Boiler cleaning ATTACHMENT-B Ref.No.- NFVP/PROD/CP&O/nit boiler/2011 Name of work :- Removing of deposits from Eleven Boilers under CP&O group of Plants, Ammonia-I Ammonia-II and Urea-II and getting these Eleven Boilers passed through Director of Boilers (M.P.) for steaming. 2.0 DETAILS OF WORK: 2.1 There are totally 11 boilers in NFL, out of which 05 boilers are required to be passed through Director of Boilers yearly and the remaining 06 boilers are required to be passed once in two years, through Director of boilers. Four boilers I.e. package boiler, HRU- I, HRU-II & HRU-III are located in CP&O group of plant; Two boilers I.e.R.G. boiler and loop boiler located in Ammonia-I. Three boilers I.e. GT/PAC HRU, R.G. Boiler and loop boiler are located in Ammonia- II and finally 31E-5 and 41E-5(HP carbamate condenser) are located in urea-ii. 2.2 The job is stagerred throughout the year. 2.3 The contractor will have to make arrangements and remove the deposits from the boiler area in a specified time (9 days total). The tentative time schedule of inspection for each boiler is as under. Sr.No.Boiler Month/year Frequency of inspection 1. HRU -I(CPP) : NOV,2012 YEARLY 2. HRU-II(CPP) : DEC,2012 YEARLY 3. HRU-III(CPP) : JAN,2013 YEARLY 4. PACKAGE BOILER(CPP) : NOV,2012 YEARLY 5. HRU-(GT) AMM.-II : APRIL,2013 YEARLY 6. 31E-5 (HP CARBAMATE : APRIL,2013 ONCE IN 2 YEARS UREA-II (CONDENSER) 7. 41E-5 (HP CARBAMATE : APRIL,2013 ONCE IN 2 YEARS UREA-II (CONDENSER) 8. R.G. BOILER (AMMONIA-II): APRIL,2013 ONCE IN 2 YEARS 9. LOOP BOILER (AMMONIA-II): APRIL,2013 ONCE IN 2 YEARS 10 R.G. BOILER (AMMONIA-I) : MARCH,2013 ONCE IN 2 YEARS 11.LOOP BOILER (AMMONIA-I) : MARCH,2013 ONCE IN 2 YEARS 2.4 The above job can be split in two or more contractors at the sole descretion of NFL. 3.0 SCOPE OF WORK: For the first five boilers.(sr.no.01 to 05) 3.1 Scaffolding and platforms have to be raised in the boiler wherever required so as to provide approach at all elevations for carrying out the job as well as inspection by Director of Boilers(OIB). Material for scaffolding and planks will be issued free of cost on returnable basis by NFL.
3.2 Removal of deposits from furnace, super heater tubes, steam and mud drum,pent house, economizer zone etc. for presenting it to Director of Boilers. 3.3 After successful hydraulic testing & permission for running boilers, all the scaffoldings have to be removed and all the left over material is to be removed from inside the furnace. 3.4 Separate rates should be quoted for each boiler. N.B. All these jobs are to be carried out under Safety work permit. 3.5 Total job of inspection of boiler will be completed in 09 nine days. The job includes shifting of scaffolding material from store, fixing and removal of deposits from boiler parts and making ready for inspection. 4.0 SCOPE OF WORK: For the remaining 06 boilers (Sr. No. 06-11) 4.1 These boilers require minor cleaning. The cleaning requires removal of deposits/scaling. After cleaning, these boilers are to be passed by Director of boilers. It is the responsibility of the contractor to get these boilers passed by director of boilers for steaming.
Chemical handling 1. Name of work :- 1.Assistance in Chemical handling& Safety &Pollution control measures, Lubrication and up keeping. ( Schdule A) 2. Removal of sludge from different lagoons/pits in CP&O group of Plants ( Sch-B). SCOPE OF WORK 1.0 The detailed scope of work for schedule-a are as follows: 1.1 HANDLING OF CHEMICALS: Preparation of solution of chemicals like Lime, Alum, FeSO4, TSP, Bleaching powder& Poly Aluminum Chloride etc. as per Plant requirement. Operation of valves, cleaning of filters, collecting samples, shifting of chemicals etc. as per Plant requirement. Approximate quantity of chemicals handled per day will be from 0.75 to 3.0 MT approx. The quantity of chemicals may vary from time to time and as per Plant requirement. During rainy season it may increase to 3 ~ 4 MT per day. Monthly payment will be released as per actual quantity of chemicals dozed in the Plant. The job of dissolving the chemicals is intermittent. However, it may be carried out in three shifts, as and when required. 1.2 SAFETY AND POLLUTION CONTROL FACILITIES: Details of jobs required to be carried out under above operation are: a) Handling of safety appliances within the Plant area including shifting of same to different locations every fifteen days frequency or as and when required. b) Fixing/removal of hoses on service air, service water, Nitrogen and low pressure steam etc. as and when required. c) Blocking the Plant drains in case of escape of effluents causing pollution within Plant area as and when required. d) Dosing of lime, ferrous sulphate,acid into the drains/pits to neutralize the effluents as and when required. All the above jobs shall form one operation. 1.3 Lubrication of machinery and other Plant activities. (Apprx.75 Ltr.oil and 25 kg grease is being handled in each month). The details of work done under the above operation will be: a) Lubrication of rotating equipments in CP&O group of Plants. This will include shifting of filled/empty oil and grease drums from individual plant oil store to concerned field equipments. b) Maintenance of filters in workable condition in the Plant.
: 7 : c) Keeping of Plant area around machinery free from oil and other spillages. This operation require on daily basis. All the above jobs shall form one operation. 1.4 Maintenance of strainers in canal and raw water sump in good conditions/removing and refilling of resins from different vessels in D.M.Plant. The details of work under the above operation will be: a) The mesh provided at the inlet of canal in Raw Water Plant is to be kept free from suspended material like vegetation and other floating materials. b) The material collected at the suction sump of the pump house should be kept free from floating material. This material is required to be lifted manually and shifted to a distant place as informed by Engineer-in-charge. c) Removal and refilling of resins from different vessels in D.M.Plant as per the requirement given by Engineer-in-charge. All the above jobs shall form one operation. 2.0 The detailed scope of work for schedule-b are as follows; 2.1 SLUDGE LAGOONS IN PTP( 3 NOS.): Removal of sludge from each lagoon, one by one as released by Engineer-in-charge. Keeping in view the exigency of Plant, the disposal of removed sludge to be lifted after the sludge gets dried to any one or more than one points located within NFL premises as per instructions of EIC. Approximate quantity of sludge within lagoons will be 3000 m3.sludge may be dry/wet containing varying amount of moisture. The availability for cleaning of each lagoon is expected between 4 to 6 weeks. Gap between release of one lagoon to other lagoon may vary between 2 to 4 months. Payment shall be considered strictly as per actual quantities of sludge handled. 2.2 RAW WATER PUMP'S SUCTION SUMP: The sump receives Raw Water from GKS canal at the northern end. 5 Nos. of vertical pumps are located on the Southern end where it receives water from Raw Water sump & from Raw Water Reservoir also. Accumulation of sludge is likely to be maximum towards northern end. Total quantity of sludge, weeds, wild growth etc. is expected to be 1500 m3. Snakes, fish etc. are also likely to be present. Sludge would be absolutely saturated with water and has to be handled by using buckets etc. manually. Job is likely to be released any time when flow stopped in Gopi Krishan Sagar canal. However, southern end of the sump is likely to remain in service at a low level so that contractor could take up said job in about 75% area of the sump towards north.
: 8 : Southern end is expected to be cleared as such maintaining low level in that portion. Time available for the job is estimated to be approximate Eight days. Disposal of the removed sludge is to be lifted after the sludge gets dried at one or more points decided by E.I.C. Payment shall be considered strictly on actual quantities of sludge handled. Bidder has to quote his best rates per m3.keeping above possibilities in mind. 2.3 SA-4, SA-5, SA-6 IN ETP: Job belong to ETP and the sludge is likely to be soft to hard deposit from place to place. Approximate quantity is estimated to be 300 m3 and removal shall be accomplished by handling wet sludge in buckets etc. and then transferring the same on a trolley/trailer for disposal to a point within factory as per instruction of EIC. The available time for completion is expected to be 7 days (max.) Payment shall be considered strictly on actual quantity of sludge handled. Bidder has to quote his best rates per m3 keeping above possibilities in mind. 2.4 GUARD POND-A NEAR 132 KV SUB-STATION: Wet / dry sludge which may contain some chemicals, having foul smell is to be removed from Guard Pond-A and to be disposed after the sludge gets dried within factory premises as decided by Engineer-in-charge. Quantity of sludge to be removed is approximately 300 m3. However, payment will be released as per the actual quantity handled. 2.5 MISCELLANEOUS POINTS LIKE: a) B/W channels around gravity sand filter(apprx. quantity of sludge shall be 12 MT.) b) B/W sump in PTP(3 time in a year)(apprx. quantity of sludge shall be 18 Te in one time cleaning.) c) Clarifier sludge sump in PTP (3 times in a year)(apprx.quantity of sludge shall be 15 MT) d) 12 SR-6 in ETP(Apprx. quantity of sludge shall be 25 MT). e) Air stripper sump in ETP (Apprx. quantity of sludge shall be 15 Te). 2.6 REMOVAL & REFILLING OF SAND: Removal, disposal and refilling of sand in 10 gravity sand filters of pre-treatment Plant. Activities involved are scrapping of old fine sand & disposal to suitable place within the Plant area decided by EIC. Also shifting of new sand after sieving from a distance of about 50 mtr. at the ground level and filling in filters.
: 9 : Area of the beds are approx. 7.5 X 10 mtr. and depth of filter is about 3 mtr. This job is time bound and to be completed within specified time given by EIC as the delay may cause limitation in operation of the Plant. If the job shall not be completed within stipulated period then Rs.2/m3/day penalty shall be imposed on the contractor. 2.7 REMOVAL & REFILLING OF ACTIVATED CARBON: There are 12 Carbon filters in D.M.Plant. The approximate quantity of activated carbon is 16.33 m3 in 4 vessels and 7 m3 in 8 vessels each. At the bottom of the vessels below the Carbon apprx. 7-9 m3 of gravel is also there. The job involves removal of Carbon and gravel from the vessels one by one into drums/bags and charging back after cleaning. If fresh carbon is to be charged old carbon is to be shifted or dumped as decided by EIC. Any number of vessels or all the vessels can be offered for emptying and charging. 2.8 REMOVAL AND DISPOSAL OF SLUDGE FROM NEW FIRE WATER TANK: There is one new firewater tank above the ground located at North East of PTP. It receives clarified water from clarifiers. The sludge keeps on collecting at the bottom of the firewater tank. Total quantity of sludge, is likely to be around 700 M 3. Sludge would be saturated with water and has to be handled by using buckets, shovels etc., manually. job shall be handed over after isolating and emptying the fire water tank. Time available for the job is around 15 days. Since the firewater tank is critical to the plant, the job should be completed strictly as per the time schedule. After removal of sludge from the fire water tank, the disposal is to be done after the sludge gets dried as decided by E.I.C. Payment shall be considered on actual quantities of sludge handled. 2.9 REMOVAL AND DISPOSAL OF SLUDGE FROM WEST SIDE LAGOON: West side lagoon is located west side of ETP/RO plant. The plant storm water drain is connected to west side lagoon. The sludge keeps on collecting at the bottom of the west side lagoon. The dimension of the lagoon is 50X30X3M. Since the lagoon is connected with the plant drain, the job is to be completed within the time schedule i.e. 21 days. So sufficient manpower tools and tackles is to be deployed so that the job is completed within the time schedule. When once the job is released the inlet to the west side lagoon is to be blocked with sand bags. Dewatering pump is to be shifted for dewatering the water. The accumulated sludge is to be removed manually by employing buckets and small drums. Disposal of the removed sludge is to be shifted after the sludge gets dried at the designated place as decided by E.I.C. Payment shall be considered strictly on actual quantities of sludge handled. 3.0 REMOVAL OF PALL RINGS, CLEANING/DESCALING AND PUTTING IT BACK IN STEAM STRIPPER-III. Steam stripper-iii is located at southeast corner of ETP. Pall rings are filled in steam stripper-iii as a packing material. In the normal course of time scale formation develops in and around pall rings and stripper
shell. Due to scale formation stripper efficiency comes down. The quantity of pall rings is 13.25 M 3. The scope of work includes: 1. Empting out of tower packing i.e. pall rings. : 10 : 2. Descaling of pall rings by chipping and acid wash. 3. Descaling of tower shall & descaling of stripper storage. 4. Descaling and cleaning of head exchanger tube (Total 250 Nos.) 5. Reloading of pall rings. The job shall be completed within 15 days from the date of handing over of steam stripper No.-III. The job should be completed strictly as per the time schedule. The job shall be released after isolating and draining and slip plating the vessel. Sufficient manpower, tools and tackles shall be deployed so that the job is completed within the time schedule. NOTES: 1. NFL reserves the right to delete any of the above mentioned jobs as per exigencies prevailing from time to time during tenure of the contract. 2. Quantities shown above are indicative only and no commitment for maximum/minimum quantities whatsoever. 3. Contractor has to use his own tools and tackles like shovels buckets, rope etc. However, special tools/fixtures as considered conducive to the speedy progress of work may be provided by Engineer-in-charge without any kind of binding upon NFL. 4. Contractor may like to use his own pump after taking permission from Engineer-in-charge. NFL may consider providing sludge pump on free basis. However, contractor is advised not to consider the same as any kind of commitment. Electrical connections and electricity will be given free of cost. 5. Payments shall be released on completion of one of the lagoon at Sl.No.2.1 and on completion of individual jobs at 2.2 to 3.0. 6. The above rates should be adequate to meet the minimum wages and all other statutory requirements of employees, working under the contract, failing which, the tender shall be summarily rejected.
Naphtha unloading Name of work:-providing services for i) smooth manning/ operation of Naphtha/NGL storage area and (ii) Unloading of Naphtha / NGL from Rail tankers/road tankers. SCOPE OF WORK SCHEDULE-I: Unloading of Naphtha/NGL from wagons. SCHEDULE-II: Operation of Naphtha/NGL storage and transfer area will be as per our requirement. Maintaining proper working condition in the entire work area is the responsibility of contractor. SCHEDULE-I: NAPHTHA/NGL UNLOADING FROM WAGONS/ROAD TANKERS: a) Measurement of quantity of Naphtha/NGL in the wagon by taking dip of the wagons. b) Check the position of level in the main storage tanks. Request the operator to adjust the valves openings as per the filling requirement in the storage tanks. c) Earthing connections should be ensured from each wagon hose connection for handling Naphtha/NGL. Buckets/drum placed under the leakage should also be earthed. After ensuring the proper connections valves should be opened. d) Road tanker - To connect/disconnect the suction of pump nozzle with road tanker using hose provided by NFL. e) Rail tanker -To connect/disconnect the suction header of the Naphtha/ NGL unloading pumps to rail tanker out let nozzles with hoses provided by NFL.(one rake of Naphtha/NGL may consist of 45 to 75 wagons depending on size & type of rake.) f) To open the suction strainers of the above pumps, cleaning of filter elements and boxing up it back. g) The naphtha spillage in the plant area especially, in CPP plant, Ammonia-II and naphtha storage area are collected in drums. The filled drums are shifted in Naphtha unloading area. When the drums are shifted, you are requested to empty out the drums to the unloading header immediately. Sufficient manpower to be supplied for emptying the drums. NOTES: 1. All tools and tackles including special tools required for above work has to be arranged by the contractor.
2. It would be the responsibility of the contractor to complete the unloading operation within the free time given by railways. I.e. the unloading of rake should be competed within 5.00 hrs. or as applicable from time to time as per railway schedule. 3. Spillage of liquid fuel, if any, is to be collected in buckets, transferring the same to barrels and then shifting to the suitable place as per the instructions of Engineer-in-charge. 4. After disconnecting the rubber/s.s. hoses subsequent to unloading of rail tankers, any Naphtha/ NGL left over in pipes are to be decanted by the contractor. 5. It would be contractor's responsibility to follow all the safety rules and regulations. SCHEDULE-II: OPERATION OF NAPHTHA/NGL STORAGE AND TRANSFER AREA AS PER OUR REQUIREMENT: NFL is having 6 Naphtha/NGL storage tanks, 4 of 4500 KL/3240 MT capacity each and 2 of 2200 KL/1584 each along with pumping facility tanks. There are four transfer pumps PC-3A/B/C/D in the area. 1. Pumps to be run as per the requirement to maintain adequate level in Captive power Plant Day tanks and Ammonia Day Tank. 2. Contractor will have to maintain required parameters, log book/log sheet supplied by NFL and follow all instructions of Shift-In-charge to entire satisfaction of the E.I.C. He has to report to Shift Engineer in shifts. 3. Pump operation will be in all the three shifts. If the area is left unmanned then contractor will be liable to penalty which can be up to Rs.200/- per shift. GENERAL: a) Management of operation and maintenance of the entire unloading shall be in the Contractor's scope. b) The Contractor is required to start normal operation within a week of receipt of work order/loi. c) Contractor shall depute his representative for communication regarding unloading operations which may start at any time during the day as per the availability of the wagons/road tankers. The representative should preferably have minimum ' B.Sc./Diploma in Engg. qualification and/or of sufficient experience to discuss technical/commercial requirements with the Engineer-in-charge or his appointed representative.
d) Contractor shall coordinate with the Engineer-in-charge. e) Employees engaged by contractor will not be allowed to carry lighter / match sticks/cigarette/bidi etc. in the working area. f) Contractor should keep close liaison with railways & transportation department of NFL to keep himself informed of the latest position of incoming NGL/Naphtha rakes. It shall be the duty of Contractor to depute a responsible person to survey the unloading area daily in General shift hours and also in the night depending upon requirement. Patrolling should be done daily and report should be submitted. g) At the time of unloading of NGL/Naphtha rake contractor's representative shall be required to be present along with sufficient number of persons so that rake could be unloaded in free time including connection /disconnection of hoses. Contractor has to plan his activities so that the rake is unloaded within free time of 5.00 Hrs. h) Naphtha/NGL rail tankers are to be emptied out within free time allowed by railways. That is the unloading of rake should be competed within the free time of 5.00 Hrs. or as applicable from time to time as per railway schedule. Any demurrage paid by NFL to Railways due to delay in unloading on the part of Contractor will be recoverable from him.