BIOMETHANATION PLANT O&M LEASE DOCUMENT

High Rate Bio-methanation Power Generation & Compressed Biogas Plant at Haibowal

Ludhiana

Bid Document For Operation & Maintenance Lease

Punjab Genco Limited

Plot No. 1 & 2, Solar Passive Complex, Sector 33-D,

Chandigarh – 160034

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NOTICE INVITING TENDER

Punjab Genco Limited, Solar Passive Complex

Plot No.1 & 2, Sector 33-D, Chandigarh-160034, Tel.: 91-172-2663328, FAX- 91-172-2646384 (Wholly Owned Company of Punjab Energy Development Agency)

E-Tender No. – PGL/2017-18

Punjab Genco Ltd. invites offers from the interested bidders to participate in the Tender for O&M Lease of High Rate Bio-methanation Power generation & CBG/CO2 Plant at Haibowal Dairy Complex, Ludhiana, Punjab. The prospective bidders are requested to submit bids as per schedule given below-

1. Date of uploading of Bid Document 26/03/2018

2. Date of Pre – Bid Meeting 13/04/2018 at 11: 30 AM

3. Last date and time for submission of e-bids 27/04/2018 upto 5:00 PM

4. Date and Time of opening of Technical e-bids 30/04/2018 at 12:30 PM

5. Cost of bid document(Rs.) 10,000/-

6. E- Processing fee(Rs.) As applicable through online mode only.

7. Earnest Money Deposit (Rs.) 2,00,000/-

1. The detailed terms and conditions, scope of work, eligibility criteria, Performance Guarantee and

place of submission of Bids etc. are given in the bid document, which can be downloaded from the www.eproc.punjab.gov.in or www.peda.gov.in.

2. Prospective bidders are requested to remain updated for any kind of notices/updates/amendments/modifications/clarifications etc. to the bid document in the website www.eproc.punjab.gov.in or www.peda.gov.in only. No separate notifications will be given for such notices/updates/amendments/modifications/clarifications etc. in the print media (press) or individually.

3. For participating in the above e-tendering process, the bidders shall have to get themselves registered with www.eproc.punjab.gov.in and get user ID and Password. Class 2/3 Digital Signature is mandatory to participate in the e-tendering process. For any clarification / query regarding bid-document or its clauses bidders can contact PGL at 0172-2646384, 8699007080 or call the helpdesk at 0172-2791326, 0172-2791226 (on government working days from 9.00 am to 5.00 pm).

4. Technical / Financial Bid Forms in bid document are for reference purposes only. Bidders have to download the Bid Forms from e-tendering website www.eproc.punjab.gov.in only after payment of bid document cost.

5. Corrigendum if any will only be uploaded on the website www.eproc.punjab.gov.in or www.peda.gov.in. No separate notice shall be published in press.

6. PGL, reserve the right to accept or reject any or all the bids and also annul the entire bidding process without assigning any reason thereof.

DIRECTOR

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INDEX

S.No. Subject

1 Section – 1 – Introduction

2 Section – 2 – Information & Instructions to bidders

3 Section – 3 – Generation Conditions of lease agreement

4 Section – 4 – Annexures

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SECTION – 1

INTRODUCTION:

Punjab Genco Limited, (PGL), (a Punjab Govt. undertaking & wholly owned subsidiary

of Punjab Energy Development Agency (PEDA) plans to operate and maintain One No.

Cattle Dung based High rate Bio-methanation Power generation, CBG bottling and CO2

recovery Plant installed at Dairy Complex, Haibowal, Ludhiana, Punjab on lease basis

for 5 Years. This Plant has been setup in the year 2004 under the UNDP – Global

Environment Facility Programme with a major objective of “Abatement of Green House

Gas emissions”. The Plant has been financially supported by the MNRE, GOI and

PEDA jointly. The Plant has a capacity of 10,000 m3/day of raw biogas generation for

which 235 tons per day of cattle dung is required as intake feed and at this level 60-70

tons of bio manure with moisture content varying from 35-50% shall be generated in de-

watering section on daily basis. The cattle dung is available from the adjoining

Haibowal Dairy complex throughout the year and the bio manure generated has a good

nutrient value and can be sold as organic manure for farming.

The salient features of the plant at “Dairy Complex, Haibowal” are briefly described in

Annexure-2 of this tender document. The plant has been commissioned under the

supervision of authorised representatives of the manufacturers/suppliers of equipment.

The newly installed 400 KWe capacity power plant with islanding feature is designed for

operations with control & monitoring system for Gas engine. The plant is designed for

operation from BIMA (Biogas induced Mixing arrangement) process control system.

The plant has been designed to run around the year with cattle dung being supplied

from the dairy complex itself by a third party/contractor. The Gas engine using biogas

being generated from the plant as fuel for power generation is designed for fully

automatic operations. In year 2015, the plant was upgraded by addition of CBG & CO2

recovery systems along with existing Power Generation & same was commissioned

successfully in October 2015.

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The break-up of Plant cost of the High Rate Bio-methanation Power generation, CBG bottling

and CO2 recovery Plant is as under:

S.No. Description Contract Price in Rs. Crore

1 Civil works 5.36

2 E&M works including PLC system

8.30

3 Compressed Biogas & Co2 recovery system (approx.)

6.93

TOTAL

20.59

The technical specifications of Gas engine and CBG/CO2 system are available vide

Annexure – 10 & 11.1 respectively for ready reference & copies of all O&M manuals &

drawings will be provided to successful bidder.

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Section 2

INFORMATION AND INSTRUCTIONS TO BIDDER 1. Purpose of the Tender The Punjab Genco Limited, (PGL) Chandigarh, is to select O&M lessee for generation of power &

production of compressed biogas from its cattle dung based High rate Biomethanation Power

Plant at Haibowal Dairy Complex in Ludhiana by maximizing outputs from the bio gas generated

from the BIMA technology based digestors and plant process and unhindered evacuation of power

supplies to Punjab State Power Corporation Ltd. The power factor, output in KW, KVAR, current

and voltage form the basis of quality power supply to PSPCL. The selling of compressed Biogas

(CBG), CO2 & bio-manure will be in the scope of Lessee.

PGL (The Lessor) invites e- bids for Operation & Maintenance of plant on Lease basis from

experienced & reputed Companies/Consortiums. The O&M LESSEE will Operate, Maintain &

Repair this plant and will co-ordinate and establish liaison with concerned authorities of PSPCL

and Dairy owners in the complex for cattle dung procurement and any other concerned

department like PPCB, Municipal Corporation etc. and will act as required to achieve the following

objectives:

Streamlined and efficient Operation and Maintenance (O&M) of the power plant on

concept to complete basis in every respect.

Minimizing plant down time and tripping’s etc. for optimum power and bio gas

generation.

Maximise Gas generation from the Digestors by optimum operations and maintaining of

the plant process control parameters.

Ensure continuous supply of designed quality and quantity of cattle dung to the plant for

feeding.

Ensure continuous sale of the bio-manure being generated from the dewatering section

in the plant, so as to retain enough space in the drying yard for future bio-manure being

generated.

Ensure commercial sales of compressed biogas produced from the plant to industrial,

domestic, automotive sectors etc.

Quality power supplies and timely revenue receipts.

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Adherence to all relevant rules and regulations, instructions and safety measures in

accordance to the existing laws and utility practices & standards.

The plant comes under the preview of PESO (Petroleum explosive safety organisation)

and Factories Act 1948 as an ordinary Hazardous zone and strict compliance to Fire

safety regulations by always keeping the fire fighting equipment in working condition has

to be ensured.

The bottling (Cylinders/cascades) or dispensing unit for compressed biogas & liquefied

CO2 along with trollies, tractors etc. to be procured / installed by the Lessee on its own

cost and must conform to PESO approvals, rules & regulations.

Adherence to standard approved maintenance schedules and operation procedures of

various plant equipment/systems.

Proper operation of plant main systems and all its auxiliary and safety systems

/equipments including effluent treatment plant, screw presses, compressors, PSA

system, H2S Scrubbers, moisture removal system, cooling tower, liquefied CO2 system,

electrical control and plant electrical auxiliary supply including DG system.

Proper availability of spares for all equipment is to be ensured and a minimum inventory

of required spares for plant operations must be maintained at the plant site.

Continuously test, monitor and maintain the plant feed, plant process, gas generation,

composition, bio-manure and ETP output parameters well with in the plant process

design limits for ensuring optimum operation levels.

The plant exhaust gases emissions and output waste water parameters must be at all

times, maintained well within limits specified by the Punjab Pollution Control Board.

Maintenance and repair of the plant including the Gas engine, compressed biogas

system, CO2 recovery system, compressors etc. has to be kept in excellent working

condition at all times.

Maintenance of fire fighting system and to ensure safety of the plant.

The O&M LESSEE is to ensure that these requirements are met in a timely manner and speedy

operation and maintenance is carried out round the clock. The energy generation at the plant is to

be maximized by minimizing plant down time, operating at higher output and efficiency of

equipment to ensure optimal utilisation of input and plant asset resources, timely Plant repairs, and

maintenance of the plant equipment shall be planned based on monthly targeted energy outputs &

plant/equipment running hours. The longer life of the plant and machinery and civil structures will

also be ensured. The optimal utilization of input feed resources to maximize power generation,

CBG/CO2 and bio-manure is the essence of the lease agreement for O&M of the plant.

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3 (a) Brief Scope of Work

The LESSEE under the conditions specified, will act on behalf of the Punjab Genco Ltd., to

achieve the objectives as specified in Section -2, clause -1 above, to coordinate, liaise, maintain

and operate the plant. The lessee shall be responsible for cleaning and de-sludging of the

collection tanks minimum twice a year, maintaining the plant site including all its areas in a neat

and clean manner with all the equipment properly maintained and serviced. The disposal of sludge

should be done to a suitable place with appropriate permission from relevant local authorities.

During the O&M lease period of the plant to supply electricity to PSPCL grid, sell compressed

biogas, Co2 & bio-manure as the case may be. The Lessee shall observe the environmental,

social, safety, labour laws and other regulations in force, obtain all necessary authorizations and

adhere to laws of the Punjab State and Govt. of India. The LESSEE is to carry out round the clock

plant operations and maintenance, record and report all plant operations, parameters, plant data

and maintain & submit data on daily, weekly, monthly and annual basis to PGL, observe and

perform manual observations for power generation, plant process control parameters, gas engine

operations, PSA Systems, CO2 recovery system, compressors, various blowers and pumps

including screw presses. The complete plant operation and generation data shall be provided by

the Lessee to the Lessor on approved formats in the soft copy in addition to the hard copies. The

LESSEE will be required to ensure continuous supply of required quantity of cattle dung of proper

characteristics free of foreign materials to the collection tanks in the plant and prepare slurry as per

required parameters for feeding into the Digestors in the plant. The plant has a number of imported

components /equipments for which necessary tie up with the vendors/local collaborators be

ensured for supply of spares. For the Gas Engine, Compressed biogas system, CO2 recovery

system, the LESSEE must ensure an O&M back up arrangement with the Suppliers Indian service

support company.

The Lessee will ensure coordination and liaison with all concerned authorities on behalf of PGL,

take all safety measures and safe custody of the plant within the laws of the state and Govt. of

India.

(b) The power plant, compressed biogas system & CO2 recovery system will be handed over to

LESSEE for operation and maintenance. The Letter of Intent (LOI) will be issued to LESSEE,

the LESSEE will be given seven days-notice from the date of issue of LOI to identify and post

his personnel, (Plant Manager, Engineers, Mechanical, Electrical Operators, Chemist and

helpers etc.). A lease agreement shall be signed by the lessor with the lessee and after

submission of PBG by lessee, the plant will be handed over to the Lessee in ‘as found

conditions’ who will immediately commence the O&M of the plant. However, prior to the

handing over the plant, the Lessee & Lessor will carry out the joint plant inspection and a defect

list to this effect will be prepared. The defects will be removed by LESSOR at its own cost. This

plant has been designed and implemented in the best possible manner for optimum power

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generation along with compressed biogas & CO2 production as per design parameters of the

individual system. The Lessee does not reserve any right to object or probe the existing plant

performance or any equipment or component of the plant. However, any system improvement

can be proposed by the Lessee with cost benefit analysis and the implementation of same will

be at the sole discretion of the LESSOR.

4. Bidders to Inspect Site and Obtain All Information

4.1. The bidders at their own cost and in their own best interest with prior permission of PGL,

should inspect, examine plant conditions, all mentioned systems and its surroundings

and satisfy themselves, before submitting their bids, in respect of the site conditions,

including but not restricted to the following which may influence or affect the O&M work

and cost thereof under the Lease Agreement.

a) Plant condition includes a general reconnaissance of plant site including all civil

structures such as collection tanks, digestors, gas holder, electrical control room

etc. and all plant and equipments in the plant including Gas engine, CBG

System, CO2 recovery system, Compressors, blowers, pumps etc. including all

instrumentation, PLC systems and plant electrical systems etc.

b) Plant conditions also include access to the site, overall health of plant

operations, systems installation etc. in connection with the O&M Lease

Agreement.

c) Plant condition also includes any other information pertaining to and needed for

carrying out the work under the Lease Agreement including information as to the

risks, contingencies and other circumstances which may influence or affect the

O&M work or the cost thereof under this Lease Agreement.

4.2. Manufacturer’s O&M manuals & drawings in respect of major plant, systems, equipment

and civil, electrical, mechanical and instrumentation equipment of plant are available in

the office of the Director, Punjab Genco Ltd., Chandigarh and the same can be seen by

the bidder on request.

4.3 Clarification and Pre-bid Conference

PGL shall hold one pre-bid conference on 20/03/2018 at 11: 30 AM at PGL office,

Chandigarh and to enable PGL to issue clarifications and replies to the queries of the

Bidders to the extent possible. For any clarification / query regarding bid-document or its

clauses bidders can contact PGL at 0172-2646384.

Bidders are requested to send their queries in writing so as to reach PGL at least three

days prior to the Pre-Bid Conference on kulbirsingh@peda.gov.in and

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gencopunjab@yahoo.in.The primary purpose of this conference will be to make

clarifications on any queries on the bidding.

Minutes of the meeting, including the text of the questions raised and the responses given

will be transmitted to all participants and also uploaded on PEDA website. Any

amendments / modifications of the proposal documents which may become necessary as

a result of the Pre-Bid Conference or otherwise, made by PGL shall be considered as an

Addendum to DNIT.

Non-attendance at the Pre-Bid Conference will not be a cause for disqualification of the

Bidder. However, all clarifications and modifications presented in the Addendum will be

binding on all the Bidders irrespective of their attendance at the Pre-Bid Conference.

5. Submission of Tender & Eligibility criteria

5.1 The tender shall be submitted at e-tender portal of Punjab Government, in the prescribed

form only by a Company (Regd. Under Companies Act 2013) / Consortium of companies or

a Public-Sector Undertaking.

5.2 It is necessary that the LESSEE should be Company/Consortium of Companies registered

under the Indian Companies Act, 2013 and foreign companies. Companies including foreign

companies forming a consortium are also eligible. The authorised signatory of the tenderer

submitting documents/ signing the Lease Agreement should be duly empowered by the

Board of Directors of the LESSEE for the said purpose. A copy of such authorisation may

be enclosed with the bid.

5.3 TECHNICAL ELIGIBILITY CRITERIA: - The bidding company/consortium having following

credentials shall be eligible for opening of their price bids:-

The bidding company/consortium must have at least two year experience in

successful operation and maintenance (as contract) or in regular Operation &

Maintenance of Biogas Plants, Biogas power generation Plants on similar/ MSW/

waste streams with minimum 10,000 m3/day plant biogas generation capacity and

minimum 500 KW of biogas power generation capacity having sufficient managerial

and technical capabilities and had carried on the operation and maintenance of high

rate bio methanation process, CBG/PSA Technology, high pressure compressors

(air or biogas) & biogas power Plants. Appropriate documentary proof establishing

the said qualifying experience needs to be submitted along with the bid.

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5.4 FINANCIAL ELIGIBILITY CRITERIA:- The bidding company/consortium having following

credentials shall be eligible for opening of their price bids :-

The bidding Company/Consortium of companies should have an average Rs. 3.0

crore annual turnover for the last three financial years i.e. 2014-15, 2015-16, 2016-

2017 and must be in profit in at least two years from the last three financial years i.e.

2014-15, 2015-16, 2016-2017.

Or

The net worth of the Company/Consortium of companies must be Rs. 2.0 crore in

each of the last three Financial Years i.e. 2014-15, 2015-16 and 2016-2017.

Note:- In case of Consortium, the experience of the lead partner shall only be considered for

the technical eligibility requirements. However, for meeting the financial eligibility requirements,

the credentials of any one of the consortium member can be considered.

5.5 The bidder shall comply the following points:-

1. Feed-stock:- The bidder will have to make its own arrangements for supply of cattle

dung at its own cost.

2. O&M of the Plant:- The bidder will have to operate and maintain the whole plant (Power

Generation, CBG and CO2 bottling including all the electrical and mechanical

equipments, gas engine and civil structure as well) at its own cost. For the purpose of

maintenance of the gas engine the bidder will have to enter into comprehensive

maintenance contract with the OEM of the gas engine for complete O&M lease period.

3. Auxiliary Consumption/Export to PSPCL: - The bidder will have to ensure that the

auxiliary power consumption of the plant is met from the power generation of the gen set

and in view of the PPA signed with PSPCL there must be net export of power to PSPCL

of minimum 30,000 KWh per month. Any deficit/shortfall in the same shall be charged at

the prevailing PSPCL LS tariff.

4. Raw Bio gas: - After the requisite amount of power production, the remaining raw bio

gas will be used in CBG unit for conversion to CNG and CO2. The bidder will have to

pay the lessor for each m3 of raw bio gas metered at the plant.

5. Organic Manure: - The bidder will be free to sell the bio manure generated from the

plant. However, the machinery required for loading/cleaning the yard will have to be

arranged by the lessee on its own.

6. CBG and CO2 Bottling: - The bidder will have to create infrastructure for CBG and CO2

dispensing like Cylinders/Cascades, dispensing unit etc. at its own expenses for

ensuring marketing/ A trial run of the CBG facility has already been completed and PGL

has obtained the consent to operate (CTO) from PESO. However, the lessee needs to

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have its own marketing tie-up for sale of the produce from the plant and the necessary

statutory clearances shall be obtained by the lessee at its own level only. The bidders

are advised to visit the plant site before submitting the bids for better understanding of

the technology and plant operational requirements.

7. R&M:- Prospective bidders may note that PGL has already planned R&M of the

infrastructure which is likely to include the replacement of main agitators, gas blowers,

feeding pumps, main feeding pipe, substrate pumps, H2S blowers, gas balloon,

upgradation in ETP system and design, SCADA, generator control panel etc. Any

outages in the plant on this account shall be a reserved outage and efforts shall be

made to keep it to the minimum possible.

5.6 Lease Period:- The lease period will be initially for 1 year, which can be further extendable

upto 5 years based on performance review.

5.7 During handing over of the plant back to the lessor, the lessee and the lessor will carry out

the joint inspection and defect list to this effect will be prepared. The defects will be

removed by lessee at its own cost or lessor at the risk and cost of lessee. In such an

eventuality, the LESSOR will retain any addition/installation of permanent nature in the plant

made by the LESSEE for the optimum operation of the plant without any cost to the

LESSOR.

5.8 Performance Guarantee:- The bidder must have an operating Bank account for the last

more than two years with any Scheduled Bank in India in case of existing companies. In

case of newly incorporated company, the company must have a bank account with any of

the scheduled banks in India. The bidder should be in position to provide a Performance

Guarantee of Rs. 50.00 Lacs (Rupees Fifty lacs only) in the shape of bank guarantee, valid

for the full duration of the O&M Lease Agreement. The term of O&M Lease will be for 5 year

unless terminated earlier for default or otherwise. The performance of the Company shall

be adjudged based on the correspondence made between the Lessee & Lessor & whether

the Lessee had complied with the observations/issues raised by the Lessor in terms of the

agreement and had achieved the Plant targets. If the performance of lessee at any time is

not found satisfactory during O & M lease period, the lease agreement can be terminated by

PGL.

5.9 Security Deposit:- The bidder is required to submit an interest free security deposit

equivalent to 2 months advance receivables for lessor calculated for a minimum raw bio-gas

production quantum of 5000 m3 per day.

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5.10 Stabilization period:- The bidders may note that beyond a stabilization period of

6 months, the lessee has to ensure a minimum raw bio-gas production of 5000 m3 per day

and an equivalent revenue to PGL on this account.

5.11 The tender documents in prescribed form should be complete and duly signed by

authorized signatory.

5.12 The Bidder shall submit the detailed experience of each of the team members to be

deputed at the plant site after issue of letter of intent. BIMA technology is one of the unique

technologies where there are no internal moving parts in the digesters. Bidder must have

the process technologist who has at least 1 year of working experience either in India or

abroad on the plant of similar or higher capacity. Process technologist shall be B. Tech. in

Chemical Engineering / M. Sc. In Microbiology or similar equivalent qualification. At least

one process engineer with bachelor degree in Chemical Engineering with at last one year

experience shall be deputed at the plant site. Laboratory chemist should be environmental

science post graduate or B.Tech in Chemical engineering with at least 1 year of experience

in working with BIMA technology based plant. CHP stations, CBG System & CO2 system

are one of the most important parts of this plant and trained manpower is the essential

requirement of this plant.

5.13 The bidder must have one trained engineer with experience of working on the similar Gas

Engines for at least 1 year. Team member of the Bidder shall have hands on experience of

handling PLC systems.

5.14 The PGL is not bound to award the Lease Agreement to any or the lowest bidder and

reserve the right to cancel the bids and/or withdraw NIT without assigning any reason.

6. STAMP FEE

The stamp fee of Rs. 100/- is to be incurred in signing/registering of Lease Agreement shall be

borne by the Lessee.

7. Earnest Money Deposit (EMD):

7.1. Earnest money deposit of Rs. 2, 00,000/- (Rs. Two Lakh only) must accompany each

tender and should be deposited only through IPG Mode.

7.2. No exemption whatsoever of any kind will be allowed to any bidder in respect of Earnest

Money Deposit.

7.3. Tenders not accompanied by Earnest money deposit shall be rejected by E-tendering

process. If during the tender validity period, tenderer withdraws his tender, the EMD

shall be forfeited.

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7.4 The Earnest Money deposit will be returned to the unsuccessful bidders within 30 days of

the award of work to the successful tenderer.

8. Documents to Form Part of Tender

Previous experience of similar works specified under clause – 5, technical and financial

capabilities of the bidder shall be the main criteria for prequalification of a bidder. The bidder

shall submit the following information/documents in the tender.

Techno commercial Bid:

a) Company/ Consortium profile of the bidder giving, but not restricted to, the

following:

i. Name of the Company/ Consortium of Companies:

ii. Address of Registered / Corporate office:

iii. Address for correspondence:

iv. Telephone nos & E-mail adresse:

v. Contact person & his telephone nos. for correspondence:

vi. Organisation setup of the company:

vii. Name and designation of the authorised signatory submitting the offer and signing the

Lease Agreement on award:

viii. Nature and constitution of the company (Documentary Proof may be enclosed).

ix. Nature of business generally performed by the company.

x. A certificate of satisfactory performance (operation & maintenance) of such plant from

the Institution/ Company (Plant Owner) needs to be attached while submitting the bid

as documentary proof showing the technical capabilities of the company in line with

eligibility criteria of DNIT.

xi. Certified & audited balance sheets of last three (3) years of the bidding company i.e.

2014-15, 2015-16, 2016-2017.

xii. Name and address of Bankers and years of account operations. Attach a certificate

from the Banker to this effect and to the effect that the bidder is capable of providing a

performance guarantee of Rs 50 Lacs (Rs. Fifty lacs only) for a period of at least 5

years.

xii Details of litigations, disputes and claims pending/lost/won of/by the company during last

three (3) years in the following format:

Client Reasons Present status

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b) Number and details of employees currently on company strength in the following format.

Levels

No. of employees

Minimum qualification of employees

Years of experience in similar Plants

Years with Company

Operation Maintenance

Supervisory level (technical) Supervisory level (managerial /finance) Managerial Level (Technical, Financial & Administrative) Technicians Certified welders Skilled workers Semiskilled workers Total

c) Details of similar works executed in the past by the bidder in the format given below. Certified

copies of the orders executed and certificates granted by the previous client(s) shall be

attached.

S. No Name of the

Plant Nature of the Plant

Name & address of client

Period of contract

Nature of works executed

Annual contract value in Rs.

d) The LESSEE shall indicate his PAN/GST no. in the bid.

e) Earnest Money Deposit (Details may be given)

f) A brief write up on how the LESSEE plans to operate the facilities.

g) The bidders shall furnish the details of manpower to be deployed for O&M, conveyance

facilities, communication facilities, technical support facilities for data analysis, fault diagnosis &

rectification of these in the prescribed formats placed at Annexure-20.

h) List of additional routine, breakdown & capital spares, consumables, standby provisions,

tools & tackles and other items in the prescribed format placed at Annexure-21.

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i) The Lessee shall ensure that minimum manpower as per details given along with the

Annexure - 20 is deployed at the plant site for O&M for which purpose, bidder is required to

deploy the number of persons and to provide technical back up support to the operating staff, to

store the required spares and consumables and to create sufficient communication and

transportation facilities but is required to furnish all these details in the prescribed formats in the

bid document. These arrangements shall be made to ensure minimising of plant down time for

which the lessee shall satisfy to the lessor for his modus operandi about these facilities and for

O&M of the plant as per Annexure-20 and Annexure-21.

j) Letter of authorization from the Competent Authority.

Financial Bid:

Schedule of rates chargeable per m3 of raw biogas used for power generation and for CBG &

CO2 bottling plant, metered at the respective feeding points from raw biogas balloon mainline,

as per terms and conditions of DNIT. An annual escalation of 5% will be applicable on the price

quoted. The bidder is to enclose this offer as per Annexure-19.2

9. Tender Validity Period

The tender shall be valid for a period of 120 days from the date of opening of Techno –

commercial bid.

10. Instructions for Filling Techno-Commercial bid & Price Schedules

10.1. All pages of the tender/bid shall be signed by the authorized signatory of the bidder.

10.2. Conditional offers shall not be considered/accepted and bid is liable to be rejected.

10.2. The price schedules shall be submitted strictly in the same formats as prescribed in

this tender document.

10.3. The prices shall be written both in words and in figures. Corrections, if any, shall be

made by crossing out, initialing, dating and rewriting. In case of conflict between the

figures and words in the prices, the later shall prevail.

10.4. Any deviation from the techno-commercial terms and conditions of this document

shall not be considered / accepted.

11. Right to Reject

The Managing Director, PGL, Chandigarh shall have the right to withdraw NIT or reject all or

any of the tenders and shall not be bound to accept the lowest or any tender or to give any

reasons for his decision.

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12. Opening of Tenders

The e-tenders shall be opened by a duly authorized committee of officers / committee member,

in the presence of bidders or their authorized representatives who may like to be present at the

time of opening of bids.

13. Revoke/Withdraw the Tender within Validity Period

The bidders shall not be entitled, during the period of validity of their offers, to revoke or

withdraw their tender or vary in any respect the tender given or any term thereof. In case of a

bidder revoking or withdrawing his tender or varying any terms in regard thereof without the

consent of the PGL, in writing, his EMD shall be forfeited and his bid will not be evaluated.

14. General

14.1. The notice inviting tender and this information and instructions to bidders shall form part

of the Lease Agreement.

14.2. All information in the tender shall be in English Language.

14.3. The above stated requirements are only informative and minimum and PGL, reserves

the right to call for any other additional information from the bidders.

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Section –3

GENERAL CONDITIONS OF LEASE AGREEMENT

1. Definitions The terms have the following meanings unless the context clearly indicates otherwise: “Plant/Power Plant/ Power House/Power Station” means the High Rate Biomethanation

Power & Compressed Biogas (CBG) Plant alongwith CO2 recovery system (as part of CBG

Plant) at Haibowal, Ludhiana, Punjab including all the land, civil structures, buildings housing

entire equipment, systems of the plant, electrical, mechanical and instrumentation, piping plant

and equipments including moving equipments like Bobcat etc , dedicated telephone lines,

telephone and fax, computer systems, components, appurtenants / auxiliaries,

communications, etc. in the Power & CBG plant area. It also includes the mobile and

immobile equipments, spares, consumables, tools and tackles and services provided for

successful operation & maintenance of the Plant.

“PEDA” means the Punjab Energy Development Agency “PGL” means Punjab Genco Ltd., Chandigarh a wholly owned subsidiary of PEDA and a

company formed and incorporated in India under the Indian Companies Act, 1956.

“PSPCL or Board” means the Punjab State Power Corporation Ltd. or its subordinate offices. “PPCB” means Punjab Pollution Control Board, Govt. of Punjab and its offices. “PWD” means Public Works Department of Punjab Govt. and its offices. “LESSEE” means company/public sector undertaking/ qualified to do business in the state of

Punjab and its permitted successors and assigns which shall be awarded with the leasing of

O&M of the plants.

“LESSOR” means Punjab Genco Ltd., Chandigarh and its permitted successors and assigns. “Property” means the power plant. “Prudent Utility Practice” means those practices, methods, techniques and standards, as

adopted from time to time, that are generally accepted for use in electric utility industries taking

into account conditions in India, and commonly used in prudent electric utility engineering and

operations to design, engineer, construct, test, operate and maintain equipment lawfully, safely,

efficiently and economically as applicable to power stations of the size, service and type of the

Plant, and that generally conform to manufacturer’s operation and maintenance guidelines.

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“Designed Energy” means the energy computation at the interconnection point on the basis of

calculations in the DPR done at the maximum rated plant intake and operation capacity after

taking into account efficiencies of various equipments & auxiliary consumption.

“Deliverable Energy” means the energy delivered to PSPCL at the interconnection point.

“Saleable Energy” means the net energy saleable to PSPCL. The saleable energy = export of

energy to PSPCL–import of energy from PSPCL for auxiliary consumption as per terms of PPA.

“Maintenance Outage” means an interruption or reduction of the power generating/CBG

production capability of the Plant for the purpose of performing work on specific components

which in the opinion of the LESSEE and the LESSOR could not be postponed until the next

Scheduled Outage and shall be scheduled by the LESSEE and allowed by the PSPCL/PGL.

“Scheduled Outage” means a planned interruption of the power generating/CBG production

capability of the Plant that is scheduled for inspection, routine and preventive maintenance,

corrective maintenance, repairs, replacement or improvement and is not a Maintenance Outage

or Forced Outage.

“Forced Outage” means an interruption of the power generating/CBG production capacity of

the Plant that is not the result of (i) a request by the LESSOR or by the PSPCL in accordance

with this Agreement (ii) a Scheduled Outage or a Maintenance Outage (iii) an event or

occurrence of Force Majeure, or (iv) a condition caused solely by the PSPCL, PGL or by the

grid system.

“Reserved Outage” means shutdown of power generating unit/CBG plant on instructions of

LESSOR or PSPCL or PPCB or any other statutory authority for reasons not attributable to the

LESSEE.

“Interconnection Point” means the point at which interconnection is made between PGL

(LESSOR’s) generation facility and the grid system of PSPCL and is located on the High

Voltage side of the generation facility of PGL (LESSOR) in the Outdoor Yard (ODY) at the

power house.

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2. Salient Features of High Rate Biomethanation Power & CBG Plant at Haibowal,

Ludhiana

Salient features of High Rate Biomethanation Power & CBG Plant are given in Annexure-2 of

this tender document.

3. Route Map of the Plant

Route map of High Rate Biomethanation Power & CBG Plant at Haibowal, Ludhiana is given in

Annexure-3 of this tender document.

4. General Layout Drawing, P&ID and Single-line Diagram of Power & CBG plant

The general layout drawing, P&I and Single Line Diagrams(SLDs) of power & CBG plant are

given in Annexure- 4- 9 of this tender document.

5. Objectives and Scope of Work

The objectives to be achieved by the LESSEE and the Scope of Work of the LESSEE have

been described in para 2 and 3 respectively of Section 2, Information and Instructions to

Bidders.

6. List of Civil Structures and Plant and Equipment

The following is the list but not limited to the civil structures and plant and equipments which will

be operated and maintained round the clock by the LESSEE at the power & CBG plant.

6.1 Civil Structures of High Rate Biomethanation Power Plant

Collection Tanks (2 nos.), Dry Well

BIMA Digestors (2nos.) cap. 5000 cum each

Gas Holder

Electrical Control Room

Effluent Buffer tank

Dewatering Station, Drying Yard,

Press Water Tank, Hopper Bottom settling tank, Aeration tank, Secondary Clarifier.

Office building, store, security room, Metering Room, Retaining and boundary walls.

CBG Plant Shed.

7.2. Mechanical, Electrical & Instrumentation Equipment

o DG set, MCC, PCC, VCB, APFC, Battery Charger, Relay Control panel, MLDB, PDB,

Transformer and associated equipments.

o Main transformer, Automatic Tab Changer Panel, and auxiliaries etc.

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o BIMA system with Agitators, pumps, PLC and instrumentation Panel, Computers and

UPS.

o Gas Engine R. Schmitt (Cap. 400KW) complete with all its auxiliaries like acoustic

enclose, H2S scrubber, Waste Heat recovery system, Dehumidifier, Air washer &

Chimney.

o CBG System complete with Boosters pumps, Moisture & H2S scrubbers, PSA

technology purification system, Purified biogas storage balloon, Biogas compressors &

biogas disposal points.

o CO2 recovery system, CO2 liquefaction units & tanks along with weighing system &

discharge platform.

o Lighting systems, exhaust fan system, air conditioners, fire extinguishers etc.

o Earth pits and earth connections in the power house

o Power and control cables in the plant.

o Two water-bore holes with water pumps, Hot water, circulation systems with all piping

Waste Heat Recovery system with exhaust, plate and Double tubular pipe heat

exchangers with hot water circulation pumps, electric water heaters and valves.

o Exhaust Stack with its ladder and aviation warning Lamp.

o All power house furniture, tools and tackle etc.

o Bus duct

o All switchyard equipments such as Current transformers (CTs), Potential transformers

(PTs), Lightening arrestors (LAs), Circuit breakers (CBs), isolators, auxiliary transformer,

overhead connections, power and control cables, earth pits and earth connections etc.

o Export and import energy meters

o Biogas flow-meters at gas engine inlet & CBG Plant inlet.

o Compressed Bio Gas analysers.

o Flare System with Flare Blowers, Engine Feed Blowers with VFD’s

o Condensate trap, Gas Balloon with its safety control, Gas volume control and

instrumentation system.

o All pumps, compressor and manual, automatic valves and piping in the plant

o Agitators, motors with gear boxes, macerator, Digestors feed pumps.

o Start up Blowers, H2S Blowers, Bima Internal Parts, EBT pumps

o Screw Presses, weigh Bridge and its computer system, Bagging Machine, Bobcat.

o All other auxiliaries in power house and switchyard such as fire fighting pumps and

system and other accessories needed for the safe operation of the facilities.

o Complete Laboratory equipment with its instruments and glassware.

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o Plant Instrumentation including Thermal mass flow meters, DPT meters, Temperature,

pressure gauges, gas flow meters, PH meters, level controllers and indicators with

instrumentation cables.

o Plant equipment and Gas Engine Spares.

o Any other item installed at the plant but not indicated.

8. Operation & Maintenance of Plant:

The operation of the plant and its equipment shall be carried out in accordance with the

operation and maintenance procedures described in the plant /equipment O&M manuals,

Relevant Safety standards and instructions of LESSOR’s officers. The plant has following

major sections:

Plant feeding and Digestors for gas generation

Power generation from the Gas engine and evacuation to the Grid

CBG System with biogas compressors

CO2 recovery system alongwith storage tank & filling station

Dewatering of the slurry and handling of bio-manure.

Effluent treatment plant.

Each of the section has to be operated in perfect synchronization with the other sections. Plant

safety is of utmost importance especially in view of the fact that the Gas in the top chambers of

the BIMA digestors is regulated under pressure and then stored in the gas holder at a lower

pressure. The fire fighting system has to be in operational condition always for ensuring

pressurised water supply in the system.

Thus, the LESSEE has to ensure that during O&M of the plant and equipments, the plant safety

is always ensured and all process control parameters are strictly adhered too.

8.1 Operation and maintenance of the Gas Engine

A. Gas-engine specification: - A 400 KW gas-engine of R. Schmitt make is installed at the

plant site. The Gas engine is a very sophisticated equipment and has its own PLC system. The

continuous operation of the Gas engine is of importance so as to ensure continuous power

generation by utilising the gas being generated from the digestors. A regular back up support

for servicing, spares and repairs be ensured from the engine manufacturers / authorised

service companies. The Gas engine servicing and maintenance schedule be strictly adhered to

in all conditions. The O&M manual of the said gas-engine is enclosed at annexure-

B. Gas-engine status:- The engine has presently clocked running hours equalling almost

12000 hours and the first scheduled maintenance/overhaul is due. The lessee needs to

immediately attend to the above requirements and bidders may further note that the engine

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supplier has mandated the periodic services after the passage of 12K, 24K, 36K and 48000

hours. The Lessee is required to enter into a comprehensive maintenance contract with the

OEM/OEM authorised representative.

8.2 Operation and maintenance of the BIMA digestors and all related equipment for

gas generation

LESSEE shall, in connection with the maintenance and operation of the BIMA digestors and all

equipment in the gas generation section will strictly adhere to the instructions given in the O&M

manuals of the technology supplier. The LESSEE will ensure cleaning and desludging of the

collection tanks by deploying mechanical /manual system minimum twice a year. All equipment

and their proper operations has to be strictly ensured with in their operational parameters and

process control limits/parameters. All piping both for slurry and Gas have to be in proper

functional orders and maintained in case of any choking/blockage. All equipment and plant

exposed surfaces painting has to be ensured at regular intervals, so as to avoid rusting,

environmental degradation.

8.3 Operation & Maintenance of CBG & CO2 systems.

CBG & CO2 recovery systems are based upon the latest & non-polluting PSA Technology for

purification of biogas to IS standards & recovering CO2 of food grade quality as a sustainability

aspect. Purified biogas processed through state of the art PSA towers controlled automatically

through PLC based control system and is stored into a unique semi-cylindrical shaped balloon

with protective cover before being fed into high pressure reciprocating & lubricated

compressors for further filling into the gas cylinders/cascades or dispending units.

Recovered CO2 is also purified in scrubbing columns, compressed & liquefied for storage into

insulated tank enabling it to be dispensed as per requirement.

Both systems are coupled with required sensors & safety features & are controlled by PLC

based control panels & circuits. The USP of the plant is minimal methane slip as it is recovered

from the CO2 circuit vide purification process & fed back to PSA systems for aggregation.

8.4 Maintenance of Screw presses and ETP.

The dewatering section and Effluent treatment plant must be kept in full operation and

availability levels as both are very critical sections of the plant and their continuous operation is

of utmost importance. All spares required in the complete electro-mechanical, instrumentation,

PLC section of the plant shall be provided by the LESSEE during the contract period. The spare

parts if taken from the PGL shall be replaced free of cost within a period of 60 days. In case of

failure to do so, PGL shall be at liberty to deduct the cost of the same from the running bills of

the lessee or procure the same at the cost of the company.

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8.5 Maintenance of Civil structures of the Plant

The civil works of all plant and appurtenances of the plant cluster have been executed to

standard design and to standard quality. It is not expected that they will require any special

treatment/attention for repairs. These works, however, will require to be maintained by the

LESSEE in good condition by regular inspection, maintenance, dusting, washing, cleaning up

and painting and polishing. Practices followed by Punjab PWD for government

structures/buildings will govern. Painting and Polishing will be done annually during the Lease

period with prior approval of the PGL. All steel members are required to be painted every year

based on standard practice to the satisfaction of LESSOR. Potholes, damages to concrete if

any will be repaired by the LESSEE at his own cost.

LESSEE will, at his own cost, repair, maintain and keep all the civil structures and buildings in

good condition and in the same operating condition as exists on the date of execution of this

agreement.

The landscaping, lawns, gardens and greenery in the Plant area shall be provided by the

LESSOR and the same shall be developed and properly maintained in a regular manner by the

LESSEE at his own expense to improve the environment at the plant.

The LESSEE shall periodically get the Weigh Bridge checked and calibrated and also the ETP

for electrical, mechanical & hydraulic failures to ensure fail safe operation of the equipment

always.

Within one week of issue of letter of intent or work order, the LESSEE will prepare a schedule

of routine, preventive and capital (special) maintenance of entire plant & equipment all civil

structures and submit the same to LESSOR for his approval. The approved schedule will form a

part of the Lease Agreement. The maintenance schedules enclosed herewith are meant for the

guidance & are not limited to final maintenance schedules to be prepared by the Lessee.

8.6 Safety of the Plant

Safety of plant is of utmost importance and any breach of safety measures especially in the gas

generation and BIMA digestors may have serious consequences and implications. Therefore,

all process parameters have to be maintained under all contingencies. The regulation and

control of pressure/release of gas in the BIMA upper chambers is to be maintained with the

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operation of automatic valves and start up blowers. Therefore, the LESSEE will ensure daily

inspection and checking of operation of Automatic valves and start up blowers & keep all in line

filter elements blockage free. Any negligence/lack of attention on this account may endanger

the safety of the BIMA digesters and LESSEE should take serious note of the above. In case

there is any breach of plant safety or any such incident of slurry overflow takes place due to

negligence or lapse in Operation & Maintenance of the plant the Lessee shall be responsible for

the damage if any and the damage occurred will be recovered from the lessee and additionally

the lessee will be subjected to penalty by the Lessor. The amount of penalty is specified in

clause 12. He will ensure safety of the power & CBG plant at all times & lapse in this respect, if

any, shall be viewed seriously & dealt accordingly.

9. Operation & Maintenance of Plant

Round the clock operation & maintenance of plant and equipments shall be carried out by the

LESSEE in accordance with technology supplier’s manuals/instructions/manufacturer’s

instructions, relevant safety codes, Power Purchase Agreement, Indian Electricity Act, Indian

Electricity Rules, LESSOR’s instructions and prudent Utility Practices etc. to minimize down

time and to optimize the quality power generation from the plant.

9.1 Operation of Plant

Round the clock operation of the plant will generate power and the quality of the electricity

generated/delivered by the “High Rate Biomethanation Power & CBG Plant” will be ensured by

a continuous monitoring of instrumented data. The KWH generated at the plant (kilo watt hours,

represents the quantum of energy generated) will be recorded by instrumented panels/Meters

and also in the log sheets manually. The total quantum of energy from 0.00 hrs of 1st April of

any year to 24.00 hrs of 31st March of the following year will form the basis of aggregated

energy outputs in the annual cycle of the unit operation in the plant. For an incomplete year the

total quantum of energy from the time and date on which a particular power plant is handed

over to the LESSEE upto the following 24.00 hrs of 31st March or from 00.00 hrs. of 1st April to

the following time and date on which the power plant is handed over back to the LESSOR, will

form the basis of aggregated energy output. The energy from the plant will represent the

aggregated energy output of the plant.

On the same pattern the raw biogas fed into the gas engine/CBG system will be logged in the

respective inlet biogas flow meter. The meter readings will be tabulated in the same manner as

mentioned above for power generation. The monthly outputs will be reckoned in the same

manner based on English calendar months.

The quality and quantity of the bio-manure being generated from the plant must be maintained

in terms of moisture and TS content.

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Besides the above the LESSEE shall ensure continuous monitoring and recording on hourly

basis of all important parameters as instructed by the LESSOR from time to time such as

quantity of the raw feed delivered in the plant, TS,VS and VFA of the slurry prepared in the

collection tanks, all process parameters of digestors i.e. temperatures, pressure, flow rates, PH,

gas flow and pressure, Gas engine operation parameters, CBG & Co2 recovery system

process parameters, Waste Heat recovery systems temperature, readings of KW, KVA, KVAR,

KWH, voltage, current, power factor & frequency, of generating unit, slurry parameters, ETP

waste water PH, COD, BOD, plant equipment operational data, pressures & temperatures of

equipments, air pressure in the compressor and the air lines, readings of export and import

energy at main & check meters installed at interconnection point and trippings etc. The

LESSEE shall furnish the requisite daily, monthly & yearly Performa /formats of data sheets/ log

sheets for recording important parameters for approval of the LESSOR within 15 days after

issue of the Letter of Intent (LOI). These formats duly completed in all respect shall be

furnished by the Lessee to the Lessor at regular specified intervals. Daily log sheets must be

transmitted to PGL office in Chandigarh by e-mail. The hard copies of all the data logs being

maintained at site will be submitted to PGL office on monthly basis.

The LESSEE shall maintain a proper log book at the plant for recording readings of various

instruments/gauges etc. and for recording all operations as and when they occur including

scheduled outages, maintenance outages, forced outages, trippings and temporary

interruptions in delivery of energy and reasons thereof. The format of the log book shall be got

approved from the LESSOR. All the plant data sheets/log sheets shall be handed over by the

Lessee to the Lessor in the duly bonded form at the end of each year.

The LESSEE shall provide all required stationery/computer stationary, inks/printer cartridges,

log books, formats etc. at his own cost.

LESSOR shall not be held responsible by the LESSEE for any failure of PSPCL to meet the

requirements set forth in next paragraphs, and due to any fluctuations or failure resulting from

PSPCL grid. Should the level of fluctuations of electricity supply in the grid exceed the limits, for

an excessively long period, the Lessee will study the issue to evolve suitable solutions with

PSPCL, & action will be taken accordingly by Lessee/PSPCL to minimise the grid non-

availability. However, the safety of the generating plant and equipment shall be the

responsibility of LESSEE.

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9.2 Maintenance of Plant

The Lessee shall commence Round the clock regular maintenance (routine, preventive,

breakdown) of all plant, systems and equipments including collection tanks & PLC system

including disposal of sludge which shall be carried out by the LESSEE in accordance with

manufacturer’s instructions ,manufacturers procedures, relevant safety codes, Electricity

Supply Act, 1948, Indian Electricity Rules, 1956 & Electricity Act 2003, LESSOR’s instructions,

prudent utility practices etc. for the plant handed over for maintenance as and when. The

routine maintenance shall include cleaning & checks of the plant equipments/components

whereas for preventive & breakdown maintenance the lessee will notify to the concerned

agency for doing the needful at the earliest. Both the collection tanks must be cleaned of all the

sludge deposited at the bottom at least once in two months, so as to ensure that foreign

particles/sludge does not travels inside the piping through the digestors feed pumps. LESSEE

must ensure that as far as possible the cattle manure delivered into the collection tanks should

be free from foreign material.

9.2.1 Routine, Preventive, Breakdown & Capital Maintenance:

9.2.1.1 Routine and preventive maintenance shall include such cleaning checks and

maintenance activities round the clock on hourly, shift wise, daily, weekly, fortnightly, monthly,

quarterly, half yearly, and yearly basis which are required to be carried out on all the

components, equipments & systems including testing & calibration of meters and instruments

of the complete power & CBG plant to minimize breakdowns proper recording of data including

testing & calibration of meters and instruments and to ensure smooth and trouble free running

of the power plant. All statutory approval renewals required for the plant operation must be

taken by the LESSEE. The LESSEE shall be responsible to carry out routine and preventive

maintenance and replacement of oils of each and every component / equipment of the power

plant and he shall provide all labour, material, consumables etc. for routine and preventive

maintenance at his own cost.

9.2.1.2 Breakdown maintenance shall mean the maintenance activity including repairs and

replacement of any component or equipment of the power plant which is required to be carried

out round the clock as a result of sudden failure/breakdown of that particular component or

equipment while the plant is running. The LESSEE shall be responsible to carry out breakdown

maintenance of each and every component of the power plant and he shall provide the required

manpower, materials, consumables, components or equipment etc. for attending breakdown

maintenance at his own cost irrespective of the reasons of the breakdown/failure. Lessee shall

be responsible for taking out complete breakdown insurance for major electro-mechanical

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equipments of the plant. However, Plant insurance for the fire, earthquake, etc. shall be the

responsibility of PGL.

9.2.1.3 Capital maintenance shall mean the major overhaul of any component or equipment of

the power plant which is not covered by routine, preventive and breakdown maintenance and

may become necessary on account of excessive wear & tear, erosion of parts due to

continuous slurry and feed handling, rusting, bio-culture action, cavitation and ageing. The

capital maintenance of power plant and all civil structures shall normally be planned to be

carried out during annual plant maintenance closure which must be synchronized with gas

engine major service and maintenance shutdown schedule or any of such activity related to

CBG system. For the purpose a joint inspection by the LESSOR and LESSEE shall be carried

out of all the major components of the power plant, about two months in advance & during plant

maintenance closure for piping and collection tank and other slurry handling components in

order to ascertain as to which components of the power plant require capital maintenance. In

this regard the decision of the LESSOR will be final and binding. However, if the condition of

any plant and component warrants its capital maintenance at any other time, a joint inspection

of the LESSOR and LESSEE shall be carried out immediately on occurrence of such situation

and capital maintenance shall be carried out by arranging the shutdown of the plant/part of the

plant, if required, in consultation with concerned authorities. The decision of the LESSOR shall

be final and binding.

The LESSOR will be free to take expert opinion of the manufacturers of plant and equipments

or any other appropriate agency during joint inspection in order to ascertain the quantum and

nature of the said capital maintenance. LESSOR will also be free to obtain the supervision for

capital maintenance from manufacturers of plant and equipment/any expert agency at its own

cost. At least one capital maintenance of the plant after 3 years of operation shall be

essentially carried out by the LESSEE before back handing over of the plant to the LESSOR

before expiry of the lease agreement if extended upto five year. However, the repair of

damages to power plant due to floods, earthquakes, civil commotion, riots, terrorist’s activities

and natural calamities etc. shall be carried by the Lessee at Lessors cost.

The manufacturer’s operation and maintenance manuals of major plant and equipment are

available in LESSOR’s office. If desired by the bidders these can be seen in the LESSOR’s

office before submission of the bid. In any case the successful bidder (LESSEE) shall be

provided by the LESSOR one set of the following immediately after issue of Letter of Intent for

guidance of the Lessee:

a. Manufacturer’s equipment O&M manuals

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b. Process Manuals

c. As built/executed drawings

d. Any other document essentially required for implementation of the Lease Agreement

The Lessee will not utilize the above items for any other purpose other than O&M of these plant

and will maintain the complete confidentiality of all these documents.

9.2.1 The period of Capital Maintenance & repair shall be accounted towards plant

availability.

9.2.2 The LESSEE shall use all reasonable efforts to give advance notice to the LESSOR and

to the PSPCL to the extent possible of any unscheduled / scheduled outage of the plant as

soon as possible before/after the outage and shall provide the LESSOR and the Board with an

estimated duration for such outage. The scope of such outage shall also be intimated. This

shall be done by telephonic communication followed by letter/fax.

The LESSEE is to carry out regular maintenance and services of the plant as per

recommended schedules and procedures of the equipment suppliers and as per approved

schedules by the LESSOR. The schedule of maintenance and overhauls which require plant

shut down shall however be intimated to the LESSOR and also to the Board’s Load Despatch

Centre to which the Plant is attached. For scheduled maintenance and overhauls the LESSEE

will take prior approval of the LESSOR.

9.3 The LESSEE will be responsible to clean and dispose off the sludge taken out of the

collection tanks by the sludge pumps at a suitable place as proposed by the LESSOR.

9.4 The LESSEE will maintain inspection book at the plant for recording of instructions given

by the LESSOR during inspections.

9.5 The LESSOR intends setting up data transmitting & real time information facilities for

monitoring O&M of the plant from its plant at Haibowal (Ludhiana) for its Chandigarh

office. The LESSOR will maintain & provide full support for its maintenance & upkeep.

9.6 The lessee has to ensure the timely and proper selling of manure being generated in the

drying yard in the plant so as to avoid any build up in the drawing yard and provide free ground

space for the future generation and the storage of bio manure.

9.7 The plant will be operated & maintained within the design limits.

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9.8 In case LESSOR observes any shortfall in the maintenance and operation response

including inadequacy of staff or their capacity to perform, the LESSOR has right to record the

same in the inspection book or issue instructions for rectification of the same by the LESSEE

which shall be complied by the Lessee at the earliest possible to the satisfaction of the Lessor.

9.9 The Lessee shall maintain the Maintenance registers/computerized files separately at

the plant. All maintenance works carried out by the Lessee shall be recorded in maintenance

registers and shall be made available for inspection to the Lessor during inspections. At the

end of each year these registers shall be handed over by Lessee to the Lessor.

10. Design Energy of the Plant

The Planned power and energy outputs for the plant calculated on the basis of the actual plant

operation and maintenance experience and plant limitations. Report data are given in the

enclosed Annexure 1. The energy computation is based on the feed material, gas quantity

generation, process parameters / limits and the percentage of methane in the biogas and also

engine efficiencies and after taking into account efficiencies of generator, main power

transformer and auxiliary consumption etc. The total Plant energy potential of the plant is 2.176

MUs per annum metered at “interconnection point”. The design capacity of the CBG plant is to

produce 3000 kgs/day of compressed biogas (CBG) and 5000 kgs/day of liquefied CO2.

However, the lessee needs to meet the minimum required net export of energy metered at the

interconnection point, on an average is 30,000 units (kwh)/month.

The LESSEE shall operate and maintain the plant in an efficient manner and in accordance

with all relevant instruction to ensure that as far as possible the quantum of energy generated

and metered at “interconnection point” at the power station & raw biogas at inlet of CBG Plant

in one year shall not be less than percentage plant availability of the plant as mentioned in pt.

no. 12 below.

11. Deliverable Energy / Saleable Energy

Deliverable energy shall be the energy delivered by the power station at the “Interconnection

point” and as measured by the export / import energy meter installed at the “Interconnection

points.”

The deliverable energy shall mean the electrical energy generated by the gas engine, as

measured at interconnection point.

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For the purpose readings of check & main energy meters installed at “interconnection points” at

generation facility & PSPCL grid shall be taken on monthly basis jointly by the LESSOR and the

LESSEE.

12. Penalties

12. a Penalty for short fall in plant availability.

Availability of the Plant :-

The percentage plant availability of the power plant shall not be less than 50%.

The percentage plant availability of the generating unit shall be calculated as per the

following formula:

PPA = (A+B+C+D)/H x 100, where

PPA = Percentage plant availability of the generating unit.

A =Total actual engine running hours during the specified period.

B = Total outage time of the generating unit during the specified period on

account of non-availability of PSPCL grid in case the plant is in running

conditions at the time of commencement of non-availability of grid.

C = Total outage time of the generating unit during the specified period on account

of reserved outages. Reserved outages will include shut down of the

generating unit on instruction of LESSOR, PSPCL, PPCB and any other

statutory authority for reasons not attributable to the LESSEE.

D = Total outage time of the generating unit during the specified period for any

other reason beyond the control of LESSEE but subject to approval by the

LESSOR.

H = Number of hours during the specified period. For an incomplete Quarter the

number of hours will be actual hours during the incomplete Quarter.

The Shutdown time of the generating unit during a Quarter or during an incomplete

Quarter on account of Scheduled Outages for capital repairs only (major overhauling of

plant) and Reserved Outages shall not be taken into account for calculating the

percentage plant availability of the generating unit.

The percentage plant availability of the generating unit and the power plant shall be

calculated for each quarter of a financial year taking into account that the plant will

operate for 320 days in a year and the Gas engine will operate for 12 hours in a day

depending upon gas generation. The other process units of the plant like drywell, ETP,

WHRU, dewatering station will run depending upon the load provided to them. In case

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the percentage availability of any quarter of the power plant during the year of operation

falls short of 50% (fifty percent) then the LESSEE will pay a penalty at the following

rates to the LESSOR for the shortfall of each percentage of plant availability of the

power plant as indicated below subject to maximum 10% penalty of the total quarterly

earnings of the LESSEE during the quarter of short fall of plant availability.

Sr. No.

Short fall in percentage plant availability.

Penalty payable in Rs. by the LESSEE

1.

During Year of Operation For short fall upto 40% of Availability.

For every short fall of one percent (i.e. 3 days) from 50% to 40% availability @ of 1% percent of quarterly earnings of the Lessor for that plant will be paid by Lessee.

The percentage plant availability will be reviewed on quarterly basis for the purpose of

applicability of penalty and in case the percentage quarterly plant availability of the

power plant falls below 40% during any year of Operation for any quarters, then Lessor

may also consider to terminate the Lease Agreement as per provisions of clause 32

hereof in addition to penalty charges.

The lessee will be given initially a time period of 90 days as the stabilization period.

During this period the PPA clause shall not be applicable and the aforesaid penalty will

be applicable after this. For incomplete quarter the penalty will be applicable from the

time and date of handing over of the plant to the LESSEE up to the following 24.00 hrs

of 31st March or from 00.00 hrs of 1st April to the following time and date on which the

power plant is handed-over back to the LESSOR.

12.b Penalty for endangering / breach of safety/fire safety of the plant systems/

equipment / structure

In case of breach of any plant safety measures, including non-adherence of plant safety

standards /non-operation of flare system/flare blowers/ fire-fighting system or any such

incident leading to endangering the safety of the plant taken place due to the negligence

of the Lessee, the Lessee shall be subjected to penalty @ 10% of the total revenue

earnings of the Lessor for the preceding one year immediate prior to the date of mis

happening. In case, mishap happens in the first year in the lease operation the penalty

shall be calculated on the basis of total revenue earned based on yearly design capacity

of the plant. This penalty shall be deducted by the Lessor from the monthly revenue

receipts from the Lessee or through any other available means with prior notice.

13. Sale of Energy and Generation of Reactive Power

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The PSPCL has agreed to purchase power and make payment to Power Generation Company

on monthly/basis. A Power Purchase Agreement (PPA) has been signed under which PSPCL

will accept all energy made available by the Power Generation Company at the interconnection

point. The LESSEE will meet the minimum generation requirements with matching MVARs

corresponding to 0.88 PF lagging, so that there is no adverse effect on Board’s system.

Monthly average PF shall be computed from ratio of KWH to KVAH injected into PSPCL system

during the month as per terms of PPA.

14 Metering, Billing & Invoicing

A. Energy: Energy Meter, (export and import) of 0.5 accuracy class having KWH, KVAH & KVARH

recording facility have been installed at Interconnection Point by the LESSOR (hereinafter

called Main Meter). The meters are capable of recording and storing half hour averages of all

the Electrical Parameters for 70 days. Similar meter, (export and import) of the same accuracy

class have been installed by the Board at the PSPCL Grid Substation where power is injected

from the plant (hereinafter called Check Meter).

All the Meters, CTs and PTs described above shall be jointly inspected and sealed by the

LESSEE, LESSOR and the Board and these shall not be interfered with by the LESSEE/

LESSOR / BOARD except in the presence of the representatives of all the three parties. For

testing and calibration of meters, a notice of at least seven (7) days shall be given by the

LESSEE or LESSOR or PSPCL for testing to enable the authorised representatives of all the

three Parties to be present.

All meters, CTs and PTs shall be checked for accuracy once in every six (6) months by the

three parties and shall be treated as working satisfactorily so long as the errors are within the

limits prescribed for such meters.

Meter readings of the Main Meter (For export of power to PSPCL) (Meter installed at

interconnection point) & Check Meter (For import of power from PSPCL) will form the basis of

billing/invoicing by the LESSOR to the PSPCL. If either of the meters are found to be defective

during these checks they will be immediately tested/calibrated/ repaired/replaced by the Lessee

at his own cost.

Where the half yearly check indicates errors in the Main Meters beyond the prescribed limit but

no such error is noticed in the Check Meters, billing for the month up to the date & time of such

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test check will be done on the basis of Check Meter by the Lessee and the Main Meters will be

re-calibrated immediately. The lessor shall maintain one set of energy meters and metering

equipment as spare for replacement of the defective meters and metering equipment and to

ensure correct metering at all time.

If during the half yearly checks, both the Main meters and the Check Meters are found to be

beyond permissible limits of error, the meters shall be immediately re-calibrated and the

correction shall be applied to the consumption registered by the Main Meters to arrive at the

correct consumption of energy for billing/invoicing purposes for the period of the month up to

the time of such check. Billing for the period thereafter till the next monthly meter reading shall

be measured by re-calibrated Main Meters.

Corrections in billing/invoicing , when ever necessary, shall be applicable to the period between

date & time of the previous test calibration and the date & time of the test calibration in the

current month when the error is observed and this correction shall be for the full value of the

absolute error. For the purpose of the correction to be applied, the meter shall be tested at

100,75,50,25 & 10 percent load at unity, 0.85 & 0.75 lagging power factors. Of these fifteen

values, the error at the load and power factor nearest the average monthly load served at the

point during the period shall be taken as the error to be applied for correction.

If both the Energy Meters located at interconnection point and PSPCL Grid Substation fail to

record the Electricity supplied then the Electricity supplied will be computed from the log sheets

maintained at Board’s Grid Substation/LESSOR’s Power Station for that period of defect which

shall be final & binding on the LESSEE, LESSOR and PSPCL subject to immediate notice by

LESSEE for such occurrence of defect in Main and Check meters.

For the purpose of test & calibration, the sub-standard meter shall be got calibrated and sealed

from a reputed testing Laboratory. This meter shall be calibrated once in every 2 years.

B. Bio-gas:-

The lessor has installed specific metering equipment including bio-gas flowmeters and bio-gas

analysers at the designated metering points for the measurement of the raw bio-gas used for

power generation and CBG plant respectively. Lessee has to ensure that all the biogas related

metering instruments are duly calibrated once in every 2 years.

A joint reading of the bio-gas flowmeters shall be taken by designated representatives of the

lessee and the lessor at the designated points at 12.00 Hrs. on the first day of every calendar

35

month. The flowmeters are equipped with data logging apparatus for recording the

measurements.

The lessor shall submit invoice/bill on or before 5th day of every month and lessee shall make

due payment of such invoice within 7 days of receipt of the bill hereinafter called the due date

by local demand draft /RTGS/NEFT.

The details of total raw biogas produced/ used for power generation, CBG and CO2 will be

submitted by the lessee to the lessor along-with the monthly power generation data. The

consumption of raw biogas is recorded on daily basis from the inlet raw biogas flow-meter

installed at the designated nodes of the bio-gas & CBG plant.

15. Billing Procedure to PSPCL:

The designated representatives of the LESSEE and LESSOR will take readings of the meters

at interconnection point at 12.00 Hrs. on the first day of every calendar month. Readings will

also be recorded at 12.00 Hrs. on the dates the change of tariff becomes effective between the

LESSOR and the Board or on the dates and times as directed by the LESSOR.

For the energy sold by the LESSOR to PSPCL, the LESSOR shall prepare monthly bills and

submit the same to the Board. All payments shall be received directly by the LESSOR from the

Board. It will be the responsibility of LESSOR to collect the payment from the PSPCL against

monthly energy bills.

16. Parallel & Integrated Plant Operations

The LESSEE shall run the plant as a part of integrated system to generate power in parallel

with the grid and shall inject three phase 50 Hz. (nominal) AC supply into PSPCL’s system at

11 KV.

In matters relating to grid operations and load despatch, the directions of State Load Despatch

Centre, PSPCL Patiala or the officer who may be authorised by the PSPCL shall be strictly

complied with by the LESSEE. Any dispute on this account shall be referred to LESSOR and to

the Chief Engineer-In charge, System Operation Organisation of the PSPCL whose decision

shall be final.

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17. Statutory Clearances

All required clearances, permissions and approvals have already been obtained by the

LESSOR. However, the LESSEE will be responsible for obtaining subsequent/periodic

permits/clearances as per statutory/obligatory provisions. The LESSEE will also comply with

the stipulations of the permits/clearances and shall ensure that such permits/clearances are

kept in force through out the lease agreement period. It was further clarified that necessary

clearances of accuracy of meters/metering equipment, protection system, correct installations

of equipment, safety provision, emission and effluent discharge levels, weigh bridge calibration

etc. required from PSPCL, Chief Electrical Inspector, PPCB, weights and measures Deptt.,

PESO and any other required clearances will also be obtained by the LESSEE. The

fees/charges on account of statutory clearance shall be reimbursed to the Lessee as per

actuals.

The LESSEE shall be responsible at his own expense to ensure that the Power plant are

operated and maintained in accordance with all legal requirements including the terms of all

consents/clearances/permits and Prudent Utility Practices within the acceptable technical limits

so as not to have an adverse effect on the PSPCL Grid System, and environment. Personnel

employed by the LESSEE shall meet any applicable laws, rules, regulations and requirements

in force from time to time in the State of Punjab/Union of India. LESSEE is required to adhere

and comply with the EPF, ESI, workers compensation Act/rules/regulations and must be in

possession of EPF/ESI code numbers.

LESSOR shall have the right to designate from time to time its officers/officials who shall be

responsible for inspecting the Power plant for the purpose of verifying the compliances of the

terms of the agreement.

18. Liaison with the LESSOR and PSPCL

The LESSEE shall closely liaise with all concerned departments on behalf of the Lessor

including the LESSOR and PSPCL all offices & Load Despatch Centre and/or other designated

officers/officials of the PSPCL & other concerned offices during the period of Lease Agreement.

During the period of this agreement is in force, the LESSEE shall give 7 days prior intimation of

its annual maintenance programme to the LESSOR & PSPCL. The LESSEE will also furnish in

the last week of every month supply plan indicating the total quantum of electricity likely to be

delivered in the next month from the plant.

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19. Temporary Interruptions in Delivery of Energy

The PSPCL/LESSOR may require the LESSEE to temporarily curtail or interrupt deliveries of

energy, when necessary, in the following circumstances:

a. For repair, replacement and removal of the equipment or any part of its system associated

with the LESSOR’s facility. However, as far as practicable such an event shall be scheduled

during the annual shut-down period of the generation facilities.

b. Load crash in PSPCL Grid System due o wide spread rains, cyclones or typhoons.

c. Conditions leading to over-loading of interconnecting transformers, transmission lines and

switch gears due to outage of some equipment at PSPCL power system.

d. If the PSPCL determines that the continued operation of the LESSOR’s generation facility

may endanger the safety of the PSPCL’s personnel or integrity of the PSPCL’s electric system

or have an adverse effect of the electric service to the PSPCL’s other customers.

e. Under Force-Majeure Conditions of the PSPCL or otherwise.

f. Instructions for the disconnection of the LESSOR’s generation facility from the PSPCL’s

system shall be notified by the designated Load Despatch Centre for the period/duration

indicated by it. However, the PSPCL shall take all reasonable steps to minimize the number &

duration of such interruptions, curtailments or reductions.

20. Manpower Deployment by LESSEE

20.1. The LESSEE will deploy the required experienced, competent & well qualified

manpower as per Power Utility Practices for round the clock smooth and efficient Operation &

Maintenance, supervision & monitoring, proper liasioning with the concerned

departments/authorities and proper interaction with the LESSOR for all related matters to the

plant and to achieve the objectives set forth in the document. The manpower deployed at the

plant for operation should be well conversant with the safety instructions.

20.2 The LESSEE will also supplement the manpower with additional qualified and

experienced personals as and when required for smooth & efficient O&M and during

annual maintenance/capital maintenance. The LESSEE will submit the details of the

personnel proposed indicating their qualification, experience etc. to be deployed by him in

techno commercial formats. Lessee is required to deploy the minimum manpower which

has been indicated in the Annexure-20 along with process technologist and process

engineer

20.3 The Lessor reserves the right to direct the Lessee to remove any of the personal

deployed for O&M if his performance or conduct is found unsatisfactory at the plant.

20.4 LESSOR will depute its staff for inspection, supervision & monitoring of operation and

maintenance of plant, schedules and other covenants to the Plant areas under the Lease

Agreement. Such visits may be made from time to time without prior information to the

38

LESSEE. An inspection book will be kept at the plant locations for any written instructions by

the LESSOR or its authorised representatives as may be necessary. The LESSEE will comply

with these instructions.

21. Spare Parts & Consumables

The LESSOR has already purchased certain spare parts for the plant. A list of these spares is

enclosed at annexure-17 and the same can be seen by the bidders before submission of their bid.

Some spares inventory for Gas engine operations has been maintained at the plant site and the

same be replenished if the spares are used by the LESSEE. The aforesaid spares parts which are

already available with the LESSOR will be made available to the LESSEE at the actual prevailing

rates.

The LESSEE will build up sufficient inventory of standby items & normal spares of its own over &

above the spares available with PGL which is required to minimise the down time of the plant.

However extra standby spares/ motors/ components/ equipments required to minimise the down

time shall be arranged by the LESSEE at his own cost. The Lessee will prepare a list of such

spares & standby items & will enclosed as Annexure-21 and shall be procured by the Lessee

immediately after issue of LOI. This list of spares is minimum & not restricted to this extent & may

vary depending on actual requirement. The Lessor can advise to the Lessee for procurement of

additional spares in discussion with the Lessee which shall be a binding on Lessee. Before taking

over the plant the Lessee will take procurement action and goods shall be procured at the earliest.

Not withstanding the above, the LESSEE shall be responsible for providing all routine, preventive

breakdown, capital maintenance spares and consumables for which LESSEE shall build up his

own inventory of spares and consumables including standby provisions based on likely

replacements during the Lease Agreement. All expenses on replacement/repair are to be borne

by LESSEE including labour and technical supervision, which may be required. The LESSEE will

have to contact the vendors/manufacturers himself for purchase of spare parts from original

equipment manufactures. LESSOR will facilitate if required to the LESSEE for the purpose of

procurement of these spares expeditiously. In case these spares from original manufacturers are

not available then LESSEE will explore the possibilities of purchasing the spare parts from other

manufacturers of the same specifications but before placement of order the LESSEE will take

approval of LESSOR to the specifications of the product and of the vendor/manufacturers.

Sufficient spare parts and consumables will be stored at the plant by the LESSEE at all times to

minimize breakdown time and consequent generation loss. The replaced components will also be

kept in the store for verification and inspection of LESSOR’s officers and if considered necessary

these replaced components will be handed over to the PGL.

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The standby items and spare parts for maintenance of plant including building will require following

types of inventory and record to be kept by the LESSEE.

Consumables

Routine maintenance spares

Breakdown maintenance spares

Capital spares and

Standby Items

The LESSEE may take insurance cover for burglary and theft for his stores at his own cost, if

so desired by him.

22 . Issue of Spares from the inventory of PGL

The Lessor will issue the available spares in the stores of PGL to the Lessee on requisition by the

Lessee. The Lessee will replenish the spares issued to them within 60 days from the date of issue

of spares. In case the spares are not replenished by the Lessee within the stipulated time period

the Lessor will deduct the cost of spares/stores at the actual prevailing rates at that time from the

monthly share of revenue receipts payable to Lessee by the Lessor.

23. Tools and Tackles & Measuring Instruments:

Immediately after handing over of the plant to the LESSEE, the LESSOR will hand over all such

tools and tackles and measuring instruments, which have been supplied with the plant and

equipment by the manufacturers. A list of these tools and tackles and measuring instruments is

attached at Annexure-16. These tools and tackles and measuring instruments shall be properly

maintained & repaired and shall always be kept in good condition by the LESSEE at his own

expense. All these tools and tackles and measuring instruments shall be returned in good

condition by the LESSEE to the LESSOR after the expiry of the Lease Agreement.

All other tools and tackles and measuring instruments required for operation and maintenance

of the plant shall be provided by the LESSEE at his own expense. These goods shall be

immediately identified and procured by the Lessee after issuance of LOI.

24. LESSEE’s Liability, Communication facility and Insurance

Immediately within fifteen days of handing over of the plant by the LESSOR to the LESSEE, the

LESSEE will obtain an Insurance Policy against loss or damage by ‘FIRE’ etc. to the complete

plant and machinery and associated switchyard.

40

The breakdown insurance cover against breakdown risk of the costly & main equipment of the

plant i.e. Gas engine complete with heating system, Main Transformer shall also be taken by

the Lessee at his own cost within fifteen days of the taking over of the Plant.

From commencement to completion of the Lease Agreement as a whole, the LESSEE shall be

fully responsible for the care thereof and for taking precautions to prevent loss or damage to the

plant. He shall be liable for any damage or loss that may happen to the civil structures, plant

and machinery and switchyards or any part thereof. The LESSOR’s plant and machinery,

materials, civil structures etc. shall always be kept in good order and condition in every respect

to the highest accepted industry standards.

The LESSEE shall maintain & avail all existing communication facilities such as telephones

provided at the plant at his own cost and will pay the bills/license fees regularly to avoid

disconnection.

The LESSEE shall at his own expense arrange for the safety provisions and shall comply with

the requirements in respect of Operation & Maintenance (O&M) of civil structures and plant and

equipment, as laid down in manufacturer’s O&M instructions for the equipments, Indian

Electricity Act, Indian Electricity Rules and Instructions given by LESSOR’s officers.

25. Disputes and Arbitration Both the parties shall comply with the provisions of this Lease Agreement and discharge the

respective obligations. In the event of a disagreement and if the issue is unresolved, a meeting

shall be held by designated representatives of the LESSOR and LESSEE to resolve the issue.

In case the issue is still unresolved provisions of this clause shall apply.

All differences or disputes between the parties arising out of or in connection with these

presents, including any question or matter of dispute and the parties are unable to resolve by

mutual agreement shall be submitted for arbitration in Chandigarh and shall be resolved in

accordance with the provisions of the Indian Arbitration and Reconciliation Act 1996 as

amended from time to time. All Legal proceedings in connection with this agreement shall be

subjected to the territorial jurisdiction of competent civil courts at Chandigarh.

In the event of differences or disputes, between the parties, either party may by written notice of

30 days to the other party seek arbitration. The arbitration shall be conducted in accordance

41

with the provisions of the Indian Arbitration and Reconciliation Act 1996 as amended from time

to time.

Notwithstanding the existence of any question, disputes and difference referred to arbitration,

the parties hereto shall continue to perform their respective obligations under this Lease

Agreement and the payment of any bill preferred shall not be withheld by the LESSOR for any

reason whatsoever during the pendency of arbitration.

26. Indemnification

The LESSEE shall indemnify and keep indemnified the LESSOR and PGL against all losses

and claims for death, injuries or damage to any person or any property whatsoever which may

arise out of or in consequence of the operation and maintenance & repairs of the plant and

structures during the Lease Agreement period and also against all claims, demands,

proceedings, damages, costs, charges and expenses whatsoever in respect of or in relation

thereto, and such liabilities shall include claims/compensations of the third party.

The Lessee shall also indemnify and keep indemnified the Lessor against all losses and claims

for damages, death, injuries or damage to any property whatsoever which may be caused due

to negligence or lapse in Operation & Maintenance of the plant including non adherence to

statutory regulations.

27. Performance Guarantee The successful bidder (LESSEE) shall within 10 days from the date of issue of Letter of Intent,

for due performance of the Lease Agreement, shall furnish a Performance Guarantee of

Rs. 50, 00,000.00 (Rs. Fifty lakhs only) in any of the following forms:

A demand draft payable on any Bank at Chandigarh in favour of Punjab Genco Ltd.,

Chandigarh.

Bank Guarantee of State Bank of India or a Nationalized Bank or any Scheduled Bank in

India (provided such Scheduled Bank certifies that the guarantee given is within the limit

prescribed by Reserve Bank of India) and in the form as acceptable to the LESSOR. The bank

guarantee shall be valid up to a period of one month after the expiry of Lease Agreement.

The performance guarantee shall be enchased by the Lessor if the Lessee fails to fulfil the

performance obligations or in case of any default.

42

The Bank Guarantee shall be provided in the prescribed Performa which is given in

Annexure-18.

28. Price Schedules The bidder shall quote his prices strictly @ of per m3 of raw biogas used/ metered in the same

format as given in Annexure-19.2 and the same shall be enclosed in financial bid. An annual

escalation of 5 % will be applicable on price quoted. However, taxes if any shall be extra.

29. Terms of Payment:

1. Payments for the raw bio-gas used in the plant for CBG/CO2 production and power

generation by the lessee has to be made to the Lessor against monthly usages.

2. The payments will be released by the LESSEE within 7 days of submission of

technically and commercially clear claims by the LESSOR.

30. Rights and Ownership of Property 30.1. Right of ownership The power plant including its land, civil structure and plant and equipments are the property of

Govt. of Punjab/ PGL/PEDA. The LESSOR enjoys a concession from Punjab Energy

Development Agency (PEDA) and Govt. of Punjab to run and operate the power plant with

other structures and equipments. The LESSOR and the owner’s viz. PGL, Govt. of Punjab,

PEDA, PSPCL& MNES, GOI shall have all rights to access and inspection of the plant at all

reasonable time and make comments and take observations on the satisfactory performance of

the plant.

30.2. Signs and Barriers LESSEE shall have the right to install and display advertising and warning signs or barriers at

the Properties, provided such signs and barriers are reasonable in their content and size and

may remove the same upon termination of this Lease; provided, however, that upon removing

the same LESSEE shall restore the Properties to the condition it was prior to the installation of

such signs or barriers.

30.3. LESSOR’s Right of Access to the Properties LESSEE agrees that LESSOR and its authorized representatives shall have the right at all

reasonable times to enter upon the Property and to examine and inspect the Properties,

including such rights of access to the Property as may be reasonably necessary for the

maintenance and operation of the power plant.

43

31. Termination of Lease 31.1. Termination of Lease due to Failure to obtain Permits or occurrence of default.

If LESSEE is unable to obtain all the necessary permits or licenses or authorizations which may

be required from any regulatory agency of the Govt. of Punjab or Govt. India or of any other

state in India to produce electric power and to carry out O&M of the power plant or LESSEE

defaults in any of the provisions of this Lease Agreement, LESSOR may, without liability of any

kind to LESSOR, declare this Lease as terminated. It is agreed, that before any termination

hereof, LESSOR shall be giving a reasonable time and notice of twenty-one (21) days to the

LESSEE to rectify such defaults.

31.2. Events of Default Defined

The following shall also be “events of default” under this Lease and the terms “event of default”

or “default” shall mean, whenever they are used in this Lease, any one or more of the following

events:

a. Failure by LESSEE to observe and perform any covenant, condition, or agreement in

this Lease Agreement on the part of LESSEE to be observed or performed, other than as

referred, for a period of twenty-one (21) days after written notice thereof specifying the failure

and requesting that it be remedied given to LESSEE by LESSOR, unless LESSOR shall agree

in writing to an extension of such time prior to its expiration.

b. LESSEE (i) Unable to rectify the defaults pursuant to various clauses of this agreement

(ii) becoming insolvent; (iii) being unable, or admitting in writing its inability, to pay its debts as

they mature; (iv) failing to promptly lift any execution, which, in the judgement of LESSOR,

impairs the ability of LESSEE to carry on its business operations; (v) making a general

assignment for the benefit of creditors or to an agent authorised to liquidate any substantial

amount of its property; (vi) entering into an agreement of composition with its creditors; (vii)

becoming the subject of an “order for relief” within the meaning of the prevalent laws; (viii) filing

a petition in bankruptcy or for reorganisation or to effect a plan or other arrangement with

creditors under the provisions of the Bankruptcy Act, as amended, or under any similar act in

any domestic or foreign jurisdiction which may now be in effect or hereafter enacted; (ix) filing

an answer to a creditor’s petition (admitting the material allegations thereof) for reorganisation

or to effect a plan or other arrangement with creditors; (x) applying to a court for the

appointment of a receiver for any of its assets; or (xi) having a receiver appointed for any of its

assets (with or without the consent of LESSEE) and such receiver not being discharged within

sixty (60) days after his appointment.

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c. Lessor unable to make the due payment against monthly bills, incentives or deemed

generation in the six months, the Lessee will give a reasonable time and notice of 30 days to

the Lessor to rectify the fault.

31.3 Force Majeure

31.3.1 Force Majeure Event

In this Agreement, "Force Majeure" means occurrence of an event which prevents the Party from

performing its obligations under this Lease Agreement and which act or event

i. Is beyond the reasonable control of and not arising out of the fault of the Affected Party,

ii. the Affected Party has been unable to prevent by the exercise of due diligence and

reasonable efforts, skill and care, including through expenditure of reasonable sum of

money, and

iii. has a materially adverse effect on the Plant.

31.3.2 Force Majeure Events

The Force Majeure Events shall mean one or more of the following acts or events:

i) Acts of God or events beyond the reasonable control of the Affected Party which could not

reasonably have been expected to occur such as extreme adverse weather or environmental

conditions, lightning, heavy rains, cyclones, tempest, whirlwind, landslides, storms, floods, volcanic

eruptions or fire (to the extent originating from a source external to the site or not designed for in

construction works);

ii) Radioactive contamination or ionising radiation;

iii) An act of war (whether declared or undeclared), invasion, armed conflict or act of foreign

enemy, unexpected call up of armed forces, blockade, embargo, blockade, rebellion, riot, religious

strife, bombs or civil commotion, sabotage, terrorism;

iv) Strikes or boycotts interrupting operations of the Plant;

v) Any judgement or order of any court of competent jurisdiction or statutory authority in India

made against the Company in any proceedings for the reason other than failure of the Company to

comply with any Applicable Law or Clearances or on account of breach thereof, or of any contract,

or enforcement of this Agreement or exercise of any of its rights under this Agreement by PEDA.

vi) Any other event or circumstance of a nature analogous to the foregoing.

31.3.3 Notification obligations

If a Party is affected by any Force Majeure event, the affected Party shall give the other

Parties written notice describing the particulars of the Force Majeure event as soon as

reasonably practicable after its occurrence but not later than five days after the date on which

45

such Party knew of the commencement of the Force Majeure event or of its effect on such

Party.

31.3.4 Obligations of Parties in case of Force Majeure event

i) The Parties shall co-operate and discuss in good faith and will develop the proposal for

remedial measures and reasonable alternative measures to remove / remedy Force Majeure

event to enable the Performance of the effected Party provided however that no Party shall be

required under this provision to settle strike or other labour dispute.

ii) Upon the occurrence and during the subsistence of any Force Majeure event, none of

the parties shall be relieved of their liabilities / obligations.

32. Additional Covenants and Explanatory Provisions 32.1 LESSEE shall not assign this Lease or sublet all or any part of the Properties. 32.2 LESSEE shall comply with all central, state, and local laws, ordinances, rules,

regulations, and executive orders pertaining to unlawful discrimination on account of race,

colour, creed, religion, origin, sex, marital status, status with regard to public assistance,

disability, or age. LESSEE shall further comply at its expense with all central, state, and local

laws and ordinances, and all applicable rules, regulations, and standards established and

orders issued by any agency of such governmental units, which are now or hereafter

promulgated in so far as they relate to LESSEE’s O&M of Biomethanation power plant and of

LESSEE’s performance of the provisions of this Lease.

32.3.1 LESSOR shall have full access to all records of LESSEE relating to the performance of

this Lease

32.3.2 LESSEE agrees to maintain records relating to all goods and services provided by it

under the terms of this Lease. LESSEE shall retain all such documentation for three (3) years

following the termination of this Lease. Such records shall be made available for audit or

inspection at any reasonable time upon request of LESSOR, the State Auditor, or their

respective authorised representatives.

32.4. LESSEE warrants that it is and will remain throughout the Lease Term duly registered

and qualified to do business in the State of Punjab.

32.5. Independent Contractor. For the purpose of this Lease, LESSEE shall be deemed to

be an independent contractor and not an employee of LESSOR. It is hereby acknowledged by

the parties that LESSOR will not be responsible to LESSEE for any and all benefits provided by

lessee to its employees, including, but not limited to, vacation, sick leave, worker’s

Compensation and Unemployment Compensation.

46

32.6. Hold Harmless. LESSEE agrees to defend and save LESSOR harmless from any

claims, demands, actions, or causes of action arising out of any act or omission on the part of

LESSEE, or its agents, servants, or employees in the performance of or with relation to any of

the work or services performed or furnished by LESSEE under the terms of this Lease.

32.7. Alteration. Any alteration, variation, modification, or waiver of the provisions of this

Lease shall be valid only after it has been reduced to writing and duly signed by both parties.

32.8. Waiver. The waiver of any of the rights and/or remedies arising under the terms of this

Lease on any occasion by either party hereto shall not constitute a waiver of any such rights

and/or remedies in respect to any subsequent breach of or default under the terms of this

Lease. The rights and remedies provided or referred to under the terms of this Lease are

cumulative and not mutually exclusive.

32.9. Interpretation. This Lease shall be interpreted and construed according to the laws of

the State of Punjab.

32.10. No Liens on Properties. LESSEE agrees to allow no lien of any nature including liens

associated with financing or work performed to be filed upon or attached to any portion of the

Properties; provided, however, that the provisions shall not operate to prohibit the collateral

assignment, leasehold mortgage, or any other security interest of a substantially similar effect

of or upon the leasehold interest granted to LESSEE by this Lease or to prohibit the creation or

any security interest in or other lien upon the Non-leased equipment or any other personal

property of LESSEE. LESSEE shall promptly cause any claim for any such lien to be released

or shall secure LESSOR, to LESSOR’s satisfaction, in the event LESSEE desires to contest

such claim.

32.11. Utilities. LESSEE shall keep the sidewalks, driveways, and parking lots, if any, located

at the power plant reasonably free of water logging and unchecked weed growth and shall keep

the grass, shrubbery, and trees, if any, properly cut and trimmed. LESSEE shall ensure that the

plant is properly maintained and kept clean. SMOKING IS STRICTLY PROHIBITED IN THE

PLANT PREMISES.

33. Taxes, Duties and Octroi

Taxes, Duties and Octroi if levied by Central/State Govt. or by Statutory Bodies on the power

plant or energy generated shall be reimbursed by the LESSOR.

34. Office Accommodation:

One office accommodation available at the Plant shall be made available to the LESSOR. This

accommodation shall be maintained by the LESSEE for office work and LESSOR’s

representatives shall have access to this office accommodation at all times.

47

35. Watch & Ward

A goods movement register for taking out/in any of the plant goods for recording of entries shall

be maintained by the lessee for reference & record at the plant. The goods movement can only

take place after the approval of the PGL plant engineer. The Security personnel will be

deployed by the LESSOR for the plant watch and ward at the cost of the lessee. Bidders may

note that presently 5 no. security personnel sourced from PESCO have already been deployed

at the plant site by PGL. The said security personnel are each being paid lumpsum monthly

emoluments @ 17616/- plus taxes extra. These rates are subject to a half-yearly revision as per

DC labour rates.

LESSEE must ensure that no unauthorised person should be allowed entry into the plant

premises. All contract labour involved in the delivery of cattle manure to the collection tanks

must not proceed beyond the collection tanks area into the plant. All contract labour must be

properly managed by the LESSEE or his sub-contractor and in no circumstances the plant shall

be used by the contract labour for loitering or stay in the plant premises.

36. Back Handing over of Power & CBG Plant by LESSEE to LESSOR

Lessee will give a compulsory prior notice of at least 6 months before handling over

the plant back to lessor any time only the expiry of minimum two years of initial O&M lease

period. From commencement to completion of the Lease Agreement as a whole i.e. up to the

time the power plant is back handed over to the LESSOR or taken over by the LESSOR, the

LESSEE shall take full responsibility for the care thereof and for taking precautions to prevent

loss or damage. He shall be liable for any damage or loss or down grading of specifications of

equipment/components that may happen to the civil structures, plant and equipments of power

station and their switchyards or any part thereof. The LESSOR’s plant and equipments,

materials, civil structures etc. shall always be kept in good working order and condition in every

respect to the highest accepted industry standards.

After the expiry of the Lease Agreement when the power plant is back handed over by

the LESSEE to the LESSOR or at any time when the power plant is taken over by the LESSOR

under the provisions of the Lease Agreement, the LESSOR after allowing for normal wear and

tear shall recover from the LESSEE all costs of shortages, damages etc. in the power plant

together with any amounts of money payable by the LESSEE. In case the

specifications/quality/performance of any component, equipment or system are downgraded

through repairs or replacements then the original one, the same shall be replaced by the

Lessee at his own cost with original/equipment component, equipment or system to the

satisfaction of LESSOR. The aforesaid recovery shall be made from the pending bills and

security deposit of the LESSOR and by any other means which the LESSOR deems fit for

effecting such recoveries.

48

Section 4

ANNEXURES The following Annexure are attached with this tender document Annexure - 0 Design Data of the Haibowal Plant

Annexure - 1 Month wise Power and Energy statement of Plant

Annexure - 2 Salient Features of the Plant

Annexure - 3 Route map of Plant (obtainable after successful bid)

Annexure - 4 General layout drawing of Plant (obtainable after successful bid)

Annexure - 5 Single line Diagram of Plant (obtainable after successful bid)

Annexure - 6 P&I Diagram of Plant (obtainable after successful bid)

Annexure - 7 Instrument Layout of the Plant (obtainable after successful bid)

Annexure - 8 Piping Layout of the Plant (obtainable after successful bid)

Annexure - 9 Layout of Fire Fighting (obtainable after successful bid)

Annexure - 10 Gas Engine Operation Manual Extracts (obtainable after successful bid)

Annexure - 11 Plant process operation and maintenance manual Extracts

Annexure - 11.1 CBG & CO2 Plant Specifications.

Annexure - 12 Extracts from manufacturer’s maintenance instructions in respect of some major plant and equipment.

Annexure - 13 List of equipment in the plant.

Annexure - 13.1 Screw Presses

Annexure - 13.2 Gas Engine (400kWe)

Annexure - 14 Indicative List of Tools & Tackles and Measuring Instruments as available with PGL Ltd., Chandigarh

Annexure- 16 List of Laboratory equipment with PGL

Annexure- 17 List of Gas engine spares available with PGL

Annexure- 18 Prescribed Performa for Performance Bank Guarantee

Annexure- 19.1 Technical Evaluation Form

Annexure- 19.2 Schedule of prices for O&M of the plant for a period of about 5 years

Annexure- 20 Schedule of O&M facilities

Annexure- 21 List of Additional Spares to be procured by Lessee

Annexure- 22 Lease Contract Agreement

49

Annexure –0

DESIGN DATA OF HAIBOWAL POWER & CBG PLANT

The design detail of the digester is as below

S.No. Details Value

Waste input

i. Wet waste 235 tons/day

ii. Dry solids 37.5 tons/day

iii. Volatile solids 30 tons/day

iv. Water requirement to reduce the solids concentration to 10%

141 tons/day

2. Digester Input

i. Dry solids 37.5 tons/day

ii. Volatile solids 30 tons/day

iii. Feed input (wet waste including dilution water) 376 tons/day

iv. Feed input (wet waste including dilution water) 376 m3/day

3. Digester Design

i. Volatile solids 30 tons/day

ii. Volatile solids loading rate 3kg/m3/day

iii. Digester volume 10,000 m3

iv. Retention time 27 days

v. No. of digesters 2

vi. Net volume of digesters 5,000 m3

vii. Gross volume of digesters 5,750 m3

4. Digester Efficiency

i. Lignin 28-35%

ii. Biodegradable VS 19.5-21.6 tons

iii. Biodegradable Volatile solids destroyed 55%

iv. Volatile solids destroyed 10.725-11.8 tons/day

v. Biogas generation (m3/kg Biodegradable VS destroyed) 0.85

vi. Biogas generated 9,116-10,000 m3/day

50

Annexure -1

Month wise Power and energy estimate of Plant (400 KW)

S.No Month No. of days

Estimated Gas generation in m3

/day

Cattle manure Tons/day

Power output in KW at generator terminals

1 January 31 10000.00 235.00 400.00

2 February 28 10000.00 235.00 400.00

3 March 31 10000.00 235.00 400.00

4 April 30 10000.00 235.00 400.00

5 May 31 10000.00 235.00 400.00

6 June 30 10000.00 235.00 400.00

7 July 31 10000.00 235.00 400.00

8 August 31 10000.00 235.00 400.00

9 September 30 10000.00 235.00 400.00

10 October 31 10000.00 235.00 400.00

11 November 30 10000.00 235.00 400.00

12 December 31 10000.00 235.00 400.00

Total

51

Annexure -2

Salient features of Biomethanation Plant: Haibowal Introduction Punjab Genco Ltd. (Company wholly owned and a promoted company of Punjab Energy

Development Agency (PEDA), a State Govt. nodal agency for promotion and development of

non-conventional and renewable energy sources, has set up one High Rate Biomethanation

Power Plant at Haibowal in Ludhiana district of Punjab State. This plant has been set up with in

the Haibowal Dairy complex, from which sufficient quantity of raw cattle manure is available for

scientific disposal of waste in the plant. The plant has been set up as sub-demonstration Plant

under the UNDP -GEF programme for Abatement of Green House Gas Emissions.

The plant has been designed based on the BIMA (Biogas Induced Mixing Arrangement)

technology of M/s Entec, Austria. The plant has two 5000 cum capacity BIMA digestors, which

are able to handle 235 tons of waste. The Biogas generated from the plant is fired in a Gas

Engine. The plant has two PLC systems for the plant process control and Gas engine control

and operations.

Salient Features 1. Process: BIMA (Biogas Induced Mixing arrangement) technology 2. CBG: PSA Technology based purification system & Co2 recovery system.

3. Type of Gas Engine: Spark ignited Internal Combustion Gas engine of R. Schmitt make

4. Screw presses for dewatering of slurry 5. The plant is designed for operation through PLC. 6. Generation voltage- 0.415 KV 7. Transmission voltage-11 KV 8. All valves in the plant are pneumatically operated 9. Blowers/Gas holder/ pumps 10. The power generated from the plant is injected to the nearest PSPCL grid as indicated herein below: Turnkey Contractor The civil works of the plant were completed on turnkey basis by M/s GSJ Envo Ltd.,New Delhi

and the turn key execution of complete electro-mechanical works were carried out by M/s

Batliboi Environmental Engg. Ltd., Mumbai. The Plant consultancy and technology was

provided by M/s Enkem Engineers, Chennai based on the BIMA technology of M/s Entec,

Austria

52

Generating Unit The plant has R. Schmitt Gas engine which operates on bio-gas generated from the

plant. This engine is a spark ignited IC engine which has its own on-board PLC control

system for auto control and grid synchronization. Generation voltage is 415 V, 50 Hz,

AC.

Plant process control operations The plant is designed for automatic operation and the complete plant process is

controlled from the PLC control station in the plant. For operation and control of the

BIMA plant process is based on Programmable Logic Controller (PLC) system, has

been installed.

Gas Holder A gas holder supplied by M/s Entec, Austria is installed between the digesters and Gas

engine, which has the storage capacity of 1000 cum with an operating pressure of 2.5

mbar.

BIMA Digestors

The plant has two digestors of 5000 cum capacity each which have no internal moving

parts. The digestors have two chambers and the gas from the upper chamber is sent to

the gas engine through automatic valves, which are controlled based on gas pressure

in the upper chamber. A set of desulphuration system has been installed on top of both

the digestors.

Gas Engine A gas engine of 400 Kwe capacity and R. Schmitt (Germany) make was installed in

year 2016 & commissioned in March’2016. The same has been installed with all

auxiliaries like H2S scrubber, air washer, acoustic canopy & dehumidifier.

CBG & CO2 Recovery Plant The Haibowal plant has latest PSA (Pressure swing adsorbers) technology-based

purification system of 350 m3/hour capacity, Moisture & H2S removal systems, high

53

pressure, reciprocating air compressors, purified CBG storage of 500 m3 capacity, CO2

extraction unit, CO2 purification unit & liquefaction system along with insulated CO2

storage tank has been installed as a part of this system. The whole plant is monitored &

controlled through PLC based controls & sensors and have been equipped with all

required safety features.

Indoor Switch Gear The indoor switch gear is comprised of:

Automatic Tab Changer, Buchholz relay, over temp relay, winding temp relay for

Transformers.

Capacitor panels for maintaining power factor.

Control & Relay Panel with over current, Earth-fault relays for 11 KV Out-door type

vacuum circuit Breaker is installed on the Main Outgoing transmission line.

Batteries & battery charger for supply of 24 V DC Control Supply to all auxiliaries

and Uninterrupted Power Supply for supply of power to Microprocessor Control system.

Auxiliary Control panel for running the plant Auxiliaries.

Microprocessor Control System (PLC based) the system for control of the plant

automatically, SCADA system.

Control, metering and protection relay panels.

Outdoor Switch Gears The outdoor switchyard comprises of:

1600 KVA Main out going transformer 415V/11 KV, outdoor type, oil cooled

(ALSTHOM).

CTs & PTs for protection & metering.

Indoor type Vacuum Circuit Breaker, 11 KV, 800A, 50 Hz, Motor charged with rated

short circuit Current of 25 KA having over current- instantaneous relays, restricted earth

fault relay & emergency tripping facility.

Transmission Line & HT indoor Switch Gear at PSPCL Grid

Transmission Lines are erected from plant outdoor switchyard to nearest PSPCL grid

for injection of power at 66 KVA Kitchlu Nagar Substation. The power is fed on the

54

11KV common bus bar in the sub-station. The transmission line have been erected and

are being maintained by PSPCL. A check meter for import and export of energy is

installed at the PSPCL sub-station.

A power purchase agreement for sale of power has already been signed between

company and PSPCL. The power from this plant is being generated at 415 volts and

stepped up to 11 KV for injection to nearest PSPCL grid. The length of transmission

lines is 3.5 Km.

55

Annexure – 11

EXTRACTS FROM PLANT PROCESS OPERATION AND MAINTENANCE MANNUAL BIOLOGICAL BACKGROUND GENERAL BIOLOGICAL PROCESS The degradation of the organic material occurs on strictly anaerobic condition (exclusion of oxygen) by microbial reactions. The degradation of organic materials requires some minimum time. If these organics are present in the substrate, certain minimum retention time is required, independently on the loading rates. If the retention time goes below this minimum, the degradation of the organics is not completed. Thus, the first steps of degradation will be continued in the effluent, resulting in the production of heavy, adverse odour. This is further explained inside. The essential parameters for the complete process are:

Temperature

pH

Mixing

Organic Loading rates

Inhibition and toxic effects TEMPERATURE The digesters are designed to be operated at a temperature between 30 to 39oC. The temperature is an essential parameter for the performance of the digester. Best results can be achieved when running the digesters close to the upper limit of this range. If the temperature falls below this range, the activity in particular of the methane bacteria will drop quickly. Thus, overload condition will occur even at normal loading rates. The result may be a complete breakdown of the process. Worst case, the digester has to be emptied and to be re-started from the beginning. On the other hand, if the temperature rises too high, most of the methane bacteria are quickly killed. The digester has to empty and the process must be re-started with initial seeding. Thus, keeping the optimum temperature range is essential. By no means, the digester may be fed, if the temperature shifts out of this range. The feeding should be stopped in such cases. pH: Together with the temperature, the pH is the other essential, basic environment condition for successful methane fermentation. The pH indicates the acidity and alkalinity of the medium. Solution with a pH below 7 are acid, those with a pH above 7 alkaline. Methane bacteria require a pH in the neutral to slightly alkaline range (7-8). Out of this range, their activity drops quickly by “extreme” pH value (<6.5->9) they are killed. Thus, keeping an optimum pH is essential for the process. When the pH shifts into the acid range, lime, caustic soda or sodium hydrogen carbonate may be added. In case of a shift into the alkaline range, hydrochloric acid may be used. Organic acids as are acetic acid or lactic acid can not be used. They are degraded and no more effective then. Additionally, they increase the organic loading rate of the digester ATTENTION: Never use sulphuric acid – H2S production – see respective section below !

56

MIXING Mixing of the digester contents is another basic criterion. During anaerobic digestion, fine gas bubbles attach to the suspended material and lift those particles to the liquid surface. In particular fibrous material may produce there a thick felt (scum production), which is difficult to remix. Thus, optimum missing is essential and besides, the feed material should as homogenous as possible. Heavy material (e.g. sand) may produce layer of sediment. In particular big, heavy matters (stones, bones etc.) can not be removed from there without emptying the digester. Thus, material of that kind is not allowed to enter the digester. Fine, heavy material (sand) becomes stuck with organic material and may produce layers almost as hard as concrete. Destruction of these layers of scum and sediments is an essential requirement for any anaerobic digester Another basic function of mixing is to guaranty an equal temperature all over the digester contents. The optimum function of the BIMA mixing system is essential. This optimum function includes:

The minimum number of mixing cycles (4-6, depending on the substrate). It is desirable to have 6 or more mixing cycles / day

The minimum mixing pressure (not below 90% of the design mixing pressure), which is 5200 mm. It is always desirable to operate at / near design mixing pressure. If required, the auxiliary start up blower must be used to guarantee this mixing ORGANIC LOADING RATE The organic loading rate is the quantity or organic material added per m3 digester capacity and day. As described earlier, this parameter is essential for the degradation of easily degradable material. Overload may result in breakdown of the process. With manure, this [parameter does normally not reach a critical limit, as the limiting parameter is rather the hydraulic retention time. However, care must be taken, if other organic material is added to enhance the gas production and hence, before adding any other organic material, approval of Enkem is required. HYDRAULIC RETENTION TIME The hydraulic retention time is the ratio liquid capacity of the digester / daily inflow. The selection of the hydraulic retention time depends on the substrate characteristics on the one hand and on the required degree of degradation on the other hand. Too short hydraulic retention times would result in serious odour problems as described earlier, even if no overload conditions can be observed. ATTENTION: Essential to feed digesters at 10% solids concentration. Dilution will lead to lesser

hydraulic retention time at full load capacity.

INHIBITION AND TOXIC SUBSTANCES The following materials are the most important ones with respect of inhibition and toxicity with respect to the feed

Volatile fatty acids

Ammonia

57

Hydrogen sulphide

Bactericides (disinfectants, antibiotics etc.) Ammonia is usually not found at critical concentrations in plain cow manure. However, it could become critical, if the press water is re-circulated and hence, before re-circulation, the Ammonia levels will have to be checked. VOLATILE FATTY ACIDS:

Volatile fatty acids are intermediates in the anaerobic digestion process. On overload conditions, they are accumulated. In higher concentration these vfa (in particular propionic acid) directly effect the methane production. The presence of valeric acid is an indicator for severe overload conditions. Thus the toxicity of vfa can be reduced by increasing the pH (=adding OH) AMMONIA In higher concentrations, ammonia acts directly toxic to the bacterial cells. Mainly, it is a product of protein degradation. Thus, the quantities of proteins in the substrate must be limited. Thus, the ammonia toxicity may be reduced by decreasing the pH (=reducing OH). HYDROGEN SULFIDE On anaerobic conditions, hydrogen sulphide (H2S) is produced during degradation of animal protein and by biological reduction of sulphates. It produces the typical smell or “rotten eggs”. As most sulphides of heavy metals are extremely poor soluble, it is suspected to act through precipitation of essential trace elements. However, other effects can not be excluded. As H2S is the un dissociated acid molecule and this is the effective, toxic form of the acid. Thus, the toxicity of H2S can be reduced by increasing the pH (= adding OH) As hydrogen sulphides is produced by reduction of sulphates – and thus also of

sulphuric acid – sulphuric acid may never be used for correction of pH!

BACTERICIDES Bactericides are used to prevent spreading of animal diseases (disinfectants) and for their treatment (antibiotics). They are highly toxic to the anaerobic bacteria and may never be added into the digester (neither directly together with the manure nor through manure of treated cattle). Spillage of these materials have to be avoided. In most cases, it is difficult to prove the presence of bactericides within the time available at the plant. However, if severe inhibition of even a break down of the anaerobic process is observed without obvious reason, the presence of bactericides must be taken into consideration. The only real protection is to produce some kind of “consciousness” in the farmers, where the manure is coming from.

58

FAILURE AND FAULTS Biological faults have to be discriminated from mechanical / electrical ones. Further more, there is a group of complex faults, where the reason can not be seen at a glance. In case a fault can not be fixed immediately we strongly recommend to contact Enkem

soonest possible.

BIOLOGICAL FAILURES Biological faults can be recognized from the trend curves of:

Gas production

Gas quality

pH

vfa how to deal with biological faults is described in the start up instructions IN ANY CASE, WE REQUEST TO CONTACT ENKEM IMMEDIATELY FOR CLARIFICATION

OF THE FURTHER PROCEDURE, IF A BIOLOGICAL FAULT OCCURS!

MECHANICAL AND ELECTRICAL FAULTS In case of fault of a mechanical or electrical equipment, it has to be repaired or replaced soonest possible. During removal and re-installation observe the safety instructions as given by the manufacturer / supplier If a key equipment is concerned and repair or replacement can not be done immediately,

contact us for clarification of the further procedure

C0MPLEX FAULTS The table below is a compilation of important complex faults, their reasons and the required reactions. However, in complex system like anaerobic degradation, this compilation can not be complete. Thus, we recommend to contact Enkem immediately, when ever a complex fault is

observed, no matter whether the reason can be identified from the table or not

NOTE: Not all faults listed below can be seen in the process computer system. Thus, it is essential to collect and evaluate the date according to the section “Data Collection, Inspection and Servicing” and to carry out the respective inspections carefully. The logbook must always be kept at last state

59

Observation Reason Reaction

No or insufficient flow (centrifugal type pump, blower)

Clogging of pump or piping Clean, Flush

Rotor / Housing damaged / eroded

Replace

Rotation speed too low (if a FC is installed)

Adjust

(Partially) closed valve Open

No or insufficient flow (Positive displacement pump)

Rotor / stator / damaged / eroded

Replace

Rotation speed too low (if a FC is installed)

Adjust

Too high pressure after pump / blower

Clogging of piping Clean, flush

(Partially) closed valve Open

Decreasing gas production despite constant / increasing feed

Gas losses Check for smell after gas check gas bag for damages:

Repair minor ones

Replace bag in case of major ones Check connection flange of gas

bag

Manhole covers

Flanges

Valves

Blowers

Air dosing

Overpressure / vacuum safety equipment

Condensate drains

Gas piping

Faulty flow meter Contact producer

Biological reasons, in particular if observed in combination with:

Decreasing gas quality

Decreasing pH

Increasing vfa

Reduce / Stop feeding

Smell after gas (Some smell possible inside gas holder and in the gas holder pit without indicating a failure)

Gas losses See above

Scum production Too little mixing Check mixing pressure and number of mixing cycles, increase so far possible apply process mixing through auxiliary scum removal

Biological reasons, in particular if observed in combination with:

Decreasing gas production

Decreasing gas quality

Decreasing pH

Increasing vfa

Reduce / stop feeding check mixing pressure and number of mixing cycles – increase so far possible apply process mixing through auxiliary scum removal

Gas losses from gas bag, gas bag being not filled or being filled to slowly

Reduced gas production See column “observation” above

Gas losses See above

Significant smell after gas (Note: there is always some

Gas losses See above

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slight smell after gas inside the gas holder and around condensate drains due to diffusion and solubility of H2S)

Reduced gas quality Biological reasons, in particular if observed in combination with:

Decreasing gas production

Decreasing pH

Increasing vfa

See above

pH out of permissible range Calibration of instrument required, instrument damaged

Check calibration Contact manufacturer

Probe too old, calibration not possible

Replace

Instrument damaged Contact manufacturer / replace

Biological reasons, in particular if observed in combination with:

Decreasing gas production

Decreasing pH

Increasing vfa

See above

Increasing vfa concentration Biological reasons See above

Digester temperature out of permissible range

Problem with heating system Check:

Hot water inflow and return temperature

Hot water pumps

Control valve

Available heat

Temperature measuring

Piping for clogging

Heat exchanger for fouling

Valves positions

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Annexure – 11.1 Compressed Biogas plant & CO2 Recovery system specification

S. No. PLANT DETAILS UNITs Specifications

1 Technology being proposed by Original Plant Proposer (OPP)

Type LPSA (Low Pressure Swing Adsorbers)

2 Biogas Up Gradation Plant Capacity by OPP

M3/day

7000 (@ 20hrs/day)

175 X 2

3 H2S removal system

Type Fe2O3, ZnO, NaoH washing and CMS

Stages of removal No. 3

Capacity M3/day 7000 raw biogas @ 20 hrs/day

Output ppm ppm Below Detectable Limit

Online output display Yes/No Yes

Online display meter make & model Tec novation & SR-94 (H2S)

Reference standard IS - 2002 Grade 2, ASME

4 Moisture removal system

type Refrigerated, Desiccant type

Stages of removal No. 5

Capacity M3/day 7000 raw biogas @ 20 hrs/day

Output ppm 50, DEW POINT (-) 55 degrees C

Online output display Yes/No Yes

Online display meter make & model GE Veridri

Reference standard ASME

5 Energizer Yes/No Yes

Type

It is BRENStech and Atmos Power proprietary item to energize the molecules to increase separation

efficiency

6 PSA Units

No. of units No. 2

Capacity of each Unit M3/day 4200

Material of Construction Mild steel

Standard of Construction ASME

Foundation type SKID MOUNTED / RCC

Foot Print of each unit 5 m X 3 m

Working Pressure Kg/cm2 0.7

Type of Mol. Sieves ZMS

Grade of Mol. Sieves 5A & 13X

Make of Mol. Sieves Cecca, France

Quantity of Mol. Sieves Kgs/unit 1840

Type of absorbent ZMS

Qty. of absorbent Kgs/unit Same (absorbent is Mol. Sieve)

62

PSA Tower Height mm 5 m X 3 m X 6m

PSA Tower Volume 1.8 Cum

No. of Isolating Valves No./Unit About 10, Pneumatic

Inlet & outlet Sizes mm 50 & 80

Type of Safety Valves Spring Loaded SRV (Safety Relief Valve)

No. of Safety Valves No./Unit 3

Additional Safety type, if provided Yes/No 2

Online flow meter (Input/Output) Yes/No E & H /B 200

Flow meter make & model E & H / B 200

Online quality parameters display (Input/Output)

Yes/No Yes, Detail: Technovation & SR-94 (CH4)

Online quality parameters instrument make & model

E & H / B 200

No. & type of Pressure Gauges No. 12

Make of Pr. Gauges H guru

Automation type PLC/Others Through PLC

Cycle time minutes 6

Equalization time minutes 10

Equalization pressure Kg./cm2 0.5

Output Biogas Purity % Maximum 95%

Output H2S Quality ppm Below detectable limit

Methane Slip % <1%

Output Moisture % (-)55 degrees C, depends on ambient

Reference standard ASME, IS - 2002 Grade 2.

7 Electrical Control Panel

Type Individual/centralized

MCC control L& T (switch gear), Select MM3010 (PLC)

Electrical Control Panel - IP class IP -55, if located in Ex-proof Zone

Electrical Control Panel automation Yes/No Yes. PLC operated

Electrical Control Panel display details of switchgear

Analog/Digital/Graphical PLC & energy meter

Electrical control Panel safeties OLR

Instrument wiring type & details Shielded wire

Electrical cabling type & details. ISI/Others Armed cable

Reference standard IEC, IP 55 , FLP Ex-Proof

8 Vacuum Pump Mazda

No. of vacuum Pumps No. 2

Rating of Vacuum Pumps 760 mm. Hg.

Capacity of Vacuum Pumps 760 mm. Hg.

Electrical Motor Rating 10 HP

Motor IP Class IP - 55

Motor efficiency 87%

Reference standard ASME

9 Co2 Recovery System Yes/No Yes

63

Make SS Gas Labs

Rated Capacity of system by OPP Kg/Hour 250 kg/hour

Type of system Cryogenic

Methane recovery system Yes/No Yes

Output Purity of Co2 % >99.9%

Output Capacity of System 250 kg per hour CO2

Reference standard ASME-SS Gas Labs

10 Biogas Compressors

Compressors type Biogas specific

Capacity M3/hr. 100

No. of compressor 2

Rating of compressor Kg/cm2 200

Compressor Make & Model Sichuman new tianyuan tech. ltd. China /

2VW-6.3/200.

Class of Compressor VW Type, 2 cylinders, 4-stage

compression, water cooling, oil free lub., reciprocating piston compressor

Class of Motor IP – 55

Drive type Direct coupling

Safeties no. & type Explosion proof grade dⅡBT4 and

interlocking via PLC

Compressor Foundation Type RCC

Reference standard IS, ASME

Compressor Safety Class grade dⅡBT4

11 Cooling Tower Yes/No Yes

Type Water Cooling

Capacity 25 tr.

Water loss % 10

Water make up M3/day ~1m3/day

Reference Standard IS, ASME

12 Hot water Generator (HWG) Yes/No Yes

Type of fuel

Capacity Kcal/hr 600,000 K.cal.

Water holding Capacity of Drum

Delta Temp.

Max. water temp. Deg.C

Reference Standard IS, ASME

13 Storage Yes

Upgraded Biogas Storage type Balloon

Upgraded Biogas Storage Capacity M3 500

No. of Upgraded Biogas Storages 1

Safety system of Biogas storages PRV / Water seal Monitor

CO2 Storage type Pressurized tank

CO2 Storage Capacity CuM 20

64

No. of CO2 Storage No. 1

Safety of storages Water seal Monitor

Foundation type RCC

Life of storage systems ~ 10 years

Reference standard ??

14 Bottling station with Nozzels & QR Couplings

Yes

Upgraded Bottling Station No. Yes

Capacity of each Bottle (Only for Sizing Purpose)

10 Kg

Capacity of Skid (Without Bottles) 400 Kg

No. of Skids (without bottles as per above capacity)

2

Bottle Pressure & rating 200 Bar

High Pressure Piping station details of MOC & Make.

SS 304

Make of Valves & Regulators Parker

Reference standard PESO

15 Piping, Hardware, Insulation& Paints

Material of Construction for Pipes & Vessels

as per OEM

Schedule & class 20 Sch & 150#

Welding type for Vessels S.S. Arc welding

Welding type for Pipes S.S. Arc welding

Welding Reference standard IS, ASME

Welding Radiography for pressures vessels

Yes/No 10%

Valves type Buttery fly

Flange class& Sch. 150# & 20 sch.

Bends Class& Sch. 20 sch.

Nuts, Bolts & Washers S.S.

Reference Standard IS, ASME

Insulation Type- Cold PU

Insulation thickness-Cold Mm Min 50 mm.

Aluminum Cladding Gauge Min 24 Gauge

Reference standard IS

Paints of equipment type As applicable

16 Electrical system standard FLP, Ex Proof.

Relays & Contactors L & T

Switch gear L & T

Cabling Armed cable

Cable dressing & channels Yes

Reference standard IEC, IP 55, FLP Ex-Proof

17 Lighting of Plant Yes

65

Type LED Light

Safety Class IEC, FLP

Illumination Level LAB-250 Lux, Office-200 lux, plant 150 lux

& outer-50 to 100 Lux

Reference Standard IEC

18 Weigh Bridge modification by OPP at floor level

Yes/No Yes

19 CCTV Yes/No Yes

Type FLP, Ex proof.

No. of Cameras 9

Type of Cameras Day & Night vision type

LCD & DVR size 32 inch & 15 days back up.

Back up Hard Disk (1 TB), Battery.

Reference Standard IEC

20 Fire safety system Yes (Only Portable cylinders)

Type

Capacity

No. of hydrant points

No. of dry Powder fire extinguishers

Stand alone Yes/ No

Integrated with Existing system Yes/No Independent bottles

Reference Standard

21 Civil Construction

Civil structure designing, construction drawings, BOM, estimation sheet & supervision

Yes/No Yes

All foundations & Misc. included Yes/No No

Complete Plant anti-skid & static proof Flooring

Yes/No No

Modifications of existing area No

Operators Cabin size - DSM Scope if Reqd. 12’ X 12’

Cabin type - DSM Scope if Reqd. Sound proof with windows on 3 sides

Air conditioning of cabin -DSM Scope

Yes/No No

Furniture - DSM Scope if Reqd. Ergonomically suitable.

Reference Standard Factories Act.1948

22 Committed Plant Performance & Efficiencies

Methane Slip % <1%

Total Plant Energy Consumption kWh/m3 < 0.6

Total Plant Water Consumption Kl/day 1 Kl/day (Evaporation & drift losses, with

recirculation)

Noise Levels (Max.) dB <105

Upgraded Biogas Purity % Maximum 95%

66

Recovered CO2 Purity % Minimum 99.9%

H2S leftover Ppm Below detectable limit

Moisture left Over Ppm 50 @ -55 degrees C

67

Annexure-12 EXTRACTS FROM MANUFACTURER’S MAINTENANCE INSTRUCTIONS IN RESPECT OF

SOME MAJOR PLANT AND EQUIPMENT

THE PLANT: The plant comprises of following systems: 2) Weigh Bridge

3) Cow dung collecting; mixing and dilution tank with the help Agitators

4) Cutting feed to size and Feeding Dung to Digester with Pumps

5) Digester where Gas is produced

6) Separation of Moisture from Gas

7) Gas holder for collection of Gas

8) Gas pumping blowers

9) Flare

10) Gas Engine to produce Electricity

11) CBG Plant to purify the raw biogas to IS standard

12) CO2 recovery system to recover food grade CO2 in liquid form

13) Waste heat recovery system

14) Chimney

15) Sludge treatment plant comprising of collecting and pumping of discharge from

digester

16) Separation of solids from liquid with the help of screw press

17) Drying of solids and maturing of same

18) Weighing and packing and keeping ready for disposal

19) Treatment of liquid before final disposal by providing aeration, clarifier

20) Electrical system comprising of:

(i) Gas Engine Panel, Synchronisation

(ii) Power Control Centre

(iii) Motor Control Centre

(iv) Neutral Grounding Resistor

(v) Bus Duct

(vi) 16000 KVA / 11KV / 433V Transformer

(vii) Remote Tap Changer

(viii) Vacuum Circuit Breaker

(ix) C.T. / P.T. Metering Panel

(x) Two Pole Structure with D.O. Fuse and Lighting Arrestor

68

(xi) Lighting and Power distribution board

(xii) Automatic Power factor correction panel

(xiii) Battery charger

(xiv) Relay and control panel

(xv) Automatic mains failure panel

(xvi) Diesel generating set

(xvii) PLC panels and indicator panel

(xviii) Earthing system

(xix) Cabling for interconnection

(xx) Lighting of plant and building

(xxi) Motors and drives for all equipments

(xxii) Computers for plant control

KAY BLOWER TROUBLE SHOOTING 1. Abnormal Sound:

S. No. Observation Action

1. Loose flange at inlet / outlet of compressor

Tighten the joints

2. Improper opening of non-return valve Correct the valve position as per flow direction

3. Low level of gear oil Fill the oil to correct (red mark) level

4. Higher R.P.M. of blower Adjust the specified R.P.M. of the blower

5. Filter choking Clean/change the filter

If you don’t find above then call Service Engineer

2. Overheating of compressor:

S. No. Observation Action

1. The filter is dirty and choked Clean/change the filter

2. Discharge pressure too high: a) Direction/operation of NRV not proper OR b) Operation of gate valve not proper OR c) Operation of safety valve not proper

Correct the valve position as per flow

Rectify/change the gate valve/delivery gate

Clean the male & female part of safety valve or change the valve

3. Oil level low / too high or oil chamber is dry

Fill the oil chamber to correct level

4. Viscosity of oil is high Fill the specified grade of oil

5. Bearing at pulley side are dry Grease the bearing or fill correct oil (for both side oil lubricating compressor)

6. Deposits on the lobes/inner wall of casing Clean the blower with

69

(For checking this open the inlet/outlet flange of the blower)

Kerosene/Diesel

If you don’t find above then call Service Engineer

3 Low volume at Delivery end:

S. No. Observation Action

1 Bypass valve is open Close/adjust the bypass valve

2 Leakage in down line/delivery line Stop the leakage

3 Filter is dirty & choked Clean/change the filter

4 RPM of Compressor is too low Correct the RPM of blower to specified limit

5 Belts are loose Tighten the belts

If you don’t find above then call Service Engineer

TRANSAIRVAC (STARTUP BLOWERS) TROUBLE SHOOTING GUIDE

Problem Cause Solution

1. At the first starting

1.1 The machine does not start

- No voltage at the electric motor

- Check electrical connections between motor and control panel

1.1 The machine does not start and fuses burn out in the control panel

- Fuses not suitable - Replace fuses with suitable type (use always delay type fuses)

- Short-circuited electric motor

- Replace electric motor or have the motor re-wound

- Short-circuit in the control panel or in high cable feeding the motor

- Replace the short-circuited item

1.3 The machine does not start and the motor overload protection switch operates

- Dust or foreign object inside the machine

- Disassemble the unit and clean the inside thoroughly. Check filter and replace filter element, when needed

2. During operation:

2.1 Lack of gas Clogged filter element - Clean or replace the filter element

2.2 The motor overload protection switch operates and the machine stops Machine-motor shafts rotate freely be hand

- Too high discharge pressure

- Check downstream pipe work and system - In case, fit and overpressure relief valve if not already fitted

- Too high inlet vacuum - Clogged filter element

- Check upstream pipe work and system and if there is a lack of gas. In case, fit and overpressure relief valve if not already fitted - Clean or replace the filter element

70

2.3 The motor overload protection switch operates and the machine stops. The machine shaft is locked

- Machine bearing failure and consequent possible seizure between impeller and casing

- Disassemble the machine body. Replace machine bearing. Remove any trace of seizure on impeller and casing halves with fine glass paper.

- Seizure between impeller and casing caused by dust, sewage or foreign objects.

- Disassemble the machine body. Remove any trace of seizure on impeller and casing halves with fine glass paper.

- Seizure between impeller and casing caused by too high discharge temperature (Over 120oC)

- Disassemble the unit. Remove any trace of seizure on impeller and casing halves with fine glass paper. Ventilate the installation room. In case, fit a gas high temperature switch at the machine outlet.

2.4 The motor overload protection switch operates and the machine stops. The motor shaft is locked, but the machine shaft can rotate freely by hand

- Motor bearing failure - Replace motor bearings. Check the motor insulation resistance. Replace electric motor or have the motor re-wound, when needed.

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ROTO PUMPS (DIGESTOR FEED PUMPS) FAULT FINDING

No. Fault Possible Causes (refer manual)

1 Pump fails to start 6,12,17,26,28,20

2 No discharge 1,2,3,4,5,24

3 Loss of capacity 3,4,5,6,9,10,12,113,18,20

4 Looses priming after start 3,4,5,8,9,12

5 Pressure head too low 3,5,13,20,25

6 Delivery fluctuates 3,4,5,6,8,12,14

7 Drive is over loaded 6,8,9,11,15,18,26,27,28

8 Pump over heats 6,9,11,18,19,26

9 Excessive power absorbed by pump 6,8,11,15,18,24,26,27

10 Noise & Vibration 3,4,5,6,9,15,18,20,25,30

11 Excessive gland or seal wear 7,11,16,31

12 Seized pump 9,12,15,26,28

13 Bearing over heat 8,15,21,22,23

14 Stator service life too short 9,18,19,26,28

REASONS FOR FAILURE

1 Wrong direction of rotation 17 Low voltage

2 Pump not primed 18 Pressure head too high

3 Air or vapor pockets in suction line 19 Stator not suitable to flow medium

4 NPSH available is too low 20 Worn out rotor/stator

5 Foot valve/strainer clogged 21 Wrong grade of lubricant

6 Viscosity greater than rates 22 Moisture in lubricant

7 Lantem ring plugged 23 Excessive lubricant in bearings

8 Speed too high 24 Discharge valve blocked/clogged

9 Liquid temperature above rates figure 25 Suction pipe leaks

10 Viscosity lower than rated 26 Pump running dry

11 Gland over tight 27 Specific gravity too high

12 Gland under tight 28 Flow medium settles and hardens

13 Pump spe4ed lower than rated 29 Electric data of pump do not suit mains

14 Belt drive slipping 30 Pump/drive mounting not firm

15 Worn or loose bearings 31 Gland flushing inadequate

16 Product entering packing area

72

KIRLOSKAR BROTHERS LIMITED (SUBSTRATE RECIRCUALTION PUMPS) 1) Operation a) Before starting the pump check the following b) The pump rotates freely by hand c) Fill the grease/oil for the bearing, if not done earlier. The bearings are packed with grease in

the factory for grease lubricated pumps. However, if the pump is stored for a longer time it is necessary to refill the grease in the bearings. Check the level of oil in the constant level oiler when oil lubricated.

d) The sealing liquid and cooling water connections are properly tightened and adjusted e) The direction of rotation of driver. It should correspond to the direction of rotation of the pump f) The pump and suction pipe is fully primed with the liquid g) Valve on the delivery side is closed h) The cock for pressure guage connection is closed i) The stuffing box packing is properly tightened 2) Starting the Pump a) Start the pump. Let the prime mover pickup its full speed b) Open the valve on delivery line slowly to reduce the starting load on the motor c) Regulate the required flow by adjusting the delivery valves d) Open the cock for pressure gauge connection

3) During running the pump check the following things and regulate, if necessary

a) The pump is running smooth b) The flow of sealing liquid and cooling water is uninterrupted. It necessary provide sight glass in

between the piping c) The bearings are not getting abnormally hot d) The gland is properly tightened to given leakage of approx. 60 drops per minute through stuffing box e) Head and capacity developed by the pump is as specified f) Power consumption is within the limit g) Ensure that there is no mechanical friction in the pump h) Stop the pump immediately, if any defects are detected. Do not start the pump unless the defects

are rectified Report immediately to the supplier, if is not possible to rectify the defects.

KIRLOSKAR BROTHERS LIMITED (SUBSTRATE RECIRCULATION PUMPS)

4) During stopping the pump a) Close the valve on delivery line b) Stop the motor c) Close the cooling water and sealing liquid connections d) If the pump is not required to be operated for a long time, drain the casing completely. If the

pump is required to be stored for long time, the bearing housing should be dried internally with hot air and should be flushed with moisture free protective, such as light oil or kerosene.

5) Technical Data a) Direction of rotation. The direction of rotation is clockwise when viewed from driving end b) Specification of bearings, oil seals, bearing lock nuts, ‘O’ rings etc.

73

EL-O-MATIC (B/F ACTUATED VALVE)

Trouble shooting – Actuator system

Important: Read these guidelines before attempting any repairs

S.No. Fault Problem Cause Remedial action

A. For solenoid operated actuators:

1. Actuator does not function

Valve jammed/seized Check valve operation through Wrench/MO, if provided otherwise remove actuator and check valve for smooth operation

Excessive friction in valve gland

Check gland packing, loosen gland if required

Solenoid valve not operating / functioning

Check solenoid coil and ensure that specified supply voltage is applied to coil

Air supply not reaching actuator

Check solenoid valve operation (listen for’click” sound). Replace coild/valve if not functioning. Check pneumatic line and connections. Check air after regulator setting (use local pressure gauge for checking supply pressure)

Insufficient air supply pressure

Check air supply pressure and ensure specified air supply pressure

Manual override engaged in manual mode (where MO is mounted)

Declutch manual override and disengage hand wheel

Equalizing valve open (if provided only for system with MO)

Check equalizing valve and close valve fully before giving air supply

Speed control valve (regulating valve) fully closed (for system with speed control valve)

Check position of speed control valve. Ensure that valve is kept partially opened

Actuator undersize for the given application

Cross check valve torque requirements. Select correct size of actuator.

2. Actuator functions but exhibits lack of power

Leakage pneumatic line Check all pneumatic connections and tighten properly. Use tefflon tape / thread sealants on threads

Leakage across pistons or between Ports A&B (can happen only due to

Pressurize Port A/B and check for leakage from the other. Change sealing

74

prolonged operation over a period of time)

parts if required

Low air supply pressure Check supply pressure and ensure correct air supply pressure

Severe misalignment between actuator and valve

Check linkage. Loosen mounting bolts and align Actuator correctly for friction free rotation

3. Full stroke of Actuator not achieved

Excessive friction in gland packaging

Check gland and loosen if required

Excessive clearance / play in adapter / linkage

Change adapter

Mounting bolts loose or wrongly oriented

Align correctly and tighten bolts

Limit stops on actuator (if provided not set correctly)

Check and reset limit stop screws to achieve required stroke

Limit stops on MO (in case of systems with MO) not set properly

Check limit stop settings on MO and readjust if required to achieve full rotation

Obstruction in valve or linkage

Check for mechanical obstructions if any and remove

Excessive spring torque (in case of spring return actuators). Low air supply pressure

Check air supply pressure and ensure specified supply pressure. Check spring selection

4 Noise inside actuator Improper clearance between rack and pinion. Broken or loosened rack bolts.

Open actuator and check tightness of rack bolts. IF loose tighten properly. If worn out replace racks/shaft.

Insufficient lubrication (Due to prolonged use at high ambient temperatures)

Open actuator, clean and lubricate with specified lubricant/grease

Metal to metal contact due to worn out sealing / guiding elements

Replace guide bands / sealing elements.

75

SEPCOM (SCREW PRESS / SEPARATOR) TROUBLE SHOOTING

Trouble Cause Remedy

Separator stops Overload Check motor protection for proper setting, if needed adjusted it to maximum value according to the table 13.2

Stopper too dry See setting instruction – 6.1

Foreign object blocks up the worm

Check separator inlet, remove foreign object, check worm and sieve

Low output of solid and liquid fraction

In flow too low Check the pump (direction of rotation) check feeding line

Lifting effect in overflow line, slurry is sucked out of the separator

Install vent valve/pipe on separator T. Reduce inflow so that the overflow pipe is filled not more than half at the maximum. Make sure that the overflow can run out freely.

Sieve blocked Clean the sieve through sieve windows or if necessary disassemble for cleaning Activate reverse control – See 16.1

Worm or sieve worn out Check worm diameter, replace the worm if needed, check sieve for wear and also replace it, if required

Sieve is worn out only in places, guiding of sieve not adjusted correctly

Adjust sieve guiding properly Centre the sieve again at the front and at the rear See mounting instructions – 10.2

Slurry mixed or pumped too often (grinded)

Install buffer tank at the separator inlet see 6.2

Solid discharge too low, stopper is too dry

Weights too far in the front See setting instructions – 6.1

Wrong direction of rotation of separator

Check electrical connections

Worm channels blocked up Check and clean the worm See disassembly – 10.1

No solids discharge, minimum liquid discharge

Abrasive components in the slurry, e.g. sand

Let abrasive components settle as far as possible before separation

Increased worm and sieve wear

Varying consistency of separated medium (slurry)

Mix and homogenize the medium (slurry) thoroughly

Strongly varying liquid content of the discharged solids

Solids contents of the medium too low. Weight too far back

Mix and homogenize the medium (slurry) properly See setting instructions 6.1

The stopper dissolves and liquid run out of at the discharge cone

Solids are too find and have no fibrous

Use a finer sieve

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Recommended maintenance schedule for transformer

S.No Inspection

frequency Items to be inspected Inspection

notes Action required if inspection shows unsatisfactory conditions

(1) (2) (3) (4) (5)

1. Hourly a. Ambient temperature b. Winding temperature c. Oil temperature d. Load (amperes) e. Voltage f. Position of Tap switch

--- Check that temperature rise is reasonable Check against rated figures

--- Shut down the transformer and investigate if either is persistently higher than normal.

2. Daily g. Inspect general condition, see if there is any unusual noise, check oil level in conservator

---

---

h. Oil level in transformer

Check against transformer oil level

If low, top up with dry oil, examine transformer for leaks

i. Oil level in bushing --- ---

j. Leakage of water into cooler

---

---

k. Explosion vent diaphragm

--- Replace if cracked or broken

l. Dehydrating breather Check that air-passages are free. Check colour of active agent.

If silica gel is pink, change by spare charge. The old charge may be reactivated for use again.

3. Quarterly a. Bushings Examine for cracks and dirt deposits

Clean or replace.

b. Oil in transformer Check for dielectric strength and water contents

Take suitable action to restore quality of oil.

4. Yearly a. Oil in transformer Check for acidity and sludge

Filter or replace

b. Winding Check for insulation value

Filter the oil and ensure proper meggar value.

c. Oil filled bushings Test oil Filter or replace

d. Gasket joints --- Tighten the bolts evenly to avoid uneven pressure

e. Cable boxes Check for sealing arrangements for filling holes. Examine compound for cracks

Replace gasket, if leaking

f. Surge diverter Examine for cracks & dirt deposits

Clean or replace

g. Relays, alarms, their circuits etc.

Examine relay and alarm contacts, their operation, fuses, etc. Check relay accuracy, etc.

Clean the components and replace contacts and fuses, if necessary. Change the setting, if necessary.

77

h. Earth resistance --- Take suitable action, if earth resistance is high.

Note: 1. With respect to on-load tab changers, the manufacturer’s recommendation should be followed. 2. The silica gel may be reactivated by heating it to 150 to 200 C. 3. Every time the drying medium is changed, oil seal should also be changed. 4. No work should be done on any transformer unless it is disconnected from all external circuits and the tank and all windings have been solidly earthed. 5. In case of anything abnormal occurring during service, our advice should be obtained, giving complete particulars as to the nature and the extent of occurrence, together with the name plate particulars in order to assist identification.

78

Annexure – 13 LIST OF EQUIPMENT AVAILABLE IN THE PLANT

S.No. Equipment Qty. Specifications

1. Macerator 1 Cap. : 40 tonns / hr. Rating : 5.5KW RPM : 1445 rpm Make : Netzsch

2. Start-Up blower 2 Type : Radial (CL42/21BDG) Gas Handled : Biogas Inlet Pressure : 101.3 mbar g, 35oC, 200 Nm3/hr. Discharge pressure : 570 mbar g Speed : 3250 rpm Motor No.: 14062 Model No.: NADH 54 A Frame No.: 160 MB - 2 Rating : 15 KW RPM : 2890 rpm Voltage : 420 V Make : Trans Air Vac International Ltd. Address : Unit 12 Croft Castle, Staffordshire, ST5 0XB, UK. Phone : 0044 1782 710282 Fax : 0044 1782 710126

3. Dry type gas holder 1 Type : Dry Type, Cylindrical Gas Bag Capacity: 1000 cum, 10.20 Dia. x 11.62 Ht Working pressure: 1.5 to 2.5 mbar Make: Entec Address: ENTEC ENV Technology, Umwelttechnik Gmbh 1, A-6972 Fussach. Ph. : +43 5578 7946-800 Fax : +43 5578 7946-800

4. Screw Press 2 Make : WAM (Sepcom) Capacity : 20 tons/day Motor :5.5 Kw Details As below in Pt. No. 4.1:

5. Gas Engine 1 Make: R. Schmitt (Germany) Sold & Service through Green Power Pvt. Ltd. Noida. Capacity : 400 kWe Cylinders : 12 WHRB : Attached H2S Scrubber : 1:5 Ratio Acoustic canopy : covered Air washer: included De-humidifier: included.

79

Annexure 13.1 SCREW PRESSES:

The Separator serves the purpose of separating a pump able mixture of solids and a liquid with a comparatively low solid content such as for instance slurry (Max 7% Total solids). As a compact device it combines the functions of two separating devices, namely that of a sieve and of a press as well.

The Technical Specifications of these machines needs to be as under:-

Denomination Data MOC, Capacity

Substrate input Cow dung substrate Suitable for max. 7.0% Total solids intake.

Manure output 35-50% moisture level output of bio manure 20T/Day

Auger/Screw Screw should be of long life and less wear & tear with minimum clearance between the Sieve and Screw for higher yield and better moisture content in the separated solid.

AISI 304 /SS 304 in Engineering/ techno polymer.

Slotted Sieve/Screen Type: For high and dry output the Sieve/Screen has to be extended Dual Type and should be of self-cleaning nature.

AISI 304 / SS 304

Sieve / Screen mesh sizes: Main screen having options of mesh sizes from 0.25 mm,0.50 mm & 0.75 mm and adjunctive module of mesh to have options of 0.50 mm,0.75 mm & 0.90 mm to choose from.

Length: to accommodate with in the space the length of the screen should not extend more than 1000 mm.

Intake housing As per Design of offered model. AISI 304 / SS 304

Housing/Body As per Design of offered model. AISI 304 / SS 304

Hopper, Feed Line & overflow end points.

Sizes As per Design of offered model AISI 304 / SS 304

Discharge All Flange class 150 Hot galvanized steel/ AISI 304 / SS 304

Manure exit port Type Self-adjusting/self-regulating backpressure mechanism without any kind of external system support.

Engineering polymer Diaphragm

Base frame Included as per Design Hot dip Galvanized steel

80

Motor 5.5Kw, wide range voltage motor, Voltage-options of 220-240 & 380-420, 4 pole, Insulation Class F, 50Hz, IP55, 1440 rpm. PTC Thermistor.

ISI Make / as per European standard IE-2 & EN-50262 in

accordance with

2004/108/EC standards

Gearbox Spur gear ration 50:1, RPM – 25-35,

Lubrication – Synthetic long drain/life type.

Grey cast iron or as per OEM Design.

Dimensions Preferred L x B x H: 2.5 x 1.0 x 3.0 Mtrs Within these limits

Weight Max. 600 kgs.

Capacity Between 60-75 m3/hr. Maximum ever preferred.

Warranty On all materials & mechanism 12 months

81

ANNEXURE 13.2 GAS ENGINE (400 kWe)

82

83

84

85

86

87

88

89

90

91

Annexure – 14

INDICATIVE LIST OF TOOLS AND TACKLES FOR THE GAS ENGINE Tools for spark plugs (Special socket, extension, torque wrench) Tools for removal of oil filter cartridges Feeler gauges Feeler gauge 0.35 mm 1 Wrench 17x19 DIN 895 1 Wrench 10 Grease gun Measuring device for valve wear Ignition voltage measuring device Adapter of measurements Ultra–thin 50 spray Pointed pliers Turning device (on per module)

92

Annexure – 16

LABORATORY EQUIPMENT – CHEMICALS, GLASSWARES

S. No. Particulars Specification Make Qty.

1. PH Meter digital with electrodes

(pH 1.0 to 14.0) ELICO 1 No.

2. Gas Chromatograph Analyses CH4, CO2, H2S, O2.

NUCON 1 No.

3. Heating Oven (RT to 250o C)

600x600x450mm Technico 2 Nos.

4. Muffle furnace (RT to 1200oC)

50x150x350mm Technico 1 No.

5. BOD incubator 10 cft size YORCO 1 No.

6. Hot plate 2ft. x 1.5ft. (Cap 3 KW)

Widscien 1 No.

7. Heating mantle RT to 120oC Widscien 1 No.

8. Water distillation plant (stainless steel)

4 Litres / Hr. Capacity

Technico 1 No.

9. Kjeldahl digestion assembly

6 nos. hot plates and regulator individual

Widscien 1 No.

11. Spectro Photo Meter UV-VIS Elico 1 No.

12. Top loading electronics balance with all accessories

200 grams with 0.01 mg accuracy

Dhona 1 No.

93

GLASS WARES

S. No. Particulars Size/Capacity Quantity

1. Beakers 100 ml 6 Nos.

2. Beakers 250 ml 6 Nos.

3. Beakers 500 ml 6 Nos.

4. Beakers 1000 ml 4 Nos.

5. Bottles reagent 250 ml 12 Nos.

6. Bottles reagent 500 ml 6 Nos.

7. Bottle reagent 1000 ml 2 Nos.

8. Bottles B.O.D. 300 ml 30 Nos.

9. Burettes 25 ml x 1/10 ml --

10. Burettes 50 ml x 1/10 ml 2 Nos.

11. Dish evaporating 80 x 45 20 Nos.

12. Cylinder 10 ml x 1/10 ml 6 Nos.

13. Cylinder 50 ml x 1/10 ml --

14. Cylinder 100 ml x 1/10 ml 6 Nos.

15. Cylinder 250 ml x 1/10 ml 6 Nos.

16. Cylinder 500 ml x 1/10 ml 2 Nos.

17. Cylinder 1000 ml x 1/10 ml 2 Nos.

18. Cylinder 2000 ml x 1/10 ml -

19. Flasks conical 150 ml -

20. Flasks conical 250 ml 12 Nos.

21. Flasks conical 500 ml 6 Nos.

22. Flasks interchangeable neck for COD 24/29 500 ml 6 Nos.

23. Condenser for reflux 24/29 300 ml 1 No.

24. Flasks volumetric 50 ml 2 Nos.

25. Flasks volumetric 100 ml 6 Nos.

26. Flasks volumetric 250 ml 6 Nos.

27. Flasks volumetric 500 ml 4 Nos.

28. Flasks volumetric 1000 ml 2 Nos.

29. Flasks volumetric 2000 ml -

30. Flaks boulding (flat bottom) 500 ml 2 Nos.

31. Flaks boulding (flat bottom) 1000 ml 2 Nos.

32. Flaks boulding (flat bottom) 2000 ml -

33. Funnels 75 ml 12 Nos.

34. Funnels 100 ml -

35. Pipettes 1 ml x 1/10 ml 12 Nos.

36. Pipettes 5 ml x 1/10 ml 12 Nos.

37. Pipettes 10 ml x 1/10 ml 12 Nos.

38. Bulb pipette 10 ml 6 Nos.

39. Bulb pipette 25 ml 6 Nos.

40. Bulb pipette 250 ml -

41. Desiccator Big 160 mm 12 Nos.

42. Desiccator Small 150 x 15 mm -

43. Test tube without rim 500 ml 24 Nos.

44. Distilling apparatus 100 ml 2 Nos.

45. Nessleiv tubes 500 ml 2 Nos.

46. Wash bottles plastic 100 ml 4 Nos.

47. Watch glass 250 ml 4 Nos.

48. Reagent Bottles Amber 500 ml 2 Nos.

49. Reagent Bottles Amber 5 litres 2 Nos.

94

50. Bottles Aspirator 10 litres 2 Nos.

51. Bottlers Aspirator 250 ml -

52. Separating Funnel 250 ml 2 Nos.

53. Wahtman 3 piece filter -

54. Filter Flask without for tubing (heaving walled)

-

55. Imhoff Cone corning of Borosil 1000 ml 2 Nos.

95

ANNEXURE-18

PRESCRIBED PERFORMA FOR PERFORMANCE BANK GUARANTEE To Punjab Genco Ltd., S.C.O 54-56, Sector-17A CHANDIGARH Whereas....................................................................... hereinafter called the ‘LESSEE’ has undertaken, in pursuance of lease agreement no. .......................................................... dated................... to operate and maintain the one high rate Biomethanation Power & CBG plant at Haibowal, Ludhiana in accordance with provisions stipulated in the lease agreement as signed with you. AND, Whereas, it has been stipulated in the condition of the said contract that the Lessee of Operation and Maintenance lease agreement shall furnish to the Punjab Genco Ltd., hereinafter, called ‘LESSOR’, with a Performance Guarantee from a scheduled bank, to cover the compliances of the LESSEES performance-obligations stipulated in the lease agreement , for an amount of Rs. 50.00 lacs (Rupees Fifty lacs only) for the full period of said lease agreement upto .....................................(date).

AND, Whereas, LESSEE has agreed to give the LESSOR the said guarantee. Therefore ____________ _______________ bank hereby affirms that the Bank, as a Guarantor will be responsible to Lessor M/s Punjab Genco Ltd on behalf of LESSEE M/s. ______________________________________ and undertakes to pay the full amount of Rs. 50.00 lacs (Rupees Fifty lacs only) upon first written demand without arguments declaring the LESSEE to be at default under the lease agreement. This amount, within limits of aforesaid guarantee without needing any proof or showing any grounds of reasons for demand, of the said amount specified here above. This performance guarantee is valid until................................ day ............... of ........................ .

Signature and Seal of Guarantor Date: Place:

96

Annexure – 19.1 Technical Bid Evaluation

Tender No. PEDA/2017-18/ S. No. Description Status

1. Name of Company.

2. Year of Incorporation.

3. Pan No./GST No.

4. Lead Member, in case of Consortium

(Please enclose Consortium

agreement)

5. Person authorised to sign the bid

(attach proof)

6. Earnest Money Deposit (EMD) of Rs.

2,00,000/-

7. Tender Document Cost of Rs. 10,000/-

8. Tender Processing Fee

9. Tech Eligibility Criteria Clause 5.3

The bidding company/consortium must have

at least two year experience in successful

operation and maintenance (as contract) or in

regular Operation & Maintenance of Biogas

Plants, Biogas power generation Plants on

similar/ MSW/ waste streams with minimum

10,000 m3/day plant biogas generation

capacity and minimum 500 KW of biogas

power generation capacity having sufficient

managerial and technical capabilities and had

carried on the operation and maintenance of

high rate bio metalation process, CBG/PSA

Technology, high pressure compressors (air or

biogas) & biogas power Plants. Appropriate

documentary proof establishing the said

qualifying experience needs to be submitted

along with the bid.

10. Financial Eligibility Criteria clause 5.4

• The bidding Company/Consortium of

companies should have an average Rs. 3.0

crore annual turnover for the last three

financial years i.e. 2014-15, 2015-16, 2016-

2017 and must be in profit in at least two years

from the last three financial years i.e. 2014-15,

2015-16, 2016-2017.

Or

• The net worth of the

Company/Consortium of companies must be

Rs. 2.0 crore in each of the last three Financial

Years i.e. 2014-15, 2015-16 and 2016-2017.

F.Y. Turnover Profitability Net-worth

2014-15

2015-16

2016-17

97

11. Bankers Certificate for capacity to

provide Performance Bank Guarantee

of Rs. 50.00 lacs

12. Litigation Details if any, During last

three years

13. No. of Employees currently on

Company Strength

14. Operative Bank Account of the

Company

15. Bid Form

16. Technically qualified/Not qualified

98

Annexure-19.2

SCHEDULE OF PRICES TO BE QUOTED BY LESSEE FOR O&M OF HIGH RATE BIOMETHANATION POWER PLANT AT HAIBOWAL, LUDHIANA FOR A PERIOD OF 5

YEARS

FINANCIAL BID: OPERATION & MAINTENANCE

S. No.

Description Rate per unit chargeable on Saleable Electricity

A Rate per m3 of raw biogas used for power generation and for CBG & CO2 bottling

plant, metered at the respective feeding points from raw biogas balloon mainline, as

per terms and conditions of DNIT.

Rate per unit of m3 of raw bio gas metered

NOTE:

3. Rates shall be quoted in Rupees or paisa & shall be written both in figures and words. 4. An annual escalation of 5 % will be applicable on price quoted. 5. Taxes extra if any.

For ------------ (Name of the Company)

Authorised Signatory

99

Annexure-20

SCHEDULE & DETAILS OF FACILTIES FOR O&M OF PLANT A. Details of Manpower to be deployed by the company. Sr.No. Designation Qualification Experience Remarks

a) Supervision Staff (Managers, Assistants & Liaisoning Officers, etc.): b) Maintenance Team (Foremen, Fitters, Electrical and Mechanical Engineers, Welders & Helpers etc.): c) Operation and process control Team (Electrical, Mechanical, Chemical Engineers, Plant Operators & Helpers, etc.): d) Technical Supporting Staff in Design & Engg., Fault Diagnosis & Remedies to the Breakdowns thereof: (This staff may not be retained on full time basis - Engineers, Supervisors & Draftsman, etc. etc.) e) Special Team to Handle Specific & Specialised Jobs/Breakdowns (Engineers, Supervisors and Foreman, etc.)

100

B. Communication Facilities (Wireless Systems, Mobile and Landline Telephones, E-Mail, etc., etc.) C. Conveyance Facilities (Car, Jeep, Scooters, Cycles, etc.) Note: i) Lessee will be at liberty to deploy any number of personnel for O&M but will be required to satisfy the Lessors for performing O&M activities. Lessor observations with regard to adequacy or inadequacy of manpower will be final and Lessee will have to comply with the same.

101

Annexure-21

LIST OF ADDITIONAL SPARES, STANDBY PROVISIONS, TOOLS & TACKLES AND MEASURING INSTRUMENTS TO BE ARRANGED BY O&M OPERATORS

A. Additional Spares B. Standby Provisions C. Tools & Tackles D. Measuring Instruments