technical specification for ash handling system

TENDER DOCUMENT

For

ASH HANDLING SYSTEM

For

108 MW CAPTIVE POWER PLANT

SHRI GIRIJA ALLOY & POWER (I) PRIVATE LIMITED Peddapuram, East Godavari District, Andhra Pradesh

TECHNICAL SPECIFICATION

MARCH 2012

Snyder Energo Private Limited No. 301, VITC Model Export Park,

#488, 14th Cross, 4th Phase, Peenya Industrial area, Bangalore – 560 058, India

E-mail: [email protected]

SHRI GIRIJA ALLOY & POWER (I) PRIVATE LIMITED


TECHNICAL SPECIFICATION FOR

ASH HANDLING SYSTEM

DOC. NO : 4 – 3614 – MECH – 011

Consultant: Snyder Energo Pvt. Ltd. Bangalore & Chennai

TECHNICAL SPECIFICATION

FOR

ASH HANDLING SYSTEM

REVISION NO. R0

ISSUED FOR FOR TENDERING

PREPD.BY/DATE SRN / 02.03.2012

CHKD. BY/DATE GN/ 05.03.2012

APPD. BY/ DATE BRC/ 07.03.2012




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Consultant: Snyder Energo Pvt. Ltd. Index i Bangalore & Chennai

Section TITLE Page No.

1 GENERAL 01

2 PROJECT SPECIFIC INFORMATION 03

3 GENERAL REQUIREMENTS 06

4 SYSTEM DESCRIPTION 09

5 DESIGN CRITERIA 12

6 SCOPE OF WORK SERVICES, TERMIANL POINT & EXCLUSIONS 18

7 DETAILED TECHNICAL SPECIFICATION 27

8 TOOLS & TACKLES AND SPARES 52

9 QUALITY ASSURANCE PLAN 53

10 PAINTING SYSTEM 54

11 ERECTION, TESTING AND COMMISSIONING 59

12 PERFORMANCE GUARANTEES & AVAILABILITY 62

13 DOCUMENTATION 64

14 LIST OF APPROVED MAKES 66

Annexure-I DATA TO BE FURNISHED BY TENDERER

Annexure-II SPECIFICATION DRAWINGS




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Consultant: Snyder Energo Pvt. Ltd. 1 of 67 Bangalore & Chennai

1.0 GENERAL

1.1 Intent of Specification

1.1.1 This specification covers the design, engineering, manufacturing, inspection, and delivery at site, unloading, storing at site, erection and commissioning, performance guarantee tests, and handing over of complete Ash handling system for two (2) nos. of 36 MW Captive Power Plant, for Shri Girija Alloy & Power (I) Private Limited., (SGAPIPL) at Peddapuram Village, East Godavari District, Andhra Pradesh. The scope of work and services shall include all necessary work and supply of equipment and material whether mentioned in these specifications or not, but are necessary for the satisfactory, reliable safe operation and maintenance of the system and required for achieving guaranteed performance of the system.

1.1.2 All the equipment/plant will conform in all respects to high standards of engineering, design and workmanship and be capable of performing in continuous commercial operation up to the Tenderer’s guarantees in a manner acceptable to the Purchaser/Purchaser’s representative, who will interpret the meaning of specifications and drawings to ensure that all the work and materials are in full accordance therewith.

1.1.3 The extent of supply under this contract includes all items shown in the appropriate sketches/drawings notwithstanding the fact that such items are not covered in specification or schedules within the terminal points. Similarly, the extent of supply also includes all items mentioned in the specification and/or schedule, notwithstanding the fact that such items are not shown in the sketches/drawings.

1.1.4 All specialised equipment/services necessary for proper testing, commissioning and performance testing of all items of the plant covered under this contract will be arranged by the Tenderer. The cost of the same will be included in the contract price

1.1.5 The precision instrument/equipment required for the performance testing of all items of the plant covered under this specification as per code requirement will be furnished by Tenderer on returnable basis.

1.1.6 All necessary coordination with regard to sub-contracted equipment will be carried out by the Tenderer. The Purchaser/Purchaser’s representative will communicate only with the Tenderer for all matters pertaining to this contract.

1.1.7 The total price quoted for this contract will be firm lump-sum all-inclusive basis and will cover all items and services necessary for the successful completion of the contract. Even if all components of a system included in this specification are not explicitly identified and/or listed herein, these will be supplied under this contract to ensure completeness of the system and facilitate proper operation and easy maintenance of the plant.

1.2 Codes and standards

1.2.1 The design and manufacturing of the ash handling system shall comply with the requirements of applicable standards such as the following and those standards specified therein, so far as they apply.




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• IS 800 : Code of practice for Construction in steel

• IS 875 : Code of practice for design loads for Buildings/structures

• IS 1893 : Criteria for earthquake resistance design of structures.

• BS 4592 : Industrial type metal floors, walkways and stair

• BS 5395 : Stairs, ladders and walkways.

• IS 8130 : Conductors for insulated electrical cables and flexible chords

• IS 3975 : Mild steel wires, strips and tapes for armoring of cables

• IS 2633 : Methods of testing weight, thickness and uniformity of coating on hot dipped galvanized articles

• IEC 540 & 540A : Test methods for insulation and sheaths of electric cables & chords.




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2.0 PROJECT SPECIFIC INFORMATION

2.1 Project

1. Purchaser Shri Girija Alloy & Power (I) Private Limited

No. 88-3-5, Gadalamma Nagar, Morampoudi, Rajahmundry - 533 103, East Godavari District, Andhra Pradesh.

2. Project 108 MW Captive Power Plant

3. Purchaser’s Consultant SNYDER ENERGO PRIVATE LIMITED, No. 301, VITC Model Export Park, # 488, 14th Cross, 4th Phase, Peenya Industrial Area, Bangalore – 560 058, India.

2.2 Location

The power project site is located at Peddapuram, East Godavari District, Andhra Pradesh. The locational details of the power project site are as indicated below:

Latitude 17˚ 04’ 17” N

Longitude 82˚ 07’ 32” E

Height above mean sea level 52.00 m

Seismic Zone Zone – II

Nearest town Peddapuram – 1.3 km

Nearest City Kakinada – 18 km

Nearest national highway NH–5 - 5 km in the East

Nearest Railway station Guduprati – 4.5 km Samalkot – 5.2 km

Nearest airports Rajahmundry – 35 km

Nearest seaports Kakinada – 18 km Vizag – around 55 km

2.3 Climatic data

Highest daily temperature 36.9 (degree C)

Lowest daily temperature 23.8 (degree C)

Annual mean of daily temperature 31.7 (degree C)

Extreme highest temperature 40 (degree C)

Relative Humidity: Maximum 81 %




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Minimum 61 %

24 hour highest rainfall 233.9 mm

Monthly highest rainfall 781.1 mm

Normal wind speed 10.4 km/h

2.4 Water System

2.4.1 Auxiliary cooling water

i) Inlet temperature : 34 degree C

ii) Outlet temperature : 42 degree C

iii) Pressure : 4 kg/cm2 (a)

2.5 Power supply

The power supplies for distribution and auxiliaries shall be as under:

Sl. No Parameter Description

i) LT distribution 415V ±10%, 3ph, 4W, 50Hz + 5% to –5%, solidly grounded system.

ii) Motor rated above 200W and below 180 kW and all motorized actuators.

415V ±10%, 3 ph, 50Hz +5% to - 5%.

iii)

For motors equal and below 200W; panel space heating, lighting and small power distribution

240V ±10%, 1ph, 50Hz + 5% to –5%, solidly grounded.

iv) Control supply for relay panel/MV breakers/LV breakers and DC emergency lighting.

110V DC, 2-wire ungrounded system.

v) DC power for control & instrumentation (if required.) +24V DC (20V-30V), - VE side grounded.

vi)

Control supply for 415V Motor contactors/AC Control circuits [to be generated in MCC/ panel by Tenderer with control transformers]

110V AC ±10%, 50Hz + 5% to –5%.

vii) Diesel Generator emergency supply 415V ±10%, 3ph, 3W, 50Hz +5% to –5%.

NOTE: a) All equipment shall be suitable for 10% combined voltage and frequency variation [absolute sum]

b) Any other power supply requirement shall be derived by the Tenderer from




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Sl. No Parameter Description

the above available power supplies

viii) Design ambient temperature for electrical equipment and devices

50 degree C.

ix) Fault levels

220 kV 40 kA

11 kV 40 kA

415V 50 kA

2.6 Instrument air (Oil free)

Pressure at the terminal point : 5 ~6 kg/cm2 (a)




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3.0 GENERAL REQUIREMENTS

3.1 The Bed and Fly ash handling systems shall be dry type dense phase pneumatic system. The function of the Bed and Fly Ash Handling is to remove coarse / fly ash from Bed ash coolers, Mechanical dust collector, air pre-heater hoppers, ESP hoppers and transport it to the storage silos. This should be carried out by pneumatic system. The equipment should be suitable to handle the ash burden from the specified fuel under all loading conditions.

3.2 Typical schematic for conveying pipes up to silo shall be provided as per the drawing No. 3-3614-100-043. The same type of arrangement shall be provided for both the boilers.

3.3 It shall be possible to selectively discharge the fly ash from any of collection point to fly ash silo.

3.4 The ash handling system shall be fully automatic. The system shall be designed in such a way that the ON cycle time of the system shall be kept to the minimum and OFF cycle time shall be maximum. All the equipment shall be designed for continuous duty of 24 hours per day. During normal running, the system operates with 10 cycles / hour and 20 cycles / hour during emergency. The size of the vessel below the ash hopper is selected based on number of cycles per hour specified.

3.5 ESP hoppers & Silo’s shall be provided with fluidisation pads and required fluidizing air blowers and accessories for proper flow of material.

3.6 Silo shall be provided with fluidization pads, isolation gates and RF type level probes and necessary instruments for safe and easy operation of the system.

3.7 All the pneumatically operated valves shall be controlled from Purchaser DCS system.

3.8 Two (2) nos. screw air compressors of suitable capacity (1W + 1S) with necessary instruments / accessories, receiver tank common for both boilers for pneumatic conveying of ash up to silo shall be provided. The compressor shall be sized considering 25% margin on the total conveying air requirement. Adequate capacity of air receiver shall be provided with necessary accessories / instruments. Air receiver should be normally large enough to supply air without pressure fluctuations.

3.9 Two (2) nos. Hopper / silo fluidizing air blower of suitable capacity (1W + 1S) with heaters and necessary instruments / accessories for both boilers for fluidization of ash silos and ESP hoppers. The blowers shall be sized considering 10% margin on the total fluidizing air requirement. Adequately sized Heaters will be provided on discharge lines of these blowers for heating the air before is let into the silo / hopper.

3.10 The design of equipment shall ensure maintenance of noise and vibration levels within the limits specified below:

3.10.1 Measured noise level produced by any rotating equipment shall not exceed 85 dB at a distance of 1.5 m from it in any direction.

3.10.2 Amplitude of vibration at bearings of rotating equipment shall confirm to the latest editions of ISO: 2372.




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3.10.3 Vibration isolators of proven performance shall be provided as part of supply for preventing transmission of vibration from one equipment to the other neighboring equipment and structures.

3.11 All parts subject to wear shall be provided with quick and easily replaceable parts. The estimated life of such parts shall be stated clearly when it is less than 10000 operational hours. Wear parts must be more than 15000 operational hours.

3.12 The ash handling system shall be designed and constructed in view of dust free operation. Fugitive dust emission in any area shall not exceed 50 mg/Nm3 for all solid particles.

3.13 Sampling points for Ash sample collection shall be provided at the hoppers/conveying lines.

3.14 The conveying pipes shall be MS Black ERW heavy duty pipes as per IS: 1239 upto 6’’ and above 6’’ as per IS 3589 heavy duty pipes. Pipe shall be in 7mm (thickness) and 6 M lengths (maximum) with flanged joints at both ends. The flanges shall be welded to the pipe from inside as well as outside.

3.15 The pipe bends shall be made of wear resistant cast basalt / Ni-Hard bends with 550 BHN. The bends shall be easily accessible for maintenance.

3.16 A target box will be provided on ash silo’s which will be connected to the ash air mixture conveying pipes. The target box allows the bed ash to get discharged into the silo. The material of construction of target box body shall be as per IS 2062 / Gr. A and the deflector shall be Alloy CI, 500 BHN.

3.17 The fly ash separated by the bag filter will be collected into a buffer hopper, which will have 30-minute surge storage capacity. The buffer hopper will be part of the bag filter assembly. Below the buffer hopper there will be special pressure feeders/air lock vessels, which will be used for further transportation of ash pneumatically through pipeline to silo.

3.18 A bag filter vent unit is mounted on top of the silo to filter exhaust air before leaving it to atmosphere. Compressed air for reverse jet cleaning of bags is supplied from plant compressed air system. To safeguard the silo from over pressure on the silo top, a pressure relief vent will be provided. This is suitably rated to open at a predetermined pressure and discharge the air to atmosphere. A level probe is provided to give alarm annunciation when bed ash reaches high level.

3.19 Bag filter shall be designed considering a maximum air to cloth ratio of 1:1.3 m3/mini/m2 and in conformity to the following parameters:

3.19.1 Efficiency : 99.5 % and above for sizes – 0.2 microns

3.19.2 Max. pressure drop : 75mm WC through bag filter

3.19.3 Bag filter shall be provided with minimum 15% more cloth area than the designed requirement. The bag material may be polypropylene, polyester nylon, nomex or glass fibre with / without antistatic properties depending on the air / gas and dust handled, temperature etc.,

3.20 The system including silo ash removal should be designed to function with minimum operator intervention




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3.21 As per the bed ash particle distribution (Maximum expected size shall be 3 inch), Tenderer to confirm the requirement of clinker grinder.

3.22 Bed ash temperature at the outlet of bed ash cooler shall be 250 Deg. C, Tenderer to confirm the requirement of Water cooled surge hopper.

3.23 Moisture may be present in the ash collection plant during cold starts of the boiler. The ash handling plant must be designed to cope with this eventuality.

3.24 All the major components should have inspection and cleaning facilities in the event of system blockage. It should be possible to isolate each section of the system for maintenance whilst retaining the remainder of the system in service. The entire plant should be capable of smooth starting after a reasonable stoppage of the system (which tripped during its full load operation for some system disturbance). The bends in the pipe work system should have material of construction proven in service. Wear resistant linings should also be considered where appropriate. Components subject to high temperatures should be insulated to protect personnel.

3.25 The ash hopper isolation valve, surge hopper isolation valves which handle ash are to be of knife gate type with plate made of stainless steel conforming to SS 304 stellited to minimum 1 mm thickness. Body and seat should be made of alloy cost iron with minimum hardness being 350 BHN.

3.26 Electrical

3.26.1 All motors considered for the system shall be LT.

3.26.2 The motor terminal box shall be complete with cable gland & lugs Starters, lockable push button stations, MCC, all cabling including galvanized cable trays, equipment /body earthing etc.

3.26.3 Lighting and lightening arrester engineering, supply, erection and commissioning for complete ash handling system including silos.

3.27 Instrumentation and controls

3.27.1 Control System including local control panel for ash unloading from silo the sequential operation with inter phase facility to communication with the purchaser DCS system.

3.27.2 Local instruments including switches, instrument cables terminal boxes, cable trays & accessories, as required to make the system complete.

3.28 General

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

3.28.2 One set special tools & tackles required for operation & maintenance, inspection & repair of equipment supplied. O & M Manuals, drawings, calculations, certificates as required.

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




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4.0 SYSTEM DESCRIPTION

4.1 The ash handling system consists of the following sub systems:

i) Bed ash handling system

ii) Fly ash handling system

iii) Bed ash disposal system

iv) Fly ash disposal system

v) Auxiliary enabling systems

Refer: Process flow diagram for Ash handling system Drawing No: 3-3614-100-043.

4.1.1 Bed ash handling system

Bed ash is collected in 2 Nos. of Bed ash collection cooler hoppers in each boiler. Since the maximum expected size of the bed ash shall be 3 Inches, Tenderer to confirm the requirement of Clinker Grinder. A surge hopper, which is water cooled, is provided below the crusher if required. The ash discharges from the surge hopper to the denseveyor. The inlet valve to the denseveyor is closed and conveying air is admitted into the denseveyor. This pressurises the denseveyor. The admission air inlet valve is closed and the discharge valve of the denseveyor is opened. The bed ash is carried along by the air stream up to the Bed ash silo. The ash separates out and gets collected in the silo. The air escapes through the bag filter, which is provided to minimise dust escape to atmosphere. Separate denseveyor cum piping arrangement is provided for each hopper.

4.1.2 Fly ash handling system

i) Mechanical dust collector hoppers (1 No. per boiler)

ii) Air-preheater hoppers (2 Nos. per boiler)

iii) ESP field 1, 2, 3, 4 and 5 hoppers (5 fields per boiler)

Fly ash collected in the hopper gets discharged to denseveyor. The ash inlet valve to the denseveyor is closed. The conveying air is admitted into the denseveyor and it is pressurised. The conveying air valve is closed and the denseveyor discharge valve is opened. The fly ash is conveyed to the Fly ash intermediate storage silo along with the air. In the silo the fly ash gets separated and gets collected. The escaping air from the silo passes through a bag filter to minimise dust pollution.

4.1.3 Bed ash disposal system

Bed ash silo shall be provided with 3 Nos. of outlet at the bottom:




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i) For disposal in dry form into closed trucks

1 No. of outlet of bed ash silo is fitted with plate valve, Electro-pneumatic operated ash discharge valve, rotary feeder and flexible unloading spout. The unloading spout is directly connected to the closed truck and the ash is unloaded onto the truck.

ii) For disposal in wet form into open trucks

1 No. of outlet of bed ash silo is fitted with plate valve, Electro-pneumatic operated ash discharge valve, rotary feeder and ash conditioners where the ash and water mix together and form wet ash, then the wet ash transferred to open truck through chute.

iii) For emergency discharge of bed ash:

1 No. of outlet of bed ash silo is fitted with plate valve for emergency discharge

4.1.4 Fly ash disposal system

i) Fly ash intermediate silo shall be provided with 3 Nos. of outlet at the bottom:

For fly ash into denseveyor 1 No. of outlet of fly ash intermediate silo is fitted with hand operated knife gate valve, bellows and denseveyor. Fly ash collected in the intermediate silo gets discharged to denseveyor. The ash inlet valve to the denseveyor is closed. The conveying air is admitted into the denseveyor and it is pressurised. The conveying air valve is closed and the denseveyor discharge valve is opened. The fly ash is conveyed to the main fly ash storage silo along with the air. In the silo the fly ash gets separated and gets collected. The escaping air from the silo passes through a bag filter to minimise dust pollution

For fly ash into open trucks 1 No. of outlet of intermediate fly ash silo is fitted with plate valve, Electro-pneumatic operated ash discharge valve, rotary feeder and ash conditioners where the ash and water mix together and form wet ash, then the wet ash transferred to open truck through chute. For emergency discharge of fly ash: 1 No. of outlet of fly ash intermediate silo is fitted with hand operated knife gate valve for emergency discharge of fly ash from intermediate fly ash silo to atmosphere.




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ii) Main Fly ash silo shall be provided with 3 Nos. of outlet at the bottom:

For disposal in dry form into closed trucks 1 No. of outlet of Main fly ash silo is fitted with plate valve, Electro-pneumatic operated ash discharge valve, rotary feeder and flexible unloading spout. The unloading spout is directly connected to the closed truck and the ash is unloaded onto the truck

For disposal in wet form into open trucks 1 No. of outlet of Main fly ash silo is fitted with plate valve, Electro-pneumatic operated ash discharge valve, rotary feeder and ash conditioners where the ash and water mix together and form wet ash, then the wet ash transferred to open truck through chute. For emergency discharge of main ash: 1 No. of outlet of main fly ash silo is fitted with plate valve for emergency discharge

4.1.5 Auxiliary enabling systems

The following systems, which are auxiliary systems for the ash handling system, are considered:

i) Two (2) nos. screw air compressors of suitable capacity (1W + 1S) with necessary

instruments / accessories, receiver tank common for both boilers for pneumatic conveying of fly ash to silo shall be provided. Adequate capacity of air receiver shall be provided with necessary accessories / instruments. (Common for both boilers)

ii) Two (2) nos. Hopper / silo fluidizing air blower of suitable capacity (1W + 1S) with heaters and necessary (Common for both boilers)

iii) It is to be noted that the instrument air requirement required for Ash handling system shall be provided by purchaser at 5~6 kg/cm2 (a) at terminal point and therefore no separate instrument air compressors are envisaged for Ash handling system




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5.0 DESIGN CRITERIA

5.1 The Tenderer shall study the specification and satisfy himself thoroughly regarding the workability and suitability of the equipment and system supplied by him to satisfy this specification. He shall take full responsibility for the guaranteed and satisfactory performance of the system

i. Fuel 100% Indonesian coal, 100% Indian coal, 60% Indonesian coal + 40% Indian coal

ii. Type of Boiler IR-CFBC

iii. Number of Boilers Two

iv. Boiler Capacity 160 TPH (each)

v. Main steam pressure 105 Ata

vi. Main steam temperature 540±5 °C

The design criteria per boiler are furnished below. The same shall be considered for the second boiler also.

5.2 Ash collection at Bed ash outlet hoppers:

Sl.No. Description Unit Design

1.0 Total bed ash collected per hopper kg/hr 1250

2.0 Design capacity per ash vessel kg/hr 1500

3.0 No of hoppers/No. of ash vessel No 02 / 02

4.0 Number of openings per hoppers No 01

5.0 Ash Density kg/m3 1000-1400

6.0 Ash Temperature (Design) oC 300

7.0 Conveying Distance mts As per the Ash collection

point detail drawing 3-3614-100-044

8.0 Hopper O/L pipe bottom elevation m +3.0 above FFL




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5.3 Ash collection at Mechanical Dust Collector outlet hoppers:

5.4 Ash collection at Air-preheater outlet hoppers:


1.0 Total Fly ash collected per hopper kg/hr 5800


3.0 No of hoppers/No. of ash vessel No 02 / 01

4.0 Number of openings per hoppers No 01



7.0 Conveying Distance mts As per the Ash collection point detail drawing 3-3614-100-044



1.0 Total Fly ash collected per hopper kg/hr 750


3.0 No of hoppers / No. of ash vessel No 02 / 02

4.0 Number of openings per hoppers

No 01








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5.5 Ash collection at ESP hoppers:


1.0 Total Fly ash collected Below ESP hoppers.

kg/hr 6825

2.0 No. of field No 05

3.0 No of openings (in the hopper) per field

No One

4.0 Collection rate in Ist field (Design capacity) kg/hr 7500

5.0 Collection rate in IInd field (Design capacity) kg/hr 7500

6.0 Collection rate in IIIrd field (Design capacity) kg/hr 750

7.0 Collection rate in IVth field (Design capacity) kg/hr 75

8.0 Collection rate in Vth field (Design capacity) kg/hr 10




12.0 Hopper O/L pipe bottom elevation m +3.0 Above FFL

NOTE: TOTAL ASH GENERATION CONSIDERING ALL THE CASE SHALL BE 16625 KG/HR WITHOUT MARGIN. FOR COMPRESSOR DESIGN CONSIDERING 25% MARGIN ON ASH QTY, 20800 KG/HR IS RECOMMENDED




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5.6 Ash Collection rate for bed silo, intermediate fly ash silo & Main fly ash silo

Sl. No. Description Ash Collection rate (TPH)

1.0 Bed Ash Silo

1.1 Capacity requirement of ash collection from the Outlet of bed ash silo into open truck 30

1.2 Capacity requirement of ash collection from the Outlet of bed ash silo into closed trucks 30

1.3 Capacity requirement of ash collection from the Emergency outlet 30

2.0 Intermediate Fly Ash Silo

2.1 Capacity requirement of ash collection from the Outlet of intermediate fly ash silo into the inlet of Main ash silo

50

2.2 Capacity requirement of ash collection from the Outlet of intermediate fly ash silo into open trucks

50


3.0 Main Fly Ash Silo

3.1 Capacity requirement of ash collection from the Outlet of main fly ash silo into open truck 50

3.2 Capacity requirement of ash collection from the Outlet of main fly ash silo into closed trucks 50


5.7 Bed ash particle distribution is given below:

Size in microns % of Passing 12500 100 6300 95.6 4750 91.7 2360 83 1180 69 850 62.5 710 58.5 600 53.4 500 48.2 425 43 300 29 212 16.1 150 5.9




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Size in microns % of Passing 75 0.5 53 0.4 45 0.3

Maximum expected size should be 3 inches.

5.8 Fly ash particle size at MDC outlet:

Size in microns Lower range (%) Upper range (%)

0-10 2 5

up to 20 18 23

up to 30 23 30

up to 40 29 38

up to 50 35 45

up to 60 39 50

up to 70 42 57

up to 80 47 61

up to 90 50 68

up to 100 55 71

up to 200 82 98

up to 300 94 100

5.9 Fly ash particle size at Air-preheater and ESP hoppers:

Size in microns (%) 0 – 9.4 55.62

9.4 –18.8 31.11 18.8- 30 9.59 30 – 53 1.24 74 – 53 0.44 74-150 0.56

150-210 1.44

5.10 Ash Analysis:

Sl. No Characteristics Value

i. Aluminium as Al2O3 57.12 %

ii. Calcium as CaO 4.36 %

iii. Iron as Fe2O3 20.76 %




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Sl. No Characteristics Value

iv. Magnesium as MgO 0.95 %

v. Phosphorus as P2O5 0.05 %

vi. Potassium as K2O 0.3 %

vii. Sodium as Na2O 0.13 %

viii. Sulphur as SO3 1.25 %

ix. Titanium as TiO2 0.84 %

x. Vanadium Pentaqxide V2O5 <0.01 %

xii. Loss on ignition 13.44

5.11 Flue gas composition:

Sl. No Characteristics Unit Value i. CO2 (% vol /vol) 13.750 13.760

ii. O2 (% vol /vol) 3.080 3.120

iii. SO2 (% vol /vol) 0.010 0.010

iv. H2O (% vol /vol) 13.00 11.68

v. N2 (% vol /vol) 70.16 71.43

vi. CO (% vol /vol) 0.000 0.000

vii. Gas Density(wet basis (kg/Nm3) 1.296 1.302




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6.0 SCOPE OF WORK, SERVICES, TERMIANL POINT & EXCLUSIONS

6.1 The scope of work and services shall include all necessary design work, basic engineering, detailed engineering, manufacturing, loading, supply, transport, unloading at site, storage, erection, testing and commission, performance testing and handing over the complete ash handling system. The scope of work and any other services not specifically mentioned above but are necessary to complete the system in all respects regardless of any omission in this specification or drawings shall be deemed to have been included in the Tenderer’s scope.

6.2 Scope of supply

6.2.1 One (1) lot of denseveyor, transmitter vessels along with isolating valves, expansion joints, inlet and outlet pneumatic operated valves, control system, level probes, adopter piece, supports for transmitter etc., below each ESP hopper as per Process flow diagram for ash handling system Drg. No. 3-3614-100-043

6.2.2 One (1) lot of bed ash conveying piping, valves, fittings and instrumentation as required up to the terminal box on top of the ash silos

6.2.3 One (1) lot of fly ash conveying piping, valves, fittings and instrumentation as required up to the terminal box on top of the ash silos

6.2.4 Two (2) Nos. of blowers (one working + one standby) for ESP hoppers / silo fluidisation along with fluidising pads, heaters, piping etc common for both boilers. Adequately capacity of heaters will be provided on discharge lines of blowers to heat the air before air is let in to the hoppers.

6.2.5 Two (2) Nos. of Screw compressors (one working + one standby) for with necessary instruments / accessories, receiver tank common for both boilers for pneumatic conveying of fly ash to silo shall be provided. The compressor shall be sized considering 25% margin on the total conveying air requirement. Adequate capacity of air receiver shall be provided with necessary accessories / instruments. Air receiver should be normally large enough to supply air without pressure fluctuations

6.2.6 One (1) lot of conveying compressed air piping from air compressor plant to various ash hoppers with valves, fittings, etc.

6.2.7 One (1) no. Pressure relief vent on the top of each silo (Bed ash, Intermediate fly ash and Main fly ash silo) to safeguard the silo from getting pressurised.

6.2.8 One (1) no. bag type vent filter on the vent line at the top of each ash storage silo. (Reverse pulse jet bag filter on fly ash storage silo top).

6.2.9 One (1) no. vent fan at the top of each ash storage silo.

6.2.10 Three (3) nos. of ash conditioners to load the ash from bed ash, intermediate ash silo and mail ash silo to open truck in wet form with necessary piping, valves, controls, instruments etc. to make the system complete in all respects.




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6.2.11 Five (5) nos. of Electro-pneumatically operated ash discharge valve, Five (5) nos. of rotary feeders and knife gate valves for discharge the ash from bed ash / Intermediate ash/ main fly ash silo to trucks.

6.2.12 Foundations materials for all equipment and their drives, this shall include supply and fixing of all rails, steel inserts, foundation bolts pipe sleeves, anchor bolts/anchorage, assemblies, bolts, nuts, washers, etc. and grouting of anchor bolts and below base plates.

6.2.13 Terminal boxes with steel adopter pipes to be fixed for each inlet to the silo.

6.2.14 Cooling water / service water inlet and outlet piping from terminal point

6.2.15 Booster fittings complete with flexible hosepipe, needle valves etc.,

6.2.16 Cabling from field instruments and local control panel to purchaser DCS system with required erection hardware

6.2.17 Vent filter and level probe for ash silo

6.2.18 Instrument air piping from terminal point

6.2.19 Silo unloading panel.

6.2.20 Electrical motors with local push button station

6.2.21 Motor control center for the drives

6.2.22 Incoming feeder & outgoing feeders with spare feeders.

6.2.23 Power and control cables between MCC and individual drives with erection hardware

6.2.24 Required sub-earthmat, earthmat for drives and equipment

6.2.25 Grouting and grouting materials with templates

6.2.26 Sand blasting, Two coats of epoxy primer and two coats of epoxy finish paint -120 Microns DFT

6.2.27 Special tools and tackles.

6.2.28 Start-up and Commissioning spares

6.2.29 Initial fill-up for lubricants as required

6.2.30 2 years operational spares list with price offer.

6.2.31 Necessary drawings and documents for the regular operation and maintenance of the complete system.

6.2.32 All other items required to make the system complete in all respects




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6.3 PROJECT MANAGEMENT / SERVICES

6.3.1 The Tenderer shall identify a separate and independent project management team headed by a Project Manager for the execution of this project.

6.3.2 The Tenderer shall provide effective management of the Contract, which shall be compatible with the Purchaser’s requirements as set out in this specification.

6.3.3 Obtaining approval from statutory bodies such as Chief Electrical Inspectorate to Government of India, Chief Controller of Explosives etc., as applicable.

6.3.4 Management Organisation

i) The Tenderer shall include an organisation chart illustrating how the management structure/lines of authority shall function during the Contract.

ii) The Tenderer shall submit the names, qualifications and experience of the proposed managerial and senior supervisory staff to be employed after award of Contract.

iii) The Tenderer shall constitute a separate commissioning team in consultation with Purchaser/Consultant before taking up of testing, commissioning and tying/connecting with other system, etc.

6.3.5 Engineering Services

i) The Tenderer shall render complete engineering services for the equipment and associated system covered in this specification, including detailed engineering, design submission and documentation as required for a good design and installation ensuring efficiency, operability, availability, maintainability and reliability of the plant.

ii) As part of document submission, the design basis reports shall be submitted for the bought out items by the Tenderer for approval by the Purchaser/Consultant. The approved design basis reports shall form the basis for procurement and engineering work.

iii) At any stage during the performance of the Contract, if the system warrants improvements in the Contracted plant and consequent modification in the equipment/system designs the Tenderer shall make the necessary design modifications and carry out the improvements in the plant with the approval of Purchaser/Consultant at no extra cost to the Purchaser.

iv) During the course of review of detailed engineering, it may be essential in Purchaser’s opinion to obtain data and information on similar equipment and plants engineered by the Tenderer. In case, Purchaser so desires the Tenderer shall submit such analogous data and information to the Purchaser.

v) The Tenderer shall interact with the Purchaser’s other agencies and the Consultant and exchange with them such technical information as are necessary to obtain the optimum and economical design and to avoid unnecessary duplication of efforts.

vi) The Tenderer shall furnish a comprehensive list of drawings and design documents, which shall be submitted by him after award of Contract indicating submission dates against each document. The list shall be subject to the approval of the Purchaser/ Consultant.




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vii) Any implementation delay because of incomplete inputs or delay in of the inputs by Tenderer in the required format for implementation in Purchaser’s DCS will be to Tenderer’s account.

viii) The documents shall be divided into two categories:

• For approval

• For information / reference only

ix) Documents submitted during bid stage, shall be revalidated or revised as required and submitted as certified document for approval/information of the Purchaser, after award of Contract. Such documents shall include but not limited to the following:

• Design basis reports

• Specification for major bought-out items

• Equipment data sheets and general arrangement drawings

• Materials for construction

• Layout drawings, foundation plan and civil load data

• Operation logic diagrams

• Typical control circuits

• Protection schemes

• Project schedule

• Quality assurance plan

• Compressor sizing calculation

6.3.6 Operating Manuals and Maintenance Instructions

i) The Tenderer shall submit to the Purchaser/Consultant, instruction manuals in English language, for all equipment covered under the Contract at least thirty (30) days before the first shipment of the respective equipment.

ii) The operating manuals and maintenance instructions shall be in sufficient detail to enable the Purchaser to operate, maintain, dismantle, re-assemble, adjust or replace all equipment and components during the lifetime of the plant. The manuals shall be specifically prepared for the contracted plant.

iii) The operating manuals and maintenance instructions in English language shall be submitted in the form of four (4) hard copies, as well as two (2) copies in Compact Disks (CDs). One (1) hard copy and one (1) copy in CD shall be furnished to Consultant. The instruction manuals shall be subject to approval of the Purchaser.

iv) If after the commissioning and the initial operation of the plant, the instruction manuals require modifications / additions, the same shall be incorporated by the Tenderer and the updated final version of the manuals shall be submitted to the Purchaser.

v) The Tenderer shall submit four (4) sets of spare parts catalogues.




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6.3.7 Plant Handbook and As-Built Documentation

i) Plant Handbook

The Tenderer shall submit to the Purchaser, a preliminary main plant handbook preferably in combination of A4 and A3 size sheets which shall contain all approved design basis and design calculations, the design and performance data of various plant, equipment and systems covering the scope of his supply including single line flow diagrams, during detail engineering stage. The final main plant handbook complete in all respects shall be submitted by the Tenderer three (3) months before start-up and commissioning activities. The main plant handbook shall be submitted in form of four (4) hard copies along with two (2) copies in CDs.

ii) “As-built” Documentation

The Tenderer shall provide and keep up to date “As built drawings of all structures constructed and all equipment and accessories and miscellaneous metal works erected or installed. These drawings shall show all changes and revisions from the original drawings and specifications. These drawings shall be kept in Tenderer’s field office but shall be made available at all times for review of the Purchaser/Consultant. Four (4) hard copies, along with two (2) copies in CDs in editable form, of all “As-Built” drawings shall be progressively handed over to the Purchaser after taking over of the plant by purchaser.

6.3.8 Sub-Contractors

i) The Tenderer shall submit to the Purchaser a list of all major items/works that Tender deems necessary to be sub-contracted, for approval. The Tenderer shall not change Sub-Contractor without prior approval of the Purchaser.

ii) A copy of all orders (which may be un-priced) placed on Sub-Contractors shall be submitted to Purchaser. The Purchaser’s Contract reference and station name shall be added to all inter works and sub-orders.

iii) The Tenderer shall ensure that their Sub-Contractors follow the requirement of the specification and have adequate control over all aspects covered by the specification.

6.3.9 Progress Reports

i) During the design, engineering and manufacturing, supply, erection, testing and commissioning stages the Tenderer shall submit to the Purchaser/Consultant reports and information on the progress of works by him and by the Sub-Contractors of all plant and materials required for the execution of the works. The progress of work shall be linked to the Project Schedule.

ii) The detailed procedure and requirements for progress reporting shall be agreed with the Purchaser during the early phase of the works, as part of regular Contract/project status reporting.

iii) The Tenderer shall also submit to the Purchaser monthly progress reports and any other reports as required by Purchaser/Lenders/Statutory authorities.




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6.3.10 Access for Progress Monitoring

The Purchaser or his nominated representatives shall be entitled to visit the premises where design and manufacturing of the plant is being carried out in order to monitor and verify progress with intimation to the Tenderer.

6.3.11 Miscellaneous

i) Packing & forwarding, transportation (ocean and inland), custom/port clearance, reconciliation with custom authorities, receiving and unloading at site, assessment of lost/damaged items in transit and arranging insurance claims and replacement of lost/damaged items in transit.

ii) Proper storage within the site and taking custody of all the materials till the plant is officially taken over by the Purchaser after complete erection and successful trial run and commissioning. Transportation of materials to their respective places of erection and erection of the complete plant & equipment as supplied under this specification.

iii) Deployment of all skilled and unskilled manpower, erection tools & tackles, construction machinery, as required for erection.

iv) Supply of all consumables, if any as necessary up to completion of trial operation.

v) Supply of necessary calibrated instruments for carrying out performance tests of plant and equipment.

vi) Quality assurance and Quality Control of all work executed at site.

vii) Conduct of shop and site tests as required.

viii) Installation, trial testing and commissioning of all equipment covered in the scope and performance testing of complete ash handling system and individual equipment to prove guarantees as agreed.

ix) All instruments and manpower necessary for carrying out performance testing of various ash handling system equipment and complete system to prove the performance guarantee shall be arranged by the Tenderer . The instruments supplied by the Tenderer during such performance testing can be taken back by him after providing the performance of the system.

x) Erection of MCC, motors, LCP, power cables and control cables in their scope including cable trays.

xi) Earthing connection up to earth pit risers.

xii) Inspection and Testing

xiii) Trial run and pre-commissioning test

xiv) Performance guarantee trials

xv) Any other services which are not specifically mentioned but are essential for the system completion shall be included in the scope of services.




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Sl.No. Description Facilities by

1 Complete Design and Engineering of all the equipment supplied (listed out under Scope of Supplies and within the Terminal points specified)

Tenderer

2 Furnishing of Foundation loading plan drawings for the equipment supplied within the terminal points specified Tenderer

3 Transportation from Tenderer ’s and sub-vendors works to power project site Tenderer

4 Unloading at site Tenderer

5 Open space for material storage, fabrication, assembly, labour accommodation with access road Purchaser

6 Safety equipment for site offices and labours Tenderer

7 First aid Purchaser

8 Ambulance Purchaser

9 Construction of site office, labour accommodation and store room Tenderer

10 Local conveyance, boarding and lodging for Tenderer representatives Tenderer

11 Overall security at site Purchaser

12 Security of Tenderer ’s equipment and other materials Tenderer

13 Comprehensive insurance Purchaser

14 Workmen compensation insurance for Tenderer ’s workmen Tenderer

15 Lighting facilities at site during erection and commissioning Tenderer

16 Erection drawings and documents, protocols (4 Sets in Hard copy and 2 Set in Editable Soft copy) Tenderer

17 O & M Manuals common for 2 units (5 Sets in Hard copy and 3 Set in Non-editable Soft copy) Tenderer

18 Final painting at site (2 coats) Tenderer

19 Telephone facilities Tenderer

20

Providing erection tools, tackles, cranes, hoists, derricks, slings, scaffolding, rigging tools, welding sets, instruments, appliances, consumables required for unloading, transporting, storing, erection, inspection, testing and commissioning to accomplish the work

Tenderer

21 O&M staff for ash handling system start-up, commissioning & operation Purchaser

22 First fill of Lubricants Tenderer

23 All Equipment base plates, lifting lugs, foundation bolts, sleeves, nuts, inserts, embedded plates Tenderer




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Sl.No. Description Facilities by

24 Supply of Grouting material and grouting work Tenderer

25 Supervision for grouting work Tenderer

26 Training / Familiarization of Purchaser’s representatives at site upto PG test Tenderer

27 Providing instrument for performance testing Tenderer

28 Performance test of Ash handling system Tenderer

29 Commissioning spares Tenderer

6.4 Work by Others

6.4.1 Purchaser will provide cabling from PCC to Tenderer’s MCC.

6.4.2 Cooling water and service water will be provided by the Purchaser at one point near A-row column of STG building (Common for both units).

6.4.3 Instrument air will be provided by the Purchaser at one point at one point near A-row column of STG building (Common for both units).

6.4.4 RCC Fly ash silo / Bed ash silo will be provided by Purchaser.

6.5 Terminal Point

Sl.No. Description Terminal points

1 Bed ash at Bed ash coolers

At the outlet of bed ash cooler pneumatically operated knife edge gate valve (+3.0 Mtrs. from FFL)

2 Fly ash at Mechanical dust collector

At the outlet of mechanical dust collector manual operated gate valve (+3.0 Mtrs. from FFL)

3 Fly ash at Air-preheater hoppers

At the outlet of Air-preheater manual operated gate valve (+3.0 Mtrs. from FFL)

4 Fly ash at Electrostatic precipitator hoppers

At the outlet of respective ESP hopper ash outlet manual operated gate valve (+3.0 Mtrs. from FFL)

5 Instrument air At one point near A-row column of STG building (Common for both units)

6 Cooling water supply / return

At one point near A-row column of STG building (Common for both units)

7 Service water supply At one point near A-row column of STG building (Common for both units)

8 Power cable At the incomer of MCC

9 Control and Signal cable Termination up to purchaser DCS

10 Electrical and Instrument earthing At the inlet of earth pit

11 UPS power supply At one point in control room




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6.6 Exclusions

6.6.1 Cooling water (supply and return) and instrument air piping beyond terminal point

6.6.2 Below ground earthing and earthing pit

6.6.3 Steam Generator

6.6.4 Steam turbo-generator

6.6.5 Coal, Limestone and Bed material handling systems.

6.6.6 Chimney

6.6.7 Air cooled condenser, condensate extraction pumps, steam duct from steam turbine exhaust flange to ACC, condensate piping from CEP to de-aerator.

6.6.8 Auxiliary Cooling Tower.

6.6.9 Laboratory for testing fuels, ambient air quality, and other effluents.

6.6.10 Battery and Battery charger

6.6.11 Station transformer, Generator Transformer and Unit Auxiliary Transformer

6.6.12 DCS system

6.6.13 HT Switchgear

6.6.14 Plant intercommunication and area illumination

6.6.15 Raw water makeup Storage.

6.6.16 DM water plant

6.6.17 Fire fighting and Fire detection system.

6.6.18 Plant air and Instrument air compressors

6.6.19 Air conditioning system.

6.6.20 Furniture and furnishings unless specifically included

6.6.21 Green belt development.

6.6.22 Effluent treatment plant and Plant sewage system.

6.6.23 RCC works, site developments, construction of roads, drainage etc.




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7.0 DETAILED TECHNICAL SPECIFICATION

7.1 Screw Air Compressors

7.1.1 2 nos. (1 working + 1 standby) 2 stage screw air compressor model with motor shall be mounted on common skid having following specifications for each compressor.

i) Discharge pressure : Vendor to specify

ii) Actual air delivery : Vendor to specify

iii) Electric system : 3 ph, 4 wire, 415 V, 50 Hz.

7.1.2 The above two compressors complete with motor & accessories will be mounted on a common skid (Base plate, rigid enough to withstand vibrations). Each compressor will have the following standard accessories.

i) Vee belt drive

ii) Slide rails for motor

iii) 1 no. Dry type suction filter

iv) 1 no. Non return valve

v) 1 no. Low oil level switch

vi) 1 no. Compressor Pulley

vii) 1 nos. air cooled intercooler

viii) 1 no. air cooled after cooler (standard, inbuilt with compressor)

ix) 1 no. pressure gauge - 1/4" BSP connections

x) 1 no. safety valves - screwed connection (IR Standard)

7.1.3 The scope also includes an independent Powder coated control panel for the skid and shall have the following specifications.

i) Non-compartmentalized, sheet metal enclosed IP 52 protection and in non-draw out execution.

ii) The busbars will be of aluminum, PVC sleeved and rated for the full incomer rating. The fault level of the switchboard will be 50kA (1S).

iii) Control voltage shall be 230/110V. A transformer 415-230/110V in the control panel shall be provided.

iv) Provision for common alarm.

v) Hour meter for each compressor.

7.1.4 The following electrical aspects shall be available on the compressor skid.

i) Only one compressor can run at a time.

ii) Switch fuse unit shall be provided on the control panel at the incomer power cable.

iii) Power fuses shall be provided in the control panel for every compressor motor.




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7.1.5 Input to the panel will be 415 V, 3 phase, 50 Hz.,4 wire. Control circuit will be of 230v AC to be derived from Tenderer.

7.1.6 Control & Indication

i) Indication Lamps for:-

• Supply ON

• Compressor 1 ON

• Compressor 2 ON

• Low oil level 1 TRIP

• Low oil level 2 TRIP

• Overload motor 1 TRIP

• Overload motor 2 TRIP

• Low pressure alarm

• Compressor 1 motor overload

• Compressor 2 motor overload

ii) elector switch for:-

• Common voltmeter

• Ammeter

• Compressor selection

• Auto-Hand-off

iii) Push buttons for:-

• Compressor start – 1

• Compressor start – 2

• Compressor stop – 1

• Compressor stop – 2

• Reset – 1

• Reset – 2

• Lamp test

iv) Voltmeter (common)

v) Ammeter – 1 & Ammeter – 2

vi) Hourmeter for compressor – 1 & Hourmeter for compressor – 2

vii) Hooter

7.1.7 The compressors shall be designed to deliver the nominal capacity at the required delivery pressure as specified in the design data & specified data sheet.




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7.1.8 The design shall be such as to ensure trouble free operation with least vibration and noise. In a screw air compressor with screw element giving an output of compressed air as specified.

7.1.9 Different parts of the compressor and accessories shall be arranged neatly in a compact manner. Due consideration shall be given for easy accessibility and maintenance of the compressors.

7.1.10 Pipes/tubes complete with valves and specialities, hangers and supports, etc. between the compressor and accessories shall be supplied by the Tenderer to form a complete unit.

7.1.11 Unless inconsistent with this specification, equipment from the standard range of manufacture of the Tenderer shall be preferred.

7.1.12 Compressor components shall be interchangeable, in general.

7.2 Valves:

7.2.1 Suction and discharge valves shall be suitable for quick opening and closing in conformity with the rotative speed of the screw element. Valves shall have effective areas permitting low air velocity along with cushioning arrangement to minimise shock. Valve discs shall be of stainless steel.

7.2.2 Valves shall be arranged to facilitate easy approach for checking from outside. They shall be suitable for efficient, noiseless operation with long life.

7.2.3 Valves shall preferably be of multiport plate type. The valve design shall be such that the valve can be easily removed for checking and maintenance.

7.2.4 Suction valves shall be suitable for alternate loading and unloading.

7.3 Lubrication:

7.3.1 A screw driven rotary compressor shall draw lubricating oil from the oil tank through a strainer and shall provide forced lubrication to main parts.

7.3.2 All instrumentation and accessories in the lubrication circuit, including discharge pressure gauge, pressure switch, relief valve etc., shall be included in the scope of supply. Suitable time delay relay or equivalent device to bypass low oil pressure switch during start-up shall be provided.

7.4 Cooling: Compressed air Cooling may be by air or water. Tenderer to specify the type of cooling considered.

7.5 Flexible Coupling: Flexible coupling is used for reduction of starting torque.

7.6 Drive Unit: Compressors shall be driven by squirrel cage induction motors.

7.7 Guard: Necessary guard for all exposed moving parts shall be provided.

7.8 Air receiver:




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7.8.1 The air receivers shall be vertical self-supporting cylindrical vessel with supporting stand. It shall be welded construction with minimum no. of joints. Receivers shall be provided with minimum two inspection windows. Receivers shall be provided with relief valves of suitable set capacity. The receivers shall be complete with auto drain connection with trap station consisting of trap, strainer, isolation and bypass valve. Receivers shall be provided with required no of nozzles.

7.9 Surge Hoppers:

7.9.1 The surge hoppers shall be fabricated from not less than 10 mm thick M.S. plates, with adequate stiffeners welded on. The hopper shall be supported on the steel supports. The hoppers shall be of welded construction and shall be provided with necessary cleats for attachment to supports. Hopper compartments shall be designed with a valley angle of not less than 65° to the horizontal. The required number of flanged openings shall be provided for attaching knife-edge gates. The design of the hopper shall be such that the problem of formation of arch is eliminated. Fluidizing pad fixing arrangement shall be provided wherever required. The hoppers shall be provided with RF type level probes.

7.9.2 The Hopper shall be lined with 5 mm thick wear resistant liner like Manganese steel.

7.9.3 The grids of the hoppers shall have square openings with adequately designed flats and rods supported on steel beams.

7.9.4 Jacketed cooling provision for water circulation shall be given to ash collection surge hoppers of bed ash hoppers, mechanical dust collector, air pre-heater hoppers and ESP hoppers as necessary.

7.9.5 A sampling point shall be provided on the surge hoppers.

7.10 Ash Transportation Vessels (Blow tank):

7.10.1 The blow tanks shall be provided beneath each of the ash collection Surge hoppers as indicated in the flow diagram.

7.10.2 The blow tanks shall be conical bottomed vessels with necessary valves and fittings.

7.10.3 The blow tank configuration shall be of bottom discharge type.

7.10.4 The blow tanks shall be designed for fully automatic operation. The blow tanks shall operate in time base/level base sequence individually/simultaneously and shall remove the ash from the respective hoppers and convey to the respective silos.

7.10.5 The blow tanks shall be designed for maximum operating pressure and for a capacity, which avoid flooding of the conveying line.

7.10.6 Each blow tank shall consist of a material feed valve, knife gate valve for isolation, air supply valve, discharge valve, vent valve/equalizer valve, instruments like RF type level switch, pressure switch etc. and other controls to meet the system operation requirement as applicable.




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7.10.7 The system shall have low-pressure signal as the indication from the end of conveying cycle or low level signal in the tank itself which will have the discharge valve located on to the flange of blow tank closed.

7.10.8 The system shall be able to operate either on timer mode/level mode or manual mode.

7.10.9 Blow tanks design shall have suitable cone angle to necessitate smooth flow of materials into the pipe. It shall avoid rat-holing and bridging problems. Surfaces which are subjected to erosion shall have sufficient hardness and extra thickness to ensure long life.

7.10.10 Internal discharge aids if required shall be provided.

7.10.11 The required supporting structures, adequate access for operation and maintenance shall be provided.

7.10.12 Solids flow control shall be obtained by fitting a suitably designed swing valve/dome valve to the blow tank.

7.10.13 At the discharge end of the blow tank pneumatically operated knife gate valve shall be provided to discharge ash in the conveying pipe.

7.11 Conveying Pipelines:

7.11.1 The pipes shall be supplied in lengths of 6 meters maximum and shall be provided with flanged joints. The flanges shall be welded on to the pipe from inside as well as outside.

7.11.2 Piping shall be laid as far as possible in a straight line from the source of supply to the point of delivery. Inclined piping shall be avoided, number of bends in the piping shall be kept as minimum as possible.

7.11.3 Integral wear back should be provided for the pipe fittings.

7.11.4 Necessary compressed air lines for conveying and boosting the flow should be provided. The same should accompany the main conveying line. The tapping should be taken from airline to feed the conveying line through boosters/density stabilizers.

7.11.5 All ductwork for venting silos including their connection to dust filters shall be considered as exhaust piping.

7.11.6 Adequate supports shall be provided to resist the sagging of pipes. Load calculation shall be carried out on the basis that the lines may be plugged with material and supports shall be provided as per standard practice.

7.11.7 Provision for blowout of line shall be provided in case of plugging of pipeline. High-pressure air blow connection shall be installed at several locations in a pipeline. These connections shall have a pipe union and a check valve located close to the conveying line.

7.11.8 Spray water piping shall be provided from the terminal point to the ash conditioner with all required valves and fittings.




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7.11.9 Ash conveying pipes shall be MS Black ERW heavy duty pipes as per IS: 1239 upto 6’’ and above 6’’ as per IS 3589 heavy duty pipes. Pipe shall be in 7mm (thickness) and 6 M lengths (maximum) with flanged joints at both ends. The flanges shall be welded to the pipe from inside as well as outside. Normal ash conveying velocity shall be 3 – 5 m/s.

7.11.10 All fittings such as bends, laterals etc. shall be of alloy cast BASALT / Ni-Hard bends with 450 - 550 BHN construction having integral/renewable type wear backs. The minimum radius of 45°/90° bends for ash conveying shall be 10 times the nominal diameter of the pipe. The pipe shall have plain end and joining of pipe shall be achieved by sleeve type coupling. The coupling shall have steel sleeve, steel flanges, gasket, tightening bolt & nut. The coupling shall be capable of 3° deflection & sufficient gap to be provided to take care of expansion in piping.

7.11.11 Gasket shall be of non-asbestos components for fly ash transport. The coupling shall permit easy rotation of pipe if required.

7.12 Valves – Extraction/Isolation valves/Knife gate valve:

7.12.1 Extraction valves shall be used for feeding fine, dry fly ash from the collecting hopper into the blow tank. This valve shall be fitted to the bottom of fly-ash collecting hoppers by a flanged connection. The discharge side of the valve shall be connected to a Dome/Swing valve/expansion joint as applicable.

7.12.2 All components of the valve subjected to wear must be made of alloy steel having hardness not less than 500 BHN. The valve must be provided with a plugged rodding port for cleaning whenever necessary.

7.12.3 The branch isolation valves in fly ash lines shall be of rugged construction. The parts subjected to wear and abrasive action of fly ash shall be made of alloy steel of hardness not less than 500 BHN. The valve shall be of pneumatically operated by a solenoid valve.

7.12.4 Manually operated or pneumatically actuated knife gate valves shall be provided according to the location requirement.

7.12.5 The inner body and knife plate of the knife gate valve shall be of stainless steel. The valve shall provide gas tight shut off.

7.12.6 Gaskets shall be of Teflon impregnated asbestos with molded silicone rubber, which provides total sealing. The knife gates shall provide leak-proof tight shut-off during operation.

7.13 Expansion joints:

7.13.1 The construction of the joint shall be as per the EJMA standards (Expansion Joint Manufacturers Association Standards). The expansion joints shall be complete with internal liner, SS bellows, external cover tie-rods and reinforcement rings.

7.13.2 The expansion joints are located below the ash collection hoppers/ash cooler in the ash flow lines. The material of internal liner and bellows shall withstand the application temperature pressure and axial and lateral movements. The flanges of the expansion joint shall be of carbon steel and drilling shall conform to ANSI B16.5 Class 150# or equivalent rating. The expansion joints shall not allow any leakage at the maximum operating pressure.




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7.13.3 Limit rod assemblies shall be provided to prevent excessive expansion. This shall consist of minimum two (2) stretcher bolts provided on either side of the joints and securely bolted to stretcher bolt plates.

7.14 Vent filters (Fabric filter units):

7.14.1 Reverse pulse jet type vent filter shall be provided on the ash silos for discharging air from the conveying medium. It shall be of outdoor installation.

7.14.2 The dust shall be collected in a fabric filter designed to handle the dust load.

7.14.3 The selected fabric shall have suitable dust releasing characteristics for the fly ash handled.

7.14.4 It shall be designed for a constant pressure drop across fabric for the required airflow rate and dust loading.

7.14.5 Fabric filter shall have sufficient porosity to permit satisfactory airflow, mechanical strength, cleaning, resistance to heat, resist chemical action if any and dimensional stability.

7.14.6 The fabric filter shall be of felt type and it shall be selected to suit the required temperature.

7.14.7 Filter unit shall be provided with adequate access for servicing.

7.14.8 The filter unit shall be located away from the entry point of the material into the silo. Additional section of casing between the filter unit and hopper shall be provided.

7.14.9 Differential pressure switch shall be provided across the filter unit.

7.14.10 The design capacity of the dust filter and fan shall be to meet the requirement of dust generation due to delivery of ash from all the lines simultaneously into the same silo. Maximum filtration velocity shall be 1.5 m/min. Emission level limited to the 50 mg/n-m3

7.15 Ash Storage Silo:

7.15.1 One no. of RCC silo bed ash silo of 110 m³, One no. of RCC intermediate fly ash silo of capacity 250 m³ and One no. of Main fly ash silo of capacity 2550 m³ shall be provided for each boiler unit by Purchaser for fly ash collection.

7.15.2 Storage silo should be fitted with vent filters sized to meet emission standards. The filters should be cleaned automatically on load by pulse-jet system. Instrumentation should be provided to warn when a filter is defective.

7.15.3 The storage silo shall be provided with two (2) outlets at the bottom. One outlet shall be fitted with Ash conditioner for loading the ash into open trucks. Second outlet at present shall be blanked connection and shall be provided with isolation valve. The storage silo shall be fitted with bag filters and fans for cleaning the vent air before discharging to the atmosphere. The storage silo shall be provided with a dedicated aeration system.

7.15.4 Suitable dust collection and dust suppression unit, complete with all accessories (rotary unloader with water spraying arrangement) shall be provided.




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7.15.5 All piping, fittings, etc required for the system shall be provided.

7.15.6 Electricals, including MCC, cables, push button stations, protection & interlocks, Control panel shall be provided

7.16 Rotary feeders:

7.16.1 Rotary feeder shall be provided for discharge of ash from silo as per the process flow diagram for ash handling system drawing no: 3-3614-100-043.

7.16.2 The design criteria shall take into account the conveying material characteristics and system requirements in the selection of rotary feeders.

7.16.3 The feeders shall be of drop through configuration. The rotary feeder shall ensure a regulated flow.

7.16.4 Each rotary feeder shall be capable of handling ash at the required rate. The parts coming in contact with ash and subject to wear such as spool piece, rotor, housing etc. shall be made of hard wear resistance cast iron to suit ash-handling application.

7.16.5 The complete assembly of the feeder shall be so designed as to facilitate easy replacement in the shortest possible time. All parts of the feeder shall be interchangeable. All wear prone parts shall be easily replaceable.

7.16.6 The bearings of the rotor shall be of self-aligning type grease lubricated and dust tight.

7.16.7 The stuffing boxes shall be equipped with packing rings and lantern rings with connection of an external air supply on the end covers, in order to ensure a purging air flow into the feeder so as to prevent dust blow out.

7.16.8 The feeder shall be driven by electric motor, helical gear reduction, chain/sprockets etc. mounted on the side of the housing. Necessary proximity type speed sensor shall be provided at the non drive end of the feeder shaft.

7.16.9 Doors or plates shall be provided to have access to the feeder interior for inspection, checking clearance for removal of jamming material and replacing seal strips.

7.16.10 Maintenance requirements and period of maintenance required to be indicated by the Contractor.

7.17 Ash Conditioner

7.17.1 The Ash conditioners are located below the bed ash silo, intermediate fly ash silo and main fly ash silos and shall be suitable for the continuous operation of 24 hours per day.

7.17.2 Capacity of ash conditioners shall be 30 Tons, 50 Tons & 50 Tons for bed ash silo, intermediate silo and main fly ash silos respectively.

7.17.3 The equipment should be capable of controlled mixing of ash with water.




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7.17.4 The speed and length of the conditioner shall be decided by the Contractor taking into consideration the filling factor, mixing time and limitation of peripheral speed of the paddle etc.

7.17.5 The MOC of trough, paddle should be abrasion resistant and of adequate thickness.

7.17.6 The equipment shall be suitably supported at appropriate height so as to discharge the material into the trucks.

7.17.7 The Ash conditioner shall be provided with top covers for inspection and removal of jammed material.

7.17.8 Necessary gearing arrangement for twin screw drive transmission shall be provided.

7.17.9 Adequate number of spray nozzles for water spray shall be provided and supported at suitable locations. The water spray nozzles shall be stainless steel construction and easily accessible through removable top cover. The spray nozzle shall be non-clog design ensuring uniform spread of water.

7.17.10 The ash conditioner shall be driven by electric motor, helical gear reduction, etc. Necessary proximity type speed sensor shall be provided at the non drive end of the feeder shaft.

7.17.11 Paddles MOC shall be of Hardox / Buiroid material, replaceable type and shall have a minimum hardness of 400 BHN.

7.17.12 The Ash conditioner shall be supported from the silo supporting structure.

7.17.13 Drain connection shall be provided for draining accumulated water in the trough.

7.17.14 The design capacity and power calculations and features shall be generally as per CEMA 350 for screw conveyors.

7.18 Fabrication:

7.18.1 All structural steel shall be of tested quality and shall conform to IS: 2062. High tensile steel. When supplied, shall conform to IS: 961. All bolts and nuts shall confirm to IS: 1363 and IS: 1364 and unless shown or specified otherwise shall be hexagonal. All nuts shall fit tight. Mechanical properties shall conform to IS: 1367. Mild steel and high tensile steel electrodes shall conform to IS: 814.

7.18.2 All workmanship shall be equal to the best practice in modern structural shops. Greatest accuracy shall be observed in the manufacture of every part of the work and all similar parts shall be strictly interchangeable.

7.18.3 Shearing or flame cutting may be used at the Tenderer ’s option provided that the resulting edge shall be reasonably clean and straight. Sheared members shall be free from distortion at sheared edges. Unless clean, square and true to shape, all flame cut edges shall be planed.

7.18.4 The welding and the welded work shall conform to IS: 816 unless otherwise specified. The permissible stresses for welding shall be taken as 75 per cent of those specified in IS: 816 where welds are not tested either by radiographic or ultrasonic methods. Random NDT checks




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shall be carried out for the critical weld joints and structures, girders, heavy columns etc. As much work as possible shall be welded in shops and the layout and sequence of the operations shall be so arranged as to eliminate distortion and shrinkage stresses.

7.18.5 The field assembling of the component parts of a structure shall involve the use of method of appliances not likely to produce injury by twisting, ending or otherwise deforming the metal. No member slightly bent or twisted shall be put in place until the defects are corrected and members seriously damaged in handling shall be rejected.

7.18.6 The Tenderer shall assume full responsibility for the correct setting out of all steel work and erecting it correctly as per alignment and levels shown on the drawings and plumbing of vertical members. Datum points will be fixed by the site incharge. Notwithstanding any assistance rendered to the Tenderer by the site incharge, if at any time during the progress of the work any error should appear, on being required to do so, the Tenderer at his own cost shall remove and amend the work to satisfaction of the site incharge.

7.18.7 Where the steel has been delivered painted, the paint shall be removed before field welding, for a distance of at least 50 mm on either side of the joints.

7.18.8 Correction of minor misfits, a reasonable amount of reaming and cutting of excess-stock from rivets will be considered a legitimate part of the erection.

7.18.9 Any error in shop work which prevents the proper assembling and fitting up of parts by the moderate use of drift pins or a moderate use of reaming and slight chipping or cutting shall immediately be reported to the site incharge and his approval of the method of correction obtained.

7.18.10 Bolts shall be inserted in such a way so that they may remain in position under gravity even before fixing the nut. Bolted parts shall fit solidly together when assembled and shall not be separated by gaskets or any other interposed compressible materials. When assembled, all joint surfaces, including those adjacent to the washers, shall be free of scales except tight mill scales. They shall be free of dirt, loose scales, burns and other defects that would prevent solid seating of the parts. Contact surfaces within friction type joints shall be free of oil, paint, lacquer, or galvanizing.

7.18.11 All high tensile bolts shall be tightened by torque wrench tightening method.

7.19 Electric Motor:

7.19.1 The driver shall be an AC electric motor of squirrel cage induction type conforming to IEC 60034 – 1 (1983). The motor above 22.5 kW (30 HP) shall be provided with space heaters. Motor shall have 15% margin over input power requirement of the driven equipment. The motor shall be able to start the driven equipment with rated load capacity and accelerate up to the rated speed satisfactorily under most arduous condition with 80% voltage at the terminal. The motor characteristics shall match with the characteristics of the driven equipment for the adequate starting, accelerating, pull up, break down and full load torque requirement of the driven system. The maximum inrush current, starting current and developed pull out torque at 110% of rated voltage shall not endanger the motor or the driven system. The motor shall operate satisfactorily at full load for at least 5 minutes with 75% rated voltage at terminal. The




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motor shall be capable to withstand sudden application of 150% of rated voltage for phase difference between incoming voltage and motor residual voltage.

7.19.2 The voltage variation for the motor shall be ± 10%, the frequency variation for the motor shall be ± 5% and the combined voltage and frequency variation shall be of ± 10%. Motor shall be of Class “F” insulation with temperature rise limited to limit of class “B” with ambient of 45 Deg. C. The temperature for design shall be considered as 50 deg C. Outdoor motor shall have IP 55 enclosure with TEFC cooling and weather protected. Motor shall be provided with cable box for accommodating higher size cables. Separate terminal box shall be provided with Cable lugs and glands for space heater. Split type terminal box with removable cover suitable for being turned for 360° at steps of 90° shall be provided.

7.19.3 MCC for ash handling system shall be located in the ESP control room shown in the Plot plan drawing no. 1-3614-100-042. Tenderer shall route all power cables and control cables from the MCC to the individual drives. The necessary hard wares like Cable glands and lugs that are required for termination shall be supplied by the Tenderer . Tenderer to indicate cable routing inside his battery limit for the cables. It will be Tenderer ’s responsibility to ensure proper interface with the purchaser’s incoming point and to avoid fouling with the pipes and other equipment inside the battery limit.

7.19.4 Tenderer shall provide two terminals for earthing of all rotating and static equipment. Grounding shall be two nos. at motor body and one no. at terminal box.

7.20 Local Push button Station

7.20.1 For all motor drives, push-button station type local control station shall be supplied.

7.20.2 Local Push button Station shall be following type:

Local PBS shall have a canopy which covers top and both sides with sheet metal material painted with the same paint used for the LCS. Local PBS shall be of sheet steel, weather proof, and gasket construction with IP-55. It shall have two push buttons, Viz., lockable stop push button and start push-button. The stop push-button shall be of red color, mushroom headed with ‘press to lock’ and lockable type feature. The start push-button shall be of green color and shrouded spring return type. Other technical details of local control station shall be as follows:

Enclosure: Enclosure of die cast �evelling or cold rolled sheet of thickness not less than 2.5 mm. Degree of protection shall be IP-55 with canopy (as per IS: 13947 part I, 1993).

Utilization Category : AC 11

Insulation Voltage : 660 V

Contact Combination : 2 NO + 2 NC

i) A detachable gland plate at bottom or a suitable knockout shall be provided for cable entry from bottom. The LCS shall have industrial type heavy-duty terminal block and the terminals shall be suitable for termination 2.5 mm² copper conductors.

ii) All pushbuttons stations shall have a fiber material name plate with following data engraved on it. - Motor KW, number, and name/application of drive




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7.21 Sequence and Interlock Control System:

7.21.1 DCS will be supplied by the Purchaser. Tenderer s to note that all the field instruments / MCC / Local control panel (for silo ash unloading) shall be interfaced with purchaser’s DCS system.

7.22 Specification for Control cables:

7.22.1 Type-1 Interconnecting cables between individual instruments to junction boxes.

7.22.2 Single twisted pair cables having 1.0 sq mm stranded annealed tinned copper conductor insulated with PVC, inner sheath of PVC, levelling tape screened with tinned copper drain wire, levelling with galvanised round steel wire and overall PVC sheathed of 1100 V insulation grade.

Type-2 Interconnecting cables between junction boxes to control panel.

7.22.3 Multi-pair twisted pair cables with individually screened and overall screened, 1.0 sq mm stranded annealed, tinned, copper conductor, insulated with PVC, inner sheath of PVC, levelling tape screened with tinned copper drain wire, levelling with galvanised round steel wire and overall PVC sheathed of 1100 V insulation grade.

7.22.4 Type-3 for connecting the individual field switches to the field junction boxes and from junction boxes to control panel.

7.22.5 Multi-core, heavy duty, 1.0sq mm flexible stranded annealed, tinned, copper conductor, insulated with PVC, inner sheath of PVC, armoured with galvanised round steel wire and overall PVC sheathed and overall shielding shall be considered. The control cables shall generally be 1100 V grade. Core number marking shall be provided for each core at every 500 mm interval.

7.22.6 Type- 4 For interconnecting the individual field RTD to the field junction boxes, field junction boxes to marshalling panel at control room, Single and Multi Triad cable shall be used.

7.22.7 Type-5 Interconnecting the field thermocouple to field transmitter. Twisted single and multi-pair shielded thermocouple compensating cable, 0.5 sq. mm stranded copper conductor, insulated with PVC Galvanized steel wire levelling and overall PVC sheathed of 1.5 KV grade shall be considered.

7.22.8 The Tenderer shall estimate and indicate in the offer the complete requirement of the cables. The cabling accessories such as cable trays, cable glands, cable tray inserts in the concrete, clamps etc., shall be included in the scope.

7.22.9 The Tenderer shall prepare the cable schedule and termination details for the control cable termination required for the interlock purposes.

7.23 General Construction:

7.23.1 The cables shall be brand new and in good condition and shall be suitable for laying in trays, trenches, ducts, conduits and underground buried installation with uncontrolled backfill and possibility of flooding by water. The terminating and straight thro’ joint kits for the cables shall




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be suitable for the type of cables offered and for storage without deterioration up to 50°C ambient temperature.

7.24 Cables:

7.24.1 Requirement and methods of tests for Armour material and uniformity of galvanization shall be as per IS: 3975 and IS: 2633. The outer sheath for the cables shall be applied by extrusion and shall be PVC compound conforming to the requirements of type ST1. To protect the cables against rodent and termite attack, suitable chemicals shall be added into the PVC compound of the outer sheath.

7.25 Testing and Inspection:

7.25.1 The cables shall be tested and examined at the manufacturer’s works. All the materials employed in the manufacture of the cable shall be subjected, both before and after manufacturer of the cable, to examination, testing and approval by purchaser / consultant. Manufacturer shall furnish all necessary information concerning the supply to purchaser’s inspectors. The inspector shall have free access to the manufacturer’s works for the purpose of inspecting the process of manufacture in all its stages and he will have the power to reject any wire or other material which appears to him to be of unsuitable description or of unsatisfactory quality.

7.25.2 Type tests shall have to be carried out to prove the general qualities and design of a given type of jointing system. The type test shall include the following tests conforming to the latest BIS specifications (or equivalent). The type test certificates shall be submitted along with the offer.

i) A.C. voltage withstand dry test for 1 minute.

ii) Partial discharge test – Discharge magnitude shall be less than 20%.

iii) Partial discharge test – Discharge magnitude shall be less than 20%.

iv) Thermal short circuit test at 250 °C for 1 second.

v) Impulse voltage withstand test with 10 impulses of each polarity.

vi) D.C. voltage withstand test for 30 minutes.

vii) Humidity test.

viii) Dynamic short circuit test.

ix) Impact test.

x) Cable Trays:

• Method : Ladder type cable trays for electrical / hot dip galvanized perforated cable trays with thickness of 2.00 mm • Size : Based on the requirements • Construction : Fabricated out of 50 x 50 x 6 MS Galvanized angles as longitudinal

Members and 25 x 3 flats as cross Members with single and double cross Member placed alternatively at a Distance of 300 mm. Power & Control will be run in same tray with Sectional barriers.




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7.26 MCC

7.26.1 Motor Control Centers (MCCs) shall be 415 V, indoor, totally enclosed, dead front, free standing units. All phase buses shall be isolated Copper and shall be silver or tin plated at all connection points or joints. Aluminium ground bus is required and shall extend the full length of the MCC. Incoming feeders to MCCs connect directly to the MCC bus. Loads are fed from MCCs through a contactor. In addition, each combination starter shall be specified with a 3 phase thermal over load relay. One No. spare starter modules for each capacity shall be provided in the MCC. The control supply voltage shall be taken from control transformer of rating 415/220 V AC.

7.26.2 Design of the MCC and selections / sizing of power cable and control cable are in the scope of the Tenderer. The MCC shall be supplied by the Tenderer. The erection materials required for laying the cables and erection of MCC are also in Tenderer’s scope.

7.26.3 Detailed Specification for Motor Control Centre

i) Introduction

This specification is for design, manufacture and supply of Ash Handling MCC. The Panels shall be built in compliance with the Statutory requirements of Electrical Inspectorate.

ii) General

The 415 V Switch board shall be dust, damp and vermin proof construction sheet steel clad totally enclosed, floor mounted, self standing type with single front compartmentalized cubicle design with single TPN bus bar arrangement with front access only, and with cable entry at the bottom and cable outlet from the bottom of the switch board. The Switchboards shall be suitable for the following operating system. Rated Voltage : 415V, 3Ph, 4Wire Rated Frequency : 50Hz Fault Level : 50 kA FOR 1 SEC. Enclosure : IP54 The design, manufacture and testing of the MCC shall comply with the latest issue of the following standards : IS 5578 - Guide for making of insulated conductors IS 11353 - Guide for uniform system of marking and identification of Conductors and apparatus terminals IS 8623 - Low Voltage Control gear and Switchyard assemblies. IS 4237 - General requirements for switchgear and control gear for voltage not exceeding 1000 V AC or 1200 V DC.




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IS 4064 - Airbreak switches, air break switch dis-connections and fuse combination units for voltages not exceeding 1000V AC or 1200V DC. IS 2959 - Specification for AC contactors of voltages not exceeding 1000 V IS 8544 - Motor starters for voltages not exceeding 1000 V IS 9224 - Low voltage fuses IS 2705 - Specification for current transformer IS 1248 - Specification for direct acting electrical indicating instruments IS 10118 - Code of practice for selection, installation and maintenance of Switchgear and control gear not exceeding 1000 V. IS 2147 - Degrees of protection provided by enclosures for low voltage Switch gear and control gear. IS 1897 - Copper strips for electrical purposes.

iii) Construction

The Switch boards shall consist of metal enclosed medium voltage Switch Fuse Unit compartments, bus work & miscellaneous equipments for this application. The complete board shall be of coordinated design so that shipping groups of the board are easily assembled together at site into a continuous lineup. Necessary standard connecting material shall be supplied. Name plates of elegant, durable design and quality shall be fixed to the individual compartments-feeder modules, bus risers, busbars, cable alleys etc. The board covered by this enquiry shall be designed, manufactured and tested in accordance with the latest revisions of the related applicable Standards listed elsewhere in this document. The framework of the board shall be constructed of preformed steel channels, angles and side sheets bolted together and suitably reinforced to form a rigid, self supporting, compact assembly to function properly under both normal and short circuit conditions.

The bus compartments shall comprise of ONE main horizontal TPN bus unit with vertical risers for connection to the individual modules. The panel shall have cable entries and outgoing as specified. The board shall be of totally metal enclosed ventilated multiple unit construction. End units shall include provisions for future main bus extensions and installation of additional units on either side with the framework suitably drilled to receive the additional modules and the busbars fitted with fishplates and associated hardware enabling future extension without involving major fabrication works on the panel in service.




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The front of the board shall comprise of individually enclosed fuse switch modules, general switch fuse modules, starter modules. Metallic barriers shall be provided between vertical sections and also between adjacent modules to ensure prevention of accidental contact with live parts during routine inspection/maintenance of functional units or cable terminations of one or more functional units when working on those of adjacent units. These barriers shall have insulating inserts as necessary for taking the interconnections etc. Doors and covers shall be of sheet steel of thickness not less than 1.6 mm cold rolled and the edges shall be reinforced against distortion by rolling/bending/or by addition of welded reinforcement members. The doors shall have concealed type of hinges. Cut outs shall be true in shape and free from sharp edges. The panel shall be provided with a metal sill frame made out of CRCA steel channel section of size 100 x 50 mm. Dust excluding gaskets of neoprene shall be used on all doors to ensure dust tightness of the interior while the board is in service. The board shall have uniform depth throughout. The hardware shall be cadmium plated & passivated; these shall be of the captive type to obviate loss of these bolts / screws etc., when the doors/covers are opened for servicing / inspection. Cold Rolled Sheet Steel of 2.5 mm. thickness shall be used for all members except for doors, covers and partitions where it may be of 1.6 mm. The switchboard shall be of the extensible type for extending on both sides. All components including the busbars shall be accessible and capable of being removed from front. The cable alleys shall also be at the front of the board. It is to be noted that the panel is proposed to be placed without any rear clearance. All the doors for the feeder modules in the front shall have individual sheet steel hinged doors with concealed hinges; these doors shall be capable of being physically lifted off the main base shell and fixed back in position while the panel is in service without necessitating removal of any screws or welding etc and with the adjacent modules in service with their doors closed. The bus bar chamber shall have screwed covers at the front, on the sides and for the top. The covers for the cable chambers and other compartments shall have covers screwed on with captive screws so that these do not fall off when the panel is in use while the operating / maintenance personnel have occasion to open & replace these covers. Removable undrilled gland plates of 10G shall be provided at the bottom of the switchboard with the holes to receive these suitably drilled on the framework and suitably tapped to enable removal of these plates and making holes in these at site for




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the cable glands of the feeders. Cable clamping arrangements shall be provided in the cable alley.

The switchboard shall have uniform height and uniform depth throughout its length. The height of the operating handle for the feeder modules, the resetting devices for the motor starters, indicating lamps, instrument fuses etc in the topmost tier which may need adjustment/replacement shall all be not more than 1950 mm from the finished operating level on the floor so that these are easily accessible for the operating / maintenance personnel without having to take recourse to ladders/steps etc. The minimum operating height of the switch handles shall not be less than 400 mm from the finished floor level including the safety rubber mat. All live parts shall be suitably shrouded with non deteriorating Insulating barriers so as to prevent any accidental contact with these by the operating / maintenance personnel while the panel is in service and the modules are opened for inspection/servicing etc.

iv) Busbars

The busbars shall be of Aluminium metal. The busbar joints shall be tinned before assembly. The design current density shall be 1.0 A/mm². The busbars shall be of uniform cross section along its entire length. No tapering of the busbar cross section is allowed. The bare busbars and risers shall after assembly of all main bus, risers, interconnections etc., receive Heat Shrinkable PVC sleeves to provide a permanent high dielectric non aging non-inflammable and non tracking protection impervious to water, tropical conditions & fungi. The joints in the busbars shall be of the bolted type and it shall be ensured that the following precautions are observed: The contact pressure must be ample and this shall be maintained during the time the panel is in service. • The surfaces of the conductors must be clean. • With flat conductors, the overlap should be equal to or greater than the width of the

bars or ten times the bar thickness whichever is greater. • The joints shall be treated by the application of joint compound to render the joint

moisture-proof. The efficiency of the joints shall be preserved by smearing the surfaces with oxide inhibiting grease just prior to making the joint. The switchboard shall be provided with suitably designed busbars for the 3 phases and neutral. The bus bar arrangements shall generally conform to IS: 5578 &IS11353. The Busbars fed by the incomer shall run continuously throughout the length of the switchboard.




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The power busbars shall have a short circuit withstand capacity of 50 kA rms for 1 sec. and a dynamic withstand capacity of 105 kA peak. The busbars shall be phase identified by colour, at intervals. Colour code shall be RED, YELLOW and BLUE for phase buses and BLACK for the neutral. Busbars shall be rated for 40 °C temperature rise over an ambient of 45 °C as measured by thermometer. The Cross section of the busbars shall be uniform throughout. Busbars shall be supported on tough, nonhygroscopic, resin bonded self extinguishing fire retardant insulators with ribbed construction to prevent tracking due to dust accumulation and to have larger creepage paths type SMC /DMC. Busbars and supports shall withstand the maximum stresses that are likely to be induced by the short circuit currents specified. The clearance between the individual bare phase power busbars and between the phase and earth busbars in air shall be not less than 25 mm and 15.8 mm respectively. All busbar joints shall be of the bolted type. Spring washers shall be used for joints to prevent loosening of the nuts and over heating. Lock nuts shall be incorporated for the bolts besides the main nuts. The bolts & nuts used in the current carrying paths shall all be of steel cadmium plated and the hardware shall have adequate cover of the �evelli-tive cadmium coating to obviate corrosion while the board is in service. The busbar chambers at the top / bottom shall be totally segregated from the rest of compartments and rendered totally inaccessible under normal circumstances. No equipment / Instrument shall be mounted on the busbar chamber.

v) Insulators

Track resistant Polyester Fiber-glass Reinforced Laminates with high impact strength & with low moisture absorption and possessing high flame retardant & long life even at high temperature shall be used throughout in the busbar systems including the vertical risers. The design of the insulation system shall be such as to provide high creepage allowances and resist dust build up. All accessible live points shall be shrouded with 3mm Hylam sheet.

vi) Earth Bus

An earth bus of ALUMINIUM shall be provided extending through all units and securely bolted to the structure with provision in each unit for mounting of earth cable lug. This shall be of the equivalent cross section as that of the NEUTRAL main bars.

vii) General Purpose Switch Fuse Modules

The switch modules shall have doors made out of 16G steel or heavier with all edges flanged 5/8 in. deep minimum. Doors shall be mounted on adjustable and removable pin type concealed hinges and so arranged that unit doors may be removed without disturbing the unit doors above or below. The switches shall be rated for AC 23 duty. Each feeder control module shall comprise of 1 switch each with 3 poles and neutral link and a set of 3 HRC fuse links for the three




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phases on the load side for protection and one neutral link capable of being disconnected with ease for testing purposes. The switches shall be of the double break load break fault make type with the fixed contacts completely enclosed within insulating shrouds. An interlock shall ensure that the switch must be open before the door can be opened and a defeat interlock shall be provided for maintenance purposes. The switch operating handles shall be capable of being padlocked in the `OFF’ position. For the purpose of standardization, similar components in the switchboard shall be of the same make/brand, identical and interchangeable. Only the operating handle of the load breakswitch shall be accessible for operation with the related door closed. The doors shall be interlocked with the associated load break switch so that the door can be opened only when the switch is in the DEENERGISED (OFF) POSITION and the DOORS SHALL NOT BE CAPABLE OF BEING CLOSED WITH THE switch in the ENERGIZED(ON) POSITION. Each compartment door shall have its own set of terminal blocks for connecting up the feeder cables; suitable name plate shall be fixed on the cover in distinct colour to designate the feeder number, feeder designation, current rating & HP/KW of the related equipment. The control desk input terminals shall be segregated. The Fuses shall be non-deteriorating HRC cartridge link type, with operation indicator. The Fuses shall be pressure fitted type and shall preferable have ribs on the contact blades to ensure good line of contact.

viii) Motor Feeder Starter Modules

The starter modules shall comprise of the following 1 – Feeder switch, similar to those outlined above for GENERAL PURPOSE SWITCH MODULES, with 3 poles with neutral. 1 – Set of HRC fuses on the outgoing side of the above switch combination. 1 – No Over Load Relay three element type directly heated front adjustable ambient temperature compensated bimetallic devices of suitable range to mate with the rating/output of the motors connected to the related starter and complete with hand resetting device and one set of isolated, normally closed contact for opening the control circuit in case of thermal trip and one set of isolated, normally open contact for wiring to an annunciation system. 1 – Motor starter of rating & type ( Direct on Line) marked with the rating of the motor connected to the related unit with the contactors; the main contacts of the contactors shall be of the double break type ( WITH 2 NO & 2 NC auxiliary contacts) designed for AC 3 duty for normal drives and AC 4 Duty for reversing with drives. Operating coils suitable for 220V AC.




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1 – Set of fuses ( HRC ) for the phase and a link for the neutral for the control circuits.

1 – Local/Remote Selector switch

1 – Set of resistor type pilot lights with metal filament lamps.

1 – Set of pilot devices comprising of Oil tight ` RESET ‘ BUTTON complete with actuator and necessary linkages.

1 – Set of terminal blocks for the power cable. The terminal blocks shall be colour coded.

1 – Set of terminal blocks for the control cable.

1 – Set of terminal blocks for the control desk input

Note: The above bills of quantities are for general type starter modules only. For additional component like CT, Ammeter, Auxiliary Contactors and wiring details refer the following Sketches.

The coil voltage for all contactors shall be 220V AC. The contactors shall pick up properly even at 85% of the rated coil voltage. The drop out voltage for the contactor coils shall be 45% of the nominal rated voltage.

The starter modules shall have doors made out of 16G steel or heavier with all edges flanged 5/8 in. deep minimum. Doors shall be mounted on adjustable and removable pin type concealed hinges and so arranged that unit doors may be removed without disturbing the unit doors above or below. Only the operating handle of the load break switch set, and the RESET push buttons shall be accessible for operation with the related doors closed.

The fuse rating in the load-break switchfuse units shall be suitably co-ordinated with the main contactor rating.

The fuse bases and carriers shall be made of non-inflammable and non-hygroscopic materials like phnolic moldings.

Fuse pullers if required for replacing the fuses shall be supplied – 2 nos for each rating.

O/L relays shall preferably be of the CT operated bi-metallic relay type with suitable range to match the rating of the motors protected. O/L relay shall be selected to suit the starting time of the drive. The O/L relays shall be provided with 1 NO + 1 NC contact.

All control modules shall be non-draw out type.

ix) Push Buttons

The push buttons shall be of the following type:

- Raised actuator with holder type.




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- Provided with etched on plates marked with its function.

The colour of the actuators shall be BLACK FOR RESET BUTTONS.

x) Interconnections

Power interconnections inside the panel shall be done with 650/1100 V grade single core PVC insulated copper conductor upto 63 Amps rating and above 63 Amps rating by Copper flats. Control wiring shall be done with 650/1100 V grade PVC single core copper conductor of minimum cross section 2.5 mm².

xi) Terminal Blocks

The terminal blocks provided in the switchboard shall be of ELMEX type and these shall be mounted near the bottom of each module unit, at a slightly upward angle, to provide clear and easy access to the terminals. Each wire at the terminal blocks shall be distinctly identified with appropriate number / letter ferrules at each end in accordance with the schematics. Wiring to the door shall be done by flexible cable and the cables shall be bunched, sleeved and cleated so that no mechanical damage can occur to the cables when the door swings. Not more than 2 wires shall be terminated at one con�evel terminal. All terminations shall be of adequate current rating and size to suit individual feeder requirements. Outgoing power terminations shall be designed for connecting PVC aluminium cables. Suitable provision shall be made for termination of higher size cables. Each control terminal block shall have 10% spare terminals. Inter module wiring in the same panel shall be through vertical cable alley. The Control circuits in each module shall be provided with two fuse fittings fitted with HRC fuses in one and solid copper link in the other. The rating of the terminal blocks shall be minimum 10A. The Terminal Blocks shall have shrouds of Hylum of thickness not less than 3mm.

xii) Current Transformers

The current transformers shall be of bar primary wound secondary cast resin type and have a short time withstand rating equal to that of the associated switchgear for one second. It shall be the responsibility of the vendor to coordinate the burden of the CT’s with the actual requirements of relays, instruments, leads etc., associated with the particular CT’s. The minimum requirement shall be 10VA burden, accuracy class 1.0 and an instrument safety factor of 5. The CT’s shall be provided with the following:




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• Test links in both secondary leads to carry out phase angle & current measurement

tests. • Earth link to which the leads of the CT’s shall be connected so as to facilitate easy

measurement of Insulation Resistance of the CT’s.

xiii) Indicating Instruments

These shall be of the following type: • 144 mm dial size for Incomers • 96 mm dial size for motor feeders with suppressed scale to indicate motor starting

current.

• Black numerals with a white dial free from parallax errors.

• Square pattern.

• Flush mounting.

• With provision for zero adjustment outside the cover • For Incomers 3 Voltmeters and 3 ammeters shall be provided without selector

switches.

xiv) Pilot Lamps

The indicting lamps shall be:

• Filament type & of low watt consumption, easily replaceable from the front. • Provided with series resistors.

• Provided with translucent lamp covers of the following colours, easily replaceable

from the front

RED for `ON’ GREEN for `OFF’ AMBER for `TRIP’

xv) Painting for panels:

All structural parts shall be thoroughly degreased and exposed to a hot phosphate chemical treating mixture followed by a sealing solution and drying agent. A coat of rust resisting paint shall then be given to the metal work and preferably cured in a drying oven. The final finish shall comprise of two coats of enamel paint preferably cured in a drying oven as above. The standard colour for the exterior shall be smoke gray/opaline green /beige and that for the interior shell white.




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All hardware both in the current carrying paths and non live parts like bolts, nuts, washers, fasteners, lifting hooks etc shall receive a protective zinc plating providing a contrasting gold colour thus eliminating any need for further protection. All sheet steel works shall undergo a process of degreasing pickling in acid, cold rinsing and phosphating and then sprayed with a corrosion resistant primer followed by stove levelling. Two coats of final paints shall be given thereafter and further stove levelling. The interior of the panel shall be egg shell white in colour and outside colour shall be smoke gray as per IS : 5 / Opaline green/Beige.All sheet steel work shall be phosphated in accordance with the following procedure and in accordance with applicable standards. Oil, grease, dirt and swarf shall be thoroughly removed by emulsion cleaning. Rust and scale shall be removed by pickling with dilute acid followed by washing with running water, rinsing with slightly alkaline hot water and drying. After phosphating, thorough rinsing shall be carried out with clean water, followed by final rinsing with dilute dichromate solution and oven drying. The phosphate coating shall be sealed by the application of two coats of ready mixed, stoving type zinc chromate primer. The first coat may be `flash dried’ while the second coat shall be stoved. After application of the primer, two coats of finishing synthetic enamel paint shall be applied, with each coat followed by stoving. The second finishing coat for the external of panels shall be applied after completion of tests. Each coat of primer and finishing paint shall be of a slightly different shade to enable inspection of the painting. The final finished thickness of paint film on steel shall be not less than 100 microns, and shall not be more than 150 microns. Finished painted appearance of equipment shall be esthetically pleasing free from dents and uneven surfaces. The vendor shall quote with Powder coating painting applied electrostatically. The powder quoting shall have film thickness of not less than 50 microns, stoved for 10 Min. at 180 °C.

xvi) Marking of Wires, Cables and Modules

All wirings and cables at the terminations at the switchboard shall have distinct marking by means of ferrules with letters/numerals printed corresponding to the wiring diagram to be furnished by the successful tenderer. All labels shall comprise white letters on a black background. The size of the lettering shall be 6 mm. The switchboard shall carry the following distinct markings / nameplates. • The manufacturers’ name/brand name.




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• The module nos. with the load designation and rating of the module in KW/Amps.

• Danger boards as per the IE Rules and the statutory regulations of the Range Electrical Inspector.

xvii) Packing and Marking

Cable shall be despatched in wooden drum of suitable barrel diameter, securely battened, with the take-off end fully protected against mechanical damage. The wood used for construction of the drum shall be properly seasoned, sound and free from defects. Wood preservatives shall be applied to the entire drum. On flange of the drum necessary information such as manufacturer’s name, type, size, voltage grade of cable, length of cable in meters, drum No. Cable code, ISI Certification mark, gross weight etc. shall be printed. An arrow shall be printed on the drum with suitable instruction to show the direction of rotation of the drum.

xviii) Tests

Switchgear shall be subjected to following tests: Temperature rise test on power circuits. Short time current tests on power circuits. Mechanical operation test. High voltage test. Electrical control, interlock and sequential operation test. Verification of wiring as per approved schematic type tests and routine tests shall be carried out on all associated equipment as per relevant standards. Certified copies of all type and routine test certificates shall be submitted for the approval before dispatch of the switchgear. `Type Test’ certificates and `Special Test’ results for cables offered.

7.26.4 Specific Requirements for the System Components:

i) The couplings provided shall be of flexible type and shall have a minimum service factor of 2 on the installed motor capacity.

ii) All bearings shall be preferably anti friction type and self aligning in nature, shall have effective dust cover. The bearing shall be selected for a minimum working life of 40000 hours. Effective lubrication shall be provided for all bearings and sliding surfaces.

iii) All the structural steel used shall meet the requirements of BS 4360 and the Steel plates used shall not be less than 5mm thick.




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7.27 Foundation:

7.27.1 All equipment foundation and other necessary civil works for equipment etc. will be provided by the purchaser based upon the drawing and the load data submitted by the Tenderer. The dimensions of the foundation and anchor bolt pitch shall be checked by the Tenderer for their correctness as per the drawings. Further, top elevation of the foundations shall be checked with respect to bench mark or the agreed plant elevation etc. All minor adjustment of foundation levels, dressing and chipping of foundations etc. as may be required for the erection of the equipment / structures shall be carried out by the Tenderer. Final grouting is in the scope of the Tenderer.

7.28 Material and Consumables:

7.28.1 The Tenderer shall provide the required consumables like steel items, grouting materials, templates, cement, concrete pre-cast slabs / blocks, scaffolding materials and tools required for the work. The materials brought by the Tenderer shall be new and conform to all safety standards.

7.28.2 All electrodes and gases like Argon, Oxygen, Acetylene, and LPG required for work shall be supplied by the Tenderer.

7.28.3 The first fill of lubricants for testing, preservation, flushing and lubricants for trial run of the equipment shall be brought by the Tenderer.

7.28.4 All services including labour shall be provided by the Tenderer for handling, filling, emptying, refilling etc.




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8.0 TOOLS & TACKLES AND SPARES

8.1 Tools and tackle

8.1.1 The tendered shall include in his offer special tools and tackle required, if any, for normal operation and maintenance of the equipment. Itemized list, price and quantity of these shall be indicated.

8.1.2 Tenderer shall bring all the required tools and tackles for efficient and methodical erection of the ash handling plant. It shall be specifically noted that Tenderer shall arrange his own equipment, tools and tackles for loading and transport of materials / equipment from storage yard to the erection site and pre-assembly works.

8.1.3 Consumables and operating supplies

i) The tendered shall include the first fill and first six month’s operational requirements of consumables and operating supplies along with the equipment. The supply of consumables and operating supplies required for erection and commissioning shall also be included in the offer.

ii) Detailed specification, quantity and make of recommended consumables and supplies required for two (2) year’s operations shall be furnished by the tendered along with the offer.

8.2 Spares

8.2.1 The Tendered shall submit with his offer separate recommended list with itemized price and quantity for the following spares for each equipment/system.

i) Commissioning spares which are required for erection and commissioning of the equipment /system until acceptance. The commissioning spares shall be included in the price schedule of the offer and delivered along with the equipment / system. The Tendered shall consider quantity of such commissioning spares based on his past experience and in case of any short fall in the quantity of this spares, additional quantity, if required, shall have to be supplied by the successful Tendered at his own cost and in time. Item listed and quantity of the commissioning spares shall be furnished for reference of the Purchaser.

ii) Maintenance spares which are required for two (2) years’ normal and trouble free operation of the equipment / system after final acceptance. Itemized list, price and quantity of these spare shall be indicated.

iii) Insurance spares which are not normally accounted for under routine replacement may be required due to error in operation or maintenance of the equipment by the Purchaser’s operating or maintenance personnel and may affect not only the operation of the particular machine but the entire system as a whole. The recommended list of such spares shall be prepared by the Tendered based on his past experience. Itemized list price and quantity of such spares shall be indicated.




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9.0 QUALITY ASSURANCE PLAN

9.1 Introduction

9.1.1 The minimum Quality Assurance / Quality Control (QA/QC) requirements and the services the Tenderer is expected to provide, is described in this section, to assure conformity with the contract specification. Quality Assurance/Quality Control procedures proposed by the Tenderer should address the QA/QC requirements under the following phases of the project:

Engineering

Procurement

Construction including commissioning testing

9.1.2 Tenderer shall submit documents to demonstrate that the Tenderer and his sub-vendors possess QA/QC programs meeting the minimum requirements set forth in this section. Tenderer shall submit a quality assurance plan along with the bid.

9.1.3 These quality plans and reference documents/standards etc. shall be subject to Purchaser’s approval without which manufacture shall not proceed. These approved documents shall form a part of the Contract. In the approved Quality Plans, the Purchaser/Purchaser’s representative shall identify the Purchaser Hold Points (PHP).

9.1.4 The Tenderer must submit an organisation chart along with a descriptive write up should also be provided outlining the proposed QA/QC program for this particular project. This chart and write up should identify the personnel responsible for the Engineering Quality Assurance Plan for the complete duration of the project.




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10.0 PAINTING SYSTEM

10.1 This section covers the general painting requirements for the power plant equipment, structures, piping etc. and any other surface required to be painted. Tenderer to carry out the painting as applicable.

10.2 Codes and Standards

10.2.1 Painting of equipment shall be carried out as per the specifications indicated below and shall conform to the relevant IS specification for the material and workmanship.

10.2.2 The following Indian Standards may be referred to for carrying out the painting job :

IS: 5 : Colours for ready mixed paints and enamels

IS: 1303 : Glossary of terms relating to paints

IS: 2379 : Colour code for identification of pipelines

IS: 1477 : Code of practice for painting of ferrous metals in

buildings (Parts I & II)

IS: 2524 : Code of practice for painting of non-ferrous metals

in buildings (Parts I & II)

IS: 158 : Ready mixed paint, brushing, bituminous, black,

Lead-free, acid, alkali, water and heat resisting

IS: 2074 : Ready mixed paint, air drying, red Oxide Zinc Chrome, priming

IS: 104 : Ready mixed paint, brushing, Zinc Chrome, priming

IS: 2932 : Enamel, synthetic, exterior (a) undercoating (b) finishing

10.3 Surface Preparation

10.3.1 All surfaces to be painted shall be thoroughly cleaned of all grease, oil, loose mill scale, dust, rust and any other foreign matter. Mechanical cleaning by power tool and scrapping with steel wire brushes shall be adopted to clear the surfaces.

10.3.2 However, in certain locations where power tool cleaning cannot be carried out, sand scrapping may be permitted with steel wire brushes and/or abrasive paper. Cleaning with solvents shall be resorted to only in such areas where other methods specified above have not achieved the desired results. Cleaning with solvents shall be adopted only after written approval of the Engineer.

10.3.3 All pressure parts with headers shall be cleaned prior to shipment, in accordance with the manufacturer’s standard procedures.




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10.3.4 The following surfaces shall be protected during surface preparation and coating/painting operations:

i) Area within 50 mm of surfaces to be welded after coating.

ii) Steel surfaces to be embedded in concrete.

iii) Name-plates and other instruction plates.

10.4 Primer Paint

After the surface is prepared, one coat of epoxy based Zinc phosphate primer paint shall be applied. After this first coat is dried up completely, second coat of epoxy based Zinc phosphate primer shall be applied. Primer shall be applied by brushing to ensure a continuous film without ‘holidays’.

10.5 Finish paint

Synthetic enamel paint conforming to IS: 2932 shall be used for finish coats. The colour/shade shall be as approved by the Purchaser’s representative. After cleaning the dust on the dried up primer, first coat of high build epoxy polyamide enamel shall be applied. After this first coat dries up hard, the surface is wet scrubbed cutting down to a smooth finish and ensuring that at no place the first coat is completely removed. After allowing the water to get evaporated completely, the second finish coat of high build epoxy polyamide enamel paint shall be applied. All the paints shall be epoxy type only.

10.6 Shop painting

10.6.1 All exposed fabricated steel materials except those galvanized shall receive protective paint coating as indicated below:

i) Two (2) coats of epoxy resin based zinc rich primer applied thoroughly and evenly to dry surfaces including duct work which have been cleaned by sand blasting conforming to Swedish Standards SA-2-½ grade minimum. The DFT of priming coat shall be 50 microns or as directed by the Engineer.

ii) Two (2) coats of finish paint epoxy based paint of approved colour having DFT min. 50 microns shall be applied for each type of paint.

iii) Painting shall not be done in frostly or foggy weather or when humidity shall be such as to cause condensation on the surfaces to be painted.

10.6.2 The structural steel work surfaces to be painted shall be thoroughly cleaned of all loose mill-scale, rust, grease, dirt and other foreign matter by sand/shot blasting only. Adequate care should be taken such that the surfaces does not possess a slick finish to which paint may not adhere properly.




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10.6.3 Inaccessible parts

Surfaces not in contact but inaccessible after assembly shall receive two (2) coats of epoxy primer positively before assembly. This shall not apply to the interior of sealed hollow sections. The inaccessible parts shall also receive two (2) coats of epoxy paint before assembly.

10.6.4 Contact Surfaces

The contact surfaces shall be cleaned by hand-wire brushing or by other methods of removing loose mill-scale, rust, weld slag or flux deposit, dirt and other foreign matter. Oil and grease deposits shall be removed by use of solvents.

10.6.5 Finished Surfaces

Machine finished surfaces shall be protected against corrosion by a rust inhibiting coating that can be easily removed prior to erection or which has characteristics that make removal unnecessary prior to erection.

10.7 Painting after erection

After erection touch-up painting, making good any damaged shop painting and completing any unfinished portion of the shop coat shall be carried out by the Tenderer free of cost to the Purchaser. The materials and specifications shall be in accordance with the requirements of good practice. All bolts, welds, and abrasions to the shop coat shall be painted with the same paint used for shop coat.

10.7.1 External Painting for Tanks

i) Primer: Two (2) coats of epoxy resin based Zinc phosphate primer of adequate DFT.

ii) Finish: Two (2) coats of Bergerthane aluminium finish paint having adequate dry film thickness.

10.7.2 Touch-up and Repairs

Touch-up and repair shall be performed as follows:

i) Defects in the painted surfaces shall be repaired in accordance with the touch-up and repair procedure laid down under the manufacturer’s written recommendations.

ii) Damaged painting and un-primed areas shall be prepared to Purchaser’s approval. The touch-up painting shall be the same as the originally applied painting. The adjacent sound painting shall be featheredged and roughened up to 50 mm beyond the area requiring repair for overlapping.

10.8 General painting practices

10.8.1 Paint application materials shall be mixed, thinned, applied, and cured in accordance with the manufacturer’s latest printed instructions and approved procedures. Paint coat materials applied to any one surface shall be the product of a single manufacturer. A gray colour is provided on the water walls and convection surface walls.




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10.8.2 Indoor mechanical and electrical equipment, surfaces requiring an insulation or lagging, or off-the-shelf items shall be painted with the painting system.

10.8.3 Interior surfaces painting application shall be performed in accordance with paint manufacturer’s written recommendations and instructions.

10.8.4 Auxiliary and local control panels shall be painted with the standard painting system. Control panel colours shall be subject to Purchaser’s acceptance.

10.8.5 Machine surfaces shall be protected with rust-preventive compound.

10.8.6 All surfaces interior and exterior of the equipment parts, as applicable, shall be shot blasted to remove all rust, scale, grease and/or other adhering foreign matter. Unless otherwise specified, all exposed surfaces of steel work, pipe work etc shall be applied with two (2) coats of approved high quality epoxy primers and finished with two (2) coats of finish epoxy paint in an approved colour to give a neat and clean finish.

10.8.7 All metal parts not accessible for painting shall be made of chemical corrosion resistant materials. All finished surfaces subject to rust shall be coated with a suitable rust preventive compound. Surfaces shall be putty filled and rubbed down to ensure first quality glossy finish.

10.8.8 Paints shall be carefully selected to withstand not only tropical heat and extremes of weather specified herein; but also acid and other chemical fumes. It shall not scale-off or crinkle or be removed by abrasion in handling. Epoxy resin based zinc rich primer paint shall be provided as per approved colour shades.

10.8.9 All exterior surfaces of uninsulated pipe work, structures, platforms & gratings, panels, instruments and equipment, wherever so directed shall be bonderised (or equivalent), given two (2) primer coats and finished with two (2) coats of lacquer (epoxy) of an approved colour to be specified at a later date. Interior surfaces shall be primed and finished with coats of light grey colour finish paints.

10.8.10 All equipment viz pipes, valves, soot blowers air heaters and fans etc. shall be tag numbered and painted at the appropriate places as approved by the Purchaser.

10.8.11 All underground pipe work shall be protected against corrosion as per latest AWWA Standards.

10.8.12 Paint shall be applied in accordance with paint manufacturer’s recommendations. The work shall generally follow relevant Indian Standards.

10.8.13 All fabricated steel structures, vessels, heat exchangers which have surface temperature less than 80 degree C shall have a minimum of two primer coats of epoxy based zinc phosphate paint prior to despatch to site. Two finish coat of high build epoxy polyamide enamel paint as applicable shall be applied at site. The dry film thickness of the four coats shall not be less than 120 microns.

10.8.14 All fabricated steel structures, vessels, heat exchangers which have surface temperature more than 80 degree C and less than 150 degree C shall have a minimum of two primer coat of Zinc phosphate and one finish coat of high build epoxy polyamide enamel prior to dispatch to site. One finish coat of high build epoxy polyamide enamel paint shall be applied at site. The dry




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film thickness of the four coats shall not be less than 120 microns. All standard bought-out items and machines such as pumps, fans, motors, valves, cylinders, electrical and instrumentation panels etc. shall generally be painted as per the manufacturers’ standard and shall meet the requirement of the exposure condition and the specific system of painting thereof. These shall also have a minimum of two primer coats and one finish coat of paint with a total dry film thickness of not less than 105 microns.

10.8.15 Over-ground pipe work inclusive of pipes, fittings, hangers, cable ducts etc., both insulated and non-insulated, shall be painted with two coats of epoxy based zinc-phosphate as primer paint before despatch. The minimum dry film thickness per coat shall be 40 microns.

10.8.16 Non-insulated pipes, having a maximum surface temperature of 60 degree C shall be applied with one intermediate coat of epoxy based zinc phosphate and two finish coats of high build epoxy polyamide enamel paint with suitable pigments over and above the primary coats. The minimum dry film thickness per coat shall be 70 microns and 25 microns for intermediate and finish coat respectively.




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11.0 ERECTION, TESTING AND COMMISSIONING

11.1 Installation of equipment

11.1.1 The successful tendered is required to carry out the erection and commissioning/ supervision of erection and commissioning of the equipment / system at site and shall therefore be responsible for satisfactory erection, testing and commissioning of the equipment / system. Notwithstanding that he might have been assisted by the Purchaser or his authorized representative.

11.2 Erection of electrical equipment

11.2.1 The erection of electrical equipment shall include but not be limited to the following:

• Installation of motors, 415 V MCC, local push – button station, control panels, limit switches, special control equipment, along with necessary support structure, consumables, etc.

• Laying power, control, signal and special cables on racks / trays / along walls / conduits

including termination of the cables and joining of cables if any.

• Installation of GI cable racks / trays / GI Conduits with supporting structures.

• Earth mat in AHS are earthing station and installation of earthing stations.

• All equipment shall be installed strictly in accordance with the equipment manufacturer’s instructions. Equipment supplied in sections or in dismantled condition shall be reassembled with all associated accessories as per the equipment manufacturer’s instructions.

• The successful tendered shall obtain approval for the installation work including drawing

from the CEIG, Government of Andhra Pradesh Modification/rectification if any as suggested by CEIG shall be carried out shout extra cost to Purchaser. Statutory fees paid by the successful tendered will be reimbursed by the Purchaser against documentary evidence.

11.3 Erection:

The responsibility of the Tenderer will include but not limited to the following:

11.3.1 Unloading the materials supplied by him at site, loading at storage yard, transporting to site using his own equipment, pre-assembly of equipment at the pre-assembly yard for inspection, checking and erection. Any fixtures and concrete block supports, steel structures, handling equipment required for temporary supporting for pre-assembly and welding / lifting and handling and supporting during pre-assembly and erection shall be done by the Tenderer using his own materials.

11.3.2 Details regarding the erection of the system and the schedule of weights shall be provided by the Tenderer along with the tender.




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11.3.3 All the works such as cleaning, checking, �evelling , aligning, dismantling of certain equipment for checking and cleaning, assembling, temporary erection for alignment, surface preparation, fabrication as per general engineering practice at site, cutting, grinding, straightening, filling, chipping, drilling, reaming, scrapping, shaping, fitting up etc. as may be applicable in such erection work are to be treated as incidental to the erection and necessary to complete the work satisfactorily shall be carried out by the Tenderer as part of the work.

11.3.4 All rotating machineries and equipments shall be cleaned, lubricated, check for the smooth rotation if necessary by dismantling and refitting before erection. If, in the opinion of the purchaser’s engineer, the equipment is to be checked for clearances, tolerances etc at any stage of the work or during commissioning period, facilities for dismantling, cleaning, lubricating and refitting shall be provided by the Tenderer.

11.3.5 The Tenderer shall take all reasonable care to protect the material and equipment during erection. Preservative painting required to be done on any equipment or part during the course of erection will have to be done by the Tenderer.

11.4 Welding:

11.4.1 All charges for testing of Tenderer’s welders including destructive and non-destructive test conducted at site shall have to be borne by the Tenderer.

11.4.2 The welded joints shall be subjected to random NDT like LPI / MPI etc. test.

11.4.3 All electrodes shall be oven dried to the required temperature before they are used in erection work.

11.5 Progress of Erection Work:

11.5.1 During the course of erection, if the progress is found unsatisfactory or if the target dates fixed from time to time for every mile stone are to be advanced, or in the opinion of the purchaser if it is found that the skilled work man and required man power are not sufficient, Tenderer will be suitably advised to increase the man power to cope up with the requirement. Otherwise the purchaser will induct sufficient man power to improve the progress and recover from the Tenderer’s bills the charges incurred for engaging the additional man power with their over heads. This is binding on the Tenderer.

11.5.2 It is obligatory on the part of the Tenderer to give weekly feed back on progress of the erection, man power employed etc. for different categories of work.

11.6 Testing and other Items:

11.6.1 Tenderer will supply necessary labour and consumables to carry out the test at site. All the tests shall be repeated till all the equipment satisfies the requirement / obligation for which the equipment is installed. All repairs arising out of the failure during testing shall be done by the Tenderer as part of the work.

11.6.2 Commissioning will involve trial runs of all the equipment erected for its performance testing and any other work incidental to commissioning.




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11.6.3 In case, any rework is required because of Tenderer’s faulty erection, which is noticed during commissioning the same has to be rectified by the Tenderer free of cost.

11.6.4 A detailed log book shall be maintained especially for rotating machinery showing the details of alignment, clearances etc. for inspection at any time.

11.6.5 All temporary supports shall be removed on completion of that particular work and the scrap should be deposited in the specified place.

11.7 Safety Requirements:

11.7.1 During the course of construction, form and scrap lumber with protruding nails and other debris shall be kept cleared from work area, passage ways and stairs in and around structures and other building area.

11.7.2 Combustible scrap and debris shall be removed at regular intervals at the course of construction.

11.7.3 Rigging equipment for material handling shall be inspected prior to use of each shift and as necessary during its use to ensure that it is safe. Defective rigging equipment shall be removed from service. These equipments shall not be loaded in excess of its recommended safe working load. They shall be removed from the work area so as not to present a hazard to the work men.

11.7.4 Proper safety precautions are to be taken and a supervisor shall be nominated to co-ordinate safety measures.

11.7.5 Cylinders shall be moved by tilting and rolling them on their bottom edges. They shall not be intentionally dragged.

11.7.6 All workmen in construction site shall wear safety helmets and safety boots. Workmen shall wear safety belts when working at heights. Tenderer shall ensure his workmen against accidents and the policy shall be presented to the purchaser on demand. All the above safety conditions are not exhaustive, but gives an idea to the Tenderer and the Tenderer shall adhere to all the safety precautions. The Tenderer shall arrange suitable flood lighting arrangement for safe and proper working condition at night times.

11.8 Time Schedule

11.8.1 The Tenderer shall strictly adhere to the time schedule given by the purchaser at the time of the execution the contract.

11.8.2 The work shall be started within 15 days from the date of acceptance of the work order released by the purchaser. This means the Tenderer personnel should reach site and establish the site office and commence the work within 15 days from the date of letter of intent.

11.8.3 The work and the scope of the Tenderer are deemed to be completed in all respects only when the trial run, testing are over and certified by the purchaser or the consulting engineer. The decision of purchaser in this regard shall be final and binding on the Tenderer.




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12.0 PERFORMANCE GUARANTEES & AVAILABILITY

12.1 The ash handling system shall perform satisfactorily to meet the guarantee requirements as specified:

12.1.1 Tenderer shall specify the procedure to verify the performance of the individual equipment like conveyor capacity, crusher capacity, screens etc along with the bid for approval.

• Capacity of pressure type pneumatic conveying system for bed ash.

• Capacity of pressure type pneumatic conveying system for fly ash (From ash hoppers to intermediate fly ash silo)

• Capacity of pressure type pneumatic conveying system for fly ash (from intermediate fly ash silo to main fly ash silo)

• Capacity of bed ash unloading system from bed ash silo in wet & dry form

• Capacity of fly ash unloading system from fly ash silo in wet & dry form

• Capacity of clinker grinder (if required)

12.1.2 Tenderer shall guarantee output and quality of the plant and equipment in accordance with the performance guarantee values as per contract specifications.

12.1.3 Tenderer shall demonstrate and establish performance guarantee for various units and achieve performance guarantee values as per contract specifications.

12.1.4 Tenderer shall supervise and direct the operation during performance tests and shall take full responsibility in this regard.

12.1.5 During performance tests, the Purchaser shall make available necessary operating & maintenance personnel.

12.1.6 Tenderer shall provide and install all measuring instrument required for checking the guaranteed performance which are not included along with the permanent measuring instruments of the system. Such instruments shall be furnished by Tenderer on a temporary basis for the duration of the performance guarantee test.

12.1.7 Emission level of dust extraction system

12.1.8 Auxiliary power consumption for ash handling system

12.1.9 Compressors and blowers shall be tested as per relevant IS for capacity (FAD), power consumption, etc.

12.1.10 Noise Level

12.1.11 Vibration level of equipment at bearings




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12.1.12 All water lines shall be hydraulically tested at 1.5 times the maximum operating pressure.

12.2 Prices for Equipment and Services

12.2.1 Price for design, engineering, manufacture, procurement, supply at site, site fabrication, assembly, erection and commissioning of the system covered under this specification shall be furnished.

12.2.2 The price for spare parts, special tools and tackles, consumables and operating supplies shall be indicated separately giving itemized prices and weights.

12.2.3 Taxes, duties and other levies to be reimbursed by the Purchaser shall be indicated in each case. Any variation in these taxes, duties and other levies or any imposition of new taxes shall be to the account of the successful Tendered.

12.3 Price Variation

12.3.1 The rendered offering firm prices shall be preferred. When a price variation clause is insisted upon, the tendered shall indicate a reasonable ceiling of variation. In case of price variation, price escalation formulae should be given in detail covering fixed portion, raw materials and wages with detailed break-up of percentage, description of raw materials, their rates and wages with detailed break-up of percentage, description of raw materials, their rates and wages of different categories of personnel prevailing on the base date.

12.4 Information to be Furnished with Tender

12.4.1 The Tenderer shall furnish in his offer the information called for in Questionnaire and different parts / sections of the tender documents without which the offer is liable to be rejected. The information shall include the following.

i) General description of the equipment offered specifying important features and materials of construction etc, to enable the Purchaser to have a proper understanding of the equipment offered and its operation.

ii) The offer shall be accompanied by necessary general arrangement drawings required for proper understanding of the system offered as well as the equipment considered in the system.

iii) The questionnaire shall be filled in and submitted along with the tender.

iv) Deviations considered by the Tendered to the specification and specified standards shall be furnished separately.

v) Schedule of Tenderer’s scope of supply / work shall be furnished separately.

vi) Proposed schedule of work in bar chart from with milestones marked on the chart.

vii) Deviations from the specification / standards.




ASH HANDLING SYSTEM

DOC. NO : 4 – 3614 – MECH – 011


13.0 DOCUMENTATION

13.1 Drawings and documents

13.1.1 Documents to be submitted along with the bid:

• For Mechanical Equipment:

Flow diagram for ash handling system

General Arrangement drawing showing overall layout, overall dimensions, elevations etc.,

Typical drawings, catalogues, leaflets for bought out items along with the make.

Detailed general arrangement drawings for fly ash transmitters, pumps, compressors etc.,

• For electrical equipments

Connection diagram for the individual units.

Schematic diagram for the complete switchboard.

Terminal connection diagram of the main terminal boards.

Sketches of the overall dimensions of the board – Plan, elevation and section views section views clearly showing the bus size.

Brand names of all components incorporated like, load-break switches, contactors, pilot device, pilot lamps, current transformers, HRC fuse fittings / links, terminal blocks, wirings, cable sockets, meters, selector switches for instruments, instrument fuse fittings/links etc.

• For Control & Instrumentation

Write-up on controls of ash handling system

Write-up on operation philosophy and interlocks with logic diagram.

• Guaranteed technical particulars for the critical components.

• Shipping dimensions of the package and its weight – gross & net (major packages)

• General:

Deviation statements giving in detail the deviations from the technical specifications outlined in this tender document giving the related page / Para no. etc.

Quality assurance plan




ASH HANDLING SYSTEM

DOC. NO : 4 – 3614 – MECH – 011


Delivery and commissioning schedule

Manufacturing facility available with the Tenderer.

Reference list, performance certificates from reputed companies.

List of erection tools and tackles.

Site organization chart.

Price Schedule.

List of drives/ electrical energy consumers with kW rating.

A list of motor and other consumers

13.1.2 The drawings /documents required to be submitted after the award of contract shall be discussed and agreed during contract stage




ASH HANDLING SYSTEM

DOC. NO : 4 – 3614 – MECH – 011


14.0 LIST OF APPROVED MAKES

SL.NO. DESCRIPTION VENDOR

A MECHANICAL

1. Screw type air compressors ELGI/ATLAS KOPCO/INGERSOL RAND/ KIRLOSKAR

2. Gear box SHANTHI/RADICON/ELECON/NEW ALLENBURY/FLENDER

3. Fluid coupling (if any) VOITH

4. Carbon steel & M.S. ERW (Black / Galvanised) SAIL/JINDAL/TISCO

5. Butterfly Valve (Air line) INTER VALVE/AUDCO/LEADER/SANT

6. Water / Air Line Valves (C.I.) - Gate / Globe / Check LEADER/CRESCENT/BDK/KSB/SANT

7. Water / Air Line Valves (G.M.) LEADER/GG/BDK/SANT

8. Ball Valves BDK/HAWA/UNIFLOW/FLOWCON/SANT

9. Y-Strainers SPIRAX/DRAYTON (GREAVES)

10. Knife gate valve AUDCO/BDK/CRESCENT

11. Expansion bellows SUR INDUSTRIES/D.WREN/PRECISE ENGINEERING/CORI

12. Blower KAY/EVEREST/SWAM/KULKARNI/SABRO (PACE)/ATLAS COPCO/INGERSOLL RAND/GEM

13. Bag filter THERMAX/FLAKT/RATHI/ABB/DUVENT

14. Victaulic coupling VICTAULIC/NANDA MILLER/INTERFIT

15. Bearings SKF/FAG

16. Paints BERGER/ASIAN/SHALIMAR/J&N

B ELECTRICAL

17. Control Panels, Lighting Panels, Misc. Panels, JBs, LPBs, MCC RITTAL/BCH/PYROTECH/BALINGA

18. LT Motors SIEMENS/ABB/CROMPTON/SIEMENS

19. Geared Motors SEW / IC BAUER / POWER BUILT / CROMPTON / BONFIGLIOLI / NEW ALLENBURY

20. Power Control & Signal Cables

UNIVERSAL / ASIAN / POLYCAB/ BCH / CAB CORP.

21. Cable Trays

VENUS STEEL / METALITE INDUSTRIES / INDIANA / GRAEATFEB ENGG. & FABRICATORS / BHARTI EXPORT / TECHNOFAB/ EQUIPTECH/ APT




ASH HANDLING SYSTEM

DOC. NO : 4 – 3614 – MECH – 011


SL.NO. DESCRIPTION VENDOR

22. Filter / Lubricator / Regulator SHAVO NORGREN / SMC

Solenoid Valves:

23. For Denseveyor System ROTEX / FESTO

24. For Bag Filter MANIK / ROTEX / ASCO / AVCON

25. Pressure Gauge WIKA / A.N. INSTRUMENT / H. GURU / GENERAL INSTRUMENTS

26. Temperature Gauge GENERAL INSTRUMENTS / H. GURU

27. Pressure Switch INDFOSS / SWITZER

28. Pneumatic Cylinder FESTO / SCHRADER / NUCON / CAMOZZI / ROTEX

29. Rotary Pneumatic Actuator EL-O-MATIC / ROTEX / VIRGO

30. Electrical Actuator ROTORK / AUMA

31. Safety Relief Valve SPIREX / LEADER

Drain Trap:

32. Mechanical type SPIREX / DRAYTON (GREAVES) / ROTEX

33. Auto type TRIDENT / ROTEX / GORC / JUCOMATIC

34. Electrical Limit Switch:

35. Lever type JAI BALAJI / BCH / TELEMECANIQUE / SIEMENS

36. Rotary type VIRGO / ROTEX / KEYSTONE

Silencer:

37. Sintered Bronze KULKARNI

38. Plastic FLUOROQUIP / FESTO

39. Polyurethane Tubing FESTO / PARKER/ CAMMOZI

40. Selector Switch / Push button SIEMENS / TEKNIC / L & T

41. Proximity Switch P & F / TELEMECHANIC / AB/ JAYASHREE

Project: 108 MW Captive Power PlantClient: Shri Girija Alloy and Power (I) Private LimitedDocument: Technical Specification for Ash handling System Document No.: 4-3614-MECH-011

Annexure - I

SL.NO DESCRIPTION

1 GENERAL

Total shipping weight, tons

Ash Vessels

Ash conditioners

Telescopic chute

Rotary Vane Feeder

Slide gate

Miscellaneous items

Electricals

Size of biggest unit to be transported (l x w x h), mm

2 EQUIPMENT – BED ASH HANDLING SYSTEM

2.1 GENERAL

Capacity, tons/batch

Frequency of evacuation, batches/hour

Specific energy consumption, J/kg/m

Conveying air

Quantity, N cu m/hr

Pressure, kscg

Instrument air at battery limit

Quantity, N cu m/hr

Pressure, kscg

Air to ash ratio

converging air velocity, m/sec.

2.2 Clinker grinder (If applicable)

Type

Quantity

Capacity

Input particle size

Max. Output Size Permissible

Is Fluid Coupling Required

Type of coupling

Operating speed, RPM

Motor power, kW

Material of construction

Grinder Chamber

Wear plates

Grinder Rolls & Teeth

Grinder Shaft

Shaft sleeve

Clinker outlet chute

2.3 Manual operated knife Gate valve at the bottom of clinker grinder

Type

Quantity

Location

Size, mm

Material of construction/thickness

Details of gate provided

ASH HANDLING SYSTEM

Tenderer to fill the data

BED ASH VESSEL 1 BED ASH VESSEL 2

`

Consultant:Snyder Energo Pvt. Ltd.Bangalore and Chennai


Annexure - I

SL.NO DESCRIPTION

ASH HANDLING SYSTEM


2.4 Surge Hopper (If required)

Quantity

Size

Capacity, cu m

Provision of RF level probe


Cooling jacket

Cooling water requirement/hopper, cu m/hr

Cooling water temperature

Inlet, Outlet oC

Provision of adopter piece


Shell thickness, mm

Hardness, BHN

Isolation valve

type

size

Material cut-off- valve

type

size

material

hardness, BHN

Vent valve

type

size

material

Expansion bellow

size

material

Adapter piece

Size

Material

Fluidizing element

Material

description

Level probe

type

Pressure vessel code

Make

Air temperature, oC

inlet

outlet

Air flow, N cu m/hr

2.5 Transporter Vessel

Make

Type

Quantity



Annexure - I

SL.NO DESCRIPTION

ASH HANDLING SYSTEM


Volume, cu m


3 EQUIPMENT – BED ASH DISPOSAL SYSTEM

3.1 Target Box (for bed ash silo)

Quantity

Box size

Material of Target plate

Thickness

3.2 Over pressure and under pressure relief valve (for bed ash silo)

Quantity

Type

make


3.3 Vent Filter (for bed ash silo)

Type

Make

MOC of filter

Filter outlet dust concentration (mg/N m3)

Quantity

3.4 Vent Fan (for bed ash silo)

Type

Make

Capacity

3.5 Fluidizing element (For bed ash silo)

Material

description

3.6 Level probe (For bed ash silo)

type


Make

3.7 Manual operated knife Gate valve at the bottom of Bed ash silo (for bed ash silo)

Type

Quantity

Location

Size, mm



3.8 Ash discharge valve (Electro pneumatic) (for bed ash silo)

Type

Quantity

Size, mm

Material of constriction/thickness

Drive unit details

3.9 Rotary vane feeder (for bed ash silo)

Type

Quantity

Capacity, TPH



Annexure - I

SL.NO DESCRIPTION

ASH HANDLING SYSTEM


Size of inlet/Outlet

MOC of

Rotor

Vane

Shaft

Outer body

Drive Bed

Diameter of shaft/Bearing

Bearing type/number

Type of Sealing

Drive unit details

Motor kw/rpm

Transmission (V-Belt/Chain)

Zero Speed switch

3.10 Twin shaft ash conditioner (for bed ash silo)

Quantity

Make

Mixing paddle:

Type

kW rating

Mixing capacity, cu m/hr


10. Body

11. Cover

12. Paddle shaft

13. Paddle

14. Spray header assembly

15. Spray nozzle

16. Spray nozzle tip dia

3.11 Telescopic Chute (for bed ash silo)

Type/Make

Quantity

Capacity, T/hr.

Motor rating, kw

Max. retraceable height

Normal compressed height

Whether level probe provided

Details of drive unit

3.12 Chutes (for bed ash silo)

Type

Thickness of chute plate




Annexure - I

SL.NO DESCRIPTION

ASH HANDLING SYSTEM


4 EQUIPMENT – FLY ASH HANDLING SYSTEM

I II I II III IV V

Capacity, tons/batch

Frequency of evacuation, batches/hour

Specific energy consumption, J/kg/m

Conveying air

Quantity, N cu m/hr

Pressure, kscg

Instrument air at battery limit

Quantity, N cu m/hr

Pressure, kscg

Air to ash ratio

converging air velocity, m/sec.

4.2 Surge Hopper

Quantity

Size

Capacity, cu m

Provision of RF level probe


Cooling jacket

Cooling water requirement/hopper, cu m/hr

Cooling water temperature

Inlet, oC

Outlet, oC

Provision of adopter piece


Shell thickness, mm

Hardness, BHN

Isolation valve

type

size

Material cut-off- valve

type

size

material

hardness, BHN

Vent valve

type

size

material

Expansion bellow

size

material

Adapter piece

Size

Material

4.1 GENERAL

MDC

APH ESP



Annexure - I

SL.NO DESCRIPTION

ASH HANDLING SYSTEM


Fluidizing element

Material

description

Level probe

type


Make

Air temperature, oC

inlet

outlet

Air flow, N cu m/hr

4.3 Manual operated knife Gate valve at the bottom of surge hopper

Type

Quantity

Location

Size, mm



4.4 Transporter Vessel

Make

Type

Quantity

Volume, cu m


5 EQUIPMENT – FLY ASH DISPOSAL SYSTEM

5.1 Target Box (For intermediate fly ash silo)

Quantity

Box size


Thickness

5.2 Over pressure and under pressure relief valve (For intermediate fly ash silo)

Quantity

Type

make


5.3 Vent Filter (For intermediate fly ash silo)

Type

Make

MOC of filter


Quantity

5.4 Vent Fan (For intermediate fly ash silo)

Type

Make

Capacity

5.5 Fluidizing element (For intermediate fly ash silo)

Material

description



Annexure - I

SL.NO DESCRIPTION

ASH HANDLING SYSTEM


5.6 Level probe (For intermediate fly ash silo)

type


Make

5.7 Manual operated knife Gate valve at the bottom of intermediate fly ash silo

Type

Quantity

Location

Size, mm



5.8 Transporter Vessel at the bottom of intermediate fly ash silo

Make

Type

Quantity

Volume, cu m


5.9 Target Box (For Main fly ash silo)

Quantity

Box size


Thickness

5.10 Over pressure and under pressure relief valve (For Main fly ash silo)

Quantity

Type

make


5.11 Vent Filter (For Main fly ash silo)

Type

Make

MOC of filter


Quantity

5.12 Vent Fan (For Main fly ash silo)

Type

Make

Capacity

5.13 Fluidizing element (For Main fly ash silo)

Material

description

5.14 Level probe (For Main fly ash silo)

type


Make



Annexure - I

SL.NO DESCRIPTION

ASH HANDLING SYSTEM


5.15Manual operated knife Gate valve at the bottom of Main fly ash silo

Type

Quantity

Location

Size, mm



5.16 Ash discharge valve (Electro pneumatic) (For Main fly ash silo)

Type

Quantity

Size, mm

Material of constriction/thickness

Drive unit details

5.17 Rotary vane feeder (For Main fly ash silo)

Type

Quantity

Capacity, TPH

Size of inlet/Outlet

MOC of

Rotor

Vane

Shaft

Outer body

Drive Bed

Diameter of shaft/Bearing

Bearing type/number

Type of Sealing

Drive unit details

Motor kw/rpm

Transmission (V-Belt/Chain)

Zero Speed switch

5.18 Twin shaft ash conditioner (For Main fly ash silo)

Quantity

Make

Mixing paddle:

Type

kW rating

Mixing capacity, cu m/hr


Body

Cover

Paddle shaft

Paddle

Spray header assembly

Spray nozzle

Spray nozzle tip dia



Annexure - I

SL.NO DESCRIPTION

ASH HANDLING SYSTEM


5.19 Telescopic Chute (For Main fly ash silo)

Type/Make

Quantity

Capacity, T/hr.

Motor rating, kw

Max. retraceable height

Normal compressed height

Whether level probe provided

Details of drive unit

5.20 Chutes (For Main fly ash silo)

Type

Thickness of chute plate


6.0 Fluidizing Blower

Quantity, No.

Volume, cu m

Flow rate, cu m/hr

Pressure, mwc

7.0Total Instrument air requirement at Terminal point, N cu m / hr. (For both units)

8.0 Cooling water requirement, cu m /hr. (for both units)

9.0 Service water requirement, cu m /hr. (for both units)

10.0 Requirement of Construction power, kW

11.0 Requirement of construction yard and storage space

Open

Covered

12.0 ELECTRICALS

12.1 LT Motors (Motor list to be furnished with details of each motor as given below):

Location – Indoor / Outdoor

Number

Make

Application

Standard followed

Nominal rating

Nominal voltage

Nominal current

Power factor at full-load

Efficiency at full-load

Speed

IEC frame sizeClass of insulation and permissible temperature rise over an ambient temperature of 50oC

Full load torque of motor

Load torque

Starting current & starting time

Type of starting

No. of permissible starts/hour

Hot condition

Cold condition



Annexure - I

SL.NO DESCRIPTION

ASH HANDLING SYSTEM


Max. Al. Cable size that can be terminated to the Terminal box of the motor

Provision of space heater

12.2 Local Push button station

make

Technical details

Degree of protection

Confirm Start/Stop provision for all motors. Power and Control Cables (Details to be furnished for cables of various voltage grades)

Name of manufacturer

Standard followed

Type of insulation/Sheath

Voltage grade, kV

Conductor material used

Mimic diagram includes

PLC make and Model No.

PLC along with all hardware and software includes

All signal / data cables required has includes

12.3 Cable Trays and SupportsWeight per meter length (ladder & perforated) of different size offered

Galvanizing details/thk of coating

12.4 Earthing

Size of Electrode / Conductor Cross-sectionConfirm provision of earthing as per IE Rules 1956 and Indian Standards IS:3043

Galvanizing details / Thk of coating

12.5 Lighting Drawings

Lighting drawing furnished

Lux level considered for each area

Fittings

Type / No. of fittings

Make of fittings



Annexure - I

Sl.No: Description Units Tenderer to fill the data1 Type and make

Air comprssor Nos

Air receiver Nos.

Electric motor Nos

Air intake filter Nos

Control equipment Nos

PipingValves and specification

2 Air compressorSpeed RPM

Discharge pressure Kg/Cm2

Piston bore - LP mm

HP mm

Piston stroke mm

Piston speed m/min

Piston displacement m3

Actual qty of free air compressed m3/hr

Vol efficiency %

Loaded BHP @compressor shaft in loaded condition HP/KW

Unloaded BHP @compressor shaft (Valves open condition) HP/KW

No of stages Nos

No of cylinders per stage Nos

Type of cylinderCylinder liner required /not

3 Type and Material bearingsMainCrankpinCross-head

4 Type of lubricationCylinder liner required /not requiredBearing

5 MOCCylinder PistonConnecting rodBearingsFrame and running gearShaftbase plateValve platesValve springsValve sheets

6 Type and size of suction and discharge valves

7 Interval at which teflon rings etc are required to be removed

8 Air outlet temperatures Deg.C (adiabatic)9 Companion flanges bolts,nuts and gaskets furnished

AIR COMPRESSOR SYSTEM



Annexure - I

Sl.No: Description Units Tenderer to fill the data


10 AirfiltersTypeRated capacity

Clear air (m2)Minimum particle size removed (microns)Whether suction air filter is provided with trapped drain valving arrangement

11 MOCOuter casingFilter mediaFlanges

12 Pressure drop across filters kg/cm2

13 Details of safety relief valve provided in intercoolerSet pressure kg/cm2

Body materialInternal elementsInlet and outlet end connectionsType and make

14 IntercoolerTypeCode of constructionNo of passes No of tubesDia of tubes mm

Tube side mediumshell side mediumCooling surface area m2

Air pressure drop through intercooler kg/cm2

Air inlet and outlet sizes mm

Air outlet temp Deg C

15 Details of safet relif valve provided in intercoolerSet pressure kg/cm2

Body materialInternal elementsInlet and outlet end connectionsType and make

16 Air receiverDesign pressure kg/cm2

Hydrostatic test pressure kg/cm2

Code of constructionNominal vol m3

Size - Dia mm

Height mm

Wall thicknessCylinder portion mm

Heads mm

Corrosion allowance included in the above mm

MOC



Annexure - I



17 Details of safety valve provided on air receiverType and makeSet pressure kg/cm2

Body material kg/cm2

Internal elementsInlet and outlet end connections

18 No of pressure switches provided on air receiver for control19 Control panel

Supply voltagePhasesWiring systemAmbient tempWheteher completely assembled and wired to terminal blockIs the assembly enclosed in dust and vermin proof sheet steel cladpanel

20 Thermost/temparature switch ( with thermowell)TypeRangeMakeQuantaty

21 Pressure indicator (with isolation valve)TypeMakeRangeDial sizeConnection

22 Temperature indicator with thermowell)TypeMakeRangeDial sizeQuantity

23 Safety valvesSize - Dia (mm)TypeSet pressureMake

24 Solenoid valveSize TypeMakeAmp/VoltQty

25 Pressure switchType / Range adjustable differential ,connectionPortMakeQty



Annexure - I



26 Limit switchType Rating /voltMakeQty

27 Condensate discharge trapTypeSizeMakeQty

28 Isolating valvesTypeSizeMakeQty

29 Four way valvesTypeSizeMakeQty

30 General description and MOCa Valves

Type and makenumber and locationSizeMOCBodyTrimEnds

b TrapsType and makeQtySizeMOCBodyTrimEnds

c PipingSizeMaterialQuantity included as per sizeType of joints

d FittingsTypeMaterialQty includedEnd details



Annexure - I



e Pressure indicatorTypeMakeQtyDial sizeRangeGraduations/ResolutionAccuracyBourdon tube materialCase finish

f Pressure switch;Range adjustable differentialTypeMakeQtyContact ratingQty

g Temperature indicatorsTypeMakeRange ,Accuracy.Dial sizeMaterial

h Panel wiring cablesTypeGradeSizeMaterialInsulation

i Instrument cablesTypeGradeSizeMaterialInsulationSheathingArmouringOuter jacketting

31 Weights (Each Unit)Air compressor kg

Electric motor kg

Intercooler kg

Air receiver kg

Suction air filters kg

Valves and specialities kg

Pipe work -Integral kg

Inter connecting kgWeight of heaviest to be handled during erection and its descritption

kg



Annexure - I



Dimension of largest piece to be handles kg

Complete shipping weight kg

32 Lube oil requiered at time of start ltrs

No of hrs of running lube oil to be changed ltrs

Air Compressor Motor

1.0 Motor Driven EquipmentQuantity No.MakeTypeDutyReference Standard

2.0 Rated Power (kW) at specified design kWambient temperature of 50 °C(a) Synchronous speed RPM(b) Rated Speed RPMFrame SizeDirection of rotation(a) Rated voltage V(b) Rated voltage variation (%) %(c) Rated frequency Hz(d) Rated frequency variation (%) %(e) Combined voltage & Frequency variation %

3.0 Full load current ANo load current ARated power factor PFEfficiency at rated voltage fora) Full load %b) 3/4 load %c) 1/2 load %d) At start %Power factor at rated voltage fora) Full loadb) 3/4 load c) 1/2 loadd) 1/4 loade) At startStarting Torque to Full load torque ratio

4.0 Method of starting(a) 100% voltage (VR)(b) 85% voltage (VR)(c) 80% voltage (VR)Pullout torque at rated voltageStarting current in percentage of rated current(a) Starting time at 100% rated voltage i) With loadii) Without load (but with driven equipment coupled)



Annexure - I



(b) Starting time at 80 % rated voltage seci) With loadii) Without load (but with driven equipment coupled)Safe stall time at 110% rated voltage(a) Hot condition(b) Cold conditionThermal time constant, in min.No. of starts per houra) Equally spreadb) Successive hotc) Successive colda) Whether suitable for plugging duty

b) No. of reversals with load per hour Minimum permissible voltage at starting (with full load) at minimum (75%) allowable voltage

5.0 Degree of protection for enclosureMethod of coolingWinding materialClass of insulationTemperature rise (over specified ambient of 50 Deg.C)Whether adequate tropical protection againstfungus, corrosion etc. providedWhether short circuiting ring is jointlessWhether all joints have & winding over hangsare adequately supportedWhether all joints have adequate safety factoragainst fatigue due to stressesa) Winding connectionb) Winding resistance per phase at 20 °CWhether cooling fan is suitable for bi-directional rotation

6.0 Motor terminal box typeMotor terminal box locationDegree of protection for terminal boxFault withstand time and current for terminal boxWhether suitability for the specified cableshave been consideredType and maximum size of cables for whichmotor terminal box is suitable

7.0 Make of bearingsType of bearings (at DE & NDE)Recommended lubricationMethod of lubrication

8.0 No. of space heaters provided and ratingWhether separate terminal box for space heater is provided



Annexure - I



9.0 No. & sizes of grounding pada) on motor bodyb) on main terminal boxc) on terminal boxes for space heatersType of mounting for motorOverall dimension of motora) Weight of statorb) Weight of rotorc) Total weightMethod of couplingGD² value of rotor



Annexure - I


1.0 Equipment Assembly1.1 Make1.2 Type1.3 Reference Standard1.4 Voltage (Normal / Maximum) volt1.5 Phase, Frequency No., Hz1.6 Short Circuit Rating

a) Interrupting Symmetrical kAb) Short time for 1 sec. kA rms

1.7 Insulation Level1-min., 50 Hz voltage withstand kV rms

1.8 Constructiona) Metal clad, air insulated, floor mounting Yes/Nob) Suitable for mounting against building wall Yes/No

1.9 Enclosurea) Degree of protectionb) Minimum thickness of sheet metal used mm

1.10 Equipment fully assembled, wired and tested at factory Yes/No2.0 Construction for MCC2.1 Design

a) Completely compartmentalised b) Working height limits from floor level mm

2.2 Control Compartmenta) Provided with individual front access door

2.3 MCC section provided witha) Removable back coverb) Full height cable chamber

2.4 Horizontal wireway for inter panel wiring providedfor each MCC

2.5 All meters, relays, lamps etc. flush mounted type2.6 Vertical Section Size

a) MCC (L x D x H) mm3.0 Busbar3.1 Make3.2 Material & Grade3.3 Reference Standard3.4 Continuous current at site condition, 50 °C

ambient and within cubiclea) Main Busbar Ampb) Vertical Busbar (minimum) Amp

3.5 Conductor Sectiona) Main Busbar mm²b) Vertical Busbar mm²

3.6 Maximum temperature rise over 50 °C ambient °C3.7 Short-time current for 1 sec. kA rms3.8 Separate chamber / phase barrier / shrouding provided for

a) Main Busbarb) Vertical Busbarc) ACB Connections

MOTOR CONTROL CENTRE (MCC)



Annexure - I



3.9 Bus Connections Unita) Silver platedb) Provided with anti-oxide greasec) Bimetallic connectors between dissimilar metals

3.10 Minimum clearance of bare busbar and connectiona) Phase to phase mmb) Phase to ground mm

3.11 Busbar support spacing mm3.12 Busbars colour code Yes/No3.13 Bus Support Insulator

a) Makeb) Typec) Reference Standardd) Voltage Class kVe) Minimum Creepage Distance mmf) Cantilever Strength kg/cm²g) Net Weight kg

4.0 Control Module4.1 Control Modules

a) Non-drawout type4.2 Power / Control disconnects silver plated for good

contacts4.3 Non-drawout Modules of same type and rating are

physically & electrically interchangeable4.4 Module sizes (L x D x H)

a) Incomer mmb) Buscoupler mmc) Outgoing Feeder with Breaker mm Switch Fuse mmd) Starter unit with DOL mm

5.0 Switches5.1 Make5.2 Type5.3 Reference Standard5.4 Switch furnished with

a) Operating handleb) Door interlockc) Provision for padlocking in ON & OFF Positions

5.5 All feeders provided with bolted disconnect link5.6 Current Rating at 50 °C ambient & within cubicle

a)b)c)d)e)f)



Annexure - I



6.0 Fuse6.1 Make6.2 Type6.3 Reference Standard6.4 Rupturing capacity6.5 Continuous current at 50 °C ambient & within cubicle6.6 Cut off current6.7 Fuse characteristics furnished for various fuse ratings7.0 Contactors7.1 Make7.2 Type7.3 Reference Standard7.4 Duty class7.5 Utilization category7.6 Operating Coil Voltage

a) Ratedb) Pick-upc) Drop-out

7.7 Continuous Current rating @ 50 °C & within cubicle A7.8 Power Consumption

a) During closing VAb) After closing VA

7.9 Auxiliary contacts furnished per Contactora) Normally Open (NO)b) Normally Closed (NC)

7.10 Auxiliary contact ratinga) Make & Continuous b) Break (Inductive) at 240V AC Amp 220V DC Amp

7.11 Time range of delayed dropout contactors furnished Sec7.12 Thermal Overload Relay & Single Phase Preventor

a) Temperature compensated?b) Hand Reset?c) No. & type of contactsd) Thermal overload characteristics furnishede) Tolerance on current injection 1 - Pole 2 - Pole 3 - Pole

8.0 Control & Indication8.1 Push Button

a) Makeb) Typec) Cat. No.d) Contact Rating Make & Continuous Amp Break (inductive) 240V AC/220V DC Amp



Annexure - I



8.2 Lampsa) Makeb) Typec) Cat. No.d) Watts / Voltagee) Series resistor Ohmf) Lamp & lens replaceable from front

8.3 Selector Switch / Control Switcha) Makeb) Type & Catalogue No.c) 3 - position stayput type / spring return to normal with LOST MOTION DEVICEd) Contact Rating i) Make & Continuous Amp ii) Break (inductive) Ampe) Key interlock furnished

9.0 Meter9.1 Make9.2 Type9.3 Reference Standard9.4 Size/Scale9.5 Accuracy class9.6 Meter Switch

a) Makeb) Typec) Cat. No.

10.0 Current Transformer 10.1 Make10.2 Type10.3 Reference Standard10.4 CT Ratios as per drawings ?10.5 Rated frequency10.6 Class / ALF or ISF / VA burden furnished for

a) Relaying CTb) Metering CT

10.7 Short-circuit withstanda) Short-time current for 1 sec kA rmsb) Dynamic current kA peak

11.0 Voltage Transformer11.1 Make11.2 Type11.3 Reference Standard11.4 Voltage Ratio11.5 Rated Frequency11.6 Accuracy Class11.7 VA burden11.8 Over Voltage factor

a) Continuousb) 30 seconds



Annexure - I



11.9 Class of insulation11.10 Temperature rise over 50 °C ambient °C11.11 Basic impulse level kV11.12 Winding connection

a) Primaryb) Secondary

13.0 Secondary Wiring13.1 Type of Insulation13.2 Voltage Grade13.3 Conductor material13.4 Conductor size (minimum)

a) Potential Circuit mm²b) Current & Control Circuit mm²

13.5 Wires identified at both ends with ferrules14.0 Terminal Block14.1 Make14.2 Type14.3 Cat. No.14.4 Voltage Grade14.5 20% spare terminals furnished15.0 Cable Termination15.1 Cable entry provision from top & bottom ?15.2 Cable termination and connection arrangement

furnished as specified15.3 Power Cable Lugs

a) Typeb) Materials

15.4 Power Cable Glandsa) Makeb) Typec) Materialsd) With tapered washers

15.5 Removeable Gland Platea) Material for multicore cableb) Material for I/C cablec) Thickness of the plate

16.0 Ground Bus16.1 Ground bus furnished ?16.2 Material16.3 Size17.0 Name Plate17.1 Material17.2 Thickness17.3 Size

a) Panelb) Equipment / Device



Annexure - I



18.0 Space Heater / Plug Socket18.1 Cubicle Heater

a) Thermostat controlledb) Wattagec) Voltage

18.2 Plug Socketa) Typeb) Rating

18.3 Provision made for motor heater supply

18.4Cubicle / Motor heater / Plug Socket circuit provided with individual switch fuse units

19.0 AC / DC Supply19.1 Isolating switch-fuse unit for incoming supply

a) AC - Type & ratingb) DC - Type & rating

19.2 Isolating switch-fuse unit at each cubiclea) AC - Type & ratingb) DC - Type & rating

20.0 Tropical Protectiona) Any special treatment for tropical protectionb) Screens are of corrosion resistant materials

21.0 PaintingFinish of MCCa) Insideb) Outside

22.0 No. of Accessories Furnished22.1 Breaker lifting / handling truck22.2 Device for slow opening and closing of breaker22.3 Test cabinet with coupling cables for testing of

breaker22.4 Racking in/out handle23.0 Test23.1 Routine tests on MCC to be performed as per specification23.2 Type test quoted

a)b)c)

23.2 Type test quoteda)b)c)

24.0 Typical Drawings / Data Furnished24.1 General arrangement24.2 Foundation plan24.3 Control scheme24.4 Bill of Materials25.0 Overall Dimensions & Weights Dimensions

(LxDxH) mm415V Bagasse Handling Motor Control Centre


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