the latest IBR regulations. The boiler shall have all the components as listed below. It will be the bidder s responsibility to indicate any components not listed in this specification but required as per the statutory regulations. Price considered for all such additional components / items shall be furnished item wise separately in their offer. It will be the successful bidder's responsibility to provide any components / items not appearing in the list, nor additionally listed by the bidder in their offer and the same are found to be required as per the statutory regulations. Successful bidder shall provide such additional components / items within the scope of the work and no additional cost will be considered for the same. List of the major mountings, accessories, tools to be supplied with the boiler are; Sr. Description Qty. No 1 Spring loaded full lift type safety valve having a total discharge 02 sets rate exceeding the maximum steam producing capacity of boiler with exhaust pipe to discharge outside the boiler house. 2 Front casing and rear casing for shell with hinged door 01 set 3 Membrane panel complete with 3 side wall tubes, headers, with 01 set end connections 4 Membrane panel drain connection 01 set 5 Combustion and setting chamber complete with bed materials 01 set 6 Plenum chamber complete with distribution plate and fuel 01 set 138

139 materials 7 Ash removal ports, ducting with sliding gate 01 set 8 Main steam stop valve with counter flange 01 set 9 Shell blow down connection for automatic blow-down system with necessary pipes, fittings up to blow-down pit located outside the boiler house 01 set 10 Blow down connection for in-bed tubes with valve 01 set 11 Steam pressure gauge of minimum size 200 mm dia (IBR 01 set certified) with siphon tube and cock. 12 Steam connection with isolating valve for fixing test pressure 01 set gauge and for removal of air 13 Water level sight glasses with safety shields and isolating valves 02 sets and drain valves connected to a drain line up to blow down pit 14 Magnetic water level controller (heavy duty) mobrey type for high, 02 sets low and extra low water level alarms with isolating valve and drain valves connected to a drain pipe up to blow down pit 15 Port for single element level controller 01 set 16 Hinged type rear access with flame observation port/fire view 01 No glass with blue tint colour glass/plain glass 17 Access ladder, top walkway platform complete with pipe railings 01 set 18 Rigid MS base frame, MS supporting structure, lifting lugs, 01 set saddles etc. (for shell and furnace etc.) 19 Fusible plug 01 set 20 Steam pressure switch for audio alarm and ID fan cut-off 01 No 21 Flue gas temperature sensor with indicator (digital type) 01 No 22 Boiler nameplate 01 No 23 Refractory and insulation works including fire bricks, fire cement, 01 set lining, mineral wool insulation and cladding etc 24 Feed water pumps with discharge lines, valves and fittings to the 02 Nos shell 25 Induces draft fan complete with gear box motor, damper, 01 set supporting base-frame, structure 26 Forced draft fan complete with gear box motor, damper, 01 set supporting base frame, structure 27 Booster fan for under bed fuel feeding complete with gear box 01 set motor, damper, base frame, structure 28 Air preheater complete with controls and dampers 01 set 29 Pollution control equipment including bag filters, MDC etc. 01 set 30 Boiler controls including IMCC, control panel, direct efficiency 01 set monitor etc. 31 Tools comprising of a set of essential tools, shovel for ash 01 set suitable for length, set of spanners, tube cleaning burshes, etc. 32 Essential spares for 2 years normal operation 01 set Important note: Recommended Spares for 2 year operation is included in the scope of supply & shall be included in the costing of the Boiler. List of essential spares & wear parts like temperature sensors, pressure gauges, draft gauges, pneumatic cylinders, gates, geared motors, solenoid valves, 139

140 bearing, coupling, seals, O rings, gaskets & other essential components, with quantity, for 2 year trouble-free operation shall be attached with the quotation. The bidders should quote their rates with the quantity break-up for essential spares considering normal operation of the plant for two years. All spare components shall be duly quantified and included in the offer with price break-up for each of the spare components. Following in brief are few essential components which are to be quoted. a) Boiler tubes - minimum 2% of the total tubes. b) Other accessories which are not listed above but are required for normal functioning of the boiler for two years of operation. It may please be noted that, any spares required during start-up and commissioning of the boiler and all its associated equipment, the same shall be deemed to be included in the quoted price of the steam raising plant BOILER AUXILLARIES 1. Ducting & Equipments FLUE GAS DUCTING Flue gases from the Outlet of boiler shall be separately taken across separate Air pre-heater & shall be connected to common Pollution Control equipment. Flue gas ducting shall be suitable to receive and convey flue gases across the Mechanical dust collector, ID Fan from individual Boilers. MS ducting between the chimney & Boiler shall be fabricated from MS sheet of minimum 4 mm thickness & shall be designed for a peak flue gas velocity of 14 to 16 m/s. fabricated ducting segments shall be welded to each other and suitably supported within the Boiler House. The flue gas ducting shall be insulated with 50mm thk glass wool insulation with 24 G Al. Sheet cladding & shall be connected to the chimney though a pair of flanges. The Main Flue gas ducting shall be connected to the pollution Control equipment, ID fan & shall have an expansion bellow. It is desirable to have Flue gas ducting from Boilers connected to the chimney separately. AIR PRE-HEATER Air pre-heater consists of pre-heater blocks with tubes & tube sheets. The pre-heater casing shall have stiffeners & shall be fully insulated. Suitable erosion allowance shall be provided at entry level of pre-heater tubes. Carbon steel tubes shall be provided in the cold suction. AIR DUCTING Air ducting shall be suitable to receive and convey air across the Air preheated, FD Fan & shall be dedicated for Boiler. MS ducting between the FD Fan & Boiler shall be fabricated from MS sheet of minimum 3.15mm thickness & shall be designed for a peak velocity of 14 to 16 m/s. Fabricated ducting segments shall be welded to each other and suitably 140

141 supported within the Boiler House. The flue gas ducting shall be insulated with 50mm thk glass wool insulation with 24 G Al. Sheet cladding 2. Chimney Sr. No. Velocity Profile Required Velocity Profile 1 Fluidizing bed (m/s) m/s 2 Furnace (m/s) m/s 3 Boiler bank (m/s) m/s 4 Air preheater (m/s) m/s Chimney shall be suitable to receive and convey flue gases from Boiler. Though one boiler is sufficient for the designed capacity of the feed plant & Chimney shall be designed for conveying flue gases of both (one planned and one future) boilers. The chimney for the boilers shall be of self supporting type, made out of mild steel sheets of suitable thickness. The steel plates and sections used in construction of the chimney along with other materials such as rivets, bolts, nuts, washers, gaskets including all consumables like welding rods etc., should conform to the relevant IS. The corrosion allowance for thickness (3 mm min.) of chimney should be considered for minimum of 20 years life. The chimney height shall be as per the Pollution Control Board's regulation. The design and construction of the chimney shall be conforming to IS: Part 1 & While calculating the load on the chimney the following shall be considered: 1) Dead load considering the weights of the chimney shell and permanent fixtures such as ladders with protection cage, platforms with railings, baffles, helical strakes, flanges, fasteners and all accessories. 2) The imposed load of minimum 1000Kg/sq.m shall be on the sampling platform. 3) Wind loads in accordance with the provisions contained in IS 875 (part 3) The wind load force on the ladders and other fixtures and accessories fixed to the chimney shall also be determined and added to the force on the chimney. 4) Earthquake loads in accordance to IS 1893: The chimney design and the foundation design for the chimney shall be determined by considering the maximum forces, effects and stress calculated from combination of any of the following combinations. Dead load + wind load Dead load + earthquake load Dead load + load due to the lining + imposed load on service platforms + wind load Dead load + load due to the lining + imposed load on service platforms + earthquake load 141

142 The chimney should consist of all the accessories and the minimum requirement of few are as follows: Base plate with gussets plate (minimum thickness of 12 mm) and base stool. Inspection door with minimum size of 500 W x 800 W shall be provided. The door shall have handles and all associated accessories. The cut-out made on the chimney should have stiffeners of not less than 50 x 50 x 6 mm angles welded on the periphery of the cut-out in the chimney. Access ladder with protection cage: The ladder should start base of the chimney and it should be up to the top of the chimney. The ladder shall be supported from the chimney with structural members of not less than 50 x 50 x 6 mm ISA and the ladder rung should be located at a distance of 250 mm from the chimney. The ladder rung should be made of 20 mm dia rod, the width of the rung should be of minimum 400mm and the ladder step should be at a frequency of 200 mm C/C. Safety enclosure or cage shall be provided for the ladder from 3m to the top. Platform for flue gas sampling and inspection: The platform width should be not less than 800mm and should have 1000mm high railings, one additional support shall be provided in the middle of the railings, toe guard support shall be provided at the bottom of the railing. There should be suitable arrangement in the platform for draining out the rain water. Sampling port shall be provided for flue gas sample analysis as per the PCB regulation. Painter's trolley. Conical cowl with cowl stays: The minimum cowl diameter should be 1.5 times the diameter of the top of the chimney section. Twin aviation lights and warning lights: Aviation obstruction light fixture shall be made of Aluminium alloy casing with separate galleries to house a set of two 40 watts (minimum) LED lamps. The lamp fixture shall have suitable red domes on the galleries and the lamp fixture shall be of reputed make. Aviation obstruction light point should be connected up to the IP 55 grade of protection Cast aluminium junction box installed at the base on the chimney with 3C x 2.5 sq.mm., PVC sheathed, PVC insulated copper cable. The circuit cable shall be run on the rigid PVC conduit, 2mm thick and shall be fixed on the chimney surface with suitable saddles and clamps mounted on the epoxy based insulators. Lightening arrestor: Lightening arrestor should be of copper with minimum 5 prongs, the lightening arrestor should be connected to two earth stations. The earthing conductor should be of size should not less than GI 25 x 6 mm / or of equivalent size and conductor material as approved by the local statutory authorities. The earthing conductor should be mounted on the epoxy based insulators and not directly fixed to the chimney surface. Two earthing conductor should run parallel from the lightening arrestor and each connected to the independent earth stations. The earth stations in turn should be interconnected with one another. 142

143 The earth station should be of GI plate conductor and constructed as per IS 3043 latest edition. The earth station should be complete with excavation, filling with charcoal / salt, watering pipe, funnel, earthing conductor, test link, 350x350 mm CI hinged cover with frame complete with all masonry works. Flue gas inlet: Flue gas ducting is separately specified. The cut-out made on the chimney should have stiffeners of not less than 50 x 50 x 6 mm angles welded on the periphery of the cut-out. The opening made on the chimney for the flue gas duct should be extended by 200 to 1000mm and terminated on counter flanges to facilitate connection of the ducting on the chimney. Helical strakes to reduce wind excited oscillations for the top 2/3rd height of the chimney. Chimney bottom should be insulated up to 3 M height by 50 mm white mineral wool followed by cladding with 3 mm MS sheet. MS sheet cladding should be of butt welded construction. All MS parts of the chimney shall be given initial surface treatment including degreasing, de-rusting etc., followed by a coat of primer. The chimney should be finally painted with two coats of suitable heat resistant paint. Foundation bolt of adequate length and diameter (min 40 mm) shall be provided along with the anchoring channel of section ISMC 150 on the bolt base. Template shall be provided by the successful bidder suitable for the foundation bolts for casting the chimney foundation. 3. Support Structure, trench covers & Platform All general purpose Structural steel shall be conform for physical & chemical composition as per IS 2062 Grade A (of latest revision). Nominal Dimensions of rolled steel Shall conform to IS for Beams, columns, Channels, Angles. Shall conform to IS for Plates, strips, flats. Shall conform to IS for Channel sections. Shall conform to IS for pipes. The structure shall be welded type consisting of suitable steel structure having columns, `I' beams, channels, angles, plates, foundation bolts etc. Platform shall be fabricated from 5 mm thick steel chequered plates suitably stiffened. Necessary MS `B' class pipe NB 32 mm railing to be provided wherever required. Complete steel structure to be painted with two coats of Redoxide Zinc Chromate primer and then 2 coats of synthetic enamel paint. Note: For sections below 100mm, re-rolled sections shall be acceptable; if they meet the respective IS with regards dimension & weight. All sections above 100mm shall be supplied from one of the preferred makes indicated at the end of this specification. 143

144 4. ELECTRICALS Electrical distribution system shall be suitable to operate, control and maintain all the parameters required for receiving the Fuel & handling up to Boiler and for all operations of the Boiler, to meet steam demand for feed manufacture for the 800 MTPD Cattle Feed Plant. Intelligent Motor Control Centre (IMCC) with required number of feeders complete with switchgears, push buttons and indications, auto-manual selection switches and facility to operate and control electrical motors etc. through central control room SCADA, remote controlled push button stations etc. as per the requirement of the plant & equipment shall be provided for effective and safe operation of the Plant. Power shall be made available in an outgoing feeder in the PCC located close to the Boiler House. The successful bidder shall lay suitable cables from the PCC up to the incomer of the IMCC, for further distribution. The intelligent panel shall house all power feeders for both boilers, for all equipments in the scope of supply. Apart from this the 20 % spare feeders based on KW rating shall be provided in the panel, for other power driven equipments located in & nearby boiler house. Power feeders of 30 HP & above shall have a suitable capacitor connected in parallel & shall be a part of the Power panel. A separate PLC panel, Boiler control panel housing annunciation & controls for boiler shall be in the supply scope. The communication between the IMCC with PLC, Boiler Control panel, shall be through suitable communication network cable. The bidder shall include computer with printer, UPS, Computer furniture, split type AC for the Control room. Required quantity of braided copper / armoured aluminium & copper power cable, copper control cable, instrument cable, GI perforated trays, plate type earth pit, earthing network, earthing conductors, load break Isolators with plug & sockets / junction boxes, (or Push Button stations for Soft starter started motors) near motors for emergency isolation and controls, rubber mats for panels, lockable push button at each floor for emergency stop etc. shall also be provided. The sizes of power cables for different capacity of loads / motor rating shall be as indicated in cable selection charts. All the power & control cables shall be laid through perforated GI cable trays and drop conduits. GI shrouds for all pumps & motors shall be provided wherever located outside the buildings. Supply & placement of electrical grade rubber mats / sock proof paint of proper size as per the Gujarat State Electrical Inspectorate rules shall be provided. 144

145 Power Cables shall be braided copper conductor cable for motors of all ratings. All cables between the outgoing feeders in MCC and plug & socket with isolator or junction boxes near motors shall be of copper / aluminium conductor as above. Connection from plug & socket isolator or junction boxes to motor junction boxes shall be with PVC insulated flexible copper cable in suitable PVC steel ribbed conduit. The electrical LT distribution system specification is detailed below. INTELLIGENT MOTOR CONTROL CENTRE (IMCC) The IMCC shall be suitable for indoor installation in the wardrobe construction for compact configuration with provision for expansion. The motor control centre shall be completely dust & vermin proof conforming to IP 44 standard. The bus bar rating of each MCC shall be capable of carrying 1.25 times of full load current of all the feeders of respective MCC plus spare feeders load and future load of the plant as described in the design basis. The Incomer of each IMCC shall have 4 poles EDO, ACB of suitable rating / Type with built in solid state / Microprocessor based protective devices / relays with all accessories. Also the Incomer shall have 3-phase 4-wire energy meter with necessary Indications, Voltmeter, and Ammeter with selector switches and CT's and phase Indication lamps. Load Manager shall be provided in each MCC for monitoring power condition and energy consumption through system automation being provided for the feed plant. (Energy meter should have bus communication facility for MIS purpose) For Incomer of the panel, the rating of the switchgear shall be 1.25 times of rated full load current of connected load (including spare feeders load and future expansion load as described in design basis) of the panel. The necessary feeders complete with switchgears for future expansion shall be provided in the IMCCs as detailed in the specifications. The outgoing cables from the MCCs in the electrical control room shall be laid in cable trays. Cable entry & exit for all the feeders of MCC shall be from the top. The cables going to plant equipment shall be laid in cable trays on pipe rack. The MCCs would receive, control & distribute electrical power at 440 V, 50 Hz AC to all electrical loads to be connected in the various sections of the plant. One no of 100 A TPN MCCB unit for welding receptacle shall be provided at appropriate location. All outgoing feeders shall have isolation facilities in the IMCC using MPCB (or MCCB as specified). Motor feeders shall include contactors, 145

146 overload protection through intelligent relay & necessary operating controls. All VFD and soft starter also shall have communication facility. All motor feeders will have Soft Starters or VFD. Variable Frequency Drive (VFD) unit will be provided for a motor feeder wherever speed control is required. Intelligent motor protection relay (intelligent controller) shall have minimum 4 nos. digital inputs & 2 no. digital outputs. Providing & laying power cables of suitable rating and no. of runs (considering load of future expansion) from PCC in electric substation to IMCC under this package is included in the scope of bidder. These cables shall be aluminium armoured cables and should be laid in trench/underground/pipe-bridge/cable trays between PCC to Boiler House as decided by site requirements. The quantity of IMCC shall be as decided by the plant load requirements and design of the bidder with the available switch board room. As indicated above the MCCs shall have power monitoring system to be hooked up with automation system through field bus for online monitoring of power from operating station. In view of no. of soft starters and VFDs, the system should have safeguards against all harmonics. The total harmonic distortion produced / generated in the plant shall be analyzed and suitable harmonic filter shall be provided as required to limit the THD within the IEC recommended guidelines. FUNCTIONAL REQUIREMENTS: To receive, control and distribute electrical power at 440 V, 50 Hz, AC in sheet steel housing and communicate real time operating parameters to Main PLC Panel. The specifications describe the requirements for the low voltage intelligent motor control centre (IMCC) which shall fundamentally provide for the following: Achieve controls through microprocessor based systems Replace hardwiring by using network technology Provide enhanced degree of diagnostic and protective functions. The IMCC shall provide comprehensive protection on motors by integrating intelligent motor protection relays (IMPR) or intelligent protection devices (IPD) inside the switchboard. The IMCC should also bundle the bus communication with the most common protocols found in the industrial networks (Modbus SL / Modbus TCP / Profibus DP / DeviceNet). Operating temperatures -40 C/+75 C. 146

147 Design Requirement and Scope of Supply (i) Statutory Requirements: Motor Control Centre is to be manufactured / assembled as per the latest applicable Indian Standards, Indian Electricity Rules, Indian Electricity Act, Fire Insurance Regulations and comply with all currently applicable statutory requirements of concerned State Electricity Inspectorate and safety codes in the locality where the equipment will be installed and as per the detailed specifications mentioned below. The manufacturer of the panel must possess a type test certificate from CPRI. The major board components and intelligent devices used in the IMCC should be of an international company (like ABB/ Schneider/ SIEMENS/ Rockwell). The IMCC should provide the flexibility to choose different solutions in motor protection and monitoring functions according to the requirements of the plant. (ii) Housing Details: (ii-a) The switchboard shall be fabricated using pressed and shaped cold rolled steel sections structure of adequate thickness. The sheet steel used for panel shall be minimum 14 SWG sheet except that the partition plates, inter-panel barriers and cubical doors may be made of 16 SWG. The switchboard shall consist of free standing front and back open able panels arranged to form a continuous line-up of wardrobe type cubicles of uniform height. Cold rolled sheets shall be used for doors and front covers. Front doors shall be hinged type with quarter turn fasteners and bus bars and cable alleys covers shall be bolted type. Each ward robe type cubicle shall house 8 to 9 feeders or as per design requirement of shipping lengths. (ii-b) Switch Board shall be extensible at both the ends by addition of vertical sections. Ends of the bus bars shall be suitably drilled for this purpose. Panels at extreme ends shall have openings, which shall be covered with plates screwed to the panel. The switchboard shall be provided with integral base frame channel painted black. The cable gland plate shall be 2.5 mm thick. (ii-c) The switchboard shall be totally enclosed, dust, weather and vermin proof and shall conform to degree of protection not less than IP 44 as per IS Gaskets of durable material shall be provided all round the perimeter of adjacent panel, panel and base frame, removable covers, doors and other openings. (ii-d) All hardware shall be corrosion resistant. All joints and connections shall be made by galvanized zinc passivated or cadmium plated high tensile strength steel bolts & nuts. Spring washers shall be provided to secure against loosening. (ii-e) The switchboard shall be non-draw out wardrobe type design except for the individual ACB cubicles used if any for incoming, outgoing and bus 147

148 coupler. Each wardrobe shall contain 8 to 9 feeder components as per design. The IMCC shall be suitable for indoor installation. Suitable cable & bus bar alleys shall be provided if required. All components of the switchboard shall generally be approachable from front. However, IMCC can be in double front execution also if specifically asked for or is required as per site requirements. The maximum and minimum operating handle / push button height of any feeder shall not be more than 1900 mm or less than 300 mm with reference to panel bottom. The total height of panel shall not exceed 2300 mm. Supporting arrangement and saddles for dressing of power and control cables shall be provided. Maximum shipping length of MCC shall be 2500 mm. Each shipping section shall be provided with suitable lifting hooks. These hooks when removed shall not leave any opening in the board. Minimum depth of cubicle for ACB shall be 1000 mm and minimum width of cable and bus bar alleys shall be 300 mm. Space heaters with toggle switches, fuses and thermostat shall be provided in each cable alley. Cabinet fans with filter kits (120 mm), 2 feet cabinet lights, protective SP MCBs and door limit switches are the other general IMCC components to be provided. (ii-f) Internal arc features: The switchboard should be designed to minimize the risks of occurrence of internal arc and whenever such an arc occurs it should prevent its effect on operators and material/equipment surrounding the switchboard. The short-circuit withstand capacity of the panel with bus bar and supports shall be minimum 50 KA/1 sec. (ii-g) Painting: All metal surfaces shall be thoroughly cleaned and degreased to remove all scales, rust, grease and dirt. Fabricated structures shall be pickled and treated to remove any trace of acid. The under-surface shall be prepared by applying a coat of phosphate paint and a coat of yellow zinc chromate primer. The under surface shall be made free from all imperfections before undertaking the final coat. After preparation of the under surfaces, the panel shall be spray painted with final two coats of approved shade of powder coating (RAL 7032 Siemens grey). Thickness of powder coating shall not be less than 60 microns. The finished panels shall be dried in stove ovens in dust free atmosphere. Panel finish shall be free from imperfections like pin holes, orange peels, run-off paint, etc. All unpainted steel parts shall be cadmium plated or suitably treated to prevent rust, corrosion, etc. (ii-h) Nameplates: Apart from panel nameplate highlighting the operating voltage, the nameplates for all incoming & outgoing feeders shall be provided on doors of each compartment. Nameplates shall be fixed by screws only and not by adhesives. Engraved nameplates shall preferably be of 3-ply (Black-White-Black) acrylic sheets or anodized aluminium. Special danger plates shall be provided as per requirement. Lettering sizes used in the panel shall be 5 mm or 15 mm as directed for feeders and main inside the panels, stickers should be provided for all components giving identification no. as per detailed wiring diagram. 148

149 (ii-i) Cooling Fan & filter assembly, lighting of panels, heater: Each section of the panel shall be provided with a set of cooling fan and filter assembly and 2 feet long T5 tube light fitting operating through a door limit switch. Each section of the panel shall also be provided with heating plate and a suitable thermostat. (iii) Bus bar Sizing Connection and Supports: The bus bars shall be made from high purity & high conductivity copper. The bus bars and supports shall be capable of withstanding the rated and short circuit current. Minimum size of power (phase) bus bars shall not be less than 200 Amps rating. Maximum current density permissible for Copper bus bars shall be 1.2 Amps/mm2. A suitable section earthing bus bar shall be provided in the panel at bottom throughout the length of the panel. Provision shall be made to connect the earthing bus bar to the plant earthing grid at two ends. All doors shall be earthed using flexible copper connections to the fixed frame of the switchboard. The bus bars shall be tinned to protect against oxidation. The bus bars shall be provided with heat shrinkable PVC insulating sleeves of 1100 V grade. Red, Yellow and Blue colour shall be used for phase bus bars and black colour shall be used for neutral bus bars. The sleeves should be non-inflammable and self-extinguishing type. All joints in main horizontal bus bars and all tap-off connections from the main horizontal bus bars shall be suitably shrouded. Supports for bus bars shall be made of suitable size non-hygroscopic and non-inflammable epoxy compound SMC / DMC blocks and these should be adequate in number so as to avoid any sag in the bus bars. The main bus bar should be spliced at each column level in order to achieve simplicity and flexibility in transportation, installation and maintenance. Sliding fishplates should be used to make the connection of the copper bars between columns. Minimum clearance between bus bars phase to phase shall be 25 mm and that between phases to neutral / earth shall be 20 mm. (iv) Power Connection: For power interconnection within the panel board: Copper flexible conductor PVC insulated cables of adequate cross section shall be used. However, for current rating above 100 Amps, Copper bus bar strips of adequate rating shall be used. Minimum size of copper flexible conductor to be used shall not be less than 4.0 mm2. Maximum flexible copper conductor size used in the panel shall be 35 sq. mm for 100 Amps feeders. Cable lugs / sockets of suitable size and type shall be used for all interconnections and cable terminations. For incoming feeders of the MCC, copper conductor cable will be used and hence the panel is to be designed for receiving these and wherever required cable boxes with bus bar extensions for receiving more no. of cables, shall be provided in panel by bidder. For all aluminium to copper connections, the copper surfaces shall be properly cleaned and supplied with oxide inhibiting grease. Copper washers shall be used in these terminations. 149

150 For all outgoing motor feeders, the suitable size terminal blocks shall be provided in cable alleys and wiring up to these from contactors shall be done by panel bidder. These terminal blocks shall be heavy-duty type to withstand high starting currents. The cable entry shall be either from top or bottom as specified in feeder details or as required for the project. Removable gland plates of minimum12 gauge thickness shall be provided on top / bottom of panel (as required), for cable entries. The cable alleys shall also be totally isolated from switchgears by suitable partition plates. To prevent accidental contacts, all junctions of interconnecting cables and bus bars also shall be shrouded suitably using coloured PVC insulation tape. Standard colour code of red, yellow and blue for phases and black for Neutral to be followed for all bus bars/conductors. (v) Auxiliary wiring and Terminals: Wiring for all controls, protection, metering, signalling etc. inside the switchboard shall be done with 1100 V grey colour PVC insulated FR copper conductors. Minimum size of these conductors shall not be less than 1.5 mm2. However, CT circuit wiring shall be done with 2.5 mm2. Control wiring to components fixed on doors shall be flexible type. The complete panel would be subdivided into different sections as required for the project. Terminal block for control wiring shall be provided for each outgoing motor feeder in the top of the cubical. 10% spare terminals shall always be available in each terminal block. Control wiring up to these terminal blocks shall be done by bidder. Full depth wire ways shall be used. Network cabling and power/control cables shall be separated. All conductors should be terminated using compression type cable sockets / lugs at both the ends. Each control wiring termination shall be identified at both the ends by PVC ferrules. The identification termination numbers should match with those on drawings. Suitable size SP MCB instead of fuses shall be used for tapping the power for control circuit wiring. Control wiring for motor feeders should be such that the "green" light of motor feeder is "ON" only when control as well as power circuit of feeders is "ON" and it shall have its own fuse. For all motor starter feeders, provision for control wiring to remote ON/OFF control is to be made. The auxiliary wiring for the same shall be brought up to terminal block in the feeder's cubicle. (vi)-switchgears: (vi-1) Air Circuit Breakers (ACBs): These shall be electrically operated, fully draw out type with built-in microprocessor based programmable protection, and suitable for 415 V, 50 Hz supply. Microprocessor based programmable protection unit shall have settings for overload, short circuit, instantaneous and earth fault currents with time delay and LED indicators to show various conditions such as Power ON, Overload, Short-circuit, Instantaneous Earth fault, Percentage load, Self Diagnostic Test etc. 150

151 Mechanical spring charging mechanism stored energy type shall be provided with mechanical indicators to show 'Open', 'Closed', 'Service' & Test positions. The circuit breaker shall be provided with mechanically operated emergency tripping device. This device shall be available on the front of the panel. The control supply shall be 240 V AC. 6 NO + 6 NC auxiliary contacts shall be provided. The interlocks shall be as under: It shall not be possible to plug in a closed circuit breaker or to draw out a circuit breaker in closed position. It shall not be possible to operate a circuit breaker unless it is in fully plugged-in, test or fully isolated position. In test position, the breaker shall be tested without energizing the power circuit. The ACB feeder cubical door cannot be opened when ACB is "ON". However, it shall be possible to defeat this interlock for inspection purpose. Closing and trip coils shall work under the following voltage variation conditions: Closing coils - 85 % to 110 % of rated voltage Trip coils - 50 % to 130 % of rated voltage For series tripping, overload, short circuit and under voltage/shunt trip release shall be provided. Built-in relays for overload, short circuit, instantaneous and earth fault protection shall be provided for incoming feeders ACB. Suitable port like RS 485 must be available in ACB for transferring/ communicating data pertaining to operation parameters, to main PLC/ DCS Panel. Current rating, short circuit current, protection relays etc. shall be as specified in feeder details. (vi-2) Moulded Case Circuit Breakers (MCCB): MCCBs shall always be provided with separate rotary operating handle mechanism with door interlocking. The MCCBs shall be of three / four pole construction (as required in the feeder details) arranged for simultaneous three / four pole manual closing or opening and automatic instantaneous tripping on short circuits. MCCBs shall be provided with adjustable type tripping device with inverse time characteristics for over load protection. Closing mechanism shall be quick make, quick break & trip free type. Operating handle shall give a clear `ON', `OFF' & `TRIP' indications. Control voltage for MCCB shall be 240 volts. The MCCBs shall be rated for continuous maximum duty as specified. The rating of the MCCBs shall be as per the feeder details. Minimum rated breaking capacities shall be as under: 151

152 MCCBs up to 200 Amps 35 KA MCCBs above 200 Amps 50 KA Note: All feeders having 3 pole MCCB shall be provided with neutral link complete with isolating link. However, the MCCBs for incoming and nonmotor outgoing feeders shall be of 4 pole construction, unless stated otherwise. (vi -3) Motor Protection Circuit Breaker (MPCB): All motors below 40 HP shall be protected by Motor Protection Circuit Breakers (MPCB) having suitable rating thermal overload relays. These shall be used along with contactors as specified in feeder details. The MPCB will have motor protection tripping characteristics, current limiting and shall have low let through energy. It shall have bi-metallic overload protection and electromagnetic release for short circuit protection. MPCB shall have inbuilt single phase protection and adjustable overload settings. In the MPCB, it shall be possible to have accessories like auxiliary contacts, trip alarm contacts, shunt release/under voltage release, as required for motor control and protection. MPCB shall give indication for ON / OFF and tripping on fault. The breaking capacity of MPCB shall not be less than 50 KA. MPCB shall have rotary operating mechanism with door interlock and provision to lock it in OFF position with a padlock. (vi -4) Switch Disconnector fuse units: The load break switches shall be heavy duty, air break type suitable for continuous maximum rating with manual quick make / break mechanism. These shall have positive isolation with positive indication of contact separation. They shall have high short circuit making and withstanding capacities. Breaking capacity shall correspond to AC 23A utilization category. Mechanical interlock shall be provided to prevent opening of door in switch 'closed' position and prevent closing of switch in door 'open' position. However, it should be possible to defeat this arrangement for testing purpose. Live terminals of the switch shall be shrouded. (vi -5) Fuses: These shall be non-deteriorating HRC cartridge link type with operation indicator which will be visible without removing fuses for the service. These shall be complete with moulded phenolic fuse base and cover. The fuse base shall be so located in the modules to permit insertion of fuse pullers and removal of fuse links without any problem. One set of fuse pullers to cover entire range of fuses used in the panel shall also be provided. (vi -6) Contactors: The rating of the power contactors shall be as required depending upon the feeder rating indicated in the specifications and as per the feeder details table provided in this specification below. Contactors coils shall be 152

153 suitable for 240 volts, 50 Hz. unless otherwise specified. All contactors shall be supplied with minimum 2 NO + 2 NC auxiliary contacts. Additional contacts if required for interlocking etc. shall also be provided. Minimum contactor rating for power shall be 9 Amp. All the three contactors of Soft starter shall be of same rating. Rating of contactors shall be based on feeder rating. All contactors of motor starters shall be suitable for AC 3 duty unless specified otherwise. (vi -7) Intelligent Motor protection relays (IMPR): Intelligent Motor protection relays (Intelligent controllers/intelligent motor management devices) are required for motor feeders instead of bimetallic overload relay as specified in the special requirement of this project/approved drawings. These shall be fixed on DIN rails or on mounting boards. The IMPR should provide the communication ports for the connection to the communication network. It should be easily integrated into the communication architecture with remote information access. It shall have minimum 4 nos. digital inputs & 2 no. digital outputs. The Thermal overload trip shall have selectable tripping class 5, 10, 15, 20, 25, 30. The reset shall be through manual, automatic or remote It shall be an open communications system, which means that it shall be directly connected to the main industrial network protocols, listed below: - ModBus SL - ModBus / Ethernet - Profibus DP - DeviceNet The IMPR should embed the relevant network protocol in built-in (native) mode. The IMPR bidder should provide user-friendly software running in a Windows environment to ease the IMPR on-relay configuration. The software should have menus and icons for easy access to the data required, guided navigation to go through all the data of the same function in one screen and with a file management system. (vi -8) Timers: The timers shall be continuously adjustable & electronic type, suitable for 240 V, 50 Hz supply. The timers for Softstarter automatic starters shall have time delay of 0 to 60 seconds between changeover of contacts. (vi -9) Push Buttons (PBs): Push buttons shall be complete with actuator and contact block and shall be generally mounted on doors of the cubicles. Colours shall be as follow: Stop/ open/ emergency - Red 153

154 Start/ close - Green It should have minimum 1 NO + 1 NC contacts. Push buttons shall conform to IP - 65 protections against dust and water ingress. (vi -10) Indication Lamps: All outgoing & incoming feeders shall be provided with ON indication lamps. Colours shall be as under: Phases : Red, Yellow & Blue ON : Red OFF : Green TRIPPED : Yellow Indicating lamps shall be of LED (cluster of high intensity light emitting diodes) type, suitable for 240 V AC supply. These shall be provided with translucent covers of red, green and amber colours as required. These lamps shall be of minimum 22.5 mm dia. Indication lamps to be provided for all feeders. (vi -11) Current Transformers (CTs): CTs shall be cast resin insulated type. Primary and secondary terminals shall be marked indelibly. CTs shall preferably be mounted on stationery parts. These shall be capable of withstanding momentary short circuit and symmetrical short circuit current for 1 second and shall have a minimum rating of 10 VA. Neutral side of CTs shall be earthed. Protection CTs shall be of low reactance, accuracy class "5P" and an accuracy limit factor greater than "10". Instrument CTs shall be of accuracy class 1.0" and accuracy limit factor less than "5.0". Separate CT's to be provided for protection and metering purpose. (vi-12) Measuring Instruments: These shall be of digital square pattern meters having approximate dimensions 96 mm X 96 mm, flush mounting type. Necessary auxiliary instruments like CTs etc. are also included in the scope of supply. All AC meters shall be of Digital type for displaying three phases reading. Suitable selector switch shall be provided if the digital meter does not have provision for simultaneous display of three phase readings. Voltmeter shall be suitable for direct line connection. Voltmeters shall be connected through MCBs only. Intelligent Panel Meter shall be provided with incoming feeder of the MCC for the measurement and digital display of Multifunctional Electrical Parameters such as voltage, current, active power, reactive power, frequency, power factor, active energy, reactive energy, etc. Data port will be provided to communicate all these parameters to Main PLC Panel through suitable data bus/ signal communication cable. All motor feeders of 15 HP and above shall be provided with ammeter. Ammeter shall also be provided for all incoming & outgoing ACB / MCCB / switches of rating 100 A & above. 154

155 Ammeters shall always be CT operated. Special Requirements of the Project: Feeder details for incoming and outgoing for this project as per battery limit to be worked out by the bidder as per the design requirements of the plant. All motor feeders will have SOFTSTARTER starter. Variable Frequency Drive (VFD) Unit will be provided for a motor feeder if specifically mentioned and required as per design requirements. Suitable Line Chokes shall be provided in VFD feeders. Each motor feeder shall consist of an MPCB/ MCCB, contactors (single contactor for SOFTSTARTER and three nos. for Softstarter started motors), an IMPR (Intelligent Motor Protection relay or intelligent controller), auxiliary relay, start& stop pushbuttons, ON/OFF/TRIP indicating lamps and SPMCB for control circuit protection Intelligent motor protection relay (intelligent controller) shall have minimum 4 nos. digital inputs & 2 no. digital outputs. If needed separate 24V DC power source (for controller only) shall be provided from suitable rating UPS. Soft Starter must have inbuilt protections for single phasing, phase sequence, over current, over voltage, under voltage etc. In case of motors having embedded thermistor winding, Soft Starters for these motor feeders should have in-built thermistor relay. (i) The following selection table shall be followed for motor feeders unless otherwise specified: Sr. No 415 V Motor HP Contactor Rating Amps MCCB Rating Amp MPCB Rating Amp Type of Starter 1 Up to 3 HP 9-9 Soft Starter 2 5 to 10 HP Soft Starter to 15 HP Soft Starter 4 20 to 25 HP Soft Starter 5 30 to 35 HP Soft Starter 6 40 HP Soft Starter 7 45 HP Soft Starter 8 50 to 60 HP Soft Starter 9 65 to 70 HP Soft Starter to 90 HP Soft Starter 155

156 to 125 HP Soft Starter to 180 HP Soft Starter to 250 HP Soft Starter to 400 HP Soft Starter For capacitor, rating of contactors / switch shall be double of rated current of capacitor. (ii) (iii) (iv) (v) (vi) (vii) For incoming feeder of rating up to 630 A, 4 pole MCCB & for rating higher than 630 A, 4 pole ACB shall be provided unless otherwise stated in the feeder details. Each incoming feeders shall be complete with earth leakage relay. For each incoming feeder, a microprocessor based data logger (Multifunction meter)to be provided to indicate and store 3 phase voltages, 3 phase current, power factor, energy consumed in KW hr and KVAR etc. In addition to the connected load to each IMCC, at least 20 % (based on KW rating of the IMCC) spare outgoing feeders complete with starters shall be provided. These spare feeders shall cover as far as possible more or less all sizes of starters including two nos. 10 HP SOFTSTARTER, two nos. 15 HP soft starters, two nos. 200A TPN SDF feeder, two nos. 100 A MCCB feeders and one 63 A TPN SDF unit to be provided for connecting welding sets. For High electrical loads (large motors) like FD fan, Crusher, ID fan etc, capacitors shall be placed in the IMCC & these shall be automatically connected to the bus, once the respective feeder is put ON. Each capacitor feeder shall have MCCB for isolation, capacitor duty contactors for ON/OFF, start/stop pushbuttons, auto/manual toggle switches, SPMCBs for control circuit etc. MCCB, 4 pole shall be provided (unless stated otherwise) for outgoing feeders of rating 63 Amps and above and preferably these shall be located at the lower portion of the panel. These feeders shall have isolating link for neutral in case 3 pole MCCBs. These non motor feeders are to be supplied as per the specific requirement specified for the project. Electrical interlocking shall be provided between various feeders as required by the process and specified in feeder details. Interlocking will also be provided in software programme of Main PLC Panel. ON/OFF operation of all motor feeders shall be possible in both Auto mode (PLC signal operation) as well as Manual mode from MCC through selector switch. Indication for ON/OFF/TRIP for all motor feeders shall be provided. 156

157 (viii) (ix) If the total operating load on MCC is more than 600 kw, (including spare feeders load and future expansion load as described in design basis) MCC shall have two incoming ACB feeders (double incomer with necessary interlocks to enable redundancy in case of cable/switch failure). Each incoming feeder shall have independent instrumentation, protection relays, etc. Provision shall be made to communicate operational parameters / data from all incoming/outgoing feeders to main PLC/ DCS Panel through suitable data bus/ signal communication cable. Operation parameters of motor feeders like ON/OFF status, actual current, trip status etc shall be communicated. Sr. No Name of Items 1 ACB and its relays 2 Moulded case circuit breaker 3 Motor protection circuit breaker 4 Switch Dis-connector fuse unit 5 HRC fuse links 6 Miniature circuit breaker 7 Contractors 8 Starter relays 9 Electronic timers 10 Push buttons 11 Indicating lamps 12 Current transformers 13 Measuring instruments 14 PVC insulated control wires 15 PVC insulated power wires 16 Terminal blocks 17 Soft starters 18 Variable frequency drive 19 IMCC panel Makes of Items 1 st 2 nd preference preference (x) (xi) Bidder has to submit GA, control & power circuit drawing for approval to purchaser before starting manufacturing of MCC. Induction motors (above 10 KW) having 3000 RPM shall require higher rating for switches, fuses, MPCB, contactors and electronic timers due to very high starting current. IMCC bidder to specially check this requirement from purchaser before preparing the drawings. Bidders should specify maximum two "makes" of the following items in order of preference: All the major components of an IMCC shall be of same make. 157

158 Wherever desired distributed I/Os with Communication adaptors or linking devices shall be installed in each shipping split or shipping section and factory wired to each starter unit. IMCC shall be connected to remote controller/scada via one network of high bandwidth. Network connection from remote controller wherever required is to be made to the communication adaptor/linking devices installed in each shipping unit. However in general it is preferred that all the intelligent relays, soft starters and VFD provided in the panels for electrical equipment shall be interfaced to the Central PLC through open protocol communication cable (open networks) for control action and data acquisition/diagnostic information directly at device level. The communication protocol (bus) for intelligent controller and packaged PLC shall be same for ease of communication. The VFD shall be dynamically controlled from the PLC depending on the program and feedback system from field. These VFD shall have Battery backup and communication port. The routing of network cables in IMCCs may be through horizontal and vertical wire ways. However more optimized approaches such as use of Trunk lines and drop lines isolated behind barriers or Independent, easy-connect ports on drop lines - are preferred. These configurations would provide independent, readily accessible ports to simplify installing, withdrawing, relocating and adding plug-in units. The configuration is preferable to daisy-chain architecture, in which moving or adding an MCC unit requires interrupting the chain and disabling downstream units. The open networks shall be such as Ethernet, Modbus, CANopen, DeviceNet and PROFIBUS. The specifications of the intelligent motor control relay (Intelligent motor management relay) shall be as given below: A) General The motor management device should confirm to IEC , & for overload and thermistor protections. The device should be suitable for operation at ambient temperature up to 60 Deg C. The components in the main circuit (i.e. Current / Voltage measuring devices) should have rated operation voltage of up to 690V. The device should offer comprehensive motor management functions including Protection, Monitoring, Control and Diagnostics functions as detailed subsequently in this specification. B) Construction The motor management & control device should be of the latest technology available. The device should be compact and preferably modular in construction. The device should have integrated communication port for direct link to higher level, with open protocol bus system like profibus preferably. The protection system should be independent / autonomous of the automation system. i.e. Motor protection & control should continue to be 158

159 available for operation in the event of a communication or automation system failure. The device should have a control voltage of either 24V DC or a wide band control voltage from 110 to 240 V AC/DC, as applicable. The basic unit shall have the following minimum status display a) Device Readiness b) Status of control supply c) Feeder fault indication d) Status of communication with PLC The device shall have facility to test/reset as standard. It shall be possible to select between manual reset (at the device) or remote reset (through PLC/SCADA from control room). The device shall have following minimum no. of Digital Inputs & Outputs as standard which should be freely assignable. 4 Digital Inputs 3 Digital outputs (Potential free) Optionally, It shall be possible to expand the no. of digital inputs / outputs, if required, using add-on modules. C) Functional Requirements Protection Functions The device shall incorporate the following protection function as standard a) Overload protection with trip class adjustable from 5 to 40. b) The device should have an in-built Thermal Motor Model (Thermal Memory). c) It shall be possible to adjust the reset time after an overload. d) Provision for connecting thermistor inputs. e) Phase failure protection. f) Unbalance protection with adjustable time delay. g) Stall protection with adjustable time delay. Monitoring Functions The device shall incorporate the following monitoring function as standard. a) Over current monitoring with adjustable time delay. b) Under current monitoring with adjustable time delay. c) Earth fault Monitoring with adjustable time delay. When threshold value of above settings exceed, it shall be possible to set the type of response (Warning, Tripping, Signalling and Disable). a) Motor Operating Hours monitoring 159

160 b) Motor Stop time monitoring c) No. of starts monitoring When threshold value of above protection setting exceeds, it shall be possible to set the type of response (Warning, Signalling and Disable) Additionally, the following monitoring functions shall be possible as an option and should be provided for feeders wherever specifically asked for. a) Under voltage monitoring b) Power factor monitoring c) Active Power Monitoring d) Phase sequence monitoring e) Temperature monitoring via PT100 / PT 1000, NTC, KTY 83/84 inputs f) Recording the curves of measured values like current, voltage, power etc. g) Monitoring of analog values using Analog I/O modules Control Functions In order to minimize the wiring & interlocks, the device shall have built-in software logics to achieve the various control functions like (a) Direct on line starter (SOFTSTARTER) (b) Reversing SOFTSTARTER (SOFTSTARTER) (c) Automatic Softstarter starter (d) Pole changing starter (e) Positioner (f) Solenoid valve The device may be chosen as per the requirement of the individual feeders. Logic Function Modules The Intelligent Motor Control and Protection Device shall offer the following in-built logic functions. (a) Truth table (b) Timer (c) Counter (d) Flashing function (e) Flickering function With the above functions it is envisaged to reduce the hardware in the feeder viz. timers. The flashing/flickering functions must facilitate multiple functionality to the same lamp - to glow constantly when the feeder is OFF and flash on the event of a trip caused by a fault. 160

161 Standard function blocks The Intelligent Motor Control and Protection Device shall have standard control function control blocks. (a) Check back signal (b) Test Position feedback (c) External fault (d) Emergency start (e) Communication Error (f) Testing the device including tripping of the feeder (g) Testing the device without tripping the feeder Diagnostics, Service & Operating Functions The motor management system shall make available the following diagnostics, service and operating data on the bus system for further processing by the higher level control system. (eg. PLC/SCADA). Operating data The following shall be available at the PLC as part of the cyclic send data 1. Motor switching state (ON,OFF direction of rotation, right, slow fast etc). 2. Current (maximum of the 3 phases). The cyclic send data should consist of a minimum of 16 bits for communicating status of various aspects of the feeder like current limit exceeded, motor operating hours exceeded etc. Diagnostic & Service data a) The device should be capable of signalling/warning in case of overload of 115% of set current. b) It should be possible to set warning or trip as response for current limits exceed, unbalance in current, earth fault, operating hours exceeded etc. c) It should be possible to read from the device the value of last trip current. d) In case of a device fault or a trip, the device shall send the diagnostic data to the PLC for the user to analyse. The diagnostic information should consist of Status information on fault type, status information on limits exceeded, Status information on warnings, device healthiness, bus fault, cooling down period (in case of overload fault), no. of starts, motor operating hours etc. e) Event log with a capacity to record last 20 events, shall be accessible whenever required. 161

162 Measured Values: The device shall by default transmit the current value (maximum of the 3 phases). However, it shall be possible to access from the PLC other related parameters like percentage of unbalance, power factor, current in the 3 phases, last trip current, time to trip (for a feeder undergoing overload), cooling down period (after an overload trip), active power, apparent power. Optionally where power/voltage monitoring is specified the following additional data should be available a) Voltage in the three phases (Line-to-Line) in Volts b) Consumed energy in kwh c) Active Power in Watts d) Apparent power in VA e) Phase voltages in V f) Power factor g) Phase sequence D) Configuring & Communication The bidder shall offer standard software for configuring the device. It shall be possible to configure a device either individually or over a communication network. For this purpose, provision for connecting a laptop should be available at the motor management device. The device shall have integrated communication facility to communicate directly on a bus system without any additional components. The device shall be able to transmit cyclic as well as acyclic data to higher-level automation. It shall be possible to define each bit in the cyclic and acyclic data sent to the PLC. The data defined as cyclic shall be fetched by master PLC in a sequential manner. i.e. one slave after other. The critical events like tripping of device or alarm shall be sent to master PLC on priority basis (acyclic transfer) irrespective of the slave sequence. In order to achieve minimum response time, the device shall be capable of transmitting data at a speed of 12Mbps, suitable for operation with high-speed bus systems. The following selection table shall be followed for cables of motors unless otherwise specified: 162

163 Minimum size of steel braided copper cable for various rating of motors (to be laid between MCC and motors) Sr. No Motor Full load Power cable rating (at Rating current Type of starter ambient temp of 45 C HP Amp Soft Starter suitable Soft Starter Suitable Soft Starter suitable Soft Starter suitable Soft Starter suitable Soft Starter suitable Soft Starter suitable Soft Starter Suitable Soft Starter suitable Soft Starter suitable Soft Starter suitable Soft Starter suitable Soft Starter suitable Soft Starter Suitable Soft Starter suitable Soft Starter suitable Soft Starter suitable Soft Starter suitable Soft Starter suitable Soft Starter Suitable Soft Starter suitable Soft Starter suitable Soft Starter suitable Soft Starter suitable Soft Starter Suitable Soft Starter suitable Soft Starter suitable Soft Starter suitable N.A Soft Starter suitable Note: Suitable de-rating factor of cables as per manufacturer's guidelines to be applied where more than one cables feeding to various motors/drives are to be laid in parallel 3 phase 415 V motor HP Aluminium conductor cable size : sqmm Soft Starter Soft Starter Supply side Motor side Supply side Motor side x x x x x

164 x x x x x x x x x 240 Note: Cables indicated above in the table shall be only armoured copper conductor cable up to 50 HP motor. Armoured aluminium cable will be used with concern to purchaser. Wherever needed as per process requirements, VFDS shall be used and these shall be clearly listed out in the offer. VFDS shall have input chokes on line side. Load side chokes wherever required are also to be included. ELECTRICAL ITEMS / ACCESSORIES: Cable trays from PCC to MCCs & further distribution inside the plant, earth pits & earth strips shall be of GI. Earthing for automation and instrumentation shall be independent of power earthing. Earthing of individual motors shall be provided with PVC insulated 4 sq mm copper wire. For higher rating motors, GI earth strip of suitable cross-section shall be provided. All Isolators, junction boxes shall be in Al. Die cast housing or thermo-plastic construction as directed by purchaser. The cable drops (power, control & instrument cables) from the overhead cable trays shall be through GI conduit pipe. Necessary 11KV 12 mm thk. Full length rubber mats should be provided for all MCCs, sub-power panels. (i) MOTOR ISOLATORS/EMERGENCY PBS, CABLE TRAYS, CABLE GLANDS, CONDUITS, CABLE CONNECTORS, CABLE ROUTE MARKER, CABLE INDICATORS (ii) LT POWER CABLES Power cables for use on 415 V system shall be of 1100 volt grade, copper conductor, PVC insulated, metal braided, rodent proof (up to 50 Sq.mm) & unless otherwise specified, aluminium conductor (above 50 Sq.mm), XLPE insulated, PVC sheathed, armoured and overall PVC sheathed strictly as per IS : 7098 PART 1/1988. The size of cable shall be as specified in cable selection chart. No copper cable of size less than 2.5 sq. mm. shall be used. (iii) LT CONTROL CABLES Control cables for use on 415 V system shall be of 1100 volts grade, copper conductor, PVC insulated, metal braided, Rodent proof armoured PVC sheathed armoured and overall PVC sheathed, strictly as per IS: 1554 (Part I) The minimum conductor diameter shall be 1.5 sq.mm. 164

165 (iv) EARTHING SYSTEM: Earth Pit Plate type earth electrode with earth pit shall be provided for this work unless otherwise advised by site engineer due to typical site conditions. Earthing electrode and pit shall be as per IS: the latest revision (code of practices for Earthing). Sketches for pipe and plate type earth electrode earthing pit have to be submitted for approval. All earth electrodes shall preferably be driven to a sufficient depth to reach permanent moist soil. Earth pit centre shall be at a minimum distance of 3 M from nearest building, unless otherwise advised. The minimum 3 M distance shall be maintained between centres of 2 earth pits. Earth electrode for PLC, instrumentation earthing shall be of copper, whereas the same for all other application (LT / MCC /Electrical panels) shall be of GI. Earthing electrodes for Main plant lighting panel shall be plate type with double earthing. Earth Bus, Earthing Lead & Earth Wire/Strip All electrical equipment is to be doubly earthed by connecting two-earth strip/ wire conductor from the frame of the equipment to an earthing pit/ main earthing ring. The earthing ring will be connected via links to several earth electrodes. The cable armoured will be earthed through the cable glands. Conductor size for connection to various equipments shall be as specified in the drawing or as instructed by the Engineer-in-charge. However, the length of the branch leads from equipment to earthing grid/ ring shall not be more than 10 to 15 meters. All hardware for earthing installation shall be hot dip galvanized. Spring washers shall be used for all earthing connections of equipment having vibrations. Size of earthing lead/ wire shall be as specified in schedule of quantities/drawings. Below Table may be considered as general guidelines. However, while deciding type & size of earth lead, the resistance between the earthing system and the general mass of the earth shall be as per IS code of practice. The earth loop impedance to any point in the electrical system shall not be in excess of 1.0 Ω in Contract to ensure satisfactory operation of protective devices. G.I. wire/ Copper wire shall be connected to the equipment by providing crimping type socket/ lug. Wherever earthing strip to be provided in cable tray, it shall be suitably bolted on cable tray and electrically bonded to the cable tray at regular interval. Excavating & refilling of earth, necessary for laying underground earth bus loops shall be the responsibility of the Bidder. Wherever earth leads/ 165

166 strips/ wire are laid in cable trenches, these shall be firmly and suitably cleared to the walls/ supporting steel structure on which cable is clamped. All LT Electrical panels shall be double earthed i.e. connected to earth pit independently and earth pit shall have GI earth plate. Earth strips for panels shall be interconnected wherever possible. Long runs of GI strip shall be connected at each end with lap type welding to ensure continuity. Sizing of earthing lead/wire Sr. No Item Size 1 Control switches / glands Copper wire 14 SWG 2 Motor / isolators up to 40 HP Copper wire up to the cable tray and GI strip 25 x 3 mm 3 Motor above 50 HP up to 125 HP GI strip 40 x 3 mm 4 Motor above 125 HP GI strip 25 x 6 mm 5 Switch board / MCC GI strip 50 x 6 mm 6 Earthing main in trenches GI strip 50 x 6 mm POWER CAPACITOR BANKS: FUNCTIONAL REQUIREMENTS The power capacitor banks shall be used to improve the power factor of an electrical system. These will be placed parallel to switchgears for motors above 30 HP in the IMCC & shall have their own switchgears for isolation with fan cooling facility. DESIGN REQUIREMENTS Each basic unit is to be built up with a number of elements. These elements shall be of two layer dielectric design (non-self-healing) using heavy Polypropylene Film, Aluminium Foil and Capacitor Tissue Paper as required, ensuring that total dielectric thickness is more than 14 micron. Capacitor element must be completely sealed with epoxy resins to provide maximum humidity protection and highest insulation. The capacitor elements are to be given adequate outside insulation and should be put in all welded surface treated containers. The outer surface shall be provided with a coat of protective primer followed by two coats of synthetic enamel paint of approved shade. The metal case shall be equipped with porcelain bushings to permit connection between power lines and active capacitors. The unit shall have built-in internal individual fuses. Externally each capacitor unit shall have two separate earthing points, name plate confirming to the requirements of IS-2834 (amended up to date), discharge resistances etc. Capacitor requirement shall be worked out as per the plant load requirements by the bidder 166

167 REMOTE CONTROL PANELS Remote Control panels other than Boiler Control panel, essentially are required for the following ; 1. Fuel handling, storage & feeding system. 2. Pollution Control Equipments. Generally, these shall be floor/structure mounted type as per site requirement. These shall be made of Al. Cast housing for wall mounting. Front cover shall be removable type with suitable rubber gaskets to make them dust, vermin and moisture proof & with a degree of ingress protection for housing shall be IP - 54/55. Each feeder of station shall be provided with name plate (white Bakelite), indication lamp, one `ON' (Green) push button and one 'OFF' (Red) push button with latch to prevent accidental starting. Green and Red push buttons shall have contact elements having 1 NO + 1 NC. Heavy duty connector to be used in RCP for internal wiring. Indication lamps to be LED type to give bright indication. These shall be of 22.5 mm dia and having operating voltage of 240 V AC. These can be floor/wall mounted type and made from CRCA sheets with suitable supporting arrangements. These can be as per the standard design of the manufacturer of the related machine. BOILER CONTROL PANEL: The complete control panel shall be supplied and installed with all instruments and components such as LED indicator type push buttons, indicating LED with window annunciator, temperature /pressure controller, digital temperature indicators etc. The control panel should be made from 14 Gauge CRCA sheet duly pre-treated and powder coated. It should also have audio alarming system for all the fault condition, which should appear, visually on annunciator window. Major instrument controls & safeties required are: Sr. Description of condition Control requirement No 1 Water level control in Through mobrey level controller for drum feed pump on-off 2 Low level in boiler Feed water pump on - visual indication 3 Extra low level in boiler ID fan cut-off with alarm, boiler trip 4 Very low level in boiler Fusible plug blow 5 High steam pressure in ID fan cut-off, alarm, boiler trip boiler 6 Steam pressure high Safety valve lift 7 Extra low in feed water Feed water pump trips with alarm tank 167

168 8 TDS controller for blow Pneumatic / electrically operated down with indicator controller for blow down valve 9 Stack temperature high Alarm and boiler trip 10 Bed temperature high Alarm and fuel feeder trip 11 Water flow measurement Water flow meter with indicator 12 Steam flow Steam flow meter with indicator measurement 13 Direct efficiency Direct efficiency monitor monitoring 14 Combustion control O2 trim 15 Blow down heat recovery Circulation pump operation depending on temp of blow down inlet temp to plate heat exchanger 16 Pressure reduction Automatically controlled through electro-pneumatic controller. A separate display shall be provided for monitoring Boiler efficiency with indications of fuel consumed with steam generated. Other Control & safety All the legal safety measures should be taken with regard to pressure, water level and flue gas temperature. In the scope of supply you can find the complete list of the control and safety equipment. The following control logic should be incorporated. Fuel Circuit The fuel in the hopper should be regulated and the fuel conveyer should be stopped and started based level of fuel in the hopper. Fuel Flow & Air Control Coarse Control The fuel feeding system controlled through VFD with an interlock based on the load on the boiler. PA motorized dampers, Secondary air motorized dampers and the quantity of fuel. All primary air and secondary air motors damper motors should be controlled through the PLC automatically with respect to the load fluctuations on the boilers up to 30% of the rated capacity. O2 Trim control system ID Fan, Primary Air Fan & Secondary Air Fan. Safety Control The O2 trim should also incorporate the safety feature in which the boiler switches off in case O2 level drops below 2.5% Safety Interlocks Pressure Range for furnace pressure control. In case of positive pressure PA & SA Fan Trip. 168

169 Pressure Switch in Drum Boiler Trip in case of high pressure Outlet Temperature of Boiler High (set point) Bag filters Bypass. Auxiliary Controls for Boiler House Equipments Fuel Circuit Crushed Fuel Storage Hopper Full Crusher & Conveyer Stop Crushed Fuel Storage Hopper Empty Crusher & Conveyer Start Boiler Trip Conveyer Stop CONTROL AND SAFETY EQUIPMENT HARDWARE 1 Pc. Regulation pressure switch 1 Pc. Safety pressure switch 1 Pc. Low water level on water level regulator (Software) 1 Pc. Low water level protection 1 Pc. Low water level protection with float 1 Pc. High water level protection with float 2 Pc. Water level gauges 2 Pc. Safety valves 1 Pc. Flue gas temperature control with digital display (for incorporation in the control panel) 1 Pc. Manometer Any other instruments/controls not mentioned but required to complete automation requirements shall be supplied, installed & commissioned by the successful bidder, as this is a total job requirement. Field Instruments, Control Valves and Accessories. General Field Instruments shall be suitable for area in which these are located. In general, field instruments shall be weatherproof, dust tight and corrosion resistant with Protection Class IP-65. Field instruments shall be suitably mounted, supported and terminated in local SS/ CA junction boxes. Dial size for all pressure and temperature gauges shall be 150 mm and any lower size selection specific to the application shall be subject to the purchasers approval. In general the minimum accuracy of the instruments shall be as below: Electronic transmitters: ± 0.2 % of FSD Pressure & temperature gauge: ± 1.0 % of FSD Conductivity transmitter: ± 0.5 % of FSD Level gauges: ± 5.mm of the reading The repeatability of pressure, temperature, level and flow switches shall be ± 2.0 % of FSD (minimum). 169

170 Measuring ranges of transmitters shall be selected in such a way that best accuracy of measured value (in the measurement range) is achieved. Material of construction of thermo well shall be SS 316 suitable for the application. The cable & instrument air inlet at the instruments would have proper protection. Instrument air tapping from header shall be of SS-304 pipe with SS-304 distributor & FRL/moisture trap etc. All field instruments/ equipments shall be provided with stainless steel (SS) tag plates with engraved tag no. and service description. The tag plate shall be secured to the instrument/equipment with SS chain. Transmitters (Temp. & Pressure): 1 Lot The transmitters shall be provided as per requirement for utility having best accuracy/reliability, as available in the market and the hard wired signals (4-20 ma) shall be connected with automation system through I/O stations. The transmitters shall have field diagnostic/configuration facility. Proper sanitary type mounting arrangement shall be provided for installation of the sensors in various tanks/ pipelines, suitable for the application. The transmitters shall have separate local digital indicators as per requirement. Measuring ranges of transmitters shall be selected in such a way that the rated value of the measuring variables appears at approx % of the span. Accuracy of the process transmitters should be plus or minus 0.2 % (minimum) of measured value or better. The sensing elements and internal parts shall be constructed with AISI 316. In case of stock and corrosive fluid application, diaphragm seal type transmitter with capillary is foreseen. The bidder to quantify the number of such transmitters required, based on the specification as well as functional requirement & offer accordingly. Gauges: 1 Lot Process gauges shall be provided for local indication on all utility lines & tanks (as necessary). Pressure gauge sensing element shall be Bourdon/Bellow/ Diaphragm type in general depending upon the process condition. Direct reading Pressure/Differential Pressure gauges shall be used of SS 316 sensing element and AISI 304 movement material. 170

171 Local temperature measurement shall be done bi-metal Temperature gauges. Temperature gauges may be direct mounted type (multi-angle) or with SS capillary extension (at least 2 Mtrs) as per the application area. The sensing element / bulb / capillary etc. shall be of SS 316 for temperature gauges. The bidder to quantify the number of such gauges required, based on the specification as well as functional requirement & offer accordingly. Temperature Elements: 1 Lot All Temperature Sensors Elements shall be of Duplex type with SS 316 sheath (sanitary type). Depending on temperature ranges, Pt-100 Resistance Temperature Detector (RTD) or thermocouple shall be used. Thermocouple / RTD heads, with chain holder, shall be of the waterproof type, with duplex terminal block, gasketed cover and stainless steel chain. Screwed covers shall be used. Proper sanitary type mounting arrangement shall be provided for installation of the sensors in various tanks/ pipelines, suitable for the application. The bidder to quantify the number of such elements required, based on the specification as well as functional requirement & offer accordingly. Process Switches: 1 Lot Local switches for pressure, differential pressure, temperature, level, proximities etc. shall be having best reliability & accuracy as available in the market & provided as per requirement. The hard wired signals shall be connected with automation system through I/O stations. The switches shall be appropriate & suitable for the selected application. The level switches shall be tuning fork type/capacitance/laser beam type as required for the application. The bidder to quantify the number of such switches required, based on the specification as well as functional requirement & offers the full details of the same with the quotation. Set points shall be adjustable throughout the range. Switching differential shall be adjustable. Control valves: 1 Lot Control valves of required turn down for process & utility application shall be provided having best reliability & accuracy, as available in the market and the hard wired signals (4-20 ma) with field configuration facility. The CVs shall be connected with automation system through field I/O stations. For steam application, control valves shall have extended bonnet. The bidder to quantify the number of such control valves required, based on 171

172 the specification as well as functional requirement & offer accordingly. The valves shall be sanitary type for process application. Level Transmitters: 1 Lot Flange mounted diaphragm seal type level transmitters (or better sensor) of sanitary design & required turn down capacity shall be used for level measurement on tanks having best accuracy & reliability suitable for Dairy application, as available in the market. For concentrated chemical tanks ultrasonic LTs shall be provided. The wetted parts shall be of SS 316 or suitable material to suit process fluid. The sensor & electronics unit of the level transmitter should be separate or with remote seal to avoid moisture condensation. The level transmitters shall have separate field display (digital) unit having hard wired signals (4-20 ma) with field diagnostic/configuration facility. Connectivity with automation system shall be through remote I/O stations. The wetted parts material shall be SS 316 / SS 316L or as per the requirement of process fluid. Accuracy of LTs should be plus or minus 0.2 % of measured value or better. The bidder to quantify the number of LTs required, based on the specification as well as functional requirement & offer accordingly. Variable Frequency Drives: 1 Lot The variable frequency drives shall be smart type having field run bus connectivity with required diagnostic features. The VFDs should be configurable from the HMI/operating console as well as in the field. The VFDs shall have best accuracy & reliability, as available in the market. The bidder to quantify the number of VFDs required, based on the specification as well as functional requirement & offer accordingly. The VFDs shall have DC choke (inbuilt harmonic filter) apart from external AC line filters as per requirement. In sensitive locations, RFI should be provided to avoid any interference to adjacent electronic unit. 6.5 IMPORTANT NOTES The main boiler unit shall have pressure parts consisting of fusion welded shell, flue tube, tube plates, tubular passes, end plates, reversing chambers, steam drier units with all associated accessories. The boiler shall also consist of front and back smoke boxes. The firing / stoking arrangement should be designed to have optimum volumetric heat release rate for complete combustion. Rear access door shall also be provided and preferably the same shall be of bolted type for easy maintenance Insulation: Supply and application of insulation of boiler, refractory materials, brick works are completely in the scope of bidder. All portions of the boiler shell are to be lagged with glass wool mattress min.100 mm 172

173 thick and density minimum 100 kg/cum to ensure a safe working temperature. The insulation shall be retained with wire mesh. The boiler shell is then to be covered with GI cladding of 20 SWG thicknesses duly pre-treated before painting with two coats of heat resistant paint. The temperature of the outer shell should not be more than 5ºC of the ambient temperature. The main steam pipe line up to and including non-return valve shall also be insulated by the bidder Feed Water system: Feed water line to the Boiler shall be drawn from the outlet port of feed water tank; a common water flow meter shall be installed on the outlet line feeding both boilers to log the water flow rate & totalized flow. An online ph correction system shall be supplied & shall be installed in the common for FW inlet line for both boilers. Water flow meter Water flow meter vortex type, suitable for operation up to 100ºC Feed water temperature & size as per Feed water pump flow rate. The unit shall have local display of flow and totaliser with a provision of data communication port for future connectivity. The meter shall have an accuracy of +_1.0 %, & a repeatability of 0.5% of measured value & turndown ration of 20:1. The unit shall have a separate terminal compartment with sturdy field housing of IP67. The assembly shall consist of pipe reducers, flanged type isolating valves, bypass valve, ground electrode, wires & other required accessories on the common feed water pipeline, as per installation directions of the meter manufacturer. If the unit requires V DC supply, the necessary stabilized supply shall be in the scope of work. Feed water pumps : Two electrically driven multi-stage vertical type centrifugal pumps to match the capacity of the boiler (one for duty and one standby) shall be supplied with 4 TPH energy efficient motor (EFF1) with ingress protection class IP 55 with TEFC motor enclosure & Class F insulation. The pump should be capable of handling water at 100ºC temperature and pressure above maximum discharge pressure generated by the boiler. The class of motor insulation and number of stages of the pump should be accordingly selected. The pumps should have SS 304 body & impellers with mechanical seals. The pumps should be supplied with suction strainer, suction isolating valves (butterfly/ball type). The delivery line of pumps connected to the boiler, shall have feed check (spring loaded Disc type) valve, discharge isolation valve (Piston type) &100mm dia. pressure gauge. Separate delivery lines from the Feed water pumps to boiler are preferable. A digital temperature sensor with indicator shall be provided at the suction header of the pump, to indicate Feed water inlet temperature. A extra low level in the feed water tank shall trip the Feed water pump with alarm. Necessary wiring, sensor shall be in the scope of bidder. 173

174 AUTO ph CORRECTION SYSTEM: The system shall have a metering pump, to doze a fixed quantity of alkaline solution into the feed water line, after checking ph online. The system shall be complete with a mixing tank with agitator. A soft water line shall be connected to fill water to prepare a solution of desired concentration is included in the scope. The system shall be common for both boiler & shall be installed on the main feeding line. 6.6 ERECTION AND COMMISSIONING: The scope of work in brief includes positioning of the boiler on foundation, connecting feed water line, steam line up to main valves, safety valve vent line outside building, ID fan, blow down lines up to blow down pit, electrical panel installation, power & control supply, installation & termination to electric, double earthing of the panel and all the equipment, fabrication of ducting as per layout, positioning of the chimney on the foundation and making all necessary connections, completing all other associated works The boiler should be transported by the bidder after receiving intimation regarding readiness of the foundation. Boiler should be insured, transported and unloaded on foundation by the bidder All mountings, fittings, accessories etc. should be installed, aligned and piping, electrical connections etc. should be carried out as per the latest engineering practices Necessary refractory materials, cement and insulation materials shall be supplied and installed Chimney and ducting should be fabricated after getting the drawings approved from the Purchaser/ Statutory Authorities For commissioning and trial run of the boiler, necessary materials for 1st charge like lubricating oil, grease etc. shall have to be supplied by the bidder After commissioning the boiler the following parameters are to be established for the Boiler and recorded by the bidder. Sr. No Parameter Instrument / Method 1 Steaming rate Steam flow meter 2 HP steam pressure Pressure gauge 3 Overall thermal efficiency Indirect method 4 Overall thermal efficiency Efficiency monitor / direct method SPM level in flue gas after To be confirmed by bidder 5 pollution control equipment 174

175 6 Fuel consumption rate From fuel feeder 7 Electricity consumption for Energy meter in the IMCC entire plant 8 Water consumption rate Water flow meter 9 Blow down rate To be confirmed by bidder 10 Ultimate analysis of fuel Lab test 11 Proximate analysis of fuel Lab test 12 LP steam pressure Pressure sensor 13 Flue gas exit temperature Temperature indicator 14 Feed water temperature Temperature indicator The bidder's have to specify the methodology proposed to be adopted by them for establishing the design parameters. It will be the successful bidder's responsibility, to provide all the necessary additional instruments required for establishing the design parameters during testing and till the time the results are achieved and accepted by the Purchaser. Thereafter, the boiler should be on trial run the plant at rated capacity for minimum four weeks, during this period training should be imparted to the authorized operating personnel before handing over the boiler to Purchaser / Project Authority in satisfactory working condition. Necessary log sheet shall be maintained by the bidder during four weeks of operation which will be signed by both the bidder s and purchaser s authorized representative. The bidder shall take statutory approval for the complete installation prior to commission the plant Cost of services for which the functioning of the boiler shall be calculated is as follows; Electricity Rs.6.75/- per KWH. The working cost of the boiler with all its associated equipment shall be as per the evaluation criteria furnished in the Quotation. The total value of the same shall be worked out and quoted by the bidder separately in their offer The erection and commissioning should be carried out as per general terms and conditions of erection contract mentioned in the specification OTHER SUPPLIES HP STEAM PIPING Steam generated from both Boilers through the steam stop valves shall be directed to a common HP steam header within the Boiler House. HP steam shall be distributed to the plant across Pipe Bridge (to be provided by purchaser) to the PRS. One PRS shall be located near or within the Boiler House for Feed Water pre-heating & molasses pre-heating. Necessary expansion loops, air vents, Drain trap assembly for HP piping as per standard practices shall be included in the scope of work. All HP pipes & fittings, PRS shall be IBR approved. 175

176 HP STEAM HEADER: HP steam lines from each of the Boilers shall be terminated on a floor supported steam header suitably located in the Boiler house at an operation level. The size of the header shall be designed for simultaneous operation of Boiler. Each of the incoming & outgoing lines with 2 spare nozzles (50 mm) shall be terminated with an isolation valve. The header shall be insulated & shall have 100 mm dia Dial type IBR approved pressure gauge & condensate drain trap assembly. STEAM FLOW METER: IBR certified Steam flow meter shall be installed on the main common HP line (before PRS) & shall be suitable for a steam throughput of 4 TPH. Flow meter shall be vortex type with density compensation feature with digital display of flow rate, total flow, pressure, temperature etc & shall have communication port capable of generating analogue output. Associated fitment for proper flow-metering shall be included in this item. Installation of the flow meter shall be as per the OEM directives. The pipe fittings, assembly, pipe interconnections, flanges shall be as per IBR approved drawing with FORM III A. Necessary services like electrical connections/compressed air etc, if required for the flow meter shall be a part of this item. The make & model of the Flow meter to be supplied shall be intimated in the quotation & the necessary literature/brochure shall be submitted along with the quotation. STEAM PRESSURE REDUCING STATION (PRS): Steam Pressure reducing station (IBR) shall be supplied as per below specifications and installed in the Main plant located near the pellet mills in the main plant. Type: Electro-pneumatic (ROBERTOR) type station assembly, (IBR certified) Throughput: 3000 Kgs/hr of steam. 1 No. Steam Pressure shall be reduced from 10.5 kg/sq.cm to 3.5 kg/sq.cm. The PRS shall comprise of following IBR certified items; 1. Moisture separator with Drain assembly. 2. Inlet pressure gauge. 3. Inlet stop valve. 4. Strainer (with SS perforated screen). 5. Pressure Reducing valve (Electro-pneumatic type) 6. Outlet isolation valve. 7. Safety valve/valves (angle type). 8. Outlet pressure gauges. 9. Manual by-pass reduction valve. 176

177 The Control system of Pressure reducing valve shall have downstream pressure sensor, P to I converter, controller, with a system for remote setpoint setting & read-out. These pipe fittings shall be assembled on a common battery, duly insulated & suitably supported for operation/ maintenance at operable height. Pressure Reducing Valve shall be automatically modulated through an electro-pneumatic system by sensing the down-stream pressure. The pressure transmitter shall provide inputs for the controlling of steam pressure. The pipe fittings, assembly, pipe interconnections, flanges shall be as per IBR approved drawing with FORM III A. The entire assembly shall be insulated (50 MM thk) & aluminium cladded as per standard practice. The Other PRS in Boiler House or nearby molasses day tank, shall be Pilot operated self-acting pressure reducing station with a throughput of 700 kg/hr for the similar pressure reduction rating. Condensate from this PRS shall be recovered & directed to the break water tank. AUTOMATIC BLOW DOWN CONTROL SYSTEM: This system shall be used to automatically blow-down Boiler water in the shell portion by sensing the conductivity & shall be dedicated for each Boiler. This system shall be used to inline measuring the conductivity for Boiler water & automatically blow-down when TDS levels in Boiler water exceed a set level. The system shall have isolating valves, pneumatically operated control valve, non return valve, conductivity sensor of suitable range and of material of construction SS 316, controller to control and monitor TDS level of the boiler water, by-pass manual blow-down valve, upstream & downstream steam piping (IBR certified) and all other associated accessories. The entire assembly shall be insulated. The system shall include controller installed in a panel for 4 digit continuous digital readout of the set TDS & push button interface for calibration & testing. Other features shall include High TDS alarm output, automatic probe conditioner for descaling probe & automatic temperature compensation. The pipe fittings, assembly, pipe interconnections, flanges shall be as per IBR approved drawing with FORM III A. BLOW DOWN HEAT RECOVERY SYSTEM: This system shall be used to recover heat from the Boiler blow-down operation & shall be dedicated for the Boiler. The system shall envisage use of the following equipments; a) Flash vessel, b) Ball Float trap, c) Plate Heat Exchanger, 177

178 d) Break water tank (common for one planned and one future Boiler). e) Circulation pump (common for one planned and one future Boiler). Flash steam recovered from the flash vessel, due to intermittent blowdown shall be connected to the Deareator head of the feed water tank. The residual heat in the condensate shall be recovered through a suitable capacity circulation pump by circulating break tank water. The operation shall be controlled through a thermostat installed on the Blow-down inlet line to the PHE. Suitable size break water tank with nozzles to receive make up water & discharge water to boiler feed water tank deareator head shall be included in the scope of work. The pipe fittings, assembly, pipe interconnections, pressure gauges, flanges shall be supplied as required as a system. A cleaning system for PHE is included in the scope. The circulation line shall be insulated. INSULATION OF HP STEAM PIPING Thermal insulation of steam lines with resin bonded mineral wool in pipe form including cladding with 22 G Al. sheet as per IS (amended as on date) should be provided. STEAM PIPES, VALVES AND FITTINGS Suitably supported Insulated High pressure steam lines from the outlet of the steam stop valve/nrv from the outlet of both Boilers to header & up to PRS, with supports, valves, standard fittings like pressure gauge, drain trap assembly etc are included in the scope of work. The HP steam lines shall be designed as per PRS throughput connected to them. Necessary expansion loops shall be supplied for every 30 mts of straight line length of piping. Expansion loops shall have drip leg with condensate thermodynamic trap assembly, & necessary air-vents (thermostatic type) shall be provided. Type : Seamless Schedule 40 (IBR approved), welded type heavy duty piping with Forged steel body & bonnet (ASTM A 105) piston type valves/nrvs with Stainless Steel spindle & piston in flange/ screwed execution. Supporting: MS shoe, guide, roller support, in mild steel painted execution generally as per specification and meeting with IBR requirements. Accessories: Pipe sleeves, roller supports arrangement of flow measurement at the entry point to the plant. Pipe Insulation: 50 mm Thk insulation mineral wool, with 24 G aluminium cladding 178

179 6.7.2 COMPRESSED AIR HANDLING SYSTEM: AIR COMPRESSOR: One number Oil free Rotary screw air compressor of suitable Free Air Delivery (FAD) for the generation of oil-free & moisture free Compressed air of quality ISO , Class 0, suitable for pneumatically operated instruments & other requirements for generation pressure of 7.5 kg/sq.cm (g). This unit shall be complete with silencing canopy, intake filter & air cooling arrangement. The compressor shall have pre-mounted electrical cubicle to house control and monitoring system with local display. The drive for the compressor shall be controlled through a Frequency driven Variable Speed Drive. The motor shall be of high efficiency type with IP 55 level of protection with TEFC enclosure. The connecting Air dryer shall be integrated with the Air compressor & shall be supplied as a single unit. Matching capacity refrigerated Air Dryer with filters, automatic drain for ensuring the required air quality is included in the scope. All standard fitments required for proper functioning of the air compressor shall be supplied along with this unit. External air receiver of minimum 1000 L (MS tank) complete with safety valve, pressure gauge, automatic drain valve, bypass valve is included in the scope of work. Drain from the Air receiver shall be taken outside the building The Flow meter shall have remote display unit mounted on the control panel with open protocol connectivity for data transfer to the central MIS system. Compressed Air, fittings, tubing s & specials for all pneumatically instruments in the scope of supply shall be executed as per best industry practices. AIR RECEIVER: Capacity: 1000 litres Function: Air receiver shall store compressed air, help equalize pressure variation in pipes, & prevent short cycle loading and unloading of compressor. Design Requirement: Receiver shall be free standing vertical tank with dished ends which shall meet the statutory requirement of pressure vessels. Receiver shall be designed conformity to IS 7983 and the material of construction shall conform to the relevant IS in Mild steel. The receiver shall be complete with safety valve, service valves, 6 pressure gauge, fusible plug, hand holes and auto drain to remove moisture, lifting hooks,. The air receiver shall be suitable for Design pressure of 12 Kg/sq.cm & shall pass Hydrotest at 18 Kg/sq.cm. 179

180 COMPRESSED AIR PIPING AND VALVES Heavy duty, Galvanized Steel ERW piping C class (shall conform to IS 1239), only welded or flanged installation, complete with SS 316 internals ball valves, flexible metal braided hoses, PVC tubes, connectors & other fitment, brass nipples, 4 port, 3 way Solenoid valves etc as per requirement. Filter-cum-regulation units shall be provided at all distribution headers near all consumption points inside the plant. FRL units if required are to be provided as per specific need. Please Note: Bidder shall not consider any compressed air generation in their scope. Only storage & distribution of compressed air shall be considered. 6.8 TECHNICAL SPECIFICATIONS FOR UTILITIES / SERVICES GENERAL REQUIREMENTS The supply of pipes, valves, fittings and accessories for utilities and services includes but not limited to that, HP and LP steam, feed water, safeties and drains The following may specially be noted. 1. For pipe sizing the following flow rates is to be considered. HP Steam: 25 m/sec Water line (suction): 1.0 mtr/sec Water line (discharge): 2.0 mtr/sec Compressed Air: 18 mtr/sec All valves for above services are to be flanged type except those below 25 mm. 3. The supply of above service pipes should be inclusive of same quality bends, tees, flanges and with necessary gaskets, bolts, nuts etc 4. Materials for piping; For raw water and soft water, pipes; Galvanized steel (ERW) IS 1239,3589, 3601,4736 (medium duty) For steam lines and compressed air line: MS 'C' class pipes (ERW) IS 1239/3601/4736 Valves (all valves for steam, water, air shall be glandless type) Service Fittings Size specifications valves 15mm to 40mm Forged carbon steel body (A105) with SS internals, piston valve with SW ends. HP steam 50mm to 100mm Forged cast steel body (ASTM A216 WCB) with SS internals piston valve (for isolation) with flanged ends. NRV 15 mm to 100mm Ferritic / austenitic SS body, disc and spring 180

181 LP Steam Water / Air of austenitic SS disc check valves with heavy duty springs, wafer pattern, sandwiched between flanges (NRV) Valves 15 mm to 40mm Forged carbon steel body (A105) with SS internals, piston valve with SW ends or CS body, SS ball, special PTFE seats, 800# with SW ends ball valves NRV 15mm to 40 mm Ferritic / austenitic SS body, disc and spring of austenitic SS disc check valves with heavy duty springs, wafer pattern, sandwiched between flanges (NRV) Valves 50mm to 100mm Forged cast steel body (ASTM A216 WCB) with SS internals piston valve (for isolation) with flanged ends. NRV 50mm to 100mm Ferritic / austenitic SS body, disc and spring of austenitic SS disc check valves with heavy duty springs, wafer pattern, sandwiched between flanges (NRV) or CS body, 13%Cr trim 150#, flanged swing check (NRV) Valves 15mm to 40mm CS body., SS ball, PTFE seats, 800# with SW or SCD ends ball valve Valves 50mm to 150mm CI body 13%Cr disc, 125# wafer type butterfly NRV All sizes CS body 13% Cr trim, wafer type check Flanges/counter flanges shall be as per BS tables: Table F for HP steam; Table D for water; Table E for air 5. Painting of pipelines with anti corrosive primer and paint of approved shade including, lettering, marking, flow directions etc., shall be as per specifications. 6.9 Details of the boiler plant with associated equipment:- Sr. No Description Requirement 1 Boiler capacity Continuous water evaporation of 4 TPH rating F&A 100 C based on net peak steam demand of kgs/sqcm 2 Operating pressure 10.5 kg/sqcm (g) 3 Boiler qty 01 No. 4 Chimney Height shall be as per statutory regulation. This shall be suitable for venting out flue gases from 1 no of 4 TPH boiler. Design considering one future boiler. 181

182 5 Chimney qty. 01 No. 6 Type of chimney MS construction, self supported and mounted on concrete foundation outside the boiler house. 7 Flue gas ducting From the boiler outlet port up to the common chimney across bag filter, ID fan etc. 8 Air ducting including FD, From FD fan, APH, PA fans up to fluidized PA, APH 9 Auto blow down system and heat recovery system bed Required 10 Steam flow meter Required 11 Air preheater Required 12 Control pollution control Required equipments like bag filter, MDC 13 Auto ph correction Required system 14 Automatic fuel, handling, Required storage and feeding system 15 PRS Required 16 Feed water tank Required 17 Water flow meter Required Items required for establishing Boiler efficiency The bidder should provide the following analyzer at their cost for establishing capacity and efficiency of the boilers during trial runs. This instrument can be taken back by the bidder after successful trials. 7.0 TECHNICAL DETAILS AND DRAWINGS TO BE FURNISHED ALONGWITH THE QUOTATION A) DRAWINGS GA drawings: The general arrangement (GA) drawing of boiler and common chimney and drawings of associated equipment like Pollution control equipment, dust extraction system, fuel handling & feeding system etc., indicating dimensions, tolerances etc., as proposed by the bidder Layout drawing: The machinery and equipment layout drawing of the entire steam generation system showing layout of the boilers with the common chimney and with all accessories including panels complete. Service piping & Schematic: Feed water schematic piping; steam piping, compressed air piping (including branch lines, valves, safety valves, Fuel handling & feeding system & detailed description of automation for the entire supply and all accessories etc., to be submitted with quotation. Electricals: The single line diagram showing electrical power distribution from the panel, details of motor HPs of all the motors, cable sizes of 182

183 feeders to various equipment etc., to be furnished. Control wiring and automation scheme diagrams of the relevant panel drawings to understand the control scheme/logic is to be submitted by bidder. Catalogues: The relevant catalogues, technical data sheets, drawings, photographs etc., of each equipment/accessory being offered to be submitted by bidder. B) EQUIPMENT List of equipment of the steam generation plant with adequate brief specification of each item including construction material, critical thicknesses, and length / height / capacity, drive details, make/model etc. A comprehensive list of essential spares for the entire supply. C) Technical Data & details (to be furnished by the Bidder) in the following proforma: S. No Description Details 7.1 Boiler Details Design code of boiler Type of combustion system Type of boiler (design) Type of fuel which can be used Type of water circulation Type of supports / installation Model No. of passes 7.2 Steam generation (F&A 100 C of water) Kg/hr 7.3 Steam quality Max. total solids ppm Silica ppm Dryness fraction 7.4 Steam pressure Kg/sq.cm (g) Safety valve-1 set pressure Kg/sq.cm (g) Safety valve-2 set pressure Kg/sq.cm (g) No. on steam drum (MOC/Size/Qty) Kg/sq.cm (g) No. of dosing line (MOC/Size/Qty) Kg/sq.cm (g) No. of pressurized water line Kg/sq.cm (g) (MOC/Size/Qty) No. of non pressurized water line Kg/sq.cm (g) (MOC/Size/Qty) Modulating pressure control range to Kg/sq.cm (g) High steam pressure alarm pressure switch Kg/sq.cm (g) setting 7.5 Boiler thermal efficiency Boiler eff (%) based on G.C.V of fuel at 100% load 183

184 Boiler eff (%) based on G.C.V of fuel at 75% load Boiler eff (%) based on G.C.V of fuel at 50% load Boiler eff (%) based on G.C.V of fuel at 25% load 7.6 Boiler water concentration limits Hardness as CaCO3 Total dissolved solids Suspended solids Alkalinity as CaCO3 ph value Free CO2 Dissolved oxygen Silica Phosphates as PO4 ppm ppm ppm ppm ppm ppm ppm ppm Sodium sulphite as SO3 ppm 7.7 Connected/ consume electrical load No. HP Total Feed water pump FD fan Booster fan ID fan Bag filter unit Mechanical dust collector Circulation pump Aspiration unit dumping hopper Conveyor for crusher Crusher Vibrating sieve Recirculation elevator Elevator for bunker filling Conveyor for bunker loading ph correction system s pump, agitator etc. Any other load 7.8 Utilities consumption at maximum rated capacity Fuel (coal or agro based briquette) Electricity Water 7.9 Boiler dimension Overall dimension of boiler Recommended size of boiler house suitable for 01 no boiler 7.10 Mechanical details of boiler Total heating surface area (sq.m) Bed coil Furnace water wall Kg/hr KWH Kg/hr 184

185 Boiler bank Air per heater Tubes OD x thickness (mm) Qty (nos) Material of construction No. of passes in the shell Shell Thickness (mm) Diameter (mtrs) Length (mtrs) Material of construction Steam- water interface area Water content at working level (cum) 7.11 Feed water and cooling water arrangement No. of pumps Standby water pumps Type of pumps NPSH required Capacity of each pump (cum/hr at MWC head) Feed water temperature indicator Cooling water Cooling water qty (m3/hr) Pressure (kg/cm2(g)) Temperature ( C) Quality Auto ph correction system Make of pump Pump type Pump capacity (l/hr) Tank capacity (L) 7.12 Valves in water feed piping Stop valve at pump outlet (yes/no) Non-return valve at pump outlet (yes/no) Pressure gauge at pump outlet (yes/no) Pump suction side isolating valve (yes/no) 7.13 Fuel handling and feeding system Bunker Type No. of bunkers per boiler Bunker storage volume Bunker MOC Type of conveyor and capacity Type of intake elevator and capacity Type of recirculation elevator and capacity Type and capacity of crusher Type and capacity of vibro screen 185

186 Type and capacity of dust extraction system for dumping hopper Type and capacity of dust extraction system of crusher Type and capacity of distribution conveyors Type of fuel feeding system Type of feeders No. of feeders Type of feeder control (VFD or Dynadrive) Drive rating (kw) No. of venture Venture MOC No. of tight shut off dumpers in bed 7.14 Other accessories Air pre-heater Type Tube size Tube MOC Sheet MOC Flow medium inside tube Flow medium outside tube Draft equipment specification FD / ID / PA fan Flow rate (m3/min) Design head (mm WC (g)) Medium Temperature ( C) Motor rating (kw) Qty Fan speed (rpm) Type Other items Size of flash vessel (dia, height, port sizes) Plate heat exchanger (H.Tr.Area) & make MOC of plates Circulation pump capacity, head, type Break water tank capacity and MOC % of BD heat after FV recoverable Type of PRV for main plant and size Model of PRV for main plant Type of PRV for boiler house and size Model of PRV for boiler house 7.15 Firing and bed arrangement Furnace Type of furnace Volume Firing / arrangement (manual/auto) Water wall construction Water wall tube size 186

187 Water wall tube MOC Header size (dia-mm) Header MOC Strip MOC No. of access doors Fluidized bed and bed tubes Total no. of plenum side partitions Height of plenum chamber MOC of nozzles Pressure drop in the nozzle In bed tubes size (dia x thk) In bed tube pitching (mm) In bed tube MOC In bed tube header MOC In bed header diameter Type of fluidized bed wall construction MOC of the furnace refractory MOC of outer layer of the refractory MOC of inner layer of the refractory Type of air distribution and MOC Mode of fuel charging Normal fuel bed depth (static) Expanded bed height Furnace draft (in mmwc) Type of refractory bricks used Arrangement for ash removal (qty) Recommended size of fuel for firing Start up fuel / chemical / lubricant Diesel (ltrs) Silica sand (dry) (kg) Charcoal for single start up (kg) Firewood dry (kg) 7.16 Flue gas and air Flue gas opening size on boiler (mm) Air pre-heater Overall size Heat transfer area Damper provided or not By-pass arrangement provided (yes/no) Details of controls provided Chimney Dia at base of chimney Dia at top of the chimney Number of chimney sections Dia at base of each section Dia at top of each section Height of each section Total height of the chimney 187

188 Plate thickness at each section Supporting arrangement Flue gas ducting Size (mm) Length (mtrs) Plate thickness (mm) Flue gas analysis (%wt) CO2 H2O SO2 O2 N Flue gas analysis (%vol) CO2 H2O SO2 O2 N Ash analysis Silica (SiO2) Iron oxide (Fe2O3) Aluminium oxide (Al2O3) Calcium oxide (CaO) Magnesium oxide (MgO) Sodium oxide (NaO) Unburnt carbon Sulphuric trioxide (SO3) Quantity of ash generation/ton of steam generation Temperature profile Flue gas Furnace temperature ( C) Boiler bank outlet ( C) Air pre heater outlet ( C) Air Inlet air ( C) Outlet air after APH ( C) Water Inlet to economizer ( C) Outlet of economizer ( C) Ductings Air ducting thickness (mm) Flue gas ducting thickness (mm) Boiler bank and APH hopper thickness (mm) Plate MOC Ducting MOC Hoppers MOC 188

189 Ash silo MOC Compressed air Air compressor FAD m3/h Type of compressor make and model Instrument air qty Pressure kg/cm2 (g) Temperature Drier make and capacity Quality and dew point Conveying air Air qty Pressure Temperature Quality 7.17 Automatic water level controls Single element controller type (yes/no) qty Type of control valve provided and size Mobrey level controller (yes/no) qty Alarm and signal provided for Low level (yes/no) High level (yes/no) Extra low level (yes/no) Low level signal from feed water tank (yes/no) 7.18 Boiler mountings and fittings Qty size make Steam stop valve Non-return valve Safety valve Feed check valve Blow down valve for shell Blow down valve for in-bed header Air vent valve Water level gauge Steam pressure gauge Steam flow meter Auto blow down system 7.19 Structural s Provision of platform for boiler (yes/no) Provision of ladder / staircase for boiler (yes/no) Structural platform for pollution control equipment Structural works for ID, PA, FD fans (yes/no) 7.20 Boiler losses (break up details of losses in % to be furnished on GCV basis) Dry stack loss Wood briquettes 189

190 Sensible heat loss Moisture in air loss Radiation loss Unaccounted loss Total loss 7.21 Critical performance parameters at full load Net effective area of heat transfer (sq.m) Flue gas temperature / stack temp ( C) Excess air % Steam to fuel ratio Water volume (ltr) Steam space (ltr) Volumetric heat release (kcal/cum) Steam generation rate (kgs/sq.m) Electricity consumption at rated capacity 8.0 TECHNICAL DETAILS AND DRAWINGS TO BE TO BE SUBMITTED AFTER AWARD OF CONTRACT The following shall be provided after award of contract: 1. The final equipment GA drawing of boilers and common chimney being manufactured after approval by purchaser 2. Final services / utilities schematic with sizes of pipe lines, valves, insulation thickness, controls, showing all instruments and accessories 3. Final foundation foot print 4. Final electrical load details in HP/KW 5. Final control schematic of the control panels, automation including the proposed architecture showing control panels, PLC, Control station etc. 6. Final list of essential spares. 9.0 SCHEDULE OF QUANTITIES Sr. Unit Description of equipment/item Capacity/ size Qty Total Amount No. rate PART (A) : DESIGN & SUPPLY OF THE FOLLOWING: Rs. Rs. 1. Solid fuel fired steam 4 TPH (Mention 1 sets generation plant complete with FD, ID, PA Fan, FW pumps the capacity) F & A 100 Deg C and all accessories, mountings kg/sq.cm (g) 2. MS self-supported chimney (suited for simultaneous operation of both the boilers) with foundation bolts including Flue gas ducting Chimney 32 m (min), & as per PCB norms 1 set 3. Air pre-heater with air ducting As per site layout 1 sets 4 Pollution Control equipment sets including Bag filter & 190

191 Mechanical dust collector 5 Auto blow-down Control system & heat recovery system including Flash vessel etc. 6 Automatic fuel handling, storage & feeding system sets Bunker shall be of capacity for one day consumption 1 Lot Fuel handling system shall be of capacity such that the one days consumption is handled in one shit of 8 hours) 1 day s requirement 7 HP Steam flowmeter Vortex sets type with digital indicator 8 Steam Pressure Reducing Stations (Robertor type) 8a. For throughput of 3000 kg/hr (10.5 to set kg/sq.cm) 8b. For throughput of 700 kg/hr (10.5 to set 9. HP steam pipes, valves and fittings, including expansion loops, air vent, drain trap assembly, steam header etc. kg/sq.cm) As per site layout 10. Water handling system 10a. Raw water pumps 30 KLPH, 1 lot 1 sets suitable head 10b. Multi-grade filter 30 KLPH, 1 set suitable head 10c. Water softener with softener pumps, magnetic flowmeter 15 KLPH, 200 m3 (OBR) 1 set 10d. Feed water Tank with, 20 KL 1 No deareator & circulation pump 10e. Water pipes, valves & fittings, Lot level sensors, level controllers etc. 10f. Water level indicators ( 2 nos for OH tank, 2 Nos for UG sump) sets 10g. Water flow meter (vortex) type sets with indicator 10h. Automatic ph correction system set 191

192 11. Compressed Air system 11a Air compressor with dryer suitable 1 11b. Air receiver with auto-drain 1000 L 1 set 11c. Air flowmeter (vortex type) set 11d. Compressed Air pipes, valves & As per site 1 Lot fittings layout 12. Structural steel platform, Trench As per site 1 Lot covers, staircase /ladder etc 13. MCC, Electrical cabling, cable tray, panel room AC, Remote Control panels, earthing network, earth pits etc. 14 Plant Automation complete with Boiler Control panel, Direct efficiency monitor, sensors, instruments, indicators, gauges, PID controllers etc layout As per site layout 1 Lot 1 lot 15 Spares for 2 years operation set. 16 Statutory approvals including Lot submission of approved drawings, Boiler Folder & documents for Boiler, PRS, HP steam piping, PCB, electrical Insp. Etc. PART (B) : LABOUR CHARGES FOR INSTALLATION, TESTING, COMMISSSIONING OF THE FOLLOWING: 1. Solid fuel fired steam 4 TPH F & A 1 sets generation plant complete with FD, ID, PA Fan, FW pumps 100 Deg and all associated kg/sq.cm (g) accessories, mountings 2. MS self-supported chimney with foundation bolts including Flue gas ducting Chimney 32 m (min), & as per PCB norms 1 set 3. Air pre-heater with air ducting As per site layout 1 sets 4 Pollution Control equipment sets including Bag filter & Mechanical dust collector 5 Auto blow-down Control system & heat recovery system including Flash vessel etc sets 6 Automatic fuel handling, 1 day s 1 Lot storage & feeding system requirement 7 HP Steam flowmeter Vortex type with digital indicator sets 8 Steam Pressure Reducing 1 set Stations (Robertor type) 8a. For throughput of 3000 kg/hr (10.5 to set 192

193 kg/sq.cm) 8b. For throughput of 700 kg/hr (10.5 to 3.5 kg/sq.cm) 9. HP steam pipes, valves and fittings, including expansion loops, air vent, drain trap assembly, steam header etc. As per site layout 10. Water handling system 10a. Raw water pumps 30 KLPH, 1 set 1 lot 1 sets suitable head 10b. Multi-grade filter 30 KLPH, 1 set suitable head 10c. Water softener with softener pump, magnetic flowmeter 10 KLPH, 200 m3 (OBR) 1 set 10d. Feed water Tank with, 20 KL 1 No deareator & circulation pump 10e. Water pipes, valves & fittings, Lot level sensors, level controllers etc. 10f. Water level indicators ( 2 nos for OH tank, 2 Nos for UG sump) sets 10g. Water flow meter (vortex) type sets with indicator 10h Automatic ph correction system set 11. Compressed Air system 11a. Air receiver 1000 L 1 set 11b. Air flowmeter (vortex type) set 11c. Compressed Air pipes, valves & As per site 1 Lot fittings layout 12. Structural steel platform, Trench As per site 1 Lot covers, staircase /ladder etc 13. MCC, Electrical cabling, cable tray, panel room AC, Remote Control panels, earthing network, earth pits etc. 14 Plant Automation complete with Boiler Control panel, Direct efficiency monitor, sensors, instruments, indicators, gauges, PID controllers, Panel room AC etc layout As per site layout 1 Lot 1 lot 193

194 LLi isst t oof f pprreef feerrrreedd Maakkeess oof f Boouugghht t oouut t ItI teemss (Noot ( t inn i oorrddeerr oof f pprreef feerreennccee) ) STEAM RAISING PLANT & ACCESSORIES Boiler feed water pump GRUNDFOS/ SALMSON/ KSB/ B.E. PUMPS HP / LP Steam / condensate FORBES MARSHALL/AUDCO / CRESCENT / Valves LEADER / THERMAX / BDK /SHARP / INTERVALVE Steam Traps & strainers SPIRAX / MAZDA / SAMSON / THERMAX Steam Pressure Reducing Valve Non Return Valves Steam Pre. Red. Station Manometer Steam /water/air flowmeter Expansion bends Pressure gauges Blow down valve Steam relief valve Water level indicator with drain cock Automatic water level controller Forced Draft / PrimaryP AirpInduced Draft / Primary Air Fan Pressure switches SPIRAX / MAZDA /THERMAX AUDCO / SPIRAX/ BDK / GG / INTERVALVE JN MARSHALL (SPIRAX) / MAZDA / THERMAX TECHNOFLOW E & H /ROSEMOUNT SPIRAX MARSHALL / MAZDA / THERMAX FORBES MARSHALL/ H GURU/ FIEBIG /GLUCK LEVCON/ SHARP/ LEADER / SANT/ SPIRAX SEMPELL/LEADER /FAINGER LASER TELEFLO/SHARP/LEADER/HAWA/ FORBES /MH BROS ABB/Yokogawa FLAKTWOODS / NADI/ LAXMI/UNIVERSAL/ AIR CONTROL DANFOSS / ALCO / HANSEN / PARKER / E&H/ SWITZER / PYROTECH / ALTOP / GIC/ WIKA / INDFOSS Resin bonded mineral LLOYD / UP TWIGA / MINWOOL / ROCKWOOL wool Conductivity & ph Transmitter E&H / EMERSON / YOKAGAWA Pressure gauges FORBES MARSHALL/ H GURU/ FIEBIG/ GLUCK Dial type thermometers FORBES MARSHALL/ H GURU/ FIEBIG/ GLUCK Temperature sensors and YOKOGAWA/ TATA HONEYWELL/ RADIX/ digital indicators/ controllers/ PYROTECH/ CHINO/ ENDRESS + HAUSER recorders VALVES, PIPES (MS & GI), FITTINGS, ACCESSORIES Water/Air Valves ( Butterfly / SAUNDERS / AUDCO / INTERVALVE / BDK / Ball) CRESCENT / LEADER Non-return Valve for water AUDCO / INTERVALVE / BDK / FORBES MARSHALL (wafer type) GI Pipes for water TATA / MST / JINDAL / ZENITH / SURYA ROSHNI MS Pipes for air, steam & TATA / JINDAL / KALYANI / MST / ISMT condensate NRV for Air Line INTERVALVE / AUDCO / LEADER MISCELLANEOUS ITEMS MECHANCAL/ELECTRICAL Geared Motor / Gear Box PBL / POWER MASTER / ELECON / RADICON/ 194

195 SHANTHIGEAR / IC BAUER / BONFIG LOLI / EURO DRIVES Electric Motors BHARAT BIJLEE / SIEMENS / ABB / KIRLOSKAR / CROMPTON GREAVES VFD SIEMENS / ALLEN BRADLEY / DANFOSS / ABB / L&T YASOKAWA Electronic Soft Starter DANFOSS / L&T/ SIEMENS / ROCKWELL (ALLEN BRADLEY) / SCHNEIDER / ABB Level Transmitter & indicator ABB TI and TIS SELECTRON Intelligent Motor Protection Relay L&T / SIEMENS / ABB / SCHNEIDER Energy Monitor ALLEN BRADLEY / SIEMENS / ABB / L&T Voltage / Current / Energy / Power factor Transducer RISHABH / ENERCON PC (Personal Computer) COMPAQ/HEWLETT-PACKARD/IBM LENEVO/ DELL / ACER / HCL / WIPRO PLC System SIEMENS / ALLEN BRADLEY / HONEYWELL/ SCHNEIDER / L&T QUANTUM / EMERSION MCCB, MPCB L&T / MDS-LEGRAND / SIEMENS / ABB / MERLIN GERIN / GE / CROMPTON GREAVES Contactors L&T / SIEMENS / ABB / SCHNEIDER Starter Overload Relays L&T / SIEMENS / ABB / SCHNEIDER Timers Electronic L&T / SIEMENS / BCH / GE Switch Fuse Units L&T / SIEMENS / ABB / SCHNEIDER / C&S/ GE MCBs SIEMENS/ L&T-HAGER / MDS-LEGRAND / GE Push Buttons ESBEE / SIEMENS / GE / VAISHNO / TEKNIC Indicating Lamps L&T / SIEMENS / VAISHNO / TEKNIC Digital Ammeter & Voltmeter ANERCON / L&T / HPL SOCOMEC / MECO Analog Ammeter & Voltmeter RISHABH / IMP / MECO / AE Current Transformer KAPPA / MECO / AE / IMP / INDCOIL LT Power Cables CCI / FORT GLOSTER / RPG ASIAN / INCAB / FINOLEX / UNIVERSAL / NICCO CCI / RPG ASIAN / FINOLEX / RR KABELS (UNILAY) LT Copper Control Cables / FORT GLOSTER / LAPP KABEL Signal & Instrument cable LAPP KABEL / POLYCAB / THERMOPAD Temperature sensors / digital indicator / controller / recorder YOKOGAWA / CHINO / TATA HONEYWELL / RADIX / PYROTECH / E & H PVC Insulated Copper wire ( for panel) FINLOEX / RRKABEL/ Cable Tray INDIANA / MEK / SUNRISE / SUPER / PILCO Isolating Switches SIEMENS / L&T / ABB / SCHNEIDER / C&S HRC fuses L&T / SIEMENS / EE / C&S IP 55 boxes for motor isolators, push buttons, HENSEL / HANSU junction boxes etc. Terminal Blocks WAGO / LAPP INDIA / CONNECT WELL / ELMEX 195

196 Selector Switch Cable Glands Cable Lugs Structural Steel Air Conditioner (Split) Power Capacitors Air lines accessories Auto Drain Valve PHE Type Water Heater KAYCEE / SALZER / L&T COMET / EX-PROTECTA / DOWELS / LAPP KABEL / BRACKO DOWELS / COMET / LAPP KABEL SAIL / TISCO / RINL / IISCO / ESSAR CARRIER / VOLTAS / BLUE STAR/ LG/ HITACHI / GODREJ MALDE / MEHER / KHATAU JANKAR / SIEMENS / EPCOS/ MOMAYA. SHAVO NORGEN / FESTO / AIRMATIC / LEGRIS / NUCON ULTRA FILTER / ZANDER TETRA PAK / APV / GEA-ECOFLEX / ISOFTC- SONDEX 196

197 DESIGN, MANUFACTURE, SUPPLY, COMMISSIONING OF 6000 MT CAPACITY MILD STEEL MOLASSES STORAGE TANKS FOR LIQUID MOLASSES. 197

198 1.0 INTRODUCTION This documents outlines the technical specifications for the Design, Manufacture, Supply, Erection, Testing and commissioning of 2 Nos. Mild Steel Bulk Storage tanks of 6000 MT capacity each for storing of liquid molasses required for the 800 MTPD Cattle Feed Plant. These technical specifications are for the guidance of the bidders only and not intended to bring out all the details of design and fabrication of the tanks. The successful bidder shall be fully responsible to undertake all the work involved in the design, engineering, supply of sheets/plates, structural, including the fabrication, testing and commissioning of these Mild Steel Bulk Storage tanks of 6000 MT capacity each and their accessories. Bidders are to note that these storage tanks being offered in this quote shall be part of the overall project and together with the main feed plant equipment they shall be fully responsible in the overall timely implementation of the project on Turnkey basis, within the battery limits defined in this slice. The work being carried out shall confirm to high standards of engineering design & workmanship. The tanks offered shall be capable of performing to meet agreed performance standards and acceptable to the purchaser/client. No exclusions of any nature are acceptable, other than those specifically detailed in this document. The bidders are required to provide all technical data/information wherever asked for. Any quote not following the quote format structure or provided with insufficient technical data/information/documents is liable to be considered as non-responsive. The Purchaser/Client will interpret the meaning of the specifications and drawings submitted by the bidder and shall have the right to reject the quote, if in their opinion, the same is not in full accordance to specifications. 2.0 SCOPE OF WORK The scope of the work for the slice is as follows: 2.1 Design, detailed engineering, supply of plates, structural etc., fabrication at site, testing and commissioning, including calibration, painting and handing over to purchaser s satisfaction of the following. A) Design and supply of Mild steel bulk storage tanks, two nos. of 6000 MT each which may be in the form of plates and other structural completely welded at site with internal supporting structure like cross bracing, king supports etc. This includes the molasses Intermediate Tank one no. of 10MT, molasses 198

199 pumping to the storage tanks and from the storage tanks to Intermediate Tank. This does not include the molasses day tank at the plant, and the distribution system to the molasses day tanks. External interconnecting structural platform with spiral staircase, platforms and walkways for the Two Bulk Molasses Mild steel storage tanks including the MS box type columns, beams, channels, angles, flats, kick plates, staircase, and railings including chequered plates etc. The steam coils for both the bulk tanks & intermediate tank to be provided. MOC of steam coils are MS C Class pipes. B) Labour for fabrication, Erection, testing and commissioning of: Mild steel bulk molasses storage tanks. The scope includes site fabrication of the tanks on the civil foundations provided by the purchaser complete as per requirement. Structure complete with platform, chequered plates, ladders, walkways, railings, steam coil etc. required for the interconnection and access for maintenance of these Bulk Molasses storage tanks Note: Commissioning of the Bulk molasses storage tanks is complete only after water fill hydro test, sandblasting, painting, calibration etc. The section wise list of equipment is as follows: STEEL BULK STORAGE TANKS FOR LIQUID MOLASSES 1. Mild Steel Molasses Storage Tank 6000 MT 2 Nos. 2. Inter Connecting Mild Steel Structural Platform, Railing with two circular rings on top, with toe guard with 6" height 3. Molasses Transferring Pumps from Sump to Storage Tanks (Pumps with Stainless steel SS 304 covers) 4. Required valves, headers, piping, overflow line back to the sump, automatic high level-low level control & temperature control with indicator accessible to SCADA, digital level transmitter with indicator etc 1 Lot. 4 Nos. 1 Lot 5. Mild Steel Intermediate Molasses Storage Tank 10 MT 1 No. 6. Molasses Transferring pumps from Storage Tanks to Intermediate Tank (Pumps with Stainless steel SS 304 covers) 2 Nos. 199

200 7. Required valves, headers, pipings, level & temp control with digital display accessible to SCADA. 1 No 2.2 Important note for Bidder: The tanks have to design as per the structural requirements of product and self load and wind, earthquake and other loading factors taken into consideration. This is a turnkey job which will have to be executed on a single responsibility basis. Bidder should consider the complete work in its totality. The tank dimensions shall be designed so as to achieve the minimum storage capacity of each tank considering the product and its bulk density. The viscosity of 2000 seconds red wood 1 at 20 Deg. C. and specific gravity of molasses may be considered to be 1.4. The Diameter of tanks shown in the site plan is approximate. It may vary as per the design of the bidder. Successful bidder has to supply the equipment as per the approved equipment drawings. The equipment components viz. plates and support structural shall be supplied on FOR site basis inclusive of packing & forwarding, insurance, freight, taxes, duties, octroi etc. The tank complete with accessories shall be covered under the warranty/guarantee clauses specified in document. Bidder has to make its own arrangement for all tools, tackles, scaffolding, welding machines and other accessories for fabricating the tank at site. The bidder shall make his own arrangement for the power required for fabrication. In case the same is arranged by the purchaser, the same shall be charged on lump sum basis at 0.5% of the whole contract value of supply and labour. This power shall be made available at one point within the site and bidder shall make his own arrangements for tap off from this point. Water for commissioning shall be arranged free of cost by the bidder near the tank and bidder shall make his own arrangements for tap off from this point The bidder shall submit a GA drawing mentioning overall dimension, thickness of bottom plate, top roof and various shell segments, sizes of all nozzles, location and sizes of king posts, cross bracings, total quantity of mild steel required for each tank etc. However, the successful bidder shall submit the detailed fabrication drawing to the purchaser for approval prior 200

201 to start fabrication, clearly indicating typical welding joints, width of sheets, details of various nozzles/components etc. 3.0 STATUTORY REQUIREMENTS The Mechanical and Structural design of these tanks shall comply with the latest relevant Indian standards. Safety and other statutory regulations/ requirements shall comply with that being followed in the country. Bidder has to submit purchased steel material test certificates to purchaser/project authority. Bidder shall provide the stability certificate from their structural consultant for the structural stability of these tanks. Calibration of tank and approval of the tanks from Excise and Weights & Measures is part of the scope. However statutory fees paid if any, shall be reimbursed on production of originals. 4.0 BATTERY LIMITS The Purchaser shall provide the RCC foundation for molasses storage steel tanks as per load details provided by the bidder. The bidder's scope of works includes design of tanks, fabrication as per approved GA drawing, certified by their structural consultant, supply of steel required as per detailed fabrication drawing prepared by bidder and approved by purchaser, fabrication of tanks on RCC foundation at site, providing all flanged type nozzles such as inlet, outlet, drain, man hole & its cover, air vents, over flow and float type level indicators etc., testing, commissioning, calibration, cleaning by sand blasting and painting. Provide inter connecting structural platform, separate staircase with railing, top railing with toe guard, valves with counter flanges for drain, inlet & outlet, over flow line up to molasses sump, level & temperature control system, steam heating system, in each tank are also in the bidder s scope of works. Transferring molasses from RCC pit to MS molasses storage tanks through pump and then from outlet of molasses storage tank up to the Intermediate tank through pumps with inlet and outlet headers shall be provided by the bidder. Bidder s scope also includes arranging inspection and obtaining approval from Excise and Weights & Measures, as required from local authorities. Bidder shall also arrange inspection and obtain approval from their structural consultant for structural stability of molasses storage tanks and also from Local factory Inspector, or from other statutory bodies if required. Water required for testing shall be provided by purchaser in one point inside the plant premises. Arranging water from this point to molasses 201

202 tank and filling water into tanks shall be done by bidder. Testing of tanks with water shall be done one by one so that same water can be used for testing of all the tanks. Molasses required for commercial production shall be provided by purchaser/project authority. All consumables like packing for flanged joints etc. and commissioning spares required if any, for installation, testing & commissioning till taking over the plant by the purchaser shall be provided by bidder and the same after taking over the plant shall be provided by purchaser / project authority. Power for fabrication Power for fabrication shall be arranged by bidder at his own cost. In case power is arranged by the purchaser, then 0.5% of entire tank contract value shall be recovered from the bidder by the purchaser. EXCLUSIONS All civil foundations for the tanks shall be provided by purchaser. Molasses shall be arranged by the purchaser/project authority. 6.0 TECHNICAL SPECIFICATIONS OF INDIVIDUAL EQUIPMENT 6.1 MOLASSES STORAGE TANKS Capacity MT (2 nos.) (Each Dia 25 Meter X 9.5 Meter Height) with steam heating coil. Intermediate Tank Capacity: 10 MT (1 no.) (Horizontal 1.75m dia X 3 M length, 6 mm MS plate body) with steam heating coil FUNCTIONAL REQUIREMENTS These are required for storage of molasses in bulk in plants DESIGN REQUIREMENTS Capacity of each tank 6000 tons with Molasses specific gravity of 1.4. Capacity of Intermediate tank: 10 tons. Material of construction - Mild steel structural steel as per IS 2062 Grade A ; IS 808 for Rolled steel for beams, channels, angles; IS 1730 for Plates, trips, flats ; IS 1239 for MS pipes. Tank to be fabricated at project site with welded construction on foundation provided by purchaser. 202

203 Molasses storage tank to be welded type, vertical and cylindrical shape, mild steel construction, circumference/base of steel plate and having internal steel structural members like cross bracings, central king post, additional king post, circumferential stiffener rings etc. Each tank to be provided with standard accessories such as spiral ladders, rung ladder (welded inside the shell), safety railing on top with toe guard, manholes (at bottom and top), inlet, outlet, air vents, float type level indicators, drain, digital level transmitter with display unit accessible to SCADA. Two adjoining tanks to be connected with working platform at top. Tanks to be fabricated at site on civil foundation (1 M above ground). Civil foundation shall be provided by the Purchaser. After fabrication, the tanks are to be tested with water for leakages and then all internal surfaces are to be cleaned by sand blasting and then provided with epoxy painting. All outside surfaces are to be sand blasted and provided with enamel primer and paint. After testing, all the two tanks to be calibrated SCOPE OF SUPPLY Bottom Plate: Minimum 16 mm thick with lap joint welding with 75 mm overlap Vertical Shell: Bottom 4.50d M - Minimum 12 mm thick Intermediate 1.50 M - Minimum 10 mm thick Next 3.0 M - Minimum 8 mm thick Roof plate - Minimum 6 mm thick Double 'V' groove welding on both sides. Steam Heating coil at the bottom of the shell (MS C class pipe 32 NB) Roof: Conical type with 6 mm thick plates having slope of 5 degree from horizontal Strengthening Structure: Central king post (1 no.) for roof supporting made from minimum 300 NB MS C class pipe, with 20 mm thick 970 mm dia MS base and crown plate at bottom and top respectively. Additional king posts (minimum 8 nos.) on suitable PCD made from of 100 NB MS C class pipe with 10 mm thick 70 mm dia MS base and crown plate at bottom and top respectively. Circumferential stiffener rings (minimum 7 nos.) at circumferential welding joints made from 100 x 50 mm MS channels. 203

204 Circumferential stiffener ring (minimum 1 no.) with full welding at circumferential welding joint of bottom plate and shell on inner side, made from 90 x 90 x 6 mm MS angle. Supporting brackets (minimum 8 nos.) at circumferential welding joint of bottom plate and shell (outside the tank), made from 200 x 100 mm MS channel 300 mm long. Curb angle (1 no.) at circumferential welding joint of roof plate and shell (outside the tank) made from 65 x 65 x 6 mm MS angle. Cross bracing between shell and central king post (set of 12 nos. minimum 1 set) made from 75 x 40 mm MS channel. Roof supports (minimum 18 nos.) made from 75 x 40 mm MS channels. Vertical stiffeners for shell (minimum 8 nos.) made from 75 x 40 mm MS channels Staircase Rung ladder welded inside the shell, made from 20 mm dia MS rods. Spiral staircase consisting of grill type steps fabricated from 20 x 5 mm MS flat (300 x 840 mm), supporting frame from 100 x 50 mm MS channels, railing on one side only from 32 NB MS C class pipes with two layers of pipes, mid and top landing with MS grating fabricated from MS flat of size 20 x 5 mm and staircase supporting pipes (6 nos.) from 32 NB MS C class pipes. Safety railing on top of the tank having two circular rings made from 32 NB MS C class pipe M high complete with vertical supports at every 30 degree angle and toe guard made of 3 mm thk.150 mm width MS sheet welded circumferentially on railing support Tank Accessories Inlet 100 NB MS C class pipe (2 nos.) with F table flange on roof of the tank. One inlet to be closed with blind flange and for other, counter flange to be provided. Manhole in shell near bottom (1 no.) of 600 mm dia, made from 12 mm thick MS plate and cover plate from 12 mm thick complete with bolts, nuts and packing etc. Manhole on roof (1 no.) of 600 mm dia. made from 8 mm thick plates complete with flanged bolted rain hat and wire mesh. Float type level indicator complete with SS 304 float, 14 gauge SS guide wires, pulleys, SS wire ropes (14 gauges), scale with marking in litres. 204

205 Automatic Level control with low level & high level control, the output compatible to SCADA for bulk tanks & Intermediate tank. Automatic Temperature control, the output compatible to SCADA for bulk tanks & Intermediate tank. Automatic level transmitter with indicator & output for PLC SCADA/DCS. Air vent at roof (minimum 8 nos.) from minimum 150 NB MS C class pipe with arrangement of rain and insect protection. Drain near bottom plate (1 no.) from 150 NB MS C class pipe complete with flanged type butterfly valve, blind flange F table, bolts, nuts and packing. Outlet near bottom (2 nos.) from 150 NB MS C class pipe complete with flanged type Butterfly valve, counter flange H table for one outlet and blind flange of table H for 2nd outlet, bolts, nuts and packing. The provision for 2nd outlet is meant for electronic level indicator. However, electronic level indicator is excluded from the scope of supply. Steam coil for bulk tanks & intermediate tank to be made from 32 NB C Class Pipe. Intermediate tank with supporting legs, level indicator & ports for the high level & low level, with required valves Testing After completion of fabrication, all jigs and fixture should be removed from inside and outside and unnecessary welding deposit should be ground smooth prior to painting, complete tank to be filled with water and kept for observation for any leakage for at least 24 hours. Any leakage observed should be plugged with welding. During testing, calibration of the tank shall be done Painting After completion of testing, the complete tank from inside and outside shall be cleaned with wire brush and SAND BLASTING. All the inside surface shall be cleaned after sand blasting followed with two coats of black epoxy primer followed by black epoxy paint. The entire outside surface after sand blasting should be painted with two coats of red oxide primer followed by two coats of black enamel paint. 205

206 6.1.4 REMARKS Bidder has to make its own arrangement for all tools, tackles, scaffolding, welding machines and other accessories for fabricating the tank at site. Bidder to follow all rules and regulation statutory requirements, workers compensation act for the labour force employed by them. Bidder would be solely responsible for any injury or accident if it happens to his persons working on project site. Bidder has to take necessary labour insurance in this regard. No accommodation would be provided for staff and labour of the Bidder at project site, however they may construct temporary hutment at their expenses within project site after taking approval from site in charge. The same shall have to be cleared / removed upon completion of the job or as & when instructed by the Engineer-in-charge. Important Notes: The load details on the foundations shall have to be provided to the purchaser to design the foundation. The steel structure for the bulk molasses storage tanks shall be as per the design of the bidder. The tanks shall be designed for wind load (highest as per historical records) and for seismic stability as per seismic zone. Stability certificate for the silos and structure shall be submitted by the successful bidder. Design calculations for the structure shall be shared with the purchaser and who shall suggest the bidder, for alteration, wherever found required. Design calculations for the tanks to be shared with purchaser without any extra cost. Staircase shall be suitably located so that quick approach to working platforms and shall be 1.2m wide with 32 NB MS C class pipe hand railing (double braced). Platforms, railing shall be extended to all working equipment to facilitate inspection, operation and maintenance. Elevation drawings for the tanks showing heights shall be furnished to the purchaser. 6.2 TECHNICAL SPECIFICATIONS FOR ERECTION, TESTING AND COMMISSIONING Erection, testing and commissioning is inclusive but not limited to the following: - Fabrication and welding of the complete bulk molasses storage tanks & intermediate tank. 206

207 - Erection / Welding / Grouting into place necessary structural platforms, walkways, hand rails etc., as per requirement. - Approval of the installation executed by the bidder by the factory inspector for structural stability and safety and by excise authorities as molasses is excisable commodity. 6.3 GENERAL REQUIREMENTS The following may be noted in general with respect to the technical specifications of the supply of feed milling equipment. 1. Capacities of tanks in MT are specified based on molasses specific gravity of Packing for flanged joints of machines/hoppers/bins etc. should be felt or rubber depending on the application. Packing to be fixed with glue rather than simple grease.. 3. Painting: The tank external shall be painted. However standard cleaning, degreasing practice before painting shall be followed, then primer coating before applying one coat of black synthetic enamel paint. Second coat of black synthetic enamel paint to be provided at site before commissioning. Supporting steel structure, transition pieces & piping etc. being fabricated at site to be applied with corrosion resistant zinc oxide primer before erecting/installing and then applying one coat of synthetic enamel paint after erection. 7.0 TECHNICAL DETAILS AND DRAWINGS TO BE FURNISHED ALONGWITH THE QUOTE A) DRAWINGS Equipment drawing: The general arrangement (GA) drawing of tanks indicating dimensions, tolerances etc., as proposed by the bidder. Layout drawing: The layout drawing of the bulk molasses tanks showing layout of the silos and connecting platforms. 8.0 TECHNICAL DETAILS AND DRAWINGS TO BE SUBMITTED AFTER AWARD OF CONTRACT The following shall be provided after award of contract: 1. The final equipment GA drawing being manufactured as per design and product specifications of purchaser 2. Final foundation foot print 3. Final layout of the 2 tanks with connecting platform 207

208 9.0 List of preferred Makes of Bought out Items (Not in order of preference) Description Structural Steel Level Measurement Molasses Pumps Motors ( Eff-1) Valves Filters Bend, Union, Clamps etc Makes SAIL / TISCO / RINL / IISCO / ESSAR E & H / Emmersion Roto General / ABB Audco / Saunders / Rotex / Flowwell Filter Concept / AGS/ other well known brand Reputed Brand 10.0 SCHEDULE OF QUANTITIES A SUPPLY Sl. No. Description STEEL BULK STORAGE TANKS FOR LIQUID MOLASSES Capacity Qty 1.0 MILD STEEL MOLASSES STORAGE TANK (Approximate Weight in MT to be indicated / tank.) MILD STEEL INTERMEDIATE TANK WITH PIPES & VALVES & all accessories. 2.0 INTER CONNECTING MILD STEEL STRUCTURAL PLATFORM, with all accessories MT 10 MT 2 NOS. 1 NOS 1 LOT. 208