Annexure-I. Specification sheet for LDO fired boiler

Transcription

1 Annexure-I Specification sheet for LDO fired boiler SN Description Specification 1. Boiler Capacity FA C: 5000 kg/hr Design code: IBR 1950 as per latest amendment Boiler working pressure: kg/cm 2 (Safety lift off pressure). Thermal efficiency: >=87% (It shall be demonstrated as per BS: 845 Part-1 Indirect method) 2. Fuel LDO (Light diesel oil) 3. Boiler material Boiler drum: SA 515/516 Gr. 70 / IS 2041 R260 Furnace: SA 515/516 Gr. 70 / IS 2041 R260 Smoke tubes: BS 3059 ERW 4. Feed water Feed pump temperature rating: 90 0 C. Two electrically driven pump with motor (one on duty and one as stand by) 5. Additional features 6. Balance of plant requirement for 5 TPH boiler including supply and erection Boiler shell of full fusion welding. Boiler out let: Saturated steam with dryness factor 0.98 or more Provision of Safety device for low water level protection. Provision of auto start and stop of Feed pump based on water level in the boiler. Provision of audio visual alarm on very low level of water in boiler. Provision of at least two safety s with 100% capacity each to relieve excess steam. Provision for manual steam / air venting. Provision of pressure switch to start and stop the boiler at the desired pressure. Provision of pressure gauge. Provision of blow down. Furnace design: Corrugated A complete set of drawing and documents shall be furnished. Operation and maintenance manual shall be submitted along with the supply. Erection procedure shall be submitted for prior to boiler erection. Provision of safety device for flame failure. The boiler unit shall consist of all its standard accessories. Feed water storage tank with structure and provision of level gauge and manhole cover, capacity: 10 KL. The height of the tank structure shall be more than 3 meter. Structure, platform with ladder for boiler and accessories. Chimney (Height and dimension as per relevant standard / codes / norms for the boiler rating). Day oil tank with foundation structure, capacity: 3.5 KL. The height of the tank structure shall be more than 2 meter. Fuel oil storage tank with suitable fuel oil transfer pump and interconnecting pipes between storage tank and fuel oil day tank. Storage tank capacity: 15 KL. The tank shall be equipped with all safety measures as per the relevant standards. All main piping and auxiliaries piping s with pipe fittings and its supports within

2 SN Description Specification the defined terminal points. It includes feed water line, fuel oil line, steam line, blow down line, flue gas line etc coming under the terminal points. LRB insulation with 22 SWG aluminum cladding, of flue gas ducting and steam line coming under the bidder scope. Ducting between Boiler exhaust outlet to Chimney. Required chemicals for maintaining chemistry of water inside the boiler. The quantity shall be for sufficient for 1 month continuous running at rated capacity. Painting of equipment and pipe lines. Pressure reducing station up to 3.5 kg/cm 2 along with suitable bypass line in steam line at suitable point between Boiler unit and connecting steam header. All IBR formalities like IBR passing of whole boiler unit up to and including the terminal points, registration and first provisional certificate including all legal fees. 7. Scope under NPCIL 8. Terminal points in scope of Supplier 9. Additional scope under Supplier LDO Fuel oil as per IS Feed / Boiler Water as per IS Various connections beyond the defined terminal points. Electrical power supply at 415 V ± 6%, 50Hz ± 3%, 3 phase. Control power supply: 240/220 V A.C., 1 Phase License and other legal requirement for fuel oil storage tank (capacity: 15 KL) including legal fees. IBR certified Boiler attendant for boiler operation. Assistance of Crane, forklift and Hydra for loading / un loading, erection and shifting of Boiler units and its accessories within the site. Civil work for Boiler and its accessories. Water: Suitable inlet flange at feed water storage tank inlet including companion flange and gasket. Steam: Suitable connection with steam header (header size: 200 mm) in UGP (Distance between the Boiler unit outlet point and UGP header inlet point is approximate 250 feet). Blow down and drain: Blow down and drain up to drain point near boiler house Flue gas: Chimney for exhaust flue gases as per the relevant standards / norms. Electricals and controls: Electrical and Control panel box with all connections terminated on panel coming from Boiler unit. Fuel: Fuel oil storage tank. Supply, Erection, Commissioning, Performance test, Record of parameters, Submission of final commissioning report. This includes deploy of required manpower, arranging required tools, tackles and instruments etc. Warranty for 12 months from commissioning or 18 months from the date of dispatch whichever is earlier. Training to NPCIL personnel for proper operation and day to day maintenance of Boiler. Cabling and laying of cable trays for cables, Instrumentation coming within defined terminal points. The supplier shall submit the list of bought items along with their Drawing / OM manual etc.

3 SN Description Specification Detail drawing for Electrical wiring diagram and Control wiring diagram. Special tools required for continuous operation of boiler, if any. As built GA drawing of the erected Boiler unit along with the associated system, lines and equipment set spare fusible plug Bought out items make: 11. Main steam Leader / LT / Forbes marshall / Inter / Steel strong stop 12. Air vent Leader / LT / Forbes marshall / Steel strong 13. Safety s Darling Musco / Fainger Lesser / LT / Forbes marshall / Tyco sanmar 14. Fusible plug Leader / Leader / LT / Forbes marshall 15. Pressure gauge 16. Blow down and drain 17. Feed check Bauumer / M/S WAAREE INSTR. LTD., MUMBAI / M/S. KROHNE MARSHAL LTD., PUNE / M/S. PRECISION INDUSTRIES, MUMBA / M/S GENERAL INSTS MUMBAI Levcon / LT / Forbes marshall / Steel strong Leader / LT / Forbes marshall / Steel strong 18. Feed pumps KBL / KSB / MP / CNP / Granfoss 19. Mobrey Malhotra / ABB / Siemens / BHEL / BEL / EIL control 20. Motors CGL / BHEL / Crompton / ABB 21. Temperature gauge 22. Contactors and relays 23. MCC cum Control panel M/S. Temp Tech, MUMBAI / Bauumer / M/S WAAREE INSTR. LTD., MUMBAI / M/S. KROHNE MARSHAL LTD., PUNE / M/S. PRECISION INDUSTRIES, MUMBA / M/S GENERAL INSTS MUMBAI LT / ABB / Siemens / BHEL / BEL / EIL IBL / ABB / Siemens / BHEL / BEL / EIL

4 Annexure-II SCHEMATIC SKETCH OF LDO FIRED STEAM BOILER SHOWING TERMINAL POINTS Provision for fuel oil make up. Fuel storage tank 15 KL. C H I M N E Y Main Steam stop STEAM HEADERS Steam line with final hook up joints up to steam header is in vendor scope Header is in NPCIL scope Day oil tank 3.5 KL. Boiler Unit 5 TPHR F/A C Feed water storage tank 10KL. Provision for feed water make up. Note: - 1. The Schematic sketch shown above is for explaining the terminal points only and not the actual design. 2. Solid line indicates scope of vendor and Dotted line indicates scope of NPCIL.

5 Annexure-III Bidder s compliance checklist SN Description Specification Bidder s compliance 1. Boiler Capacity FA C: 5000 kg/hr Design code: IBR 1950 as per latest amendment Boiler working pressure: kg/cm 2 (Safety lift off pressure). Thermal efficiency: >=87% (It shall be demonstrated as per BS: 845 Part-1 Indirect method) 2. Fuel LDO (Light diesel oil) 3. Boiler material Boiler drum: SA 515/516 Gr. 70 / IS 2041 R260 Furnace: SA 515/516 Gr. 70 / IS 2041 R260 Smoke tubes: BS 3059 ERW 4. Feed water Feed pump temperature rating: 90 0 C. Two electrically driven pump with motor (one on duty and one as stand by) 5. Additional features 6. Balance of plant requirement for 5 TPH boiler including supply and erection Boiler shell of full fusion welding. Boiler out let: Saturated steam with dryness factor 0.98 or more Provision of Safety device for low water level protection. Provision of auto start and stop of Feed pump based on water level in the boiler. Provision of audio visual alarm on very low level of water in boiler. Provision of at least two safety s with 100% capacity each to relieve excess steam. Provision for manual steam / air venting. Provision of pressure switch to start and stop the boiler at the desired pressure. Provision of pressure gauge. Provision of blow down. Furnace design: Corrugated A complete set of drawing and documents shall be furnished. Operation and maintenance manual shall be submitted along with the supply. Erection procedure shall be submitted for prior to boiler erection. Provision of safety device for flame failure. The boiler unit shall consist of all its standard accessories. Feed water storage tank with structure and provision of level gauge and manhole cover, capacity: 10 KL. The height of the tank structure shall be more than 3 meter. Structure, platform with ladder for boiler and accessories. Chimney (Height and dimension as per relevant standard / codes / norms for the boiler rating). Day oil tank with foundation structure, capacity: 3.5 KL. The height of the tank structure shall be more than 2 meter. Fuel oil storage tank with suitable fuel oil transfer pump and interconnecting pipes between storage tank and fuel oil day tank. Storage tank capacity: 15 KL. The tank shall be equipped with all

6 SN Description Specification Bidder s compliance safety measures as per the relevant standards. All main piping and auxiliaries piping s with pipe fittings and its supports within the defined terminal points. It includes feed water line, fuel oil line, steam line, blow down line, flue gas line etc coming under the terminal points. LRB insulation with 22 SWG aluminum cladding, of flue gas ducting and steam line coming under the bidder scope. Ducting between Boiler exhaust outlet to Chimney. Required chemicals for maintaining chemistry of water inside the boiler. The quantity shall be for sufficient for 1 month continuous running at rated capacity. Painting of equipment and pipe lines. Pressure reducing station up to 3.5 kg/cm 2 along with suitable bypass line in steam line at suitable point between Boiler unit and connecting steam header. All IBR formalities like IBR passing of whole boiler unit up to and including the terminal points, registration and first provisional certificate including all legal fees. 7. Scope under NPCIL 8. Terminal points in scope of Supplier 9. Additional scope under Supplier LDO Fuel oil as per IS Feed / Boiler Water as per IS Various connections beyond the defined terminal points. Electrical power supply at 415 V ± 6%, 50Hz ± 3%, 3 phase. Control power supply: 240/220 V A.C., 1 Phase License and other legal requirement for fuel oil storage tank (capacity: 15 KL) including legal fees. IBR certified Boiler attendant for boiler operation. Assistance of Crane, forklift and Hydra for loading / un loading, erection and shifting of Boiler units and its accessories within the site. Civil work for Boiler and its accessories. Water: Suitable inlet flange at feed water storage tank inlet including companion flange and gasket. Steam: Suitable connection with steam header (header size: 200 mm) in UGP (Distance between the Boiler unit outlet point and UGP header inlet point is approximate 250 feet). Blow down and drain: Blow down and drain up to drain point near boiler house Flue gas: Chimney for exhaust flue gases as per the relevant standards / norms. Electricals and controls: Electrical and Control panel box with all connections terminated on panel coming from Boiler unit. Fuel: Fuel oil storage tank. Supply, Erection, Commissioning, Performance test, Record of parameters, Submission of final commissioning report. This includes deploy of required manpower, arranging required tools, tackles and instruments etc. Warranty for 12 months from commissioning or 18 months from the date of dispatch whichever is earlier. Training to NPCIL personnel for proper operation and day to day

7 SN Description Specification Bidder s compliance maintenance of Boiler. Cabling and laying of cable trays for cables, Instrumentation coming within defined terminal points. The supplier shall submit the list of bought items along with their Drawing / OM manual etc. Detail drawing for Electrical wiring diagram and Control wiring diagram. Special tools required for continuous operation of boiler, if any. As built GA drawing of the erected Boiler unit along with the associated system, lines and equipment. 1 set spare fusible plug Bought out items make: Main steam Leader / LT / Forbes marshall / Inter / Steel strong stop 11. Air vent Leader / LT / Forbes marshall / Steel strong 12. Safety s Darling Musco / Fainger Lesser / LT / Forbes marshall / Tyco sanmar 13. Fusible plug Leader / Leader / LT / Forbes marshall 14. Pressure gauge 15. Blow down and drain 16. Feed check Bauumer / M/S WAAREE INSTR. LTD., MUMBAI / M/S. KROHNE MARSHAL LTD., PUNE / M/S. PRECISION INDUSTRIES, MUMBA / M/S GENERAL INSTS MUMBAI Levcon / LT / Forbes marshall / Steel strong Leader / LT / Forbes marshall / Steel strong 17. Feed pumps KBL / KSB / MP / CNP / Granfoss 18. Morbey Malhotra / ABB / Siemens / BHEL / BEL / EIL control 19. Motors CGL / BHEL / Crompton / ABB 20. Temperature gauge M/S. Temp Tech, MUMBAI / Bauumer / M/S WAAREE INSTR. LTD., MUMBAI / M/S. KROHNE MARSHAL LTD., PUNE / M/S. PRECISION INDUSTRIES, MUMBA / M/S GENERAL INSTS MUMBAI 21. Contactors LT / ABB / Siemens / BHEL / BEL / EIL and relays 22. MCC cum IBL / ABB / Siemens / BHEL / BEL / EIL Control panel Pre-qualification criteria: 23. The bidder must be the manufacturer of the offered Boiler. 24. The bidder must submit General Arrangement drawing along with the quotation showing the detail scope of work under the Supplier. 25. The boiler manufacturer must be an ISO-9001 certified. 26. The bidder should have supplied at least 03 similar Boiler unit of same rating or higher rating in last 1 year (1 year from tender due date). The bidder shall submit the PO copies. 27. The offered item shall be one from the standard production range of the bidder. The bidder shall submit the product catalogue for verification of the same. 28. The annual turnover of the bidder in last 3 consecutive year shall be Rs.1 crore or more. The bidder shall submit the relevant documents for verification.

8 SN Description Specification Bidder s compliance Specific terms and conditions: 29. Mega package concession will not be applicable. 30. The item shall be as per the attached Annexure-I. 31. The bidder shall refer attached Annexure-II for more clarity on terminal points coming under the bidder scope. 32. The bidder must fill it's compliance in the Bidder's compliance checklist completely in the attached Annexure-III under the heading 'Bidder's compliance'. The offer otherwise will be liable for rejection. 33. Incomplete offer shall also be liable for rejection. 34. The tendered items will not be split among different bidders and purchase order shall be placed to overall lowest technically accepted bidder i.e. Comparative statement will be made combined for all the indent items together. For item no.3, payment will be made as per the actual length erected and commissioned. 35. The bidder shall submit the Bill of material for the complete Boiler unit and it's accessories within one month from placement of Purchase order, for approval by NPCIL. 36. The supplier shall arrange for pre-dispatch inspection as per the attached QAP in Annexure-IV.

9 Sr.No. 1.0 COMPONENT/ OPERATION RAW MATERIAL BOUGHT OUT ITEMS 2.0 IN PROCESS 2.1 WPS PQR 3.0 WELDING 3.1 WELD FIT-UP CHARACTERISTIC Chemical Composition CLASS Major Annexure-IV QUALITY ASSURANCE PLAN (LDO fired steam Boiler) TYPE OF CHECK TC Review / Sample check QUNATUM OF CHECK REF. DOCUMENT 100% Material specn. ACCEPTANCE NORM Applicable specn./ FORMAT OF RECORD MTC / Lab. TC INSPECTION P W R 2 2,1 Mechanical properties - do - - do - - do - - do - - do - - do - 2 2,1 Dimensions - do - Measurement - do - - do - - do - 2,1 Essential variables Parameters major Verification 100% As per IBR As per IBR Alignment Major Visual 100% Drg./ WPS Drg./ WPS Test reports records Orientation Major Visual 100% - do - - do - - do REMARKS Dimension Major Measurement 100% - do - - do - - do ROOT RUN Weld quality Major 3.3 BACK GAUGING WELDING Surface defects Major 3.4 FINAL RUN Weld soundness Major 4.0 PUMPS, MOTORS FANS Characteristic curves of pumps, and fans Major Visual / PT check Visual / PT check Visual / PT check 100% 100% 100% RT Examination 100% Review of test certificates, type routine test certificate of motors 100% 1 RT report 2 Test reports 2 2,1

10 Sr.No COMPONENT/ OPERATION CALIBERATION TEST FOR INSTRUMENTS CONTROL EQUIPMENT FINAL ASSEMBLY WORKMANSHI P, FINISH CLEANLINESS FINAL INSPECTION OF INDIVIDUAL SUB-ASSEMBLY SIMULATION TEST FOR CONTROL HYDROTESTIN G OVERALL DIMENSION PAINTING MARKINGS PACKING, RELEASE SHIPMENT FINAL DOCUMENTATI ON COMMISSIONI NG AT SITE CHARACTERISTIC CLASS TYPE OF CHECK QUNATUM OF CHECK Accuracy Major Calibration 100% General condition - do - Visual 100% General condition - do - Visual 100% Performance - do - Functional requirement 100% Leak tightness Major Proof test 100% Terminal dimension Painting quality Equipment Tag No. REF. DOCUMENT As per instrument standard ACCEPTANCE NORM As per instrument standard FORMAT OF RECORD INSPECTION P W R Major Measurement 100% 1 Major Visual Random - do - - do - 1 Packing quality Major Visual 100% - do - - do - 1 Compilation of documents Performance - do - Major Verification 100% Functional requirement 100% Tender document Tender document 1 REMARKS 1 CHP

11 LEGEND : P - Performed by W - Witnessed by R - Reviewed by CHP - Customer Hold Point MTC - Material Test Certificate I.R. - Inspection Report T.C. - Test Certificate PT - Penetrant Test RT - Radiography Test 1 - NPCIL 2 - Vendor QC / Sub Vendor QC or External Laboratory NOTES : 1) Scope of IBR inspection is not indicated in the QAP. Boiler supplier shall indicate scope of IBR inspection as per the IBR requirement. 2) Wherever witness by NPCIL is indicated, this will not be construed as customer hold point. The supplier to intimate NPCIL in advance for such stages and NPCIL (QS) would witness if so desired. 3) Wherever CHP is specifically mentioned, further work shall be taken up only after witness clearance by NPCIL (QS).