Procurement, Fabrication, Supply, Erection and ...iitb.ac.in/sites/default/files/tenders/2017-06/TenderDocument... · Subsequently the entire system of the three projects is expected

Procurement, Fabrication, Supply, Erection and Commissioning of High Temperature Molten Salt Loop With Central Receiver, Molten Salt Storage,

Heat Exchangers and Allied Works

Tender Number – 201601548

Indian Institute of Technology Bombay

IIT Bombay Tender Number – 201601548

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Contents Section – 1: Invitation to the Bidders ....................................................................................................................... 1

Section – 2: Introduction ............................................................................................................................................... 6

2.1 Project Brief ............................................................................................................................................................ 7

2.2 Project Site Location ........................................................................................................................................... 8

2.3 Broad Scope of Supply and Services ............................................................................................................. 8

Section – 3: Prequalification criteria ........................................................................................................................ 9

Section – 4: Instruction to bidders ......................................................................................................................... 11

Section – 5: Scope of work and scope matrix ..................................................................................................... 21

5.1 Scope of work ...................................................................................................................................................... 22

5.2 Scope matrix ........................................................................................................................................................ 30

Section – 6: Technical bid ........................................................................................................................................... 38

6.1 Technical work specification ........................................................................................................................ 39

A. Technical specifications – Piping and mechanical work ............................................................ 39

B. Technical specification - Structural Steel work ............................................................................. 85

C. Technical specifications for instrumentation work. .................................................................... 96

D. Technical specification – Electrical work ....................................................................................... 111

E. Technical specifications of Molten Salt, selective coating and heat transfer compound

117

6.2 Technical Deviations: ..................................................................................................................................... 121

Section – 7: Price bid .................................................................................................................................................. 122

7.1 Price bid Table .................................................................................................................................................. 123

7.2 Payment schedule ........................................................................................................................................... 125

7.3 Cost drivers ........................................................................................................................................................ 127

A. Schedule of quantities - Structural steel work ............................................................................. 127

B. Schedule of quantities – Piping & Mechanical work .................................................................. 127

C. Schedule of quantities – Electrical work ........................................................................................ 136

D. Schedule of quantities – Instrumentation work .......................................................................... 142

E. Schedule of quantities – Molten Salt, selective coating and heat transfer compound . 162

F. Schedule of quantities – Spares .......................................................................................................... 163

Section – 8: Annexures .............................................................................................................................................. 170

Annexure 1: Drawing list ..................................................................................................................................... 171

Annexure 2: Document List ................................................................................................................................ 173

Annexure 3: Deviation Statement Form ........................................................................................................ 177

Annexure 4: Integrity pact .................................................................................................................................. 178


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Annexure 5: Format for earnest money deposit/bid bond ................................................................... 188

Annexure 6: Format for performance bank guarantee ........................................................................... 190

Annexure 7: Format for deviations/exclusions schedule ...................................................................... 192

Annexure 8: Previous supply order format ................................................................................................. 194

Annexure 9: Checklist ........................................................................................................................................... 195


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Section – 1: Invitation to the Bidders


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Tender Details

Tender Number: 201601548

Tender Type: Open

No. of Covers: 2

Tender Date: 26.05.2017

Form of Contract: Supply

Payment Instruments

Payment Mode : Offline

Instrument Type:

As per Tender Document

Covers Information

Cover. No Cover Type Description Document

Type

1 Technical Tender Document,

Pre-qualification responses

Tender Fee, EMD,

Integrity Pact and

Technical Specification

Site visit

/Inspection/Examination

Certificate

2 Commercial Commercial Bid / Price Bid

Tender should be submitted on the schedule to tender and returned with your

covering letter in the enclosed form duly signed. Tender should be sent in the

sealed cover super scribed with Tender Number and Due Date.

Two Bid System:

The two bid system will be followed for this tender. In this system bidder must submit

their offer in separate sealed envelopes as – Technical Bid and Commercial Bid.

Separate technical bid and commercial bid envelopes should be clearly marked as

"Envelope No. 1 – Technical Bid" and "Envelope No. 2 - Commercial Bid". Both these

sealed covers are to be put in a bigger cover which should also be sealed and duly


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superscribed with our Tender No. & Due Date and to be submitted to the concern

department/section mentioned in tender document.

Note: The technical offer should not contain any price information. If the price

quoted is submitted in technical bid the tender will be rejected at the sole

discretion of IIT Bombay.

Initially Technical Bids will be opened and evaluated by the purchase committee.

Commercial bids of only Technically qualified bidders will be opened later.

Contract/ Purchase Order will be awarded to the lowest bidder (L1) among them.

Tender Fee Details

Tender Fee (INR)

500/-

Payable to: The Registrar, IIT Bombay

Payable at: Mumbai

Earnest Money Deposit Details

EMD Fee (INR):

7,40,000/-

In favour of: The Registrar, IIT Bombay

EMD Fee Type: Fixed Payable at: Mumbai

Item Details /Item

Name

Item Description

Procurement, Fabrication, Supply, Erection and Commissioning of High Temperature Molten Salt Loop with Central Receiver, Molten Salt Storage, Heat Exchangers and Allied Works

This Tender document is for ‘Molten Salt Loop with Central Receiver, Salt Storage and Heat Exchanger’ which includes development of central receiver and thermocline storage system. This project will be implemented at NTPC NETRA (Owner) at Greater NOIDA, Uttar Pradesh for testing and performance evaluation. Basic and detailed engineering of the Solar Thermal Energy Collector and Thermal Energy Storage has been carried out by IITB (Client) and its Detailed Engineering Consultant (DEC). The bidder is expected to carry out the required procurement, fabrication, supply, erection and commissioning of high temperature molten salt loop with central receiver, molten salt storage, heat exchangers and allied works. This has to be done as per detailed engineering documents, drawings and Bill of Materials (BOM).

Pre-Qualification: As Per Tender

Document

Bid Validity

(Days)

180


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Period of Work/

Delivery Period

32 weeks

Product Sub

Category

Product Category Others Pre Bid Meeting

Date & Time

19th June, 2017,

3.30 PM

Contract Type Tender Pre Bid Meeting

Address

Materials

Management Division,

IIT Bombay

Location

Pincode

IIT Bombay

Campus

400076

Critical Dates

Bid Submission End

Date and Time

05th July, 2017

1.00 PM

Bid Opening Date

and Time

05th July, 2017

3.30 PM

Place of Submission Materials

Management

Division, IIT

Bombay

Bid opening

place

Materials

Management Division,

IIT Bombay

Other Condition: Suppliers should provide previous purchase order details in the

technical bid along with the necessary documents as per the requirement of

prequalification criteria.

Warranty : Warranty as per mentioned in technical specifications

Technical Clarification

Name

Department

Email

Contact No.

Prof. Shireesh B. Kedare

Department of Energy Science &

Engineering.

[email protected]

022-25767835

Tender Inviting Authority

Name

Joint Registrar


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Address

Date: -------------

Materials Management Division, IIT

Bombay,

Powai, Mumbai 400076

Signing Authority:

Joint Registrar (MM)


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Section – 2: Introduction


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2.1 Project Brief This project is targeted towards development and setup of indigenous 3.5 MWe x 24 hour/day

Solar Thermal Power Plant. The research and development component of the targeted initiative

was divided into several projects over the last 2 to 3 years. Each of these projects were formulated

in tune with the overall perspective and handled independent of each other involving various

faculty members across the departments at IIT Bombay.

Setting up of the above mentioned indigenous Solar Thermal Power Plant would now require

development and testing of prototypes of various Concentrated Solar Power (CSP) components

conceptualized till now and experimented with. This prototype development and testing is being

taken up as three R&D projects mentioned below;

1. Molten salt loop with central receiver, salt storage and heat exchanger.

2. Heliostat reflector development with tracking and flux measurement.

3. Linear Fresnel Reflector (LFR) based collector development with receiver and steam

storage.

These R&D projects are being taken up in parallel.

This tender document pertains to ‘Molten Salt Loop with Central Receiver, Salt Storage and Heat

Exchanger’ (listed at 1 above) is targeted towards development and set up of a molten salt loop

to collect solar thermal energy from central receiver and store it in a thermocline thermal storage

tank. The solar thermal energy is directed onto the central receiver by the heliostats which are

part of another project (listed at 2 above). The project will run concurrently with heliostat project

and Linear Fresnel Reflector project at the same site (listed at 3 above). These three projects will

be integrated at the end of successful commissioning and testing of each project independently.

Subsequently the entire system of the three projects is expected to deliver turbine quality steam.

This project will be implemented at NTPC NETRA at Greater Noida, Uttar Pradesh for testing and

performance evaluation.

This molten salt loop project consists of a "hot" salt loop to pick up solar thermal energy at

receiver and store in a thermocline tank. Stored energy is then used to generate steam in "cold"

salt loop. Molten salt loops operate between 290 ⁰C and 565 ⁰C. So all the equipment and piping

are of special grades of stainless steel. Fabrication of all the equipment and piping will therefore

require high degree of precision in manufacturing and skills and knowledge associated with

superior materials of construction and sophisticated manufacturing processes.

General classification of the scope:

• Construction of central receiver, thermocline storage tank and salt piping

• Heat exchangers, steam piping, structures, utilities

• Electrical, instrumentation and controls


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2.2 Project Site Location

Address : NETRA NTPC Limited

E-3, Ecotech II, Udyog Vihar, Greater Noida, Uttar Pradesh 201306

Location : 28°30’10”N 77°27’57”E

Climate :

Summer : In summer i.e. from March to June the weather remains hot and

temperature ranges from maximum of 45°C (i.e. 113°F) to minimum

of 23°C (73°F).

Monsoon : Monsoon season prevails during mid-June to mid-September with an

average rainfall of 93.2 cm (36.7 inches), but sometimes frequent

heavy rain causes flood.

Winter : Temperatures fall substantially down to as low as 3 to 4º C at the peak

of winter. Greater Noida experiences problems of fog and smog.

Bidders are request to visit the site location and access the conditions. Bidders are required to

submit an undertaking in support of the same.

2.3 Broad Scope of Supply and Services The broad scope of supply and services are following:

• Supply of items listed in BOQ as per the indicated specifications

• Fabrication including QA and conducting all shop acceptance tests as required

• Packing, loading, transportation and unloading of material at site including all clearances

from concerned authorities

• Receipt, storage and preservation of equipment at the site

• Mechanical, structural, process equipment/vessels, electrical, controls and

instrumentation erection including conducting all field tests in coordination with the

technical consultant for detailed engineering.

• Supply of skilled manpower to carry out specific tasks as explained in the technical

information section.

• Compliance of all statutory requirements

It is not the intent to specify herein all aspects of engineering and construction. The Bidder shall

be responsible for providing all materials, equipment and services, specified or otherwise (unless

specifically excluded) which are required to fulfil the intent of ensuring operability and the

reliability of the complete system covered under this specification. Sub-vendors for all bought out

and out sourced items shall be finalized in consultation with IITB and DEC.


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Section – 3: Prequalification criteria Pre-qualification criteria and process along with details and format of data to be submitted for

selection:

Two-bid system will be followed where-in the technical bid will be opened first and evaluated.

Bidders whose technical criteria are acceptable as per the selection criteria (elaborated below),

will be considered for opening of the respective price bids. All bids qualifying the prequalification

criteria will be stand eligible for opening of commercial bid. Bidder with lowest commercial bid

will be awarded the contract.

The technical bid provided by the bidder should contain the details outlined below:

1. Technical capability: The bidder should furnish the details of in-house or outsourced

resources like tools, machinery, skills related to fabrication of structural and mechanical

systems and manpower involved in the project.

2. Financial capability:

a. The bidder should have successfully executed at-least one multidisciplinary

procurement, construction and commissioning project of value not less than INR

1,00,00,000/- during last five years ending 31st March, 2017.

b. Bidder shall submit financial statements such as balance sheets and P&L

statements of the last 3 financial years.

3. Qualification Requirement:

a. The bidder shall have successfully completed minimum three similar work of

procurement, construction and commissioning (the term “similar work” implies

mechanical works like high temperature and pressure piping and equipment

erection, high pressure IBR steam generators, structural steel works, mechanical,

electrical and instrumentation controls involving PLC, SCADA, process control,

control valves, packaged instrument air system, construction of control room etc.)

b. Bidders shall have executed minimum 3 projects involving procurement, supply,

installation and commissioning of PLC systems with SCADA

Detailed format for the data to be submitted for the qualification requirement is given under

different headings below.

Bidder shall submit information sought below of successful completion of the works meeting the

criteria stated above and other works executed in the last five years. A purchase committee may

also choose to get the feedback from bidder’s client to check the fulfilment. Following information

/ documents shall be provided of the works executed.

1. Name of the client with corporate address, site address

2. Name of contact person(s) and phone/email of the contact person

3. Description and scope of job (mechanical, electrical, instrumentation controls and civil

works, manufacturing of high pressure IBR equipment, heat exchangers, procurement,

supply, and installation and commissioning of PLC systems with SCADA)

4. Order value in Indian Rupees

5. Year of start and job completion

6. Documentary evidence provided, like copy of POs, reports, appreciation letters, etc.


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The decision of the purchase committee on the eligibility of the bidder shall be final and

binding on the bidder.


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Section – 4: Instruction to bidders


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1. Bidder must be a qualified entity (firm/company).

2. Bidder shall submit the list of jobs intended to be sub-contracted along with the

details of sub-bidders. The bidder in the event of his tender being accepted, shall

not assign or delegate the contract or any part thereof, without the prior approval

of IITB.

3. Bidder shall submit financial statements such as Balance Sheets and P&L

statements of the last 3 financial years.

(Note: The word ‘Bidder’ used in the document is as per the definition stated in point 1 above)

4. The site will be offered on AS IS WHERE IS for the execution of this job and it will

be the sole responsibility of the bidder to ensure that they abide by the various

rules and regulations, bye-laws and other statutory requirements, etc., imposed

by the Government / semi-Government / Owner and / or other local authorities

governing execution of this job.

5. Before submitting the bid, the bidder is advised to visit, inspect and examine the

site and its surroundings. The bidder has to submit in writing that he has

indeed visited, inspected and examined the site and its surrounding. The

bidder has to look at access to the site and evaluate the site conditions of operation

at his own cost. The bidder before tendering should clearly understand the scope

of work and must satisfy himself with the required quantities of material,

accommodation as may be required and no claim subsequently on account of

ignorance shall be entertained. No consequent extra claims on any

misunderstanding or otherwise shall be allowed by the IIT Bombay.

(Site address for visit:

NTPC Energy Technology Research Alliance (NETRA)

Plot No. 3, block E, Ecotech-II, Udhyog Vihar,

Greater Noida, Gautam Budh Nagar, (Uttar Pradesh) 201 306

INDIA

Bidder has to provide specific date for visit at site to IITB project office. Office

will convey contact of local person & other arrangement as required.

Bidders are requested to carefully examine and understand the specifications and


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seek clarifications, if required, to ensure that they have understood the

specifications. Bidder’s offer should not carry any sections like clarifications,

interpretations and/or assumptions. However, if the bidder feels that, in his

opinion, certain features brought out in his offer are superior to what has been

specified, these may be highlighted separately.

6. The bid shall be evaluated as complete package and not on the basis of individual

items.

7. The quantities of the various items mentioned in the schedule are approximate

and may vary up to any extent or be deleted altogether. The quoted rates of each

item shall remain firm.

8. The bidder will have to make his own arrangement to transport the required

materials outside and inside the working place and leaving the premises in a neat

and tidy condition after the completion of the job to the satisfaction of the IITB

Engineer, the Detailed Engineering Consultant (DEC) and NTPC-NETRA.

9. The bidder will have to arrange for site office and temporary shed on his own

expense for safe keeping of materials and should provide necessary security

arrangements for safe guarding the materials. IITB will not be responsible for any

claims in this regard.

10. As far as possible, the bidders should endeavour not to stipulate any counter terms

/ conditions or modifications of tender clauses and should quote strictly as per

tender conditions. IITB reserves the right to reject offers not meeting its technical

requirements and commercial conditions.

11. The bidder shall get prior approval from DEC and IITB for release of purchase

order to sub-vendors and bidders.

12. The bidder shall furnish to the DEC and IITB the duplicate copies of all purcha se

orders placed for this project and the test reports received from the vendor to the

DEC’s check and information.

13. Bidder has to take labour license from the licensing authority of Greater Noida.

Bidder should follow all relevant safety norms.

14. Warranty shall be 12 months from the date of commissioning / 18 months from the date

of supply whichever is later, except where warranty is specifically stated otherwise than

above and ceases earlier than the general warranty stated above.

15. The bidder shall arrange at his own expense for concerned Engineers to attend


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pre-bid meetings, technical discussions and project progress review scheduled by

IITB. The venue for the meetings will be at IITB campus or at the project site.

16. All material constructed or otherwise, shall be considered as the property of

bidder till the handover of the project.

Preparation and Submission of offers:

17. The Quotation MUST BE ENCLOSED IN A SEALED COVER superscribing Tender

number / due date & should reach the undersigned on or before due date

mentioned in the tender notice. If the quotation cover is not sealed, it will be

rejected.

18. Tender should be dropped in the tender box kept in the office of concerned

Department / Section or to Indenter. No tender is to be handed over to our staff

personally unless otherwise specified. All communications are to be addressed to

the undersigned only. In case due date happens to be holiday the tender will be

accepted and opened on the next working day.

19. The bid can be submitted in person or through post/ courier (IITB shall not be

responsible for any postal delays or any other reason for not submitting the bid in

the specified time and resulting in disqualification / rejection of any bid) so as to

reach on or before the due date and time.

20. The leaflets catalogue, etc. should be sent invariably so that a proper evaluation of

the equipment offered is possible.

Cost of Bidding:

21. The Bidder shall bear all costs associated with the preparation and submission of

its Bid and the Purchaser shall not be responsible or liable for those costs

regardless of the conduct or outcome of the bidding process.

Validity of the Bid:

22. 180 Days from the last date of submission of bid.

Amendment of Bidding Documents:


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23. At any time prior to the deadline for submission of bids, IITB may, for any reason,

whether on its own initiative or in response to the clarification request by a

prospective BIDDER may modify the bid document.

24. All prospective BIDDERs who have downloaded the bidding document should visit

IITB, website for amendments / modifications which will be binding on them.

Deadline for Submission of Bids:

25. Bids must be received by IITB before the due date and time at the address

specified in the tender document. In the event of the specified date for the

submission of bids being declared as a holiday for IITB, the bid closing deadline

will stand extended to the next working day up to the same time.

Late Bids:

26. IIT Bombay will not be responsible:

i) For delayed / late quotations submitted / sent by post / courier etc.

ii) For submission / delivery of quotations at wrong places other than the

mentioned in the tender.

iii) Fax / Email / Telegraphic / Telex tenders will not be considered.

iv) Any bid inadvertently received by IIT Bombay after the deadline i.e. due

date & time for submission of bids, will not be accepted and returned

unopened to the BIDDER.

Confidentiality:

27. Information relating to the evaluation of Bids, and recommendation of Contract

award, shall not be disclosed to Bidders or any other persons not officially

concerned with such process until information on Contract award is

communicated to all Bidders.

28. Any attempt by a Bidder to influence the Purchaser in the evaluation of the Bids

or Contract award decisions may result in the rejection of its Bid.


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29. Notwithstanding, from the time of Bid opening to the time of Contract award, if

any Bidder wishes to contact the Purchaser on any matter related to the bidding

process, it shall do so in writing.

Deviation, Reservations and Omissions:

30. During the evaluation of Bids, the following definitions apply:

(a) “Deviation” is a departure from the requirements specified in the Bidding Documents.

(b) “Reservation” is the setting of limiting conditions or withholding from complete acceptance of the requirements specified in the Bidding Documents. (c) “Omission” is the failure to submit part or all of the information or documentation required in the Bidding Documents.

Correction of Arithmetical Errors:

31. Provided that the Bid is substantially responsive, the Purchaser shall correct

arithmetical errors on the following basis:

(a) if there is a discrepancy between the unit price and the line item total that is

obtained by multiplying the unit price by the quantity, the unit price shall prevail

and the line item total shall be corrected, unless in the opinion of the Purchaser

there is an obvious misplacement of the decimal point in the unit price, in which

case the line item total as quoted shall govern and the unit price shall be corrected.

(b) if there is an error in a total corresponding to the addition or subtraction of

subtotals, the subtotals shall prevail and the total shall be corrected.

(c) if there is a discrepancy between words and figures, the amount in words shall

prevail, unless the amount expressed in words is related to an arithmetic error, in

which case the amount in figures shall prevail subject to (a) and (b) above.


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Bidders shall be requested to accept correction of arithmetical errors. Failure t0

accept the correction in accordance with the same, shall result in the rejection of

the Bid.

Evaluation of Bid:

32. IITB evaluate technical and commercial acceptable offers on landed net Price

basis.

33. In case any BIDDER is silent on any clauses mentioned in this tender documents,

IITB shall construe that the BIDDER had accepted the clauses as per the invitation

to tender no further claim will be entertained.

34. No revision in the terms and conditions quoted in the offer will be entertained

after the last date and time fixed for receipt of tenders.

Corrupt & Fraudulent Practices:

35. IITB requires that bidders, suppliers, contractors and consultants, if any, observe

the highest standard of ethics during the procurement and execution of such

contracts. In pursuit of this policy,

a. The terms set forth below are defined as follows: i. “Corrupt practice” means the offering, giving, receiving, or soliciting,

directly or in directly, of anything of value to influence the action of a

public official in the procurement process or in contract execution.

ii. “Fraudulent practice” means a misrepresentation or omission of facts in

order to influence a procurement process or the execution of a contract.

iii. “Collusive practice” means a scheme or arrangement between two or

more bidders, designed to establish bid prices at artificial, non-

competitive levels.


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iv. “Coercive practice” means harming or threatening to harm, directly or

indirectly, persons or their property to influence their participation in the

procurement process or affect the execution of a contract.

b. IITB will reject a proposal for award if it determines that the Bidder

recommended for award has, directly or through an agent, engaged in corrupt,

fraudulent, collusive or coercive practices in competing for the Contract in

question.

Communication for Nonparticipation of Tenders:

36. For registered vendors with IITB, in case you choose not to participate in the

tender a regret letter by way of fax/letter/email may be submitted before the due

date duly superscribing “Regret” and tender No. If no communication received by

the due date and time, it shall be inferred that you are not interested in

participation and your name is liable to be removed from the vendor's list.

Cancellation of Tender:

37. Notwithstanding anything specified in this tender document, Purchaser / IITB in

his sole discretion, unconditionally and without having to assigned any reasons,

reserves the rights:

a. To accept OR reject lowest tender or any other tender or all the tenders.

b. To accept any tender in full or in part.

c. To reject the tender offer not confirming to the tender’s terms.

38. To give purchase preference to Public Sector undertakings when applicable as per

Govt. Policy/ Guidelines.

39. Offer which deviates from the vital conditions (as illustrates below) of the tender

shall be rejected:

a. Nonsubmission of complete offers.

b. Receipt of offers after due date and time and or by email / fax (unless

specified Otherwise).

c. Receipt of offers in open conditions.


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Price Bid:

40. Bid Prices MUST BE SUBMITTED IN ENCLOSED PRICE BID FORM ONLY.

41. If the price is not quoted in Price Bid Form provided in tender document

then, IITB will reject bid. If supplier wish to give pricing details may be

attached in separate sheet.

42. Any new taxes and duties liable on the subject contract due to change in legislation

during the contract period shall be reimbursed subject to the applicability of the

said act to the satisfaction of the purchaser and the production of documentary

evidence after availing of statutory concession, benefits etc.

43. The supplier shall pay and bear all other liabilities, taxes and duties not specifically

agreed by the Purchaser in the contract.

44. VAT/Other Govt. Taxes: Excise Duty (ED), other taxes, levies, like Service Tax (ST),

Education Cess, etc., are to be indicated separately. BIDDER should mention

Central and State Sales Tax/VAT Registration, PAN Number are to be necessarily

indicated in the offer.

45. IITB are not authorised to issue any Sales Tax forms like form “C” & “D”.

Legal Matter:

46. All Domestic and International disputes are subject to Mumbai Jurisdiction Only.

Transfer and Subletting:

47. The seller shall not sublet, transfer, assign or otherwise part with the acceptance

to the tender or any part thereof, either directly or indirectly, without the prior

written permission of the Purchaser.

Force majeure:


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48. Force Majeure will be accepted on adequate proof thereof.

Penalty/ Liquidated Damages:

49. Timely delivery is essence of the contract and hence if any consignment be

delayed, liquidated damages at the rate 0.5% of the price of the delayed

consignment, for each week or part whereof shall be levied and recovered subject

to maximum of 5% of total purchase order value.

50. IITB reserves the right to cancel the order in case the delay is more than 10 weeks.

Penalties if any will be recovered by forfeiting PBG.

Any deviation from the clauses of the tender, technical and financial, should be compiled

in Annexure – 3 and 7. The deviations will be discussed during the pre-bid meeting and

the outcome of the meeting will be taken as final.


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Section – 5: Scope of work and scope matrix


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5.1 Scope of work

SCOPE OF SUPPLY, FABRICATION, ERECTION AND COMMISSIONING:

Overall layout as shown in the attached drawing C530/ME/GA/A1/309 will be followed as a

broad guideline for the available space for molten salt loop location.

In general, the scope includes detailed engineering of some items such as PLC and electrical

panels, IBR specific design of heat exchangers (if any in addition to that provided by the DEC),

procurement, fabrication, transport, insurance, delivery, loading, unloading, storage, security,

statutory compliances including IBR, erection, commissioning of following components:

1. Central receiver assembly with insulation and selective coating

2. Thermocline storage tank

3. Molten salt to steam heat exchangers consisting of water preheater, evaporator

and steam superheater.

4. Molten salt circulation pumps for "charging" and "discharging" circuits.

5. Feed water tank

6. Feed water pumps

7. Electrical heaters for salt melting, system start up and operations.

8. Piping, valves and fittings on molten salt lines, steam lines and feed water line.

9. Silencers for steam vent valves

10. Electrical system for drive motors and heaters.

11. Set of instruments on salt lines, water and steam lines.

12. SCADA system and PLC based control panel

13. Electrical heating of receiver for initial loop and temperature distribution testing

by IITB.

14. Steam trace tubing and heat transfer compound

15. Utilities

i. Feed water dosing system

ii. Instrument air system and blanketing

iii. Cooling water system for receiver rim cooling, dummy receiver cooling,

sample cooler, camera etc.

iv. Motorised hoists

16. Salt

Detailed specifications etc. are presented in Technical work specifications and data sheets

attached to this tender document following the brief below.

All codes, standards referred to in this and related documents imply latest revision of the code /

standard.

A. Heliostat receiver assembly with insulation

The receiver assembly consists of SS tube coils placed within the receiver cavity as per

drawings and details. The stainless steel tube coils shall be of SS 316 Ti grade suitable for 600 ⁰C

design temperature and 5 bar pressure with cyclic temperature variations from ambient

temperature to design temperature in a daily operation. Inlet outlet headers are also of equivalent

stainless steel material.


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The tube coils shall be within an insulated front-open housing of carbons steel plates and inner

SS lining with insulation sandwiched in between supported on structural members.

The receiver tube coils shall be coated with a selective coating having high absorptivity in the

solar spectrum and low emissivity in the thermal spectrum.

The receiver assembly shall be provided with retractable heaters designed for daily pre-heating

of the receiver tube coils for commissioning the plant.

The receiver assembly shall have heavy duty electrical heaters which shall simulate the design

heat capacity of the receiver cavity for initial testing of the receiver and precommissioning trials

of the plant. These heaters shall subsequently be removed and discarded and the entry points

sealed with insulation plugs as per design and details before commissioning the plant with

reflected radiation from the heliostats (R&D project 2 – refer project brief).

B. Thermocline storage tank

Thermocline tank has a function of thermal storage. Hot molten salt coming from the receiver

adds heat into the storage tank. A temperature gradient gets established along the tank height

due to density difference. Thus cold salt is at the bottom of the vessel and hot salt is on top.

In the charging circuit cold molten salt from the bottom of the tank is pumped to the receiver and

hot salt from the receiver is fed from the top through a distributor.

In the discharging circuit, hot molten salt from top layer of the tank is pumped to the heat

exchanger and cold salt returning enters the bottom through the distributor.

C. IBR approval

Feed-water and steam generating system from outlet feed water pump to isolating valve at super

heater outlet including the steam tracing system comes under the purview of IBR. It is the bidder’s

responsibility to understand the project scheme, identify the items of supply and work therein

which require IBR approval irrespective of whether requirement of IBR approval is mentioned at

the specification of the respective item / work or not. It is the bidder’s responsibility to design (if

any required in addition to the design details and calculation provided by DEC) and make relevant

documents, design calculations and drawings as per IBR formats, liaise with IBR, arrange visits to

workshops and site, obtain IBR certificates from suppliers for supplies, obtain IBR approval for

manufactured items, obtain approval IBR for completed installation etc. and finally arrange for

provisional order (PO) from IBR authorities. It is the bidder’s responsibility to conduct the work

at site in full compliance with the IBR requirements (IBR approved welder, stage-wise inspections

etc.). All expenses including incidental expenses shall be to bidder’s account and shall be deemed

included in the overall price of the contract. For pre-commissioning of the project, the bidder shall

submit a complete dossier of all IBR documents including copies of application forms, letters of

correspondences, IBR certificates of items such as pipes, pipe fittings, valves, IBR certificates of

fabricated items such as heat exchangers in the state of manufacture, IBR visit reports and

instructions, if any, copies of payment receipts, Provisional IBR Certificate original in requisite

forms duly approved and countersigned by IBR authority / local authority empowered by Central

Boiler Board of India with required arrangement for display of the same. Submission of the final

IBR certificate shall be a pre-requisite for payment at the appropriate stage of payment.


24 | P a g e

D. Molten salt to steam heat exchanger

The purpose of the heat exchanger is to transfer heat stored in the thermocline tank in the form

of molten salt to water and convert it to superheated steam. The heat exchanger is in three

separate units – water preheater, evaporator or boiler and superheater. All the heat exchangers

are shell type with molten salt in helical tube coils.

All heat exchangers shall be supplied with passivation treatment to all water / steam surfaces.

1. Preheater:

The preheater shall be a vertical cylindrical vessel with a helical tube coil for flow of hot salt. The

vessel is considered as a standard pipe with the ends being suitable cap sections. However, the

bidder may make his own design using suitable plates duly formed to the shape and dimensions

given in the drawing and details.

2. Evaporator section

The evaporator shall be a vertical cylindrical vessel with a helical tube coil for flow of hot salt. The

vessel is considered as a standard pipe with the ends being suitable cap sections. However, the

bidder may make his own design using suitable plates duly formed as per the requirements of

ASME BPVC to the shape and dimensions given in the drawing and details.

The evaporator to have provisions for all the ancillary controls, instrumentation and safety as

prerequisites to a standard shell type boiler under the provisions of the Indian Boiler Regulations.

3. Superheater section

The superheater shall be a vertical cylindrical vessel with a helical tube coil for flow of hot salt.

The vessel is considered as a standard pipe with the ends being suitable cap sections. However,

the bidder may make his own design using suitable plates duly formed to the shape and

dimensions given in the drawing and details.

Design Codes and Procedure: The heat exchanger being a steam generator, is under Indian Boiler

Regulation. So Design Code - IBR 1950 and latest amendments thereof.

E. Molten salt circulation pumps

There are two salt circuits viz.

1. the charging circuit (charging the thermocline tank with hot molten salt) and

2. the discharging circuit (discharging the stored thermal energy of the molten salt to

superheated steam generation).

Each above circuit shall be operated by its molten salt circulation pump. Both pumps shall be

vertical centrifugal pumps, top mounted on the thermocline tank. The pumps shall be designed

for the extreme duty conditions. The pumps may be line shaft or cantilever type. Piping drawings

and details provided in the tender are based on cantilever design.

The pumps shall be designed, procured, inspected, tested at vendor’s works, delivered to site,

installed and commissioned by the vendor based on the broad specifications given here and the

data sheet issued. The scope of supplies shall include pump with motor, base frame, coupling,

fasteners, safety guards, inlet and outlet flanges, cooling system, controls, safety devices, etc. Any


25 | P a g e

other item required for the safe operations of the pump as per the process conditions is deemed

included in the scope unless specifically excluded.

F. Boiler feed water tank

Capacity - 2000 L(nominal)

Type - Cylindrical vertical, insulated

Material - Carbon steel

Accessories - Steam preheating coil to heat make-up water from 30 °C to 80 °C

Chemical dosing provision

Manhole, drain, vent etc.

Please refer - C530/ME/GA/A1/314 – G.A. of Feed Water Tank.

G. Boiler feed water pumps

The pumps shall be selected, procured, inspected, tested at vendor’s works, delivered to site,

installed and commissioned by the vendor based on the broad specifications given here and the

data sheet issued. The scope of supplies shall include pump with motor, base frame, coupling,

gear box / chain drive, fasteners, foundation bolts, safety guards, pressure safety valve, pulsation

damper, inlet and outlet non-return valves, lubricating system, lubricants, controls, safety

devices, weather hood etc. Any other item required for the safe operations of the pump as per the

process conditions is deemed included in the scope unless specifically excluded. The motor shall

be operated with VFD.

H. DM water transfer pump and cooling water circulation pump

The pumps shall be selected, procured, inspected, tested at vendor’s works, delivered to site,

installed and commissioned by the vendor based on the broad specifications given here. The

scope of supplies shall include pump with motor, base frame, coupling, foundation bolts, belt

drive with safety guards, etc. Any other item required for the safe operations of the pump as per

the process conditions is deemed included in the scope unless specifically excluded.

I. Electrical heaters

Electrical heaters are required for start-up as well as operations of the plant. The heaters and

controls, safety (of element and assembly etc.) thereof shall be procured, inspected, tested at

vendor’s works, delivered to site, installed and commissioned by the bidder based on the

specifications given herein. 320 kW electrical heaters shall be dismantled and removed by the

bidder along with their panel after successful testing of the central receiver.

J. Piping, valves and fittings on molten salt lines, steam lines and feed water line.

Piping of following duties and types are considered in the project.

Sr. no. Duty General specification 1 Raw water UPVC, Class 3, IS 4985 / equi. 3 D. M. water CPVC, Sch 40, ASTM F441/441M 4 Cooling water IS 1239 Cl. C 5 Boiler feed water with LP dosing including

delivery to LFR A 106 Gr. B, sch 40


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Sr. no. Duty General specification 6 Saturated steam including import saturated

steam A 106 Gr. B, sch 40

7 Superheated steam including import superheated steam

A 335 Gr. P91

8 Boiler blowdown A 106 Gr. B, sch 40 9 Boiler water sampling A 106 Gr. B, sch 40 10 Molten salt – charging circuit A312 TP321, sch 40 11 Molten salt – discharging circuit A312 TP 321, sch 40 12 LP dosing A 106 Gr. B, sch 40 13 HP dosing A 106 Gr. B, sch 40 14 Steam tracing of salt piping to and from receiver A213, SS 304 tube, 8mm OD,

1mm thk. 15 Fittings Unless specified otherwise

elsewhere in the tender: For MS and SS, Forged, 3000# or higher, of MOC similar to respective pipe specification for fittings < 40 mm NB nominal size and seamless sch 40 for > 40 mm NB. Flanges as per ASME B16.5. Gaskets for molten salt circuit and steam shall be spiral metal wound ring gaskets, type CR, 3.2 mm thick – spiral metal SS 321, filler graphite for steam, ceramic for molten salt, outer ring – MS as per ASME B16.2. All other gaskets shall be ring gasket, non-asbestos, 3mm thk. Fasteners – Bolts as per ASTM A193 Gr. B7, Nuts as per ASTM A194 Gr. 2H for salt and steam piping. As per IS 1367 for rest of the piping. Passivation treatment shall be carried out for the steam circuit.

Scope includes procurement, fabrication, flushing, testing and commissioning of the piping with

all fittings, gaskets, fasteners at flange joints etc., supports, etc. complete. All fabrication

procedures as per relevant codes and material requirement to be strictly followed.

Steam piping including steam tracing tubes is under IBR. Scope includes all activities by bidder

for complete compliance with IBR requirement from obtaining IBR approvals for plan,

procurement and approval of IBR materials, etc. to obtaining IBR approval for final completed

installation.

Please refer C530/PI/Sch/A4/021 - Piping schedule &

C530-PI-DS-A4-007-R0- Insulation Schedule


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K. Silencer at vent

Superheated steam generated from the LFR system will be connected at the discharge of the

superheater of the molten salt project. The common superheated steam discharge line will then

be provided to discharge the superheated steam to a high point of the tower through a silencer.

Silencer is being provided for noise attenuation to comply with CPCB / UP PCB norms. Design,

fabrication, erection, commissioning of the silencer in compliance with all related statutory

requirements is included in the scope of the bidder.

L. Electrical system for drive motors and heaters.

Please refer technical specifications – Electrical heaters, electrical for details.

M. Set of instruments on salt lines, water and steam lines.

Please refer technical specifications – instrumentation for details

N. SCADA system and PLC based control panel

Please refer technical specifications – instrumentation for details

O. Boiler feed water dosing system

LP dosing shall be provided for the feed water tank. HP dosing shall be provided to the evaporator.

The bidder’s scope includes design, manufacture, procure, testing and supply, erection and

commissioning of skid mounted dosing systems (LP dosing and HP dosing).

The Chemical Dosing Systems shall be used to store, mix and dose metered quantity of chemicals

for boiler feed water treatment (LP dosing) and for evaporator (HP dosing).

The systems shall be duly mounted on common skids requiring only hook up connection to make

the system complete and operable. Each dosing system will have its own control panel for all

operations and controls of the unit.

P. Instrument air plant.

Instrument air plant shall be provided for following main uses:

1. Supply and maintenance of cover gas in thermocline tank at 150 – 200 mmWC

2. Supply of instrument air for operation of several on/off and control valves.

3. Supply of instrument air for bubbler level instrument for thermocline tank.

4. Supply of flushing air for draining of receiver and molten salt piping.

The instrument air compressor, integrated air dryer and air receiver shall be provided with

acoustic enclosure to comply with the noise emission norms. The entire package shall be

controlled by an electronic control panel capable of remote operation from PLC through Modbus.

Q. Motorised hoists.

Electrical motorised hoists with trolleys shall be provided to enable maintenance activities

related to receiver, pumps, heat exchangers and cleaning mechanism.

The scope of work includes procurement, packing, transportation and installation,

commissioning, load testing of the electric hoists and training at site.


28 | P a g e

R. Salt

Salt shall be premixed mixture of sodium and potassium nitrates as per specification provided in

this tender. The salt shall be supplied in sealed bags duly weather proof and stored in a suitable

covered temporary stores at site to be constructed at site by the bidder. On readiness of the

equipment, the salt packs shall be handled with all due care by the bidder. The bidder shall create

a temporary arrangement at the thermocline tank to cut open the pack, break the agglomerated

salt into manageable lumps, if necessary and lower the same into the tank. The bidder shall

exercise all due caution to ensure that there is no contamination of the salt during these activities.

The undamaged surplus unused salt bags shall be handed over to stores on commissioning of the

project. Damaged bags shall not be accepted and shall not be considered for payment as

contamination of salt is not acceptable.

S. Quality Assurance and Control

1. Quality Assurance Plan (QAP) shall mean the procedures as well as test methods and

facilities by Bidder in order to assure that the all the equipment and items of work are of

the highest possible quality i.e. either equal to or better than the requirement specified.

2. Quality Control (QC), shall mean all the tests, measurement, checks and calibration which

are to be carried out in Bidder’s shop in order to compare the actual characteristics of the

equipment/unit/system with the specified ones, along with furnishing of the relevant

documentation (certificates/records) containing the data or result of these activities. The

bidders are required to furnish a detailed & comprehensive list of the inspection facilities

available at their shop along with the bids.

3. Bidder shall submit a comprehensive document of QAP /QC measures contemplated by

him for implementation with regard to this specification for approval of IITB/ Inspection

Agency. It is contractual obligation of the Bidder to develop and implement adequate

QA/QC systems.

4. QA/QC system shall cover all products and services required for the equipment as per

scope defined in enquiry specification including job sub contracted by the Bidder.

5. On award of contract the vendor shall submit all the testing procedure including PWHT,

NDT etc. to TPI for approval and a copy of the approval shall be furnished to DEC / IITB

for reference / records. Records of all the QAP & test records shall be duly maintained and

produced to the TPI visiting the vendor’s shop for the purpose of inspection. The

comprehensive records & all the relevant reports shall be finally sent to DEC / IITB along

with the supply of equipment.

6. The approval of the work by TPI /DEC / IITB Inspector and his release of the equipment

for shipment / erection shall in no way release the bidder from or relieve the bidder of,

any responsibility for carrying out all the provision of this specification and the fulfilment

of the guarantee, nor does DEC / IITB by such approval and release, assume any

responsibility whatever for such provisions and guarantee.

7. The bidder shall lay down all the inspection and testing requirements in the quality plan

which shall identify the activities requiring DEC / IITB’s approval, review witnessing, etc.

8. As a minimum the following points shall be included in the Quality Control Plan:

a. Review of material certificates and verification of the materials of construction for

conformity with requisition requirements

b. Review of material certificates and verification for heat marks for pipes and flanges

for conformity to the specification

c. Review of material certificates for salt?


29 | P a g e

d. Verification of the Vendors design calculation for the equipment in accordance with

the design code

e. Verification for the Vendors welding procedure and procedure qualification for the

equipment in accordance with the design code

f. Dimensional check in accordance with approved “final” drawings

g. Painting and lining requirement as detailed in this specification shall be inspected

h. Final release

9. The bidder shall engage an approved TPI.

T. Pre-commissioning

a. System testing / start-up (pre-commissioning) for the various systems in the plant would

be carried out under the supervision of the consultant. The bidder shall furnish, as part of

his work, at no additional cost, on round-the-clock basis, skilled personnel and

supervision, to carry out the same. The number and category of skilled personnel to be

deployed by the bidder shall be decided by the Engineer-in-charge in advance and the

bidder shall provide such personnel as and when required by him.

b. System testing would include all equipment and systems indicated in the scope of work

of the bidder, various electrical heating systems, performance of package equipment,

testing of receiver with electrical heating, testing of salt loop with electrical heating etc.

c. All tools, tackles shall be provided by the bidder along with the skilled personnel. Defects

noted during these tests shall be rectified by the bidder at his own cost, if the defects are

attributable to the bidder’s work.

d. After completion of system the start-up (pre-commissioning) shall be commenced and

any defects noticed in the plants, which are attributable to the bidder shall be attended to

by the bidder at his own cost, as and when they are brought to his notice by the IITB. IITB

shall have the right to have these defects rectified at the risk and cost of the bidder if he

fails to attend to these defects immediately. After the operating conditions are fully

achieved in all the plants and the requirements stated in elsewhere in this Contract are

fulfilled, the bidder would be eligible for applying for completion certificates.

e. Where the works are carried out at the cost of the bidder, the Engineer-in-charge would

recover twice the actual cost incurred towards labour, supervision and materials,

consumables or otherwise. This includes overheads and all such amounts payable by him

shall be deducted from pending bills or the security deposits.

U. Commissioning

a. Entire system will be commissioned as per directions of the Engineer-in-charge

b. The bidder will provide required assistance with required manpower including

engineers, technicians, labourers etc. as described in pre-commissioning.

V. Special note

The bidder shall state construction power and water requirement in the bid document. Bidder

shall provide 2 sets of Govt. calibrated water meter (class B) and energy meter (class 1) for

metering of water and electricity provided at site by NTPC. The accuracy and performance of the

meters shall bidder’s responsibility for the entire duration of the project.

Only bore well water is available at site. Bidder shall make his own arrangement of water for

construction and potable water for construction personnel with all related arrangements with

respect to adequacy and hygiene.


30 | P a g e

The bidder shall also provide and maintain hygienic temporary sanitation arrangement for

construction personnel throughout the duration of the project.

The bidder shall ensure that the site is cleared of all debris, waste, temporary structures etc. on

completion of the project as a precondition for final payment.

The bidder shall also arrange 170 KL, tanker loads of DM water (with test certificates) for

precommissioning, commissioning and test runs of the plant as per required schedule.

The bidder shall submit Quality assurance plan for all items of supply and execution along with

the bid document.

Security required all materials at site for the project shall be in contractor’s scope.

Any failure on the part of the bidder to progress with / complete the work / rectify work defects

including those informed during precommissioning (refer precommissioning section above) as

per schedule will entitle the client to deploy resources as required to complete the work and

recover all such costs towards deployment of the resources at twice the cost incurred by the client

from pending bills or the security deposits of the contractor. The decision of the client in this

regard shall be final and binding on the contractor.

All drawings issued for this tender shall not be reproduced in any manner and shall only be used

for the purpose of bidding.

5.2 Scope matrix

R = Responsible for the activity / document

A= Has the approving / acceptance authority

I = Inspection

S= Supervision

W = Witness

Sr.

no.

Work Responsibility

Bidder Consultant

(DEC)

Client

(IITB)

A Overall, detailed, weekly planning schedule, safety

and statutory compliances, site supervision and

management R A A

B QA for all supplies and work including

documentation R A A

C IBR approval


31 | P a g e

Sr.

no.

Work Responsibility

Bidder Consultant

(DEC)

Client

(IITB)

1 Study of P&ID and identification of items for IBR

requirement. R - -

2 Documentation for IBR requirement, visits of IBR

authority to bidder’s works, site and all other

relevant actions etc. R - -

3 Obtaining final IBR approval for the installation

and submission of IBR approval to NTPC. R A A

C Clearing site of grass, dirt, debris and disposal,

appropriate place outside premises as specified by

local bodies

R A A

D Temporary store for salt receipt storage, handling,

opening packs, breaking, mixing, transferring etc.,

erection of store, dismantling, removal,

reinstatement of clear land R I, A I

E Bidder’s site office, stores - design, procurement,

construction, erection, dismantling, removal,

reinstatement of clear land R A A

F Central receiver assembly with insulation

1 Detailed design, drawing and specifications - R A

2 Procurement, PMI etc., set ups, fit-ups, fabrication,

testing, transport, erection, assembly,

commissioning including insulation etc. R I, A A

G Thermocline Storage tank with insulation

1 Conceptual Design, specifications, design data - R A

2 Detailed fabrication drawing R I, A A

3 Procurement, PMI etc., set ups, fabrication, testing,

transport, erection, commissioning including

insulation etc. R I, A A


32 | P a g e

Sr.

no.

Work Responsibility

Bidder Consultant

(DEC)

Client

(IITB)

H Heat exchangers with insulation

1 Conceptual design, specifications, design data,

design calculations, fabrication drawing - R A

2 Detailed design, IBR drawing, IBR, PV calculations,

design document R A A

3 IBR approvals, stage wise etc. R - -

4 Procurement, PMI, IBR approvals for materials R I, A A

5 TPI R I, A A

6 Procurement, fabrication, finishing, assembly,

finishing, erection R I, A -

7 Pre-dispatch IBR inspection, IBR certification R A A

8 Dispatch, Receipt at site, handling, storage R I, A A

9 Local IBR approval R A -

10 Erection, Testing, precommissioning,

commissioning R I, A A

11 Final local IBR approval, documentation R A A

I Molten Salt pumps

1 General specifications - R A

2 Procurement, PMI, performance curves R A A

3 Pre-dispatch inspection, trials, acceptance R W, A W,A

4 Dispatch, receipt, handling, assembly, erection,

pre-commissioning, commissioning, R I, A A

J Boiler Feed water tank with insulation


33 | P a g e

Sr.

no.

Work Responsibility

Bidder Consultant

(DEC)

Client

(IITB)

1 General design, drawing and specifications - R A

2 Detailed fabrication drawing R A A

3 Procurement, PMI, fabrication, transportation,

erection, commissioning. R I, A A

K Boiler Feed Water Pumps

1 General Specifications - R A

2 Procurement, PMI, performance curves R A A

3 Pre-dispatch inspection, trials, acceptance R W, A W,A

4 Dispatch, receipt, handling, assembly, erection,

pre-commissioning, commissioning, R A A

L Electrical heaters, preheaters with controls


2 Detailed design, procurement, fabrication,

assembly, finishing, erection R A A

3 Testing, precommissioning, commissioning R A A

M Piping, fittings, valves for molten salt, steam,

water etc.


2 Procurement, installation R A A

IBR approvals, certification R A A


N Silencers


34 | P a g e

Sr.

no.

Work Responsibility

Bidder Consultant

(DEC)

Client

(IITB)


2 Design, Procurement, installation R A A


O Electrical PCC, MCC, cables, trays etc.

1 SLD, general design, construction specifications - R -

2 Detailed design and engineering of panels R A -

3 Procurement, fabrication, assembly, FAT,

documentation, delivery, installation,

commissioning of panels R I, A W, A

4 Procurement, installation, termination etc. of

cables, cable trays, glands, etc. R I, A -

P Instruments ( gauges, sensors, transmitters,

instrumentation cabling etc. )


2 Procurement, installation, certification of

instruments, cables, loop testing, R A A


Q Instrumentation

1 Detailed specifications of PLC, I/O list, cables,

trays, etc., cables schedule, termination schedule,

indicative BOM, instrument list, layout, location

plan, hook-up plan - R A

2 Detailed Engineering of PLC system, enclosure,

instruments, etc. R A -


35 | P a g e

Sr.

no.

Work Responsibility

Bidder Consultant

(DEC)

Client

(IITB)

3 Procurement, supply, fabrication, assembly of

panels, consoles, hardware, development

software, other software etc. R I, A -

4 FAT, documentation of PLC, SCADA system (as-

built drawings, datasheets, test certificates,

inspection certificates, warranty certificates, type

test certificates etc.) R I, A I, A

5 Logic development for PLC system R A A

6 SCADA R A A

7 Procurement, installation, erection of cable trays,

glands, etc. R A -

8 Testing, precommissioning, commissioning R I, A W, A

9 Equipment manuals, documentation R A A

R DM Water receipt, storage, transfer.

1 General specifications, dimensions - R -

2 Procurement, supply, installation, commissioning

etc. R A A

3 calibration of DM water tank by strapping method

– IS 2007, and water draw off method by a

certified calibration agency. R A A

S Raw water receipt, storage, transfer

1 General specifications, dimensions - R -


etc. R A A

T Cooling water system


36 | P a g e

Sr.

no.

Work Responsibility

Bidder Consultant

(DEC)

Client

(IITB)

1 General specifications - R -


etc. R A A

U Instrument air package and piping



etc. R A A

V Feed water dosing systems


2 Design, procurement, supply, installation,

commissioning etc. R A A

W Salts ( KNO3, NaNO3 )

1 Specifications ( composition ) - R A

2 Procurement, supply, dust-free, enclosed storage

of salt R A A

3 Approved work method, removing packaging,

breaking, clean handling, transporting, dumping

into thermocline tank in required proportion. All

requisite PPE, precautions to avoid contamination.

Handover of undamaged surplus salt packs to

stores R S A

X Pre-commissioning R S, I, A A

Y Commissioning R S, I, A A

Z Spares R I, A A


37 | P a g e

Sr.

no.

Work Responsibility

Bidder Consultant

(DEC)

Client

(IITB)

AA Handover of all work entrusted to the bidder vide

this document to consultant R I, A A

AB Final Documentation: Documentation of all

supplies & services which are entrusted to the

bidder. This document to be submitted to the

consultant. R I, A A


38 | P a g e

Section – 6: Technical bid


39 | P a g e

6.1 Technical work specification

A. Technical specifications – Piping and mechanical work

Heliostat receiver assembly with refractory

The receiver assembly consists of helical coils made out of stainless steel 316 Ti grade tubes

suitable for 600 ⁰C design temperature and 4 kg/cm2(g)bar pressure with cyclic temperature

variation from ambient temperature to design temperature in a daily operation. Inlet outlet

headers are also of equivalent stainless material.

The coils are placed in an insulated housing of ceramic and mineral wool insulation sandwiched

between SS sheet lining on the inside and carbons steel plates on the outside, resting on structural

members. The inner lining is supported from the carbon steel plates as shown in the drawing. The

carbon steel plates are rested on structural steel supports from the tower structure.

The receiver tube coils shall be coated with a selective coating as per specifications mentioned

below. All processes – surface preparation, cleaning, application of coating, curing etc. shall

strictly be in compliance the tender specification.

The equipment to be used for coating and curing and procedure adopted by the bidder has to be

approved from DEC and IITB. Selective coating application procedure has been described in the

at the end of this section

Details of the receiver coils are as below:

Sr.no. Item / parameter Specification

1 Description Vertical, helical coil with supports and

stiffeners of same material.

2 Material of construction A213, TP 316Ti

3 Construction standard ASME Sec VIII, div-1,2013

4 Material of construction A213, TP 316Ti

5 Operating temperature range 290 ⁰C – 565 ⁰C

6 Operating pressure 3.0 kg/cm2(g)

7 Design temperature / pressure 600 ⁰C / 4.0 kg/cm2(g)

8 Hydrostatic pressure 6.0 kg/cm2(g)

9 Radiography 100 %

10 Fluid molten salt.

11 Dimensions in mm

Coils 1 & 2 Coils 3, 4 & 5 a Coil OD 1100 mm 700 mm b Coil tube 19 OD x 2 thk 19 OD x 2 thk c Coil pitch 57 mm 38 mm


40 | P a g e

d Coil turns 44 nos 66 nos. e Joints Forged SW, 3000#

Thermocline storage tank

Design parameters

Sr.no. Item / parameter Specification 1 Vessel type Vertical, cylindrical with top and

bottom dish ends, insulated. 2 Capacity ( nominal ) 10 m3 3 Shell ID / height / thk 1800 mm / 3,450 mm / 10 mm 3 Dish ends, thk 10 % tori spherical, 10mm 4 Material of construction A240 Gr 321 5 Operating temperature range 290 ⁰C – 565 ⁰C 6 Operating pressure 0.6 kg/cm2(g) 7 Design temperature / pressure 600 ⁰C / 1.0 kg/cm2(g) 8 Hydrotest pressure 2.25 kg/cm2(g) 9 Radiography 10 % 10 Tank mountings

a Top mounted Molten Salt pumps 2 nos, 500 mm Ø ID, b Manhole 1 no., 460 mm Ø ID c Top mounted temperature

transmitter clusters 5 nos, 50 NB, N1

d Distribution pipe 273 OD x 6.35 thk x 3,971 long, A240 TP 321, , perforations - 10Ø x 8 x 41 nos.

e Side mounted electrical heaters 16 no.s, 65 NB flanges, 600#, N7 f Top mounted bubbler level

transmitter 1 no.,

g Internal ladder Ø16 x 620 rungs, 14 nos. h Legs 4 nos, 150 NB A240 TP 321, 1500 long i Nozzle schedule N1 – 50 NB x 150# x 5 nos

i # N2 – 40 NB x 600# x 1 no. ii # N3 - 25 NB x 600# x 1 no.

iii # N4 - 15 NB x 600# x 1 no. iv # N5 - 15 NB x 600# x 1 no. v N6 - 25 NB x 600# x 1 no., drain

vi N7 - 40 NB x 150# x 1 no. vii # N8 - 15 NB x 600# x 1 no.

# - within distributor pipe, all pipes will have perforations similar to distributor

Manufacturing Procedures:

The tank is at atmospheric pressure so strictly it is not a pressure vessel and does not come under

a code. However, considering the severity of the duty, all the manufacturing practices of ASME

Section VIII, division 1 shall be followed by the bidder.


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Molten salt to steam heat exchangers

Design parameters:

1. Preheater

Sr.no. Item / parameter Specification Heat duty, design 40 kWth Tube side 1 Tube Side fluid Molten Salt 2 Inlet / outlet temperatures ⁰C 355 / 290 3 Design temperature ⁰C / pressure kg/cm2 565 / 4.0 4 Material of construction A213 TP 321 5 Permissible pressure drop < 5 mlc Shell side 6 Shell side fluid Boiler feed water 7 Inlet / outlet temperatures ⁰C 45 / 213.3 8 Design temperature ⁰C / pressure kg/cm2 220 / 50.0 9 Material of construction A106 Gr. B, Seamless 10 Permissible pressure drop < 5 mlc 11 The Preheater is designed with following considerations:

Fully drainable molten salt helical coil tube, non-removable Shell with saddle support, nozzles, fittings and insulation, pressure gauge and other instrumentation.

2. Evaporator

Sr.no. Item / parameter Specification Heat duty, design 95 kWth Tube side 1 Tube Side fluid Molten Salt 2 Inlet / outlet temperatures ⁰C 513 / 355 3 Design temperature ⁰C / pressure kg/cm2 565 / 4.0 4 Material of construction A213 TP 321 5 Permissible pressure drop < 5 mlc Shell side 6 Shell side fluid Boiler feed water / steam 7 Inlet / outlet temperatures ⁰C 213 / 253 8 Design temperature ⁰C / pressure kg/cm2 260 / 45.0 9 Material of construction A106 Gr. B, Seamless 10 Permissible pressure drop < 5 mlc 11 The evaporator is designed with following considerations:

Fully drainable molten salt helical coil tube, non-removable Shell with saddle support, nozzles, fittings and insulation. Water level indicator and controller Steam safety valves, main steam stop valve, blow down valve etc. fittings as required for a standard shell type boiler fulfilling statutory requirements, pressure gauge and other instrumentation.

3. Superheater section


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Sr.no. Item / parameter Specification Heat duty, design 31.5 kWth Tube side 1 Tube Side fluid Molten Salt 2 Inlet / outlet temperatures ⁰C 565 / 500 3 Design temperature ⁰C /

pressure kg/cm2 565 / 4.0

4 Material of construction A213 TP 321 5 Permissible pressure drop < 5 mlc Shell side 6 Shell side fluid Superheated steam 7 Inlet / outlet temperatures ⁰C 253 / 425 8 Design temperature ⁰C /

pressure kg/cm2 425 / 45.0

9 Material of construction ASTM A 335 Gr. P91 Seamless

10 Permissible pressure drop < 5 mlc 11 The superheater is designed with following considerations:

Fully drainable molten salt helical coil tube non-removable. Instrumentation as shown in the P&ID

1. The heat exchanger being a steam generator, is under Indian Boiler Regulation. So Design

Code - IBR 1950 and latest amendments thereof are applicable. In addition to the

requirements specified in the drawing and specifications, the exchangers shall be designed,

fabricated, inspected and tested in accordance with the requirements of IBR. Approval of CIB

of the State in which the equipment is being manufactured as well as the State where the

equipment is being installed shall be the responsibility of the bidder at no extra cost.

2. The scope of supply & work covers design and engineering (only where the design issued with

this tender is required to be modified for IBR approval), manufacture/procurement of raw

materials, fabrication, assembly, inspection, testing, painting, insulation, protection and

packing, transportation and delivery to site and installation & commissioning of the supplied

heat exchanger as per this specification.

3. The typical scope of supply and work is given below but not limited to the followings till

successful installation and commissioning of the heat exchanger at site:

4. Scope

a. Detailed mechanical design as per ASME and IBR requirements has been provided with

the tender. Bidder’s scope includes further detailing for fabrication / changes for IBR

approval, complete procurement of all materials and bought-out items, fabrication at

shop, inspection & testing, primer painting, insulation and supply of heat exchangers

with internals as per details and spares in accordance with the applicable equipment

specification and other documents enclosed with enquiry.

5. Mechanical design (this shall apply to modifications in design, if required for IBR approval)

a. Further mechanical design of Equipment, if required, for compliance with the latest code

/ standard of construction, IBR shall be the responsibility of the bidder. Strict compliance


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with the requirement of codes/equipment specification & any other referred document

shall be ensured.

b. Detailed design calculations for adequacy of strength of all individual parts shall be made

by bidder and submitted to DEC for comment & approval. After receipt of approval from

IITB / DEC the design of equipment shall be considered as final. Any change/comment

made on design calculations and drawings to satisfy the requirements of code/enquiry

documents “to make the equipment perfectly fit for smooth operation” shall have to be

incorporated by Bidder without any commercial implications.

c. Design conditions for the equipment shall be as per equipment specification sheets &

Technical Specification enclosed with the enquiry. Minimum required thicknesses of

various components shall be calculated based on design parameters considering

different types of loadings conditions including effect of static head of liquid column,

wind pressure, force of moment owing to connected piping & other attachments as

platform etc. Equipment shall also be designed for hydrostatic condition. Final thickness

shall be decided giving due consideration for corrosion allowance & thinning allowance.

d. Wind analysis shall be performed as per the relevant standard. Wind forces shall be

increased by 20% (over & above design code requirement) to cater the effect of piping

system, platforms and ladders etc.

e. Local stresses in vessel wall resulting from nozzle load shall be determined by WRC 107/

WRC 297 or PD5500/G code requirements. Forces and moments acting on nozzles shall

be considered in the design of vessel and resultant stresses shall not exceed allowable

stresses as per applicable codes/standards/specifications. The forces and moments on

nozzles shall be furnished during detailed engineering after award of contract. Bidder

shall take care of the same during mechanical design of equipment without any

delivery/commercial implications to IITB.

f. All carbon steel (CS) & low alloy steel (LAS) pressure parts shall have minimum of 3.0

mm corrosion allowance unless otherwise specified. All internals CS/ LAS parts including

low temperature materials shall have at least 1 mm corrosion allowance on either side

unless otherwise specified.

g. Each Lifting Lug shall be designed with shock factor 2.

h. Bolts of size M36 and above shall be designed and spaced so as to permit tightening with

a hydraulic stud-tensioner. The bolts shall have an extra threaded length at one end of

approximately 1 bolt diameter and shall be provided with threaded protection caps. Hex

nuts shall have suitable holes for manual tightening. Equipment having bolt size above

M36 shall be supplied with hydraulic bolt tensioning device along with commended

spares and operating manual indicating tightening torque.

6. Special requirements (these shall apply to modifications in design, if required, for IBR

approval)

a. Detail of components thicknesses of various parts wherever indicated in the equipment

specification sheet are indicative and minimum. However, during detailed engineering,

if thicknesses need to be increased to meet code/standard requirements for the adopted

code/standard under corroded condition for all load combination including nozzle loads


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the same shall be considered by Bidder without any delivery/commercial implication.

b. The design of equipment supports and anchor bolts shall be the responsibility of the

Bidder. The type, number and location etc. indicated in the equipment specification

sheets shall be adhered, changes, if any shall be indicated in offer. Further adequacy of

the same must be checked by the Bidder & design calculation shall be submitted to DEC

for approval during design/drawing approval stage.

c. ASME Section VIII, Div. 1, Appendix “S” shall be considered mandatory for bolted flange

connections. However, flange shall be designed as per Appendix “2” for different loading

conditions.

d. Local vessel stress calculations for external structural attachments, such as platform

cleats, pipe support cleats and lifting lugs shall be performed & submitted to DEC for

approval.

e. International System of Units (SI) System and English language shall be used for all

drawing and documents.

f. Deviations, if any, shall be clearly spelt out in the offer with proper reference to clause

numbers. In absence of any such indication it shall be assumed that the offer complies

with all the requirements and such assumptions shall be strictly binding on bidder.

g. Equipment saddle wear plate material shall be the same as the shell material. Bidder shall

check adequacy of tube bundle against flow induced vibration and shall submit the

design calculation for DEC approval.

h. Parts which simultaneously come in contact with both shell side and tube side fluids,

shall be designed considering pressure acting on one side only or the combination of

pressures, whichever results in higher thickness of parts.

i. In case of girth flange design, minimum width of gasket shall be checked to withstand

required design condition.

j. Unless otherwise stated inlet nozzles on shell side shall be provided with impingement

plate in compliance with TEMA requirement if not specified in datasheet. The flow area

around solid impingement plate shall be at least equal to the inlet nozzle cross-section.

In case of two phase flow impingement baffle shall be perforated. Impingement baffle

plate shall extend at least 25 mm beyond the projection of the nozzle bore. The clear

distance from the nozzle (at the inner surface) to the impingement plate shall be at least

0.25 x nozzle diameters if not specified in equipment data sheet. The nominal thickness

of the impingement baffle shall be at least 6 mm.

7. Scope of supply

a. Bidder shall include the following items in scope of supply besides supply of equipment

including internals & spares etc. referred under Scope.

i. Lifting lugs/Erection lugs as required

ii. All external cleats/pads required for ladders, platforms, pipe support pads including

cleats for earthing connections etc. Details of pads & cleats for ladders, platforms &

pipe supports shall be defined during approval of design & drawing stage. Such


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details shall have to be incorporated by Bidder without any commercial/delivery

implication. However, Bidder shall include cost of such attachments in the Bid based

on his experience.

iii. Name plate with bracket

iv. Foundation / Anchor / Holding down bolts with nuts and washers

v. Cleats for earthing connections (2 numbers diagonally opposite to each other)

vi. All specials instrument & fixtures required to verify the guarantee

vii. Shipping saddle with proper reinforcement for transportation and loading/

unloading.

8. Material of construction

a. Material of construction for equipment shall be selected as per equipment data sheet &

Technical Specification.

b. The following additional material requirements as indicated below shall be considered

by Bidder:

i. All raw materials including bought-out items, whatsoever required, to

complete the supplies shall be procured and supplied with due identifiable mill

material test certificates & inspection reports duly certified by authorized

inspection agency.

ii. For coarse grained and high tensile materials in carbon steel (UTS > 52

Kg/mm2) and low alloy steel, guaranteed impact strength shall be ensured at

a temperature 150°C below envisaged hydraulic test temperature as a

precaution against brittle fracture during hydraulic test. 5.2.3 Carbon steel &

LAS shall be procured in fully killed condition. CS & LAS plates shall be

normalized / annealed. CS & LAS plates above 50 mm thickness shall be

vacuum degassed and examined by Ultrasonic Testing (UT) at surfaces & edges

as per ASTM A435 and other equivalent applicable material specification

code/standard. Bend test as per supplementary requirement S-14 of SA -20.

iii. All forgings except for flanges as per ANSI shall be UT tested as per applicable

material specification & shall be examined according to ASTM A388 with

criteria shown in ASME Section VIII.

iv. All forgings including self-reinforced nozzles & nozzle flanges shall be

examined for surface defects by MP/PT testing after machining as per

applicable material specification, code & standard.

v. Material used for pressure parts and attachment to pressure parts shall be

impact tested (Charpy-V) as per design code & specifications. Impact test

temperature shall be minimum of MDMT, impact test temperature specified in

applicable material code or given in job specification whichever is lower.

vi. All external/internal attachments, pads/cleats directly welded to the

equipment shall be of same materials as that of equipment, unless otherwise

specified.


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9. Fabrication

a. The Bidder shall comply in all respects with the provision of the applicable codes,

standards and specification during fabrication with respect to tolerances, welding,

fabrication, forming of heads, radiography, heat treatment, inspection, testing and

quality control etc. unless & otherwise specified.

b. Plates of different thicknesses shall be made flush with the inner surfaces of equipment

unless otherwise stated.

c. All dish heads shall preferably of single piece construction. Larger heads which cannot

be formed in one piece shall be fabricated as follows with prior approval from IITB / DEC.

i. In two pieces, with the welding seam included in the middle third and

preferably on the centre line.

ii. In petal construction, with meridian seams and a central cap of diameter not

larger than 0.75 times the vessel outside diameter.

d. Due provisions must be kept for venting out entrapped gases during welding of pads,

flanges and liner plates etc.

e. All welding shall be carried out by qualified welders using approved procedures in

compliance with the requirements of codes, standards & specifications and shall be duly

certified by the concerned inspecting authority. All welding procedures must be got

approved from authorized inspecting authority & IITB / DEC before starting any

fabrication job. Welding of all parts must be completed before heat treatment. For all

welds, Welding Procedure Specification (WPS) must be provided.

f. All welds shall be full penetration welds with back chipping and re-welding from the

second side. For those joints which are inaccessible for back chipping the root run shall

be carried out with TIG process. Single side welding with backing strips is not permitted.

g. All sharp corners shall be rounded off with smooth radius. Inside edge of manhole and

hand hole at the internal surface shall be rounded to minimum radius 5 mm.

h. All flange bolts shall straddle center line unless otherwise stated.

i. In case of nozzle with butt-end construction, extra length shall be provided to facilitate

hydraulic testing and subsequently cutting and edge preparation to suit piping welding

at site. All nozzles less than or equal to NB 65 mm shall be stiffened with three equispaced

plate ribs of the same material as that of shell.

10. Painting

a. Surface cleaning of the heat exchanger, external surface by sand blasting to Sa2 -1/2

grade conforming to Swedish Standard SIS – 05 5900 – 1967 followed by 2 coats of heat

resistant primer. Inner surface will be cleaned by wire brushing and passivated.

b. The heat exchanger body and piping shall be thermally insulated by rock wool of density

120 kg/m3 and aluminum sheet cladding of 20 gauge covered with tight sealing, to

prevent heat loss and external insertion of water and foreign elements.

11. Inspection & testing


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a. The equipment shall be inspected and tested (including NDT) in accordance with

applicable codes, standards and specifications referred in the enquiry. The equipment

shall be inspected during various stages of manufacturing starting from identification of

raw materials to final completion as per agreed Quality Assurance Plan (QAP) which shall

be furnished by bidder along with their bid and successful bidder after award of contract

shall submit QAP to IITB / DEC / Third Party Inspection agency for their approval.

However, all the bought-out items must be supplied with test certificates and inspection

reports.

b. The third party inspection is in the scope of the bidder. It shall be the responsibility of

the Bidder to make available to the inspector all the drawings, calculations and other

documents. However, the IITB / DEC / inspection agency shall have free access for

inspection at bidder’s / sub-vendor’s shop at all stages of manufacturing. Further the

following tests / procedure are mandatory to be witnessed / reviewed by concerned

third party inspection agency.

i. Review of drawings & design calculations

ii. Welding procedure specifications approval

iii. Heat treatment procedure approval (if applicable)

iv. Hydraulic test

v. Review of NDT tests reports e.g. RT, UT, MP / PT & hardness etc. including Leak

test, Ferrite check, Iron contaminated test, Inter-granular corrosion test etc.

vi. Review of material test certificates & Positive material identifications

vii. Review of PWHT charts (if applicable).

viii. Review of production test coupons

ix. Witness of hydraulic testing

c. All imported raw materials shall only be inspected by TPI. The cost of the same shall be

considered by bidder in their scope.

d. The exchanger shall be considered acceptable for dispatch only after final certification

for acceptance is issued by concerned inspector.

e. Production control coupons, when required as per codes & standards shall be subjected

to mechanical tests as required. In case of heat treated equipment test coupons shall be

given similar heat treatment as for the equipment. Test plates for production testing shall

be sufficient for performing all tests.

f. Formed heads cold formed or hot formed below normalizing temperature shall be

subsequently normalized and weld seams if any shall be fully radiographed after

forming.

g. All nozzle reinforcing pads wherever applicable shall be tested pneumatically at 0.5

Kg/cm2g pressure with soap solution on attachment welds. Vent holes shall be plugged

with non-hardening mastic to prevent ingress of water.

h. All completed equipment shall be tested hydraulically as per the requirements of codes,


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standards & specifications in presence of the inspecting authority. Pneumatic test of

completed equipment shall be carried out only when specially mentioned in the

specification sheets. Chloride content in water used for testing shall not exceed 30 ppm

for SS equipment and 40 ppm for CS and low alloy steel equipment. Duration of test shall

be as per applicable codes & standards. Test medium/water shall be tested for the

chlorine contents before filling the equipment.

i. The temperature of test water shall comply with requirement of IBR.

j. Unless otherwise stated gaskets used during testing shall be same as specified for

operating conditions. After testing, gaskets used during testing shall be replaced by new

gaskets.

k. NDT Requirements

i. The following NDT requirements are mandatory in addition to codes, standards &

specification requirements.

ii. UT examination

a. All butt - welds in thickness greater than 50mm as supplement to

radiograph.

b. FPW of nozzle attachments of thickness above 50mm as supplement to

radiography

c. All forgings

d. All butt welds after hydro test

iii. MP / PT examination

a. All edges of plates and opening in shell of CS having thickness equal to &

above

b. 40mm and LAS / SS having thickness more than 25mm

c. Root and final layer of all butt welds

d. All weld surfaces after PWHT

e. Knuckle surfaces of dished ends/ tori conical sections and pipe bends

f. All forgings after machining

g. All fillet & butt weld after hydro testing

iv. Radiography

a. All weld seams of formed head, if made in more than one segment shall

be full radiographed after forming

b. When spot radiography is specified, all T – Joints & minimum 10% of total

weld length (excluding T joints) shall be radiographed

c. All nozzles fabricated from plates shall be 100% radiographed

d. All butt welds irrespective of thickness (100% radiographed) before


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PWHT and hydro test

e. For LAS welds radiography shall also be done after final PWHT and joints

which cannot be radiographed shall be 100% UT tested.

v. Hardness test

a. Weld and Heat affected zone (HAZ) of all pressure bearing welds in Cr-

Mo steel vessels shall be tested after final heat treatment using a portable

hardness tester. Hardness value shall not exceed 215 HB for steel having

Cr < 2 % and 240 HB for steel having Cr ≥ 2%.

vi. Further NDT requirement as per MC41-1E shall be complied with by the Bidder.

12. Quality assurance & control

a. Quality Assurance (QA) shall mean the organizational set up, procedures as well as test

methods and facilities developed by Bidder in order to assure that the equipment leaving

Bidder’s shop is of the highest possible quality i.e. either equal to or better than the

requirement specified.

b. Quality Control (QC), shall mean all the tests, measurement, checks and calibration which

are to be carried out in Bidder’s shop in order to compare the actual characteristics of

the equipment/unit/system with the specified ones, along with furnishing of the relevant

documentation (certificates/records) containing the data or result of these activities. The

bidders are required to furnish a detailed & comprehensive list of the inspection facilities

available at their shop along with the bids.

c. Bidder shall submit a comprehensive description (manual) of QA/QC measures

contemplated by him for implementation with regard to this specification for approval

of IITB / DEC/ Inspection Agency. It is contractual obligation of the Bidder to develop

and implement adequate QA/QC systems.

d. QA/QC system shall cover all products and services required for the equipment as per

scope defined in enquiry specification including job sub contracted by the Bidder.

e. On award of contract the vendor shall submit all the testing procedure including PWHT,

NDT etc. to TPI for approval and a copy of the approval shall be furnished to DEC / IITB

for reference / record. Records of all the QAP & test records shall be duly maintained and

produced to the TPI visiting the vendor’s shop for the purpose of inspection. The

comprehensive records & all the relevant reports shall be finally sent to DEC / IITB along

with the supply of equipment.

f. The approval of the work by TPI /DEC / IITB. Inspector and his release of the equipment

for shipment / erection shall in no way release the bidder from or relieve the bidder of,

any responsibility for carrying out all the provision of this specification and the

fulfillment of the guarantee, nor does DEC / IITB by such approval and release, assume

any responsibility whatever for such provisions and guarantee.

g. The bidder shall lay down all the inspection and testing requirements in the quality plan

which shall identify the activities requiring DEC / Client’s approval, review witnessing,

etc.


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h. As a minimum the following points shall be included in the Quality Control Plan:

i. Review of material certificates and verification of the materials of construction

for conformity with requisition requirements

ii. Review of material certificates and verification for heat marks for pipes and

flanges for conformity to the specification

iii. Verification of the Vendors design calculation for the equipment in accordance

with the design code

iv. Verification for the Vendors welding procedure and procedure qualification

for the equipment in accordance with the design code

v. Dimensional check in accordance with approved “final” drawings

vi. Painting and lining requirement as detailed in this specification shall be

inspected

vii. Final release

i. The bidder shall engage an approved TPI.

13. Performance & mechanical guarantee

a. Bidder shall guarantee the equipment against faulty design (if any required to be done by

the bidder), improper material of construction and poor workmanship, with respect to

specifications. Approval by DEC / Third Party Inspection Agency / IITB for design

calculations (if any done by bidder), drawings & other documents will not in any way

absolve the Bidder from his responsibility. Should any repair or replacement be necessary

owing to any type of failure on account of design material and workmanship of the item,

Bidder shall in view of this guarantee be bound to replace the same either in part or whole

without any commercial implications to IITB. Repaired or replaced part shall also be

covered by same guarantee as in case of main supply.

b. Hydrodynamic & Performance Guarantee

c. Bidders shall stand guarantee of supplied internals against the process parameter

indicated in equipment specification sheets. All special instruments, fixture required to

verify the guarantees as outlined in the equipment specification shall have to be brought

by the supplier on draw-back basis.

d. The material used shall be new and best of its kind available and shall conform to relevant

Indian and International standards. All the material used shall be free form surface

defects, rusts, cracks and deformation. Bidder’s shall guarantee for materials,

workmanship and satisfactory performance of the equipment to be supplied against this

specification for 18 months from the date of receipt of last consignment at site or 12

months from the date of commissioning whichever is earlier. Any defects including due

to faculty design/material/ workmanship found during the guarantee period shall be

rectified by bidder at his own cost to the entire satisfaction of the purchaser. Vendor shall

take full responsibility for the design (if any done by the bidder), quality of material and

workmanship, guaranteed operation and smooth performance etc. of the equipment. This

technical specification is only guidance to bidder and hence all the items necessary for


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safe and satisfactory operation and guaranteed performance of the equipment shall be

included in his offer though these might not have been specifically mentioned in this

specification. The conditions regarding guarantee of equipment shall also be governed by

the relevant clauses of general commercial condition. Bidder shall perform performance

test of the capacity of heat exchanger mentioned under process data sheets. The

performance test shall be carried out for continuous period of 72 hours and if during such

period, the performance data is met, the performance test shall be deemed to have been

carried out successfully. If the performance test could not be carried out successfully for

a continuous period of 72 hours, the performance test shall be carried out again.

14. Third party Inspector (TPI): The successful bidder shall engage the TPI from approved TPIs.

The cost for engaging the TPI shall be borne by the bidder. The TPI shall be engaged during

the phase-wise inspection while manufacturing of the heat exchanger. The schedule shall be

submitted for review of DEC / IITB.

15. Documentation:

a. Detailed fabrication drawings shall be prepared by Bidder clearly indicating all design

data, nozzle data, details of all parts with tolerances, all welding joints details and

detailed bill of materials etc. Location of weld seams, construction notes, welding

processes, detailed specification of electrodes including NDT tests etc. as applicable shall

be clearly indicated in the drawing. Fabrication drawing shall also indicated Civil load

data’s i.e. Empty Weight, operating weight & hydro test weight of the equipment

including base shear force and base moment for civil foundation design. Drawing

submitted for approval must be complete in all respects and thoroughly checked and

approved by Bidder’s competent authority before submitting to IITB / DEC/Third Party

Inspection Agency.

i. All drawings shall be drawn in AUTOCAD to scale. Manual drawing shall not be

accepted.

ii. All documents / drawings shall be in English language and in Metric system. Further

the following documentation shall be submitted by Bidder for review & approval as

per IITB / DECs requirement besides other documentation listed elsewhere.

a. 3 sets of hard copies of Rev. 0 of GA drawing, design calculation etc. with soft

copies to DEC for review.

b. 3 sets of hard copies of Rev. 1 of GA drawing, design calculation etc. with soft

copies to DEC for review. Vendor shall also submit 02 hard copies of Rev. 0,

Rev. 1 and further revision of GA drawing, design calculation etc. with soft

copies to DEC / IITB for review. Soft copies shall also be sent to DEC / IITB.

c. 6 sets of all final documents such as design calculations, fabrication drawings,

test certificates, material test reports, repair procedure along with the

reproducible & soft copies, hard copies etc. shall be properly arranged, indexed

and bound in one folder and submitted to IITB / DEC. All fabricated drawings

to be furnished in *.DWG/DXE format on rewritable CD of reputed make.

16. Dispatch

a. Equipment shall be dispatched with Nitrogen (N2) filling. In case of site welding &


52 | P a g e

assembly of equipment, the same shall be filled with Nitrogen (N2) after testing at site.

Dry Nitrogen shall be filled at a pressure of 0.5 kgf/cm2 and equipment shall be fitted

with a pressure gauge and valve.

b. All internals & spare parts shall be packed separately in wooden packet to avoid damage

in transport.

17. Spares (Erection & commissioning, 2 years’ operation & Special Spares etc.)

a. Bidder shall supply all spares including bolting, gasket and packing required during

commissioning and up to performance guarantee test. All spares shall be packed

separately in wooden packet to avoid damage in Transport. All commissioning spares

shall be packed & marked separately to avoid any mix up at site. Bidder shall supply 2

years operational spares separately.

Please refer drawings C530/ME/GA/A1/304, C530/ME/GA/A1/305 Sheet-1,

C530/ME/GA/A1/305 Sheet-2 and C530/ME/GA/A1/306

Molten salt circulation pumps

1. The scope includes, design, procurement, fabrication, assembly, testing, supply, erection,

commissioning of molten salt pumps for the following operating parameters.

2. Charging circuit molten salt pump

Sr. no. Parameter Value 1 Type Vertical centrifugal, submerged pump 2 Fluid Molten Salt 3 Flow 3 m3 / hr, required1. 4 Head 50 mlc 5 Suction pressure 1.8 bar a 6 Fluid temperature normal / max 290 ⁰C / 500 ⁰C 7 Drive Direct with coupling 8 Cooling air cooled only

3. Discharging circuit molten salt pump

Sr. no. Parameter Value 1 Type Vertical centrifugal, submerged pump 2 Fluid Molten Salt 3 Flow 1 m3 / hr, required2. 4 Head 30 mlc 5 Suction pressure 1.1 bar a 6 Fluid temperature normal / min 565 ⁰C / 400 ⁰C 7 Drive Direct with coupling 8 Cooling air cooled only

4. The design of the pumps will take into consideration the effects of thermal distortion.

5. The pumps shall be adequately designed to mitigate thermal distortions by proper design

of heat dissipation.

6. Both line-shaft and cantilever pump designs are acceptable.

1 - if low flow rate is not available, higher flow rate will be used with bypass flow system

2 if low flow rate is not available, higher flow rate will be used with bypass flow system


53 | P a g e

7. The pumps shall be provided with suitable lifting arrangement to enable installation in

the tank.

8. The pumps shall be supplied with mounting flanges suitable for quick release eyebolt

flanges of the vessel.

9. The sealing of the pump shall be designed for 500mm WC pressure of inert cover gas in

the tank.

10. The sealing shall be designed for air cooling only.

11. The pumps shall be designed to eliminate radial loads

12. The pumps shall be designed to allow uniform thermal expansion of the pump

components.

13. The discharge pump shall be designed for minimal submergence.

14. Material test certificates

Please refer datasheets C530/ME/DS/A4/310 and C530/ME/DS/A4/311 respectively for

charging and discharging circuit molten salt pumps

Boiler feed water tank

Capacity - 2,000 L (nominal).

Type - Cylindrical vertical (Preferred) with provision for mounting on a structure

Material - Carbon steel

Accessories - Steam preheating coil to heat make up water from 30 0C to 80 0C

Chemical dosing provision

Manhole, drain, vent etc.

For all mountings, fittings and instruments please refer C530/ME/GA/A1/314 – GA and

fabrication details of Feed water tank

Boiler feed water pump

i. The pumps shall be procured, inspected, tested at vendor’s works, delivered to site,

installed and commissioned by the vendor based on the broad specifications given here

and the data sheet issued. The scope of supplies shall include pump with motor, base

frame, coupling, gear box / chain drive, fasteners, foundation bolts, safety guards,

pressure safety valve, pulsation damper, inlet and outlet non-return valves, lubricating

system, lubricants, controls, safety devices, weather hood etc. Any other item required for

the safe operations of the pump as per the process conditions is deemed included in the

scope unless specifically excluded. The motor shall be with as per specifications – refer

electrical section.

ii. The equipment to be offered against this tender will be of proven design by way of a

record of long time, trouble free field operation, without any deficiency and problem

whatsoever. As such, manufacturing technicalities to achieve high engineering quality and

performance guarantee for compliance with this specification shall be the prime

responsibility of the successful bidder.

iii. Applicable standards:


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Sr. no. Specification Description 1 ANSI -B3.11 Load ratings for Ball Roller Bearings 2 ANSI -B16.5 Steel Pipe Flanges and Flange Fittings. 3 ASTM -E 71 Industrial Radiographic Standards for steel

castings. 4 ASTM -E 94 Recommended Practice for Radiographic

testing. 5 ASTM -E 165 Methods of Liquid Penetrant Inspection. 6 ANSI B1.1 Unified and American screw threads 7 ASTM E 142 Method for controlling quality of Radiographic

Testing. 8 ASME Boiler and Pressure

Vessel Code Section VIII DIV-1. Boiler and Pressure Vessel Code

9 Hydraulic Institute Standards Section D -Reciprocating Pumps. 10 IS0 International Standard Organization

(Dimensional Standards for pipes and BW fittings and metric screw threads).

11 IS -5 Colours for ready mixed paints and enamels or epoxy paints.

iv. Design and Construction

a. The parts of the pump shall be designed to handle the liquid at the pressure and

temperature indicated on the attached pump data sheet. The pressure retaining parts

shall, as a minimum requirement, meet the requirements of ASME section VIII, Div-1.

b. Pumps shall be designed in accordance with good engineering practice and fabricated

as per the requirement of the applicable standards and codes.

c. Pumps shall be suitable for continuous operation. Castings and forgings shall confirm

to their respective material specification and shall be free of flaws and objectionable

imperfections and conforming to the highest quality of workmanship.

d. The material used for manufacturing of the pumps shall be new and of tested quality.

Correlating certificates for all the materials shall be produced by the bidder if

demanded by the purchaser's representative. As a minimum, test certificates shall be

furnished for materials of all pressure retaining components.

e. The pump shall be of triplex plunger type. Horizontal pumps are preferred. Compact

design of the pump motor unit is desirable. The direction of rotation shall be at the

discretion of the bidder. Exposed moving parts shall be enclosed by an adequate guard

for personnel protection. The pumps shall be located outdoor.

f. Pump design shall be appropriate to give minimum of 25 years of continuous service.

The pump shall be designed to facilitate ease of maintenance, inspection and repairs.

g. The pump shall be suitable for continuous operation under the following conditions:

Sr. no. Item Specification3 1 Type Triplex, reciprocating piston pump 2 Medium Boiler feed water 3 Operating

temperature 85 ⁰C

3 Refer datasheet for details


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Sr. no. Item Specification3 4 Discharge head 450 mlc 5 Pump NPSH < 2 m 6 Flow Rate 300 lph 7 Drive Electrical motor, Std. 3 phase, 415 VAC, 50

Hz., squirrel case induction motor, with VFD operation

8 Quantity 2 Nos ( 1W + 1S ) . h. All components subjected to pumps discharge pressure shall be designed for at least

45 kg/cm2(g). Those components exposed to suction pressure shall be designed for

at least 10 kg/cm2(g).

i. The materials of the main pump components shall comply with the requirements of

appropriate ASTM Standards. The cylinder block, suction, discharge connections shall

be stainless steel (SS 316L) or better. Material for all other parts will be at the

discretion of the manufacturer but shall be subject to approval by Purchaser.

j. The cylinder block shall be provided with replaceable liner or bushings. The liner and

plunger material shall be corrosion and wear resistance and the combination shall not

gall.

k. Lubrication of the plunger packing shall be with pumped fluid only. The plunger

packing and crankcase sealing arrangements shall be such that there will be no

contamination of the pumped fluid or its leakage with oil or grease. The pump shall

be provided with a plunger leakage collection arrangement which does not expose the

pumped fluid leakage to pump room or crank case atmosphere. Preferred

arrangement is triple packing with the interspace between the adjacent packings and

the first (primary) interspace connected to the pump suction while the second

(secondary) interspace provided for leak off connection.

l. All liquid and valves shall be readily accessible for maintenance. All valves shall have

renewable seats designed for easy replacement. To prevent galling, the difference in

hardness between valves and seats shall be at least 30 BHN. Sufficient free area

through valves shall be kept to restrict liquid velocities below lm/sec. at design

capacity. Inlet and outlet connections shall be flanged conforming to ANSI B 16.5 and

rating suitable for the pressure specified

m. Antifriction bearing life rating shall be computed in accordance with ANSI B for a

rating life of 60,000 hours.

n. Each pump-motor unit shall have its own lubrication system. The system shall be such

that no dismantling of any part of the unit is necessary to replenish or replace the

lubricant. For a unit using a pressure lubrication system, a pressure switch, to the

approval of the Purchaser, shall be provided for sensing the lubricating oil pressure.

Pressure indication shall also be provided.

o. Bearings shall give satisfactory service when lubricating oil is added or / changed at

intervals of not less than 6 months operation.

p. Crank case or packing box vents shall be protected with a mesh filter.

q. Pumps shall carry name plates with the following information.

Sr. no. Information 1 Tag no. 2 Serial no.


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Sr. no. Information 3 Model no. 4 Size 5 Capacity and pressure 6 Max. operating temperature

r. Materials

i. Materials for pressure casings and major internal parts in contact with the

liquid shall be specified by the vendor and shall be subject to purchaser's

approval. Unless otherwise specified, ASTM A 193 Gr B8M material shall be

used for bolting of liquid and pressure joints.

ii. Unless otherwise specified, small internal parts such as screws, nuts, keys,

lock washers and pins shall be of the material equal to in corrosion resistance

to valves.

iii. Name plates, rotation arrow plates etc. shall be AISI 304 stainless steel,

attached by pins and similar material.

s. Pulsation Suppression Devices

i. The details of the pulsation suppression device shall be furnished by the

vendor.

ii. Unless otherwise specified, pulsation suppression devices shall be designed

in such a way as to give amplitude of pulsation within the limits of + 3% of

mean. The pulsation suppression devices shall be chosen to suit operating

pressure.

iii. The pulsation suppression device and gas charging assembly shall be supplied

by the vendor along with necessary instruction for maintenance and use. The

supply shall include all the required interconnecting parts & components.

t. Relief valve

i. Relief valves shall be as per ASME Sec. VIII Div-1.

ii. Unless otherwise specified relief valve, for packed plunger pump shall be

furnished by the vendor and shall be mounted on pump discharge flange or

manifold. The relief valve setting pressure shall be equal to the rated

discharge pressure of 45 Kg/cm2. Relief valve shall be single coil type and

shall be of a reputed make.

iii. Material of construction of relief valve shall be stainless steel (SS 316 L)

iv. End connection of relief valve shall be flanged type and shall be connected to

discharge to suction side.

v. Relief valve shall be selected to pass 100% rated capacity of pump when fully

open and to limit accumulation pressure to 110% of rated discharge pressure.

u. Maintenance

i. The design shall be such that maintenance can be performed by persons with

those skills and tools normally available in modern power plants. Any special

tools shall be supplied by the Bidder.

ii. All units of same design supplied to this specification shall be interchangeable

for installation purposes and all spare parts shall be suitable for installation

in any of the units.

v. Threaded Fasteners


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i. Threaded fasteners shall conform to IS0 metric threads or ANSI B 1.1 and shall

be provided with corrosion resistant positive locking devices. Frictional

locking devices shall not be used.

w. Balance and Vibration

i. The unit shall be designed to operate with a minimum of vibration. Any

vibration isolation equipment required in the pump base assembly shall be

indicated. Supplier shall also indicate the guaranteed maximum vibration

level for the Unit under normal operating conditions, at both high and low

pressure levels indicated in para. 5.16. 11

x. Electric Motor Drivers

i. The motor brake horse power provided shall be at least 10% higher than the

I maximum horse power (including gear and coupling losses) required for the

rated capacity of the pump.

y. Base Plate

i. Common base plate for the pumps and driver along with bolts with nuts shall

be provided by Vendor.

ii. Base plate shall have a raised tip to contain stuffing box leakages.

iii. The pump shall be mounted on a trolley such that the pump shall be moved to

location as and when required and connected to suction and discharge piping

using flexible metallic hoses.

iv. Base plate shall have sufficient strength and rigidity to take the worst

combination of pressure, torque and connected piping induced loads, and

horizontal loads. The details of the pump base and bolts shall be subject to

purchaser's approval.

v. Inspection and Testing

a. Inspection

i. The bidder shall be responsible and provide for and perform all the inspection

and testing specified herein. The inspection and testing shall be conducted in

a manner satisfactory to and shall be subject to the approval of the Purchaser.

The Purchaser / Purchaser's representative shall have access to all bidder's /

sub-vendor's plants where manufacture or testing of equipment is in

progress.

Bidder shall provide the Purchaser with advance notification of the tests

specified as witness tests.

All materials designated as in conformance with an ASTM Standard shall be

tested as required by such standard.

Proof in the form of certified test reports or mill certificates that the required

tests have been carried out at the source will be acceptable, but if these are

not available, these tests shall be performed by the Bidder.

ii. Liquid Penetration inspection

The first and last passes of all pressure containing welds, all external and

accessible internal surfaces of the pressure bearing parts, the rotating and

reciprocating parts, after final machining and before assembly, shall be

inspected by a Liquid penetration method.


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Magnetic particle inspection shall be in conformity with ASTM E 109 or ASTM

E 13 B. Any suitable method specified therein is acceptable. Demagnetization

is required.

Castings showing defects greater than those shown in ASTM E 125 of the

degree listed below are not acceptable.

Sr. no. Type Degree 1 I & V, (linear discontinuity end

porosity) All indications to be removed

2 II (Shrinkage) 1 3 III (Inclusions) 1 4 IV (Internal Chills) 1

Liquid penetration inspection shall be in conformity with ASTM E 165. The

temperature of the part shall be between 50°F and 100°F. Penetrant and

developer shall be removed on completion of inspection. The cleaning agent

as well as the penetrant and developer shall not contain halogens and

sulphur. Any indication of defects on any of the components inspected by dye

penetrant inspection will not be acceptable.

iii. Radiographic Inspection:

All pressure containing castings shall be fully radiographed in accordance

with ASME Pressure Vessel Code Section VIII Div.1 and shall meet the

requirements specified therein.

All welds in pressure containing parts shall be fully radiographed in

accordance with ASME pressure vessel code section VIII Div.1.

b. Tests

Pumps and pump driver's unit shall be tested for the following:

i. Hydrostatic Test

Pressure containing parts including auxiliaries shall be tested hydrostatically

with liquid at a minimum of 1.5 times the pressure specified.

Tests shall be continued for a sufficient period of time to permit complete

examination of parts under pressure, but not less than 30 minutes.

ii. General Performance Test

The Pump shall be subjected to a performance test in accordance with the

Standards of the Hydraulic Institute Test code for power Pumps, Section VIII

- PP. The tests shall be performed using ordinary water at a temperature not

in excess of (110°F) 43.5"C. For the purpose of this test each pump shall be

connected to its own motor. The pump flow, power input to the motor, and

the pump efficiency shall be determined over a range of total head from zero

to at least maximum rated head. The Bidder shall submit test curves showing


59 | P a g e

Total Head, efficiency, brake horsepower and volumetric efficiency plotted as

ordinates on the same sheet with pump capacity as abscissa. After the pump

performance curves have been determined the pump shall be run

continuously for 24 hours at rated head using ordinary water. A plunger

leakage test shall be carried out during this run with the primary seal leakage

cavity at atmospheric pressure. The leakage shall not exceed the value stated

in the Tender as "the normal leak rate" to be expected. Vibration readings at

suitable points shall be recorded during the test. The leakage through

secondary seal cavity shall be measured with primary seal cavity maintained

at a minimum pressure of 0.5 Kg/cm2g.

iii. Strip Test

After the performance test, the liquid end shall be stripped off, to check for its

wear and workmanship. Shafts under packing shall be checked for any

abnormal rubbing and wear.

iv. NPSH Test

Vendor shall perform the test to verify NPSH required for each pump.

c. Inspection or Test Failure

i. In the event the equipment or any part thereof fails to meet inspection or test

requirements specified herein, the bidder shall notify the Purchaser or his

authorized representative. The bidder shall obtain permission from the

Purchaser before repair or subsequent use of such equipment or part. If the

repairs including redesign, are likely to affect the results of tests of work

previously completed, appropriate re-inspection and re-testing shall be

conducted.

vi. Finish a. All exterior unfinished carbon steel surfaces shall be coated with a rust preventive

primer followed by two coats of PU paint subjected to the approval of the Purchaser

or his authorized agency. The colour shall be grey corresponding to shade No. 693 of

IS5.

vii. Drawings and documents

a. The bidder shall submit following documents for seeking approval of the supply of the

pump

i. Outline dimensioned drawing of the assembled unit including motor,

indicating trolley and mounting details.

ii. Cross sectional view of the unit showing clearly all working parts.

iii. Catalogues / Technical data sheets giving in sufficient detail the

constructional, operational and maintenance features.

iv. Sub-vendor data sheets duly filled in and signed by the vendor.

b. Subsequent to approval for supply, bidder shall submit the following documents for

approval.

i. Six copies each of certified dimensional outline drawings, cross sectional and

assembly drawings including parts list & drawing giving trolley details.

c. After completion, the bidder shall submit 4 copies of the following:


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i. As built drawings.

ii. All test certificates for major pressure retaining parts.

iii. Performance test reports

iv. All relevant catalogues for proprietary items.

v. Instruction manual which shall cover installation, operation and maintenance

procedures. It shall also include recommended spare parts with replacement

schedule, lubrication requirements and recommended lubricant etc.

Please refer datasheet C530/ME/DS/A4/312 for more details.

Centrifugal pump

Scope

This specification covers the design, material, construction features, manufacture, inspection,

testing the performance at the Vendor’s/Sub-Vendor’s Works and delivery to site of Horizontal

Centrifugal Pumps.

Codes and standards

The design, material, construction, manufacture inspection and performance testing of Horizontal

Centrifugal Pumps shall comply with all currently applicable statutes, regulations and safety codes in

the locality where the Equipment will be installed. Nothing in these specifications shall be construed to

relieve the Vendor of this responsibility. The Equipment supplied shall comply with the latest applicable

Indian Standards listed below. Other National Standards are acceptable, if they are established to be

equal or superior to the Indian Standards.

List of Applicable Standards

Sr. no. Heater no. Mounting equipment

1 IS : 1520 Horizontal Centrifugal Pumps for clear cold fresh water.

2 IS : 5120 Technical requirements of roto dynamic special purpose

pumps.

3 API : 610 Centrifugal pumps for general refinery service.

4 IS : 5639 Pumps Handling Chemicals & corrosion liquids.

5 IS : 5659 Pumps for process water.

6 HIS Hydraulic Institute Standards, USA

7 ASTM-1-165-65 Standards Methods for Liquid Penetration Inspection.

In case of any contradiction with aforesaid standards and the stipulations as per the technical

specifications as specified hereinafter the stipulations of the technical specifications shall prevail.

Design requirements

1. The Pump shall be capable of developing the required total head at rated capacity for

continuous operation. Also the pumps shall be capable of being operated to give

satisfactory performance at any point on the HQ characteristics curve over the operating


61 | P a g e

range of 40% to 120% of the duty point. The maximum efficiency of pump shall be

preferably be within +/- 10% of the rated design flow as indicated in the data sheets.

2. The total head capacity curve shall be continuously rising from the operating point

towards shut-off without any zone of instability and with a minimum shut-off head of 15%

more than the design head.

3. Pumps shall run smoothly without undue noise and vibration. Peak to peak vibration

limits shall be restricted to the following values during operation.

Speed Antifriction Bearing Sleeve Bearing

1500 rpm and below 75.0 micron 75.0 micron

4. The noise level shall not exceed 85 dB. Overall sound pressure level reference 0.0002

microbar (the standard pressure reference for air sound measurement) at a distance of 1

M from the equipment.

5. The pumps shall be capable of starting with discharge valve fully open and close

condition. Motors shall be selected to suit to the above requirements. Continuous Motor

rating (at 50 ⁰C ambient) shall be at least ten percent (10%) above the maximum load

demand of the pump in the entire operating range to take care of the system frequency

variation and no case less than the maximum power requirement at any condition of the

entire characteristic curve of the pump.

6. The kW rating of the drive unit shall be based on continuously driving the connected

equipment for the conditions specified. However, in cases where parallel operation of the

pumps is specified, the actual motor rating is to be selected by the Bidder considering

overloading of the pumps in the event of tripping of operating pump(s).

7. Pumps shall be so designed that pump impellers and other accessories of the pumps are

not damaged due to flow reversal.

Design construction

Design and construction of various components of the pumps shall conform to the following

general specifications. For material of construction of the components, data sheets shall be

referred to.

1. Pump Casing

a. Pump casing shall have axially or radially split type construction. The casing shall be

designed to withstand the maximum shut-off pressure developed by the pump at the

pumping temperature.

b. Pump casing shall be provided with a vent connection and piping with fittings &

valves. Casing drain as required shall be provided complete with drain valves, piping

and plugs. It shall be provided with a connection for suction and discharge pressure

gauge as standard feature. It shall be structurally sound to provide housing for the

pump assembly and shall be designed hydraulically to minimum radial load at part

load operation.

2. Impeller

a. Impeller shall be closed, semi-closed or open type, and it shall be designed in


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conformance with the detailed analysis of the liquid being handled.

b. The impeller shall be secured to the shaft, and shall be retained against

circumferential movement by keying, pinning or lock rings. On pumps with overhung

shaft, impellers shall be secured to the shaft by a lockout or cap screw which tightness

in the direction of normal rotation.

3. Impeller/Casing Wearing Rings

a. Replaceable type wearing rings shall be provided at suitable locations of pumps.

Suitable method of locking the wearing ring shall be used. Wearing rings shall be

provided in pump casing and/or impeller as per manufacturer’s standard practice.

4. Shaft

a. The critical speed shall be well away from the operating speed and in no case less than

130% of the rated speed.

b. The shaft shall be ground and polished to final dimensions and shall be adequately

sized to withstand all stresses from rotor weight, hydraulic loads, vibration and

torques coming in during operation.

5. Shaft Sleeves

a. Renewable type fine finished shaft sleeves shall be provided at the stuffing

boxes/mechanical seals. Length of the shaft sleeves must extend beyond the outer

faces of gland packing of seal end plates so as to distinguish between the leakage

between shaft and shaft sleeve and that past the seals/gland.

b. Shaft sleeve shall be fastened to the shaft to prevent any leakage or loosening. Shaft

and shaft sleeve assembly should ensure concentric rotation.

6. Bearings

a. Heavy duty bearings, adequately designed for the type of service specified in the

enclosed pump data sheet and for long, trouble free operation shall be furnished

b. The bearings offered shall be capable of taking both the radial and axial thrust coming

into play during operation. In case, sleeve bearings are offered additional thrust

bearings shall be provided. Antifriction bearings of standard type, if provided, shall

be selected for a minimum life 16,000 hrs. of continuous operation at maximum axial

and radial loads and rated speed.

c. Proper lubricating arrangement for the bearings shall be provided. The design shall

be such that the bearing lubricating element does not contaminate the liquid pumped.

Where there is a possibility of liquid entering the bearings suitable arrangement in

the form of deflectors or any other suitable arrangement must be provided ahead of

bearings assembly.

d. Bearings shall be easily accessible without disturbing the pump assembly. A drain

plug shall be provided at the bottom of each bearings housing.

7. Stuffing Boxes


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a. Stuffing box design should permit replacement of packing without removing any part

other than the gland.

b. Stuffing boxes of packed ring construction type shall be provided wherever specified.

Packed ring stuffing boxes shall be properly lubricated and sealed as per service

requirements and manufacturer’s standards. If external gland sealing is required, it

shall be done from the pump discharge. The Bidder shall provide the necessary piping

valves, fittings etc. for the gland sealing connection.

8. Mechanical Seals

Wherever specified in pump data sheet, mechanical seals shall be provided. Unless

otherwise recommended by the tenderer, mechanical seals shall be of single type with

either sliding gasket or bellows between the axially moving face and shaft sleeves or

any other suitable type. The sealing faces should be highly lapped surfaces of

materials known for their low frictional coefficient and resistance to corrosion against

the liquid being pumped.

9. Pump Shaft Motor Shaft Coupling

The pump and motor shafts shall be connected with an adequately sized flexible

coupling of proven design with a spacer to facilitate dismantling of the pump without

disturbing the motor. Necessary coupling guards shall also be provided.

10. Base Plate

A common base plate mounting both for the pump and motor shall be provided. The

base plate shall be fabricated steel and of rigid construction, suitably ribbed and

reinforced. Base plate and pump supports shall be so constructed and the piping unit

so mounted as to minimize misalignment caused by mechanical forces such as normal

piping strain, internal differential thermal expansion and hydraulic piping thrust.

Suitable drain troughs and drip lip shall be provided.

11. Assembly and Dismantling

Assembly and dismantling of each pump with drive motor shall be possible without

disturbing the grouting base plate or alignment.

12. Drive Motor (Prime Mover)

The kW rating of the drive shall be based on continuously driving the connected

equipment for the conditions specified. In case, where parallel operation of the pumps

are specified, the actual motor rating is to be selected by the tenderer considering

overloading of the pumps in the event of tripping of operating pumps.

Testing

The manufacturer shall conduct all tests required to ensure that the equipment furnished shall

conform to the requirements of this specification and in compliance with the requirement of

applicable Codes and Standards. The particulars of the proposed tests shall be submitted to the

DEC/ IITB for approval before conducting the tests.

a. Hydrostatic Tests


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All pressure parts shall be hydraulically tested at 200% of pump rated head or at

150% shut off head whichever is higher. The test pressure shall be maintained for

1/2 hr. and no leakage shall be permitted. While arriving at the above pressure,

the maximum suction head specified in Data Sheet shall be taken into account.

b. Performance Tests

The bidder shall furnish manufacturer’s test certificates

c. Mechanical Balancing

All rotating components of the pumps shall be statically balanced. In addition to

static balancing, rotating components of the pumps shall be balanced dynamically

at or near the operating speed. Tenderer shall furnish acceptance norm for this

test.

d. Visual Inspection

Pumps shall be offered for visual inspection by the bidder before shipment. The

components of the pumps shall not be painted before inspection.

e. NPSH Test

NPSH test shall be conducted with water as medium if required. NPSH shall not

be mandatory in case type test certificates are furnished for the similar rating of

pumps.

f. Noise and Vibration Measurement

Noise and vibration shall be measured during the performance testing at shop as

well as during the site test.

i. The noise level shall not exceed 85 dBA. Noise level measurement will be

made as per applicable internationally acceptable standard. The

measurement shall be carried out with calibrated integrating sound level

meter meeting the requirement of IEC:651 or BS:5969 or IS:9779. Sound

pressure level will be measured all around the pump and motor set at a

distance of one meter from the nearest surface of the machine and at a

height of 1.5 m from the floor level. A minimum of six (6) points should be

covered for measurement. The measurement shall be done with a slow

response on the A-weighted scale. The average of the A-Weighted sound

pressure measurements expressed in decibels to a reference 0.0002

microbars shall not exceed the specified value.

ii. The tests shall be carried out on the machine operating at rated speed and

as near as possible to the rated power. Corrections for background noise

and correction on account of test environment will be considered in line

with applicable standard. For this purpose, all the additional data required

should necessarily be collected during the test.

iii. Vibration check will also be done as per HIS. Vibration would be checked

at thrust bearing locations on horizontal, radial and vertical direction. The

acceptance limits would be as per HIS. The instrument used would be IRD

308 or equivalent with velocity pick-up. Vibration limits to be specified as

per the speed of the pump.


65 | P a g e

g. Material Test Certificate

i. Material of the various pump components shall be tested in accordance

with the relevant standards. Test certificates for these shall be furnished

for IITB / DEC’s approval.

ii. Where stage inspection is desired by IITB / DEC / TPI all material test

certificates shall be correlated and verified with the actual material used

for construction before starting fabrication by IITB / DEC / TPI’s inspector

who will stamp the material. In case mill test certificate for the material

are not available, the supplier shall carry out physical and chemical tests

at his own cost from a testing agency, approved by IITB / DEC, as per the

requirement of specified material standard. The sample for physical and

chemical testing shall be drawn up in presence of IITB / DEC / TPI’s

inspector who shall also witness the testing.

h. Non Destructive Testing

i. UT shall be carried out on shafts of diameter more than 50 mm.

ii. DP tests shall be carried out on shaft and impeller.

iii. No weld repair shall be allowed on cast iron.

i. Field Testing

i. After installation, the pumps offered shall be operated to prove

satisfactory performance as individual equipment as well as a system run.

If the performance at site is found not to the requirements then the

equipment shall be rectified or replaced by the bidder, at no extra cost to

the IITB. The procedure of the above testing will be mutually agreed

between the DEC / IITB and the bidder. Noise and vibration tests shall also

be repeated at site.

ii. Based on observation of the trial operation, if modifications and repairs

are necessary, the same shall be carried out by the bidder to the full

satisfaction of the engineer in charge and then the performance and

guarantee tests to be repeated at site as per relevant clauses of the

specification.

Electrical heaters

Sr. no. Heater no. Mounting equipment Rating / heater

Qty Total heat duty

1 EH-01 Thermocline tank 4 kW 16 4 kW 2 EH-02 Evaporator 15 kW 1 15 kW 3 EH-03 Preheater 15 kW 1 15 kW 4 EH-04 Receiver start-up 15 kW 5 75 kW 5 EH-05 Receiver testing 40 kW 7 280 kW 6 EH-06 Receiver testing 40 kW 1 40 kW

1. The equipment shall comply with the latest edition of Indian Standards / IEC / BS /

VDE / IEEEE / NEMA or equivalent. In case of imported equipment, standards of the

country of origin, if equivalent / stringent than applicable Indian standards, shall be

applicable.


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2. The equipment shall also conform to the provisions of Indian Electricity Rules and

other statutory regulations currently in force.

3. The electrical heater and panel shall also comply to the requirements of licensor’s

specifications, if any.

4. The offered equipment shall be brand new and shall be of proven track record.

5. The heaters and panels shall be suitable for installation and operation in environment

as per the geographic location of the site and the equipment, their positions and

surroundings and the tower structure etc. as shown in the drawing and details with this

tender.

6. Design basis:

a. The heaters and panels shall be designed to provide continuous operation at

rated output, at the specified process conditions.

b. Over temperature protection shall be provided.

c. Suitable controls shall be provided to enable maintenance of the heaters.

7. Power supply :

a. Power supply shall be 415 VAC, TPN, 50 Hz,

8. Safety:

a. All components shall be designed to provide a maximum degree of safety during

all operating conditions, inspection and maintenance with proper clearance

between various components and devices. The heaters shall be located as per the

details and shall be designed to withstand prevailing environmental conditions.

9. Construction:

a. 4 kW, Thermocline tank heaters, 16 no.s EH-01: Heater assembly, consisting of 3

elements, each of 1.33 kW, made out of 10.5 mm diameter incoloy-800 tube,

brazed to 65mm NB x 15mm thick S.S.304 flange, length – 900 mm, cold – 150

mm, stand off - 250mm.

b. 15 kW, evaporator heater EH-02: Heater assembly consisting of 3 nos. elements,

each of 5 kW, made out of 16 mm diameter incoloy-800 tubes, brazed to 80 mm

NB, 600 class, S.S. 304 flange, length of element below flange - 1500 mm, stand-off

- 200 mm.

c. 15 kW, water preheater EH-03: Heater assembly consisting of 3 nos. elements,

each of 5 kW, made out of 16 mm diameter incoloy-800 tubes, brazed to 80 mm

NB, 600 class, S.S. 304 flange, length of element below flange - 1500 mm, stand-off

- 250 mm. The heater shall be mounted inside 80 NB pipe for inline heater EH-03

as per GA drawing attached with the tender.


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d. 15 kW, Receiver heaters, 5 no.s, EH-04: Heater assembly consisting of 3 nos. of

elements, each of 5 kW, made out of 16 mm diameter incoloy-800 tube, brazed to

80mm NB, 150 class S.S.304 flange, length of element – 2500 mm, the elements

will be supported by baffles and stud. The assembly will have safety

thermocouple. The heaters shall have a loose fit cap at top which shall remain at

the cut-out in the receiver cavity wall to prevent convection heat loss. The cap will

fit on the top of the heater and will be carried up as the heaters rise in the cavity

for daily startup heating of the receiver coils.

e. 40 kW, Receiver testing heaters EH-05, 7 no.s & EH-06, 1 no.: Heater assembly

consisting of 15 nos. of elements, each of 2.666 kW, made out of 8 mm diameter

incoloy-800 tube, brazed to 250mm NB, 150 class S.S.304 flange, length of

element – 2500 mm, the elements will be supported by baffles and stud. The

assembly will have safety thermocouple. Heaters EH-05 will have reflectors made

of SS 316, buffed and polished on the inside subtending an angle of 150º at the

centre of the heater. These heaters EH-05 and EH-06 shall be dismantled and

removed along with their panel from site and handed over as directed by the site

in-charge by the bidder after successful testing of the molten salt loop.

f. Heater elements

i. Heater elements shall be constructed of 80Ni, 20 Cr resistance wire

surrounded by MgO powder.

ii. The heater elements shall be protected against over-temperature.

g. Enclosures / Terminal boxes / panel

i. The enclosures / terminal boxes shall be suitable for the site conditions and

other relevant information provided in this tender.

ii. The enclosures / terminal boxes shall have a minimum ingress protection

rating of IP-55. Separate earth terminals shall be provided inside and outside.

iii. Panel shall be free standing, constructed of sheet steel, powder coated,

equivalent to IP-55, with lockable hinged doors, with sufficient component

spacing to allow cooling and provided with cooling fans, if required.

iv. Panels shall be bottom cable entry only.

h. Inspection and testing :

i. Heaters: Following electrical tests shall be carried out

1. High voltage test

2. Insulation resistance test of heaters to earth

3. continuity test on each phase of the heater

ii. Panels / terminal boxes

1. Insulation resistance test


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2. Electrical continuity test

iii. Site acceptance testing: A full load test of heaters in its service conditions

shall be carried out to confirm the design output. In addition, interfaces with

other connected systems shall be tested with particular emphasis on controls

and protection.

Please refer data sheet C530/EE/DS/A4/413

Piping, valves and fittings on molten salt lines, steam lines and feed water line

The scope of work shall be read in conjunction with other parts of this document. The scope of

work of bidder shall include the following:

Piping work (molten salt, feed water and steam piping, instrument air, cooling water, etc.)

1. Procurement, supply, shop & field fabrication, testing, painting (non-insulated piping)

and erection and commissioning of piping, installation of specialty items including supply

and erection of following materials but not limited to the same.

a. Pipes (All sizes and schedules)

b. Flanges (All sizes, types and Pressure ratings)

c. Fittings (All sizes, types and schedules)

d. Valves (All sizes, types and ratings)

e. Gaskets (All sizes, types and ratings)

f. Studs, Nuts or M/c Bolts (all types)

g. Specialty items like MOV, Control valves etc.

h. Installation of traps, strainers, sample coolers etc.

2. Procurement, supply, fabrication and erection, painting etc. of pipe supports like shoes,

clamps including bolting materials, saddles, guides, dummy pipes, stops, anchors, clips,

cradles, hangers, turn buckles, springs used in clamps for pulsating/ vibrating lines,

spring washers, supporting fixtures, brackets, cantilevers, struts, tee-posts, including

erection of spring supports, expansion bellows, steam and condensate manifolds and

sway braces. Bare pipes of all sizes shall be supported with corrosion pad or pad and shoe

on pipe rack / sleepers.

3. Site Fabrication of piping items.

a. Fabrication of piping specials like special radius bends, reducers, miters, etc.

b. Fabrication of plain and threaded nipples from pipes as required during erection.

c. Fabrication of swage nipples as and when required.

d. Fabrication of odd angle elbows like 60°, 30°, or any other angle from 90°/45°

elbow as and when required.

e. Fabrication of flanges, reducing flanges, blind flanges, spectacle blinds, crosses,

jump overs etc. as and when required.

f. Fabrication of circular pipe for steam rings, utility lines at all levels and elevations.

g. Fabrication of stub in connections with or without reinforcement.

h. Grinding of edges of pipes, fittings, flanges, etc. to match mating edges of uneven

/ different thickness wherever required as per specifications including beveling

of plain end pipes.

i. Threading of all small bore piping as per piping material specifications.

j. Drilling on blind flange for inserting / joining small bore lines.


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k. Fabrication and welding of reinforcement pads at branch pipe locations wherever

required.

4. Modifications like providing additional cleats for extension of stem of valve, locking

arrangement of valves, providing chain operation facility etc. as and when required.

5. Obtaining approval from statutory authority (IBR), for drawings prepared by consultant

/ suppliers / bidders required as per instructions of Engineer-in-charge.

6. As-built marking of Isometrics, bill of materials & supporting details of lines up to and

including 1½" related to instruments & pump flushing / cooling, purging, pump vents,

drains & Non IBR lines and lines specified as field routed within the unit battery limit

including subsequent approval from Engineer-in-charge as and when required is in

bidder’s scope of work.

7. Non-destructive examination / testing as per Job Specification for Non-Destructive

Examination Requirements of Piping Specification.

8. Fabrication and erection of small structures for pipe supports and valve operation /

attending some instruments etc., providing brackets from structures for pipe supports,

modification / extension of platforms, providing additional platforms / ladders for

improving / providing accessibility, including supply of necessary materials.

9. Providing insert plates with anchor fasteners in concrete structures / paved floors and

repair of platform gratings around pipe openings and providing suitable members for

support under the platform grating. Materials required for above are in bidder’s scope of

supply.

10. Flushing and testing of all piping systems as per standard requirements for inspection,

flushing and testing of piping systems. The accessories required for blinding the line like

flange, blind flange, gasket (all sizes, type and rating), stud-bolts, flexible hoses etc. are to

be arranged by the bidder. During flushing the discharged water / air shall be drained /

routed as directed by the Engineer In-Charge.

11. Hydraulic bolt tensioning & torqueing shall be performed on flange joints as per the

standard requirements

12. Wherever piping class breaks of high pressure / low pressure are involved, the high-

pressure circuit shall be tested up to piping class spec. break and the low-pressure circuit

shall be tested up to the nearest flange of high-pressure piping.

13. Providing stiffeners for all small bore (1.5” and below) branches. Materials required for

above are in Bidder’s scope of supply.

14. Internal grinding of welds of orifice flanges to render smooth surface.

15. Fabrication of saddles for supports from bidder supplied carbon steel & stainless steel

plates.

16. All piping must have high point vents and low point drains. All process drains, vents and

bleeds used and required for plant operation shall be in accordance with P&IDs. ¾” NB

maximum or line size if line size is less than ¾” NB size, valve high point vent and low

point drains are to be provided for all systems for hydrostatic / pneumatic testing /

flushing.

17. Bidder shall prepare welding specifications for all weld joints where dissimilar welding

will be performed, and obtain approval from DEC.

18. Supply and application of primer including surface preparation to piping, pipe supports

and structural steel work for pipe supports as per specification and instructions of

Engineer-in-charge.


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19. Any other incidental / intermediate / ancillary or any enabling work not specifically

mentioned in any specification but required to complete the work.

20. Providing marked up As-built GADs / Isometrics of all lines under the scope of this tender.

All As-built drawings shall be approved by the Engineer in–Charge and shall be supplied

in CDs and Hard Copies.

Silencer for steam vent

The silencer shall be for the following parameters:

Sr. no. Parameter Value 1 Medium Superheated steam 2 Service Discharge of steam to atmosphere at the end of

steam discharge piping after main outlet steam valve 3 Upstream pressure,

temperature 40 bara, 425 ⁰C

4 Steam flow rate (max) 500 kg/hr. 5 Downstream noise level < 85 dB at 1.5 m distance /

1. Scope: Includes design, engineering, procurement, manufacturing, supply, inspection,

packing, insurance, transport, loading, unloading, storage, erection, testing and

commissioning along with all spares, etc. complete.

2. The silencer shall be inclusive of inlet nozzle, support brackets, lifting lugs, drain nozzle,

weather cowl with bird screen, manufacturer’s name plate etc. complete

3. The Vent Silencer shall be designed to bring down the noise level to 85±4 dBA at 1.5m

distance at a directivity of 360 degree from the existing noise level in free field conditions.

The noise reduction shall be demonstrated at the time of commissioning and handover.

4. The bidder shall submit detailed design drawings and noise calculations for approval

prior to fabrication in triplicate.

5. The external surface of the vent silencer shall be sand blasted and painted with 3 coats of

HR aluminium paint.

6. The bidder shall submit as-built drawings in triplicate.

Instrument air plant

1. Purpose

Instrument air system consisting of screw / reciprocating air compressor, desiccant type

air dryer and pre filter is required to supply dry and filtered air with minimal oil content.

2. Main specification

The instrument air system shall consist of following items, with specifications given

against each. Ambient parameters shall be considered for Greater Noida, Uttar Pradesh.

a. Air compressor

i. An independent Air Compressor unit capable of continuously supplying

compressed air to the machine, powered by a 3 phase A.C. electric motor of

suitable rating and complete with


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a. Receiver Tank (conforming to ASME Norms), made of IS 2062, fitted with

Safety Valves, pressure gauge, and drain valve.

b. Pressure Relief Valve,

c. Automatic Pressure Switch,

d. Suction Filter,

e. Oil Sight Glass,

f. Drain Valve,

g. Starter for the motor

ii. Air delivery: 150 SCFM or more

iii. Working pressure at outlet of Integrated Desiccant Type Air Dryer: 7.5

Kg/cm2.

iv. Receiver Air tank capacity: 500 litres minimum.

v. Compressor shall be designed for continuous duty.

vi. Maximum noise level of compressor should be < 67 dB (A) at normal load

condition, one meter away from the machine / enclosure.

b. Adsorption type air dryer:

The Instrument air unit should have an adsorption type Air Dryer

i. Moisture Trap (with automatic and manual drain).

ii. The unit shall provide and stable pressure dew point ( -15 C to -20 C) &

avoid freezing during extended un-load run operation.

iii. Air dryer should be able to deliver compressed air from the machine

according to ISO – 8573-1 having the following parameters of air:

a. Solid particles / dust: Class – 1

b. Humidity: Class – 3

c. Oil content: Class – 2

iv. Purge loss shall be stated.

c. Downstream filters

i. General purpose pre-filter - A suitable and efficient Pre Filter for Compressor

Unit as per the requirement mentioned above for oil & other foreign particles

removal from air.

d. Control Panel:

Control panel for monitoring continuously & accurately (through microprocessor

based Regulator and Electronic Controller) the data and for controlling the

performance through feedback to the operator and interlocking arrangements.

Built in protection systems, inclusive of the following, should be provided for safe

and fool proof operation of the complete compressor system.

i. Phase sequence protection relay,

ii. Phase failure protection relay,

iii. Motor overload Trip,

iv. High Air / Oil Discharge Temperature Trip.


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v. Protection against starting on load,

vi. Suitable for controlling the compressor operation locally, remotely or via.

Local Area Network.

vii. Maintenance schedule display and alerts

viii. Usage statistics

e. All accessories to meet the specification and make the unit operable at site shall

be provided by the bidder with permanent arrangement as required.

3.0. Spares and consumables

Bidder shall supply 4 sets of all filters (air and oil), compressor oil for 2 years of

continuous operation (@ 24 hr. / day basis. Bidder shall also include 2 years

comprehensive maintenance contract with the OEM. Complete list of spares &

consumables (inclusive of the following spares & consumables) is to be provided,

giving individual item’s part identification no, its application, life (in hrs of use),

recommended quantity and unit cost.

4.0 Other requirements

a. Safety feature should be incorporated for safety of operator and the machine.

b. Anti-vibration mountings should be provided on the compressor frame for vibration

isolation from Screw element, Motor and Oil Separator Tank.

c. Documentation: Three sets of Operation and Maintenance Manuals documents are to be

supplied along with the unit with detailed electrical drawings ( SLD and CWD ).

d. Guarantee: Bidder shall provide full and complete guarantee from the OEM for two years

trouble free performance from date of successful commissioning / final acceptance.

e. Civil work: Bidder shall submit civil foundation drawings from OEM.

f. Space requirement: Bidder shall submit GA drawing of the package and indicating space

requirement for installation and maintenance of the package.

g. Notes:

a. Technical literature and catalogues of the offered package unit shall be submitted in

advance.

b. Compressor performance is measured according to ISO 1217, 4th Edition, and Annex.

C. Tolerances are applicable.

c. Operating Sound Level: Operating sound levels for machines equipped with

recommended standard motors and enclosures are guaranteed +/-3 dB(A) according to

Pneurop/Cagi PN8NTC2, tolerance: 3 dB(A).

h. Training: Bidder shall arrange for operation and maintenance training to client / site

personnel for handover. The training shall be duly documented.

Motorised hoists

The design of electric hoists shall be compact modular type, reliable and have proven quality. Only

reputed makes shall be offered.

The requirement is as below:


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Sr. No. Description Qty.

1 5 Te for receiver maintenance, outdoor, elevation

141.6m

1

2 2 Te for pumps etc., indoor, elevation 125.6m 1

3 2 Te for cleaning mechanism without trolley, indoor,

in parking area for cleaning mechanism, ground floor

1

Design specification for electric hoists

Sr. no. Item Specification / description

1. Number of hoist As per table above

2. Type of hoist Standard Electric hoist

3. Duty of the hoist Class II

4. Capacity as per table above

5. Height of the Lift as per equipment details

6. Hoisting speed as per manufacturer’s standard

7. Traversing speed as per manufacturer’s standard

8. Head Room (Distance between bottom

of monorail & hook top most position)

≤ 500 mm ( preferred )

9. Method of operation Push button pendant suspended at the

bottom. ( hang with suitable chain )

10. Electric Supply A.C. 415V 3∅

11. Monorail size As per details in structural drawings

12. Length of Travel As per details in structural drawings

Material of construction

All materials used shall be of sound quality and shall conform to latest relevant standards as given

below,

Sr. no. Item Specification / description 1. Steel Plates IS-2062, Grade B 2. High Tensile Bolts BS-970 (EN-24) or IS equivalent 3. Hooks and Clevises IS-1875 Class 3A and IS-3815, BS-482 &

BS2903 4. Steel Pinions BS-970 (EN-24) or IS equivalent 5. Steel Shafts and Axles BS-970 (EN-8) or IS equivalent


74 | P a g e

Sr. no. Item Specification / description 6. Pins and Screws BS-970 (EN-8) or IS equivalent 7. Steel Castings IS-1030 (Gr-II) 8. Iron Castings IS-210 (Grade 4 or better) 9. Steel Forging IS-2004, class-III (carbon % 0.25 - 0.35.) 10. Hoisting rope IS 2266 (Steel Core) 11. Monorails IS-3443, 50C12 12. Wheels En-9 forged

Design requirements

1. General design requirements for electric hoists:

The hoist shall be as per latest IS-3938 & IS-807 and of class-II duty (In-door / Outdoor

service) type, rigid and shall have adequate margins to give excellent performance, safety

arrangements for preventing overloading, over stressing on hoist component. The hoist

design shall be modular construction for easy maintenance. All efforts shall be made to

make the hoist as compact as possible.

a. Design requirements: Mechanical

i. Gear train: In order to ensure smooth operation & long life of gear train all gear

transmission shall be achieved from accurate machine cut spur gears at each

stage. The gears shall run in totally enclosed oil bath giving positive splash

lubrication to all gears & bearing. All gears in gear train shall be anti-friction

bearing mounted.

ii. Bearings: All supported / gears / shaft / wheels shall be mounted on the anti-

friction ball / roller bearings. For wheel, bearings shall of spherical roller type and

for hook block thrust ball bearings shall be used. The bearings shall be SKF / FAG

only. The test certificate for the bearing from the manufacturer shall be provided.

iii. Rope drum: The rope drum shall be of carbon steel fabricated seamless

construction, having spiral grooves machined to suit wire rope. The rope drum

shall be Ultrasonic tested. The drum shall have dimensions to meet IS: 3938. (In

order to make hoist compact higher diameter drums may be used). The revolution

of rope drum shall be on self-aligning ball bearings, which ensures smooth

running.

iv. Rope guide: A rope guide completely encircling the drum shall be provided so that

the rope shall be held in its grooves at all times and cannot get uncoiled even when

the rope is unloaded. Or any other suitable means for rope guiding so that the

verticality of the wire rope to be maintained within 1: 12.

v. Wire rope: Extra flexible long durable steel wire rope with an appropriate factor

of safety shall be used, which ensures long life. Replacement of wire of wire rope

shall be very easy.

vi. Runner wheels: The runner wheels shall be mounted on ball bearings. The trolley

drive assembly shall be attached to one of the runner angles and can be adjusted

to suit various joist sizes.

vii. Bottom block assembly: The forged hook conforms to IS: 3815 and shall be

supported on a thrust bearing, allowing the load to swivel freely. Provision shall


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be made to lock the swivelling of hook as & when required. Sheaves shall be

provided with guards to retain the rope in position.

viii. Frame: The frame, which supports the load shall consist of steel side plates and

steel runner plates of adequate section. The gear train and electrical control gear

shall be attached to the side plate and shall be housed inside separate fabricated

steel covers. A gasket shall be provided between cover and side plate for oil

sealing.

ix. Lubrication: The gears and bearings shall run in oil bath. The positive constant

splash lubrication to gears and bearings shall be ensured for faster heat

dissipation, smoother operation and longer life. The provision shall be made for

lubricating oil level indicator.

b. Design requirements: Electrical

i. Feeders for Electric Hoists:

One-point supply to each hoist shall be provided from the PMCC. Further

distribution shall be in Bidder’s scope. This shall include local starter panel, push

button station, other control, cables, cable trays and other consumables required

for satisfactory commissioning.

ii. Motors

All motors shall conform to latest IS 12615 and either of Siemens, Bharat Bijlee,

Crompton Greaves makes only. Drives for travel of the hoist as well as hoist shall

comprise of totally enclosed, fan cooled (IP55) squirrel cage induction motors

suitable for operating on a 415 V, 3 phase, 50 Hz AC electrical supply. The hoisting

motor shall be foot-mounted type. The motors used shall be special hoist duty

type (S4 duty) with CDF 1.5, and dual speed double winding suitable for frequent

starting, reversing and braking. The motors should operate satisfactorily for

voltage variation of ±10% & frequency variation of ±5%. The testing of motor for

type & routine test shall be carried out. Test for noise and variation measurement

also shall be carried out.

iii. Hoist brake

The hoist motor shall be fitted with an electro-magnetic brake designed and built

to arrest and hold safely the full load capacity of the hoist. The brake shall be

connected across the motor terminals for fail safe features. The brake shall be

easily accessible for its setting. The brake shall be rated for half an hour

continuous operating and for 150 % load capacities and shall be suitable for

selected class of duty cycles. The brake shall be of reputed make like BCH / Speed

O control / Electro-mag makes.

iv. Controls and control system

The hoist shall be designed to operate by push button pendant station. The push

button pendant shall be suspended along with steel link chain in order to avoid

stretch on control pendant wire. The push button pendant and control cabinet

shall be of light weight design.

The control panel consists of contactors, Overload Relays, Single Phase Protection

devices, transformer, rectifier and fuse etc. shall be provided on the hoist body


76 | P a g e

itself with suitable dust and weatherproof cover. The control panel shall be easily

accessible on hoist. All control equipment shall be suitable for operating on

control voltage 110 V AC to ensure safety to operator. A separate isolator switch

shall be provided by supplier for the electric supply to control system and shall be

of AC-24 duty.

Stop, start and directional changes shall be accomplished by reversing magnetic

contactors by push buttons operating a control circuit. In all cases the push button

shall be spring loaded and shall return to off positions when released. They shall

be suitably interlocked such that the push buttons of two reverse motions (e.g.

hoist up & down etc.) cannot be simultaneously operated.

Contactors & overload relays: All contactors, overload relays shall be of reputed

company (Siemens, Telemechanic) make and rated to permit 150 switching

operations per hour. Overload relays with built in SPP (Single Phase Protection

System) shall be considered. Wherever designed the reversing contactors shall be

provided with electrical and mechanical interlocks between forward and reverse

contactors.

The contactors shall be provided with a three element, positive acting, ambient

temperature compensated, time lagged, hand reset type thermal overload relays

with adjustable setting to suit the rated motor current. Resetting of the relay shall

be feasible from front door of the panel. The contactors shall be AC4 duty only.

v. MCCBs/MPCBs:

All MPCBs/MCCBs shall be of reputed make like and shall conform to IEC 60947.

All switchgear components shall be of ABB/Siemens/Schneider/L&T.

vi. Cables:

a. All cable shall be of 1.1 KV grade and control panel wiring shall be of insulated

and sheathed copper conductors for control circuit wiring.

b. Conductor section of main power circuit cables shall be selected taking into

consideration simultaneous operation of the hoist and trolley. The minimum

cross section of copper conductor wire/cable for power and control circuit

shall be 2.5 mm2 & 1.5 mm2 respectively.

c. Limit switch: A limit switches shall be provided for hoisting and trolley travel

operation in order to restrict the motion at both extreme ends. For hoisting

rotary as well as gravity type limit switch shall be provided.

Painting

All surfaces shall be cleaned thoroughly, preferably by sand blasting. All oils and greases shall be

removed prior to painting. Two shop coats of primer shall be provided at the supplier’s works

followed up two final epoxy coats.


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Spares and maintenance tools

1. Spares: The supply shall include necessary spares for 3 years trouble free service.

2. Maintenance tools: The supply shall include the required maintenance tools for the hoist.

Documentation

1. All material and routine test certificates

2. Operating and maintenance manuals

3. Guarantee / Warranty document

LP, HP dosing system:

Refer data sheet C530/UT/DS/A4/601

Technical Requirements

1. The equipment shall meet the duty requirements and performance parameters as

specified.

2. The equipment shall be designed for outdoor and unprotected location.

3. Dosing Tank

a. Tank shall be designed and fabricated as per the requirements of process data sheet.

4. Dosing Pumps

a. Pumps shall be designed, manufactured and tested in accordance with API-675.

b. Pumps shall be with suitable speed control to enable variable rate of dosing.

c. All coupling, gears and exposed rotating parts shall be provided with adequate

guards of non-sparking type.

d. Strainers shall be provided before inlet of the pumps.

e. Pump shall be supplied with calibration pot. The upper graduation level of

calibration pot shall be lower or equal to the maximum liquid level in the tank. The

vent of the pot shall be with valve and kept inverted ‘U’.

5. Structural Skid

a. Complete dosing package shall be mounted on a single structural skid suitable for

single lift.

b. The skid shall be designed and built to ensure that all the equipment along-with

accessories, panel and piping are mounted suitably for convenient

operation/maintenance.

c. All the components of the system shall be mounted on the skid, fully assembled,

piped with inlet and outlet piping terminated at the skid edge with appropriately

rated flanges.


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6. All electrical devices shall meet the requirements of the area classification and

electrical specification attached elsewhere in the bid. The instrumentation for the skid

shall be provided.

7. Interconnecting piping material specifications of the assembly shall be suitable. Bidder

to note that only SS piping shall be used.

8. Inspection and Testing

a. All equipment shall be subjected to inspection and testing at Vendor’s works by

purchaser/ his authorized inspection agency.

b. Manufacturer’s Quality Assurance (QA) plans shall be submitted for Purchaser’s

approval before taking up manufacturing.

c. Fittings, valves, instruments etc. shall be duly tested and manufacturer’s test

certificates shall be furnished.

d. All the pressure vessels shall be hydrostatically tested and inspected. The total skid

shall be hydro-tested at applicable pressure.

e. Any or all the tests, at Purchaser’s option, shall be witnessed by Purchaser/ his

authorized inspection agency. However, such inspection shall be regarded as check-

up and in no way absolve the Bidder of his responsibility.

Thermal Insulation

1. General Requirements

Thermal insulation shall be provided mainly for the following reasons.

a. Conservation of heat and maintenance of temperature as per design cycle.

b. Personnel protection

c. Insulation thickness as mentioned shall be provided.

2. Technical Requirements

a. All Insulating materials, accessories and protective covering shall be non-sulfurous,

incombustible, low chloride content, chemically rot-proof, non-hygroscopic and shall

be guaranteed to withstand continuously and without deterioration the maximum

temperature to which they will be subjected under the specified conditions.

b. The use of insulation of finishing materials containing asbestos in any form is not

permitted. The insulation compound shall not contain any substance detrimental to

health.

c. Insulation mattress / section shall be supplied in thickness of 25, 40, 50 and 75 mm.

Insulation of higher thickness shall be made up in multiple layers using

mattress/slabs of thickness specified above. However, if the required thickness is not

achieved, the mattress/slabs in increment of 5mm shall be acceptable. The minimum

thickness shall not be less than 25 mm, the number of layers shall be minimum and

the innermost layer shall be the thickest.

d. The durability and adherence of insulation layer on the bottom of the equipment is of

particular importance, therefore, special attention shall be paid to this when the

insulation is designed and applied.


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e. Special fire protection measures shall be taken for the steam lines running in the

immediate vicinity of oil lines. The sheet metal jacketing shall be made oil proof by

inserting self-adhesive flexible tapes.

f. Rock wool insulation mattress shall be of long fibered rock processed into fibrous

form bonded with a binder. No kind of slag wool inclusion is acceptable.

g. Clean water shall be used in mixing insulating or covering components. Care shall be

taken that brackish or salt water is not used for this purpose.

h. All insulation shall conform to the quality requirements laid down below and test

certificates on samples from the lot to be supplied shall be furnished to the Purchaser

for approval.

i. The use of asbestos in any form for insulation and elsewhere is not permitted.

j. The thermal conductivity of the insulating material to be considered for the design of

thickness of insulation shall be the maximum value as per the relevant standard to

which the material belongs.

3. Material of insulation

a. Insulation wool:

Insulation wool

Sr. no. Particular Type # 1 Type # 2

1 Material Lightly resin bonded mineral

( rock ) wool

Resin bonded mineral ( rock )

wool pre-formed pipe sections/

blocks

2 Apparent

density

100 kg/m³ for temp. 60 - 400

⁰C

140-150 kg/m³

150 kg/m³ for above 400 ⁰C

3 Material

standard

& testing

code

IS: 8183 IS: 9842

4 Applicable

service

Piping system & equipment

with operating temp. range

of 60 - 650 ⁰C

Piping system of 350 NB and

below with temp. in range of 60-

400o C

b. Cladding material: Cladding material for all insulated surfaces. equipment, piping etc.

confirming to ASTM B 209-1060 temper H-14 or IS-737 Gr.19000/H2 shall be

provided as follows,


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Cladding material Sr. no. Insulation dia. With lightly bonded

mattresses With preformed pipe sections

1 For dia of insulated surfaces of 450 mm & above and for flat surface

18 swg -

2 For dia of insulated surfaces less than of 450 mm.

20 swg 20 swg

c. Binding and lacing wires

Binding and lacing wires Sr. no. Temperature Material Thickness 1 Upto 400 ⁰C. Galvanised steel 20 swg 2 Above 400 ⁰C. Stainless steel 20 swg

d. Straps, bands, screws, wire mesh:

i. Materials of straps and bends shall be as under:

ii. Bands shall be 20 mm wide and 0.6 mm thick c)

iii. For securing aluminium sheathing material, stainless steel or anodized aluminium

bands shall be used.

iv. Screws shall be of stainless steel, self-tapping type.

v. Hexagonal wire mesh shall be conforming to following:

Hexagonal wire mesh Sr. no. Temperature Material Thickness 1 Upto 400 ⁰C. Galvanized steel 20 swg 2 Above 400 ⁰C. Stainless steel 20 swg

e. Bonding agent

i. Shall be alkali silicate based, formulated with surface drying additives-self

setting.

ii. Shall be suitable for temperature applications upto 900 ⁰C.

iii. Shall be non-corrosive, nontoxic and non-inflammable.

iv. Shall be free from unreacted matter.

v. Shall not require internal, or external drying; thus eliminating requirement of

steam heating.

f. Others accessories

The bidder shall also provide other accessories such as ceramic boards, sealants

and washers as required within the quoted price.

4. Application Procedure for Thermal Insulation and Refractories

a. General


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i. All surfaces to be insulated shall be cleaned of all foreign materials such as

dirt, grease, paint residue, loose scale and rust etc., and shall be dry before the

application of insulation.

ii. Before applying the insulation, the bidder shall check that all instrument

tapping, clamps, lugs and other connections on the surface to be insulated

have been properly installed as per the relevant erection drawing.

iii. Firm anchoring shall be welded onto the pads/strips already provided on the

body of the casings/ equipment. Pads/strips in addition to those already

provided shall be attached only with the approval from purchaser.

iv. All flanged joints shall be insulated only after the final tightening and testing.

b. Installation on valves and fittings

i. All valves, fittings and specialties shall be insulated with the same type and

thickness of insulation as specified for the connected piping with the special

provisions and or exceptions as given below.

ii. All valves and flanges shall be provided with removable box type of insulation

covered with box fabricated from aluminium sheets of thickness same as the

connected pipe cladding. Adjoining pipe insulation shall be bevelled back to

permit removal bolts and nuts or bands. The portion of the valve which

cannot be covered by box type insulation shall be filled by loose insulating

material of packing density at least equal to that of the insulating material of

adjoining pipe. The insulation for valves/flanges shall be applied after the

finishing has been applied over the connected piping. The cladding shall be

applied in such a manner that the bonnet flange can be exposed easily without

disturbing the complete insulation and cladding.

iii. For expansion joints the insulation, wherever applicable, shall be applied in

such a way that it does not hinder the functioning of the joint.

iv. Safety valves shall be suitably insulated.

c. Installation on piping

i. All vertical pipes shall be provided with the suitable insulation supports to

prevent collapsing/crushing of insulation due to its self-weight. Support rings

shall be provided at a spacing of 3 metres on all vertical piping with a vertical

length of 4 meter or above.

ii. Longitudinal joints of insulation mattresses sections of horizontal piping shall

be on the bottom or at the sides of the pipe.

iii. When more than one layer of insulation mattress/section is required on

piping the circumferential joints on adjacent layers shall be staggered by at

least 150 mm and longitudinal joints shall be staggered by at least 50 mm.

iv. Mattress type insulation shall be formed to fit the pipe and applied with the

mattress edges drawn together at the longitudinal joints and secured by

lacing wire. Pipe section insulation shall be fitted on pipe using binding wires.


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v. Where insulation is applied in two or more layers each layer of mattress shall

be backed with hexagonal wire mesh. For the first layer of insulation and in

case of single layer insulation, hexagonal wire mesh shall be provided on both

the surface of the mattress. For pipe sections, the preformed sections shall be

held in place by binding wires without any wire mesh.

vi. The ends of all wire loops shall be firmly twisted together with pliers, bent

over and carefully pressed into the surface of the insulation. Any gap in the

insulation shall be filled with loose mineral wool or finishing cement.

vii. Insulation mattress/section ends shall be terminated at a sufficient distance

from the flanges to facilitate removal of bolts.

viii. The insulation shall be held in place by fastening over with binding wire for

insulation surface with diameter upto and including 550 mm and with metal

bends for insulation surfaces with diameter over 550 mm. The fastening shall

be done at intervals of 250 mm except where specified otherwise. The ends

of the binding wires shall be hooked and embedded in the insulation. The

straps shall be mechanically stretched and fastened with metallic clamping

seals of the same materials as the strap.

ix. Insulation for application on bends and elbows shall be cut into mitred

segments, sufficiently short to form a reasonably smooth internal surface.

After the application of insulation material in place, insulating cement shall

be applied as required to obtain a smooth surface.

x. Weather hoods shall be provided for insulated piping passing through

floors/walls.

xi. All pipe attachments coming on horizontal pipes, inclined pipes and bends

shall be insulated along with pipe such that there will be no insulation applied

to hanger rod and the component connecting hanger rod to pipe attachment.

All pipe attachments exposed to weather shall be provided with weather

proof.

xii. Upstream of all drain lines and the lines connected to steam traps, shall be

insulated upto and including first isolating valve for heat conservation. Rest

of such lines such as downstream of the drain valves, traps etc. and other lines

such as safety valve discharges, vents, etc. shall be insulated for personnel

protection.

d. Installation on equipment

i. Insulation applied to the equipment shall be reinforced with hexagonal wire

mesh. One layer of wire mesh shall be provided on the equipment surface

prior to application of insulation.

ii. Installation on horizontal cylindrical vessel/tanks (including heaters, heat

exchanger etc.).

a. All the surfaces of insulation layers, applied on horizontal cylindrical

vessels shall be securely fastened by bands upto vessel/tank outer


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diameter of 150 mm and below. Where vessel/tank outer diameter

exceeds 1500 mm, binding wire passing through insulation clips

provided both longitudinally and circumferentially at 500 mm centers

shall be used. Gaps in the insulation shall be filled with loose mineral

wool and finished with finishing cement so as to obtain a smooth surface

for the application of cladding. The bidder shall provide support

ribs/lugs on the surface of the vessel/tank as necessary. The bidder shall

obtain the approval of the 'Purchaser' and the equipment supplier's field

engineering representative before performing any welding on

equipment. The bidder shall perform any heat treatment requirement

as per recommendation of equipment supplier.

iii. Installation on vertical cylindrical vessel/ tanks (including flash tanks etc.):

a. All vertical vessels/tanks shall be provided with support rings/ribs with

other necessary framework to take up the weight of the insulation prior

to heat treatment. The bidder shall obtain the approval of the

'Purchaser' and the equipment supplier's field engineering

representative before performing any welding on equipment. The

bidder shall perform any heat treatment requirement as per

recommendation of equipment supplier.

b. The mattresses shall be held in position by means of 9 SWG steel wire

nails, the nails being 25 mm longer than the thickness of insulation to be

applied. After the mattresses have been placed over the nails, the nails

shall be bent and embedded in the insulation. Alternatively, wire loops

may be tack welded at 250-mm centers to hold the insulation in place.

iv. Installation of cladding

a. All insulation shall be protected by means of an outer covering of

aluminum sheathing. All insulation/cladding joints shall be sealed and

made effectively weather and waterproof. All flat surfaces shall be given

suitable slope to prevent collection of pools of water on the cladding

surface. All sheathing shall be protected internally by the application of

two coats of bitumastic paint.

b. All longitudinal joints shall have a minimum overlap of 50 mm and shall

be located at 45 deg. or more below the horizontal for horizontal

equipment. Joints shall be made with cheese headed self tapping

galvanized steel screws at 150 mm centers.

c. All circumferential joints shall have a minimum overlap of 100 mm and

shall be held in position by stainless steel or anodized aluminium bands,

stretched and clamped.

d. Removable box type cladding for valves and flanges shall be fitted on the

connected pipe cladding, with bands.

e. Aluminum cladding shall not come directly into contact with either the

equipment surface or with the supporting arrangement on the


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equipment surface. To this end, adequate layers of 3 mm thick ceramic

board shall be provided between the cladding and any supporting

arrangement equipment surface, and fitted with self-tapping

screws/metal bands, as applicable.

f. For bends, fittings etc. the cladding shall be provided in segments as to

ensure a smooth finish of the cladding.

g. For cladding on vertical pipes/equipment, provision for load take up

shall be made at every 2 to 4 meters along pipe/equipment axis.

h. All joints shall be sealed with acrylic emulsion weather barrier.

i. Galvanic corrosion shall be prevented by carefully avoiding permanent

contact of aluminum cladding with copper, copper alloys, tin, lead, nickel

or nickel alloys including Monel metal.

v. Testing and guarantees

a. All tests, as per the applicable material standards and as specified shall

be carried out in accordance with the methods prescribed. Purchaser

shall have the right to witness any or all of the tests conducted by the

bidder at the shop or laboratory.

b. The Bidder shall guarantee that if on actual measurement the specified

maximum insulation surface temperatures are exceeded, the bidder

shall either replace the insulation with a superior material or provide

additional insulation thickness at no extra cost.

Suggested makes / suppliers

Sr. no. Item(s) Makes / suppliers

1 Molten Salt pumps Auro Pumps, Process Pumps (I) Pvt. Ltd,

Flowserve, Ensival Moret, equivalent

2 Boiler feed water pumps Dampf Kolben, Positive Metering, Hironisha

Systems, equivalent

3 Centrifugal pumps KSB, Kirloskar, Crompton. equivalent

Motors Siemens, Crompton, Kirloskar, ABB, Hindustan,

equivalent

4 Electrical heaters Rashmi Heaters, Pune, Lakshmi Electrical,

Navbharat Electrical, equivalent

5 Valves Belloseal Valves, Valvola Corporation, Flow

Serve, Uniklinger, KSB, equivalent.

6 Steam Silencers Trustwell Engineers, Anpam Engineering,

Acoustics India, Decimin Control, equivalent


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Sr. no. Item(s) Makes / suppliers

7 Instrument Air packages Aditi Engineers, Elgi Equipments, Ingersoll Rand,

equivalent

8 Dosing systems Metapow / Ravi Industries / NM Enterprise,

equivalent

9 Mineral wool insulation Lloyd Insulations, Rockwool India, Minwool Rock

Fibres, Goenka Rockwool (India) Pvt. Ltd., NGP

Industries Ltd., equivalent

10 Ceramic insulation Murugappa Morgan, Unifrax India Pvt. Ltd.,

Varsha Refractories, equivalent

11 PLC and components Allen Bradley

12 Salt Enesoon, BASF, Coastal Chemical, Haifa,

equivalent, SQM

13 Structural steel Please refer Technical specifications – Structural

Steel work.

14 Electrical items Please refer Technical specifications – Electrical

work.

B. Technical specification - Structural Steel work

SCOPE:

This specification covers the general requirements for supply of steel material, where specified,

fabrication and delivery at site of structural and miscellaneous steelwork.

APPLICABLE CODES AND SPECIFICATIONS:

1. Materials:

a. IS: 226/2062 -Structural Steel (Standard Quality).

b. IS: 808 -Rolled Steel Beam, Channel and Angle Sections.

c. IS:814 -Specifications for Covered Electrodes for Metal Arc Welding for

Structural Steel.

d. IS: 1161 -Specification for Steel Tubes for structural purpose.

e. IS:2074 -Ready Mixed Paint, Red Oxide Zinc Chromate and Priming.

f. IS: 823 -Code of Procedure for manual metal arc welding of mild steel.

g. IS: 919 -Recommendations for limits & fits for engineering (Part I & II).

2. Codes of practice:

a. IS: 800 -Code of Practice for Construction in Steel.

b. IS: 816 -Code of Practice for use of Metal Arc Welding for General

Construction in mild steel.

3. All steel to be supplied by the bidder:


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a. The BIDDER shall furnish to the DEC duplicate copies of all mill orders covering the

material ordered by him for this project and the test reports received from the Mills

for the Engineer’s check and information.

b. It is not the intention of the IITB / DEC that all the steel materials to be supplied by

the BIDDER for the work shall be specifically purchased from the rolling mills. The

Bidder’s stock material may be used, provided he satisfactorily demonstrates, the

specified grade and quality by furnishing test certificates. IITB / DEC shall have the

right to test random samples from the steel materials proposed to be used for work,

by the BIDDER at the Bidder’s cost. all steel materials supplied by the BIDDER shall

be in sound condition, of recent manufacture, free from defects, loose mill scale, slag

intrusions laminations, pitting, flaky rust, etc. and be of full weight and/or thickness

specified. The lengths/sizes of steel sections and plates shall be as supplied by the

steel mills.

c. Unidentified stock material may be used, only with the prior permission from DEC in

writing, for short sections of minor importance or for small unimportant works and

connections where, in the opinion of IITB / DEC, the quality of such materials would

not adversely affect the strength and/or durability of the structure. IITB / DEC may

also permit use of such materials for other works, if adequate random samples taken

out and tested demonstrate conformity with specification and requirement for the

work for which these materials are proposed to be carried out to the requirement for

this work. He is, however, not to commence plumbing, water supply and drainage

work unless drawings for such work or parts thereof are officially released as

"Released for Construction". revisions to drawings and any new drawings made to

include additional work by the BIDDER shall be considered as part of this specification

and contract. Bidder shall be responsible for obtaining approval of the drawings from

local authorities, if required, and he shall not be entitled for any extra payment on this

account.

4. Substitutions:

a. Wherever the BIDDER, in order to accommodate his/other materials in stock, desires

to substitute structural steel or plates for the sizes shown on drawings, such

substitutions shall be made only after authorization in writing is given by IITB / DEC.

b. The ENGINEER may also direct the substitution to be made, when he considers that

such substitutions are necessary.

5. Drawings prepared by DEC:

a. Checked and approved design drawings will be furnished to the BIDDER for execution

of the work and these shall form a part of this specification. The BIDDER shall study

these drawings, when made available, in detail for all information contained therein,

which pertains to, and is required for his work. Bidder shall also prepare fabrication

drawings showing all details as required for fabrication work& submit the same to

DEC for approval prior to starting the work. The drawings shall be approved &

returned to the bidder within 20 days from the day of receipt of the same.

Discrepancies, if any, shall be brought tithe notice of DEC.

b. IITB / DEC reserves the right to make changes. Revisions to drawings, even after

release of shop drawings, are very likely to be made to reflect additional data/details

received and more updated requirements. Revisions to drawings and any new

drawings made which include additional work required to be carried out by the


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BIDDER shall be considered part of this specification and contract and IITB / DEC shall

entertain no extra claims on this account.

c. Unless otherwise specified, the drawings and specifications are intended to include

everything obviously requisite and necessary for the proper and entire completion of

the work and the job shall be carried out accordingly for completeness as required

and as directed by IITB / DEC.

6. Fabrication

a. General:

All workmanship and finish shall conform to IS: 800. all materials shall be finished

straight as per the tolerance limits as specified. A holes and edges shall be free of

burrs. Shearing and chipping shall be neatly and accurately done and all portion of

work exposed to view shall be neatly and accurately done and finished. Material in the

shop shall be kept clean and shall be protected from weather.

b. Connections:

i. Shop connections shall be effected either by welding, or bolting, as specified on

the drawings. Bolts shall be in accordance with specifications.

ii. However standard M.S. bolts conforming to IS:1363 may be used for field

connections for light members such as purlins, girts, staircase stringers, hand

railings, landings beams, etc.

iii. Where necessary, tapered washers or flat washers or spring washers shall be used

with bolts. The length of the bolt shall be such that at least one thread of the bolt

project beyond the nut.

iv. In all cases where bearing is critical, the unthreaded bolt shall bear on the

members assembled. A washer of required thickness maybe provided to exclude

the threads from the bearing thickness, if a longer grip bolt has to be used for this

purpose.

v. A connections and splices shall be designed for full strength of members or loads

indicated, unless otherwise approved. Column splices shall be designed for the full

tensile strength of the minimum cross-section at the splice.

vi. A members likely to collect rain water shall have drain holes provided.

vii. Not more than one shop splice shall be provided to make up the full length of a

member.

c. Straightening:

Rolled material, before being worked, shall be straightened. If straightening or

flattening is necessary, it shall be done by methods that will not injure the

material. Long plates shall be straightened by passing through a mangle or

levelling rolls and structural shapes by the use of mechanical or hydraulic

bar/section straightening machines. Heating and/or forging shall not be resorted

to without the prior approval of DEC in writing.

d. Cutting:

i. Cutting may be carried out by shearing, cropping, sawing or machine flame

cutting, if permitted by the ENGINEER. all re-entrant corners shall be shaped

notch free to a radius of at least 12 mm. Sheared or cropped edges shall be dressed

to a neat workman like finish flame and shall be free from distortion and burrs.

The cutting machine flame cut edges shall be removed.


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ii. Hand flame cutting shall be undertaken only if so permitted by IITB / DEC and

shall be carried out by an expert in such work. Hand flame out edges shall be

ground smooth and straight.

iii. Edge planning of sheared, cropped or gas cut edges is not intended unless the

sheared, cropped or gas cut edges are such as to warrant it or is specifically called

for.

e. Punching and drilling:

i. Holes in secondary members such as purlins, girts, lacing bars, etc., may be

punched full size through material not over 12 mm thick. Holes must be clean cut,

without burr or ragged edges. Holes for all other connections shall be drilled

accurately and the burrs removed effectively. Where several parts are to be

connected to very close tolerance, such parts shall first be assembled tightly

clamped together and drilled through.

ii. Sub-punching maybe permitted before assembly, provided the holes are punched

3 mm smaller in diameter than the required size and reamed after assembly to

the full diameter. The thickness of materials punched shall not exceed 16mm.

iii. When batch-drilling is carried out in one operation through two or more

separable parts, these parts shall be separated after drilling and the burrs

removed.

iv. Holes for turned and fitted bolts shall be drilled to slightly smaller diameter and

reamed to a diameter of the shank or barrel subject to H 8 tolerance specified in

IS: 919.

v. Where reamed members are taken apart for shipping or handling, the respective

pieces reamed together shall be so marked that they may be reassembled in the

same position in the final setting up. No interchange of reamed parts will be

permitted. Poor matching, over-drilling, and orality in holes shall be a cause for

rejection. Burning holes with gas is strictly prohibited.

f. Welding:

i. Electrodes for shielded-arc manual welds shall comply with the requirement of

IS: 814 and shall be of approved make only. Approved makes are Advani Oerlikon,

D&H & ESAB.

ii. The Electrodes for manual arc welding shall be suitable for use in the position and

type of work, as laid down in the above specifications and type of work, and as

recommended by the manufacturers. Electrodes classification group 1 and 2 as

given in IS:814 shall be used for welding steel conforming to IS:226.

iii. Welding plant and accessories shall have capacity adequate for the welding

procedures laid down and shall satisfy appropriate standards and be of approved

make and quality. The BIDDER shall maintain all welding plants in working order.

All the electrical plant in connection with the welding operation shall be properly

and adequately earthed and adequate means of measuring the current shall be

provided.

iv. All weld shall be made only by welders and welding operators who have been

properly trained and previously qualified by tests and to perform the type of work

required as prescribed in the relevant applicable standards.

v. All welds shall be free from defects like blow holes, slag inclusions, lack of

penetration, undercutting, cracks etc. All welds shall be cleaned of slag or flexed


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show uniform sections, smoothness of weld metal, feather edges without overlap

and freedom from porosity.

vi. Fusion faces and surfaces adjacent to the joint for a distance of at least 50 mm on

either side shall be absolutely free from grease, paint, loose scales, moisture or

any other substance which might interfere with welding or adversely affect the

quality of the weld. Joint surfaces shall be smooth, uniform and from fins, tears,

laminations, etc. Preparations of fusion faces shall be done in accordance with the

approved fabrication drawings by shearing, chipping, machining or machine

flame cutting except that shearing shall not be used for thickness over 8 mm.

vii. Members to be joined by fillet welding shall be brought and held as close together

as possible and in no event shall be separated by more than 6 mm. If the

separation is 1.5 mm or greater, the fillet weld size shall be increased by the

amount of separation. This shall only apply in the case of continuous welds. The

fit-up of joints at contact surfaces which are not completely sealed by welds shall

be close enough to exclude water after painting.

viii. The separation between facing surfaces of lap joints and butt joints with backing

plate shall not exceed 1.5 mm. Abutting parts to be butt welded shall be carefully

aligned and the correct root gap maintained throughout the welding operation.

ix. Misalignments greater than 25 percent of the thickness of the thinner plate, or 3

mm, whichever is smaller shall be corrected and in making the correction the

parts shall not be drawn into a slope sharper than 2 degrees (1 in 27.5)

x. Prequalified welding procedures recommended by appropriate welding

standards and know to provide satisfactory weld shall be followed. For non-

standards procedures, qualifications, tests etc. as prescribed in IS: 823 shall be

made to verify the adequacy of the procedures. Welding procedures shall be

prepared by the BIDDER and submitted to DEC for approval before start of

welding. This shall include all details of welding procedure with reference to

provisions of IS: 823 and IS:4353, latest.

xi. Approval of the welding procedure by IITB / DEC shall not absolve the BIDDER of

his responsibility for correct and sound welding without undue distortion in the

finished structure.

xii. No welding shall be done when the surface of the member is wet nor during

periods of high wind, unless the welding operator and work are properly

protected.

xiii. In joints connected by fillet welds, the minimum sizes of single fillet welds or first

runs and minimum full sizes of fillet welds shall conform to the requirements of

IS: 816 and IS: 823.

xiv. Fillet weld larger than 8 mm shall be made with two or more passes.

xv. A complete penetration butt weld made by manual arc welding, except when

produced with the air of backing material or welding in flat position, from both

sides in square-edge material not over 8 mm. thick with root opening not less than

one-half the thickness of the thinner part joined, shall have the root of the initial

layer gouged out on the back side before welding is started from that side, and

shall be so welded as to secure sound metal and complete fusion throughout the

entire cross section.


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xvi. Each layer of all multiple layer welds, except root and surface runs, may be

moderately peened with light blows from a blunt tool. Care shall be exercised to

prevent scaling or flaking of weld and base metal from over peening.

xvii. Inspection of welds: All welds shall be inspected for flaws by any of the methods

described under clause "TEST OF WELDS" the choice of the method adopted shall

be determined by DEC.

xviii. The BIDDER shall include the costs of carrying out the tests in the cost of

structural steel work itself.

xix. The correction of defective welds shall be carried out as directed by DEC without

damaging the parent metal. When a crack in the weld is removed, magnetic

particle inspection or any other equally positive means as prescribed by DEC shall

be used to ensure that the whole of the crack and material upto 25mm. beyond

each end of the crack has been removed. Cost of all such test and operations

incidental to correction shall be to the Bidder’s account.

g. Tolerances:

The dimensional and weight tolerance for rolled shaped shall be in accordance

with IS: 852. The acceptable limits for straightness (slope and camber) for rolled

or fabricated members are:

Struts and columns -L/1000 or 10 mm. whichever is smaller.

For all other members not primarily L/500 or 15 mm in compression such as

purlins, whichever is girts, bracing and the web members of smaller trusses and

latticed girders.

Where `L' is the length of finished members of such lesser length as DEC may

specify.

h. Material testing:

Even if mill tests reports are available for any steel materials the same shall be got

tested by the BIDDER to IITB / DEC’s satisfaction to demonstrate conformity with

the relevant specification at a lab approved by DEC.

i. Dimensions, workmanship & cleanliness: Members shall be inspected at all stages of fabrication and assembly to verify that

dimensions, tolerances, alignment, surface finish and painting are in accordance

with the requirements shown on the approved shop drawings.

j. Drilling holes for other works:

Holes in members required for installing equipment or steel furnished by other

manufactures or other bidders shall be drilled at no extra cost to IITB / DEC, in

the Bidder’s shop as part of this contract, the information for which will be

supplied by the IITB / DEC/ before fabrication of the steel.

k. Handrails:

i. Handrails shall be provided on open sides of platform, stairways and around all

opening as shown on drawings. Handrails shall be of standard weight mild steel

pipe of flush welded construction, ground smooth, provided with double rail, top


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rail about 1 metre above platform level and pipe posts spaced as shown on

drawings.

ii. Smooth uniform curves and bends shall be provided at stair return and

also wherever required/specified. Posts connected to curb plates shall have a neat

closure at the bottom and 6 mm thick plate neatly welded to posts for attachments

to curb plate. all necessary fittings including inner dowels at splices, brackets,

bolts, bends, flanges and chains, where required shall be furnished by the BIDDER.

Open ends of the pipe posts shall be plugged and welded. A minimum radius of 3

times the pipe diameter shall be provided at all points of direction change in the

handrail.

iii. The rate quoted for handrails shall be per running metre of complete handrails

including posts, fitting, etc. It shall be clearly understood that individual lengths

of runners, posts, etc. will not be measured for purposes of payment.

CHEQUERED PLATE: Chequered plates used shall be as shown on drawings. Chequered plate

shall be fixed by8 mm. diameter cadmium plated MS. screws with counter sunk heads at a

maximum spacing of 400 mm. Members supporting the chequered plate shall have matching

holes tapped in them. The chequered plate pattern shall be approved by DEC. Chequered plates

may also be required to be welded to the structural steel framing. The decision in this regard will

be given by the IITB / DEC.

l. Marking of members:

i. After checking and inspection, all members shall be marked for identification

during erection. This mark shall correspond to distinguishing marks on

approved erection drawings and shall legibly be painted and stamped there

on. The erection mark shall be stamped with metal dye with figures at least 20

mm high and to such optimum depth to be clearly visible, even after a member

is galvanized.

ii. All erection marks shall be on the outer surface of all sections and near one

end, but clear of bolt hole. The markings shall be so stamped that they are

easily discernible when sorting out members. The stamped marking shall be

encircled boldly by a distinguishable paint to facilitate easy identification.

iii. Erection marks on like pieces shall be at identical locations. Members having

lengths of 7.0 M or more shall have the erection mark at both ends.

iv. In addition, colour code marking, wherever specified, shall be clearly painted

on the member in the manner specified.

v. Separate colour code or identification marks, shall be adopted for members

fabricated from steel supplied by the IITB / DEC and the BIDDER.

m. Errors:

Any error in shop work which prevents proper assembling and fitting up of parts

in the field by moderate use of drift pins or moderate amount of reaming will be

classified by DEC as defective workmanship. all charges incurred by IITB either

directly or indirectly because of the poor workmanship will be deducted from the

amount due to the BIDDER before payments made. The amount of such deduction

will consist of the sum total of the costs labour direct or indirect, material, plant,


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transportation, equipment rental and overhead expenses. In case IITB / DEC

choose to reject the material because of poor workmanship, the cost of all

handling and returning of the material to the BIDDER, if he so desires, shall

entirely be to Bidder’s account. all the replacement materials shall conform to the

same specification as for the original materials, & shall be supplied free and in all

such cases, the cost of handling, transport and delivery to site shall be borne by

the BIDDER.

n. Painting:

i. All fabricated steel material, except those galvanized, shall receive protective

paint coating.

ii. The surface of steelwork to be painted shall be thoroughly cleaned of all loose mill

scale, rust, grease, dirt and other foreign matter by hand tool cleaning, power tool

cleaning, flame cleaning or sand/shot blasting as specified and as directed. In

power brushing, sufficient care shall be exercised not to burnish mill scale to a

slick finish to which paint may not adhere properly.

iii. The paint treatment specified shall be applied either by brushing or spraying on

the thoroughly cleaned and dry surface. Airless spraying shall be done if so

specified. Surfaces inaccessible after assembly shall receive an additional coat of

the specified paint prior to assembly.

iv. Paint shall be stirred frequently to keep the pigment in suspension. all paint

delivered to the fabrication shop shall be ready mixed in original sealed

containers as packed by the paint manufacturers and no thinners shall be

permitted. No painting shall be done in frosty/foggy weather or when the

humidity is high enough to cause condensation on the surface to be painted. Paint

shall not be applied when the temperature of the surface to be painted is 50 deg

centigrade or higher.

o. Method of measurement:

i. For the purpose of payment, the weight of the actual, completed structures shall

be calculated from the approved drawings for different items of work. The

BIDDER shall submit to the IITB / DEC relevant materialist containing weight of

each item.

ii. Bolts, washers & nuts shall not be taken into account in calculating the weight of

the completed structure. The rates of structural to include the weight of Nuts,

bolts & washers etc. No allowances will be permitted for galvanizing, welding or

for rolling margins. One ton for the purpose of payment shall mean ONE METRIC

TON i.e. 1000 kg.

iii. The weight of all member made out of standard rolled sections such as beam,

channels, angles, etc. shall be based on the standard IS book weight of the member,

without deducting for holes, notches, bevel cuts, etc. Where a component consist

of a cut joint or channels, the full weight of the rolled section shall be considered,

only if more than half the depth of the section is used. Otherwise only half the

section unit weight shall be considered for calculation of the weight of the

component. Deductions shall be made in the weight of gussets/plates for skew

cuts and notches of 900 sq.cm. or larger.


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iv. For gussets/plates used in trusses, bracings columns, beams, etc. the area shall be

that of the minimum circumscribing rectangle, except as stated in 11.3 above.

v. The weight of any built-up member shall be separated into the weight of each

component.

p. Structural steel work in tubes:

i. Scope: This specification covers the specific technical requirements for the

following.

ii. Supply, inspection, and testing at site of tubular structural steelwork.

iii. Fabrication, erection and testing at steelwork.

iv. Supply, erection and testing of materials:

Materials for tubular steelwork supplied by BIDDER shall conform to IS: 1161.

The class of tubes shall be as specified on drawing / BOQ. all materials shall be

free from injurious defects.

v. Fabrication erection and testing of tubular steelwork:

a. The supply and erection of tubular steelwork shall include inspection,

delivery at site, cleaning, cutting, aligning welding connecting and installing a

tubular steelwork in position as shown on drawing and as directed by

Engineer.

b. Wherever tubes of different thickness are to be butt welded the necessary

bevelling

c. shall be carried out by the BIDDER at no extra cost to the IITB / DEC.

d. The BIDDER shall be supplied with the drawings for tubular steelwork

connections. The tubes shall be cut to the exact shape and welded properly.

The thickness of the weld shall be as specified on drawing. Welded joint shall

be ground smooth.

vi. Welding:

a. Tack welds used in assembling tubes shall be made by qualified welder, or

shall be removed. Tack welds which are not to be removed shall be made with

an electrode which is the same as or equivalent to the electrode be used for

the first pass.

b. All welds shall be full penetration, homogenous with no voids. Any cracks or

blowholes that appear on the surface of joint shall be removed by chipping

c. All stipulations for welding work as mentioned in this specification (para 6.6)

shall apply for the welding of tubular steelwork, in addition to that mentioned

above.

d. Prior to commencement of welding, welder qualification test shall be taken

After the welder is approved than & than he can proceed with the welding.

e. When the end of a tube is not automatically sealed by virtue of its connection

by welding to another member, the end shall be properly and completely

sealed. Before sealing, the inside of the tubes should be dryland free from

loose scale.

q. Storing and handling

i. Storage of structures shall be preferably be done in such a manner that

erection sequence is not affected.

ii. While storing, care shall be taken so that structures do not come in direct

contact with the earth surface and accumulated water. Girders, beams,


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columns etc. shall be placed and stored in such a manner that during rain, no

accumulation of water on the structures takes place.

iii. Stacking of the structures shall be done in such a way that, erection marks are

visible easily and handling does not become difficult. Wherever required,

wooden sleepers / grilles may be used.

iv. Handling and storage of materials shall be as per IS:7969-1975, ensuring

Watch and Ward, Safety, Inventory control.

r. Galvanising:

Wherever specified, spray galvanising shall be carried out as per specifications below:

Sr. no. Aspect Specification A 1 Surface preparation Sand blasting ( NACE No. 10 /SP10 ) 2 Quality of Zinc According to IS : 13229-1991, Min Zinc 98.5% 3 Method of application Molten Zinc spray 4 Spray interval Within 4 hrs of sand blasting in dry weather 5 Dry film thickness of zinc coating at

any point on the steel surface 85 Micron ( Minimum )

6 Overall quality of HDG Zinc coatings shall be uniform, adherent, reasonably smooth and free from imperfections such as flux, ash, bare patches, black spots, pimples, lumpiness and runs, rust stains, bulky white deposits as per IS 2629 practice

B Tests & Inspection Zinc purity and quality report. Uniformity of coating DFT measurement on various sections/parts

C Documentation As per tests and inspection

List of recommended makes / manufacturers for steel

General:

The makes and manufactures shall be preferably from the following list. In case some of the

items not available in the market or some of the particular products are not producing by the

following manufacturer or in case of change in trade name etc. equivalent makes or re-

designated product shall be used conforming to the specific IS codes with the prior approval of

IITB / consultant.

In case of some items not covered in this list like fasteners, fixtures etc. may be procured form

the market conforming to IS codes with test certificates and prior approval from the IITB /

consultant.

Sr. no. Item Manufacturer

1 Structural Steel SAIL, RINL, Tata Steel, JINDAL, ESSAR or as approved by IITB / DEC

2 Electrodes ADOR ( Advani Oerlikon ), D & H, ESAB or equivalent approved manufacturers as approved by IITB / DEC

3 Paint BERGER, SHALIMAR, AKZONOBEL, SIGMA Coating,


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ASIAN PAINTS, Grand Polycoat Or As Approved By IITB / DEC


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C. Technical specifications for instrumentation work.

Instrumentation work - General 1. Definitions

a. SCADA - Supervisory Control & Data Acquisition System

b. PLC- Programmable Logic Controller

c. First block valve - First block valve shall mean the valve / valves that are

mounted directly on equipment, columns, vessels, pipe, standpipe etc. and shall be

operated to isolate the instrument and connected instrument piping from the above

items.

d. Supports - Supports shall mean the MS angles, flats, channels that are

generally provided to support the main cable ways, cable ducts, junction boxes, angle

trays, perforated trays, instrument piping, signal tubing, instrument air supply lines

etc., at specified intervals from the structures, concrete columns etc., to keep all items

firmly secured against vibration, warping, bending etc.

2. General conditions

a. The bidder shall during the execution of his work use exclusively new material to

the standards laid down in this or any supplementary documents given thereafter.

Any inconsistency or ambiguity in the design documentation supplied by IITB

shall be resolved by the "Engineer In-charge" before work commences.

b. The bidder shall carry out the work in accordance with the standards listed herein

and in accordance with any local statutory regulations and supplementary

documentation.

c. The bidder shall instruct his staff, skilled and semi-skilled on the standards

required by the IITB and shall ensure that only competent staff handle or work on

the instrument system.

3. Workmanship, tidiness & safety

a. The bidder shall not allow rubbish & scrap materials from his operations to lay

about the site. Such rubbish & scrap shall be collected daily and be deposited at a

place approved by the "Engineer In-charge".

b. No dangerous or noxious wastes products, chemicals or materials shall be

disposed of on the site without approval of "Engineer In-charge".

c. The bidder shall be responsible for protecting installed equipment from damage

& pilferage, and shall ensure that all covers, caps, screws and weather protection,

etc. are replaced at the end of each working day.

d. Only the best trade practices are to be used, and all work must be done to the

satisfaction of the "Engineer In-charge" who should be consulted on any point

requiring clarifications. The Bidder is free to suggest to the "Engineer In-charge"

alternative methods for the execution of the work where this would result in

improvement.

e. Upon completion of the work, the bidder shall promptly remove his equipment

and return to the relevant place any unused materials supplied by the "Engineer

In-charge". Finally the bidder must clear the site of all rubbish and scrap deposited

by him to the satisfaction of the "Engineer In-charge".

f. The bidder shall ensure that adequate precautions are taken during use and

storage of pressure bottles. Bottles left unattended to shall be isolated at the main

stop valve.


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g. The bidder shall prepare a comprehensive bar chart programmed for carrying out

the installation before the commencement of the actual work.

h. The bidder shall submit before commencement of the actual work, a

comprehensive list of tools, tackles, and test equipment which will be employed

by him for carrying out the installation.

4. Standards

a. The instrumentation installation and calibration works shall be carried out

generally in accordance with various latest editions of international standards (

IS, ISO, API, ANSI) in instrumentation listed below but not limited to the following

-

i. API-RP-551 on "Process Measurement Instrumentation".

ii. "International Society of Automation (ISA)" Standards Library for

Measurement and Control: Guidelines for Quality, Safety & Productivity.

iii. Manufacturer's standards and Practices.

5. Bidder’s scope of work

a. The Scope of work includes complete instrumentation installation, calibration,

testing & providing commissioning & startup assistance & making “AS BUILT “

drawing markups.

b. The bidder shall have full knowledge of all applicable Local regulations & laws &

all specific rules applicable at site.

c. The instrumentation installation work covers various jobs listed under the

"Schedule of Quantities". However, to ensure proper execution and completeness

of instrumentation works any or all of the following shall also form the part of the

scope and shall be covered in the quoted rates.

d. Fabrication of pipe nipples, including threading wherever required.

e. Filling of seal pots with filling liquids as per instructions from "Engineer In-

charge".

f. Seal welding of screwed fittings as required by standards.

g. Laying of cables from Junction box located at the battery limit to field in the cable

Tray on the pipe rack, branch cable trays, up to field instruments / local panels

etc. including glanding termination on both sides. For underground cables (if any)

the scope includes excavation, sand filling, brick laying and back filling & glanding

termination on both sides.

h. Connection of purging devices for instruments as per drawings.

i. Minor civil works like chipping of pavement and grouting on the pavements the

instrument panels / supports / stanchions and chipping, refilling and finishing of

the pavement for conduits.

j. Sealing of cables / tube entries into the control panels after laying and testing of

all tubes, cables etc.

k. Rotation of control valve bonnet wherever required.

l. Reversing the action of control valves either by replacement of springs,

accessories or in positioner wherever required.

m. Painting of all structural supports for trays, pipes, junction boxes, instruments,

ducts, trays etc., as per agreed painting specification.


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n. Identification with approved colour of paint the instruments / impulse lines

manifold connected with alarm / trip circuit. Also, punching of tag numbers on

items shall be carried out as per instructions of "Engineer In-charge".

o. Coordination with mechanical and other sub-bidders for proper installation of

line / vessels / equipment mounted instruments like control valves, on-off valves,

orifice assemblies, level transmitters, level gauges other type flow meters, safety

& thermal relief valves & any other type of line / vessel mounted instruments

which are not covered above, which involve removal of instruments,

disconnection of tubes / cables, reconnection for alignment and proper

installation etc. Drilling holes on all panels, shut down cabinets, power supply

cabinets, control panels, pneumatic enclosures, junction box etc., for cables /

glands.

p. Grounding of shield of all shielded cables to respective instrument earth bus

provided in the JB / local panel.

q. Laying and termination at both ends between instrument earth buses provided in

JB / local panel to instrument earth pit provided by others.

r. Supply of all types of consumables required for the execution of the job.

s. Submission of monthly material appropriation statements for cables, tubing,

piping materials fittings, indicating the quantity issued and expended in standard

performances. Bidder should build up his own site office and material storage

facility within the compound.

t. Preparation and submission of "as built" drawings (marked up copies) as

required.

u. Start-up and commissioning assistance.

v. Submission of final material appropriation statements for all the materials issued

by the IITB.

w. Where requested by the IITB / "Engineer In-charge" or his authorized

representatives, all or any of the works detailed above and works as per "Schedule

of Quantities" shall also be performed on package units, local panels / cabinets /

gauge board installed by package units or by others.

x. Sealing of safety valves / switches with standard lead seals after final setting in

the presence of Engineer In-charge.

y. Installation and termination of tubing, cables etc., for analyzers (if any) & its

accessories like sample coolers etc.

z. Bidder shall remove instruments installed in package skid for calibration. After

calibration instrument shall be installed back with related tubing & wiring.

aa. Bidder shall dismantle limit switch, solenoid valve, positioner, Air filter regulator

from control valve/ On-Off valve, tag it properly prior to control valve / On-Off

valve shall install back after clearance from the Engineer in-Charge.

bb. Any other work not mentioned above, but required for the proper execution of

the works.

cc. Bidder to specify direct & indirect work hours rate in the quotation with break-

up.

dd. Installation of PLC system cabinets, SCADA PC Stations

ee. Grounding of Junction boxes / cabinets will be done by electricians

ff. All package instruments, Junction boxes & local panel (LCP) are pre-installed &

pre-wired by respective package vendors up to skid installed JB or panel.


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gg. Supply, Laying & termination of home-run cabling between instrument junction

boxes to control system &/or Package Vendor Junction boxes / LCP to control

system.

6. Bidder’s scope of supply

a. The Scope of supply of Bidder includes instrument tubes & fittings, instrument

cable tray with cover plate, cable duct if any, air manifolds, condensate pots,

canopies & steel, all the consumables required to execute the work at site & the

material listed under Clause 17 below.

7. Installation of instruments

a. Each instrument or item of equipment, to be installed by the bidder shall be

inspected visually for any damage. The Bidder shall then take it from where it is

stored, lift it into position and ensure it is levelled, plumbed and firmly secured.

The bidder shall be responsible for transporting equipment to be installed by him

from the stores to the place of installation.

b. The bidder shall responsible for all material until acceptance by the Client after

completion of job. Care shall be taken by bidder to protect from damage,

deterioration due to atmosphere & weather condition. The bidder shall properly

maintain a Register of material. The register shall be available to the Client as &

when required.

c. Throughout the construction period, instruments shall be adequately protected

where necessary, by covering with plastic bags of an approved type. The bidder

shall supply and fit these bags as required.

d. Instruments shall not be bracketed directly off process lines except where

specified by the "Engineer In-charge".

e. Local mounted instruments shall be bracketed, mounted in sub-panels or placed

on a suitable pedestal. They shall wherever necessary, be secured to the nearest

suitable firm steelwork or masonry in a manner prescribed by the "Engineer In-

charge"; wherever possible instruments shall be located so that they are protected

from damage by passing or falling objects.

f. Local instruments with the exception of those on lines and vessels shall be

mounted with the centre line at approximately 1.5 metre above platform or floor

in a position accessible for operation and maintenance.

g. Handrails shall not be used for supporting instruments without prior approval

from the "Engineer In-charge".

h. Instruments shall be installed in strict accordance with the appropriate hook-up

diagrams or as per the Manufacturer's recommendations, wherever hook-up

diagrams are not available. The bidder is not permitted to deviate from these

diagrams without prior written approval by the Engineer In-charge.

8. Impulse piping / tubing

a. General -

i. Instrument piping & tubing to be installed can be classified in the following

categories:

a. Air supply & transmission piping / tubing

b. Instrument process impulse piping / tubing

ii. Pipes / Tubes shall be bent using pipe / tube benders; any hot bending will be

totally rejected. These shall be cut using pipe / tube cutting device. Hot cutting

will not be allowed.


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iii. Pipes or tubes installed, but not connected, shall have the ends closed in an

approved fashion to prevent the entry of foreign material; e.g. for a period of

up to one-week adhesive tape may be used, for a longer period caps or plugs

shall be used.

iv. Where instrument pipes / tubing are run parallel to each other, joints should

be systematically staggered & neatly offset.

v. All threaded joints shall be jointed with Teflon tape and no other pipe jointing

compound shall be used except on high temperature service where graphite

sealing compounds shall be used.

vi. Where compression fittings are used, fittings shall be installed in strict

accordance with manufacturer's recommendation.

vii. Where stainless steel compression fittings are used, the Bidder must ensure

that stainless steel nuts and olives are fitted unless otherwise specified by the

"Engineer In-charge".

viii. Any discrepancies between the materials / fittings specified and the materials

/ fittings provided shall be brought to the notice of the "Engineer In-charge"

without delay.

ix. The number of joints in the pipework shall be kept to a minimum consistent

with good practice.

x. Sufficient flexibility shall be provided in meter leads, air supply and tubing

lines to allow for movement (e.g. expansion) of the lines or equipment to

which connected.

b. Air supply & transmission piping / tubing -

i. Horizontal runs of pipes & tubes shall have pipes / tubes laid vertically one

above the other as far as possible and shall be run with the minimum number

of changes of direction consistent with good practice and neat appearances.

ii. All pneumatic signal tubing shall be cleaned by blowing thru' with filtered air

before connection to Instruments.

iii. Single core tubing shall be run in such a manner as to give the maximum

protection against mechanical damage.

iv. Where permanent enclosure trunking or conduits, etc. are left with space for

tubes to be pulled in at some future date, a galvanized draw wire of adequate

size shall be left in the enclosure.

c. Instrument process impulse piping / tubing -

i. All impulse piping / tubing shall in general be run with a slope of not less than

1 in 10 unless otherwise specified. The slope of the impulse pipework shall be

down from the tapping point for liquids, steam and condensable and up from

the tapping point for gas service unless special provisions are made for

venting and draining.

ii. Special attention shall be given to the correct sitting of vents and drains to

ensure that they are at the highest or lowest points of the piping run.

iii. Impulse lines shall be kept as short as possible consistent with good practice.

iv. Threading of pipe/ nipple shall be done by bidder as specified in Instruments

Hookups.


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v. Stainless steel piping shall be joined by compression fittings, socket welding

flanges or by screwed connections depending upon the piping specification

for the project. This will be shown on the instrument hook-up drawing.

vi. Handrails must not be used to support instrument lines

9. Piping and tubing supports

i. Piping and tubing shall be adequately supported wherever possible to prevent

any mechanical damage.

ii. Angle iron or fabricated cable trays shall be used for continuously supporting

four or more copper, SS, plastic tubes and the tubes shall be secured to the

tray at not more than 500 mm intervals.

iii. Three or four tubes may in certain cases be secured by appropriate clips at

not more than 500 mm intervals to mild steel strip (not less than 16

SWG/1.6mm) or laid in small section angle bar; such routes must be approved

by the Engineer In-charge.

iv. Capillaries of filled systems shall be run independently of all other lines and

shall be continuously supported using mild steel angle with clips at not more

than 500 mm intervals.

v. Support trays shall be run with the breadth of the tray in a horizontal / vertical

plane. Where the engineer agrees that the tray must be run with the breadth

horizontal, the tray must be provided with additional supports to prevent

sagging.

vi. Conduit may be used to replace cable tray under certain circumstances. In

such cases, the trunking, etc. shall be supported to the satisfaction of the

"Engineer In-charge".

10. Instrument cable installation

i. The bidder must ensure that wherever an electrical specification is issued the

appropriate sections shall be read in conjunction with this specification and

any omissions or ambiguities should be resolved by the Engineer In-charge.

ii. The cable installation drawings and documentation provided by the "Engineer

In-charge" will normally specify or incorporate regulations for the elimination

of electrical noise pick-up. However, the following general rules apply.

iii. Parallel runs of instrument cables and power cables should be avoided but

where parallel runs must be made cable spacings specified in the

documentation must be maintained.

iv. Where instrument and power cables cross in close proximity the cross shall

be made at the right angles.

v. Thermocouple cables shall be run completely independently of other

instrument cables with a minimum separation and with cross over at right

angles.

vi. Multi-core / multi-pair cables shall not be bent to radius less than the

manufacturer's recommendations.


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vii. Multi-core / multi-pair cables shall be cut after the exact site measurements

are taken between ends and the cable drum shall be selected before cutting

the lengths to avoid any wastage.

viii. Where cables are run through pipes, the entry and exit shall be smooth and

free from burrs. Cables must be pulled into such pipes in a way that ensures

there is no damage to the cable.

ix. Joints shall only be made at terminals in instruments or approved equipment.

No intermediate joints shall be made on cable tray or in conduit. Cables must

be run in accordance with the design documentation.

x. All copper cables shall be terminated at junction boxes and instruments by

proper glanding.

xi. The panel wiring connections shall be done in an approved manner by

qualified electrician.

xii. Where conduit terminates at a cabinet, terminals box trunking or ducting, it

shall be secured lock-nutted, brushed and ferruled in an approved manner.

Sharp edges shall be removed and conduit not otherwise connected shall be

terminated in smooth brushes.

xiii. Clips and saddles securing to steel work or tray shall be metal, preferably

aluminium / Hot Dip Galvanized (GI); clips shall be spaced at 500mm

intervals.

xiv. Conduit shall not be fixed by hook bolts unless agreed by the "Engineer In-

charge". Where hook bolts are used they shall be supplied by the bidder from

a manufactured source and not performed at site.

xv. Conduit junction boxes shall be provided at distances not exceeding three

random lengths of 3 meters, not more than two right angle bends occurring in

one pull.

xvi. All cables shall be identified close to their termination point by cable number

as per cable schedule / junction box schedule. PVC ferrule / S.S. tag plate shall

be used and these identification tags shall be securely fastened to the cables.

11. Instrument cable duct / tray

i. The GI Ladder / Perforated cable trays shall be properly supported at a

regular interval of maximum 1.5 meter from insert plates or steel structures.

Wherever insert plates are not available supports on concrete structures &

ceiling shall be fixed with minimum 10mm diameter expansion bolts. Angle

supports for perforated trays shall be fabricated from 50 mm x 50 mm x 6 mm

MS angles as a minimum.

ii. All supports shall be cut with hacksaw only. Any work executed by gas cutting

for making holes or cutting pieces will be totally rejected. Free ends of angle

supports shall not have sharp edges and shall be properly rounded off.

iii. Perforated GI trays shall be used for branch cables from the main Cable

Ladders/Trays. Width of trays shall be as per Schedule of Quantity. Trays shall

be laid generally as per site conditions with the approval of Engineer-In-

Charge.


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12. Painting

i. All the supports / Structural Steel shall be painted as per painting

specifications detailed below

ii.

iii. All ferrous materials for brackets and supports and other materials not

already protected in an approved way shall be cleaned and primed before

erection with primer as per painting specifications specific to the project.

iv. All the supports / Structural Steel installed by the bidder shall be painted as

agreed with Engineer in-charge.

d. Identification of lines and instruments

i. All site mounted instrument, junction boxes, air header isolation valves,

tubing and wiring terminations shall be labeled or tagged in a manner

approved by the Engineer In-charge.

ii. The Engineer In-charge will provide a table of the label details for labels.

iii. All cable terminations shall be identified by ferrules (cross).

13. Testing

i. All the necessary test equipment for performing the following tests shall be

provided by the bidder.

ii. The bidder shall furnish a list of test and calibration equipment that will be

provided by him.

iii. All pneumatic signal lines shall be disconnected and blown through with

instrument air for 15 minutes to remove traces of oil, dust and moisture.

iv. All instrument air mains shall be isolated from the instrument and

pressurized pneumatically, 1.5 times maximum working pressure and

isolated from the source of pressure. The pressure shall not fall by more than

0.1 kg / cm² in ten minutes.

v. All thermocouple, electric and electronic instrument wiring shall be tested for

resistance between conductors and earth and for insulation between

conductors with a potential not less than 500V D.C. These tests shall be carried

out with all conductors disconnected except from the test instruments. The

resistance shall not be less than 10 mega ohms.

vi. Electrical continuity of cable armoring or braiding, conduits and any

associated flexible tubing, earthing conductor and / or equipment enclosures

are to be checked.

vii. Correct operation of all alarms and function of interlocks shall be checked.

viii. The written results of all tests in duplicate for retention by the IITB / Engineer

In-charge shall be approved by the "Engineer In-charge".

ix. The bidder is responsible for supplying the necessary test equipment and

reasonable evidence of the satisfactory condition of this shall be provided, if

required.

x. All errors or faulty workmanship discovered during this testing or during

subsequent testing and commissioning shall be corrected by the bidder at his

cost.


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xi. All test results shall be recorded in the approved formats.

14. Calibration

i. All test equipment used for calibration shall have the approval of Agency

approved by above mentioned authorities. On demand, calibration certificates

shall be submitted to "Engineer In-charge".

ii. All instruments shall be calibrated strictly as per manufacturer's instructions

prior to installation. The scope of calibration includes all field and control

room instruments of all types namely, pneumatic, electronics, electrical, etc.

iii. Bidder shall use his own oil free instrument air compressor for calibration

purposes.

iv. Calibration Procedure for different items is outlined below. However, the

detailed procedure shall be submitted to Engineer In-charge for approval

before proceeding with calibration.

v. All pressure and differential pressure transmitters shall be calibrated to the

settings as per Instrument data / specification sheets and instruction of

Engineer In-charge. Pressure instruments shall be loop checked by applying

impulse to the instrument using instrument air regulator and standard gauge

or using portable hydro pump and standard gauge.

vi. All thermocouple receiver instruments shall be calibrated by generating

millivolt signals suitable for span and type of thermocouple specified.

vii. Receiver instruments and controllers shall be calibrated and aligned using

test hook-up as per instructions from manufacturer's / Engineer In-charge.

viii. Pressure gauges and pressure transmitters shall be calibrated at 0%, 25%,

50%, 75% & 100% and vice versa of range using dead weight tester.

ix. DP transmitters shall be calibrated at 0%, 25%, 50%, 75% & 100% and vice

versa of range using mercury, water column manometers and / standard

gauges / squeeze bulb / regulator.

x. Temperature gauges shall be calibrated with thermo-oil baths at 0%, 25%,

50%, 75% and 100% and vice versa of range.

xi. Control valves and positioner shall be checked for hysteresis and linearity and

calibrated for rated strokes. Prior to calibration, valves shall be cleaned

externally. The stem is then lubricated if required, and stroked few times to

extreme positions of plug to ensure that movement is free from friction. The

valve shall then be calibrated for rated stroke and linearity also. Subsequently

the valves shall be checked for hysteresis to the accuracy of 1% FS with

positioner and 5% FS without positioner.

xii. Stroke speed has to be evaluated for all trip / shutdown valves.

xiii. All calibration readings shall be recorded in the agreed formats and submitted

to Engineer In-charge for approval. Where significant deviations from

specifications are obtained, the matter shall be brought to the immediate

notice of the Engineer In-charge for corrective actions.

xiv. The bidder shall clearly state in his offer the complete list of calibration and

test equipment along with the range, accuracy and quantity which he

proposes to use for this job.


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xv. All on-off valves to be tested with operating the solenoid valves for on-off

action and limit switch actuation.

xvi. All safety valves shall be tested for mentioned Cold Differential Set Pressure

(CDSP) with suitable test bench & fluid.

15. Loop test

i. Loop test shall be performed after calibration of all instruments and leak test

of signal lines. Loop tests are conducted to check the functional performance

of all elements comprising the loop, thereby ensuring proper connections and

operations.

ii. Bidder should bring all the field cable and terminate in the Junction box

located in the field & further termination to the system cabinet inside the

equipment room. Bidder shall assist the system vendor in the loop testing,

iii. Before proceeding for loop tests the calibration results of individual elements

shall be recorded and approval obtained from "Engineer In-charge" for

correctness of installation, measurements and calibration results.

iv. Loop testing for all control loops shall be generally simulation of process

conditions and shall fix points namely 0%, 25%, 50%, 75% and 100% of full

scale inputs. Detailed procedure shall be submitted to "Engineer In-charge"

for approval before proceeding with the loop testing.

v. In case of shutdown system field / receiver pressure switches are simulated

for abnormality by disconnecting the wires at terminal and function of all

associated systems are checked.

vi. After the loop test is complete, the bidder shall connect back any terminations

and connections removed for loop test inside the battery limit.

vii. A loop shall be considered as handed over only after measurements in that

particular loop are complete and certified by "Engineer In-charge", in addition

to loop sheets being duly filled in all respects and approved and accepted by

"Engineer In-charge" and the IITB.

viii. In case of loops in which certain instruments of the loops are calibrated by

other agency, loop testing shall be performed in coordination with the agency

involved. Any defect in the calibration of the instruments, same shall be

rectified to the satisfaction of the "Engineer In-charge". However, defect in

calibration of the instruments in the scope of other agency; same shall be

rectified by the agency involved. After the calibration has been rechecked by

other agency / agencies the loop checking would be performed to the

satisfaction of "Engineer In-charge", and this part covers under the scope of

the contract.

ix. Final certified loop sheets shall be submitted in number of copies as agreed

with Engineer In-charge.

1Installation drawings

i. Installation drawings / documents will be furnished to the bidder after award

of contract. These generally will include:


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ii. Instrument Location Plan drawings, showing information like indicative

position of field instruments, junction boxes, indicative routes of cables, main

ducts / cable trays.

iii. Cable Schedules, Instrument Junction Box Schedules, Junction Box Wiring

Diagrams

iv. Individual Instrument Specifications / Data sheets.

v. Bill of Materials.

vi. Installation Standards / Hook-ups.

16. Drawings and documents to be provided by bidder

i. Filling and submission of Test Reports & Forms.

ii. The drawings for materials that is included in his scope of supply and

installation.

iii. Two sets of layout drawings, hook ups, interconnection diagrams, cable

schedules etc., duly incorporating the changes / modification carried out

during the course of execution of works, as built markups.

17. All materials to be supplied by the bidder at his own cost

i. The procurement and supply in sequence and at the appropriate time of all

materials and consumables shall be entirely the bidder's responsibility and

his rates for execution shall be inclusive for all these items. They are as follows

but not limited to them.

ii. All industrial gases like oxygen, acetylene or inert gases, compressed air and

all types of electrodes, brazing rods, flux etc. for welding purposes, with

necessary facilities for testing the welded joints.

iii. Teflon tape and other pipe jointing compounds for threads and material for

sealing of cable entries to control room, local panels, insulation tapes, sealing

compounds for conduit fittings.

iv. Bolts and nuts for supports, U-bolts with nuts, clamps for tubes and pipes,

anchor bolts for panels, expansion bolts (pinch anchor / Rawl bolts) for

various sizes for fixing to concrete structures.

v. Paints, primers and solvents.

vi. Plastic sleeve ferrules for identification of tubes / wires at panel junction

boxes.

vii. All materials for minor civil works like grouting etc.

viii. All accessories for electrical wiring like cable lugs, ferrules for identification

etc.

ix. Spool pieces and blinds for testing, wherever required.

x. Nozzle cleaning wires.

xi. Any other item not specified, but required for the completion of the job.

xii. Note: The bidder shall submit in sealed packets all samples of all consumables

like bolts, nuts, lubricants, ferrules, lugs etc. for approval from Engineer In-

charge which form the standards for installation work.

e. Schedule of rates


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Schedule of rates shall be furnished in the appropriate formats as issued specific to the

Project. Refer – Schedule of quantities – Instrumentation work

i. Preamble to schedule of rates i prices (sor)

a. The Schedule of Rates Prices (SOR) shall be read in conjunction with the

drawings, the Conditions of Contract and the Specifications as these

documents are jointly explanatory and descriptive of the works included

in the Contract. Any interpretation of the scope of work, made from SOR

or Technical Specification in isolation shall not be valid for any extra

claims.

b. The quantities of work and material in Schedule of Rates Prices (SOR) are

not to be considered as limiting or exceeding the amount of work to be

done and material to be supplied by the Bidder. The quantities in the

Schedule of Rates Prices (SOR) are an estimate of the amount of work.

c. General directions and descriptions of work and materials given

elsewhere in the Contract documents are not necessarily repeated in the

Schedule of Rates Prices (SOR). Reference is to be made to the other

documents for information and guidance.

d. A price or rate in figures is to be entered against each item in the Bills of

Quantities, against which quantities are in SOR.

e. The prices and rates inserted in the Schedule of Rates Prices (SOR) are to

be the full inclusive value of the work described under the various items,

including all cost and expenses which may be required for preliminary

and for the completion of the work described, together with all cost and

obligations set forth or implied in the Conditions of Contract, the

Specifications and the Drawings.

f. The rates quoted shall include supply of all the materials by the Bidder

Viz. Cement, sand, bricks, structural steel, consumables like welding rods,

gases, insulation material, ferrules, etc. and nothing whatsoever will be

supplied by the IITB except stated in the Scope of Supply

g. The Bidder shall note that the Structural Steel materials shall be procured

from approved manufacturers' only. Prior approval shall be obtained for

procurement from Engineer in-charge.

h. IITB reserves the right to cancel/ delete/ curtail any item or group of work

if necessary. Such a step shall not be construed as reason for changing the

rates.

i. Quoted painting rates shall include the colour coding and lettering on the

equipment as per project specification.

j. Quoted rates shall include preparation of AS BUILT Drawings & Final Field

documentation etc. for all the site activities which will be submitted by the

bidder in required number of copies to the IITB. Editable soft copy of all

the documents shall be part of as-built documentation.

ii. Inclusions to be considered in unit rates -

a. In general activities involving checking/adjustments (e.g. limit switches

on valves, timer settings, checking solenoid valve operation, checking

annunciations/operation of indicating and mimic lamps etc.) which shall

be carried out during loop checking, no separate unit rates shall be


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applicable and the same shall be deemed to be a part of loop checking. All

loop checking shall be done by actual simulation like operating final

control element from PLC/SCADA, applying actuating pressure to the field

sensors / transmitters (as per range set) etc. and response reporting to

SCADA, PLC as Range, alarm, Set value, trip value, cross ferruling, open

loop resistance / voltage etc. shall be recorded tag-wise as a part of loop

checking activity. Format for loop checking and cross-ferruling shall be

followed by bidder based on joint agreement at site with the DEC and IITB

concern for Instrumentation work.

b. Supply of consumables as required, shall be built into the unit rates. No

separate rates shall be paid for supply of such items. These include items

like welding and filler rods, argon/nitrogen, required for welding;

sealants like PTFE tape, M-seal etc. used in impulse lines; ferrules, lugs,

Insulation/polyester tapes, cable sealing compounds, tagging etc. used in

cable laying and terminations; oxygen and acetylene required for gas

cutting; primer and final paint required in painting; polyethylene bags,

thermocouple required for protecting the instruments; and so on.

c. Unit rates quoted for supply of materials shall be inclusive of Inspection,

documentation, all taxes/levies, packing, forwarding and transport

charges, handling charges of the bidder etc.

d. Supply charges for structural steel include charges for required fasteners

like nut bolts etc. (except for Anchor fasteners for which separate rates

are applicable). Weight of these fasteners will not be considered for

measurement and no separate charges for installation of fasteners are

applicable. For structural steel, unit rates of installation shall include

surface preparation (shot blasting), all fabrication and installation,

including welding, supporting, painting, etc.

e. For canopies of field instruments, local panels and junction boxes, etc., the

unit rate of for fabrication + installation shall be quoted per sq. meter

based on 3 mm MS plates, duly painted and including all fasteners as

required. Canopy shall be of galvanized material. Coating / thickness of

galvanizing to be of 66 Micron.

f. Unit rates for cable laying/Installation shall include: laying of cables in

trays/ducts/conduits/angles, dressing, clamping, tagging, glanding,

termination with lugs, ferruling, continuity checks and meggering.

Materials like Clamps, fasteners (bolts, nuts, washers etc. ), ferrules, lugs,

tag plates, and Green insulating Sleeves for cable screen etc. are included

in unit rates cable laying/installation. For cables laid in conduits: sealing

of conduit ends or intermediate joints with sealant (including supply of

sealant) is also included in unit rate of cable laying/installation.

g. Unit rate for fibre optic cable installation shall include cost of termination

and installation of converter (any special equipment required and skilled

manpower required for these terminations shall be arranged by bidder

and cost for the same shall be included in unit rate of fibre optic cable

laying/installation)”

h. Unit rates for cable conduit laying shall include intermediate fittings, pull

boxes, making necessary threading with die/taps, termination, sealing of


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joints with sealant etc. Unit rate of supply of conduit includes

clamping/supporting material like "U" bolts, packing material required to

avoid galvanic corrosion etc.

i. Supply of clamping material like self-clamps, U bolts (and other fasteners),

packing material for avoiding galvanic corrosion etc. shall be included in

unit rates of installation. For welded impulse pipes the unit rates of

installation shall also include the necessary charges for checks including

supply of DP test material.

j. Unit rates for installation of RTDs and T/C shall include checking of sensor

for short Circuit /open circuit and insulation failure, prior to installation.

No other checking activity is envisaged.

k. For all instruments with capillaries, unit rates for installation shall include

laying, dressing, clamping of the capillary. Supply of necessary

clamping/supporting material shall be included in unit rates of

installation.

l. Unit rates for panel mounted instruments shall include mounting of

instruments and bins using clamps, termination of tubing/wiring (lugging

wherever required), ferruling, dressing of wires, clamping using binding

straps, flushing of tubing etc. For alarm annunciators no separate rate

shall be given for checking operation of the annunciator. The same shall

be considered part of loop checking.

m. Unit rate for calibration of instruments, control valves, safety valves shall

include cost of Consumables required (e.g. compressed air, Nitrogen etc.).

n. Unit rates for installation of following instruments/equipment shall

include the supply of fasteners, Tag Plates as required:

i. Power Distribution Boxes, Local Panels, Control Cabinets/Panels.

ii. Pressure, DP, Temperature Transmitter, Switches, Temperature

Elements.

iii. Air Filter Regulators, Solenoid Valves.

iv. Transducers / Transmitters / Converters

v. Back of Panel Instruments, Relays, Contactors etc.

vi. Junction Boxes.

vii. Auto/Manual or Push Button Stations, Hooters, Flashing Lights,

etc.

viii. Remote mounted Pressure Gauges.

ix. DP Gauges and Pressure Gauges with capillaries.

x. Purge Rota meters with DP Regulator and Air Filter Regulator.

o. For items not covered in the tender but required to be

installed/calibrated, rates of similar Items in the tender shall be taken for

approval prior to start of execution and billing. If the same is not possible

rates shall be derived from available rates after mutually discussed and

agreed upon with IITB.

p. Installation rate for all items in Schedule of Rates (SOR) shall include, all

machinery, tools and tackle required for shifting of respective items from

stores to place of installation, receiving, handling, unloading, unpacking,

checking for damage/ short supply and informing IITB, replacement of

damaged parts, assembly of all loose items, preservation of all items,


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transporting equipment, instrument etc. from IITB’s storage point or any

other location within the project site to location of installation /

calibration. This shall also include following -

q. Levelling, aligning, grouting, bolting, minor civil work including chipping

& then doing finishing work, etc.

r. Cleaning either mechanically or manually

s. Inspection & Testing as per Site testing & inspection formats.

t. Required Documentation as per specification & site requirements.

u. Unit rate / price quoted for supply of all instrument & erection, bulk items

shall include the required detail engineering, vendor's drawing checking,

third party inspection, documentation charges and all associated jobs.

v. Rates for all the items of Schedule of Rates include all cost involved for the

performance of the completed item considering all parts of the offer

document. In case any activity though specifically not covered in

description of item under 'Schedule of Rates' but is required to complete

the work which could be reasonably implied/ informed from the consent

of Offer Document, the cost for carrying out such activity of work shall be

deemed to be included in the item rate.

f. Quality assurance

The Bidder shall maintain an effective quality system. A concise description of the

Bidder’s system and its proposed application to the scope of work, including

references where applicable to a quality manual or similar authorized company

document, is required with the quotation.

A List of documents, in dossier form, shall be retained as evidence or proof that the

product or service supplied complies with specific requirements.

A quality plan, indicating the verification activities that will be applied in order to

achieve the required quality will be required to be submitted for approval

Technical specifications of various instrumentation items

Please refer annexures as below

Document ref : Rev. Document content

C530/I&C/IN/A4/501 R0 Instrument Index

C530/I&C/IN/A4/502 R0 Cable Schedule

C530/I&C/IN/A3/503 R0 Control System I/O List

C530/I&C/SP/A4/504 P0 Specification for Pressure and DP Transmitter

C530/I&C/SP/A4/505 P0 Specification for Temperature Transmitter

C530/I&C/SP/A4/506 R0 Flow Element (Wedge type)


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Document ref : Rev. Document content

C530/I&C/SP/A4/508 R0 Specification for Pressure gauge

C530/I&C/SP/A4/509 R0 Specification for Dial Thermometer

C530/I&C/SP/A4/510 R0 Specification for Level Switch

C530/I&C/SP/A4/511 R0 Specification for Level gauge

C530/I&C/SP/A4/512 R0 Specification for Multipoint Temperature Element

C530/I&C/SP/A4/513 P0 Specification for Globe type control valve

C530/I&C/SP/A4/514 P0 Specification for On-Off valve

C530/I&C/SP/A4/515 P0 Specification for Safety Relief Valve

C530/I&C/SP/A4/516 R0 Specification for Instrument cable

C530/I&C/SP/A4/517 R0 Specification for Instrument Junction Box

C530/I&C/SP/A4/518 R0 Specification for Instrument Cable Gland

C530/I&C/SP/A4/519 R0 Specification for Instrument Cable Tray

C530/I&C/SP/A4/520 R0 Specification for Instrument Tubing and

C530/I&C/SP/A4/521 P0 Solenoid valve

C530/I&C/SP/A4/522 R0 Vortex Flowmeter Datasheet

C530/I&C/SP/A4/523 R0 Rotameter Datasheet - Molten Salt

C530/I&C/SP/A4/524 R0 Specification for PLC based Control System

C530/I&C/SP/A4/525 R0 Specification for Instrument Installation Contract

C530/I&C/LD/A3/527 R0 Cause & Effect Charts

C530/I&C/WD/A3/526 R0 Loop Wiring Diagram

D. Technical specification – Electrical work

Scope:

This document describes the scope of supply, installation, testing & commissioning of complete

electrical system and defines guidelines for the design of electrical system for this project.

System parameters:

Distribution Voltages shall be as per table given below:

Equipment System Voltage No. Of phases & Grounding


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Frequency

3 Ph. loads like Motors,

Heaters etc.

415V 3 PH, 50HZ Grounded

1 Ph. loads 230V 1 PH, 50HZ Grounded

PLC 230V 1 PH, 50HZ Grounded

Electrical scope of supply

Scope includes supply of following equipment & material:

Sr. No. Description Qty. Specification clause

1 PMCC 1 no. C530/EE/SP4/407

2 Feeder Pillar 1 no. C530/EE/SP4/407

3 Lighting DB 1 no. C530/EE/SP4/407

3 AC Induction motors 1 lot C530/EE/L4/410

4 UPS 1 lot C530/EE/L4/408

5 Electrical Cables 1 lot C530/EE/SP/A4/411

6 Local control stations 1 lot C530/EE/SP/A4/411

7 Earthing Material 1 lot C530/EE/SP/A4/411

8 Erection material like Cable terminations,

cable trays, cable ties etc.

1 lot C530/EE/SP/A4/411

Codes and standards: The design of electrical system and the installation shall be in accordance with the relevant Indian

Standards, IEC Standards, CEA guidelines, Indian Electricity Act & rules and Local Rules and

Regulations.

Standard Title

IS 2147 Degrees of protection provided by enclosures for low voltage switchgear and

control gear

IS 3427 Code of practice for installation and maintenance of switchgear

IS 8623 Low-Voltage Switchgear and Control gear Assemblies


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Standard Title

IS 10118 Code of Practice for Selection, Installation and Maintenance of Switchgear

and Control gear

IS 12021 Control Transformers for Switchgear and Control gear for Voltages Not

Exceeding1 000 VAC. - Specification (First Revision)

IS/IEC 60715 Dimensions of low-voltage switchgear and control gear - Standardized

mounting on rails of mechanical support of electrical devices in switchgear

and control gear installations

IS/IEC 60947 Low-voltage Switchgear and Control gear

IS 900 Code of practice for installation and maintenance of induction motors

IS 1231 Dimensions of Three-phase Foot-mounted Induction Motors

IS 2223 Dimensions of flange mounted ac induction motors

IS 4029 Guide for Testing Three Phase Induction Motors

IS/IEC 60034 :

Part 1

Rotating electrical machines : Part 1 Rating and performance

IS/IEC 60034 :

Part 5

Rotating electrical machines : Part 5 Degrees of protection provided by the

integral design of rotating electrical machines (IP CODE) - Classification

IS/IEC 60034 :

Part 8

Rotating electrical machines : Part 8 Terminal markings and direction of

rotation

IS 12615 Permissible limits of noise level for rotating electrical machine

IEC 62040 Uninterruptible power systems (UPS)

IS 3043 Code of Practice for Earthing

IS 2309 Code of Practice for Protection of Buildings and Allied Structure against

Lighting

IS 732 Code of Practice for Electrical Wiring Installation

IS 9537 Conduit for Electrical Installations: Rigid Plan Conduits of Insulating

Materials

IS 5831 PVC insulation and sheath of electric cables

IS 3975 Mild steel wires, formed wires and tapes for armouring of cables

IS 7098 : Part 1 Cross-linked polyethylene insulated PVC sheathed cables: Part 1 For

working voltage up to and including 1 100 V


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Standard Title

IS 8130 Conductors for Insulated Electric Cables and Flexible Cords

IS 1554 : Part 1 PVC insulated (heavy duty) electric cables: Part 1 For working voltages upto

and including 1 100 V

Central Electricity Authority Regulations

General

1. Bidder shall carry out Supply and Electrical Installation work as per various parts of these

documents in an approved manner in required time schedule. Responsibility lies with the

Bidder for the proper execution of the erection work according to the existing laws and

by-laws. Bidder shall conform in all respects to the requirements of local and other

statutory authorities, issue of notice, as and when required by them All materials are in

Bidder’s scope of supply and shall comply with all currently applicable IS and IEC

Standards.

2. Bidder shall furnish all the equipment drawings for client’s approval before

manufacturing. Manufacturing shall be done as per drawings approved for

manufacturing. Any deviations w.r.t specification/tender shall be highlighted clearly by

the bidder along with the bid (see deviations clause).

3. All the items/equipment as specified in this specification are minimum requirement for

this package for tendering purpose; any more equipment, material, device or system if

required for completeness of this package as well as for safe & smooth operation and good

engineering practice, are included in scope of bidder without any cost or time implication.

4. If any equipment supplied by the bidder fails at site during erection, commissioning or

service (within guarantee period), the vendor shall repair and put back into successful

operation the failed equipment within the time frame and procedure of repair agreed with

the purchaser depending on nature of failure at no extra cost to the purchaser.

5. Bidder shall carryout the installation in accordance with construction drawings,

manufacturer’s drawings/manual’s installation instructions and as per specific

instructions of Engineer In-Charge and as per various parts of this tender document.

6. Sufficient sets of tools and tackles shall be available at site for smooth execution of the job

7. All meters and testing equipment shall be calibrated by authorized testing and calibrating

agencies. All meters and testing equipment shall be calibrated every six months.

Brief specification for supply items

1. Electrical Cable

Please refer specification C530/EE/SP/A4/411

Quantities of cables shall be supplied shall be as per electrical cable schedule-

C530/EE/CS/A4/406.

2. Summary of Electrical cables

Please refer schedule C530/EE/SP/A4/411


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3. Cable terminations

Unarmoured cables shall be terminated by single compression type cable glands &

armoured cable shall be terminated by double compression cable gland.

4. Summary of cable glands


5. Summary of cable lugs


6. GI cable trays

Cable tray shall be GI perforated type.

7. Local control stations

Local control stations with stay put type STOP push button & spring return type start push

button shall be provided for each motor.

Quantity as per present load list -8 nos.

8. Welding receptacles

415V, 63A TPNE, interlocked welding receptacles- 2nos. shall be supplied

9. Light fixtures

Following light fixtures suitable for 230V, 1ph supply shall be provided. For details refer

Lighting layout-C530/EL/GA/A1/405.

Preferred make of light fixtures: Philips/Wipro/Crompton

10. Lighting junction boxes

4 way, Industrial, suitable for 3C 2.5 sq.mm Cu cable- 10 nos. shall be provided.

11. GI lighting pole

GI lighting pole suitable for LED street light poles to be mounted on wall or column to be

provided by bidder -

60mm dia pipe type P1 suitable for mounting on handrail as per lighting layout: -7 nos.

60mm dia pipe type P2 suitable for mounting on wall or structural column as per lighting

layout: -7 nos.

12. Switchboxes

Decorative type switchboxes with 5A sockets & 20 A sockets shall be provided in Control

room & MCC room.

13. Earthing Material


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a. Earth Pit

3000mm long, 40 mm dia GI pipe electrode shall be provided in the chamber as per IS-

3043.

b. BOQ of earthing material

i. Safety equipment, antiskid mats, danger sign boards as required shall be provided

by the bidder.

ii. Electrical Installation

iii. Panel installation

iv. All panels shall be installed as described in respective specification. All supporting

material & hardware shall be in the bidder’s scope.

14. Cable Installation

Cable routes and mode of installation shall be generally be as shown in the construction

drawings. Cable shall be secured using cable ties. Multicore cables laid on cable trays shall

be tied individually with nylon tie at each rung or by 25 x 3 mm Aluminium clamps of

every 1.0 m interval on horizontal run and at every 600 mm interval on vertical run.

Cables routed on Walls / Structures shall be cleated with GI spacers and saddles at every

300 mm interval. GI spacer for cleating shall be 3 mm thick and saddles shall be minimum

2mm thick (8X35mm). The spacer shall be tightly fixed on walls using PVC plugs and GI

screws

15. Earthing Installation

a. Location of earth pits shall be decided such that fouling with column

footings/rafts is avoided. It should be located at minimum 1000 mm from the

boundary of building. The earth pits shall not be within a distance of 1500 mm

from hot places which may have hot/damp discharges.

b. All connections of earthing conductor shall be welded or bolted with appropriate

hardware. In case of Cu earthing conductor the same shall be brazed or bolted

with cadmium hardware. Contact surfaces shall be free from scale, paint, enamel,

grease, rust or dirt. Cables used as earth conductor shall be connected by

crimping type lugs.

c. Earthing connections above the ground to equipment earthing pads/terminals

shall be bolted type. Connections buried in earth/concrete shall be

welded/brazed type.

d. The pieces to be welded shall be held by pressure clamp and then

welding/brazing operation shall be carried. This is to ensure good contact joint.

The joints shall be cooled naturally to its ambient. If it is Galvanized Aluminium

conductor, bituminous paint shall be applied at joint.

16. Lighting Installation

Lighting luminaries shall be mounted as per mounting type indicated in the layout

drawing and as detailed in installation standards. Fabrication of supports for luminaries

shall be done as per installation standards. All hardware required for installation of

lighting system shall be supplied by bidder.

17. Reference documents attached:

a. Electrical Load list: C530/EL/LL/A4/401


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b. Electrical Cable Schedule: C530/EL/CS/A4/406

18. Technical specifications of electrical motors

a. Refer data sheet - C530/EE/SP/A4/410

19. Technical specifications of UPS

a. Refer data sheet - C530/EE/SP/A4/408

b. Bidder shall submit GA, SLD & BOM. Manufacturing can be taken up once the panel

drawings are approved by client for construction.

c. This specification indicates minimum requirement for the equipment, any other

equipment, components required for satisfactory operation shall be included by

bidder in his scope.

d. Bidder shall include commissioning spares & 2 years maintenance spares in the

scope.

20. Technical specifications of Low voltage Switchgear panel

a. Refer data sheet C530/EE/SP/A4/407

b. Bidder shall submit GA, SLD & BOM along with offer. Manufacturing can be taken

up once the panel drawings are approved by client for construction.

c. This specification indicates minimum requirement for the equipment, any other

equipment, components required for satisfactory operation shall be included by

bidder in his scope.

d. Bidder shall include commissioning spares & 2 years maintenance spares in the

scope.

Note:

Make of Switchgear components shall be Siemens / L&T/ Schneider.

E. Technical specifications of Molten Salt, selective coating and heat transfer

compound

Specification of molten salt

Sr. No. Description Specification

1 Composition Mixture ( premixed ) of sodium and

potassium based nitrate and nitrite

salts

Proportion – NaNO3 : KNO3 59.5 + 1% : 40.5 + 1%

2 Impurities, max permissible Vendor to state actual

Chlorides 0.05 % + 0.002%

Sulphates 0.01 % + 0.001%

Carbonates 0.02% + 0.002%

Nitrites 0.001 % + 0.0002%

Moisture VTS


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Other Nil

Anti-caking agent Nil ( strictly not permissible )

3 Solidus, Liquidus temperatures VTS

4 Physical properties

a Solid

i Bulk density kg/m3 VTS ( required ~ 1950 + 50 )

ii Particle size Vendor to provide sieve analysis

iii Melting point ⁰C VTS

iii Specific heat kcal/kg ⁰C VTS

iv Latent heat of fusion kcal/kg VTS

b Liquid

i Average specific heat kcal/kg ⁰C VTS

ii Density kg/m3 VTS

iii Viscosity cP VTS

iv Thermal conductivity kcal/hr m ⁰C VTS

v Heat transfer coefficient kcal/hr m2 ⁰C VTS

5 Documents

a MSDS Vendor to provide

b Test certificates Vendor to provide TCs for

properties as per respective ASTM

standard, Tests shall have been

carried in an internationally

reputed laboratory or

manufacturer’s laboratory with

traceability of test equipment and

calibrations to international

standards

6 Other

a Pack size Salt shall be supplied in 25 kg packs


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b Packing quality Sea worthy

Specifications of selective coating:


1 Description Selective coating with high solar absorptivity and low thermal emissivity and capable of withstanding high temperatures

2 Colour Black 3 Solar absorptivity ≥ 0.95

4 Maximum temperature 800 °C

5 Quantity 3 gallons 2 gallons are sufficient for

coating. Balance 1 gallon is to cover wastage during applying the paint

6 Life The paint at the time of application should be under recommended shelf life from shipping date and in sealed condition

7 Thinner Xylene, if required 8 Cleaning agents Trichloroethane, methyl ethyl

ketone(butanone) or suitable industrial solvents

8 Suggested makes Pyromark 2500 - Tempil

Selective coating application procedure:

a. Degrease all surfaces to be painted with trichloroethane

b. Grit blast surfaces using 60 – 120 mesh garnet abrasive (or sand blasting)

i. Position the nozzle nearly perpendicular to the surface and use a continuous

motion to obtain a uniform, lightly roughened surface; a single-pass with-

minimum-overspray method is recommended

ii. Remove excess grit/sand using clean, oil-free compressed air

c. Re-clean all blasted surfaces using trichloroethane

d. Mix Pyromark 2500 for ~20 minutes prior to use

e. Before painting, solvent clean the surface with methyl ethyl ketone; allow surface to

air dry. Application in rain and dew should be avoided.

f. Apply paint using spray techniques to obtain a wet film thickness sufficient to yield a

dry film thickness of ~50μm.

i. Apply paint in only a single layer

g. Air dry 18 hours


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h. Heat the coils as per the heating rate given below (maximum heating rate of 10°C

per minute when possible)

i. Heat to 120°C, hold for ~2 hours

ii. Heat to 250°C, hold for ~2 hours

iii. Heat to 540°C, hold for ~1 hour

iv. Heat to 700 °C, hold for 1 hour

Specifications of heat transfer compound:


1 Description Heat transfer compound or cement to enhance heat transfer between molten salt pipe and steam tracing tubes

Should have high thermal stability and bonding capability and strength

Should resist thermal and mechanical shocks

2 Maximum exposure temperature 590 °C 3 Quantity 12 gallons 4 Life The heat transfer compound at the

time of application should be under recommended shelf life from shipping date and in sealed condition

5 Suggested makes T99 - Thermon

Application procedure:

a. The heat transfer compound must be applied on surfaces of traced valves, instrument

bodies and molten salt pipes and their surfaces must be prepared prior to application.

b. Oil, grease, dirt, rust scale etc. if any on the surfaces must be removed. The use of solvents

and emulsions along with scraping, chipping and wire brushing are some of the common

pre-treatment techniques for steel surfaces that can be used.

c. If the heat transfer is water soluble, application in rain and dew should be avoided.

d. Primer should not be used on surfaces coated with heat transfer compound

e. The steam tracing tube should be surrounded by the heat transfer compound filled inside

inside stainless steel channels. Galvanized channels should not be used.

f. The heat transfer compound should be hand trowelled to fill steel channels. The channels

should be securely tightened with steel wires or bands on the applied surface. (Please

refer illustrative figure below)

g. The heat transfer compound, accessories such as channels, tie wires or bands to be used

and application procedure adopted by the bidder has to be approved from DEC and IITB


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6.2 Technical Deviations: 1. Any deviation or variation from the scope, requirement and/or intent of this specification

shall be clearly defined under Deviation Schedules of the relevant Bid forms irrespective

of the fact that such deviations/ variations may be standard practice or a possible

interpretation of the specification by the Bidder.

2. Except for those deviations/ variations covered under Deviation Schedules which are

accepted by the IITB / DEC before the award of the Contract, it will be the responsibility

of the bidder to fully meet the intent and the requirements of the specification within the

quoted price.

3. Before submitting his bid, the bidder should inspect and examine the site and its

surroundings and should satisfy himself in all respects. No consequent extra claims on

any misunderstanding or otherwise shall be allowed by the Employer.

4. In case of any conflicts / contradiction among various sections / annexure / chapters /

appendices / tender drawings of bid documents, the same shall be referred to the

Employer for clarifications whose decision shall be final and binding. No extra claims shall

be allowed on this account.

5. If there is any deviation in the work as felt necessary by the Client (IITB) & communicated

so officially then this will be charged at the rate previously quoted in the price bid.

Maximum 5% of the Purchase Order (PO) Value will be allowed for rise in the cost

due to deviations


122 | P a g e

Section – 7: Price bid


123 | P a g e

7.1 Price bid Table

Description of Item &

Specification

Qty

&

Units

Total

Price

(in Rs.)

VAT , WCT,

Service

Tax & other

taxes /

charges if any

please

specify details

(%/ in Rs.)

Total

Price

(in Rs.)

Procurement, Fabrication,

Supply, Erection and

Commissioning of High

Temperature Molten Salt Loop

with Central Receiver, Molten

Salt Storage, Heat Exchangers

and Allied Works

1 No.

1. The bidder should quote the price on the total price basis for the scope mentioned in scope of

work, materials, tools & tackles, manufacturing, fabrication, transportation, construction,

facilitation of intermittent & final inspection, including statutory payments and compliances as

applicable for and arising from the work ( no cost will be borne by NTPC / IITB / DEC ),

manpower, travel, boarding & lodging, construction and potable water for labour, own and DEC

/ Client personnel, temporary power arrangements etc. for the entire duration of the contract

including extension, if any, thereof.

2. The bidder is required to provide item rates in Cost Drivers Details vide separate sheet.

3. Bidder is requested to visit the site before bidding to inspect the site and its surroundings and

ascertain and satisfy himself in all respects to understand the site and surroundings, the

development necessary by way of site clearing, filling, drainage, access roads, fences, sheds,

material required for temporary and / or construction power and water, permits and

procedures etc. to estimate all costs related to the work. No extra claims of any nature on any

misunderstanding or otherwise shall be allowed. The site visit shall be conducted entirely at

bidder’s cost.


124 | P a g e

Validity - The bidder shall hold the bid valid for 180 days from the date of submission of

quotation/tender.

Delivery period ..........................days

PAN No:............................................................................................

VAT/TIN Registration No:.......................................................

Signature: ......................................................................................

Place: Name:..................................................................................

Date: Business Address:..........................................................

Affix Rubber Stamp:..................................................................

Note: Price Bid and Cost Drivers Details should be submitted in given format only. For

additional information / extra items above format may be typed and used.


125 | P a g e

7.2 Payment schedule Procurement, Construction and Commissioning (PCC) Contract for “Procurement, supply,

construction, fabrication, erection, testing and commissioning of High Temperature

Molten Salt Loop with Central Receiver, Molten Salt Storage, Heat Exchangers and allied

works” shall be a Total Price of Tender Contract.

Bidder shall ascertain all work item quantities in conformity to Tender Drawings and quote Total

Price

Bidder shall also furnish Item Rates and amount against all “Cost Driver Items of Price Bid”.

This shall form basis to arrive at compensation towards additional work ordered / reduction for

deleted work, if any.

PCC Contractor can raise one invoice per two calendar month, as per Delivery / Site

Activity Linked Payment Schedule.

Note: No invoice will be considered against incomplete work.

Sr. No. Key Deliverables Payment

(%)

Delivery in Weeks from

PO Date

1 Supply of pipes, pipe fittings, valves 6% 8

2 Pumps, dosing systems, steam silencer, all tanks 6% 12

3 Supply of instruments, PLC, SCADA 8% 12

4 Supply of salt 5% 12

5 Receiver with coils, thermocline tank, heat exchangers, vent pot

6% 16

6 Supply of electrical items including electrical heaters 21% 16

7 Supply of control valves and instrument air package 5% 18

8 Supply of spares 5% 24

9 Complete erection of equipment, piping and insulation, electrical, instrumentation

18% 25

10 Testing and commissioning of complete system 10% 30

11 Project handover 10% 32


126 | P a g e

The bidder should quote period of Delivery from PO Date for Key Deliverables Listed so as to fit

within an overall delivery period not exceeding 32 weeks from the date of Letter of intent / PO

whichever is earlier. The overall delivery period shall be inclusive of design, procurement,

fabrication, construction, erection, testing, pre commissioning, commissioning, documentation,

training etc. complete.


127 | P a g e

7.3 Cost drivers

A. Schedule of quantities - Structural steel work

Sr. No. Item Description Qty Unit Unit Rate

Rs.

Amount

Rs.

1 Procurement and supply of structural steel as per

drawings and details, consisting of plates, rolled

steel sections such as channels, angles, rods / pipes

/ tubes etc., straightening of the steel if required,

fabrication of steel structures, as per drawings,

loading, transportation, unloading and delivery at

erection site of all fabricated structures, erection,

alignment and welding of all structures true to line,

level, plumb and dimension including rectification

if any splicing, site assembly all as per technical

specifications, drawings and instruction of the

Engineer-in-Charge including painting as per

specifications. painting

a Structural steel for pipe supports, frames,

miscellaneous supports etc. 300 kg

a Structural steel for miscellaneous equipment

platforms, ladders, supports etc. 8 MT

2 Supply and fixing of nickel plated anchor fasteners,

nuts bolts etc. 100 kg

3 Structural steel for receiver support 4 MT

TOTAL =

B. Schedule of quantities – Piping & Mechanical work


Rs.

Amount

Rs.

1 Procurement, supply, transport, lifting,

installation, testing ( including PMI ), installation,

commissioning of heliostat receiver assembly,

SR 01, consisting of 2 large coils, 3 small coils,

header, inlet and outlet piping, all of A213 TP 316

Ti tubes, socket weld joints, 100% radiography,

cavity lining, insulation of mineral wool and


128 | P a g e


Rs.

Amount

Rs.

ceramic fibres, outer encasing, opening for heaters,

supports for coils etc. complete, comprising below

items, coating of receiver coils with selective

coating

a Coils, 1,100 mm OD 2 No.

b Coils, 700 mm OD 3 No.

c Receiver header, tube 19mm OD x 2 thk, ~10.35m

long with approx. 10 bends, 3 Tee joints, 5 nos

joints to coils, 4m portion outside receiver

insulated to 200mm thk as per insulation schedule 1 No.

d Receiver housing with insulation, supports etc 1 No.

2 Procurement, supply, transport, installation,

testing (including PMI), installation,

commissioning of Molten Salt storage tank

(Thermocline tank, TCS-01) including supports,

insulation, etc. complete. 1 No.

3 Design, procurement, supply, transport, testing

(including PMI), installation, commissioning of

molten Salt – steam heat exchangers including

insulation etc.

a Preheater, PH-01 1 no.

b Evaporator, E-01 1 no

c Superheater, SH-01 1 no.

4 Procurement, supply, installation, testing,

commissioning of molten salt pumps as per

specifications.

a Charging circuit molten salt pump, MSP-1 1 no

b Discharge circuit salt pump, MSP-2 1 no


commissioning of water pumps as per details and

specifications. 1 no.


129 | P a g e


Rs.

Amount

Rs.

a Boiler feed water pumps, FWP-1 & FWP-2, triplex,

plunger pumps 2 no

b DM water transfer pump, P9402, centrifugal, CS

construction 1 no

c Cooling water circulation pump, P9403,

centrifugal, CS construction 1 no

6 Procurement, supply, transport, testing ( including

PMI ), installation, painting ( for uninsulated piping

), commissioning of piping ( pipes, pipe fittings,

valves pipe supports fixtures excluding structural

steel, etc. ) including insulation as per details and

drg

a CS, SA 106 Gr. B, Seamless, Sch. 40, including

fittings A105, 3000# below 40 NB, else fittings

seamless Sch. 40, gaskets shall be 2.5 thk, spiral

wound SS 304, graphite filled, outer ring CS, inner

ring SS 304, mfg. std. B16.20

i 15 NB 150 m.

ii 20 NB 18 m

iii 25 NB 54 m

iv 40 NB Q.R. m

v 50 NB 24 m

b SA-312 TP 321 seamless, Sch. 40, including fittings

SS 321, 3000#, gaskets shall be 2.5 thk, spiral



i 15 NB 40 m.

ii 20 NB Q.R4. m

iii 25 NB 120 m

iv 40 NB 12 m

4 Q.R. means quote rate. Cost should not be added in the bid. Unit rate is asked for future requirements, if any


130 | P a g e


Rs.

Amount

Rs.

c Alloy steel, A335, P91, Seamless Sch. 40, including

fittings forged P91, 3000# below 40 NB, else

seamless Sch. 40, gaskets shall be 2.5 thk, spiral



i 15 NB 18 m.

ii 20 NB Q.R. m

iii 25 NB 120 m

iv 40 NB Q.R. m

v 50 NB Q.R. m

d CS, IS 1239, Class C, hot dip galvanised including

fittings CS seamless Sch. 40, ring gaskets shall be

non-asbestos, 3 mm thk

i 15 NB 120 m.

ii 20 NB 420 m

iii 25 NB 180 m

iv 40 NB 6 m

v 50 NB 6 m

vi 25 NB for cooling coils 100 m

e CPVC, Sch 40. IS 1239, Class C, including fittings

seamless Sch. 40, ring gaskets shall be non-

asbestos, 3 mm thk

i 15 NB 6 m.

ii 20 NB Q.R. m

iii 25 NB 54 m

iv 40 NB 12 m

v 50 NB 6 m

vi 200 NB 6 m


131 | P a g e


Rs.

Amount

Rs.

f UPVC, Class 4, IS 4985 / equi., including fittings of

equivalent rating, ring gaskets shall be non-

asbestos, 3 mm thk

i 15 NB 12 m.

ii 20 NB Q.R. m

iii 25 NB 180 m

iv 40 NB 6 m

v 50 NB 6 m

g Steam tracing, ASTM 213, TP 304, seamless tube,

8mm OD x 1mm thk., including socket weld fittings

A182 SS304, 3000#. 150 m.

h Copper cooling piping, ASTM B 88, Type L,

Hardness F 40, 99.9% copper, including fittings,

brazing / soldering, compression fittings etc.

complete. 120 m.

7 Metallic Expansion bellows for IA, 15 NB, sch. 40,

flanged ASA 150 #, 150 long. 4 No.

8 Procurement, supply, installation, insulation,

testing and commissioning of valves with end

fittings etc. complete

a Forged Globe Valve for Steam, 15 NB

Tag nos : HV9107, HV9108, HV9110, HV9111,

HV9112, HV9113, HV9115, HV9116, HV9117,

HV9117, HV9118, HV9119, HV9123, HV9125,

HV9137, HV9141, HV9142, HV9143 17 nos.

b Forged Globe Valve for Steam, Size 25 NB

Tag nos : HV9109, HV9114, HV9120, HV9121 4 nos.

c Non slam check valve for Steam Size, 15NB

Tag nos : NRV9104, NRV9106, NRV9107 3 nos.

d Non slam check valve for Steam, Size 25NB 1 nos.


132 | P a g e


Rs.

Amount

Rs.

Tag nos. : NRV9105

e Steam Trap, Size 15NB

Tag nos. : ST9101, ST9102 2 no.

f Solenoid valve, Size 15 NB

Tag no. : SV-9205 / 9206 2 no.

g Safety relief valve, Size 15 NB

Tag no. : PSV-9101 1 no.

h Safety relief valve, Size VTS

Tag no. : PSV-9102 A/B 2 no.

i Safety relief valve, Size VTS

Tag no. : PSV-9103 1 no.

j Globe Valve - Molten Salt Service, Size 15NB

Tag no : HV9001, HV9002, HV9003, HV9004,

HV9005, HV9006, HV9007, HV9010, HV9011,

HV9012, HV9013, HV9014, HV9016, HV9017,

HV9018, HV9019, HV9020 17 nos.

k Globe Valve - Molten Salt Line, Size 25NB

Tag no : HV9008, HV9009, HV9015, HV9021 4 nos.

l Non slam check valve – Molten Salt Size, 25NB

Tag no. : NRV9001, NRV9003, 3 nos.

m Pressure relief Valve – Instrument air, Size 25NB

Tag no. : OPRV9001 1 no.

n Ball Valve for Hot Water, Size 15NB

Tag no : HV9103, HV9104, HV9124, HV9126,

HV9128, HV9129, HV9130, HV9131, HV9132,

HV9133, HV9134, HV9135, HV9136, HV9139,

HV9140 16 nos.

o Ball Valve for Hot Water, Size 20NB 4 nos.


133 | P a g e


Rs.

Amount

Rs.

Tag no : HV9101, HV9102, HV9105, HV9106

p Ball Valve for Hot Water, Size 50NB

Tag no : HV9127 1 no.

q Non slam check valve – Hot Water Line, Size 15NB

Tag no. : NRV9103, NRV9108 2 nos.

r Non slam check valve – Hot Water Line, Size 20NB

Tag no. : NRV9101, NRV9102 2 nos.

s Y type Strainer – Hot Water Line, Size 20NB

Tag No.: STR9101, STR9102 2 nos.

t Carbon Steel Ball Valve – Cooling Water Line, Size

25NB

Tag no : HV9423, HV9424, HV9425, HV9426,

HV9427 5 nos.

u Non slam check valve – Cooling Water Line, Size

25NB

Tag no. : NRV9402 1 no.

v Y type Strainer – Cooling Water Line, Size 20NB

Tag No. : STR9402 1 no.

w True Union Ball Check Valve (CPVC), Size 25NB

Tag no. : NRV9401 1 no.

x CPVC Ball Valve, Size 15NB

Tag no : HV9406, HV9407, HV9408, HV9409,

HV9410, HV9411, HV9418, HV9419, HV9420,

HV9422 10 nos.

z CPVC Ball Valve, Size 25NB

Tag no : HV9402, HV9404, HV9405, HV9412,

HV9415, HV9416, HV9417 7 nos.


134 | P a g e


Rs.

Amount

Rs.

aa CPVC Ball Valve, Size 40NB

Tag no : HV9443, HV9414 4 nos.

ab Y type Strainer (CPVC), Size 40NB

Tag No.: STR9404 1 no.

ac UPVC Ball Valve – Raw Water Line, Size 15NB

Tag no : HV9439,HV9440,HV9441 3 nos.

ad UPVC Ball Valve – Raw Water Line, Size 25NB


ae UPVC Ball Valve – Raw Water Line, Size 40NB


af Globe type Control Valve, Size 15 NB

Tag no : FV-9001, FV-9002, FV-9101, LV-9106, LV-

9101, PV-9204, TV-9101, TV-9105 8 nos.

ag Globe type Control Valve, Size 40 NB

Tag no : PV-9002 1 no.

ah Globe type Control Valve, Size 25 NB

Tag no : PV-9004, PV-9005, PV-9105, TV-9005 4 nos.

ai On-Off Ball Valve, Size 15 NB

Tag no : XV-9201, XV-9202 2 nos.

aj On-Off Ball Valve, Size 25 NB

Tag no : BV-9107 1 no.

ak CS butterfly valves, Sixe 200 NB

Tag no : HV9403, HV9413 2 no.

9 Procurement, fabrication, supply, installation,

insulation, testing, commissioning, of Vent pot as

per details and specifications 1 No.


135 | P a g e


Rs.

Amount

Rs.

10 Procurement, fabrication, supply, assembly,

installation, testing and commissioning of

mechanism consisting of gears, pulleys, sprockets,

chains, roper, supports, shafts, bearings, hooks,

anchors, D-shackles etc. complete for operating

dummy receiver platform 500 kg

11 Procurement, fabrication, supply, assembly,

installation, testing and commissioning of

mechanism for receiver heaters with motorised

winch as per design and details. 1 No.

12 Design, procurement, supply, installation,

insulation, testing, commissioning of steam

silencer as per details and specifications. 1 No.

13 Design, procurement, supply, installation, testing,

commissioning of instrument air plant in acoustic

enclosure including air receiver, auto-drain valve,

drain piping, etc. complete as per details and

specifications. 1 no.

14 Design, procurement, supply, installation, testing,

commissioning of skid mounted dosing system

with motorized stirrer, dosing pump, tank with

instrumentation including control panel etc.

complete as per details and specifications. 1 no.

a HP boiler feed water dosing system, DT-01, DP-01 1 no.

b Same as above by LP dosing system, DT-02, DP-02 1 no.


commissioning of sample cooler for evaporator. 1 no.

16 Procurement, supply, assembly, installation,

testing, commissioning of 80 kW cooling system

using radiator including skid, fan, panel etc.

complete. 1 no.

17 Procurement, supply, assembly, installation,

testing, commissioning of electrical hoists as per

details and specifications

a for receiver maintenance, 5 MT 1 no.


136 | P a g e


Rs.

Amount

Rs.

b for salt pumps maintenance, 2 MT 1 no.

c for workshop, 2 MT 1 no.

18 Procurement, supply, erection, testing,

commissioning of 10 cum HDPE tanks T9402,

T9403, with manhole, covers, drain, vent etc.

complete

a 10 cum HDPE tanks T9402, T9403, 2 no.

b 5 cum HDPE tanks, T 9401 1 no.

c 200 ltr MS insulated cooling water tank T9405 1 no.

Water meter, class B, as per pipe size, for water

measurement for dosing, numeric counter,

totaliser 2 no.

19 Procurement, supply, erection of heavy duty

slotted angle rack for stores, 4m H x 2.7mW x

600mm x 3 nos, shelves of 2.5mm thk, all members

powder coated, UDL load 100 kg/900 width,

including installation etc. complete with

aluminium access ladder 1 no.

Total

C. Schedule of quantities – Electrical work


Rs.

Amount

Rs.

1 Design, procurement, supply, testing installation,

commissioning of LV Switchgear Panels as per

specifications C530/EE/SP/A4/407

a PMCC 1 No.


137 | P a g e


Rs.

Amount

Rs.

b Feeder Pillar 1 No.

c PDB 1 No.

2 Supply, installation, testing, commissioning of UPS

and Batteries as per specifications

C530/EE/SP/A4/408 1 LS

3 Supply, installation, testing, commissioning of AC

Motors as per specifications C530/EE/SP/A4/410,

along with pumps 1 LS

4 Supply, installation, testing, commissioning of

electrical cables as per specifications

C530/EE/SP/A4/411

a 3C x2.5 sq.mm Cu, XLPE insulated armoured cable 625 m

b 3C x10 sq.mm Al, XLPE insulated armoured cable QR m

c 3.5C x35 sq.mm Al, XLPE insulated armoured cable 600 m

d 3.5C x50 sq.mm Al, XLPE insulated armoured cable QR m

e 3.5C x150 sq.mm Al, XLPE insulated armoured

cable QR m

f 3.5C x240 sq.mm Al, XLPE insulated armoured

cable QR m

g 3.5C x300 sq.mm Al, XLPE insulated armoured

cable 50 m

h 4C x2.5 sq.mm Cu, XLPE insulated armoured cable 1100 m

i 4C x10 sq. sq.mm Al, XLPE insulated armoured

cable 500 m

i 5C x 2.5 sq. sq.mm Cu, XLPE insulated armoured

cable 350 m

5 Earthing Material

a 8 swg GI wire 100 m

b 25 x 3 GI earth Strip 100 m


138 | P a g e


Rs.

Amount

Rs.

c 50 x 6 GI earth Strip 120 m

d 75 x 10 GI earth Strip 200 m

e 8 swg GI wire 80 m

f 3000 mm long, 40 mm dia. GI pipe electrode with

chamber 4 Nos.

6 GI perforated Cable trays

a 50 mm wide, 25mm height, 2 m thick GI perforated

cable tray 30 m

b 150 mm wide, 50mm height, 2 m thick GI ladder

cable tray 50 m

c 300 mm wide, 100mm height, 2 m thick GI ladder

cable tray 80 m

d 600 mm wide, 100mm height, 2.5 m thick GI ladder

cable tray 60 m

7 Double compression type cable glands for

following sizes

a 3C x2.5 sq.mm Cu, XLPE insulated armoured cable 200 Nos.

b 3C x10 sq.mm Al, XLPE insulated armoured cable QR Nos.

c 3.5C x35 sq.mm Al, XLPE insulated armoured cable 20 Nos.

d 3.5C x50 sq.mm Al, XLPE insulated armoured cable QR Nos.

e 3.5C x150 sq.mm Al, XLPE insulated armoured

cable QR Nos.

f 3.5C x240 sq.mm Al, XLPE insulated armoured

cable QR Nos.

i 3.5C x300 sq.mm Al, XLPE insulated armoured

cable 4 Nos.

j 4C x2.5 sq.mm Cu, XLPE insulated armoured cable 70 Nos.

k 4C x 6 sq. sq.mm Al, XLPE insulated armoured cable 22 Nos.


139 | P a g e


Rs.

Amount

Rs.

l 5C x 2.5 sq. sq.mm Al, XLPE insulated armoured

cable 24 Nos.

8 Cable lugs

a 2.5 sq.mm Cu, 1050 Nos.

2.5 sq.mm Al 90 Nos.

b 10 sq.mm Al QR Nos.

c 16 sq.mm Al 20 Nos.

d 25 sq.mm Al QR Nos.

e 35 sq.mm Al 60 Nos.

f 50 sq.mm Al QR Nos.

g 70 sq.mm Al QR Nos.

h 150 sq.mm Al 4 Nos.

i 120 sq.mm Al QR Nos.

j 240 sq.mm Al QR Nos.

k 300 sq.mm Al 12 Nos.

9 Local Control stations

a LCS with 1 no. Start +1 no. STOP push buttons for

DOL & VFD motors 7 Nos.

b LCS for 2 nos.Start + 1 no. STOP push buttons for

RDOL motors 3 Nos.

10 415V, 63A TPNE welding receptacles 2 Nos.

11 Light Fixtures

a 31W LED square light fixtures for recessed

mounted on false ceiling 8 Nos.

b 40W LED batten for indoor rooms 17 Nos.

c 70W LED Flood light fixtures for area lighting QR Nos.


140 | P a g e


Rs.

Amount

Rs.

d 35W LED street light fixtures for periphery lighting 14 Nos.

12 4 way, Industrial Lighting junction boxes 10 Nos.

13 GI lighting pole

a 60mm dia pipe type P1 suitable for mounting on

handrail as per lighting layout 7 No.

b 60mm dia pipe type P2 suitable for mounting on

wall or structural column as per lighting layout 7 Nos.

14 Switchboxes 1 LS

15 Safety equipment, antiskid mats, danger sign

boards 1 LS

16 Design, procurement, supply, transport, testing,

installation, commissioning of electrical heater

assemblies with safety panels, etc. complete

a Electrical heater assembly, 16 x 4 kW = 64 kW in

thermocline tank, EH-01 1 No.

b Electrical heater assembly, 15 kW in evaporator

heat exchanger, EH-02. 1 No.

c Electrical heater assembly, 15 kW inline electrical

water heater, EH-03. 1 No.

d Electrical heater assembly, 5 x 15 kW for receiver,

EH-04. 1 No.

e Electrical heater assembly, 7 x 40 kW = 280 kW,

for receiver testing with reflectors, including

dismantling and removal of the same and plugging

the openings of the receiver as per details, EH-05 1 No.

e Electrical heater assembly, 1 x 40 kW = 40 kW, for

receiver testing without reflectors, including

dismantling and removal of the same and plugging

the openings of the receiver as per details, EH-06 1 No.

Total


141 | P a g e


Rs.

Amount

Rs.


142 | P a g e

D. Schedule of quantities – Instrumentation work

Sr. No. Description

Qty Unit

Installation Calibration &

Loop check

Supervision of

installation Supply

Grand

total Remarks

UR Total UR Total UR Total

1.0 Inline instruments

1.1 Control valves – globe type

1.1.1 Size = 1/2" 6

No

s

N/

A N/A * * N/A N/A

1.1.2 Size = 1" 6 No.

N/

A N/A * * N/A N/A

1.1.3 Size = 1-1/2” 1 No.

N/

A N/A * * N/A N/A

1.2 On-off valves – ball type

1.2.1 Size = 1/2" 2

No

s

N/

A N/A * * N/A N/A

1.2.2 Size = 1" 1 No.

N/

A N/A * * N/A N/A

1.3 Safety/thermal relief valves

1.3.1 3/4" x 1" 3

No

s.

N/

A N/A

N/

A N/A * * N/A N/A


143 | P a g e

Sr. No. Description

Qty Unit


Loop check

Supervision of

installation Supply

Grand

total Remarks


1.4 Flow elements -

1.4.1 Vortex flow meter - 1/2" 2

No

s.

N/

A N/A

N/

A N/A * * N/A N/A

1.4.2 Wedge type - 1/2" with spool

piece 2

No

s.

N/

A N/A

N/

A N/A * * N/A N/A

1.5 Solenoid valves

1.5.1 Size = 1/2"

2

No

s

N/

A N/A * * N/A N/A

2.0 Off-line field instruments

2.1 Pressure transmitters ( remote

seal diaphragm with capillary )

process conn.: 2" or 3" ANSI

150# 3

No

s. 2" Pipe

mounting 2.2 Pressure transmitters with

threaded connection, process

conn.: 1/2" NPT 2

No

s.


144 | P a g e

Sr. No. Description

Qty Unit


Loop check

Supervision of

installation Supply

Grand

total Remarks


2.3 Flow ( DP type ) transmitters (

remote seal diaphragm with

capillary ) process conn.: 2" or

3" ANSI 150# 2

No

s.

2.4 Level ( Bubbler DP type )

transmitters with threaded

connection process conn.: 1/2"

NPT with purge meter & DP

relay 1 No.

2.5 Level ( DP type ) transmitters

with threaded connection

process conn.: 1/2" NPT 3

No

s.

2.6 Float and tape level indicator,

SS 316 tape, float, guide ropes,

pulley, SS 304 dead weight, GI

protection conduit, Epoxy / PU

coated aluminium enclosure

with digital roller display. 2

No

s.

2.7 Pressure gauge process

connection: 2" 150#, RF (

diaphragm seal direct mount

type ) 6

No

s.

Bracket/Wa

ll mounting


145 | P a g e

Sr. No. Description

Qty Unit


Loop check

Supervision of

installation Supply

Grand

total Remarks


2.8 Pressure gauge – process

connection: 1/2" NPT threaded 9 No.

2.9 Temperature transmitters ( 2"

pipe mounted ) 14

No

s.

2" Pipe

mounting

2.10 Bimetal temperature gauge

local mounted with screwed

thermowell 1

No

s.

2.11 K-Type thermocouple with

screwed thermowell –

connection size - 1/2" NPT 13

No

s.

2.12 K-Type thermocouple, skin

type with incoloy sheath for

receiver 3

No

s.

2.13 K-Type thermocouple, skin

type 8

No

s.

2.14 Float type level switch 6 No.

2.15 Level gauge ( magnetic / reflex

type )


146 | P a g e

Sr. No. Description

Qty Unit


Loop check

Supervision of

installation Supply

Grand

total Remarks


2.15.1 CC distance - 1500 mm

3

No

s.

N/

A N/A

2.15.2 CC distance - 1000 mm

5

No

s.

N/

A N/A

2.16 Multi-point temperature

element assembly with

transmitters

2.16.1 K-type thermocouple, 10 point

Type for thermocline tank 4

No

s.

Bracket/Wa

ll mounting

2.16.2 K-type thermocouple, 10 point

skin Type for receiver 1

No

s.

2.17 Water meter, class B, 40 NB

1

No

s.

2.18 Supply of HART calibrator

1

No

s.

3.0 Control room mounted system components -


147 | P a g e

Sr. No. Description

Qty Unit


Loop check

Supervision of

installation Supply

Grand

total Remarks


3.1.1 PLC, cabinet with Ethernet

switch - Floor mounted type,

800 x 800 x 2100 mm ( W x D x

H ) ( supply & fabrication of

base plate frame by contractor

), software and software

development etc. complete 1 No.

N/

A N/A

3.1.2 SCADA station - desktop PC ( 2

Nos. ) with printer, Ethernet

switch, software and software

development etc. complete 1 Set

N/

A N/A

4.0 Instrumentation work in package equipment

4.1 Dosing systems pump control

panel 2

No

s. N/A N/A

4.2 Instrument air

4.2.1 Pressure gauge

2

No

s. N/A N/A

4.2.2 Safety relief valve

1

No

s. N/A N/A


148 | P a g e

Sr. No. Description

Qty Unit


Loop check

Supervision of

installation Supply

Grand

total Remarks


4.2.3 Pressure regulating valve

1

No

s.

4.2.4 Blanketing valve

1

No

s.

Instrument installation material

5.0 Junction boxes

5.1 JB for 6 pair signal cable ( 24

terminals ) 9

No

s.

N/

A N/A N/A N/A

6.0 Instrument signal & alarm cables ( Bidder's job includes laying, dressing, clamping, glanding, ferruling, testing ( meggering,

continuity & loop checking ) and termination of cables at both ends including supply of materials such as ferrules, crimping lugs

and clamps etc.

6.1 signal cable - 1pair x 1.5 sqmm,

shielded & armoured cable,

outer sheath PVC ( grey ) 500

Mtr

s

N/

A N/A N/A N/A

6.2 RTD signal cable - 1TRIAD X

1.5 sqmm, shielded & 100

Mtr

s

N/

A N/A N/A N/A


149 | P a g e

Sr. No. Description

Qty Unit


Loop check

Supervision of

installation Supply

Grand

total Remarks


armoured cable, outer sheath

PVC ( grey )

6.3 K-type thermocouple signal

cable - 1pair x 1.5 sqmm,


outer sheath PVC ( yellow )

100 Mtr

s

N/

A N/A N/A N/A

6.4 signal cable - 6 pair x 1.5 sqmm

individual and overall shielded

& armoured cable, outer

sheath PVC ( grey)

200 Mtr

s

N/

A N/A N/A N/A

6.5 signal cable -12 pair x 1.5

sqmm individual and overall


outer sheath PVC (grey)

200 Mtr

s

N/

A N/A N/A N/A

6.6 signal cable -12 pair x 1.5

sqmm individual and overall


outer sheath PVC (grey)

200 Mtr

s

N/

A N/A N/A N/A

6.7 Power cable - 3 Core X 1.5

sqmm, shielded & armoured

cable, outer sheath PVC (black)

200 Mtr

s

N/

A N/A N/A N/A


150 | P a g e

Sr. No. Description

Qty Unit


Loop check

Supervision of

installation Supply

Grand

total Remarks


6.8 Ethernet cable - CAT5, 4 Pair x

0.5 sqmm, 100

Mtr

s

N/

A N/A N/A N/A

6.9 Fibre optic cable – 6 core

100

Mtr

s

N/

A N/A N/A N/A

7.0 Cable glands ( Rate of installation shall be included in Cable Laying rate) - Weatherproof SS 316 double compression type with

check nut for Mxx glands ( all cable gland make : Cosmos / Comet / EX-Protecta). all cable glands shall be provided with PVC

shrouds / gland hood

7.1 Cable Gland 1/2" NPT (

Instrument side ) 50

No

s.

N/

A N/A N/A N/A

7.2 Cable Gland M20 ( JB side )

40

No

s.

N/

A N/A N/A N/A

7.3 Cable Gland M40 - suitable for

6 pair x 1.5 sqmm ( cable

overall OD-20-23 mm ) 10

No

s.

N/

A N/A N/A N/A

7.4 Cable Gland M40- suitable for



No

s.

N/

A N/A N/A N/A


151 | P a g e

Sr. No. Description

Qty Unit


Loop check

Supervision of

installation Supply

Grand

total Remarks


7.5 Cable Gland M40- suitable for


overall OD-26-30 mm )

Thermocouple cable 15

No

s.

N/

A N/A N/A N/A

7.6 Cable Gland M20 - suitable for

3 CORE X 1.5 sqmm ( cable


No

s.

N/

A N/A N/A N/A

8.0 Impulse tubing / piping/ sample tubing ( Tube laying rate includes the installation of tube fitting, valve & other accessories )

8.1 Seamless tube - SS316 : 12 mm

OD X 1.5mm thick 200

Mtr

s

N/

A N/A N/A N/A

8.2 Male connector - SS316 : 1/2"

NPT(M) X 12 mm OD, 3000# 100

No

s.

N/

A N/A N/A N/A

Part of

impulse

tubing

8.3 Tube tee - SS316 : 12 mm OD,

3000# 12

No

s.

N/

A N/A N/A N/A

8.4 Nipple - SS316 : 1/2" NPT X

100 mm long, Sch-80S 25

No

s.

N/

A N/A N/A N/A

8.5 Pipe Tee (equal)-3000# -

SS316 : 1/2" NPT (F) 12

No

s.

N/

A N/A N/A N/A


152 | P a g e

Sr. No. Description

Qty Unit


Loop check

Supervision of

installation Supply

Grand

total Remarks


8.6 Plug - SS316 : 1/2" NPT (M),

3000# 35

No

s.

N/

A N/A N/A N/A

8.7 Globe valve - SS316 : 1/2" NPT

(F), 800# 10

No

s.

N/

A N/A N/A N/A

8.8 Globe valve (IBR certified) -

SS316 : 1/2" NPT (F), 800# 4

No

s.

N/

A N/A N/A N/A

8.9 Condensate pot with vent plug

( 4" Size with 3 x 1/2" NPT (F)

) IBR certified complete

assembly suitable for design

pressure & temp. 40 BARG &

425 ⁰C.

MOC -SS316 4

No

s.

N/

A N/A N/A N/A

8.10 Tubing union - SS316 : 12 mm

OD, 3000# 15

No

s.

N/

A N/A N/A N/A

9.0 Pneumatic tubing ( tube laying rate includes the installation of tube fitting, valve & other accessories )

9.1 12mm OD X 1mm thk seamless

SS 316 tube 120

Mtr

s

N/

A N/A N/A N/A


153 | P a g e

Sr. No. Description

Qty Unit


Loop check

Supervision of

installation Supply

Grand

total Remarks


9.2 1/2" NPT (M) x 6mm OD SS

316 make connector, 3000# 8

No

s.

N/

A N/A N/A N/A

Part of

signal

tubing 9.3 Tubing union 6mm OD, SS 316,

3000# 4

No

s.

N/

A N/A N/A N/A

10.0 Cable trays: ** ( Refer Note-2 )

10.1 Ladder trays - GI Collar 100

mm thickness 4mm

10.1.1 150 mm wide ( Ladder type),

4mm thick U/R

Mtr

s. N/A N/A N/A N/A

10.1.2 300 mm wide ( ladder type),

4mm thick U/R

Mtr

s. N/A N/A N/A N/A

10.2 Perforated trays - GI

10.2.1 50 mm wide ( Perforated type),

4mm thick U/R

Mtr

s. N/A N/A N/A N/A

10.2.2 100 mm wide ( Perforated type

), 4mm thick U/R

Mtr

s. N/A N/A N/A N/A


154 | P a g e

Sr. No. Description

Qty Unit


Loop check

Supervision of

installation Supply

Grand

total Remarks


10.3 150mm wide Tray fittings,

4mm thick

10.3.1 150mm wide 90 deg.

horizontal bend, R=300 mm U/R

No

s. N/A N/A N/A N/A

10.3.2 150mm wide 90 deg. vertical

outside bend, R=300 mm U/R

No

s. N/A N/A N/A N/A


4mm thick

10.4.1 300mm wide 90 deg.


No

s. N/A N/A N/A N/A


4mm thick ( Perforated )

10.5.1 100mm wide 90 deg.


No

s. N/A N/A N/A N/A

10.6 50mm wide Tray fittings, 4mm

thick ( Perforated )

10.6.1 50mm wide 90 deg. horizontal

bend, R=300 mm U/R

No

s. N/A N/A N/A N/A


155 | P a g e

Sr. No. Description

Qty Unit


Loop check

Supervision of

installation Supply

Grand

total Remarks


10.7 Coupler plates (3mm thk.) of

suitable size for FRP trays

along with SS hardware

( for ladder tray, total 4nos. of

coupler plates required for

joining 2 trays) U/R

No

s. N/A N/A N/A N/A

10.8 Coupler plates (4mm thk.) of

suitable size for FRP trays

along with SS hardware

( for perforated tray, total

2nos. of coupler plates

required for joining 2 trays) U/R

No

s. N/A N/A N/A N/A

11.0 Structural steel for supports - painting of structural steel including supply of paint and providing 3 coats of paints ( 1 coat primer

and 2 coats finished ) for all structural works to be included in the scope of bidder. (refer typical mounting drawings)

11.1 ISMC 100 x50, 1600 LG U/R

Kgs

. N/A N/A N/A N/A

As required 11.2

Base plate 250 x 250 6 thk U/R Kgs

. N/A N/A N/A N/A

11.3 ISA 65 x 65x 6 thk. U/R

Kgs

. N/A N/A N/A N/A


156 | P a g e

Sr. No. Description

Qty Unit


Loop check

Supervision of

installation Supply

Grand

total Remarks


11.4 Gusset plate 70 x 140 x 6 thk. U/R

Kgs

. N/A N/A N/A N/A

11.5 Earth bar Flat 50 x 6Thk, 50LG U/R

Kgs

. N/A N/A N/A N/A

11.6 Pipe (ERW), 2" NB, MS for

instrument supports, 1400

long U/R

No

s. N/A N/A N/A N/A



Long U/R

No

s. N/A N/A N/A N/A



Long U/R

No

s. N/A N/A N/A N/A

11.9 Top plate 52.5 Dia 6 thk.

U/R

No

s. N/A N/A N/A N/A

11.10 Anchor fasteners / bolts, M10,

40 mm Long U/R

No

s. N/A N/A N/A N/A

11.11 Plate 150 x 150 x 10 thk.

U/R

Kgs

. N/A N/A N/A N/A


157 | P a g e

Sr. No. Description

Qty Unit


Loop check

Supervision of

installation Supply

Grand

total Remarks


11.12 Plate 150 x 150 x 6 thk.

U/R

Kgs

. N/A N/A N/A N/A

11.13 Gusset plate 200 x 110 x 6 thk.

U/R

Kgs

. N/A N/A N/A N/A

12.0 FRP canopies

FRP with UV stabilised, fire retardant properties, mounting of box - 2" pipe mount with SS hardware, colour - grey

as required

12.1 FRP canopies for transmitters (

4mm thick) U/R

No

s. N/A N/A N/A N/A

12.2 FRP canopies for junction

boxes / control boxes ( 4mm

thick) U/R

No

s. N/A N/A N/A N/A

13.0

Unit rates for supply of labour– Including all

statutory dues and charges, food,

accommodation, sanitary, potable water etc.

arrangements etc. complete on per man-day

basis of 10 hr. shift.

(Including Tools, Accessories and Consumables like

Teflon Tape etc.)


158 | P a g e

Sr. No. Description

Qty Unit


Loop check

Supervision of

installation Supply

Grand

total Remarks


13.1 Instrument technician N/A N/A N/A N/A N/A N/A

13.2 Electrician N/A N/A N/A N/A N/A N/A

13.3 Instrument fitter N/A N/A N/A N/A N/A N/A

13.4 Welder N/A N/A N/A N/A N/A N/A

13.5 Helper N/A N/A N/A N/A N/A N/A

13.6 Supervisor N/A N/A N/A N/A N/A N/A

14.0 Information for the estimation of loop checking and interlock checking :- (Effort Cost to be included in various

activities mentioned above) PLC I/O Count -

14.1 Analog inputs / outputs 73 no.

14.2 Digital inputs 8 no.

14.3 Digital outputs 8 no.

14.4 RTD / Thermocouple inputs 140 no.

15.0 Consumables & miscellaneous items ( Supply Cost to be included in various activities mentioned above) - quantity

as required


159 | P a g e

Sr. No. Description

Qty Unit


Loop check

Supervision of

installation Supply

Grand

total Remarks


15.1 Cutting gases N/A N/A N/A N/A

15.2 Welding electrodes N/A N/A N/A N/A

15.3 Soldering/ brazing materials N/A N/A N/A N/A

15.4 Sealing materials / Teflon

tapes N/A N/A N/A N/A

15.5 Clamps/ cable & wire binders,

crimping lugs for wires & earth

wires

N/A N/A N/A N/A

15.6 Nuts & bolts (SS) for fixing

junction boxes, cable trays N/A N/A N/A N/A

15.7 Marking ferrules N/A N/A N/A N/A

15.8 Other items as required N/A N/A N/A N/A

16.0 Details of testing

16.1 Control valves - Leakage test of

pneumatic connections.


160 | P a g e

Sr. No. Description

Qty Unit


Loop check

Supervision of

installation Supply

Grand

total Remarks


16.2 On / off valves – Functional

checks and leakage test of

pneumatic connections

16.3 Temperature elements:-

Testing of resistance / voltage

change with temperature.

16.4 Pressure & differential

pressure transmitter

calibration check & functional

check.

17.0 Painting of structural items (Instrument tray supports, stanchion, JB frames, air manifold frames etc.)---- 2 coats of primer

with 2 coats epoxy paint, surface preparation with wire brush, shade of epoxy will be informed by site.

TOTAL

Note:

Bidder shall terminate field cables in system cabinets, shall coordinate with other for loop checking

Cable trays shall be required with coupler plates for 45 deg & 90 deg vertical inside & outside as well as for horizontal bends. Bidder to

consider the cost in the cable tray rates for ladder & perforated cable trays along with nuts & bolt as required.

The quantities mentioned for cables, cable tray & associated fittings, structural steel are based on instrument location plans/ tray layout

plant. Bidder to verify the site condition & crosscheck the quantity as required before supplying.


161 | P a g e


162 | P a g e

E. Schedule of quantities – Molten Salt, selective coating and heat transfer compound

Sr.

No. Item Description Qty Unit

Unit Rate

Rs.

Amount

Rs.

1 Molten salt

1 .1 Procurement and supply to site and storage thereof

at site until directed to use, molten salt as per

specification and approval in suitable pack such as

to properly maintain the salt properties as per

specifications. 20 MT

1.2 Lifting, shifting, transport of the salt from storage

to molten salt storage tank and unloading the salt

into the molten salt storage tank as directed with

all required precautions to avoid any

contamination of the salt during the entire process.

Disposal of the molten salt packaging outside the

premises will be the vendor’s responsibility. This

process may be intermittent and may be carried

out over several days as directed by engineer in-

charge. 1 LS

1.3 Labour supply rate for salt handling other than that

covered in the above items

1.3.1 unskilled labour

UR

man-

hr

1.3.2 supervisor

UR

man-

hr

2 Selective coating

2.1 Selective coating 3 gal

2.2 Thinner(xylene) As required

2.3 Trichloroethane, methyl ethyl ketone(butanone) As required

3 Heat transfer compound

3.1 Heat transfer compound/cement 12 Gal


163 | P a g e

Sr.


Unit Rate

Rs.

Amount

Rs.

3.2 Stainless steel channels flexible width = 51mm;

height = 25 mm; length = 1.2m 25 No.

3.3 Stainless steel channels width = 30 mm; height= 21

mm; length = 1.2m 150 No.

3.4 Stainless steel banding 120 m

3.5 Stainless steel tie wire 200 m

F. Schedule of quantities – Spares

Sr.


Unit Rate

Rs.

Amount

Rs.

1 Reference Item B.1, receiver coils

a receiver coil, 1,100 mm OD, inlet 0.5m outside

receiver, outlet 800mm long 2 no.

b receiver coil, 700 mm ODl, inlet 500mm long, outlet

0.5m outside receiver 1 no.

2 Spares for MSP1

a Impeller, SS316L 1 No.

b Stuffing box sleeve, hard faced, SS316L 1 No.

c Stuffing box bush, hard faced, SS316L 1 No.

d Spider sleeve, SS316L 3 No.

e Spider bush, SS316L 3 No.

f Gasket set, graphite 1 Set

g Hardware set 1 Set

h Pump, motor bearing set 1 Set

i Coupling, Disco Flex 1 No.


164 | P a g e

Sr.


Unit Rate

Rs.

Amount

Rs.

j Shaft, SS 316 1 No.

3 Spares for MSP2

a Impeller, SS316L 1 No.

b Stuffing box sleeve, hard faced, SS316L 1 No.

c Stuffing box bush, hard faced, SS316L 1 No.

d Spider sleeve, SS316L 3 No.


f Gasket set, graphite 1 Set

g Hardware set 1 Set

h Pump, motor bearing set 1 Set

i Coupling, Disc-o-flex 1 No.

j Shaft, SS 316 1 No.

4 Spares for FWP-1, FWP-2

a Plunger, SS316L 3 No.

b Stuffing box packing 3 set

c Drive Belt 4 No.

d NRV, SS 304 1 set

e Pump, motor bearing set 1 Set

f Drive chain with locks, in lieu of c 2 set

g Gear oil 5 ltr

5 Spares for DM water pump

a Impeller, CS 1 No.

b Stuffing box packing 2 No.

c Pump, motor bearing set 1 Set

d coupling elastomer 3 No.


165 | P a g e

Sr.


Unit Rate

Rs.

Amount

Rs.

6 Spares for cooling water circulation pump

a Impeller, CS 1 No.

b Stuffing box packing 2 No.

c Pump, motor bearing set 1 Set

d coupling elastomer 3 No.


Common Spare pump for DM water and cooling

water

7 Spare valves

a Same as B.8.a 2 No.

b Same as B.8.b 1 No.

c Same as B.8.c 1 Set

d Same as B.8.d 1 No.

e Same as B.8.e 1 No.

f coil, spring and seat for B.8.f 2 set

g spring, disc and seat for B.8.g 1 set

h spring, disc and seat for B.8.h 1 set

i spring, disc and seat for B.8.i 1 set

j Same as B.8.j 2 No.

k Same as B.8.k 1 No.

l Discs and spring for B.8.l 1 set

m spring, disc and seat for B.8.m 1 set

n Seats and seals for B.8.n 2 set

o Seats and seals for B.8.o 1 set

p Seats and seals for B.8.p 1 set


166 | P a g e

Sr.


Unit Rate

Rs.

Amount

Rs.

q spring, disc and seat for B.8.q 1 set

r spring, disc and seat for B.8.r 1 Set

8 Spares for instrument air plant

a inlet, outlet air and oil filters 4 set

b Compressor oil 20 ltr.

c Belts 2 Set

d Auto drain valve 1 No.


9 LP & HP dosing system, each

a filters 4 set

b Discharge pump 1 No.

c Belts 2 Set

d Auto drain valve 1 No.


10 Radiator based cooling system

a inlet, outlet hoses with hose clamps etc. 1 set

b fan impeller with motor 1 No.

11 Electric hoists

a 3 years operation and maintenance spares 1 set

12 Instrumentation system

a PLC, Digital input module, of each type 1 No

b PLC, Digital output module, of each type 1 No.

c PLC, Analog input module, of each type 1 No.

d PLC, Analog output module, of each type 1 No.


167 | P a g e

Sr.


Unit Rate

Rs.

Amount

Rs.

e Amplifier Card for pressure/ DP transmitter of

each type 1 No.

f Amplifier Card for temperature transmitter of each

type 1 No.

g Integral LCD Display unit ( minimum 1 no. of each

type ) 2 No.

h O-rings for Electronic Transmitters ( minimum 2

nos. of each type ) 10 No.

i SPDT Switch for Level Switch 1 No.

j Multipoint Thermocouple Element 1 set.

k Pressure Gauge of each type & range 1 No.

l Rotameter of each type & range 1 No.

m Thermocouple Element of each type 1 No.

n Receiver thermocouple elements 2 sets

o Fuse Links, Packet of 10 nos. of each type & rating 1 Pkt

p Lamps, Push Buttons & Selector Switches of each

type 1 No.

13 Electrical items

a Cable compression type cable glands for following

sizes, 10% of each type and size or 6 nos.

whichever is more 1 Lot

b Light Fixtures, 10% of each type and size or 1 no.

whichever is more 1 Lot

c Switchgear etc.

i Contactors of all types and ratings, 10% of each

total qty or 1 no. each whichever is more 1 LS

ii MCCBs, MCBs of all types and ratings, 10% of each

total qty or 1 no. of each whichever is more 1 LS.


168 | P a g e

Sr.


Unit Rate

Rs.

Amount

Rs.

iii Relays of all types and ratings, 10% of each total

qty or 1 no. of each whichever is more 1 LS.

iv LED lamps, Switches, pushbuttons, 10% of each

total qty or 1 no. of each whichever is more 1 LS.

v CTs of each types and ratings, 10% of each total qty

or 3 nos whichever is more. 1 LS.

d Meters, testers

i Auto-ranging digital clamp meter –Meco Model :

3600 - 1200A DC & 1000A AC(TRMS), 3¾ Digit

3999 Counts, 40 Segment Bargraph, Auto -

Ranging, Peak hold, Max, Zero, Data hold functions,

APO, accessories or equivalent 2 No.

ii Auto-ranging Digital Multimeters – TRMS Super &

all accessories 4-1/2 Digits 20,000 Counts or

equivalent 2 No.

iii Multifunction process calibrator, Meco model 333

and all accessories or equivalent 2 No.

iv Digital Earth Tester, Meco Model : DET 2016 with

all accessories or equivalent 2 No.

v Battery meter – Meco BM 63 with all accessories or

equivalent 2 No.

vi Veerobot TLS-SLD-SLDR-77, Soldron 50W,

Soldering Kit, 1 x 50W Original Soldron Soldering

Iron in VEEROBOT branded box, 1 x Solder Stand,

1 x 50 Gram Solder Wire, 1 x White High Quality

Flux, complete 2 No.

e UPS spares as per OEM recommendation 1 LS

14 General Consumables

a Multi-purpose Grease 2, Balmer Laurie 1 kg

b Cotton hosiery waste, 50 kg bags 100 kg

c Cotton yarn waste, white, 50 kg bags 100 kg

d Hydrazine Hydrate, 35% in 25 kg packs 1500 kg


169 | P a g e

Sr.


Unit Rate

Rs.

Amount

Rs.

e TSP, Assay > 98%, P2O5 content > 17.5% 1 kg

15 Digital water hardness tester, accuracy 2 No.

16 Hand operated , hydraulic Pallet Truck 2.5 Ton

capacity, steel powder coated, with heavy duty

polymer castor wheels, 2 nos brake wheels 1 No.

17 Heavy duty, handheld industrial platform ( 72cm x

48cm ) trolley, steel powder coated, 5” heavy duty

polymer castor wheels, 150 kg load, 2 nos brake

wheels

18 Supreme 515 x 310 x 200 mm Premium Plastic

BIN-50, or equivalent 25 No.

19 Supreme Plastic Pallet SIM 1210120 PDD LW

1200x1000x125 mm, or equivalent 5 No.

20 Electronic weighing balance 1000gm x 0.1g, auto-

zero, auto-taring, auto standby, LED display, 100g

beaker. 1 No.

21 Electronic heavy duty platform weighscale

stainless steel construction, 100kg x 10g. LED

display 1 No.

22 Polyester, 3 Mtrs, 2 Ton, Double Ply Webbing Slings

Flat Belt 2 No.

23 4’ x 2’ table, steel structure with laminated

plywood top, reclinable, fabric covered cushioned

chairs with PU arms-rest and castors, for stores etc. 3 No.


170 | P a g e

Section – 8: Annexures


171 | P a g e

Annexure 1: Drawing list

Sr No. Document No. Rev. Document Title

1 C530/PI/PFD/A3/001 R0 Process Flow Diagram

2 C530/PI/GA/A0/005 R0 Piping Layout

3 C530/PI/GA/A1/006 R0 Piping Layout - Section

4 C530/GEN/SK/A1/011 P0 Receiver Heater Assembly Schematic

5 C530/PI/PID/A1/012 R0 P & ID For Raw Water & DM Water For

Molten Salt Loop

6 C530/GEN/SK/A4/015 R0 Schematic for Steam Tracing of Molten

Salt Line

7 C530/ST/GA/A1/202 R0 G.A & Fabrication details of Pipe supports

8 C530/ME/GA/A1/304 R0 G.A. of Fabrication Details of superheater

9 C530/ME/GA/A1/305 Sheet-1 R0 G.A. of Fabrication Details of Evaporator

10 C530/ME/GA/A1/305 Sheet-2 R0 Fabrication Details of Evaporator

11 C530/ME/GA/A1/306 R0 G.A. of Fabrication Details of Preheater

12 C530/ME/GA/A1/307 R0 Vent Pot

13 C530/ME/FB/A1/308 R0 G.A. of Receiver Structural

14 C530/ME/GA/A1/309 Sheet 1 of 2 P0 Receiver Tower Equipment Layout

15 C530/ME/GA/A1/309 Sheet 2 of 2 P0 Receiver Tower Equipment Layout

section

16 C530/ME/GA/A4/314 R0 Fabrication details of Feed Water Tank

17 C530/ME/GA/A1/321 P0 Receiver heater mechanism

18 C530/EL/SLD/A1/402 R0 Single Line Diagram for molten salt loop

19 C530/EL/GA/A1/403 R0 Cable Tray Layout

20 C530/EL/GA/A2/404 R0 Earthing Layout

21 C530/EL/GA/A1/405 R0 Lighting Layout


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Sr No. Document No. Rev. Document Title

22 C530/EE/GA/A4/414 R0 Electrical Heater Assembly before

Preheater

23 C530/I&C/HD/A4/528 sheet 1 of 14 R0 Process & Air Hook-up Diagrams for flow

transmitter wedge element + DP TX

24 C530/I&C/HD/A4/528 sheet 2 of 14 R0 Process & Air Hook-up Diagrams for level

transmitter, bubble type.


transmitter diaphragm seal





28 C530/I&C/HD/A4/528 sheet 6 of 14 R0 Process & Air Hook-up Diagrams for

pressure transmitter diaphragm seal


Pressure transmitters steam service


pressure transmitters gas service


pressure gauge with diaphragm seal


pressure gauge with snubber


pressure gauge with syphon


pressure gauge

35 C530/I&C/HD/A4/528 sheet 13 of 14 R0 Process & Air Hook-up Diagrams for E/P

positioner control valve

36 C530/I&C/HD/A4/528 sheet 14 of 14 R0 Process & Air Hook-up Diagrams for ON-

OFF Valve

37 C530/I&C/LD/A4/529 R0 Instrument Location Plan and Cable tray

Layout


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Annexure 2: Document List

Sr. No. Document No. Rev. Document Title

1 C530/PI/DS/A4/018 P0 Specification for Globe Valve for Steam

2 C530/PI/DS/A4/019 P0 Specification for Non slam check valve for

Steam

3 C530/PI/DS/A4/020 P0 Specification for Steam Trap

4 C530/PI/MTO/A4/021 R0 Piping MTO

5 C530/GEN/DS/A4/022 P0 Technical specifications of Molten Salt

6 C530/PI/DS/A4/023 R0 Water Meter

7 C530/PI/DS/A4/024 P0 Specification for Carbon Steel Ball Valve -

Cooling water line

8 C530/PI/DS/A4/025 P0 Specification for Non slam check valve –

Cooling Water Line

9 C530/PI/DS/A4/026 P0 Specification for Y type Strainer – Cooling

Water Line

10 C530/PI/DS/A4/027 P0 Specification for True Union Ball Check

Valve (CPVC)

11 C530/PI/DS/A4/028 P0 Specification for CPVC Ball Valve

12 C530/PI/DS/A4/029 P0 Specification for Y type Strainer (CPVC)

13 C530/PI/DS/A4/030 P0 Specification for UPVC Ball Valve - Raw

water Line

14 C530/PI/DS/A4/031 P0 Specification for Y type Strainer (CPVC) –

Soft Water

15 C530/PI/DS/A4/032 P0 Specification for Float valve – Soft water Line

16 C530/PI/DS/A4/033 P0 Specification for UPVC Ball Valve – Soft

Water Line


UPVC

18 C530/PI/DS/A4/035 P0 Specification for Ball Valve for Hot Water


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19 C530/PI/DS/A4/036 P0 Specification for Non slam check valve – Hot

Water Line

20 C530/PI/DS/A4/037 P0 Specification for Y type Strainer – Hot Water

Line

21 C530/PI/DS/A4/038 P0 Specification for Globe Valve - Molten Salt

Line


Molten Salt

23 C530/PI/DS/A4/040 P0 Specification for Pressure relief Valve –

Molten salt

24 C530/ME/DS/A4/310 P0 Specification Molten Salt Pump for Cold

Circuit

25 C530/ME/DS/A4/311 P0 Specification Molten Salt Pump for Hot

Circuit

26 C530/ME/DS/A4/312 P0 Specification of Boiler feed water pumps

27 C530/ME/DS/A4/313 P0 Specification of Cooling water pumps

28 C530/EL/LL/A4/401 R0 Electrical load list

29 C530/EE/CS/A4/406 R0 Cable Schedule

30 C530/EE/SP/A4/407 R0 Technical specification for MCC / Electrical

Control Panel / Distribution Boards/

Battery, Inverter and Power pack

31 C530/EE/SP/A4/408 R0 Technical specification for UPS & Battery

32 C530/EE/SP/A4/410 R0 Technical Specification for AC Motors

33 C530/EE/SP/A4/411 R0 Technical specification for supply of Bulk &

Erection material including cable, earthing,

lighting, cable trays, glands, lugs

34 C530/EE/DS/A4/413 R0 Technical Datasheet for Electrical Heater

35 C530/I&C/IN/A4/501 R0 Instrument Index

36 C530/I&C/IN/A4/502 R0 Cable Schedule


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37 C530/I&C/IN/A3/503 R0 Control System I/O List

38 C530/I&C/SP/A4/504 P0 Specification for Pressure and DP

Transmitter

39 C530/I&C/SP/A4/505 P0 Specification for Temperature Transmitter

40 C530/I&C/SP/A4/506 R0 Flow Element (Wedge type)

41 C530/I&C/SP/A4/508 R0 Specification for Pressure gauge

42 C530/I&C/SP/A4/509 R0 Specification for Dial Thermometer

43 C530/I&C/SP/A4/510 R0 Specification for Level Switch

44 C530/I&C/SP/A4/511 R0 Specification for Level gauge

45 C530/I&C/SP/A4/512 R0 Specification for Multipoint Temperature

Element

46 C530/I&C/SP/A4/513 P0 Specification for Globe type control valve

47 C530/I&C/SP/A4/514 P0 Specification for On-Off valve

48 C530/I&C/SP/A4/515 P0 Specification for Safety Relief Valve

49 C530/I&C/SP/A4/516 R0 Specification for Instrument cable

50 C530/I&C/SP/A4/517 R0 Specification for Instrument Junction Box

51 C530/I&C/SP/A4/518 R0 Specification for Instrument Cable Gland

52 C530/I&C/SP/A4/519 R0 Specification for Instrument Cable Tray

53 C530/I&C/SP/A4/520 R0 Specification for Instrument Tubing and

54 C530/I&C/SP/A4/521 P0 Solenoid valve

55 C530/I&C/SP/A4/522 R0 Vortex Flowmeter Datasheet

56 C530/I&C/SP/A4/523 R0 Rotameter Datasheet - Molten Salt

57 C530/I&C/SP/A4/524 R0 Specification for PLC based Control System

58 C530/I&C/SP/A4/525 R0 Specification for Instrument Installation

Contract

59 C530/I&C/LD/A3/527 R0 Cause & Effect Charts


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60 C530/I&C/WD/A3/526 R0 Loop Wiring Diagram

61 C530/UT/DS/A4/601 R0 Data Sheet for Dosing System


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Annexure 3: Deviation Statement Form Following are the Technical deviations and variations from the Technical specifications

S. No. Item Statement of deviations/variations

The following are the particulars of the deviations from the requirements of the tender document

terms and conditions:

S. No. Item Statement of deviations/variations

These deviations and variations are exhaustive. Except these deviations and variations, the entire

work shall be performed as per your specifications and documents.

Signature of bidder

Date

Note:

The technical compliance/deviation should be supported by relevant technical literature.

If specification in Superior/inferior than asked for the enquiry, it should be clearly brought

out in the justification.

If the bidder offers more than one model, then the technical compliance statement must be

enclosed for each and every model separately.


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Annexure 4: Integrity pact

(To be printed on Supplier's letterhead)

INTEGRITY PACT

General

This pre-bid pre-contract Agreement hereinafter called the Integrity Pact is made on

............................ day of the month of .................................. , between, on one hand, the President

of India acting through Joint Registrar, Materials Management Division of Indian Institute

of Technology, Bombay hereinafter called the “BUYER” of the First Part and

M/s.......................................................................................................represented by Shri

...............................................................,Director /Chief Executive Officer/ General Manager

hereinafter called the “BIDDER/Seller” of the Second Part.

WHEREAS the BUYER proposes to procure

................................................................................................. (Name of the Stores/Equipment/Item)

and the BIDDER/Seller is willing to offer/has offered the stores and WHEREAS the

BIDDER is a private company/public company/Government

undertaking/partnership/registered export agency, constituted in accordance with the

relevant law in the matter and the BUYER is an Autonomous Body/Department of the

Government of India performing its functions on behalf of the President of India.

NOW, THEREFORE, to avoid all forms of corruption by following a system that is fair,

transparent and free from any influence/prejudiced dealings prior to, during and

subsequent to the currency of the contract to be entered into with a view to :-Enabling

the BUYER to obtain the desired said stores / equipment at a competitive price in

conformity with the defined specifications by avoiding the high cost and the distortionary

impact of corruption on public procurement, and Enabling BIDDERs to abstain from

bribing or indulging in any corrupt practice in order to secure the contract by providing

assurance to them that their competitors will also abstain from bribing and other corrupt

practices and the BUYER will commit to prevent corruption, in any form, by its officials

by following transparent procedures. The parties hereto hereby agree to enter into this

Integrity Pact and agree as follows:


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Commitments of the BUYER

1.1 The BUYER undertakes that no official of the BUYER, connected directly or indirectly

with the contract will demand, take a promise for or accept, directly or through

intermediaries, any bribe, consideration, gift, reward, favour or any material or

immaterial benefit or any other advantage from the BIDDER, either for themselves or

for any person, organization or third party related to the contract in exchange for an

advantage in the bidding process, bid evaluation, contracting or implementation

process related to the Contract.

1.2 The BUYER will, during the pre-contract stage, treat all BIDDERs alike, and will

provide to all BIDDERs the same information and will not provide any such

information to any particular BIDDER which could afford an advantage to that

particular BIDDER in comparison to other BIDDERs.

1.3 All the officials of the Buyer will report to the appropriate Government office any

attempted or completed breaches of the above commitments as well as any

substantial suspicion of such a breach.

1. In case any such preceding misconduct on the part of such official (s) is reported by

the BIDDER to the BUYER, with full and verifiable facts and the same is prima facie

found to be correct by the BUYER, necessary disciplinary proceedings, or any other

action as deemed fit, including criminal proceedings may be initiated by the BUYER

and such a person shall be debarred from further dealings related to the contract

process. In such a case while an enquiry is being conducted by the BUYER the

proceedings under the contract would not be stalled.

Commitments of BIDDERs:

2. The BIDDER commits itself to take all measures necessary to prevent corrupt

practices, unfair means and illegal activities during any stage of its bid or during any

pre-contract or post-contract stage in order to secure the contract or in furtherance

to secure it and in particular commit itself to the following:

3.1. The BIDDER will not offer, directly or through intermediaries, any bribe,

consideration, gift, reward, favour, any material or immaterial benefit or other

advantage, commission, fees, brokerage or inducement to any official of the

BUYER, connected directly or indirectly with the bidding process, or to any

person, organization or third party related to the contract in exchange for any


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advantage in the bidding, evaluation, contracting and implementation of the

Contract.

3.2. The BIDDER further undertakes that it has not given, offered or promised to give,

directly or indirectly any bribe, gift, consideration, reward, favour, any material

or immaterial benefit or other advantage, commission, fees, brokerage or

inducement to any official of the BUYER or otherwise in procuring the Contract

or forbearing to do or having done any act in relation to the obtaining or execution

of the Contract or any other Contract with the Government for showing or

forbearing to show favour or disfavour to any person in relation to the Contract

or any other Contract with the Government.

3.3. BIDDERs shall disclose the name and address of agents and representatives and

Indian BIDDERs shall disclose their foreign principals or associates.

3.4. BIDDERs shall disclose the payments to be made by them to agents / brokers or

any other intermediary, in connection with this bid/contract.

3.5. The BIDDER further confirms and declares to the BUYER that the BIDDER is the

original manufacturer/ integrator/ authorized government sponsored export

entity of the defense stores and has not engaged any individual or firm or

company whether Indian or foreign to intercede, facilitate or in any way to

recommend to the BUYER, or any of its functionaries, whether officially or

unofficially to the award of the contract to the BIDDER, nor has any amount been

paid, promised or intended to be paid to any such individual, firm or company in

respect of any such intercession, facilitation or recommendation.

3.6. The BIDDER, either while presenting the bid or during pre-contract negotiations

or before signing the contract, shall disclose any payments he has made, is

committed to or intends to make to officials of the BUYER or their family

members, agents, brokers or any other intermediaries in connection with the

contract and the details of services agreed upon for such payments.

3.7. The BIDDER will not collude with other parties interested in the contract to

impair the transparency, fairness and progress of the bidding process, bid

evaluation, contracting and implementation of the contract.

3.8. The BIDDER will not accept any advantage in exchange for any corrupt practice,

unfair means and illegal activities.

3.9. The BIDDER shall not use improperly, for purposes of competition or personal

gain, or pass on to others, any information provided by the BUYER as part of the

business relationship, regarding plans, technical proposals and business details,

including information contained in any electronic data carrier. The BIDDER also


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undertakes to exercise due and adequate care lest any such information is

divulged.

3.10. The BIDDER commits to refrain from giving any complaint directly or through any

other manner without supporting it with full and verifiable facts.

3.11. The BIDDER shall not instigate or cause to instigate any third person to commit

any of the actions mentioned above.

3.12. If the BIDDER or any employee of the BIDDER or any person acting on behalf of

the

BIDDER, either directly or indirectly, is a relative of any of the officers of the

BUYER, or alternatively, if any relative of an officer of the BUYER has financial

interest/stake in the BIDDER's firm, the same shall be disclosed by the BIDDER at

the time of filing of tender.

The term relative for this purpose would be as defined in Section 6 of the Companies

Act 1956.

3.13. The BIDDER shall not lend to or borrow any money from or enter into any

monetary dealings or transactions, directly or indirectly, with any employee of the

BUYER.

4. Previous Transgression

4.1. The BIDDER declares that no previous transgression occurred in the last three years

immediately before signing of this Integrity Pact, with any other company in any

country in respect of any corrupt practices envisaged hereunder or with any Public

Sector Enterprise in India or any Government Department in India that could justify

BIDDER's exclusion from the tender process.

4.2. The BIDDER agrees that if it makes incorrect statement on this subject, BIDDER can

be disqualified from the tender process or the contract, if already awarded, can be

terminated for such reason.

5. Earnest Money Deposit

5.1. Earnest Money Deposit is mandatory to be enclosed in the tender.

5.2. While submitting bid, the BIDDER shall deposit an amount mentioned in tender

document as Earnest Money, with the IIT Bombay through the following

instruments:


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A confirmed Bank Guarantee by an Indian Nationalized Bank promising

payment of the guaranteed sum to the BUYER on demand within three

working days without any demur whatsoever and without seeking any

reasons whatsoever. The demand for payment by the IIT Bombay shall be

treated as conclusive proof of payment.

The Earnest Money shall be valid upto a period of 180 days or the

complete conclusion of the contractual obligations to the complete

satisfaction of both the BIDDER and the BUYER whichever is later.

No interest shall be payable by the BUYER to the BIDDER on Earnest

Money for the period of its currency.

If successful bidder fails to submit the Performance Guarantee Bond

within 30 days from the date of placing of Purchase Order then purchase

order will be canceled and EMD will be forfeited.

If there is any difficulty in submitting Bank Guarantee then Demand draft

can be submitted in the favour of 'The Registrar, IIT Bombay' payable at

Mumbai.

Return of EMD: In case of successful BIDDER, EMD in the form of Bank

guarantee will be returned within 30 days from the date of submission of

Performance Guarantee Bond.

For unsuccessful bidder, Bank Guarantee will be returned within 30 days

from the date of placing the Purchase Order.

In case of Demand Draft, amount of EMD will be returned within 60 days

from the date of placing the purchase order.

6. SECURITY DEPOSIT /PERFORMANCE GUARANTEE:

6.1. Performance Guarantee Bond is mandatory.

6.2. Successful tenderer/ bidder should submit performance guarantee as prescribed

above to be sent to Joint Registrar, Materials management Division, IIT Bombay on

or before 15 days from the due date of issue of order acknowledgment. The PGB to


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be furnished in the form of bank guarantee as per proforma or annexure of the

tender documents, for an amount covering 10 % of the purchase order value.

The Performance Guarantee should be established in favour of “Registrar,

IIT Bombay”.

PBG to be established through any of the National Banks (whether situated

at Mumbai or outstation) with a clause to enforce the same on their local

branch of Mumbai or any scheduled bank (other than national bank) situated

at Mumbai. Bonds issued by co-operative banks will not be accepted.

Performance Guarantee Bond shall be for the due and faithfully performance

of the contract and shall remain binding, notwithstanding such variations,

alterations for extensions of time as may be made, given, conceded or agreed

to between the successful tenderer and the purchaser under the terms &

conditions of acceptance to the tender.

The successful tenderer is entirely responsible for due performance of the

contract in letter and spirit and all other documents referred to in the

acceptance of tenders.

The PBG shall be kept valid during the period of contract and shall continue

to be enforceable for a period of two years or upto warranty period

whichever is later from the date of order acknowledge. In case PBG needs

extensions upto extension period then supplier shall initiate extensions to

PBG one month prior to expiry of PBG.

For successful suppliers, if PBG is not submitted within 15 days from the date

of Order Acknowledgement, then the Purchase Order will be cancelled with

forfeiting of EMD.

No interest shall be payable by the buyer to the Bidder on PBG.

7. Sanctions for Violations

7.1. Any breach of the aforesaid provisions by the BIDDER or any one employed by it or

acting on its behalf (whether with or without the knowledge of the BIDDER) shall

entitle the BUYER to take all or any one of the following actions, wherever required:

-


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i. To immediately call off the pre-contract negotiations without assigning any

reason or giving any compensation to the BIDDER. However, the proceedings

with the other BIDDER(s) would continue.

ii. The Earnest Money Deposit (in pre-contract stage) and/or Security

Deposit/Performance Bond (after the contract is signed) shall stand forfeited

either fully or partially, as decided by the BUYER and the BUYER shall not be

required to assign any reason therefore.

iii. To immediately cancel the contract, if already signed without giving any

compensation to the BIDDER.

iv. To recover all sums already paid by the BUYER, and in case of an Indian

BIDDER with interest thereon at 2% higher than the prevailing Prime Lending

Rate of State Bank of India, while in case of a BIDDER from a country other

than India with interest thereon at 2% higher than the LIBOR. If any

outstanding payment is due to the BIDDER from the BUYER in connection with

any other contract for any other stores, such outstanding payment could also

be utilized to recover the aforesaid sum and interest.

v. To encash the advance bank guarantee and performance bond/warranty

bond, if furnished by the BIDDER, in order to recover the payments, already

made by the BUYER, along with interest.

vi. To cancel all or any other Contracts with the BIDDER. The BIDDER shall be

liable to pay compensation for any loss or damage to the BUYER resulting from

such cancellation/rescission and the BUYER shall be entitled to deduct the

amount so payable from the money(s) due to the BIDDER.

vii. To debar the BIDDER from participating in future bidding processes of the

Government of India for a minimum period of two years, which may be further

extended at the discretion of the BUYER.

viii. To recover all sums paid in violation of this pact by the BIDDER(s) to any

middleman or agent or broker with a view to securing the contract.

ix. In cases where irrevocable Letters of Credit have been received in respect of

any contract signed by the BUYER with the BIDDER, the same shall not be

opened.

x. Forfeiture of Performance Bond in case of a decision by the BUYER to forfeit

the same without assigning any reason for imposing sanction for violation of

this Pact.


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7.2. The BUYER will be entitled to take all or any of the actions mentioned at para 7.1(i)

to (x) of this Pact also on the Commission by the BIDDER or any one employed by it

or acting on its behalf (whether with or without the knowledge of the BIDDER), of

an offence as defined in Chapter IX of the Indian Penal code, 1860 or Prevention of

Corruption Act 1988 or any other statute enacted for prevention of corruption.

7.3. The decision of the BUYER to the effect that a breach of the provisions of this Pact

has been committed by the BIDDER shall be final and conclusive on the BIDDER.

However, the BIDDER can approach the independent Monitor(s) appointed for the

purposes of this Pact.

8. Fall Clause

8.1. The BIDDER undertakes that it has not supplied/is not supplying similar

product/systems or subsystems at a price lower than that offered in the present

bid in respect of any other Ministry/ Department of the Government of India or

PSU and if it is found at any stage that similar product/system or sub-system was

supplied by the BIDDER to any other Ministry/Department of the Government of

India or PSU at a lower price, then that very price, with due allowance for elapsed

time, will be applicable to the present case and the difference in the cost would

be refunded by the BIDDER to the BUYER, if the contract has already been

concluded.

9. Independent monitors

9.1. The BUYER has appointed Independent Monitors (hereinafter referred to as

Monitors) for this Pact in consultation with the Central Vigilance Commission

(Chief Vigilance Officer, Indian Institute of Technology, Bombay).

9.2. The task of the Monitor shall be to review independently and objectively, whether

and to what extent the parties comply with the obligations under this Pact.

9.3. The Monitor shall not be subject to instructions by the representatives of the

parties and performs their functions neutrally and independently.

9.4. Both the parties accept that the Monitor have the right to access all the documents

relating to the project/procurement, including minutes of the meetings.


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9.5. As soon as the Monitor notices, or believes to notice, a violation of this Pact, he

will so inform the Authority designated by the BUYER.

9.6. The BIDDER(s) accepts that the Monitor has the right to access without

restriction to all Project documentation of the BUYER including that provided by

the BIDDER. The BIDDER will also grant the Monitor, upon his request and

demonstration of a valid interest, unrestricted and unconditional access to his

project documentation. The same is applicable to Subcontractors. The Monitor

shall be under contractual obligation to treat the information and documents of

the BIDDER/Subcontractor(s) with confidentiality.

9.7. The BUYER will provide to the Monitor sufficient information about all meetings

among the parties related to the Project provided such meetings could have an

impact on the contractual relations between the parties. The parties will offer to

the Monitor the option to participate in such meetings.

9.8. The Monitor will submit a written report to the designated Authority of BUYER/

Secretary in the Department/within 8 to 10 weeks from the date of reference or

intimation to him by the BUYER / BIDDER and, should the occasion arise, submit

proposals for correcting problematic situations.

10. Facilitation of Investigation

In case of any allegation of violation of any provisions of this Pact or payment of

commission, the BUYER or its agencies shall be entitled to examine all the documents

including the Books of Accounts of the BIDDER and the BIDDER shall provide

necessary information & documents in English and shall extend all possible help for

the purpose of such examination.

11. Law and Place of Jurisdiction

This Pact is subject to Indian Law. The place of performance and Jurisdiction is the

Seat of the BUYER.

12. Other Legal Actions

The actions stipulated in this Integrity Pact are without prejudice to any other legal

action that may follow in accordance with the provisions of the extant law in force

relating to any civil or criminal proceedings.

13. Validity


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13.1 The validity of this Integrity Pact shall be from date of its signing and

extend upto 5 years or the complete execution of the contract to the

satisfaction of both

the BUYER and the BIDDER/ Seller, including warranty period, whichever is

later. In case BIDDER is unsuccessful, this Integrity Pact shall expire after six

months from the date of the signing of the contract.

13.2 Should one or several provisions of this Pact turn out to be invalid, the

remainder of this Pact remains valid. In this case, the parties will strive to

come to an agreement to their original intentions.

14. The Parties hereby sign this Integrity Pact.

BUYER BIDDER

Joint Registrar (MMD), IIT Bombay Signature with seal

Date & Place: Date & Place:

Witness Witness

1. _______________________ 1. _________________________

(Indenter)

2. ______________________ 2.______________________

______________________ _____________________


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Annexure 5: Format for earnest money deposit/bid bond (To be typed on Non-judicial stamp paper of the value of Indian Rupees of One Hundred)

(to be established through any of the nationalized banks (whether situated at Mumbai or outstation) with a clause to enforce the same on their local branch at Mumbai or any scheduled bank (other than nationalised bank) situated at Mumbai. Bonds issued by cooperative banks are not accepted)

LETTER OF GUARANTEE To, Registrar, Indian Institute of Technology, Powai, Mumbai -400076 IN ACCORDANCE WITH YOUR TENDER No:................... dated.................. for supply of ….............................., M/s. ............................. (hereinafter called the “Bidder”) having its Registered Office at …........................, wish to participate in the said bid for the supply ….................................................... as an irrevocable Bank Guarantee against Earnest Money Deposit for an amount of Rs. …................... (Rupees...............................) valid up to …............ (180 days from the date of issue of Bank Guarantee), is required to be submitted by the bidder as a condition precedent for participating in the said bid, which amount is liable to be forfeited by the Purchaser on (1) the withdrawal or revision of the offer by the bidder within the validity period, (2) Non acceptance of the Letter of Indent / Purchase order by the Bidder when issued within the validity period, (3) failure to execute the contract as per contractual terms and condition with in the contractual delivery period and (4) on the happening of any contingencies mentioned in the bid documents. During the validity of this Bank Guarantee: We, ….......................(Bank name) having its registered Office at ….......................guarantee and undertake to pay immediately on first demand by …................................... the amount of Rs................... (Rupees………………………….) without any reservation, protest, demur and recourse. Any such demand made by the IIT Bombay shall be conclusive and recourse. Any such demand made by the purchaser shall be binding on the Bank irrespective of any dispute or difference raised by the Bidder. The Guarantee shall be irrevocable and shall remain valid up to …............(180 days from the date of issue of Bank Guarantee) If any further extension is required, the same shall be extended to such required period on receiving instruction form the Bidder, on whose behalf the is Guarantee is issued.

Notwithstanding anything contained herein:


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Our liability under this Bank Guarantee shall not exceed (Rupees..........................). This Bank

Guarantee shall be valid up to …...........................................(date). We are liable to pay the

guaranteed amount or any part thereof under this Bank Guarantee only and only if you

serve upon us a written claim or before …............ (date). This Bank further agrees that the

claims if any, against this Bank Guarantee shall be enforceable at our branch office at

................................... situated at .............................. (Address of local branch).

Yours Truly

Signature and seal of the guarantor:

Name of Bank:

Address:

Date:

Instruction to Bank: Bank should note that on expiry of Bond Period, the Original Bond

will not be returned to the Bank. Bank is requested to take appropriate necessary action

on or after expiry of bond period.


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Annexure 6: Format for performance bank guarantee

FORMAT FOR PERFORMANCE GUARANTEE BOND

(To be typed on Non judicial stamp paper of the value of Indian Rupees of One Hundred) (To be established through any of the national banks (whether situated at Mumbai or outstation) with a clause to enforce the same on their local branch at Mumbai or any scheduled bank (other than nationalised bank) situated at Mumbai. Bonds issued by cooperative banks are not accepted.) To, Registrar, Indian Institute of Technology, Powai, Mumbai -400076

LETTER OF GUARANTEE

WHEREAS Indian Institute of Technology, Bombay (Buyer) have invited Tenders vide Tender No............................... dated.................................................................... .for purchase of ........................................................ AND WHEREAS the said tender document requires that any eligible successful tenderer (seller) wishing to supply the equipment / machinery,etc. in response thereto shall establish an irrevocable Performance Guarantee Bond in favour of “Registrar, Indian Institute of Technology, Bombay” in the form of Bank Guarantee for Rs ................................ (10% (ten percent) of the order value) and valid till two year from the date of issue of Performance Guarantee Bond may be submitted within 30 (Thirty) days from the date of Acceptance as a successful bidder. NOW THIS BANK HEREBY GUARANTEES that in the event of the said tenderer (seller) failing to abide by any of the conditions referred in tender document / purchase order / performance of the equipment / machinery, etc. this Bank shall pay to Indian Institute of Technology, Bombay on demand and without protest or demur Rs ........................ (Rupees......................................) This Bank further agrees that the decision of Indian Institute of Technology, Bombay (Buyer) as to whether the said Tenderer (Seller) has committed a breach of any of the conditions referred in tender document / purchase order shall be final and binding. We .......................................... (Name of the Bank & branch) hereby further agree that the Guarantee herein contained shall not be affected by any change in the constitution of the Tenderer (Seller) and/ or Indian Institute of Technology, Bombay (Buyer). Notwithstanding anything contained herein: 1. Our liability under this Bank Guarantee shall not exceed Rs. ......................... (Indian


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Rupees ..................................... only). 2. This Bank Guarantee shall be valid up to .................... (date) and 3. We are liable to pay the guaranteed amount or any part thereof under this bank guarantee only and only if IIT Bombay serve upon us a written claim or demand on or before.......................... (date) This Bank further agrees that the claims if any, against this Bank Guarantee shall be enforceable at our branch office at ........................................ situated at .............................. (Address of local branch).

Yours Truly Signature and seal of the guarantor:

Name of Bank:

Address:

Date:

Instruction to Bank: Bank should note that on expiry of Bond Period, the Original Bond will not be returned to the Bank. Bank is requested to take appropriate necessary action on or after expiry of bond period. Submitted Earnest Money Deposit will be treated as null and void after acceptance of Performance Bank Guarantee by IIT Bombay.


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Annexure 7: Format for deviations/exclusions schedule

Format for Deviations / Exclusions schedule Proposal Ref No. and Date Name and Address To, Indian Institute of Technology Bombay Department of Energy Science and Engineering Sub : IIT-B Tender Ref : Dear Sir, We declare that the following are the only deviations, variations and exceptions / exclusions to the supply, services terms and conditions as outlined in your Bidding Documents. The Schedule has been filled in accordance with the Bidding Documents. Except these deviations, subject to the approval and acceptance by IIT-B, the entire work shall be performed as per your requirements and bidding documents. Further, we agree that additional conditions, if any found elsewhere in the offer other than those stated below, save that pertaining to any rebates / discounts offered, shall not be given effect to :

Sr. No Clause No. Page No.

Statement of deviation & variation / exclusion

Statement of deviation & variation / exclusion Cost of withdrawal of deviation & variation / exclusion

Date Place Signature Name Designation Common Seal


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Notes:

1. The bidder may use additional sheets of like size and format, if required 2. The technical compliance/deviation should be supported by relevant technical

literature. 3. If specification in Superior/inferior than asked for the enquiry, it should be

clearly brought out in the justification. 4. If the bidder offers more than one model, then the technical compliance

statement must be enclosed for each and every model separately.


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Annexure 8: Previous supply order format

Name of the Firm ___________________________________

Order

placed by

(Full

address of

Purchaser)

Order

No.

and

Date

Description

and quantity

of ordered

equipment

Value

of

Order

Date of

completion

of

delivery

as per

contract

Remarks

indicating

reasons for

late

delivery, if

any

and

justification

for price

difference

of

their supply

order &

those

quoted to us

Has the

Equipment

being

installed

satisfactorily

(Attach a

Certificate

from

the

Purchaser/

Consigner)

Contact

Person

along

with

Teleph

one

No.,

Fax No.

and

email

address

Signature and Seal of the Manufacturer / Bidder ________________________

Place: _____________________

Date: _____________________


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Annexure 9: Checklist

Checklist The following items must be checked before the Bid is submitted: 1. Envelope “1” Technical Bid a) Demand Draft of Rs.500/- (Rs. Five Hundred only) towards cost of Bid document

b) Bank Guarantee for Rs. 7,40,000 /-- (Rs. Seven Lakh forty thousand only) towards

Earnest Money Deposit.

c) INTEGRITY PACT as per format

d) Eligibility Criteria & prequalification Criteria Responses (each pages duly sealed and signed by the authorized signatory)

e) Copy of this tender document duly sealed and signed by the authorized signatory on every pages.

f) Technical Bid responses

g) The bidder has to submit in writing that he has indeed visited, inspected and examined the site and its surrounding. (on Company Letter Head)

2. Envelope “2” a) Price Bid/commercial bid:

i. Price bid table ii. Cost drivers

Your quotation must be submitted in two envelopes Technical Bid (Envelope 1) and Price Bid/commercial bid (Envelope 2) superscribing on both the envelopes the Tender no. and the due date and both these sealed covers are to be put in a bigger cover which should also be sealed and duly superscribed with our Tender No. & Due Date.