Technical Specs Ethanol Sugauli - Final

8/11/2019 Technical Specs Ethanol Sugauli - Final

1/108

Doc No. : GDP/EPC-BID-E/09-10/026 (F)

Date : June 8, 2009

Assign No. : GPD/SDE/H PCL/08-09/045

Date : September 12, 2008

ENGINEERING, PROCUREMENT & CONSTRUCTION

(EPC) BID DOCUMENT

60 KLPD Capacity Ethanol Plant

Village Sugauli, District East Champaran, Bihar

Technical Specifications

Prepared For

Hindustan Petroleum Corporation Ltd. (HPCL)(A Govt. of India Enterprise)

Petroleum House, 17, Jamshedji Tata Road,

Mumbai 400 022

Prepared By

MITCON Consultancy Services Ltd. (MITCON)Kubera Chambers, Shivajinagar

Pune - 411 005

June, 2009


2/108EPC Bi d Document for Ethanol Plant at Sugauli, Di st. East Champaran, Bih ar, Technical Specifi cations

Doc No. : GDP/EPC-BI D-E/09-10/026 (F)

Date : June 8, 2009



EPC BID DOCUMENT



CONTENTS

Chapter No. Title Page No.

1. Intent of Specifications 1

2. Project information 2

3. Design Basis, Scope of Supply, Services & Terminal

Points

5

3.1 Design Basis 5

3.2 Scope of Supply 12

3.3 Services 15

3.4 Terminal Points 15

4. Technical Specifications 18

4.1 Juice Concentration 18

4.2 Syrup Bulk Storage 19

4.3 J uice Handling & Pasteurization 19

4.4 Continuous F ermentation 20

4.5 Multi-pressure Vacuum Distillation 23

4.6 Molecu la r Sieve Dehydration 28

4.7 Alcohol Storage 29

4.8 Utility 31

4.9 Water Treatment Plant 32

4.10 Condensate Polishing Unit 32

4.11 Piping & F ittings 33




Date : June 8, 2009



EPC BID DOCUMENT



CONTENTS (CONTD.)


5. Spent Wash Treatment 35

5.1 Bio-methanation 35

5.2 Evaporation 36

5.3 Composting 39

6. Electrical Distribution System 44

6.1 General Design Basis 44

6.2 Scope of Work 49

6.3 Diesel Generating Set 50

7. Control & Instrumentation System 52

7.1 Process Control Ph ilosophy 52

7.2 Parts Interchangeable 52

7.3 Security 53

7.4 Spare Philosophy 53

7.5 System Specifications 53

7.6 Operator Interface 55

7.7 Operator cum Engineering Sta tion 55

7.8 Other Hardware Requirements 56

7.9 Instrument List 58




Date : June 8, 2009



EPC BID DOCUMENT



CONTENTS (CONTD.)


8. Civil Works 63

8.1 Major Civil Works 63

8.2 Design Data 64

8.3 System Descr iption & Specification 64

8.4 Design Criteria 65

8.5 Foundations 66

8.6 Machine Foundations 66

8.7 Genera l Design Considerations 69

8.8 Design of Miscellaneous Items 73

8.9 Architectura l Concepts & Design 74

8.10 Construction 77

8.11 Effluent Treatment Plant 82

8.12 Buildin gs & Civil Works 83

8.13 Important & Common Notes 90

9. Fire Fighting & Protection 92

9.1 General 92

9.2 Ba sic F ire F ighting System 92

9.3 Fire Water Piping 96

9.4 Valves 96

10. Spares 97

11. Inspection & Testing 98

12. Drawings, Data & Information 99

13. Guaranteed Performance Parameters 100




Date : June 8, 2009



LIST OF APPENDICES

Appendix No. Title

I Process Flow Diagram

II Product Specifications

III Design Basis

IV Scope of Work

V Other Inputs & Specifications

VI List of Approved Makes

VII Drawings to be Submitted by the Tenderer s

VIII General Guidelines for Erection & Commissioning

I X Genera l Construction Specifica tions

X Data Sheets for Electrical Distribution System to be submitted by

Tenderers

XI List of Workshop Equipment

XII Preliminary Plant Layout, Integrated Sugar, Ethanol & Cogen PowerProject

XIII Terms & Conditions for Erection & Commissioning


6/108EPC Bid Document for Ethanol Plant at Sugauli , Dist. East Champaran, Bih ar, Techni cal Specifi cations 1

Chapter 1

Intent of Specifications

The ma in intent of the specifications h as been to define the equipment, electrical,

auxiliaries an d civil works for the proposed 60 KLPD capacity ethanol plant including

spent wash treatment with bio-methanation / evaporation & bio-composting, envisaging

latest and commercially proven technologies, being set up co-extensively with 3500 TCD

capacity sugar plant and 20 MW high efficiency grid connected cogen power plan t, at

Sugauli in East Champaran district of Bihar State.

The ethan ol plant component will include all equipment, associated systems, electrical

distribution system, instrumentation an d control, piping and a uxiliar ies, civil works,treatment of spent wash including biogas digesters / evaporation and bio-composting, etc.

The in tent of the specifications also ha s been to ach ieve continu ous a nd efficient

operations throughout the operation of the ethanol plant for 270 days, 130 season days

and 140 off season days based on own molasses an d 50% mixed juice transferred from

the sugar plant.

The main goals set are as under:

(a) Providing specific equipment, associated systems, electrical distribution system

an d a ssociated civil works, main ly to a chieve the tar geted production rate,

optimum fermenta tion / distillation / dehydration efficiencies a nd lowest steam

an d power con sumption of the ethanol plant, as well as achieve continuous

operation.

(b) The design basis for selection of all equipment will consider average 60 KLPD,

on 24 hr basis and 270 days annua l operation, based on own molasses and 50%

mixed juice transferred from the sugar plant (The provision for adding on ENA

plan t later on should be considered).

(c) Achieving targeted electricity consumption for the ethanol plant and associatedspent wash treatment facility of 400 kWh / KL and total steam consumption of 8

TPH / KL during cane crushing season.

(d) Ensuring targeted biogas generation from the digesters (for supply of biogas to

cogen power plan t of 16.67 Nm3/KL ethan ol manufacture), 250 / 100 BOD /

COD after evaporation and targeted bio-composting production, meeting the

BSPCB / CPCB / MoEF norms.



Chapter 2

Project Information

Name and Address : DGM (Pipeline Projects)

M/s. Hindustan Petroleum Corporation Ltd.

(A Govt. of India Enterprise)

8, Shoorji Vallabhdas Marg

Ballard Estate, Mumbai 400 001

Ph : 022 2263 7153, 2265 4110 (D)

Fax : 022 2263 7184

E-mail : [email protected]

Project Site : Near Village Sugauli,

District East Champaran, Bihar

Constitution & Type : A Government of India Enterprise

Project Title : Engineeri n g , P r o c u r e m e n t , C o n s t r u c t i o n &

Commissioning of Eth an ol Plan t & spent wash

treatment / bio-composting facility at the Project Site

EPC Consultant : MITCON Consultancy Services Ltd.

" Kubera Chambers" , 1st Floor

Shivajinagar, Post Box No. 923,

PUNE-411005, (INDIA)

Ph. No.: 020 2553 3309 / 2553 4322

Fax No.: 020 2553 0305 / 2553 3206

Products : Absolute alcohol or ethanol

(co-extensively with 3500 TCD suga r & 20 MW Co-

generated Power plants)



Project overview : This E PC bid is invited for design, engineering,

manufacture, procurement, supply, transportation to

site, transit an d storage, insurance, storing at site,

project management, civil works, mech anical works,

e lec t r i ca l works a nd I & C works , e rec t ion ,

installation, testing, commissioning, performance

testing, putting into successful commercial opera tion

an d ha nding over of 60 KLPD ethan ol plan t ,

associated spent wash trea tment through digesters

a n d e vap or a tion , f ol lo wed by b io-composting

facility as specified.Installed Capacity : 60 KLPD ethanol for 270 days operation on 50%

mixed juice and molasses available from the sugar

plant

Site location : Near Sugauli town

Distance from nearest town /

city

: Sugauli, 2 Km

D i st a n c e f r o m n e a r e s t

railway station

: Sugauli, 0.5 Km

Motihari, 25 Km

Distance from nearest airport : Patna, 185 Km

Distance from near est watersource

: Gandak River, 2 km

Distance from nearest BSEB

EHV substations

: Sugau li, 33 KV (2 Km) & Motihar i (132 KV), 25

Km

Annual Rainfall : 1241 mm

Ambient air temperature

Maximum

Minimum

:

:

460C

50C

Data for Seismic Design : Zone IV

Relative Humidity : 70% (average)

Climatic Conditions : Tropical, dry & arid



Design wind pressu re : I n accor dance with pr ovisions of Indian Standards

IS:875.

Design c o o l i n g w a t e r

temperature

: 320

C

Soil characteristics at site :

Iso-ceramic level (No. of

stormy days/year)

: 20

Construction power & water : Construction power and water is in the scope of EPC

vender.



Chapter 3

Design Basis, Scope of Supply, Services & Terminal points

3.1 Design Basis (Also referAppendix III)

3.1.1 The proposed ethanol plant will have manufacturing capacity of 60 KLPD,

with 99.8% purity by volume and 1.6 KLPD impure spirit of 95% purity

by volume. The ethanol plant will be provided requ ired stea m and power

from cogen power plant for 270 operating days, 130 season days & 140

off-season days.

3.1.2 Ethanol plant will operate on 50% mixed juice diverted from the sugar plant

& available molasses during season & on stored concentrated syrup &

saved molasses during off-season. The required quantity of mixed juice

will be used for ethanol manufacture dur ing season & the balance will be

converted into concentra ted syrup & stored for off-season requirements.

3.1.3 Out of 1750 TPD mixed juice diverted to ethan ol plant, 50% or 875 TPD

will be used for ethanol manufacture during season & balance 50% or 875

TPD will be concentra ted & stored for off-season requirement. One MT of

mixed juice will generated a bout 56.81 Ltrs of ethanol, hence with 875TPD mixed juice about 49.71 KL of ethanol per day will be manufactured.

3.1.4 With 95% maximum utilization of the ethanol plant, 57 KL per day ethanol

will be manufactured both during 130 season days & 140 off-season days.

3.1.5 Hence, for balance requirement of ethanol manufacture of 7.29 KL per day,

molasses available from sugar process during season will be used. With

40% fermentable sugar in molasses, one ton of molasses will yield 227.24

lit of eth a no l. He nc e, for 7.29 KLPD balance ethanol manufacture,

molasses requirement will be 32.08 TPD.

3.1.6 Out of total molasses generation of 84.88 TPD (1750 TCD x 4.85%) will

yield required per day, 32.08 TPD will be used for ethanol manufacture in

season & 52.8 TPD or 6864 MT of molasses will be saved for off-season

operation.



3.1.7 The concentrated syrup of 875 TPD or 113750 MT during 130 season

days will be used for 140 off-season days. Hence, based on 56.81 ltrs

ethanol manufacture per MT of concentra ted syrup, 46.16 KLPD ethanol

will be manufactured from stored concentrated syrup for 140 off-season

days. The balance quantity of 10.84 KLPD (57 KLPD @ 95% maximum

utilization 46.16 KLPD) ethan ol will have to be manufactured from

saved molasses.

3.1.8 F or 10.84 KLPD ethan ol man ufactur e, 47.70 TPD molasses will be

required. F or 140 off-season days, total molasses requirement will be 6678

MT. With saved molasses of 6864 MT, the off-season molasses

requirement will be easily met.

3.1.9 The overall design para meters of the ethan ol plan t are given in th e

following table:

Sr.

No.

Item Ethanol Plant

(on Mixed Juice /

Own Molasses

during season &

Conc.Syrup / saved

molasses during off-season)

1 Cane crushing, TCH 146

2 No. of hrs. per day 24

3 Cane Crushing per day, TPD 3500

4 No. of gross season days 130

5 Annual Cane crushing, MT 455000

6 Screened mixed juice to Ethanol (50%),

TPD

1750

7 Screened mixed ju ice used duringseason, TPD (50% of diverted mixed

juice)

875

8 Screened mixed juice concentrated per

day during season, TPD (50% of

diverted mixed juice)

875



Sr.

No.

Item Ethanol Plant

(on Mixed Juice /

Own Molasses

during season &

Conc.Syrup / saved

molasses during off-

season)

9 No. of days of operation of Ethanol

Plant

- Own molasses & Cane juice

- Saved molasses & Con. Syrup

270

130

140

10 Fermentable sugar content, % W by W 1011 Fermentable sugar concentration in

juice, % W by W

10

12 Ethanol capacity, KLPD 60

13 Maximum capacity utilization, %

(KLPD)

95

(57)

14 Molasses Generation, % cane 4.85

15 Molasses Production, TPD (MT) 84.88

(11034)

16 Filter cake, % cane 3.5

17 Filter cake production, TPD (MT) 61.25

(7963)

18 Ethanol recovery, liters / MT of

molasses

227.24

19 Ethanol recovery, litres /MT of cane

juice

56.81

20 Steam requirement, TPH (@ 8 Kg/cm2)

- Season (ethanol manufacture &

syrup concentration)

- Off-season (ethanol manufacture)

20.00

10.2521 Power r equ iremen t, MW

- Season

- Off-season

1.00

0.90

22 Water requirement, KL/ KL of Ethanol

- Season

- Off-season

15.00

20.00



Sr.

No.

Item Ethanol Plant

(on Mixed Juice /

Own Molasses

during season &

Conc.Syrup / saved

molasses during off-

season)

23 Spent wash generation per lit of Ethanol

with evaporation, Ltr/KL

3.00

24 Total spent wash generation per annum,

KL (270 days)

48600.00

25 Annual Compost Production, MT (at 1:2ratio of press mud / filler material)

16200.00

3.1.10 The ethan ol manu facture fr om diverted mixed juice & molasses will

involve state of the ar t technologies like continuous / batch fermentation,

multi pressure vacuu m distillation & molecular sieve dehydration system.

These systems will ensur e optimum utilization of raw materials i.e. mixed

ju ice / concentr ated syrup & mola sses, highest yields & lowest stea m,

power & water consumptions. The in -built automation system will ensure

optimum manpower required for operation of the plant.

3.1.11 The eth an ol plant wil l involve differen t sections inclu ding juice

pasteur ization & concentra tion, syrup & molasses bulk storage, continuous

fermentation, multi pressure distillation, molecular sieve dehydration,

effluen t & water tr eatment plan t, ethanol storage, misc. labora tory &

workshop, etc.

3.1.12 The mechanical design basis is indicated below:

For design of static equipment like fermentors, pre-fermentors etc.

the following factors have been taken into consideration:

(a) Wind pressure = 150 Kg/m2

(b) Seismic factor = 0.04 As per Indian Standards

The Seismic factor Alpha = 0.04 corresponds to Zone 4 as per

Indian Standards 1893



The static equipment like SS fermentors will be designed generally

as per API 650.

All equipment will be supported laterally to the structura l members

an d no direct load due to wind a nd seismic forces ha ve been

considered. All tanks like Fermentors, Beer well etc will be

supported / rested using civil foundations.

Specifications of the materia l of construction for the equipment

will be as per generally ASTM 240 for stainless steel sheets and

coils. Materia l of construction for Copper column trays, body

flanges for columns.

The material of constru ction of all body flanges and bolts will beCS and gaskets will be EPDM.

All pressure vessels like distillation columns, condensate pot, etc.

will be genera lly designed as per ASME Sec. VIII Div. I.

All distillation columns will be supported laterally to the structura l

members and no direct load due to wind and seismic forces have

been considered.

All shell & tube type heat exchangers will be generally designed as

per TEMA C.

The baffle thickness in case of above heat exchangers is restricted

to2/ 3 mm.

Hydro testing of critical equipment wherever a pplicable will be

carr ied out at our fabrication facility before dispatch.

Pipin g an d valves specification will be gener ally as per ANSI

standards.

Pipes - CS ANSI B 36.10 SS 304 ANSI B 36.19

Flanges - ANSI B 16.5, 150 # and Stubend - MSSP 43 TYPE

Instrumentation specification will be genera lly as per ISA.



The following are the design standards used for the equipment for

design.

-Pressure Vessels and distillation columns as per ASME

- Storage tanks as per API

- Heat Exchangers as per TEMA

- Piping and valve as per DIN/JIS

- Instruments as per ISA.

3.1.13 Design consideration for selection of electrical equipment, power supply &

power distr ibution are indicated below:

Ambient temperature : 50 C

Humidity : 90%

Altitude : >1000 M above MSL

System Fau lt Level :

: 50 kA for 1 Sec. for 415V system

: 9 kA for 1 Sec. for lighting circuits

415 V + 10%, 50Hz + 5 %, 3 Ph ase for power distribution

available from cogen power plant to ethanol plant

415 V + 10% , 50Hz + 5 %, TPN for plan t load operating at415V supply

Control voltage 110V AC, 50Hz for MCCs and PCCs

Power Supply for Tripping and Closing Circuits of Circuit

breakers : 110 V, D.C.

415 V power su pply will be given to Ethanol Plant Switchboard

located at cogen power plant . F ur ther downstream power

distribu tion will be in the scope of EPC contractor for ethanol

plant

230 V Single phase power supply shall be derived throu gh Phase& Neutral for single phase power consumer in the ethanol plant, if

any



3.1.14 Effluent Treatment

The spent wash generated in the ethanol plant will be treated in following

stages, to meet the BSPCB / CPCB / MoEF norms. :

1) Bio-methanation The spent wash from the ethan ol plant will be

passed throu gh bio-meth anation pr ocess to gener ate bio-ga s and

reduce the BOD / COD to the targeted levels.

2) 4 effect evaporation - The spent wash a fter bio-methanation will be

passed through a mu ltiple effect eva porator system in which hea t

recovered from one effect is used to concentrate spent wash in second

effect evaporator with continuous recirculation of concentrated spent

wash with in the system until desired concentration is obtained. Thisentire concentration process will be carried out under vacuum leading

to less consumption of steam and maximum concentration of spent

wash with in less period of time.

3) Bio-composting - Composting is a biological process in which organic

matter is degraded under controlled conditions. It involves microbial

mineralization.

The mixing of concentrated spent wash from evaporation plant and

press-mud (50-70% moisture) will be carried ou t in trenches with the

help of excavator-cumloader for mixing, tu rn ing, loading a ndunloading of compost material. Addition of cow dung will provide

bacteria l culture r equired for composting.

3.1.15 Fire Fighting & Protection

Fire protection system to be offered based on site plan. The system is

designed as per International rules (NFPA) & equivalent standards. List of

Reference:

NFPA-10- Standard for portable Fire Extinguishers.

NFPA -11 - Standard for Low expansion foam system

NFPA-13 Standard for sprinkler system insta llation .

NFPA -14 - Standard for the installation of Standpipe, Pr ivate Hydrant

& Hose System.

NFPA -15 Standard for water spray system

NFPA -24 Private F ire Service mains & their appurtenances.

NFPA -30 F lammable & combustible Liquids Code

NFPA -72 National F ire Alarm Code



3.2 Scope of Supply (Also refer Appendix IV)

3.2 .1 General

The scope of work will include design, engineering, manufacture / procure,

supply, erection an d commissioning of equipment, associated systems, internal

electrical distribution system and associated civil works for the entir e ethanol

plant and associa ted spent wash trea tment / bio-composting facility, as deta iled

hereunder for achieving the guaran teed performance parameters specified for each

section and for steam & power consumptions. The Contractor will also need to

complete all associated electrical, mechanical and instrumentation work required

for installation, commissioning of the en tire equipment, an d proving th eperformance at site.

The Contractor will be responsible for providing an efficient, reliable and state of

ar t technology equipment. The specifications in th is section, attempt to define the

scope and specifications. However, the onus of providing the appropriate

equipment and auxiliaries for successful commissioning, performance proving

and operation, entirely rests with the Contractor.

The scope of work for the equipment, associated systems and civil works covered

under the specifications will include, but not limited to the following.

(a) Design, engineering, supply, fabrication, manufacture / procure, assembly,

shop testing an d inspection at man ufactur er ' s works, erection an d

commissioning

(b) Providing all labourers, materials and equipment for testing at shop / site,

as required.

(c) All spare parts required for the commissioning.

(d) Spare parts required for two (2) years of trouble free operation

(e) Specia l tools and tackles r equired for opera tion and maintenance,

inspection, and repair of the equipment / systems offered.



The specifications a re intended to cover the design, engineering, manufacture /

procure, supply, erection , testing and commission ing of the entir e ethanol plant

and associated spent wash treatment / bio-composting equipment, associated

systems, electrical distribution system, necessary piping / supports / valves /

instruments, DCS based control & instrumentation system, necessary structures

and civil works.

Supplies and services shall be rendered in conformity with proven engineering

pr in ciples , ta king in to accou nt th e cu rren t state of th e ar t tech nology. Th e

requirements of the contract must be fulfilled in its entirety.

The supplies an d services within the scope sha ll be rendered inclusive of all

appliances and interconnecting arrangements with other supplies, necessary for

installation of all accessories and for satisfactory operation, maintenan ce andrepair.

The scope of supply and services shall include all necessary work and supply of

equipment and material whether mentioned in th ese specifications or not, but

which are necessary for the satisfactory, reliable, safe operation, maintenance and

required for achieving guaranteed performance parameters.

Any equipment, devices or material even if not included in this EP C bid, but

found necessary for the safe and satisfactory functioning of the un it under this

EPC bid, shall be supplied, erected and commissioned by the Contractor at no

extra cost to the Owner, a s though , such equipment, material or work wereoriginally specified and formed par t of the scope of work.

3.1.2 Major Equipment

(a) Ju ice concentration plant, syrup bulk storage, juice pasteurization plant,

continuous fermentation section, multi-pressure distillation section,

molecular sieve dehydration plant, water treatment plant, alcohol storage

section, interconn ecting piping & accessories an d miscellaneous like

weigh bridge, laboratory, workshop, etc.

(b) Bio-methanation plant including bio-gas digester, de-gasing pond, lamellaclarifier, gas holder, central agitator, lateral agitator, over / under pressure

release device, flare burners, safety & secur ity devices, spent wash pumps,

sluge r ecycling pu mps, bio-gas blowers, interconnecting piping &

accessories, electrical control panel and cabling, instrumentation, etc.

(c) Evapora t ion p lant for spent wash af t er b io-methanation including

evaporator calendr ia, flash vessels, vacuum / feed / r ecycle-cum-forward

pu mps and motors, pr e-heater s, surface condenser s, internal piping &

valves, electrical panel & cabling, instrumentation, etc.



(d) Composting plant for treatment of spent wash after evaporation to meet

the BSPCB / CPCB / MoEF norms including a erotillers, tractors with

hydraulic blades, trolley with creeper gear box, HDPE piping & spraying

unit , JCB machines, pumps, motors, electr ical panel & cabling,

interconnecting piping & accessories etc.

(e) Steam and power consumption reduction equipment for achieving the

related guaranteed performance parameters.

3.1.3 Electrical Distribution System

11 KV feeders from cogen power plant, all internal electrical distribution system

within th e ethan ol plan t for 1 1 KV, 440 V systems including distribution

transformers, power & con tro l cables, accessories, earthing & lightening

protections, a ll ma ndatory safety devices, instrumen tation, illumination, etc. will

be included in the contractor s scope.

3.1.4 Control & Instrumentation

All necessary control & instrumentation equipment for efficient operation of the

pr oposed eth anol plant and associa ted spen t wash tr ea tmen t / bio-composting

equipment, associated systems and electrical distribution system or otherwise for

the entire ethanol plant, will be in the scope of the Contractor.

3.1.5 Civil Works

All necessary civil works including foundations, structura l, ear th work, etc.

required for installation of the proposed ethanol plant equipment, associated

systems and electrical distribution system will be in the scope of the Contractor.

3.1.6 Fire Fighting & Protection

F ire protection system shall be provided for the a bove plant as per th e design

ba sis . Scope of work includes design, en gineering, supply of equipments and

componen ts required for fire pr otection system for a ll area s as per systemmentioned below. Following works are also to be included in the scope.

Construction of firewater storage tanks

Construction of fire pump house

Ear thing of equipments

Erection of fire fighting piping & equipment

Any type of civil work



3.3 Services

3.3.1 Design and Engineering

(a) Preparation of design calculations and detailed drawings

(b) Prepa ration of BOQ

(c) Preparation of manufacturing drawings

(d) Preparation of quality assurance and inspection plans and implementation

schedule.

(e) Preparation of schedule for site testing and commissioning.

3.3.2 Erection and Commissioning

(a) Inspection of civil work in foundations, trenches and allied jobs.

(b) Unloading, unpacking, shifting to locations, positioning, aligning and

fixing of equipment which are included in contract

(c) Pre-commissioning checks.

(d) Commissioning , testing and trials runs and performance proving

(e) Completion of documentation and records.

3.3.3 Statutory Approvals

(a) Obtaining approvals on drawing and designs from local authorities, as

required.(b) Arranging inspections and approvals for commissioning of plant electrical

from Local authorities and Chief Electrical Inspector.

(c) All approvals from Government agencies are in the scope of the Tenderer.

3.3.4 Inspections / Review Meetings

(a) Making the arrangements for periodical and final inspection of all major

equipment at own or sub-contractor s works.

(b) Attending the periodical review meetings at site or at the agreed locations.

3.4 Terminal Points

3.4.1 Screened & Mixed Juice

From the dischar ge end of juice mass flow meter (after proportioning device &

juice transfer pumps, including valve), located in the milling section of the sugar

plant for transfer of 50-45% of juice to ethanol plant

3.4.2 Raw water



At the specified intake point at the raw water storage tank outlet header located in

the sugar plant

(Contractor s scope covers suitable ra w water tra nsfer pumps & accessories,

pipeline fr om ma in reser voir up to ethanol plant, spen t wash tr ea tmen t / bio-

composting facility and internal water storage / distribution, including all fittings /

supports / valves, etc.)

3.4.3 Steam supply

At the LP h eader of cogen power pla nt loca ted at 1.5 m level beside the

powerhouse building, towards the sugar plant side.

(Contractor s scope covers LP steam pipeline from LP header of cogen powerplant up to ethanol plant / spent wash distribution and bio-composting facility and

internal distribution pipelines, including all flanges, valves, accessories, supports,

etc.)

3.4.4 Power supply

At 2 nos. 11 KV feeders identified in 11 KV switch boa r d in cogen pla n t TG

building

(11 KV (UE), XLPE insulated Aluminium conductor cables from cogen power

plant up to the ethanol plant, 11 KV / 440 V distr ibu tion transfor mers and 440 Vintern al power distribution system including rela ted panels / switchboar ds /

star ters / ca bles / protections, and related distribution system including pan els /

switchboar ds / starters / ca bles / protections, etc. & all ear thing will be in the

contractor s scope).

3.4.5 Compressed air

Necessa ry size compressor & accessories, distribution header & pipelines, valves,

fittings, etc. required for the sugar plant included in the contractor s scope.

3.4.6 Molasses

At the delivery header of the molasses tran sfer pumps, near the molasses storage

tank located in sugar plant, for tra nsfer of mola sses to ethanol plant (the

contra ctors scope covers pipeline, fittings, valves, etc. from molasses tra nsfer

pumps up to storage tanks in ethanol plant and fur ther distribution within).



3.4.7 Steam Condensate

At the outlet header of steam condensate transfer pumps, including valve, located

in the ethanol plant.

3.4.8 Filter Cake

At the discha rge chu te end, below the vacuum filters located in the sugar plant,

for transfer to bio-composting facility

3.4.9 Ethanol

At the outlet of positive displacement flow meter of ethanol bulk storage tanks

3.4.10 Effluent

Bio-composting facility based on trea ted spent wash in the bio-methanation &

evaporation plants meeting the BSPCB / CPCB / MoEF norms.

3.4.11 Civil Works

Entire civil works & structural in the ethanol plant and spent wash treatment / bio-

composting facility area will be in the Contractor s scope.


23/108



4.2 Syrup Bulk Storage Section

Sr.

No.

Item of Equipment Outline

Specifications

Material of

Construction

Qty.

1. Syrup / Molasses

tank with accessories

like Cooling system,

Vent, Drain, etc.

Vertical

Cylindrical type,

with 8000 m3

capacity

M.S. 7

2. Molasses Pit Rectangular

Underground type,

with 100 MT

capacity

RCC 1

3. Syrup/MolassesPump

Gear / Lobe type,with 35 TPH

capacity

C.I. 1+1

4. Syrup/Molasses Filter Basket strainer

type

SS 304 1+1

4.3 Juice Handling & Pasteurization

Sr.

No.


Specifications

Material of

Construction

Qty.

1. Juice Holding Tank Cyl i n d r i c a l /

Verti c a l t y p e ,

w i t h 4 0 m 3

capacity

SS 304 1

2. Juice Transfer Pump Centr ifugal type,

w i t h 3 5 T P H

capacity

Wetted Parts :

SS 304

1+ 1

3. J uice pasteurizer PHE type Plates: SS316 1+1

4. Juice Cooler PHE type Plates: SS316 1+1



4.4 Continuous Fermentation Section

4.4.1 Syrup Handling Section

Sr.

No.


Specifications

Material of

Construction

Qty.

1. Syrup Receiving Tank Cylindrica l /

vertical, conical

bottom type, with

3 m3 capacity

MS 1

2. Weighed Syrup Tank Cylindrical,

vertical, flat

slopping bottomtype, with 60 m3

capacity

MS 1

3. Syrup Weighing

System

Load cell type,

with 3 MT

capacity

-- 1

4. Weighed Syrup Pump Gear type, with 15

TPH capacity

CI 1+1

4.4.2 Yeast & Fermentation Section

Sr.

No.

Item of Equipment Outl ine

Specifications

Material of

Construction

Qty.

1 Culture Vessels

CV I

CV II

CV III

With air sparger,

heating & cooling

system

Cylindrical,

vertical & jacket

type, with

capacities 0.2 m3,

1 m3 & 5.5 m3

SS 304 1 Set

2 Culture VesselTransfer pump

Trolley Mountedtype, with 5 m3/hr

capacity

Wetted PartsSS

1

3 Pre F ermenter along

with Air Sparger &

Broth Mixer

Cylindrical,

vertical, conical

bottom type, with

50 m3 capacity

SS 304

2



Sr.

No.


Specifications

Material of

Construction

Qty.

4 Pre Fermenter

Recirculation pump

Centrifugal type,

with 25 m3/hr

capacity

Wetted Parts

SS

2

5 F ermenter with

Sparger, & safety

system, Broth Mixer

Cylindrical,

vertical, Conical

Bottom type, with

350 m3 capacity

SS 304 Minimum

4

6 F ermented Wash

Coolers

PHE type Plates: SS

316

Minimum

4

7 Fermenter

Re circulation Pump

Centrifugal type,

with 250 m3/hrcapacity

Wetted Parts

SS

4+1

Spare instore

4.4.3 Wash Clarification Section

Sr.

No.


Specifications

Material of

Construction

Qty.

1 Wash Settling Tank Cylindrical,

vertical, Conical

Bottom type, with

225 m3 capacity

SS 304 1

2 Sludge Settling Tank Cylindrical,

vertical, Conical

Bottom type, with

60 m3 capacity

SS 304 1

3 Sludge Trough Cylindrical,

vertical type, with

0.5 m3 capacity

SS 304 2

4 Sludge transfer Pump 2 m3/hr capacity Wetted Parts

SS

2+2

5 Wash Holding Tank Cylindrical,

vertical, conicalbottom type, with

350 m3 capacity

SS 304 1

6 F ermented Wash Feed

Pumps

Centrifugal type,

with 30 m3/hr

capacity

Wetted Parts

SS

1+1



4.4.4 Utility & Chemical Dosing Section

Sr.

No.


Specifications

Material of

Construction

Qty.

1. Air Blowers Water Ring type,

with 350 Am3/hr

capacity

SS 304 2 + 1

2. Air F ilter HEPA type SS 304 1

3. CO2 Scrubber Sieve trays type,

with 800 mm

diameter having 6

nos. trays

SS 304 1

4. Acid Dosing tank Cylindrical,

vertical type, with1 m3 capacity

MS 1

5. Acid Dosing pump Centrifugal type,

with 1 m3/hr

capacity

Alloy 20 1+1

6. Antifoam dosing tank Cylindrica l,

vertical type, with

1 m3 capacity

SS 304 1

7. An tifoam dosing

pump

Gear type, with 1

m3/hr capacity

SS 304 1+1

8. Nutr ient Dosing Tank

with Agitator

Cylindrical,

vertical type, with

2 m3 capacity

SS 304 1

9. Nutr ient Dosing Pump Centr ifugal type,

with 2 m3/hr

capacity

Wetted Parts

SS

1+1

10. PF & Fermenter

cleaning nozzles

-- SS 304 6

11. CIP Tank Cylindrical,

vertical type, with

10 m3 capacity

SS 304 1

12. CIP Pump Centrifugal type,with 15 m3/hr

capacity

SS 304 1+1

13. Piping, Valves

and instrumentation

-- -- LOT



4.5 Multi-pressure Vacuum Distillation

Sr.

No.


Specifications

Material of

Construction

Qty.

1. Analyzer Column

(Vacuum)

Rh Grid Trays

type, with 2000

mm diameter, 20

no. of trays and

750 mm tray

spacing

Shell

SS 304

Trays

SS 304

1

2. Degasifying Column

(Vacuum)

Sieve Trays type,

with 1250 mm

diameter, 6 no. oftrays and 750 mm

tray spacing

Shell

SS 304

TraysSS 304

1

3. Rectifier Column

(Pressure)

Bubble Cap Trays

type, with 1500

mm diameter, 72

no. of tra ys and

250 mm tray

spacing

Shell

SS 304

Trays

SS 304

1

4. Aldehyde Column

(Vacuum)

Bubble Cap Trays

type, with 1600

mm diameter, 30no. of tra ys and

300 mm tray

spacing

Shell

SS 304

TraysSS 304

1

5. Analyser

Condenser-I

(Beer Heater)

Shell & Tube,

Horizontal type,

with 75 m2 heat

transfer area

having 25.4 mm

OD tube, 3000 mm

long

Shell

SS 304

Tubes

SS 304

1

6. Analyser

Condenser-II

Shell & tube,

Horizontal type,

with 75 m2 heat

transfer area

having 25.4 mm

OD tube, 3000 mm

long

Shell

SS 304

Tubes

SS 304

1



Sr.

No.


Specifications

Material of

Construction

Qty.

7. Analyser

Condenser-III

Shell & Tube,

Horizontal type,

with 7 m2 heat

transfer area

having 25.4 mm

OD tube, 3000 mm

long

Shell

SS 304

Tubes

SS 304

1

8. Analyser Reboiler Shell & Tube,

Vertical type, with

230 m2 heattransfer area

having 25.4 mm

OD tube, 3000 mm

long

Shell

SS 304

TubesSS 304

1+1

9. Aldehyde Condenser

I

Shell & Tube,

Horizontal type,

with 35 m2 heat

transfer area

having 25.4 mm

OD tube, 3000 mm

long

Shell

SS 304

Tubes

SS 304

1

10. Aldehyde Condenser

II

Shell & Tube,

Horizontal type,

with 7 m2 heat

transfer area

having 25.4 mm

OD tube, 3000 mm

long

Shell

SS 304

Tubes

SS 304

1

11. Analyser Reboiler

Vent Condenser

Shell & Tube,

Horizontal type,

with 10 m2 heattransfer area

having 25.4 mm

OD tube, 3000 mm

long

Shell

SS 304

TubesSS 304

1



Sr.

No.

I tem of Equipment Outline

Specifications

Material of

Construction

Qty.

12. Rectifier PCV

Condenser

Shell & Tube,

Horizontal type,

with 3 m2 heat

transfer area

having 25.4 mm

OD tube, 3000 mm

long

Shell

SS 304

Tubes

SS 304

1

13. Rectifier Reboiler Shell & Tube,

Horizontal type,

with 180 m2 heattransfer area

having 25.4 mm

OD tube, 3000 mm

long

Shell

SS 304

TubesSS 304

1

14. Analyzer Condenser

Tank

Cylindrical,

vertical type with

1 m3 capacity

SS 304 1

15. Rectifier Reflux Tank Cylindr ical,

Vertical type, with1 m3 capacity

SS 304 1

16. RS Intermedia te tank Cylindr ica l,

Vertical type, with

1 m3 capacity

SS 304 1

17. Steam Condensate

Tank

Cylindrical,

Vertical type, with

2 m3 capacity

SS 304 1

18. FW Preheater PHE type SS 316 Plates 1+1

19. Rectifier Feed

Preheater

PHE type SS 316 Plates 1


31/108



Sr.

No.


Specifications

Material of

Construction

Qty.

30. Vacuum Pump Centrifugal type,

with 350 Nm3/hr

capacity

CI with SS

304 internal

1+1

31. Cold Water Overhead

Tank

Cylindrical,

Vertical type, with

40 m3 capacity

M.S. 1

32. Hot Water Tank Cylindrical,

Vertical type, with

2 m3 capacity

M.S. 1

33. Siphon, Manometer

Bottles, Vapour

Bottles, Mixing

Bottles

Standard SS 304 Lot

34. Piping & Valves Wi t h s t a n d a r d

specs

SS 304 & MS Lot

35. Instrumentation PLC system with

control valves,

pressure &

Temperature

transmitters

Standard Lot


33/108


34/108



Sr.

No.


Specifications

Material of

Construction

Qty.

6 SDS Tank Vertical Cylindrical

type of 100 m3

capacity

M.S. 1

7 Vent condenser Shell & Tube Heat

Exchanger type, with

heat transfer area of

3 m2

M.S. 4

8 Fire Arrester Standard type SS 304 9

9 Ethanol transfer

Pump

Centrifugal type of

40 m3/hr capacity

Wetted part SS 2+2

10 RS Transfer Pump Centr ifugal type of

20 m3/hr capacity

Wetted part SS 1+1

11 IS Transfer Pump Centrifugal type of

20 m3/hr capacity

Wetted part SS 1+1

12 FO Transfer Pump Centrifugal type of

10 m3/hr capacity

Wetted part SS 1+1

13 SDS Tank Transfer

Pump

Centrifugal type of

15 m3/hr capacity

Wetted part SS 1+1

14 Ethanol Flow Meter Positive

displacement type

flow meter of 40

m3/hr capacity

SS 304 1

15 IS F low Meter Positive

displacement type

flow meter of 20

m3/hr capacity

SS 304 1

16 Piping & Valves As per standard -- Lot

17 Instrumentation Local instruments

like pressure gauges

Lot


36/108



4.8.2 Instrument Air System

Sr.

No.

Item of

Equipment

Outline

Specifications

Material of

Construction

Qty.

1. Instrument Air

Compressor

With adequa te

capacity

CI 1+1

2 Air Dryer for

compressor

With adequa te

capacity

Silica /

refrigerant type

1

4.9 Water Treatment Plant

Sr. No. Description Qty.

1. Ch emica l Dosin g System 2 Nos.

2. Raw Water Pump 2 Nos.

3. Sand F ilter 1 No.

4. Activated Ca rbon F ilter 1 No.

5. Softener 1No.

6. In ter Connection Piping 1 Lot

7. Rota meters 3 Nos.

4.10 Condensate Polishing Unit

Sr. No. Description Qty.

1 Screen for Separation 1 No.

2 Settling tank 1 No.

3 Equilization Tank 1 No.

4 F eed Pump 2 Nos.

5 Reactor with F lare Stack & Sludge recircula tion system 1 No.

6 Secondary Aeration system with Tank & Agita tor 1 No.

7 Clarifier 1 No.

8 Clor ination / Ozonation Dosing System 1 No.

9 Sand F ilter 1 No.

10 Activated Ca rbon F ilter 1 No.11 In ter Connection Piping 1 Lot

12 Instrumenta tion & MCC & electr icals Lot


38/108



4.11.3 Piping Specs For Fermentation & Distillation Section

Sr. No. Pipe MOC Sch. No /

Class / Thk

1 SS 304 (upto 50 NB) Sch 10

2 SS 304 (above 50 NB) Sch 5

3 Mild Steel (upto 150 NB) B-Class (IS 1239)

4 Mild Steel (150 NB - 450 NB) 4.8 mm

5 Copper 1.2 mm



Chapter 5

Spent Wash Treatment

5.1 Bio-methanation

Sr.

No.


Specifications

Material of

Construction

Qty.

1. Raw Spent Wash

Settling Tank (5 Day

Storage Tank)

Civil Pit type with

250 micron HDPE

and brick lining on

earthen embankment

Earthen

embankment

with Brick

lining

1

2. BiomethanatedSpent Wash Holding

Tank (2 Day Storage

Tank)

Civil Pit type with250 micron HDPE

and brick lining on

earthen embankment

Earthenembankment

with Brick

lining

1

3. Concentrated Spent

Wash Holding Tank

(2 Day Storage

Tank)

Civil Pit type with

250 micron HDPE

and brick lining on

earthen embankment

Earthen

embankment

with Brick

lining

1

4. Raw Spent Washfeed Pump Centrifugal type SS 304 1+1

5. Bio-methanated

Spent Wash feed

Pump

Centrifugal type SS 304 1+1

6. Degassing Pond Cylindrical / vertical

type

MS + Epoxy 1

7. Clarifier Pack of plates type MS + Epoxy 1

8. Biodigester with

Agitators, safety

systems, support,

ladders etc.

Cylindrical / vertical

type

MS + Epoxy 1

9. Gas Holder Cylindrical / vertical

type with RCC Tank

MS 1

10. Biogas Blower Twin Lobe type - 1+1

11. Flare Burner Mechanical type - 1

12. F lame Arresters - 2

13. Sludge recycle

Pump

Suitable SS 316 1+1



Sr.

No.


Specifications

Material of

Construction

Qty.

14. Process Water Pump Centrifugal type SS 304 1+1

15. Piping, Valves

and instrumentation

- - LOT

16. MCC & Electr icals

with Plant & Yard

Lighting

- - LOT

5.2 Evaporation

Sr.

No.


Specifications

Material of

Construction

Qty.

1. H ea t exch an ger for

Effect I

Falling Film Type AISI 304 Shell

with AISI 316

ERW Tubes &

C.S. Flanges

1


Effect II


with AISI 316

ERW Tubes &

C.S. Flanges

1


Effect III

Forced Circulation

Type

AISI 304 Shell

with AISI 316

ERW Tubes &

C.S. Flanges

1


Effect IV


with AISI 316

ERW Tubes &

C.S. Flanges

1


Effect V

Suitable AISI 304 Shell

with AISI 316ERW Tubes &

C.S. Flanges

1

6. Su rfa ce con dn . F or

Evaporator

Shell & Tube Type AISI 304 Shell

with AISI 316

ERW Tubes &

C.S. Flanges

1



Sr.

No.


Specifications

Material of

Construction

Qty.

7. V a p o u r L i q u i d

Separator I

Vertical Type AISI 304 1


Separator II



Separator III

Flashing Type AISI 304 1

10 V a p o u r L i q u i d

Separator IV


11 V a p o u r L i q u i d

Separator V

Suitable AISI 304 1

12 Pre-heaters Shell & tube type AISI 304 Shell

with AISI 316

ERW Tubes &

C.S. Flanges

2

13 Re-heaters Shell & tube type AISI 304 Shell

with AISI 316

ERW Tubes &

C.S. Flanges

1

14 Thin Slop Holding

Tank cum

Evaporator Feed

Tank

-- AISI 304 1

15. Product Tank -- AISI 304 1

16. Process Condensate

Tank

-- AISI 304 1

17. CIP Tank -- AISI 304 1

18. Insulation As per standard

design guidelines

Mineral Wool

with 22 gauge

Aluminium

Cladding

LOT

19. Feed Pump Centrifugal type withmotor

Wetted PartCF8

1

20. E f f e c t I

R e c i r c u l a t i o n /

Transfer pump.

Centrifugal type with

motor

Wetted Part

CF8

1

21 E f f e c t II

R e c i r c u l a t i o n /

Transfer pump.

Centrifugal type with

motor

Wetted Part

CF8

1


43/108



Sr.

No.


Specifications

Material of

Construction

Qty.

30. Insulation (Wherever

required from

process point of

view)

50 mm thick Minera l

Wool with 22 SWG

AL cladding

LOT

31. MCC & E le ctr ic al

for evaporation

Standard Standard LOT

Note:

1. The mater ial of const ruction of flanges and nu t bolts for heat

excha nger s will be Carbon Steel & Gaskets will be NBR / EPDM /CAF.

2. All tubes will be Electric Resistance Welded types.

3. The equipment specificat ions given are tentat ive and the exact

specifications will be confirmed only after discussion with client as per

his requirement & detailed engineering.

5.3 Composting

5.3.1 Land Preparations & Formalities

a) Preparation of Plan and demarcation of Land.b) Contour Survey of Land with 1.0 meter interval.

c) Location map showing Identif ication of the proximity of other water

bodies with in 1 KM radius from proposed Area.

d) Map with Wind direction .

e) Soil testing report containing.

Co-efficient of Permeability.

Angle of Repose.

Hydrau lic Gradient.

Sieve analysis.

f) Pr ocess flow sheet along with inpu t of spent wash an d cha ra cteristic ofcompost material after treatment.

g) Approval of BSPCB/ CPCB for the drawing.



5.3.2 Composting Yard

a) Cleaning, leveling and compaction of soil.

b) Providing spraying and pipe line network as per design , using HDPE pipe

(max pressure 6kg/cm2)

inclusive of all accessories (i.e. Tees, Joints,

F langes, Valves, Reducers and Non return valves etc.)

c) Excavation of trenches to lay the pipes up to optimum required depth.

d) Providing and laying of 250 micron thick HDPE sheet inside the prepared

surface.

e) Laying of pipe line with proper cushion.

f) Backfilling and compaction of excavated earth after laying the pipes.

g) Providing brick on edge l ining over HDPE sheet for bottom surface &

joints will be filled in with fine sand. The br icks are laid in blocks of 5 mtr

square. Ther e will be gap of 150 mm between two blocks which will befilled with PCC 1:3:6 proper curing is required.

h) P rovidin g a n d la yin g Ma in h ea der 1 10 mm OD , H D P E pi pe of

6kg/cm2pressure.

i) Providing and Laying Distr ibution line of 110 mm OD, HDPE pipe of

6kg/cm2pressure.

j) Providing and fixing Chamber outlets 63 mm OD HDPE pipe of 6kg/cm2

pressure with butterfly/ Ball valve and quick release coupler.

k) Provision of 30m long fire hose ( ISI mark) with SS 304 adaptor hose

shank at both ends for auto spraying, suitable for above Quick release

coupling for online filling.

l) Providing and constructing Round / Square chambers pre cast / in situ asper design . (Chamber dia of 800 mm and depth as required a s per ground

level.)

5.3.3 Leachate Management System

a) Excavation for Gutter and leachate collection pit.

b) Design th e pr ofile of Gu tter s and construction of collection pit in flat

brick in Cement mortar in 1:5 ra tio and maintain slope as required.

c) Formation of bunds as per design.

d) Providing pathways in flat brick lining in between gutter and bund.

e) Net f in ish ed pla ster in cemen t mor ta r 1: 4 for th e collection pit

internally.

f) Green belt will be developed all along the boundary of compost yard and

lagoon to control the issue of foul odor .



5.3.4 Lagoons (30 Days Storage Capacity)

(Consider production of spent wash as 350 m3per day)

a) Excavation of Soil and preparation of land.

b) Pr oviding impervious soil bund wherever necessary as per design.

c) Preparation of embankment in Black cotton soil for all four sides in 1:2

slopes, while preparation of embankment proper compaction will be done.

d) Providing and laying of 250 micron thick HDPE sheet inside the prepared

surface.

e) Providing brick lining over HDPE sheet for bottom and slopes, lining will

be filled in cement mortar 1:5 with poin ting.

f) Construction of toe wall to avoid underscoring of the embankment during

heavy rains.

g) Lagoon bottom and embankment top will be provided with bricks on edgeand joint to be filled in fine (sieved) sand.

h) Two coat of tar epoxy paint (120 micron total) will be provided at the

bottom of the lagoon.

i) Provis ion of f encing around the Lagoon to prevent tr espasser s and

wandering animals, with RCC poles and barbed wires.

5.3.5 Laboratory Shed (4m X 4m size)

a) The Labora tory shed will be provided to facility for mainta in the check

over the samples of spent wash and compost.

b) I t will have 2.5 mtrs heigh t br ick wall, plaster ed fr om both sides andremain ing height will be provided with suitable grill. The sizes of this

should be 4 mtrs x 4 mtrs and height of 3.75 mtrs.

c) Shed should have locking arrangement.

5.3.6 Garage Shed (5m x 4m size)

a) The Gar age shed will be provided for par king an d work shop facility.

The size of this shed should be 5mtrs x 4 mtrs and height of 4.5 mtrs.

b) It will have brick wall of 230 mm thk up to 1 meter heigh t, plastered from

both side and above wall grill or sheet claddin g will be provided, r oofing

with GI sheet will be considered.

c) It should have one side open and three sides closed.


47/108



d) Contractor / Supplier will also have to provide information on WCA,

Insurance Policy for material, equipment, P.F etc.

e) Contr actor / supplier will give opera tion an d tria l of mach ine with

spraying system at least for continuous 60 days.

f) Contractor / supplier should provide manual for running of the plant. He

will also give training to factory workers for minimum period of 15 days.

g) It will be sole respon sibility of contr actor / supplier to satisfy BSPCB

officials about the effective management of spent wash.

h) The plan t shou ld be able to consume minimum of 350m3

spent wash

produced in a day.

i) The contractor / supplier should provide a pump and a spent wash (HDPE)

pipe line fr om th e 5 da ys la goon s loca ted nea r th e distillery pla nt at a

distance of 800 meters. Also quote cost of this pipe line per running meter

basis in case of any decrease or increase of length of the pipe line.j) Th e contr actor / su pplier sh ou ld pr ovide compost cu lture fr ee of cost

dur in g 60 days t r ial operat ion. They should also quote rate an d

consumption per day of culture separa tely.



Chapter 6

Electrical Distribution System

6.1 General Design Basis

6.1.1 Design Criteria in Equipments / Power Distribution

a. All Busbars shall be Air insulated and of ALUMINIUM. Busbar size shall

be selected based on Temperature limit of 85 C at Busba r for the rated

current.

b. Power Ca bles (H V & LV) sh a ll be XLPE a r mou red ALUMI NI UM

conductors above an d including 6 sq. mm. size. Power cables including

and less than 4 sq. mm. shall be copper conductor.

c. Squirrel Cage Motors up to 15 KW shall have automatic DOL Starter

suitable for operating from MCC, DCS and PB Station near Motors.

d. Motor rating above 15 KW up to 200KW shall be with Automatic Star

Delta Starter suitable for operating from MCC, DCS and PB Station

near Motors.

e. Motor rating above 200KW shall be operated with Soft Starter suitable for

operating from starter, DCS and PB Station near Motors. Starter sha ll have

bypass contactor with AC3 rating.

f. VFD shall be provided as per the functional requirement.

g. Following spare feeders shall be considered in Power Distribution

- In 11 KV Switchboard - 1 No. Transformer feeder

- In Cogen Aux. L. T. Panel - As per SLD

- Panels in other areas including PCC / MCC / DB - 1 No. of Each

Rating

h. MCC shall be floor mounted self supporting, dust and vermin proof, fixed

type construction.

i. Power Control Center (PCC) shall have Switch Disconnector Fuse up to

630A an d above 800A these sha ll ha ve Man ua lly opera ted Draw Out

(MDO) type ACB. ON indication sha ll be provided on outgoing feeders.



j. Motor Con trol Center (MCC) shall h ave Switch Disconnector F use u nit,

Contactor and Bimetallic Over Load (O/L) relay for star ters. Starters on

MCCs shall have ON & TRIP indication. The selection of switchgear

components shall be minimum with one stage higher than Type II

co ordination as per IS 13947

k. Motor protection shall be provided in ACVF Drives & Soft Starters, as

inbuilt protection functions.

l. Rating of Switchboard incomer ACB/SDF shall be 1.2 times the operating

load current. Protection & Indication (For HV Switch board)

m. F lameproof equipments such as Push Button Stations, junction boxes,

Lighting Switches, L lighting F ixtures etc sha ll be considered with

hazardous area classification in Ethanol plant.

n. Push Button Sta tion with Shrouded type actua tor for ON push

button, Lockable Mushroom type actuator for OF F Push button with

Aluminum die cast enclosure shall be provided. Push Button Station

for Motors above 15KW rating shall be provided with su ppressed

scale Ammeter. Pu sh Button Station for VF D sha ll ha ve Speed

Setting Potentiometer and speed indicator in addition to Push Buttons

and Ammeter

6.1.2 Power & Distribution Transformer

The following criteria shall be applicable for the sizing of Transformer

a) Total Connected Load shall be calculated based on Motor List.

b) Oper a ting Load sh all be ca lcula ted excluding Standby Loa ds and

equipment for maintenance such as Crane.

c) Load F actors shall be considered on Operating Loads according to

Load F actor to consider shall be as below:

- Motor Loads with DOL / S/D Starter / Soft Starters :

0.85

- Motor Loads with VFDs 0.75

-

Lighting Loads : 1.0- Utility Plug Sockets : 0.5

- Cranes, winches etc. : 0.1

d) Average Power Factor 0.8 shall be considered to arrive at KVA.

e) Equipment Efficiency shall be considered 90% as average.

f) On such Calculated load + 20% Margin shall be considered.

g) If necessary percentage impedance shall be increased more than the

impedance indicated in IS to limit 415 V side Fa ult Level to 50KA for

1 sec.



6 .1 .3 Power Factor Improvement

a) Plant PF shall be required to improve above 0.95

b) This is achieved by providing:

Capacitors across HV Motors as per recommendation of manufacturer.

Provide Automatic Power Correction Panel with required no. of APP

type capacitor banks in 415V PCC in Cogen Plant, Sugar Plant and

Distillery plan t. In Suga r Pla nt fixed type ca pacitors ca n be

connected additionally near MCC with appropriate capacitor duty

contactor and FSU feeder in MCC.

c) To determine number of capacitors following consideration be given

Operating KW & Average operating P .F.

Drive with VF D shall maintain P.F . above 0.95. These loads shall notto be considered for deciding capacitor rating.

6.1.4 LV Power Control Centre (PCC)

The following points sha ll be considered while designing a nd selection of

components.

a) TYPE OF FEEDERS :

Incomers : D.O. 3-Pole ACB

Emergen cy Power

Supply Feeder

: D.O. 4-Pole ACB

Outgoing Feeders : SDF up to 630 A

: MDO Type ACB Above 800A

b) BUSBARS Color Coded Sleeved Aluminum

Bus bar Size shall be selected as per following

norms:

Continuous current car rying capacity as per the

Rated Current of Incomer

Temperature Rise Limit

Short Circuit Withstand Capacity

6.1 .5 Motor Control Centre (MCC) :

The following points shall be considered while designing & selecting

components.

a) Incomer

Feeder

- MDO ACB above 800 A up to 2000 A

Fixed Switch Fuse Disconnector up to 630 A



b) Outgoing

Starter

Feeder

Feeders shall be comprising of:

Switch Fuse Disconnector

Contactors

Thermal Overload Relay

Timer in case of Star Delta Starters

Push Buttons

Indicating Lamps

c) Bus bar Above 125A rating

d) Control

Logic

- Plant shall be capable of operation from MCC, DCS

located at Central Contr ol Room or locally from

Push Button Station near motor.

- It will be possible to start the Motor locally throughenable command from PLC.

- P . F . a n d KW p a r a me te r of I n c om er s h a l l b e

communicated to PLC.

- ON/ OFF Status of the Motor shall be communicated to

PLC.

e) Provision

o f Spare

feeders

In MCC total 10% spar e feeders sha ll be provided,

depending on feeder ra tings in MCC following feeders

shall be provided.

6.1.6 LV Bus Ducting

Bus duct up to 3200A shall be CRCA enclosure with color coded sleeved

Aluminum bus bar. Short circuit rating shall be 50KA, 1 sec.

6.1 .7 Battery & Battery Charger

a) Battery: - VRLA Maintenance Free

- Capacity shall be determined by total operating load

& 20% margin

- AH shall be determined for 8 hour backup time

b) Battary :

Charger

Float and Float cum Boost with 20% capacity

c) DCDB : Built in with Battery cha rger pan el with In comer as

MCCB & Outgoing as MCB



6.1.8 Grounding / Earthing System & Lightening Protection

a) Earthing shall be done according to IS 3043 1987.

b) Earthing sh all be carried out by G.I . Strips & Wires. Earth Electrodes

sha ll be G.I. Pla te type & Pipe type as per requ irement. However,

Tran sformer Neutral will be connected to G.I. Earth Electrode through

Copper Strip.

c) Total Resistance of Earthing system shall be Less than one ohm.

d) Plant shall be protected against lightning according to IS 2309-1989.

6.1.9 Cables

The following consideration shall be given for Cable Sizing and Selection onNominal Current Capacity

a) Ambient Temperature in Air/Ground

b) Continuous Load Current

c) Short Circuit Withstand Capacity

d) Voltage Drop at the Starting of Motor limited to 15% & 5% at Steady

state up to motor terminals.

e) Deration Factor due to type of Laying & Grouping.

f) Generally Power and Control cables shall be stranded.

g) XLPE insulated cables upto & including 4 sq.mm shall be with stranded

copper conductors. Cables of 6 sq.mm & above size shall be with Al.conductor

6.1.10 Cable Trays, Accessories & Support

a) Generally Cable trays shall be prefabricated Hot Dip Galvanized Iron

b) Cable Trays sha ll be run in Vertical formation as far a s possible.

c) HV & LV Power Cables shall have separating distance of 300mm

d) Separa ting distance be tween Power and Contro l cable sha l l be

300mm.

e) Instrument cables & screened shall run on perforated cable tray having

300 mm separating distance of 300 mm.

6.1.11 Illumination System

a) The Lux Level in var ious indoor areas shall be as per IS. In plant

areas, the lighting shall be provided as per functional requirement.



b) HPMV Well Glass with integral con trol gear box fittings (IP55)

sha ll be provided in plant areas. Industrial FL. Lamp fittings will

be pr ovided in sub sta tion and other indoor areas. Mirror Optic

fixtures shall be provided in CCR. In outdoor areas HPSV Lamp

fixtures (IP 55) sha ll be provided.

c) The lighting shall be catered by Main Lighting DB. LDB & SLDB

conn ected by Al. condu ctor ca bles. The Emergency power su pply

from 415V DG set will be made available to lighting transformer in

case of failure of power

6.1.12 HV & LV Motors

Motors sha ll be as per IS 325. LV motors shall be IP 55 degree of protection

an d for HV motors the degree of protection sha ll be IP 55 (CACA). Motors

shall have insulation of class F and temperature r ise limit of class B. Motors

shall be designed with 50 C ambient. Flame proof Enclosure shall be

provided for motors where ever required.

6.2 Scope of Work

In line with th e overall ba ttery limits for the ethanol plant and associated spent

wash treatment / bio-composting facility and particularly for the electrical power,the Tenderers will have to consider following in the scope of work for electrical

distribution system:

415 V Cable from cogen power plant 415 V distribution board up to ethanolplant 11 KV switchyard.

41 5 V pan el compr isin g of VCB, CTs / P Ts, meters, protective relays,required cables and terminations, etc.



415 V distr ibution network within th e ethan ol plant including main

distribution pa nel, incoming / out going cables / bus bars, CTs / P Ts,

protection relays, annunciator, indicating lamps, push buttons, DCDB, battery

& charger, safety devices, distribution boar ds, incoming / outgoing cables,indicating lamps, push buttons, etc. for all drives.

Pr ovision of flame proof equipment includin g flame proof push bu tton

stations, junction boxes, lighting fixtures, star ters, etc. wherever needed as perthe statutory requirements will be provided.

High ma st lighting fixture with 30 m h igh tower inclu ding cradle, motor

operated mechanism, 8 nos. 400 W, metal halide lamps total 2 nos. to be

installed at designa ted places as a dvised by Owner with a ll electricalconnections.

Lightening protection for buildings in ethanol plant area as per IS 2309.

6.3 Diesel Generating Set For Emergency Electrical Power Supply

One No: 150 kW ra ting diesel set with 0.80 power factor shall be installed for the

ethanol plant.

The diesel gener ating set sha ll be continuously ra ted comprising multiple

cylinder diesel engine ha ving necessary protections such as low lube oilpressure tr ip, high engin e temper ature trip, over speed tr ip etc. and shall be

fitted with speed control knob speedometer, hour meter battery charging meter,

oil pressure and temperature gauges, radiator etc.

The diesel engine sha ll be coupled with suitable altern ator capa ble of

developing continuously the rated power at 3 phase, 4 wire, 50 Hz at normal

voltage of 440 V AC. Alternator to be suitable for voltage range of 440 V AC

an d conforming to IS-4722 specifications. The alternator shall be fitted with

minimum one ETD in each phase for thermo protection of the alterna tor

windings. The alternator shall be designed for an ambient temperature of 45 deg.

C. The alternator shall be self excited and self regulated.

The diesel set sha ll be complete with base fra me, couplings, one M.S.

fabrica ted, diesel service tank of 10 HL capacity, inter-connecting piping, D.C.

storage battery and self starting mechanism for starting of engine.



One 2 mm thick for the back side an d 1.6 mm thick for the other sides cold

rolled sheet steel fabricated floor mounted, dust and vermin proof panel for the

diesel set shall be provided. The panel shall be fitted with air circuit breaker,

over current relay, earth fault relay, reverse power relay, over voltage relay, reed

type frequency meter, neutral isolating switch, three phase 4 wire unbalanced

energy meters, kW meter, 3 phase power factor meter, 3 nos. ampere meters,

one no voltmeter with selector switch, ON-OFF indicting lamps.

The panel shall have neutral and phase bus bars of electric grade (EC-91E)

aluminum and shall be designed to withstand symmetrical short circuit current

of 35 KA (RMS) for one second. The pan el sha ll be designed for an ambient

temperature of 45 Deg C the operating temperature of the bus bars sha ll not

exceed 85 Deg. C. All the meters shall be class 1.50 per cent accuracy and shall

conform to IS-1248 specifications. All the meters shall be square type of 100 mmsq. with 90 per cent deflection Inter connecting electrical cable 3 cores from the

diesel set to the main distribution panel and to the auxiliary panel changeover

switch shall be provided.



Chapter 7

Control & Instrumentation System

7.1 Process Control Philosophy

PLC is a microprocessor/micro controller based system having fun ctional

distribution, data base distribution associated with software and hardware. PLC

system is used widely in industrial automation where we have to monitor the

pr ocess and contr ol as per ou r need. Th e system is equipped with following

processing modules connected to it. The automation indicated below will have DCS

connectivity.

Control system

The closed loop control, interlock, sequence contr ols and data acquisition a re

performed in the control system.

Communication system

Pentium computer (IV as a minimum) is used to download the software, ladder

logic, and other programs to communicate with PLC on proprietary network. These

computers will also act as an operator station for man machine interface. Computers

shall be provided with monitors, printers, mouse an d keyboard a nd stan dar d

peripherals.

7.2 Parts Inter-changeability

In order to minimize spare part-stocking requirements the PLC may offer h igh

degree of interchange ability.

The system incorporates modular design using plug in assemblies.

It may be possible to modify application software on line.

Universa l removable termina l strips shall be used to connect field wiring to

individual circuit board assemblies.



7.3 Security

Password secur ity is provided for at least for three different level of access.

Memory protect key switch is th er e t o pr event alteration of program and

configuration data through interface device.

7.4 Spare Philosophy

Provision of connecting I/O cards as spare.

Provision of spare wired slots to accommodate I/O modules for future expansion.

7.5 System Specification

System hardware

The system offers following subsystems connected to it.

- Communication within PLC system

- The system is reliable, high speed, and peer-to-peer communication.

- Cyclic redundancy check (CRC) used for all data communication on this link.

- The BUS of IEEE standard and of latest version.

- The BUS system capable of being extended through a connection of Modem.- PLC is provided with E thernet port to communicate with any other third party

device.

- Ethernet card of 32-bit PCI card

- Communication with external device through TCP / IP protocol.

Power supply module

The system power supply suitable for 220 V AC UPS, 50 Hz, Single-phase

operation. Power supply module are having fuses rated suitably for the n ominal

current requirements. Power supply is of SMPS type and delivers DC voltage levels

required for the system operation.

Digital input module

Digital input module is used to convert external bina ry signal (potential free) from

field to internal signal level of PLC.

Each input is isolated and be provided with individual fuse.



All cards is reported on computer monitor

LED indications are provided for fault status indication on the front of individual

module (channel wise).

Digital output modules

Digital output module converts the internal voltage level of PLC in to external

binary signal level required to opera te actuating / indicating devices.

Digital output module sources current while energizing field outputs. Potential free

contacts made available for start / stop signal.

DO is protected with short circuit protection.

Each output is isolated and provided with individual fuses.

All cards status is reported on computer monitor

Analog input module

Analog input modules are used to accept field analog signals.

Modules is accepting 4-20 ma , 1-5 V DC signa ls an d pr ovide power to field

transmitter.

Analog output module

Analog output modules are used to give input to the fina l control elements.

AO modules provide isolation to all channels.

Processor module

The processor module is data a cquisition an d control processor system. The

processor is of microprocessor based (Intel 80486/equivalent/better ) and CPU shall

be of 32 bits with floating point ar ithmetic calculation with math co-processor.

Processor unit access system I/O modules through local I/O bus. This module shall

have capability to implement logic scheme.

Long life lithium battery can be used to maintain the contents of CMOS RAM. 30%

memory shall be provided for application I/O after final commissioning of system.

CPU can be programmed by external PC via communication bus.



7.6 Operator Interface

The operator interface with PLC is through PC. The PC can also be used for control

and monitoring of plant.

PCs can be provided with following peripherals

- Monitor (Monitor shall be of 17 size and Pixel resolution shall be 1024 x

768 or better)

- Printer (One no. for logging of alarm and shall be 132 column dot matrix)

- Key board (104 keys keyboard shall be provided)

- Mouse (three-button mouse shall be provided)

7.7 Operator Cum Engineering Station

Operator cum engineering station can be used for engineering as well operator

function in addition to the operator stations specified above. Selection of operator

/ engineer ing function ca n be selectable by password. The engineering station

offered may have provision for performing the following engineering functions.

Database configuration including configuration of a ll displays and loops

system.

Automatic downloading of the configurations in each system.

Configura tion of var ious control functions or control blocks to implementvar ious control strategies and downloading the same into the control

stations.

Conf igura t ion/ reconf igura t ion of a l ar m se t tings , the i r va lues ,

addition/deletion of a larm from groups, controller tuning like changing

P,I,D values, dead time values etc.

Defining the key lock functions or engineer keyboard functions.

On-line compilation of all types of dynamic graphic displays.

Plant/group alarm inhibits function.

Start/stop of each system, including printers.

Enabling/disabling of different instruments/ peripheral connected to thesystem.

Preparation and compilation of logs/reports/ historical trend points.

Calling of detailed self-diagnostic displays for maintenance aid.

Loading, editing, compiling and executing of all progra ms written using

high level languages supported by the system.



7.8 Other Hardware Requirement

System cabinets

Control cabinets shall be free standing type with dimensions as r equired. The

vendor shal l ensure that al l the equipment speci f ied can be proper ly

accommodated in the respective cabinets and if necessary offer cabinets with

higher dimensions. All cabinets shall be of Rittal make.

Control Cabinet sha ll be completely metal en closed. Control cabinet enclosures

shall provide a degree of protection not les

Documents

Technical Specs Ethanol Sugauli - Final