NOTICE INVITING E-TENDERING TECHNICAL BID DOCUMENT … · 2021. 2. 6. · foundation bolts, fasteners, shim plates & grouting material, etc, as required for equipment foundation,

Doc. No. : GPEC/PNQ/AHS/20-21/CPN/67

Date : February 05, 2021

Assign No. : PWR-2020-03133

Date : October 21, 2020

NOTICE INVITING E-TENDERING

TECHNICAL BID DOCUMENT

(Volume II of II)

FOR

ASH HANDLING SYSTEM PACKAGE

AT

M/s. Shri Dudhganga Vedganga Sahakari Sakhar Karkhana

Limited Bidri (Mauninagar) – 416 208

Tal. Kagal, Dist. Kolhapur

Prepared by

MITCON Consultancy & Engineering Services Ltd. Kubera Chambers, 1st Floor,

Dr. Rajendra Prasad Road, Shivajinagar

Pune - 411 005, Maharashtra State, India

February 2021





TECHNICAL BID DOCUMENT (Volume II)

ASH HANDLING SYSTEM AND ACCESSORIES FOR

M/s. Shri Dudhganga Vedganga Sahakari Sakhar Karkhana

Limited

TABLE OF CONTENTS

Chapter No.

Title

1. SCOPE OF WORK 1.1 Intent of Specifications 1.2 Scope of Supply & Work 1.3 Electrical 1.4 Instrumentation & Control 1.5 Civil 1.6 Erection & Commissioning 1.7 General 1.8 Performance Test 1.9 Lighting 1.10 Earthing 1.11 Terminal Points 1.12 Exclusions

1 1 1 2 2 2 2 2 3 3 3 3 3

2. TECHNICAL SPECIFICATIONS

2.1 General Technical Requirements 2.2 Design Basis 2.3 Detailed Technical Specifications 2.4 Induction Motors 2.5 Specifications for Electrical Equipments 2.6 Cables 2.7 Cable Termination & Testing 2.8 Cable Trays & Supporting System 2.9 Electrical & Instrumentation 2.10 Instrumentation 2.11 Specific Requirements for The System Components 2.12 Inspection / Performance Test 2.13 Erection & Commissioning 2.14 Drawings & Documentation Requirements 2.15 List of Approved Make of Components

4 4 5 6 6

10 12 14 15 15 16 18 19

19 19 20 21

Bid Document for Fuel & Ash Handling System and Accessories





TABLE OF CONTENTS (Contd..)

LIST OF APPENDICES

Appendix

No.

Title

I.

Data Sheets & Schedules

1. Bidder Information 2. Belt Conveyor 3. Submerged Belt Conveyor 4. Screw Conveyor 5. A.C. Electric Motor 6. Electricals 7. Instrumentation & Control 8. Schedule of Special Tools &Tackles for Maintenance 9. Schedule of Weights & Dimensions 10. Schedule of Recommended Operational Spares 11. Schedule of Erection Tools & Tackles 12. Schedule of Bidders Experience 13. Schedule of Requirements 14. Schedule of Engineering, Manufacturing, Shipment.

Erection & Commissioning 15. Schedule of Testing & Inspection 16. Scheduling of Guarantees

22-41

TECHNICAL Bid Document for Ash Handling System for SDVSSKL 1

CHAPTER 1

PACKAGE SPECIFICATIONS 1.1 Intent of Specifications

This specification is intended to cover the design, engineering, manufacture, shop fabrication, assembly, pre assembly, tests and inspection at manufacturer’s works, packing shipping and erection & commissioning of Ash handling system for 60 TPH new boiler to SDVSSKL

System description is detailed below

1.2 Scope of Supply and work

The scope of work covered under this specifications include but not limited to the following

II. Ash handling System :

Submerged belt type conveyor (SBC-1A) to collect & convey the ash from the boiler bed. This conveyor has to be mounted in a MS trough; the belt should be submerged in water with a level of minimum 250 mm.

Belt Conveyor no ABC-1A to feed ash from APH hopper to existing cross ash conveyor.

Belt Conveyor no ABC-2A to feed ash from Economizer hopper to existing cross ash conveyor.

Screw conveyors (ASC-1A) to feed the ash from ESP hoppers on to cross belt conveyor

Belt Conveyor no ABC-3A to feed ash from screw conveyor no ASC-1A to existing cross ash conveyor.

The technical parameters of above conveyors are tabulated below.

S No

Description Submerged Belt

conveyor (SBC-1)

Belt conveyor no ABC-

1A

Belt conveyor no

ABC-2A

Screw Conveyor (ASC-1A )

Belt conveyor no ABC-

3A

1 Capacity TPH

2.0 1.0 1.5 3 3

2 Material Bagasse ash

Material temperature

250 100 100 100 100

3 C/C distance Mtr

15 25 25 10 25

4 Lift Mtr. 2.1 3 3 0 3

5 Angle of Inclination

160 160 160 0 160

6 Type of Conveyor

Belt S H R grade

Belt S H R grade

Belt S H R grade

Screw Belt S H R grade

7 Width/ Diameter

1000 mm 500 mm 500 mm 400mm 500 mm


1.3 Electrical

All AC motors required for the conveyors. The motor terminal box shall be

complete with cable gland & lugs of flame proof Type Terminal Starters lockable push button stations, MCCs, all cabling including galvanized cable trays, all cabling from DCS to the marshalling cabinet of control panel, equipment /body earthing etc. Lightning protection for the structures, as required with necessary vertical /horizontal conductors, each earth electrodes & connection to earth pit.

1.4 Instrumentation and Controls:

Safety switches for the system including zero speed, pull chord at a spacing of 30 Mtrs on both sides or minimum ine pair, belt sway switches at a spacing of 60 Mtrs, emergency switches, as applicable. Control System including control panel for the sequential operation with inter phase facility to communication with the boiler control system. ( DCS) Local instruments including switches, instrument cables, terminal boxes, cable trays & accessories, as required to make the system complete.

1.5 Civil:

Supply of all structural steel embedment and R.C.C foundations work like, foundation bolts, fasteners, shim plates & grouting material, etc, as required for equipment foundation, checking and certifying before and after concreting for the accuracy of levels, centre lines, bolts fixing etc. All relevant designs, drawings with load data are to be furnished for foundation designs.

1.6 Erection & Commissioning:

Erection & commissioning of the entire system 1.7 General:

Any other item not specifically mentioned above but required for satisfactory performance of the ash handling system

Consumable materials as required for erection & commissioning including electrodes. First fill lubricants, flushing oil, etc.

Commission spares & two year operating spares.

Two coats of primer, one coat of finished paint & final painting at site.


1.8 Performance Test

Performance test for the guaranteed parameters as given in the schedule of guarantees is to be conducted by vendor in presence of PURCHASER/ Consultants Representatives at no extra cost.

1.9 Lighting

Lighting has to be provided for all the conveyor system for easy maintenance during the night hours and also to facilitate for the personnel to walk through the walkways & is in the scope of vendor

1.10 Earthing

Earthing if required has to be provided by the Bidder.

1.11 Terminal Points:

1 Ash From the outlet of bed Ash , APH, Economizer & ESP hoppers & up to the existing ash storage silo

2 Electrical Purchaser will provide supply to incomer of ash handling MCC. Further electrical distribution Including MCC, will be in bidders scope

1.12 Exclusions:

Civil works, buildings &foundation for equipment.


CHAPTER 2

TECHNICAL SPECIFICATIONS

2.1 General Technical Requirements

2.1.1 General

This specification is intended to cover the design, manufacture, delivery, erection & commissioning of ash handling system for the new boiler. The supplies & services within the scope shall be rendered inclusive of all appliances & interconnecting arrangements with other supplies, necessary for installation of all accessories, needed for proper & reliable, continuous operation, satisfactory maintenance & repair The scope of supply and services shall include all necessary work and supply of equipment & material whether mentioned in these specifications or not, but which are necessary for the satisfactory, reliable and safe operation and maintenance of the plant Any equipment, device or material even if not included in the original bid but found necessary for the safe and satisfactory functioning by the contractor at no extra cost.

2.1.2 Codes and Standards

Fuel & Ash handling system will be designed as per following standards.

IS :11592 - Code of practice for selection and design of

conveyors IS:1891 - Specification for rubber conveyor IS:4776 - Specification for troughed belt conveyors IS :7155 - Code of practice for conveyor safety IS :8531 - Specification for pulleys for belt conveyors IS : 8598 - Specification for idlers for belt conveyors IS 800 - Code of practice for General Construction in

Steel IS 1893 - Criteria for Earthquake Resistance, Design of

Structures IS: 325 - Three phase induction motors IS 7403 - Code of practice for selection of Worm & helical

gear box IS 14206 - On site non mechanical jointing of plied textile

reinforced rubber conveyor belting- code of practice Part-1 : Hot Vulcanising

IS:1554 - P V C insulated (heavy duty) electric cables IS:2705 - Current transformers IS:3043 - Code of practice of Earthing IS :8623 - Low voltages switch gear & control gear


assemblies IS :9224 - Low voltage fuse supplementary requirements for

Fuse links for the protection of semi conductor Devices

IS :10118 - Code of practice for selection, installation and Maintenance of switch gear and control gear

IS :13947 - Low voltage switch gear and control gear 2.2 Design Basis

The ash handling system covered under this specification shall be designed to achieve the following objectives.

2.2.1 Performance parameter

The performance parameters are as follows.

2.2.2 Material Handling System

1 Material Handled Ash from Boiler bed, Economizer, ESP Hoppers of Boiler.

Ash from furnace through submerged ash conveyor will be normally wet when it is discharged on to the belt.

2 Bulk Density Bagasse Ash: 180 Kg/ Cu.M

3 Material Temperature

Ash temperature as given in elsewhere in the bid document

4 Nature of Ash Material

The ash collected will Contain unburnt slop Particles & also occasionally unburnt Bagasse

5 Ash analysis ( 0 % )

SiO2 50 - 60

Al2O3 10 - 13

Fe2O3 10 - 12

CaO 3 - 5

MgO 3 - 4

TiO2 2 - 4

P2 O5 1 - 2

Na2O 0.5 -1.5

K2O 4.5 - 6.0

SO3

2.2.3 Site Data

Refer Volume I Project information


2.3 Detailed Technical Specifications

General

This section of the bid document indicates the detailed requirements of the various equipment & system. The Bidder, if he feels so, may depute his representative for site study. However this does not absolve the bidder from his responsibility of performance of the system 2.3.1 Belt Conveyor

The length of the conveyors is indicated in the scope of work are drive pulley center to discharge pulley center (c-c) distance & they are approximate. The exact length and lift of the conveyor shall be determined by the bidder based on the design parameters indicated and taking into consideration the dimensions and arrangement of the equipment offered by him. The carrying capacity indicated are the rates at which the equipment shall be guaranteed to operate continuously. The angle of inclination of conveyor belts shall not exceed 18 deg to the horizontal. The belt conveyors and accessories shall be suitable for continuous operation under severe duty working condition. Design &construction feature of the belt conveyor shall be in accordance with IS:11592. The scope of supply shall include but not limited to the belting, idlers, (carrying, return, impact, SACI & SCRI ), pulleys including head, tail/ take up, snub, bend., belt internal/ external cleaners, take up units, drive unit complete with electric motors, reduction gear boxes, gear type flexible coupling, for both high speed and low speed sides, base frames, integral hold back device, electric safety switches, auxiliaries like skirt board, deck plates, dust seals, coupling guards, take up guards, maintenance platform and ladder for all take ups etc., structural item like stringers, short supports, take up frames, conveyor gallery, walkway, conveyor support columns and frames, hoods and all other accessories that may be necessary to make each conveyor and the system complete. The belt shall be of Nylon- Nylon type with suitable top and bottom cover. The number of plies and weight of duck shall be suitably selected with due regard to load/flexibility of troughing. Vulcanizing shall be considered for the joints. The idlers shall be made of seamless /ERW steel tubes. The idler rollers shall be fitted with deep groove ball bearings. Troughed idlers shall be concentric and shall have 3 rolls, 20 deg. Troughing angle. All bearings shall be designed for a minimum life of 40000 working hours. The return idlers shall be single roller flat type and covered with rubber sleeve wherever required. Impact idlers shall be provided below each loading point. The roller assemblies shall be designed to prevent dust accumulation.


The spacing for the troughing and return idler shall be as per IS 11592.Shorter spacing shall be considered for the bends and for reasons of heavy loading. The impact idlers spacing shall not be more than 300 mm. Self aligning carrying and return idlers shall not be more than 20 Meters apart and more than 15 meters from each terminal. The conveyor pulley shall be welded steel construction with closed ends. The pulley diameter shall be designed for maximum belt life and confirm to IS specification. The entire assembly of the pulleys shall be balanced and grooved rubber lagging shall be provided for the drive pulleys. The take-up shall be screw type for short conveyors upto 30 Mt. length. Skirt board shall be provided at loading zones and in other places to prevent spillage. The skirt plate thickness shall be minimum 6 mm and the rubber strip thickness shall be minimum 10 mm. The deck plates shall be 2.0 mm for the entire length of the belting. The belt conveyor shall be complete with coupling guards, discharge / feed hoods, side sheeting, pulley guards drives supporting structure, maintenance platforms and drive platform with adequate space on both sides to attend to drive unit. All conveyors shall have removable type hinged hoods with industrial hinged & painting & side sealing arrangement. The hood & side sheeting shall be fabricated from minimum 2.0 mm thick M S sheets with suitable stiffeners & clamping arrangement.

2.3.2 Screw Conveyor The screw conveyor assembly shall include the screw flight, pipe shaft, trough, trough cover, end cover, bearings, hanger bearings , end shaft, trough end seals, saddles, inlet & outlet spouts, drive unit complete with electric motors, reduction gear box, couplings for both sides, weather hood for drive box, structural items like short supports, drive platform, approach and all other accessories that may be necessary to make the conveyor complete . The screw flight shall be of 6mm thickness (minimum). The trough & trough end cover thickness shall be minimum 6 mm &12 mm thickness respectively. Provision for thermal expansion shall be provided if the outlet flange of discharge point is directly connected to the screw conveyors. Necessary expansion bellows are in the bidders scope. Hard facing of the screw flight shall be out on the carrying side for 1” face width (minimum)


Packed gland seal shall be provided at tail or drive shaft opening in the trough ends to prevent material leakage. Pitch of the screw shall be 0.8 to 1 D where ‘D’ is the diameter of the screw. However, to meet the required capacity, the pitch may be maintained short, half or long.

2.3.3 Submerged Belt Conveyor The submerged belt conveyor assembly shall include belt, idlers, pulleys, trough, pressure pulleys, return rollers, take-up arrangement, drive unit complete with reduction gear box, belt internal & external scrapers etc. to make the system complete in all respect. Inter connecting chutes, supporting structure, safety / indicating instruments, drive assembly, supports, maintenance platform, frames, drive base, approach etc. as required by the conveyor.

Water piping, inlet & outlet drains up to the terminal points as required by the system

Minimum of 200 mm water seal has to be maintained at the discharge point of chutes in to the trough of the submerged belt conveyor. The inside of trough shall be quoted with one coat of Tar paint and the trough material shall be minimum 10 mm thick.

The belt speed shall be limited to 10 M/Min.

2.3.4 Discharge Gates Manually operated discharge / diverter gates shall be provided whenever required to facilitate flexibility of operation and maintenance of the system. The gate shall be fabricated from minimum 10 mm thick M S plates. The gate shall be provided with antifriction bearings with suitable seal for free movement. The gate shall be of rack & pinion type. All the conveyors shall be provided with discharge /receiving chutes for the flow of material. The chutes shall be fabricated minimum 6 mm MS plates. Whenever required suitable liner plates shall be provided to withstand the erosion due to falling material.


2.3.5 Discharge Hood & Chutes

All the conveyors shall be provided with discharge/receiving chutes for the flow of material. Also the discharge chute shall be designed to cover the belt scrappers at the bottom of the belt. The chutes shall be fabricated from minimum of 6mm MS plates. Properly designed discharge for effective de-dusting and dust tight flexible rubber access door (min 400sq.mm) shall be provided the height of the discharge hood shall be minimum 1500mm from the belt top. Deflectors shall be provided in discharge hoods wherever the belt conveyors are discharging at 90 degrees. The back end of discharge chute and return belt shall be properly sealed by replaceable rubber strip to avoid dust nuisance. Sufficient number of poke holes (min 100NB pipe) and access door (min400sq.mm) to be provided in long chutes with access platform and staircase.

2.3.8 Supporting Structure.

The complete supporting structure required for the equipments shall form part of bidder’s scope of supply. All supporting structures shall be designed for a wind pressure in line with IS standard.

All junction towers shall have maintenance platforms, stair cases, landings, side sheeting, top roof sheeting with pearling, hand rails & toe plates. All floors & landings shall be provided with minimum 2500 mm clear head room.

The Purchaser’s responsibility ends with the provision of the required RCC foundation at FFL. All RCC foundation required for columns, support shall be provided by the purchaser. The complete structural work above finished floor shall be of steel

Minimum requirement of structural steel members & sizes is as under

S NO ITEM/ EQUIPMENT ASH HANDLING

1 Decking plate Decking plate should be throughout the bottom side to form section "C" having height of side plate should be min 100 MM above the belt Top having thick of 2 mm. MS. Plate with bolting construction

2 Hood Cover Hood cover should be of Transparent PVC sheets having gauge 14 SWG ( 2 mm. thick in one piece to be bolted at site.


2.4 Induction Motors

2.4.1 Performance & Characteristics

Motors shall be capable of giving rated output without reduction in the expected life span when operated continuously under either of the following supply conditions :

Variation of supply from rated motor voltage + 10% Variation in supply frequency from rated frequency + 5% Combined voltage and frequency variation + 10%

Motors shall be suitable for full voltage direct-on line starting. Motors shall be capable of starting and accelerating the load with the applicable method of starting, without exceeding acceptable winding temperature, when the supply voltage is in the range of 85% of the rated motor voltage to maximum permissible voltage. The locked rotor current of the motor shall not exceed 600% of full load current (subject to tolerance as per the applicable standard) Motors shall be designed to withstand 120% of rated speed for two minutes without any mechanical damage, in either direction of rotation. The motor vibrations shall be within the limits specified in applicable standard. All motors above 15 KW will be energy efficient type.

2.4.2 Insulation

Any joints in the motor insulation such as at coil connections or between slot and end winding section, shall have strength equivalent to that of the slot sections of the coil. The insulation shall be given tropical and fungicidal treatment for successful operation of the motor in hot, humid and tropical climate. The tropicalising treatment shall be as per the applicable standard

2.4.3 Temperature Rise

For motors specified for outdoor installation : Heating due to direct exposures to solar radiation should be taken into account.

2.4.4 Bearings

Greased ball bearings or greased roller bearings shall be of reputed make.


The bearings shall be constructed such that the loss of lubricating fluid is kept to a minimum and greasing shall be possible without any dismantling operation. The bearings shall prevent dirt and water from getting into the motor. Bearing lubricant shall not find access to motor windings. If the bearings are oil lubricated, a drain plug shall be provided for draining residual oil and oil level sight gauge shall be provided to show precise oil level required for stand still and running conditions.

2.4.5 Terminal Box

Terminal boxes shall be of weather proof construction designed for outdoor service, to eliminate entry of dust and water, gaskets of neoprene shall be provided to cover joints and between box and motor frames. The terminal box shall be suitable for top and bottom entry of cable. Unless other wise approved, the box shall be capable of being turned through 3600C in step of 900C. The terminal shall be of the stud type with necessary plain washers, spring washers and check nuts. They should be substantially designed for the current carrying capacity and shall ensure ample phase to phase and phase to ground clearances. Suitable cable glands and cable lugs shall be supplied by the motor vendor to match Purchaser’s cables. Glands to be provided on motors by vendor.

Notes :

Motor terminal inside the terminal box shall be of the stud type with necessary plain washers, spring washers and check nuts and shall be provided with cable lugs specified above. The manufacturer shall specifically indicate compliance with regard to cable box size, lug size and type of glands as specified above.

2.4.6 Paint & Finish

Motor external parts shall be finished and painted to produce a neat and durable surface which would prevent rusting and corrosion. The equipment shall be thoroughly degreased, all rust, sharp edges and scale remove and treated with one coat of primer and finished with two coats of grey enamel paint. The motor fan shall also be painted to withstand corrosion.

2.4.7 Heating During Idle Periods

All motors rated 30 kw and above shall be provided with space heating facility suitable for 240 V, 1 phase, 50 Hz AC. The terminals


for the same shall be brought out separately.

2.4.8 Accessories

Two independent earthing points shall be provided on opposite sides of the motor, for bolted connection of the Purchaser’s earthing conductors, as specified in the Data Sheet. These earthing points shall be in addition to earthing stud provided in the terminal box.

2.4.9 Tests

Motor shall be subjected to all the routine tests as per applicable standard in the presence of the Purchaser’s representative. Copies of the test certificates of type and routine tests, as specified in the distribution schedule, shall be furnished for the Purchaser’s approval.

2.5 Specifications for Electrical Equipments - The panel shall be self supporting, free standing, floor mounted, modular type

with construction having degree of protection IP 54 as per IS 2147. - The panel shall be fabricated from 14 SWG CRCA sheet steel for frame &

load bearing surfaces. Door & partitions may be fabricated from 16 SWG CRCA if no components are mounted on them.

- The panel shall be painted with 2 coats of primer after pre treatment and 2 coats of Polyurethane / epoxy paint with shade 631 of IS 5. Alternately epoxy powder coating shall be done in place of paint.

- Stiffeners shall be provided at corners & between modules to make panel rugged. The stiffeners will necessarily be required for relay compartments or doors where heavy components are mounted.

- The openable covers shall be provided with lift off type hinges, quarter turn door locks and flexible copper wire for earth connection.

- The panel shall be dust and vermin proof. Synthetic or neoprene gaskets shall be provided at all openings

- The panel shall be of dead front construction suitable for front operated and back maintained functioning.

- Panel shall be provided with compact fl.lamp of 29 w capacity operated by door operated limit switch. Panel shall also have space heaters and thermostat arrangement.

- Panel shall be provided with 3 pin switch socket combined unit of 5 Amp capacity.

- Lifting hooks shall be provided at the top of the panel. - The hardware components used in the panel shall be hot dipped galvanised. - The control components shall be fixed on mounting plate by drilling & tapping. - Aluminium anodized legend plates shall be provided for all the components.

For components mounted on front face, legend plate from inside shall also be provided.

- Pre-treatment by 7 or 5 tank process shall be done before painting / powder coating the panel.

- The panel shall be designed to ensure maximum safety during operation inspection, connection of cables and maintenance. Inside panel, checking and removal of components shall be possible without disturbing other units.

- Cable entries will be from bottom. The opening of cable entry shall be


covered by 3 mm thick gland plates. - The panel shall be provided with all necessary components / devices and

instruments as per the enclosed schematic diagram and functional requirements.

- The components such as protective relays, auxiliary relays, push buttons, switches, instruments shall be flush mounted on the front side of a panel.

- The control wiring shall be done with PVC insulated flexible copper wire. For CT secondary circuits 2.5 sq.mm. wire shall be used. For control wiring 1.5 sq.mm. wire shall be used.

- Earthing bus bar of suitable cross section shall be provided throughout the length of panel.

- The panel shall be fully wired All the terminals shall be brought out for cable connections. 10 % spare terminals shall be provided on each terminal block. Separate terminal block shall be provided for different voltages. All wire shall have P.V.C. ferrules as per wiring diagram.

- Proper shrouding to incoming and outgoing terminals shall be provided to ensure safety during operation, inspection and maintenance.

- Indicating lamps shall be with multiple LEDs & shall be suitable for the voltage specified .

- All the components in the panel shall be properly labelled. The labels shall be made of non rusting metal or engraved PVC material properly fixed by screws.

- The panel layout shall be made in such a way that it will always facilitate easy removal and reconnection of control cables without disturbing other wiring.

- Centre lines of control switches, push buttons and indicating lamps shall be matched so as to give neat appearance. Similarly top lines of indicating instruments and relays shall also be matched.

- The panel shall be provided with electrolytic grade aluminium bus bar of suitable cross section so as to maintain max current density of 1 AMP/ sq.mm.

- Bus bars shall be provided with colour coded heat shrinkable sleeves. - Bus bars shall be supported by high quality epoxy insulators provided at

specified distances so as to withstand to the given fault level of 350 MVA. - The bus bar chambers shall be provided with suitable ventilation

arrangements so as to limit the maximum temperature of 85 degree C while carrying rated current.

- Proper clearance shall be maintained between phase bus bars and between bus bars and enclosure as per the approved standards.

- The panel shall be inspected at manufactures works before dispatch to site. - All routine tests shall be carried out on the panel in presence of purchaser or

his representative. These tests shall include following,

a. Verification of components ratings and operation. b. High voltage measurement test. c. Insulation Resistance measurement. d. Control testing.

- Approval on following drawings shall be obtained before manufacturing the panels

a. General arrangement drawing. b. Wiring Diagram. c. Detail bill of material.


2.6 Cables a. All the cables required for the work will be supplied by bidder. This shall

include taking the delivery at site, shifting to locations, cut to lengths, laying, dressing, testing and commissioning with termination arrangements.

b. The cables shall be laid in trenches, trays or conduits Cable routing given on the drawings shall be checked in the field to avoid interference with structures, piping ducting and minor adjustments shall be made to suit the field conditions.

c. All cables shall be carefully measured and then only cut to the required length leaving sufficient length for final connections to the equipment on site.

d. The bidder shall confirm the exact requirement of cable for particular feeder by measuring at site along the actually finalized route. He shall prepare cut length schedule of cables before taking up cable laying.

e. Cables shall be laid in complete uncut length from one equipment to other. f. Cables shall be neatly arranged in the trenches/trays in such a manner, that

crisscrossing is avoided and final take off to the motor/switch gear facilitated. Arrangement of cables within the trench/ tray shall be the responsibility of the bidder.

g. All cables shall be identified close to their termination point by cable numbers as per schedule. Cable numbers will be punched on aluminum strips (2 mm thick) securely fastened to the cable and wrapped around it.

h. Temporary ends of cables shall be protected against dust and moisture to prevent damage to the insulation. While laying the cable, ends of cables shall be taped with PVC tape

i. Cables shall be handled carefully during installation to prevent mechanical injury to the cables. Ends of cables leaving trenches shall be coiled and provided with protective cover until the final termination to the equipment is completed.

j. Where cables rise from trenches to motor, control station, lighting panels etc. They shall be taken in GI pipes for mechanical protection upto a minimum of 1000 mm above ground level. The diameter of the GI pipe shall be at least 3 times the diameter of the cable. The upper end of pipe shall be sealed to prevent ingress of water.

k. Cable ends shall be carefully pulled through conduits to prevent damage to the cable.

l. Wherever cables are taken in conduits, the bidder shall ensure that the area of conduit filled in by cables shall be as under :-

1 Cable in pipe : 53 %

2 Cable in Pipe : 50 %

3 Cables in pipe : 43 %

More than three cables : 40 % If more cables are passing, additional conduit shall be laid after the cables are installed and all testing is complete, conduit ends above grade shall be plugged with suitable weather proof plastic compound.

m. Where cables pass through foundation wall or other underground structures the necessary ducts or openings will be provided in advance for the same. However, should it become necessary to cut holes in existing foundations, structures, the electrical bidder shall identify the same and obtain an approval before cutting the same.

n. Cables installed above ground level shall be run in trays, exposed on walls


ceilings / structures and shall be run parallel to or at right angles to beams walls or columns. The cables shall be so routed that they will not be subjected to heat.

o. Individual cables or small groups which run along structures will be clamped by means of 16 SWG GI saddles on 25 x 6 mm saddle bars at a spacing of 300 mm. The cost of such saddles shall be included in the cost of installation of cable.

p. Cables shall be supported so as to prevent sagging. G.I. clamps required as per the diameter and number of cables shall be on cables at every 300 mm. Cable carrier system i.e. cable trays / supports and supporting steel shall be painted black before laying of cables.

2.7 Cable Termination & Testing

All PVC cables shall be terminated at the equipments/ panel by means of single compression type glands and tinned copper lugs. Power cables shall be identified with red, yellow and blue PVC tapes. Where copper to aluminum connections are made necessary bimetallic washers. shall be used. In case of control cables, all cores shall be identified at both ends by their terminal numbers by means of grooved PVC ferrules. Wire numbers shall be as per inter-connection diagrams to be furnished to the bidder. Bidder shall drill holes for fixing glands wherever necessary at no extra cost. The cable shall be taken through adequate size gland inside the panel or any other electrical equipment. The individual cores shall then be dressed and taken along the cable ways . Cable leads shall be terminated at the equipment terminals by means of crimped type solder less connectors. Crimping shall be done by hydraulic crimping tool and conducting jelly shall be applied on the conductor. Insulation of the leads should be removed immediately before the crimping After completion of the termination the waste material such as PVC insulation removed from cables, cable pieces & armour strips etc. Shall be immediately removed from the work place and shall be to appropriate place allotted for this purpose.Before energising the cables following tasks shall be carried out – checking of identification Nos. Measurement of resistance. Insulation resistance. Pressure Testing in case of 11KV XLPE cable. Proper records shall be maintained for future reference.

2.8 Cable trays & supporting system a. Cable trays of sizes as per drawing shall run in concrete trenches or

overhead supported from columns, slabs etc. b. Cables shall be clamped in both horizontal and vertical runs by suitable

clamps. c. Cable trays and supporting system shall be adequately provided to provide

mechanical support during operating as well as short circuit conditions. d. The cable trays and supports shall be applied with two coats of red oxide

primer and two coats of epoxy paint. e. Cable trays shall be fabricated from MS angles and strips as per sizes given

in respective drawing.


2.9 Electrical and Instrumentation

The motor control center shall be sheet steel single front, factory assembled, totally enclosed, self supporting, floor mounted, dust and vermin proof cubicle type construction with multi-tier compartmentalized arrangement. It shall have a series of uniform height placed side by side having front access for operation and rear access for maintenance.

1. The design manufacture & testing of the assembly shall comply with the Indian standards IS :8623-1993.

2. The panel shall be suitable for the following operating system.

Rated voltage : 415 V, 3ph, 4 wire Rated frequency : 50 Hz Fault level : 50kA for 1 sec Enclosure : IP 52

3. The cubicles shall be made of heavy gauge pressed cold rolled sheet of Thickness not less than 2 mm with neoprene gasket at all joints & opening including doors. The operating height of the devices on the panel will be limited between 450 mm to 1800 mm.

4. The main bus bars shall be of electrical grade aluminium &shall have continuous Current rating as required but not less than the current rating of the incoming isolators. The bus bars shall be so designed & dimensioned that with the passage of normal rated current the temperature rise does not exceed 40 Deg . C over an ambient of 45 Deg . C . The bus bar shall be completely sleeved with non-shrinkable PVC material & shrouded at joints. Supports at regular intervals shall be provided with SMC / DMC insulting medium Clearances between bus bars of phases & phase & earth shall be maintained at all places .

5. The control circuit voltage adopted for MCC will be 220 V AC which shall be Supplied by providing control transformer of ratio 415/220V. the control bus of the MCC will be of electrolytic grade copper &will be designed to carry the transformer rated secondary current as well as to withstand the available short circuit level

6. The MCC shall provision for future extension by bolting additional

sections. End units shall include provision for future main bus extensions & installation of additional units on either side with the framework suitably drilled to receive the additional modules and bus bars fitted with fish plates and associated hardware enabling future expansion without involving major fabrication works on the panel in service .The panel shall be supplied complete with base mounting channel of min 50 mm in height for facilitating grouting on the floor.

7. The panel shall be connected to an earth bus bar running throughout

the length Of the board .The minimum earth bus size shall be 300 Sq. mm copper provision shall be made to connect earthing bus bar to the plant earthing grid at the ends.


8. The switch gear panel shall be formed using distinct vertical sections

each Comprising following compartments.

A completely metal enclosed horizontal bus bar compartment running horizontally at top .

Individual feeder modules organised in multi tier mode.

Completely enclosed vertical bus bars serving all feeder modules in the Vertical panel.

Cable termination compartment

Perforated sheet steel / insulating material enclosed horizontal auxiliary Bus way for control supply and space heater supply.

9 Each section shall be provided with space heater controlled by

thermostat & Control switch

10. MC.C.B. /SFU modules with HRC cartridge type fuses shall be

provided for all feeders .The switches shall be of rated for AC23 duty . The doors shall be interlocked with the associated load break switch so that the door can be open3ed only when the switch is in the de –energised position and the doors shall not be capable of being closed with switch in the energised position.

11. The starter modules shall be complete with feeder switch, set of fuses

for Power & control circuits ,over load relays with built –in single phasing prevention ,contactor rated for AC4 duty with minimum 2NO & 2NC , resistor type pilot lights for ON , OFF & TRIP conditions ,control switch for anti –condensation heaters for motors of rating above 30k W, start & stop push buttons &ammeters for motors of rating above 7.5 k W and pilot devices comprising of oil tight RESET button complete with actuator and necessary linkages. Switch gear shall be coordinated for all starter module shall have selector switch for operation from MCC/ local / control room .

12. Current transformers of minimum 10 V A burden with accuracy class

1.0 Shall be provided for ammeters. Ammeter and voltmeter of 144 mm dial with selector switches shall be provided in incomer circuit. Ammeters in motor feeders shall be of 96 dial size with suppressed scale.

13. All wiring & cables at the termination at the switchboard shall have distinct marking by means of ferrules with letters / numerals printed corresponding to the wiring diagrams to be furnished by the bidder . Name plates of anodized aluminium shall be provided for all compartments and bar chamber including vacant space.

14. The following documents shall be supplied along with the bid :


a) Connection diagram for all units b) Schematic diagram of complete switchboard c) Terminal connection diagram of the main terminal board d) Sketches of the overall dimensions of the board clearly showing the

bus bar size e) Brand name of all components incorporated. f) Shipping dimensions of the board g) Deviation statement, if any, from this specification.

15. Switch gear assembly shall be subjected to the tests stipulated in IS :

8623 –1993 in the presence of owner / consultant or their representative. Certificate copies of all type and routine tests shall be submitted before dispatch of the switch gear. Type test certificates for the major components shall be submitted.

16. MCC shall have minimum of one module per size as spare. All motors to be of squirrel cage induction type & shall be selected for voltage & frequency variation of +/-10 and + /-5% respectively with combined variation of 10% with temperature rise not 3exceeding limits of clause ‘B’ insulation over an ambient of 45 Deg C. However ,motors shall have class ‘f’ insulation. All motors to be of TEFC enclosure with IP 55 protection .Motors shall be of Energy Efficient’ Type Motors rated above 30 kW shall have space heaters.

2.10 Instrumentation

The ash handing system will be controlled basically by the relay based control Panel & it should be possible to hook up the same to DCS system for the entire power plant in future by others . The DCS system envisaged will be common for boiler ,turbine, material handing system ,ash handing system etc. The ash handing system vendor shall supply all the primary sensors that are required for the sequential /safe operation of the system offered .All field wiring from the sensors will be terminated suitably in a terminal box.


2.11 Specific Requirements for the System Components

The reduction gear box used shall be helical type completely enclosed with flash lubrication. The gear box shall be rated 24 hours continuous working with a minimum service factor of 2.0 on the installed motor capacity. The couplings provided shall be of gear type flexible type and shall have a minimum service factor of 2 on the installed motor capacity. All bearings shall be preferably anti friction type and self aligning in nature The bearings shall have effective dust cover. The bearing shall be selected for a minimum working life of 40000 hours Effective lubrication shall be provided for all bearings and sliding surfaces . All the structural steel used shall meet the requirements of IS: 2062 and the Steel plates used shall not be less than 5mm thk. All the conveyors shall be covered by removable type hoods .The hoods shall be fabricated from minimum 2 mm thick by MS sheets/ Metapoly sheets with suitable stiffeners and clamping arrangement.

2.12 Inspection / Performance Test

The inspection shall include design basis, materials workmanship ,during and Fabrication and erection . The vendor shall carry out performance of the system to demonstrate that the System function as required by the contract and that the system / components meets the performance. Duration of performance test shall be for 8 hrs.

2.13 Erection and Commissioning

The supplier shall be required to erect all mechanical & electrical equipment ,Steel work, chutes, hoppers, instruments and controls cables and conduits. etc complete in all respect up to the stage of commissioning with the contract and as per the relevant drawing and erection instructions.

The supplier shall provide all skilled .semi skilled and unskilled workers, Supervisory staffs, tools and tackles, erection materials hoisting & testing equipment and other related services required to complete the erection and commissioning all equipment with auxiliaries. The work shall include the following.

Receipt of material at site

Providing storage and safe custody of the equipment.

Checking of the foundations before & after casting.

Alignment , leveling and grouting .

Current / drilling / welding as required on the existing structure /


buildings.

Complete assembly and erection materials .

Minor rectification work wherever required.

Final painting .

Initial lubrication and greasing.

Trial run and commissioning. 2.14 Drawings & Documentation Requirements

2.14.1 Drawings /documents to be submitted along with the bid

As a minimum required the following information / document shall be supplied to fully describe the scope of work & services offered

1. Filled in data sheet and the schedules. 2. Material of construction for all components. 3. Make, type and details for bought out items. 4. Overall assembly drawings for the equipment . 5. Recommended drive details. 6. Equipment catalogues for all the items offered 7. Terminal point details. 8. Time schedule indicating important milestone activities 9. A detailed write–up on the system proposed and on the equipment

selected. 10. Layout for the handling system. 11. Equipment Size / Power / Belt Selection Calculation. 12. Bearing Selection basis.

2.14.2 Documents to be submitted after award of the contract

1. Overall assembly drawing showing the drive arrangement.equipment. 2. Detailed layout for each system 3. Filled up data sheets for each equipment 4. Load /foundation details for the equipment and structure 5. Copy of material certificates/ inspection reports. 6. Logic diagram / wiring diagram, as required. 7. Quality plan 8. Layout drawings for the total ash handling system. 9. Equipment Size / Power selection calculation 10. Bearing selection details. 11. Complete motor data. 12. Technical specification / layout /wiring for the control panels/ MCC. 13. Cable schedule 14. O& M Manual.

Note : The drawing should show layout dimensions, assembly, dimensions, the support locations, load details, material of construction, location of drives, thickness of materials used, maintenance space etc. The drawings require approval from purchaser/consultant before proceeding ahead with manufacture/erection.


2.15 List of Approved Make of Components

1 GEAR BOX : Radicon, Flender, Elecon

2 ELECTRIC MOTORS : Siemens, Kirloskar Bharat Bijlee, ABB 3 COUPLINGS (Gear Type) : Fenner, Unique 4 BEARINGS : SKF/FAG 5 CONVEYOR BELT : Dunlop, Andrew Yule, Ravasco, MRF 6 FUSE SWITCH UNIT : L & T, Siemens 7 FUSES & FUSE BASE : GEC Alsthom ,Siemens 8 CONTACTORS : L& T ,Siemens 9 BIMETAL RELAYS : Siemens. L&T 10 PUSH BUTTON & INDICATION LAMPS : Siemens, L &T, Vaishnav 11 TERMINALS : Elmex, IEC 12 METERS : AE, Simco, Rishab, 13 CABLES : CCI, Universal, Ploycab , Finolex 14 SAFETY SWITCHES : JAYASHREE, KANA, R.R.

Bidder should submit the list of Vendors for the other Major items for approval


Appendix I

Data Sheets and Schedules

Data Sheet No 1

BIDDER INFORMATION

S No Description Unit

1 Bidder’s complete Company Name and Postal Address

2 Tender reference and Date

3 Proposal Validity ( No of days)

4 Whether particulars of past similar experience furnished?

Yes/No

5 Name and particulars of Collaborator, if applicable

6 Equipment warranty period from the date of commissioning

7 Whether furnished offer is as per the specifications

Yes/No

8 Whether list of deviations/exclusions taken furnished

Yes/No

9 Whether all taxes & duties included in the price schedule?

Yes/No

10 Whether offer for 2 years operational spares included?

Yes/No

11 Whether all commissioning spares included in the base offer?

Yes/No

12 Whether a project schedule with commissioning date is enclosed?

Yes/No

13 Whether equipment performance guarantee furnished?

Yes/No

14 Whether the drawings required as per the specification enclosed?

Yes/No

15 Whether quality plan enclosed Yes/No


Data Sheet No 2

BELT CONVEYOR (To be filled up for all conveyors)


1 Conveyor No

2 Conveyor Type

3 Profile Centres

4 Orientation

5 Material handled

6 Bulk density

7 Particle size

8 Lump Size ( Max)

9 Capacity TPH

10 Volumetric capacity Cu. m /sec

11 Belt Speed M/sec

12 C-C distance Mtrs

13 Lift Mtrs

14 Power required at driving pulley KW

15 Motor out put Power KW

16 Recommended Motor kW and RPM and Frame Size

KW

17 Belt Width Material Construction/Grade Cover Grade Factor of Safety Make

MM

18 Gear Box Make Type Reduction Ratio Service Factor

19 Coupling Make Model No Type Input side Output Side


Data Sheet No 2

BELT CONVEYOR (Contd..)


20 Head Pulley Selection basis Head Pulley D X L X T Shaft Diameter Rubber Lagging Tail Pulley D X L X T Shaft Diameter Snub / Bend Pulley D X L X T Shaft Diameter Take Up Pulley D X L X T Shaft Diameter

MM MM MM MM MM MM MM MM MM

21 21.1 21.2

21.3

21.4

Idlers Idler Classification Carrying Idler Type Pipe Dia / Length Spacing Idler Housing Shaft dia Impact Idler /Transition Idlers Type Pipe Dia / Length Spacing Idler Housing Shaft dia Rubber Rings Dia /Material Return Idler Type Pipe Dia / Length Spacing Idler Housing Shaft dia

MM MM

MM

MM MM

MM MM

MM MM

MM

22 Take Up Type

23 Bearing Type / make

24 Belt Cleaners Internal External

25 Hold Backs / Brakes


Data Sheet No 2

BELT CONVEYOR (Contd..)


26 Coasting Time Sec

27 Skirt Board Type / Location Material Thickness Rubber Skirt Skirt Length

28 Deck Plate Location Material Thickness

29 Hood Type Hood plate thickness

30 Guide rollers Spacing

31 Conveyor Frame type Short Support

32 Discharge chute Plate Thickness

33 Drive Base Frame

34 Gallery

35 Walk-way

36 Safety Switches Zero speed/ Pull Cord /Belt Sway Contact Protection Make

37 Foundation Bolts

38 Painting

39 Quantity

40 Approx. Erection Weight of steel ( excl. belting,gear box & motor ) but including supporting structure


Data Sheet No 3

SUBMERGED BELT CONVEYOR


1 Conveyor No

2 Conveyor Type

3 Profile Centres

4 Orientation

5 Material handled

6 Bulk density

7 Particle size

8 Lump Size ( Max)

9 Capacity TPH


11 Belt Speed M/sec


13 Lift Mtrs

14 Power required at driving pulley KW



KW

17 Belt Width Material Construction/Grade Cover Grade Factor of Safety Make

MM




Data Sheet No 3

SUBMERGED BELT CONVEYOR (Contd..)


20 Head Pulley Selection basis Head Pulley D X L X T Shaft Diameter Rubber Lagging Tail Pulley D X L X T Shaft Diameter Snub / Bend Pulley D X L X T Shaft Diameter Take Up Pulley D X L X T Shaft Diameter

MM MM MM MM MM MM MM MM MM

21

21.1

21.2

21.3

21.4

Idlers Idler Classification Carrying Idler Type Pipe Dia / Length Spacing Idler Housing Shaft dia Impact Idler /Transition Idlers Type Pipe Dia / Length Spacing Idler Housing Shaft dia Rubber Rings Dia /Material Return Idler Type Pipe Dia / Length Spacing Idler Housing Shaft dia

MM MM

MM

MM MM

MM MM

MM MM

MM


Data Sheet No 3

SUBMERGED BELT CONVEYOR (Contd..)


22 Take Up Type

23 Bearing Type / make

24 Belt Cleaners Internal External

25 Hold Backs / Brakes

26 Coasting Time Sec

27 Skirt Board Type / Location Material Thickness Rubber Skirt Skirt Length

28 Deck Plate Location Material Thickness

29 Trough Type Size width X Length X Height

30 Guide rollers Spacing

31 Conveyor Frame type Short Support

32 Discharge chute Plate Thickness

33 Drive Base Frame

34 Gallery

35 Walk-way

36 Safety Switches Zero speed/ Pull Cord /Belt Sway Contact Protection Make

37 Foundation Bolts

38 Painting

39 Quantity

40 Approx. Erection Weight of steel ( excl. belting, gear box & motor ) but including supporting structure


Data Sheet No 4

SCREW CONVEYOR (To be filled up for all the screw conveyors)


1 Conveyor No

2 Conveyor Type

3 Profile Centres

4 Orientation

5 Material handled

6 Bulk density

7 Particle size

8 Lump Size ( Max)

9 Capacity TPH


11 Tip Speed M/sec


13 Lift Mtrs

14 Power required at driving shaft KW



KW

17 Screw Diameter Pitch Material of Construction

MM




Data Sheet No 5

A C ELECTRIC MOTOR

Note: Use separate sheets for each motor


1 Driven Equipment Designation

2 No of Drive Motors

3 Make

4 Frame Size

5 Application Standard

6 Type of Motor

7 Service designation

8 Nominal applied voltage V

9 Nominal output KW

10 Rated speed RPM

11 Allowable voltage variation range V

12 Allowable frequency variation range Hz

13 Full load current of motor Amps

14 Efficiency at rated voltage at 100, 75, 50 % load %

15 Method of starting

16 Starting current at rated voltage ( multiple of full load current)

17 Cold start-up time to reach full rpm with/without load

Secs

18 Hot start-up time to reach full rpm with/without load

Secs

19 Locked rotor withstand time cold / hot secs

20 Degree of protection

21 Method of cooling

22 Insulation class

23 Ambient temperature

24 Temperature rise

25 Type of bearing

26 Type of terminal box

27 Type of coupling to driven equipment

28 Fault withstand current and time

29 Whether motor foundation plan enclosed


Data Sheet No 6 ELECTRICALS


1 Make

2 Standard

3 Rated voltage

4 Rating of bus bar at 45 Deg. c ambient in enclosure

5 Material of bus bar

6 Confirm short time rating of bus bar of 50 kA for 1 sec

7 Confirm that the minimum degree of protection of enclosure is IP 52

8 Overall dimensions

9 Thickness ( minimum 2 mm)

10 Make and type of load break isolator

11 Minimum rupture capacity of 46 kA HRC fuses

12 Make and type of contactors

13 Electrical endurance of contactor

14 Make and type of bimetal overload relays

15 Confirm provision of differential mechanism in bimetal relay for single phasing protection

16 Local Pushbutton station / power isolator

16.1 Make

Confirm provision of lockable P B in dust and oil tight enclosure

Confirm provision of power isolators provided near the motor

17 Cables Make/ Voltage grade

18 Confirm whether Cable tray is included or not


Data Sheet no 7

INSTRUMENTATION & CONTROL

S. No Description Unit

1

Instrument schedule listing range, make and type of all field mounted Instruments and Control drives

Yes / No

2

Details of the recommended protection and interlocking envisaged for the material handling system

Yes / No

3

Whether annunciation list is furnished?

Yes / No

4

Whether write-up for protection and inter-lock system is enclosed?

Yes / No

5

Whether I / O list is furnished?

Yes / No


Data Sheet No 8

SCHEDULE OF SPECIAL TOOLS AND TACKLES FOR MAINTENANCE

Note: The special tools and tackles for the routine & emergency maintenance

shall be listed here

S No Component Description Places where

the tool is to be used

Remarks


Data Sheet No 9

SCHDULE OF WEIGHT AND DIMENSIONS Note : The weights and overall dimensions of major packages shall be listed here.

SI. No Description of the items contained in the package

Overall Dimensions

of the Package in

metres

Gross Weight (in KG)

Package Shipping Ref. No.


Data Sheet No 10

SCHEDULE OF RECOMMENDED OPERATIONAL SPARES Note : The spares recommended should be adequate for 2 years of operation.

SI. No Name of the spare part

Catalogue /Drawing

No. identifying the Spares

Required Qty .of Spares

Qty .of the item in use.

Price


Data Sheet No 11

SCHDULE OF ERECTION TOOLS & TACKLES Note : The bidder shall give below the list of erection tools and tackles required to be used.

SI. No.

Particulars

Quantity

Remarks


Data Sheet No 12

SCHEDULE OF BIDDERS EXPERIENCE

SI.No. Name of the customer with address & contact person’s

Name

Fuel Details of Handing system

Year of Commencing Commercial operation


Data Sheet No 13

SCHEDULE OF REQUIREMENTS

Description with parameters

Equipment Quantity

Normal Maximum


Data Sheet No 14

SCHDULE OF ENGINEERING, MANUFACTURING, SHIPMENT, ERECTION AND COMMISSIONG

SI. NO. Description Weeks (Start to End)


Data Sheet No 15

SCHEDULE OF INSPECTION MANUFACTURER & BOUGHT OUT ITEMS

Note: Bidders are required to fill inspection procedures scheduled to be followed for the ASH handing system equipment including bought out items such as belts, instruments, rollers etc.

Sr. No.

Equipment Type of Test / Inspection

Stage of inspection

Owner to witness


Data Sheet No 16

SCHEDULE OF GUARANTEES

Handling Capacity

a) Submerged Ash Conveyor b) Other Ash Conveyors

Total Power consumption for a) Ash Handling Conveyors