Procurement, Fabrication, Supply, Erection and Commissioning of High Temperature Molten Salt Loop With Central Receiver, Molten Salt Storage, Heat Exchangers and Allied Works
Tender Number – 201601548
Indian Institute of Technology Bombay
IIT Bombay Tender Number – 201601548
Contents Section – 1: Invitation to the Bidders ....................................................................................................................... 1 Section – 2: Introduction ............................................................................................................................................... 6 2.1 Project Brief ............................................................................................................................................................ 7 2.2 Project Site Location ........................................................................................................................................... 8 2.3 Broad Scope of Supply and Services ............................................................................................................. 8 Section – 3: Prequalification criteria ........................................................................................................................ 9 Section – 4: Instruction to bidders ......................................................................................................................... 11 Section – 5: Scope of work and scope matrix ..................................................................................................... 21 5.1 Scope of work...................................................................................................................................................... 22 5.2 Scope matrix ........................................................................................................................................................ 30 Section – 6: Technical bid ........................................................................................................................................... 38 6.1 Technical work specification ........................................................................................................................ 39 A.
Technical specifications – Piping and mechanical work ............................................................ 39
B.
Technical specification - Structural Steel work ............................................................................. 85
C.
Technical specifications for instrumentation work. .................................................................... 96
D.
Technical specification – Electrical work ....................................................................................... 111
E.
Technical specifications of Molten Salt, selective coating and heat transfer compound 117
6.2 Technical Deviations:..................................................................................................................................... 121 Section – 7: Price bid .................................................................................................................................................. 122 7.1 Price bid Table .................................................................................................................................................. 123 7.2 Payment schedule ........................................................................................................................................... 125 7.3 Cost drivers ........................................................................................................................................................ 127 A.
Schedule of quantities - Structural steel work ............................................................................. 127
B.
Schedule of quantities – Piping & Mechanical work .................................................................. 127
C.
Schedule of quantities – Electrical work ........................................................................................ 136
D.
Schedule of quantities – Instrumentation work .......................................................................... 142
E.
Schedule of quantities – Molten Salt, selective coating and heat transfer compound . 162
F.
Schedule of quantities – Spares .......................................................................................................... 163
Section – 8: Annexures .............................................................................................................................................. 170 Annexure 1: Drawing list ..................................................................................................................................... 171 Annexure 2: Document List ................................................................................................................................ 173 Annexure 3: Deviation Statement Form........................................................................................................ 177 Annexure 4: Integrity pact .................................................................................................................................. 178
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IIT Bombay Tender Number – 201601548 Annexure 5: Format for earnest money deposit/bid bond ................................................................... 188 Annexure 6: Format for performance bank guarantee ........................................................................... 190 Annexure 7: Format for deviations/exclusions schedule ...................................................................... 192 Annexure 8: Previous supply order format ................................................................................................. 194 Annexure 9: Checklist ........................................................................................................................................... 195
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Section – 1: Invitation to the Bidders
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Tender Details
Tender Date: 26.05.2017
Tender Number: 201601548
Form of Contract: Supply
Tender Type: Open No. of Covers: 2 Payment Instruments
Instrument Type:
Payment Mode : Offline
As per Tender Document
Covers Information Cover. No
Cover Type
Description
1
Technical
Tender Document,
Document Type
Pre-qualification responses Tender Fee, EMD, Integrity Pact and Technical Specification Site visit /Inspection/Examination Certificate 2
Commercial
Commercial Bid / Price Bid
Tender should be submitted on the schedule to tender and returned with your covering letter in the enclosed form duly signed. Tender should be sent in the sealed cover super scribed with Tender Number and Due Date. Two Bid System: The two bid system will be followed for this tender. In this system bidder must submit their offer in separate sealed envelopes as – Technical Bid and Commercial Bid. Separate technical bid and commercial bid envelopes should be clearly marked as "Envelope No. 1 – Technical Bid" and "Envelope No. 2 - Commercial Bid". Both these sealed covers are to be put in a bigger cover which should also be sealed and duly
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superscribed with our Tender No. & Due Date and to be submitted to the concern department/section mentioned in tender document. Note: The technical offer should not contain any price information. If the price quoted is submitted in technical bid the tender will be rejected at the sole discretion of IIT Bombay. Initially Technical Bids will be opened and evaluated by the purchase committee. Commercial bids of only Technically qualified bidders will be opened later. Contract/ Purchase Order will be awarded to the lowest bidder (L1) among them. Tender Fee Details Tender Fee (INR)
Payable to: The Registrar, IIT Bombay
500/-
Payable at: Mumbai
Earnest Money Deposit Details EMD Fee (INR):
In favour of: The Registrar, IIT Bombay
7,40,000/EMD Fee Type: Fixed Payable at: Mumbai Item Details /Item Item Description Name Procurement, Fabrication, Supply, Erection and Commissioning of High Temperature Molten Salt Loop with Central Receiver, Molten Salt Storage, Heat Exchangers and Allied Works
This Tender document is for ‘Molten Salt Loop with Central Receiver, Salt Storage and Heat Exchanger’ which includes development of central receiver and thermocline storage system. This project will be implemented at NTPC NETRA (Owner) at Greater NOIDA, Uttar Pradesh for testing and performance evaluation. Basic and detailed engineering of the Solar Thermal Energy Collector and Thermal Energy Storage has been carried out by IITB (Client) and its Detailed Engineering Consultant (DEC). The bidder is expected to carry out the required procurement, fabrication, supply, erection and commissioning of high temperature molten salt loop with central receiver, molten salt storage, heat exchangers and allied works. This has to be done as per detailed engineering documents, drawings and Bill of Materials (BOM).
Pre-Qualification:
As Per Tender Bid Document (Days)
Validity 180
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Period of Work/ Delivery Period
32
weeks Product Category
Sub
Product Category
Others
Pre Bid Meeting 19th June, 2017, Date & Time 3.30 PM
Contract Type
Tender
Pre Bid Meeting Materials Management Division, Address IIT Bombay
Location
IIT Bombay Campus
Pincode
400076
Critical Dates Bid Submission End 05th July, 2017 Date and Time 1.00 PM Place of Submission
Bid Opening Date 05th July, 2017 and Time 3.30 PM
Materials Bid Management place Division, IIT Bombay
opening Materials Management Division, IIT Bombay
Other Condition: Suppliers should provide previous purchase order details in the technical bid along with the necessary documents as per the requirement of prequalification criteria. Warranty : Warranty as per mentioned in technical specifications Technical Clarification Name
Prof. Shireesh B. Kedare
Department
Department Engineering.
Email Contact No.
of
Energy
Science
&
[email protected] 022-25767835
Tender Inviting Authority Name
Joint Registrar
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Address Date: -------------
Materials Bombay,
Management
Division,
IIT
Powai, Mumbai 400076 Signing Authority: Joint Registrar (MM)
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Section – 2: Introduction
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2.1 Project Brief This project is targeted towards development and setup of indigenous 3.5 MW e x 24 hour/day Solar Thermal Power Plant. The research and development component of the targeted initiative was divided into several projects over the last 2 to 3 years. Each of these projects were formulated in tune with the overall perspective and handled independent of each other involving various faculty members across the departments at IIT Bombay. Setting up of the above mentioned indigenous Solar Thermal Power Plant would now require development and testing of prototypes of various Concentrated Solar Power (CSP) components conceptualized till now and experimented with. This prototype development and testing is being taken up as three R&D projects mentioned below; 1. Molten salt loop with central receiver, salt storage and heat exchanger. 2. Heliostat reflector development with tracking and flux measurement. 3. Linear Fresnel Reflector (LFR) based collector development with receiver and steam storage. These R&D projects are being taken up in parallel. This tender document pertains to ‘Molten Salt Loop with Central Receiver, Salt Storage and Heat Exchanger’ (listed at 1 above) is targeted towards development and set up of a molten salt loop to collect solar thermal energy from central receiver and store it in a thermocline thermal storage tank. The solar thermal energy is directed onto the central receiver by the heliostats which are part of another project (listed at 2 above). The project will run concurrently with heliostat project and Linear Fresnel Reflector project at the same site (listed at 3 above). These three projects will be integrated at the end of successful commissioning and testing of each project independently. Subsequently the entire system of the three projects is expected to deliver turbine quality steam. This project will be implemented at NTPC NETRA at Greater Noida, Uttar Pradesh for testing and performance evaluation. This molten salt loop project consists of a "hot" salt loop to pick up solar thermal energy at receiver and store in a thermocline tank. Stored energy is then used to generate steam in "cold" salt loop. Molten salt loops operate between 290 ⁰C and 565 ⁰C. So all the equipment and piping are of special grades of stainless steel. Fabrication of all the equipment and piping will therefore require high degree of precision in manufacturing and skills and knowledge associated with superior materials of construction and sophisticated manufacturing processes. General classification of the scope: • • •
Construction of central receiver, thermocline storage tank and salt piping Heat exchangers, steam piping, structures, utilities Electrical, instrumentation and controls
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2.2 Project Site Location Address
: NETRA NTPC Limited E-3, Ecotech II, Udyog Vihar, Greater Noida, Uttar Pradesh 201306
Location
: 28°30’10”N 77°27’57”E
Climate
:
Summer
: In summer i.e. from March to June the weather remains hot and temperature ranges from maximum of 45°C (i.e. 113°F) to minimum of 23°C (73°F).
Monsoon
: Monsoon season prevails during mid-June to mid-September with an average rainfall of 93.2 cm (36.7 inches), but sometimes frequent heavy rain causes flood.
Winter
: Temperatures fall substantially down to as low as 3 to 4º C at the peak of winter. Greater Noida experiences problems of fog and smog.
Bidders are request to visit the site location and access the conditions. Bidders are required to submit an undertaking in support of the same.
2.3 Broad Scope of Supply and Services The broad scope of supply and services are following: • • • • •
• •
Supply of items listed in BOQ as per the indicated specifications Fabrication including QA and conducting all shop acceptance tests as required Packing, loading, transportation and unloading of material at site including all clearances from concerned authorities Receipt, storage and preservation of equipment at the site Mechanical, structural, process equipment/vessels, electrical, controls and instrumentation erection including conducting all field tests in coordination with the technical consultant for detailed engineering. Supply of skilled manpower to carry out specific tasks as explained in the technical information section. Compliance of all statutory requirements
It is not the intent to specify herein all aspects of engineering and construction. The Bidder shall be responsible for providing all materials, equipment and services, specified or otherwise (unless specifically excluded) which are required to fulfil the intent of ensuring operability and the reliability of the complete system covered under this specification. Sub-vendors for all bought out and out sourced items shall be finalized in consultation with IITB and DEC.
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Section – 3: Prequalification criteria Pre-qualification criteria and process along with details and format of data to be submitted for selection: Two-bid system will be followed where-in the technical bid will be opened first and evaluated. Bidders whose technical criteria are acceptable as per the selection criteria (elaborated below), will be considered for opening of the respective price bids. All bids qualifying the prequalification criteria will be stand eligible for opening of commercial bid. Bidder with lowest commercial bid will be awarded the contract. The technical bid provided by the bidder should contain the details outlined below: 1. Technical capability: The bidder should furnish the details of in-house or outsourced resources like tools, machinery, skills related to fabrication of structural and mechanical systems and manpower involved in the project. 2. Financial capability: a. The bidder should have successfully executed at-least one multidisciplinary procurement, construction and commissioning project of value not less than INR 1,00,00,000/- during last five years ending 31st March, 2017. b. Bidder shall submit financial statements such as balance sheets and P&L statements of the last 3 financial years. 3. Qualification Requirement: a. The bidder shall have successfully completed minimum three similar work of procurement, construction and commissioning (the term “similar work” implies mechanical works like high temperature and pressure piping and equipment erection, high pressure IBR steam generators, structural steel works, mechanical, electrical and instrumentation controls involving PLC, SCADA, process control, control valves, packaged instrument air system, construction of control room etc.) b. Bidders shall have executed minimum 3 projects involving procurement, supply, installation and commissioning of PLC systems with SCADA Detailed format for the data to be submitted for the qualification requirement is given under different headings below. Bidder shall submit information sought below of successful completion of the works meeting the criteria stated above and other works executed in the last five years. A purchase committee may also choose to get the feedback from bidder’s client to check the fulfilment. Following information / documents shall be provided of the works executed. 1. Name of the client with corporate address, site address 2. Name of contact person(s) and phone/email of the contact person 3. Description and scope of job (mechanical, electrical, instrumentation controls and civil works, manufacturing of high pressure IBR equipment, heat exchangers, procurement, supply, and installation and commissioning of PLC systems with SCADA) 4. Order value in Indian Rupees 5. Year of start and job completion 6. Documentary evidence provided, like copy of POs, reports, appreciation letters, etc.
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IIT Bombay Tender Number – 201601548 The decision of the purchase committee on the eligibility of the bidder shall be final and binding on the bidder.
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Section – 4: Instruction to bidders
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1. Bidder must be a qualified entity (firm/company). 2. Bidder shall submit the list of jobs intended to be sub-contracted along with the details of sub-bidders. The bidder in the event of his tender being accepted, shall not assign or delegate the contract or any part thereof, without the prior approval of IITB. 3. Bidder shall submit financial statements such as Balance Sheets and P&L statements of the last 3 financial years. (Note: The word ‘Bidder’ used in the document is as per the definition stated in point 1 above) 4. The site will be offered on AS IS WHERE IS for the execution of this job and it will be the sole responsibility of the bidder to ensure that they abide by the various rules and regulations, bye-laws and other statutory requirements, etc., imposed by the Government / semi-Government / Owner and / or other local authorities governing execution of this job. 5. Before submitting the bid, the bidder is advised to visit, inspect and examine the site and its surroundings. The bidder has to submit in writing that he has indeed visited, inspected and examined the site and its surrounding. The bidder has to look at access to the site and evaluate the site conditions of operation at his own cost. The bidder before tendering should clearly understand the scope of work and must satisfy himself with the required quantities of material, accommodation as may be required and no claim subsequently on account of ignorance shall be entertained. No consequent extra claims on any misunderstanding or otherwise shall be allowed by the IIT Bombay. (Site address for visit: NTPC Energy Technology Research Alliance (NETRA) Plot No. 3, block E, Ecotech-II, Udhyog Vihar, Greater Noida, Gautam Budh Nagar, (Uttar Pradesh) 201 306 INDIA Bidder has to provide specific date for visit at site to IITB project office. Office will convey contact of local person & other arrangement as required. Bidders are requested to carefully examine and understand the specifications and 12 | P a g e
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seek clarifications, if required, to ensure that they have understood the specifications. Bidder’s offer should not carry any sections like clarifications, interpretations and/or assumptions. However, if the bidder feels that, in his opinion, certain features brought out in his offer are superior to what has been specified, these may be highlighted separately. 6. The bid shall be evaluated as complete package and not on the basis of individual items. 7. The quantities of the various items mentioned in the schedule are approximate and may vary up to any extent or be deleted altogether. The quoted rates of each item shall remain firm. 8. The bidder will have to make his own arrangement to transport the required materials outside and inside the working place and leaving the premises in a neat and tidy condition after the completion of the job to the satisfaction of the IITB Engineer, the Detailed Engineering Consultant (DEC) and NTPC-NETRA. 9. The bidder will have to arrange for site office and temporary shed on his own expense for safe keeping of materials and should provide necessary security arrangements for safe guarding the materials. IITB will not be responsible for any claims in this regard. 10. As far as possible, the bidders should endeavour not to stipulate any counter terms / conditions or modifications of tender clauses and should quote strictly as per tender conditions. IITB reserves the right to reject offers not meeting its technical requirements and commercial conditions. 11. The bidder shall get prior approval from DEC and IITB for release of purchase order to sub-vendors and bidders. 12. The bidder shall furnish to the DEC and IITB the duplicate copies of all p urc ha se orders placed for this project and the test reports received from the vendor to the DEC’s check and information. 13. Bidder has to take labour license from the licensing authority of Greater Noida. Bidder should follow all relevant safety norms. 14. Warranty shall be 12 months from the date of commissioning / 18 months from the date of supply whichever is later, except where warranty is specifically stated otherwise than above and ceases earlier than the general warranty stated above. 15. The bidder shall arrange at his own expense for concerned Engineers to attend 13 | P a g e
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pre-bid meetings, technical discussions and project progress review scheduled by IITB. The venue for the meetings will be at IITB campus or at the project site. 16. All material constructed or otherwise, shall be considered as the property of bidder till the handover of the project. Preparation and Submission of offers: 17. The Quotation MUST BE ENCLOSED IN A SEALED COVER superscribing Tender number / due date & should reach the undersigned on or before due date mentioned in the tender notice. If the quotation cover is not sealed, it will be rejected. 18. Tender should be dropped in the tender box kept in the office of concerned Department / Section or to Indenter. No tender is to be handed over to our staff personally unless otherwise specified. All communications are to be addressed to the undersigned only. In case due date happens to be holiday the tender will be accepted and opened on the next working day. 19. The bid can be submitted in person or through post/ courier (IITB shall not be responsible for any postal delays or any other reason for not submitting the bid in the specified time and resulting in disqualification / rejection of any bid) so as to reach on or before the due date and time. 20. The leaflets catalogue, etc. should be sent invariably so that a proper evaluation of the equipment offered is possible.
Cost of Bidding: 21. The Bidder shall bear all costs associated with the preparation and submission of its Bid and the Purchaser shall not be responsible or liable for those costs regardless of the conduct or outcome of the bidding process.
Validity of the Bid: 22. 180 Days from the last date of submission of bid. Amendment of Bidding Documents:
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23. At any time prior to the deadline for submission of bids, IITB may, for any reason, whether on its own initiative or in response to the clarification request by a prospective BIDDER may modify the bid document. 24. All prospective BIDDERs who have downloaded the bidding document should visit IITB, website for amendments / modifications which will be binding on them. Deadline for Submission of Bids: 25. Bids must be received by IITB before the due date and time at the address specified in the tender document. In the event of the specified date for the submission of bids being declared as a holiday for IITB, the bid closing deadline will stand extended to the next working day up to the same time.
Late Bids: 26. IIT Bombay will not be responsible: i) For delayed / late quotations submitted / sent by post / courier etc. ii) For submission / delivery of quotations at wrong places other than the mentioned in the tender. iii) Fax / E-mail / Telegraphic / Telex tenders will not be considered. iv) Any bid inadvertently received by IIT Bombay after the deadline i.e. due date & time for submission of bids, will not be accepted and returned unopened to the BIDDER. Confidentiality: 27. Information relating to the evaluation of Bids, and recommendation of Contract award, shall not be disclosed to Bidders or any other persons not officially concerned with such process until information on Contract award is communicated to all Bidders. 28. Any attempt by a Bidder to influence the Purchaser in the evaluation of the Bids or Contract award decisions may result in the rejection of its Bid.
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29. Notwithstanding, from the time of Bid opening to the time of Contract award, if any Bidder wishes to contact the Purchaser on any matter related to the bidding process, it shall do so in writing. Deviation, Reservations and Omissions: 30. During the evaluation of Bids, the following definitions apply: (a) “Deviation” is a departure from the requirements specified in the Bidding Documents. (b) “Reservation” is the setting of limiting conditions or withholding from complete acceptance of the requirements specified in the Bidding Documents. (c) “Omission” is the failure to submit part or all of the information or documentation required in the Bidding Documents. Correction of Arithmetical Errors: 31. Provided that the Bid is substantially responsive, the Purchaser shall correct arithmetical errors on the following basis: (a) if there is a discrepancy between the unit price and the line item total that is obtained by multiplying the unit price by the quantity, the unit price shall prevail and the line item total shall be corrected, unless in the opinion of the Purchaser there is an obvious misplacement of the decimal point in the unit price, in which case the line item total as quoted shall govern and the unit price shall be corrected. (b) if there is an error in a total corresponding to the addition or subtraction of subtotals, the subtotals shall prevail and the total shall be corrected.
(c) if there is a discrepancy between words and figures, the amount in words shall prevail, unless the amount expressed in words is related to an arithmetic error, in which case the amount in figures shall prevail subject to (a) and (b) above.
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Bidders shall be requested to accept correction of arithmetical errors. Failure t0 accept the correction in accordance with the same, shall result in the rejection of the Bid. Evaluation of Bid: 32. IITB evaluate technical and commercial acceptable offers on landed net Price basis.
33. In case any BIDDER is silent on any clauses mentioned in this tender documents, IITB shall construe that the BIDDER had accepted the clauses as per the invitation to tender no further claim will be entertained. 34. No revision in the terms and conditions quoted in the offer will be entertained after the last date and time fixed for receipt of tenders.
Corrupt & Fraudulent Practices: 35. IITB requires that bidders, suppliers, contractors and consultants, if any, observe the highest standard of ethics during the procurement and execution of such contracts. In pursuit of this policy, a. The terms set forth below are defined as follows: i.
“Corrupt practice” means the offering, giving, receiving, or soliciting, directly or in directly, of anything of value to influence the action of a public official in the procurement process or in contract execution.
ii.
“Fraudulent practice” means a misrepresentation or omission of facts in order to influence a procurement process or the execution of a contract.
iii.
“Collusive practice” means a scheme or arrangement between two or more bidders, designed to establish bid prices at artificial, noncompetitive levels.
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iv.
“Coercive practice” means harming or threatening to harm, directly or indirectly, persons or their property to influence their participation in the procurement process or affect the execution of a contract.
b. IITB will reject a proposal for award if it determines that the Bidder recommended for award has, directly or through an agent, engaged in corrupt, fraudulent, collusive or coercive practices in competing for the Contract in question. Communication for Non-participation of Tenders: 36. For registered vendors with IITB, in case you choose not to participate in the tender a regret letter by way of fax/letter/email may be submitted before the due date duly superscribing “Regret” and tender No. If no communication received by the due date and time, it shall be inferred that you are not interested in participation and your name is liable to be removed from the vendor's list. Cancellation of Tender: 37. Notwithstanding anything specified in this tender document, Purchaser / IITB in his sole discretion, unconditionally and without having to assigned any reasons, reserves the rights: a. To accept OR reject lowest tender or any other tender or all the tenders. b. To accept any tender in full or in part. c. To reject the tender offer not confirming to the tender’s terms. 38. To give purchase preference to Public Sector undertakings when applicable as per Govt. Policy/ Guidelines. 39. Offer which deviates from the vital conditions (as illustrates below) of the tender shall be rejected: a. Non-submission of complete offers. b. Receipt of offers after due date and time and or by email / fax (unless specified Otherwise). c. Receipt of offers in open conditions.
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Price Bid: 40. Bid Prices MUST BE SUBMITTED IN ENCLOSED PRICE BID FORM ONLY.
41. If the price is not quoted in Price Bid Form provided in tender document then, IITB will reject bid. If supplier wish to give pricing details may be attached in separate sheet. 42. Any new taxes and duties liable on the subject contract due to change in legislation during the contract period shall be reimbursed subject to the applicability of the said act to the satisfaction of the purchaser and the production of documentary evidence after availing of statutory concession, benefits etc. 43. The supplier shall pay and bear all other liabilities, taxes and duties not specifically agreed by the Purchaser in the contract. 44. VAT/Other Govt. Taxes: Excise Duty (ED), other taxes, levies, like Service Tax (ST), Education Cess, etc., are to be indicated separately. BIDDER should mention Central and State Sales Tax/VAT Registration, PAN Number are to be necessarily indicated in the offer. 45. IITB are not authorised to issue any Sales Tax forms like form “C” & “D”. Legal Matter: 46. All Domestic and International disputes are subject to Mumbai Jurisdiction Only.
Transfer and Subletting: 47. The seller shall not sublet, transfer, assign or otherwise part with the acceptance to the tender or any part thereof, either directly or indirectly, without the prior written permission of the Purchaser.
Force majeure:
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48. Force Majeure will be accepted on adequate proof thereof.
Penalty/ Liquidated Damages: 49. Timely delivery is essence of the contract and hence if any consignment be delayed, liquidated damages at the rate 0.5% of the price of the delayed consignment, for each week or part whereof shall be levied and recovered subject to maximum of 5% of total purchase order value.
50. IITB reserves the right to cancel the order in case the delay is more than 10 weeks. Penalties if any will be recovered by forfeiting PBG. Any deviation from the clauses of the tender, technical and financial, should be compiled in Annexure – 3 and 7. The deviations will be discussed during the pre-bid meeting and the outcome of the meeting will be taken as final.
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Section – 5: Scope of work and scope matrix
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5.1 Scope of work SCOPE OF SUPPLY, FABRICATION, ERECTION AND COMMISSIONING: Overall layout as shown in the attached drawing C530/ME/GA/A1/309 will be followed as a broad guideline for the available space for molten salt loop location. In general, the scope includes detailed engineering of some items such as PLC and electrical panels, IBR specific design of heat exchangers (if any in addition to that provided by the DEC), procurement, fabrication, transport, insurance, delivery, loading, unloading, storage, security, statutory compliances including IBR, erection, commissioning of following components: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
16.
Central receiver assembly with insulation and selective coating Thermocline storage tank Molten salt to steam heat exchangers consisting of water preheater, evaporator and steam superheater. Molten salt circulation pumps for "charging" and "discharging" circuits. Feed water tank Feed water pumps Electrical heaters for salt melting, system start up and operations. Piping, valves and fittings on molten salt lines, steam lines and feed water line. Silencers for steam vent valves Electrical system for drive motors and heaters. Set of instruments on salt lines, water and steam lines. SCADA system and PLC based control panel Electrical heating of receiver for initial loop and temperature distribution testing by IITB. Steam trace tubing and heat transfer compound Utilities i. Feed water dosing system ii. Instrument air system and blanketing iii. Cooling water system for receiver rim cooling, dummy receiver cooling, sample cooler, camera etc. iv. Motorised hoists Salt
Detailed specifications etc. are presented in Technical work specifications and data sheets attached to this tender document following the brief below. All codes, standards referred to in this and related documents imply latest revision of the code / standard.
A. Heliostat receiver assembly with insulation The receiver assembly consists of SS tube coils placed within the receiver cavity as per drawings and details. The stainless steel tube coils shall be of SS 316 Ti grade suitable for 600 ⁰C design temperature and 5 bar pressure with cyclic temperature variations from ambient temperature to design temperature in a daily operation. Inlet outlet headers are also of equivalent stainless steel material. 22 | P a g e
IIT Bombay Tender Number – 201601548 The tube coils shall be within an insulated front-open housing of carbons steel plates and inner SS lining with insulation sandwiched in between supported on structural members. The receiver tube coils shall be coated with a selective coating having high absorptivity in the solar spectrum and low emissivity in the thermal spectrum. The receiver assembly shall be provided with retractable heaters designed for daily pre-heating of the receiver tube coils for commissioning the plant. The receiver assembly shall have heavy duty electrical heaters which shall simulate the design heat capacity of the receiver cavity for initial testing of the receiver and precommissioning trials of the plant. These heaters shall subsequently be removed and discarded and the entry points sealed with insulation plugs as per design and details before commissioning the plant with reflected radiation from the heliostats (R&D project 2 – refer project brief).
B. Thermocline storage tank Thermocline tank has a function of thermal storage. Hot molten salt coming from the receiver adds heat into the storage tank. A temperature gradient gets established along the tank height due to density difference. Thus cold salt is at the bottom of the vessel and hot salt is on top. In the charging circuit cold molten salt from the bottom of the tank is pumped to the receiver and hot salt from the receiver is fed from the top through a distributor. In the discharging circuit, hot molten salt from top layer of the tank is pumped to the heat exchanger and cold salt returning enters the bottom through the distributor.
C. IBR approval Feed-water and steam generating system from outlet feed water pump to isolating valve at super heater outlet including the steam tracing system comes under the purview of IBR. It is the bidder’s responsibility to understand the project scheme, identify the items of supply and work therein which require IBR approval irrespective of whether requirement of IBR approval is mentioned at the specification of the respective item / work or not. It is the bidder’s responsibility to design (if any required in addition to the design details and calculation provided by DEC) and make relevant documents, design calculations and drawings as per IBR formats, liaise with IBR, arrange visits to workshops and site, obtain IBR certificates from suppliers for supplies, obtain IBR approval for manufactured items, obtain approval IBR for completed installation etc. and finally arrange for provisional order (PO) from IBR authorities. It is the bidder’s responsibility to conduct the work at site in full compliance with the IBR requirements (IBR approved welder, stage-wise inspections etc.). All expenses including incidental expenses shall be to bidder’s account and shall be deemed included in the overall price of the contract. For pre-commissioning of the project, the bidder shall submit a complete dossier of all IBR documents including copies of application forms, letters of correspondences, IBR certificates of items such as pipes, pipe fittings, valves, IBR certificates of fabricated items such as heat exchangers in the state of manufacture, IBR visit reports and instructions, if any, copies of payment receipts, Provisional IBR Certificate original in requisite forms duly approved and countersigned by IBR authority / local authority empowered by Central Boiler Board of India with required arrangement for display of the same. Submission of the final IBR certificate shall be a pre-requisite for payment at the appropriate stage of payment.
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IIT Bombay Tender Number – 201601548
D. Molten salt to steam heat exchanger The purpose of the heat exchanger is to transfer heat stored in the thermocline tank in the form of molten salt to water and convert it to superheated steam. The heat exchanger is in three separate units – water preheater, evaporator or boiler and superheater. All the heat exchangers are shell type with molten salt in helical tube coils. All heat exchangers shall be supplied with passivation treatment to all water / steam surfaces. 1. Preheater: The preheater shall be a vertical cylindrical vessel with a helical tube coil for flow of hot salt. The vessel is considered as a standard pipe with the ends being suitable cap sections. However, the bidder may make his own design using suitable plates duly formed to the shape and dimensions given in the drawing and details. 2. Evaporator section The evaporator shall be a vertical cylindrical vessel with a helical tube coil for flow of hot salt. The vessel is considered as a standard pipe with the ends being suitable cap sections. However, the bidder may make his own design using suitable plates duly formed as per the requirements of ASME BPVC to the shape and dimensions given in the drawing and details. The evaporator to have provisions for all the ancillary controls, instrumentation and safety as prerequisites to a standard shell type boiler under the provisions of the Indian Boiler Regulations. 3. Superheater section The superheater shall be a vertical cylindrical vessel with a helical tube coil for flow of hot salt. The vessel is considered as a standard pipe with the ends being suitable cap sections. However, the bidder may make his own design using suitable plates duly formed to the shape and dimensions given in the drawing and details. Design Codes and Procedure: The heat exchanger being a steam generator, is under Indian Boiler Regulation. So Design Code - IBR 1950 and latest amendments thereof.
E. Molten salt circulation pumps There are two salt circuits viz. 1. the charging circuit (charging the thermocline tank with hot molten salt) and 2. the discharging circuit (discharging the stored thermal energy of the molten salt to superheated steam generation). Each above circuit shall be operated by its molten salt circulation pump. Both pumps shall be vertical centrifugal pumps, top mounted on the thermocline tank. The pumps shall be designed for the extreme duty conditions. The pumps may be line shaft or cantilever type. Piping drawings and details provided in the tender are based on cantilever design. The pumps shall be designed, procured, inspected, tested at vendor’s works, delivered to site, installed and commissioned by the vendor based on the broad specifications given here and the data sheet issued. The scope of supplies shall include pump with motor, base frame, coupling, fasteners, safety guards, inlet and outlet flanges, cooling system, controls, safety devices, etc. Any 24 | P a g e
IIT Bombay Tender Number – 201601548 other item required for the safe operations of the pump as per the process conditions is deemed included in the scope unless specifically excluded.
F. Boiler feed water tank Capacity -
2000 L(nominal)
Type -
Cylindrical vertical, insulated
Material -
Carbon steel
Accessories - Steam preheating coil to heat make-up water from 30 °C to 80 °C Chemical dosing provision Manhole, drain, vent etc. Please refer - C530/ME/GA/A1/314 – G.A. of Feed Water Tank.
G. Boiler feed water pumps The pumps shall be selected, procured, inspected, tested at vendor’s works, delivered to site, installed and commissioned by the vendor based on the broad specifications given here and the data sheet issued. The scope of supplies shall include pump with motor, base frame, coupling, gear box / chain drive, fasteners, foundation bolts, safety guards, pressure safety valve, pulsation damper, inlet and outlet non-return valves, lubricating system, lubricants, controls, safety devices, weather hood etc. Any other item required for the safe operations of the pump as per the process conditions is deemed included in the scope unless specifically excluded. The motor shall be operated with VFD.
H. DM water transfer pump and cooling water circulation pump The pumps shall be selected, procured, inspected, tested at vendor’s works, delivered to site, installed and commissioned by the vendor based on the broad specifications given here. The scope of supplies shall include pump with motor, base frame, coupling, foundation bolts, belt drive with safety guards, etc. Any other item required for the safe operations of the pump as per the process conditions is deemed included in the scope unless specifically excluded.
I. Electrical heaters Electrical heaters are required for start-up as well as operations of the plant. The heaters and controls, safety (of element and assembly etc.) thereof shall be procured, inspected, tested at vendor’s works, delivered to site, installed and commissioned by the bidder based on the specifications given herein. 320 kW electrical heaters shall be dismantled and removed by the bidder along with their panel after successful testing of the central receiver.
J. Piping, valves and fittings on molten salt lines, steam lines and feed water line. Piping of following duties and types are considered in the project. Sr. no. 1 3 4 5
Duty Raw water D. M. water Cooling water Boiler feed water with LP dosing including delivery to LFR
General specification UPVC, Class 3, IS 4985 / equi. CPVC, Sch 40, ASTM F441/441M IS 1239 Cl. C A 106 Gr. B, sch 40
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IIT Bombay Tender Number – 201601548 Sr. no. 6
8 9 10 11 12 13 14
Duty Saturated steam including import saturated steam Superheated steam including import superheated steam Boiler blowdown Boiler water sampling Molten salt – charging circuit Molten salt – discharging circuit LP dosing HP dosing Steam tracing of salt piping to and from receiver
15
Fittings
7
General specification A 106 Gr. B, sch 40 A 335 Gr. P91 A 106 Gr. B, sch 40 A 106 Gr. B, sch 40 A312 TP321, sch 40 A312 TP 321, sch 40 A 106 Gr. B, sch 40 A 106 Gr. B, sch 40 A213, SS 304 tube, 8mm OD, 1mm thk. Unless specified otherwise elsewhere in the tender: For MS and SS, Forged, 3000# or higher, of MOC similar to respective pipe specification for fittings < 40 mm NB nominal size and seamless sch 40 for > 40 mm NB. Flanges as per ASME B16.5. Gaskets for molten salt circuit and steam shall be spiral metal wound ring gaskets, type CR, 3.2 mm thick – spiral metal SS 321, filler graphite for steam, ceramic for molten salt, outer ring – MS as per ASME B16.2. All other gaskets shall be ring gasket, non-asbestos, 3mm thk. Fasteners – Bolts as per ASTM A193 Gr. B7, Nuts as per ASTM A194 Gr. 2H for salt and steam piping. As per IS 1367 for rest of the piping. Passivation treatment shall be carried out for the steam circuit.
Scope includes procurement, fabrication, flushing, testing and commissioning of the piping with all fittings, gaskets, fasteners at flange joints etc., supports, etc. complete. All fabrication procedures as per relevant codes and material requirement to be strictly followed. Steam piping including steam tracing tubes is under IBR. Scope includes all activities by bidder for complete compliance with IBR requirement from obtaining IBR approvals for plan, procurement and approval of IBR materials, etc. to obtaining IBR approval for final completed installation. Please refer
C530/PI/Sch/A4/021 - Piping schedule & C530-PI-DS-A4-007-R0- Insulation Schedule 26 | P a g e
IIT Bombay Tender Number – 201601548
K. Silencer at vent Superheated steam generated from the LFR system will be connected at the discharge of the superheater of the molten salt project. The common superheated steam discharge line will then be provided to discharge the superheated steam to a high point of the tower through a silencer. Silencer is being provided for noise attenuation to comply with CPCB / UP PCB norms. Design, fabrication, erection, commissioning of the silencer in compliance with all related statutory requirements is included in the scope of the bidder.
L. Electrical system for drive motors and heaters. Please refer technical specifications – Electrical heaters, electrical for details.
M. Set of instruments on salt lines, water and steam lines. Please refer technical specifications – instrumentation for details
N. SCADA system and PLC based control panel Please refer technical specifications – instrumentation for details
O. Boiler feed water dosing system LP dosing shall be provided for the feed water tank. HP dosing shall be provided to the evaporator. The bidder’s scope includes design, manufacture, procure, testing and supply, erection and commissioning of skid mounted dosing systems (LP dosing and HP dosing). The Chemical Dosing Systems shall be used to store, mix and dose metered quantity of chemicals for boiler feed water treatment (LP dosing) and for evaporator (HP dosing). The systems shall be duly mounted on common skids requiring only hook up connection to make the system complete and operable. Each dosing system will have its own control panel for all operations and controls of the unit.
P. Instrument air plant. Instrument air plant shall be provided for following main uses: 1.
Supply and maintenance of cover gas in thermocline tank at 150 – 200 mmWC
2.
Supply of instrument air for operation of several on/off and control valves.
3.
Supply of instrument air for bubbler level instrument for thermocline tank.
4.
Supply of flushing air for draining of receiver and molten salt piping.
The instrument air compressor, integrated air dryer and air receiver shall be provided with acoustic enclosure to comply with the noise emission norms. The entire package shall be controlled by an electronic control panel capable of remote operation from PLC through Modbus.
Q. Motorised hoists. Electrical motorised hoists with trolleys shall be provided to enable maintenance activities related to receiver, pumps, heat exchangers and cleaning mechanism. The scope of work includes procurement, packing, transportation and installation, commissioning, load testing of the electric hoists and training at site.
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IIT Bombay Tender Number – 201601548
R. Salt Salt shall be premixed mixture of sodium and potassium nitrates as per specification provided in this tender. The salt shall be supplied in sealed bags duly weather proof and stored in a suitable covered temporary stores at site to be constructed at site by the bidder. On readiness of the equipment, the salt packs shall be handled with all due care by the bidder. The bidder shall create a temporary arrangement at the thermocline tank to cut open the pack, break the agglomerated salt into manageable lumps, if necessary and lower the same into the tank. The bidder shall exercise all due caution to ensure that there is no contamination of the salt during these activities. The undamaged surplus unused salt bags shall be handed over to stores on commissioning of the project. Damaged bags shall not be accepted and shall not be considered for payment as contamination of salt is not acceptable.
S. Quality Assurance and Control 1. Quality Assurance Plan (QAP) shall mean the procedures as well as test methods and facilities by Bidder in order to assure that the all the equipment and items of work are of the highest possible quality i.e. either equal to or better than the requirement specified. 2. Quality Control (QC), shall mean all the tests, measurement, checks and calibration which are to be carried out in Bidder’s shop in order to compare the actual characteristics of the equipment/unit/system with the specified ones, along with furnishing of the relevant documentation (certificates/records) containing the data or result of these activities. The bidders are required to furnish a detailed & comprehensive list of the inspection facilities available at their shop along with the bids. 3. Bidder shall submit a comprehensive document of QAP /QC measures contemplated by him for implementation with regard to this specification for approval of IITB/ Inspection Agency. It is contractual obligation of the Bidder to develop and implement adequate QA/QC systems. 4. QA/QC system shall cover all products and services required for the equipment as per scope defined in enquiry specification including job sub contracted by the Bidder. 5. On award of contract the vendor shall submit all the testing procedure including PWHT, NDT etc. to TPI for approval and a copy of the approval shall be furnished to DEC / IITB for reference / records. Records of all the QAP & test records shall be duly maintained and produced to the TPI visiting the vendor’s shop for the purpose of inspection. The comprehensive records & all the relevant reports shall be finally sent to DEC / IITB along with the supply of equipment. 6. The approval of the work by TPI /DEC / IITB Inspector and his release of the equipment for shipment / erection shall in no way release the bidder from or relieve the bidder of, any responsibility for carrying out all the provision of this specification and the fulfilment of the guarantee, nor does DEC / IITB by such approval and release, assume any responsibility whatever for such provisions and guarantee. 7. The bidder shall lay down all the inspection and testing requirements in the quality plan which shall identify the activities requiring DEC / IITB’s approval, review witnessing, etc. 8. As a minimum the following points shall be included in the Quality Control Plan: a. Review of material certificates and verification of the materials of construction for conformity with requisition requirements b. Review of material certificates and verification for heat marks for pipes and flanges for conformity to the specification c. Review of material certificates for salt? 28 | P a g e
IIT Bombay Tender Number – 201601548 d. Verification of the Vendors design calculation for the equipment in accordance with the design code e. Verification for the Vendors welding procedure and procedure qualification for the equipment in accordance with the design code f. Dimensional check in accordance with approved “final” drawings g. Painting and lining requirement as detailed in this specification shall be inspected h. Final release 9. The bidder shall engage an approved TPI.
T. Pre-commissioning a. System testing / start-up (pre-commissioning) for the various systems in the plant would be carried out under the supervision of the consultant. The bidder shall furnish, as part of his work, at no additional cost, on round-the-clock basis, skilled personnel and supervision, to carry out the same. The number and category of skilled personnel to be deployed by the bidder shall be decided by the Engineer-in-charge in advance and the bidder shall provide such personnel as and when required by him. b. System testing would include all equipment and systems indicated in the scope of work of the bidder, various electrical heating systems, performance of package equipment, testing of receiver with electrical heating, testing of salt loop with electrical heating etc. c. All tools, tackles shall be provided by the bidder along with the skilled personnel. Defects noted during these tests shall be rectified by the bidder at his own cost, if the defects are attributable to the bidder’s work. d. After completion of system the start-up (pre-commissioning) shall be commenced and any defects noticed in the plants, which are attributable to the bidder shall be attended to by the bidder at his own cost, as and when they are brought to his notice by the IITB. IITB shall have the right to have these defects rectified at the risk and cost of the bidder if he fails to attend to these defects immediately. After the operating conditions are fully achieved in all the plants and the requirements stated in elsewhere in this Contract are fulfilled, the bidder would be eligible for applying for completion certificates. e. Where the works are carried out at the cost of the bidder, the Engineer-in-charge would recover twice the actual cost incurred towards labour, supervision and materials, consumables or otherwise. This includes overheads and all such amounts payable by him shall be deducted from pending bills or the security deposits.
U. Commissioning a. Entire system will be commissioned as per directions of the Engineer-in-charge b. The bidder will provide required assistance with required manpower including engineers, technicians, labourers etc. as described in pre-commissioning.
V. Special note The bidder shall state construction power and water requirement in the bid document. Bidder shall provide 2 sets of Govt. calibrated water meter (class B) and energy meter (class 1) for metering of water and electricity provided at site by NTPC. The accuracy and performance of the meters shall bidder’s responsibility for the entire duration of the project. Only bore well water is available at site. Bidder shall make his own arrangement of water for construction and potable water for construction personnel with all related arrangements with respect to adequacy and hygiene. 29 | P a g e
IIT Bombay Tender Number – 201601548 The bidder shall also provide and maintain hygienic temporary sanitation arrangement for construction personnel throughout the duration of the project. The bidder shall ensure that the site is cleared of all debris, waste, temporary structures etc. on completion of the project as a precondition for final payment. The bidder shall also arrange 170 KL, tanker loads of DM water (with test certificates) for precommissioning, commissioning and test runs of the plant as per required schedule. The bidder shall submit Quality assurance plan for all items of supply and execution along with the bid document. Security required all materials at site for the project shall be in contractor’s scope. Any failure on the part of the bidder to progress with / complete the work / rectify work defects including those informed during precommissioning (refer precommissioning section above) as per schedule will entitle the client to deploy resources as required to complete the work and recover all such costs towards deployment of the resources at twice the cost incurred by the client from pending bills or the security deposits of the contractor. The decision of the client in this regard shall be final and binding on the contractor. All drawings issued for this tender shall not be reproduced in any manner and shall only be used for the purpose of bidding.
5.2 Scope matrix R = Responsible for the activity / document A= Has the approving / acceptance authority I = Inspection S= Supervision W = Witness Sr. no.
A
B
C
Work
Responsibility Bidder
Consultant (DEC)
Client (IITB)
Overall, detailed, weekly planning schedule, safety and statutory compliances, site supervision and management
R
A
A
QA for all supplies documentation
R
A
A
and
work
including
IBR approval 30 | P a g e
IIT Bombay Tender Number – 201601548
Sr. no.
1
2
3
C
Work Bidder
Consultant (DEC)
Client (IITB)
Study of P&ID and identification of items for IBR requirement.
R
-
-
Documentation for IBR requirement, visits of IBR authority to bidder’s works, site and all other relevant actions etc.
R
-
-
Obtaining final IBR approval for the installation and submission of IBR approval to NTPC.
R
A
A
R
A
A
Temporary store for salt receipt storage, handling, opening packs, breaking, mixing, transferring etc., erection of store, dismantling, removal, reinstatement of clear land
R
I, A
I
Bidder’s site office, stores - design, procurement, construction, erection, dismantling, removal, reinstatement of clear land
R
A
A
Clearing site of grass, dirt, debris and disposal, appropriate place outside premises as specified by local bodies
D
E
F
Responsibility
Central receiver assembly with insulation 1
Detailed design, drawing and specifications
-
R
A
2
Procurement, PMI etc., set ups, fit-ups, fabrication, testing, transport, erection, assembly, commissioning including insulation etc.
R
I, A
A
G
Thermocline Storage tank with insulation 1
Conceptual Design, specifications, design data
-
R
A
2
Detailed fabrication drawing
R
I, A
A
3
Procurement, PMI etc., set ups, fabrication, testing, transport, erection, commissioning including insulation etc.
R
I, A
A
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IIT Bombay Tender Number – 201601548
Sr. no.
Work
Responsibility Bidder
Consultant (DEC)
Client (IITB)
Conceptual design, specifications, design data, design calculations, fabrication drawing
-
R
A
Detailed design, IBR drawing, IBR, PV calculations, design document
R
A
A
3
IBR approvals, stage wise etc.
R
-
-
4
Procurement, PMI, IBR approvals for materials
R
I, A
A
5
TPI
R
I, A
A
6
Procurement, fabrication, finishing, assembly, finishing, erection
R
I, A
-
7
Pre-dispatch IBR inspection, IBR certification
R
A
A
8
Dispatch, Receipt at site, handling, storage
R
I, A
A
9
Local IBR approval
R
A
-
R
I, A
A
R
A
A
H
Heat exchangers with insulation 1
2
10
Erection, Testing, commissioning
precommissioning,
11
Final local IBR approval, documentation
I
Molten Salt pumps
J
1
General specifications
-
R
A
2
Procurement, PMI, performance curves
R
A
A
3
Pre-dispatch inspection, trials, acceptance
R
W, A
W,A
4
Dispatch, receipt, handling, assembly, erection, pre-commissioning, commissioning,
R
I, A
A
Boiler Feed water tank with insulation
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IIT Bombay Tender Number – 201601548
Sr. no.
Responsibility Bidder
Consultant (DEC)
Client (IITB)
1
General design, drawing and specifications
-
R
A
2
Detailed fabrication drawing
R
A
A
3
Procurement, PMI, fabrication, transportation, erection, commissioning.
R
I, A
A
K
Boiler Feed Water Pumps 1
General Specifications
-
R
A
2
Procurement, PMI, performance curves
R
A
A
3
Pre-dispatch inspection, trials, acceptance
R
W, A
W,A
4
Dispatch, receipt, handling, assembly, erection, pre-commissioning, commissioning,
R
A
A
-
R
A
R
A
A
R
A
A
L
Electrical heaters, preheaters with controls 1
General specifications
2
Detailed design, procurement, assembly, finishing, erection
3 M
fabrication,
Testing, precommissioning, commissioning Piping, fittings, valves for molten salt, steam, water etc.
1
General specifications
-
R
A
2
Procurement, installation
R
A
A
IBR approvals, certification
R
A
A
Testing, precommissioning, commissioning
R
A
A
3 N
Work
Silencers
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IIT Bombay Tender Number – 201601548
Sr. no.
Work
Responsibility Bidder
Consultant (DEC)
Client (IITB)
1
General specifications
-
R
A
2
Design, Procurement, installation
R
A
A
3
Testing, precommissioning, commissioning
R
A
A
O
Electrical PCC, MCC, cables, trays etc. 1
SLD, general design, construction specifications
-
R
-
2
Detailed design and engineering of panels
R
A
-
3
Procurement, fabrication, assembly, FAT, documentation, delivery, installation, commissioning of panels
R
I, A
W, A
Procurement, installation, termination etc. of cables, cable trays, glands, etc.
R
I, A
-
-
R
A
R
A
A
R
A
A
Detailed specifications of PLC, I/O list, cables, trays, etc., cables schedule, termination schedule, indicative BOM, instrument list, layout, location plan, hook-up plan
-
R
A
Detailed Engineering of PLC system, enclosure, instruments, etc.
R
A
-
4
P
Instruments ( gauges, sensors, transmitters, instrumentation cabling etc. ) 1
General specifications
2
Procurement, installation, certification instruments, cables, loop testing,
3 Q
of
Testing, precommissioning, commissioning Instrumentation
1
2
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IIT Bombay Tender Number – 201601548
Sr. no.
Responsibility Bidder
Consultant (DEC)
Client (IITB)
Procurement, supply, fabrication, assembly of panels, consoles, hardware, development software, other software etc.
R
I, A
-
FAT, documentation of PLC, SCADA system (asbuilt drawings, datasheets, test certificates, inspection certificates, warranty certificates, type test certificates etc.)
R
I, A
I, A
5
Logic development for PLC system
R
A
A
6
SCADA
R
A
A
7
Procurement, installation, erection of cable trays, glands, etc.
R
A
-
8
Testing, precommissioning, commissioning
R
I, A
W, A
9
Equipment manuals, documentation
R
A
A
3
4
R
DM Water receipt, storage, transfer. 1
General specifications, dimensions
-
R
-
2
Procurement, supply, installation, commissioning etc.
R
A
A
calibration of DM water tank by strapping method – IS 2007, and water draw off method by a certified calibration agency.
R
A
A
3
S
T
Work
Raw water receipt, storage, transfer 1
General specifications, dimensions
-
R
-
2
Procurement, supply, installation, commissioning etc.
R
A
A
Cooling water system
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IIT Bombay Tender Number – 201601548
Sr. no.
Work
Responsibility Bidder
Consultant (DEC)
Client (IITB)
1
General specifications
-
R
-
2
Procurement, supply, installation, commissioning etc.
R
A
A
U
Instrument air package and piping 1
General specifications
-
R
-
2
Procurement, supply, installation, commissioning etc.
R
A
A
-
R
-
R
A
A
V
Feed water dosing systems 1
General specifications
2
Design, procurement, commissioning etc.
W
supply,
installation,
Salts ( KNO3, NaNO3 ) 1
Specifications ( composition )
-
R
A
2
Procurement, supply, dust-free, enclosed storage of salt
R
A
A
Approved work method, removing packaging, breaking, clean handling, transporting, dumping into thermocline tank in required proportion. All requisite PPE, precautions to avoid contamination. Handover of undamaged surplus salt packs to stores
R
S
A
X
Pre-commissioning
R
S, I, A
A
Y
Commissioning
R
S, I, A
A
Z
Spares
R
I, A
A
3
36 | P a g e
IIT Bombay Tender Number – 201601548
Sr. no.
AA
AB
Work
Responsibility Bidder
Consultant (DEC)
Client (IITB)
Handover of all work entrusted to the bidder vide this document to consultant
R
I, A
A
Final Documentation: Documentation of all supplies & services which are entrusted to the bidder. This document to be submitted to the consultant.
R
I, A
A
37 | P a g e
IIT Bombay Tender Number – 201601548
Section – 6: Technical bid
38 | P a g e
IIT Bombay Tender Number – 201601548
6.1 Technical work specification A. Technical specifications – Piping and mechanical work Heliostat receiver assembly with refractory The receiver assembly consists of helical coils made out of stainless steel 316 Ti grade tubes suitable for 600 ⁰C design temperature and 4 kg/cm2(g)bar pressure with cyclic temperature variation from ambient temperature to design temperature in a daily operation. Inlet outlet headers are also of equivalent stainless material. The coils are placed in an insulated housing of ceramic and mineral wool insulation sandwiched between SS sheet lining on the inside and carbons steel plates on the outside, resting on structural members. The inner lining is supported from the carbon steel plates as shown in the drawing. The carbon steel plates are rested on structural steel supports from the tower structure. The receiver tube coils shall be coated with a selective coating as per specifications mentioned below. All processes – surface preparation, cleaning, application of coating, curing etc. shall strictly be in compliance the tender specification. The equipment to be used for coating and curing and procedure adopted by the bidder has to be approved from DEC and IITB. Selective coating application procedure has been described in the at the end of this section Details of the receiver coils are as below: Sr.no. Item / parameter
Specification
1
Description
Vertical, helical coil with supports and stiffeners of same material.
2
Material of construction
A213, TP 316Ti
3
Construction standard
ASME Sec VIII, div-1,2013
4
Material of construction
A213, TP 316Ti
5
Operating temperature range
290 ⁰C – 565 ⁰C
6
Operating pressure
3.0 kg/cm2(g)
7
Design temperature / pressure
600 ⁰C / 4.0 kg/cm2(g)
8
Hydrostatic pressure
6.0 kg/cm2(g)
9
Radiography
100 %
10
Fluid
molten salt.
11
Dimensions in mm a Coil OD b Coil tube c Coil pitch
Coils 1 & 2 1100 mm 19 OD x 2 thk 57 mm
Coils 3, 4 & 5 700 mm 19 OD x 2 thk 38 mm 39 | P a g e
IIT Bombay Tender Number – 201601548 d Coil turns e Joints
44 nos Forged SW, 3000#
66 nos.
Thermocline storage tank Design parameters Sr.no. Item / parameter 1 Vessel type 2 3 3 4 5 6 7 8 9 10 a b c d e f g h i i ii iii iv v vi vii
Capacity ( nominal ) Shell ID / height / thk Dish ends, thk Material of construction Operating temperature range Operating pressure Design temperature / pressure Hydrotest pressure Radiography Tank mountings Top mounted Molten Salt pumps Manhole Top mounted temperature transmitter clusters Distribution pipe
Specification Vertical, cylindrical with top and bottom dish ends, insulated. 10 m3 1800 mm / 3,450 mm / 10 mm 10 % tori spherical, 10mm A240 Gr 321 290 ⁰C – 565 ⁰C 0.6 kg/cm2(g) 600 ⁰C / 1.0 kg/cm2(g) 2.25 kg/cm2(g) 10 % 2 nos, 500 mm Ø ID, 1 no., 460 mm Ø ID 5 nos, 50 NB, N1
273 OD x 6.35 thk x 3,971 long, A240 TP 321, , perforations - 10Ø x 8 x 41 nos. Side mounted electrical heaters 16 no.s, 65 NB flanges, 600#, N7 Top mounted bubbler level 1 no., transmitter Internal ladder Ø16 x 620 rungs, 14 nos. Legs 4 nos, 150 NB A240 TP 321, 1500 long Nozzle schedule N1 – 50 NB x 150# x 5 nos # N2 – 40 NB x 600# x 1 no. # N3 - 25 NB x 600# x 1 no. # N4 - 15 NB x 600# x 1 no. # N5 - 15 NB x 600# x 1 no. N6 - 25 NB x 600# x 1 no., drain N7 - 40 NB x 150# x 1 no. # N8 - 15 NB x 600# x 1 no. # - within distributor pipe, all pipes will have perforations similar to distributor
Manufacturing Procedures: The tank is at atmospheric pressure so strictly it is not a pressure vessel and does not come under a code. However, considering the severity of the duty, all the manufacturing practices of ASME Section VIII, division 1 shall be followed by the bidder.
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IIT Bombay Tender Number – 201601548 Molten salt to steam heat exchangers Design parameters: 1. Preheater Sr.no. Item / parameter Specification Heat duty, design 40 kWth Tube side 1 Tube Side fluid Molten Salt 2 Inlet / outlet temperatures ⁰C 355 / 290 3 Design temperature ⁰C / pressure kg/cm2 565 / 4.0 4 Material of construction A213 TP 321 5 Permissible pressure drop < 5 mlc Shell side 6 Shell side fluid Boiler feed water 7 Inlet / outlet temperatures ⁰C 45 / 213.3 8 Design temperature ⁰C / pressure kg/cm2 220 / 50.0 9 Material of construction A106 Gr. B, Seamless 10 Permissible pressure drop < 5 mlc 11 The Preheater is designed with following considerations: Fully drainable molten salt helical coil tube, non-removable Shell with saddle support, nozzles, fittings and insulation, pressure gauge and other instrumentation.
2. Evaporator Sr.no. 1 2 3 4 5 6 7 8 9 10 11
Item / parameter Specification Heat duty, design 95 kWth Tube side Tube Side fluid Molten Salt Inlet / outlet temperatures ⁰C 513 / 355 2 Design temperature ⁰C / pressure kg/cm 565 / 4.0 Material of construction A213 TP 321 Permissible pressure drop < 5 mlc Shell side Shell side fluid Boiler feed water / steam Inlet / outlet temperatures ⁰C 213 / 253 2 Design temperature ⁰C / pressure kg/cm 260 / 45.0 Material of construction A106 Gr. B, Seamless Permissible pressure drop < 5 mlc The evaporator is designed with following considerations: Fully drainable molten salt helical coil tube, non-removable Shell with saddle support, nozzles, fittings and insulation. Water level indicator and controller Steam safety valves, main steam stop valve, blow down valve etc. fittings as required for a standard shell type boiler fulfilling statutory requirements, pressure gauge and other instrumentation.
3. Superheater section
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IIT Bombay Tender Number – 201601548 Sr.no. 1 2 3 4 5 6 7 8 9 10 11
Item / parameter Specification Heat duty, design 31.5 kWth Tube side Tube Side fluid Molten Salt Inlet / outlet temperatures ⁰C 565 / 500 Design temperature ⁰C / 565 / 4.0 pressure kg/cm2 Material of construction A213 TP 321 Permissible pressure drop < 5 mlc Shell side Shell side fluid Superheated steam Inlet / outlet temperatures ⁰C 253 / 425 Design temperature ⁰C / 425 / 45.0 pressure kg/cm2 Material of construction ASTM A 335 Gr. P91 Seamless Permissible pressure drop < 5 mlc The superheater is designed with following considerations: Fully drainable molten salt helical coil tube non-removable. Instrumentation as shown in the P&ID
1. The heat exchanger being a steam generator, is under Indian Boiler Regulation. So Design Code - IBR 1950 and latest amendments thereof are applicable. In addition to the requirements specified in the drawing and specifications, the exchangers shall be designed, fabricated, inspected and tested in accordance with the requirements of IBR. Approval of CIB of the State in which the equipment is being manufactured as well as the State where the equipment is being installed shall be the responsibility of the bidder at no extra cost. 2. The scope of supply & work covers design and engineering (only where the design issued with this tender is required to be modified for IBR approval), manufacture/procurement of raw materials, fabrication, assembly, inspection, testing, painting, insulation, protection and packing, transportation and delivery to site and installation & commissioning of the supplied heat exchanger as per this specification. 3. The typical scope of supply and work is given below but not limited to the followings till successful installation and commissioning of the heat exchanger at site: 4. Scope a.
Detailed mechanical design as per ASME and IBR requirements has been provided with the tender. Bidder’s scope includes further detailing for fabrication / changes for IBR approval, complete procurement of all materials and bought-out items, fabrication at shop, inspection & testing, primer painting, insulation and supply of heat exchangers with internals as per details and spares in accordance with the applicable equipment specification and other documents enclosed with enquiry.
5. Mechanical design (this shall apply to modifications in design, if required for IBR approval) a.
Further mechanical design of Equipment, if required, for compliance with the latest code / standard of construction, IBR shall be the responsibility of the bidder. Strict compliance 42 | P a g e
IIT Bombay Tender Number – 201601548 with the requirement of codes/equipment specification & any other referred document shall be ensured. b.
Detailed design calculations for adequacy of strength of all individual parts shall be made by bidder and submitted to DEC for comment & approval. After receipt of approval from IITB / DEC the design of equipment shall be considered as final. Any change/comment made on design calculations and drawings to satisfy the requirements of code/enquiry documents “to make the equipment perfectly fit for smooth operation” shall have to be incorporated by Bidder without any commercial implications.
c.
Design conditions for the equipment shall be as per equipment specification sheets & Technical Specification enclosed with the enquiry. Minimum required thicknesses of various components shall be calculated based on design parameters considering different types of loadings conditions including effect of static head of liquid column, wind pressure, force of moment owing to connected piping & other attachments as platform etc. Equipment shall also be designed for hydrostatic condition. Final thickness shall be decided giving due consideration for corrosion allowance & thinning allowance.
d.
Wind analysis shall be performed as per the relevant standard. Wind forces shall be increased by 20% (over & above design code requirement) to cater the effect of piping system, platforms and ladders etc.
e.
Local stresses in vessel wall resulting from nozzle load shall be determined by WRC 107/ WRC 297 or PD5500/G code requirements. Forces and moments acting on nozzles shall be considered in the design of vessel and resultant stresses shall not exceed allowable stresses as per applicable codes/standards/specifications. The forces and moments on nozzles shall be furnished during detailed engineering after award of contract. Bidder shall take care of the same during mechanical design of equipment without any delivery/commercial implications to IITB.
f.
All carbon steel (CS) & low alloy steel (LAS) pressure parts shall have minimum of 3.0 mm corrosion allowance unless otherwise specified. All internals CS/ LAS parts including low temperature materials shall have at least 1 mm corrosion allowance on either side unless otherwise specified.
g.
Each Lifting Lug shall be designed with shock factor 2.
h.
Bolts of size M36 and above shall be designed and spaced so as to permit tightening with a hydraulic stud-tensioner. The bolts shall have an extra threaded length at one end of approximately 1 bolt diameter and shall be provided with threaded protection caps. Hex nuts shall have suitable holes for manual tightening. Equipment having bolt size above M36 shall be supplied with hydraulic bolt tensioning device along with commended spares and operating manual indicating tightening torque.
6. Special requirements (these shall apply to modifications in design, if required, for IBR approval) a.
Detail of components thicknesses of various parts wherever indicated in the equipment specification sheet are indicative and minimum. However, during detailed engineering, if thicknesses need to be increased to meet code/standard requirements for the adopted code/standard under corroded condition for all load combination including nozzle loads
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IIT Bombay Tender Number – 201601548 the same shall be considered by Bidder without any delivery/commercial implication. b.
The design of equipment supports and anchor bolts shall be the responsibility of the Bidder. The type, number and location etc. indicated in the equipment specification sheets shall be adhered, changes, if any shall be indicated in offer. Further adequacy of the same must be checked by the Bidder & design calculation shall be submitted to DEC for approval during design/drawing approval stage.
c.
ASME Section VIII, Div. 1, Appendix “S” shall be considered mandatory for bolted flange connections. However, flange shall be designed as per Appendix “2” for different loading conditions.
d.
Local vessel stress calculations for external structural attachments, such as platform cleats, pipe support cleats and lifting lugs shall be performed & submitted to DEC for approval.
e.
International System of Units (SI) System and English language shall be used for all drawing and documents.
f.
Deviations, if any, shall be clearly spelt out in the offer with proper reference to clause numbers. In absence of any such indication it shall be assumed that the offer complies with all the requirements and such assumptions shall be strictly binding on bidder.
g.
Equipment saddle wear plate material shall be the same as the shell material. Bidder shall check adequacy of tube bundle against flow induced vibration and shall submit the design calculation for DEC approval.
h.
Parts which simultaneously come in contact with both shell side and tube side fluids, shall be designed considering pressure acting on one side only or the combination of pressures, whichever results in higher thickness of parts.
i.
In case of girth flange design, minimum width of gasket shall be checked to withstand required design condition.
j.
Unless otherwise stated inlet nozzles on shell side shall be provided with impingement plate in compliance with TEMA requirement if not specified in datasheet. The flow area around solid impingement plate shall be at least equal to the inlet nozzle cross-section. In case of two phase flow impingement baffle shall be perforated. Impingement baffle plate shall extend at least 25 mm beyond the projection of the nozzle bore. The clear distance from the nozzle (at the inner surface) to the impingement plate shall be at least 0.25 x nozzle diameters if not specified in equipment data sheet. The nominal thickness of the impingement baffle shall be at least 6 mm.
7. Scope of supply a.
Bidder shall include the following items in scope of supply besides supply of equipment including internals & spares etc. referred under Scope. i.
Lifting lugs/Erection lugs as required
ii.
All external cleats/pads required for ladders, platforms, pipe support pads including cleats for earthing connections etc. Details of pads & cleats for ladders, platforms & pipe supports shall be defined during approval of design & drawing stage. Such
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IIT Bombay Tender Number – 201601548 details shall have to be incorporated by Bidder without any commercial/delivery implication. However, Bidder shall include cost of such attachments in the Bid based on his experience. iii.
Name plate with bracket
iv.
Foundation / Anchor / Holding down bolts with nuts and washers
v.
Cleats for earthing connections (2 numbers diagonally opposite to each other)
vi.
All specials instrument & fixtures required to verify the guarantee
vii.
Shipping saddle with proper reinforcement for transportation and loading/ unloading.
8. Material of construction a.
Material of construction for equipment shall be selected as per equipment data sheet & Technical Specification.
b.
The following additional material requirements as indicated below shall be considered by Bidder: i.
All raw materials including bought-out items, whatsoever required, to complete the supplies shall be procured and supplied with due identifiable mill material test certificates & inspection reports duly certified by authorized inspection agency.
ii.
For coarse grained and high tensile materials in carbon steel (UTS > 52 Kg/mm2) and low alloy steel, guaranteed impact strength shall be ensured at a temperature 150°C below envisaged hydraulic test temperature as a precaution against brittle fracture during hydraulic test. 5.2.3 Carbon steel & LAS shall be procured in fully killed condition. CS & LAS plates shall be normalized / annealed. CS & LAS plates above 50 mm thickness shall be vacuum degassed and examined by Ultrasonic Testing (UT) at surfaces & edges as per ASTM A435 and other equivalent applicable material specification code/standard. Bend test as per supplementary requirement S-14 of SA -20.
iii.
All forgings except for flanges as per ANSI shall be UT tested as per applicable material specification & shall be examined according to ASTM A388 with criteria shown in ASME Section VIII.
iv.
All forgings including self-reinforced nozzles & nozzle flanges shall be examined for surface defects by MP/PT testing after machining as per applicable material specification, code & standard.
v.
Material used for pressure parts and attachment to pressure parts shall be impact tested (Charpy-V) as per design code & specifications. Impact test temperature shall be minimum of MDMT, impact test temperature specified in applicable material code or given in job specification whichever is lower.
vi.
All external/internal attachments, pads/cleats directly welded to the equipment shall be of same materials as that of equipment, unless otherwise specified. 45 | P a g e
IIT Bombay Tender Number – 201601548 9. Fabrication a.
The Bidder shall comply in all respects with the provision of the applicable codes, standards and specification during fabrication with respect to tolerances, welding, fabrication, forming of heads, radiography, heat treatment, inspection, testing and quality control etc. unless & otherwise specified.
b.
Plates of different thicknesses shall be made flush with the inner surfaces of equipment unless otherwise stated.
c.
All dish heads shall preferably of single piece construction. Larger heads which cannot be formed in one piece shall be fabricated as follows with prior approval from IITB / DEC. i.
In two pieces, with the welding seam included in the middle third and preferably on the centre line.
ii.
In petal construction, with meridian seams and a central cap of diameter not larger than 0.75 times the vessel outside diameter.
d.
Due provisions must be kept for venting out entrapped gases during welding of pads, flanges and liner plates etc.
e.
All welding shall be carried out by qualified welders using approved procedures in compliance with the requirements of codes, standards & specifications and shall be duly certified by the concerned inspecting authority. All welding procedures must be got approved from authorized inspecting authority & IITB / DEC before starting any fabrication job. Welding of all parts must be completed before heat treatment. For all welds, Welding Procedure Specification (WPS) must be provided.
f.
All welds shall be full penetration welds with back chipping and re-welding from the second side. For those joints which are inaccessible for back chipping the root run shall be carried out with TIG process. Single side welding with backing strips is not permitted.
g.
All sharp corners shall be rounded off with smooth radius. Inside edge of manhole and hand hole at the internal surface shall be rounded to minimum radius 5 mm.
h.
All flange bolts shall straddle center line unless otherwise stated.
i.
In case of nozzle with butt-end construction, extra length shall be provided to facilitate hydraulic testing and subsequently cutting and edge preparation to suit piping welding at site. All nozzles less than or equal to NB 65 mm shall be stiffened with three equispaced plate ribs of the same material as that of shell.
10. Painting a.
Surface cleaning of the heat exchanger, external surface by sand blasting to Sa2 -1/2 grade conforming to Swedish Standard SIS – 05 5900 – 1967 followed by 2 coats of heat resistant primer. Inner surface will be cleaned by wire brushing and passivated.
b.
The heat exchanger body and piping shall be thermally insulated by rock wool of density 120 kg/m3 and aluminum sheet cladding of 20 gauge covered with tight sealing, to prevent heat loss and external insertion of water and foreign elements.
11. Inspection & testing
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IIT Bombay Tender Number – 201601548 a.
The equipment shall be inspected and tested (including NDT) in accordance with applicable codes, standards and specifications referred in the enquiry. The equipment shall be inspected during various stages of manufacturing starting from identification of raw materials to final completion as per agreed Quality Assurance Plan (QAP) which shall be furnished by bidder along with their bid and successful bidder after award of contract shall submit QAP to IITB / DEC / Third Party Inspection agency for their approval. However, all the bought-out items must be supplied with test certificates and inspection reports.
b.
The third party inspection is in the scope of the bidder. It shall be the responsibility of the Bidder to make available to the inspector all the drawings, calculations and other documents. However, the IITB / DEC / inspection agency shall have free access for inspection at bidder’s / sub-vendor’s shop at all stages of manufacturing. Further the following tests / procedure are mandatory to be witnessed / reviewed by concerned third party inspection agency. i.
Review of drawings & design calculations
ii.
Welding procedure specifications approval
iii.
Heat treatment procedure approval (if applicable)
iv.
Hydraulic test
v.
Review of NDT tests reports e.g. RT, UT, MP / PT & hardness etc. including Leak test, Ferrite check, Iron contaminated test, Inter-granular corrosion test etc.
vi.
Review of material test certificates & Positive material identifications
vii.
Review of PWHT charts (if applicable).
viii.
Review of production test coupons
ix.
Witness of hydraulic testing
c.
All imported raw materials shall only be inspected by TPI. The cost of the same shall be considered by bidder in their scope.
d.
The exchanger shall be considered acceptable for dispatch only after final certification for acceptance is issued by concerned inspector.
e.
Production control coupons, when required as per codes & standards shall be subjected to mechanical tests as required. In case of heat treated equipment test coupons shall be given similar heat treatment as for the equipment. Test plates for production testing shall be sufficient for performing all tests.
f.
Formed heads cold formed or hot formed below normalizing temperature shall be subsequently normalized and weld seams if any shall be fully radiographed after forming.
g.
All nozzle reinforcing pads wherever applicable shall be tested pneumatically at 0.5 Kg/cm2g pressure with soap solution on attachment welds. Vent holes shall be plugged with non-hardening mastic to prevent ingress of water.
h.
All completed equipment shall be tested hydraulically as per the requirements of codes, 47 | P a g e
IIT Bombay Tender Number – 201601548 standards & specifications in presence of the inspecting authority. Pneumatic test of completed equipment shall be carried out only when specially mentioned in the specification sheets. Chloride content in water used for testing shall not exceed 30 ppm for SS equipment and 40 ppm for CS and low alloy steel equipment. Duration of test shall be as per applicable codes & standards. Test medium/water shall be tested for the chlorine contents before filling the equipment. i.
The temperature of test water shall comply with requirement of IBR.
j.
Unless otherwise stated gaskets used during testing shall be same as specified for operating conditions. After testing, gaskets used during testing shall be replaced by new gaskets.
k.
NDT Requirements i.
The following NDT requirements are mandatory in addition to codes, standards & specification requirements.
ii.
UT examination
iii.
iv.
a.
All butt - welds in thickness greater than 50mm as supplement to radiograph.
b.
FPW of nozzle attachments of thickness above 50mm as supplement to radiography
c.
All forgings
d.
All butt welds after hydro test
MP / PT examination a.
All edges of plates and opening in shell of CS having thickness equal to & above
b.
40mm and LAS / SS having thickness more than 25mm
c.
Root and final layer of all butt welds
d.
All weld surfaces after PWHT
e.
Knuckle surfaces of dished ends/ tori conical sections and pipe bends
f.
All forgings after machining
g.
All fillet & butt weld after hydro testing
Radiography a.
All weld seams of formed head, if made in more than one segment shall be full radiographed after forming
b.
When spot radiography is specified, all T – Joints & minimum 10% of total weld length (excluding T joints) shall be radiographed
c.
All nozzles fabricated from plates shall be 100% radiographed
d.
All butt welds irrespective of thickness (100% radiographed) before 48 | P a g e
IIT Bombay Tender Number – 201601548 PWHT and hydro test e. v.
Hardness test a.
vi.
For LAS welds radiography shall also be done after final PWHT and joints which cannot be radiographed shall be 100% UT tested.
Weld and Heat affected zone (HAZ) of all pressure bearing welds in CrMo steel vessels shall be tested after final heat treatment using a portable hardness tester. Hardness value shall not exceed 215 HB for steel having Cr < 2 % and 240 HB for steel having Cr ≥ 2%.
Further NDT requirement as per MC41-1E shall be complied with by the Bidder.
12. Quality assurance & control a.
Quality Assurance (QA) shall mean the organizational set up, procedures as well as test methods and facilities developed by Bidder in order to assure that the equipment leaving Bidder’s shop is of the highest possible quality i.e. either equal to or better than the requirement specified.
b.
Quality Control (QC), shall mean all the tests, measurement, checks and calibration which are to be carried out in Bidder’s shop in order to compare the actual characteristics of the equipment/unit/system with the specified ones, along with furnishing of the relevant documentation (certificates/records) containing the data or result of these activities. The bidders are required to furnish a detailed & comprehensive list of the inspection facilities available at their shop along with the bids.
c.
Bidder shall submit a comprehensive description (manual) of QA/QC measures contemplated by him for implementation with regard to this specification for approval of IITB / DEC/ Inspection Agency. It is contractual obligation of the Bidder to develop and implement adequate QA/QC systems.
d.
QA/QC system shall cover all products and services required for the equipment as per scope defined in enquiry specification including job sub contracted by the Bidder.
e.
On award of contract the vendor shall submit all the testing procedure including PWHT, NDT etc. to TPI for approval and a copy of the approval shall be furnished to DEC / IITB for reference / record. Records of all the QAP & test records shall be duly maintained and produced to the TPI visiting the vendor’s shop for the purpose of inspection. The comprehensive records & all the relevant reports shall be finally sent to DEC / IITB along with the supply of equipment.
f.
The approval of the work by TPI /DEC / IITB. Inspector and his release of the equipment for shipment / erection shall in no way release the bidder from or relieve the bidder of, any responsibility for carrying out all the provision of this specification and the fulfillment of the guarantee, nor does DEC / IITB by such approval and release, assume any responsibility whatever for such provisions and guarantee.
g.
The bidder shall lay down all the inspection and testing requirements in the quality plan which shall identify the activities requiring DEC / Client’s approval, review witnessing, etc.
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IIT Bombay Tender Number – 201601548 h.
i.
As a minimum the following points shall be included in the Quality Control Plan: i.
Review of material certificates and verification of the materials of construction for conformity with requisition requirements
ii.
Review of material certificates and verification for heat marks for pipes and flanges for conformity to the specification
iii.
Verification of the Vendors design calculation for the equipment in accordance with the design code
iv.
Verification for the Vendors welding procedure and procedure qualification for the equipment in accordance with the design code
v.
Dimensional check in accordance with approved “final” drawings
vi.
Painting and lining requirement as detailed in this specification shall be inspected
vii.
Final release
The bidder shall engage an approved TPI.
13. Performance & mechanical guarantee a. Bidder shall guarantee the equipment against faulty design (if any required to be done by the bidder), improper material of construction and poor workmanship, with respect to specifications. Approval by DEC / Third Party Inspection Agency / IITB for design calculations (if any done by bidder), drawings & other documents will not in any way absolve the Bidder from his responsibility. Should any repair or replacement be necessary owing to any type of failure on account of design material and workmanship of the item, Bidder shall in view of this guarantee be bound to replace the same either in part or whole without any commercial implications to IITB. Repaired or replaced part shall also be covered by same guarantee as in case of main supply. b. Hydrodynamic & Performance Guarantee c. Bidders shall stand guarantee of supplied internals against the process parameter indicated in equipment specification sheets. All special instruments, fixture required to verify the guarantees as outlined in the equipment specification shall have to be brought by the supplier on draw-back basis. d. The material used shall be new and best of its kind available and shall conform to relevant Indian and International standards. All the material used shall be free form surface defects, rusts, cracks and deformation. Bidder’s shall guarantee for materials, workmanship and satisfactory performance of the equipment to be supplied against this specification for 18 months from the date of receipt of last consignment at site or 12 months from the date of commissioning whichever is earlier. Any defects including due to faculty design/material/ workmanship found during the guarantee period shall be rectified by bidder at his own cost to the entire satisfaction of the purchaser. Vendor shall take full responsibility for the design (if any done by the bidder), quality of material and workmanship, guaranteed operation and smooth performance etc. of the equipment. This technical specification is only guidance to bidder and hence all the items necessary for
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IIT Bombay Tender Number – 201601548 safe and satisfactory operation and guaranteed performance of the equipment shall be included in his offer though these might not have been specifically mentioned in this specification. The conditions regarding guarantee of equipment shall also be governed by the relevant clauses of general commercial condition. Bidder shall perform performance test of the capacity of heat exchanger mentioned under process data sheets. The performance test shall be carried out for continuous period of 72 hours and if during such period, the performance data is met, the performance test shall be deemed to have been carried out successfully. If the performance test could not be carried out successfully for a continuous period of 72 hours, the performance test shall be carried out again. 14. Third party Inspector (TPI): The successful bidder shall engage the TPI from approved TPIs. The cost for engaging the TPI shall be borne by the bidder. The TPI shall be engaged during the phase-wise inspection while manufacturing of the heat exchanger. The schedule shall be submitted for review of DEC / IITB. 15. Documentation: a.
Detailed fabrication drawings shall be prepared by Bidder clearly indicating all design data, nozzle data, details of all parts with tolerances, all welding joints details and detailed bill of materials etc. Location of weld seams, construction notes, welding processes, detailed specification of electrodes including NDT tests etc. as applicable shall be clearly indicated in the drawing. Fabrication drawing shall also indicated Civil load data’s i.e. Empty Weight, operating weight & hydro test weight of the equipment including base shear force and base moment for civil foundation design. Drawing submitted for approval must be complete in all respects and thoroughly checked and approved by Bidder’s competent authority before submitting to IITB / DEC/Third Party Inspection Agency. i.
All drawings shall be drawn in AUTOCAD to scale. Manual drawing shall not be accepted.
ii.
All documents / drawings shall be in English language and in Metric system. Further the following documentation shall be submitted by Bidder for review & approval as per IITB / DECs requirement besides other documentation listed elsewhere. a.
3 sets of hard copies of Rev. 0 of GA drawing, design calculation etc. with soft copies to DEC for review.
b.
3 sets of hard copies of Rev. 1 of GA drawing, design calculation etc. with soft copies to DEC for review. Vendor shall also submit 02 hard copies of Rev. 0, Rev. 1 and further revision of GA drawing, design calculation etc. with soft copies to DEC / IITB for review. Soft copies shall also be sent to DEC / IITB.
c.
6 sets of all final documents such as design calculations, fabrication drawings, test certificates, material test reports, repair procedure along with the reproducible & soft copies, hard copies etc. shall be properly arranged, indexed and bound in one folder and submitted to IITB / DEC. All fabricated drawings to be furnished in *.DWG/DXE format on rewritable CD of reputed make.
16. Dispatch a.
Equipment shall be dispatched with Nitrogen (N2) filling. In case of site welding & 51 | P a g e
IIT Bombay Tender Number – 201601548 assembly of equipment, the same shall be filled with Nitrogen (N2) after testing at site. Dry Nitrogen shall be filled at a pressure of 0.5 kgf/cm2 and equipment shall be fitted with a pressure gauge and valve. b.
All internals & spare parts shall be packed separately in wooden packet to avoid damage in transport.
17. Spares (Erection & commissioning, 2 years’ operation & Special Spares etc.) a. Bidder shall supply all spares including bolting, gasket and packing required during commissioning and up to performance guarantee test. All spares shall be packed separately in wooden packet to avoid damage in Transport. All commissioning spares shall be packed & marked separately to avoid any mix up at site. Bidder shall supply 2 years operational spares separately. Please refer drawings C530/ME/GA/A1/304, C530/ME/GA/A1/305 Sheet-1, C530/ME/GA/A1/305 Sheet-2 and C530/ME/GA/A1/306 Molten salt circulation pumps 1. The scope includes, design, procurement, fabrication, assembly, testing, supply, erection, commissioning of molten salt pumps for the following operating parameters. 2. Charging circuit molten salt pump Sr. no. 1 2 3 4 5 6 7 8
Parameter Type Fluid Flow Head Suction pressure Fluid temperature normal / max Drive Cooling
Value Vertical centrifugal, submerged pump Molten Salt 3 m3 / hr, required1. 50 mlc 1.8 bar a 290 ⁰C / 500 ⁰C Direct with coupling air cooled only
3. Discharging circuit molten salt pump Sr. no. Parameter Value 1 Type Vertical centrifugal, submerged pump 2 Fluid Molten Salt 3 Flow 1 m3 / hr, required2. 4 Head 30 mlc 5 Suction pressure 1.1 bar a 6 Fluid temperature normal / min 565 ⁰C / 400 ⁰C 7 Drive Direct with coupling 8 Cooling air cooled only 4. The design of the pumps will take into consideration the effects of thermal distortion. 5. The pumps shall be adequately designed to mitigate thermal distortions by proper design of heat dissipation. 6. Both line-shaft and cantilever pump designs are acceptable.
1
2
- if low flow rate is not available, higher flow rate will be used with bypass flow system if low flow rate is not available, higher flow rate will be used with bypass flow system 52 | P a g e
IIT Bombay Tender Number – 201601548 7. The pumps shall be provided with suitable lifting arrangement to enable installation in the tank. 8. The pumps shall be supplied with mounting flanges suitable for quick release eyebolt flanges of the vessel. 9. The sealing of the pump shall be designed for 500mm WC pressure of inert cover gas in the tank. 10. The sealing shall be designed for air cooling only. 11. The pumps shall be designed to eliminate radial loads 12. The pumps shall be designed to allow uniform thermal expansion of the pump components. 13. The discharge pump shall be designed for minimal submergence. 14. Material test certificates Please refer datasheets C530/ME/DS/A4/310 and C530/ME/DS/A4/311 respectively for charging and discharging circuit molten salt pumps Boiler feed water tank Capacity - 2,000 L (nominal). Type - Cylindrical vertical (Preferred) with provision for mounting on a structure Material - Carbon steel Accessories - Steam preheating coil to heat make up water from 30 0C to 80 0C Chemical dosing provision Manhole, drain, vent etc. For all mountings, fittings and instruments please refer C530/ME/GA/A1/314 – GA and fabrication details of Feed water tank Boiler feed water pump i. The pumps shall be procured, inspected, tested at vendor’s works, delivered to site, installed and commissioned by the vendor based on the broad specifications given here and the data sheet issued. The scope of supplies shall include pump with motor, base frame, coupling, gear box / chain drive, fasteners, foundation bolts, safety guards, pressure safety valve, pulsation damper, inlet and outlet non-return valves, lubricating system, lubricants, controls, safety devices, weather hood etc. Any other item required for the safe operations of the pump as per the process conditions is deemed included in the scope unless specifically excluded. The motor shall be with as per specifications – refer electrical section. ii. The equipment to be offered against this tender will be of proven design by way of a record of long time, trouble free field operation, without any deficiency and problem whatsoever. As such, manufacturing technicalities to achieve high engineering quality and performance guarantee for compliance with this specification shall be the prime responsibility of the successful bidder. iii. Applicable standards:
53 | P a g e
IIT Bombay Tender Number – 201601548 Sr. no. 1 2 3 4 5 6 7 8 9 10 11
iv.
Specification ANSI -B3.11 ANSI -B16.5 ASTM -E 71
Description Load ratings for Ball Roller Bearings Steel Pipe Flanges and Flange Fittings. Industrial Radiographic Standards for steel castings. ASTM -E 94 Recommended Practice for Radiographic testing. ASTM -E 165 Methods of Liquid Penetrant Inspection. ANSI B1.1 Unified and American screw threads ASTM E 142 Method for controlling quality of Radiographic Testing. ASME Boiler and Pressure Boiler and Pressure Vessel Code Vessel Code Section VIII DIV-1. Hydraulic Institute Standards Section D -Reciprocating Pumps. IS0 International Standard Organization (Dimensional Standards for pipes and BW fittings and metric screw threads). IS -5 Colours for ready mixed paints and enamels or epoxy paints.
Design and Construction a. The parts of the pump shall be designed to handle the liquid at the pressure and temperature indicated on the attached pump data sheet. The pressure retaining parts shall, as a minimum requirement, meet the requirements of ASME section VIII, Div-1. b. Pumps shall be designed in accordance with good engineering practice and fabricated as per the requirement of the applicable standards and codes. c. Pumps shall be suitable for continuous operation. Castings and forgings shall confirm to their respective material specification and shall be free of flaws and objectionable imperfections and conforming to the highest quality of workmanship. d. The material used for manufacturing of the pumps shall be new and of tested quality. Correlating certificates for all the materials shall be produced by the bidder if demanded by the purchaser's representative. As a minimum, test certificates shall be furnished for materials of all pressure retaining components. e. The pump shall be of triplex plunger type. Horizontal pumps are preferred. Compact design of the pump motor unit is desirable. The direction of rotation shall be at the discretion of the bidder. Exposed moving parts shall be enclosed by an adequate guard for personnel protection. The pumps shall be located outdoor. f. Pump design shall be appropriate to give minimum of 25 years of continuous service. The pump shall be designed to facilitate ease of maintenance, inspection and repairs. g. The pump shall be suitable for continuous operation under the following conditions: Sr. no. 1 2 3
3
Item Type Medium Operating temperature
Specification3 Triplex, reciprocating piston pump Boiler feed water 85 ⁰C
Refer datasheet for details
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IIT Bombay Tender Number – 201601548 Sr. no. 4 5 6 7
h.
i.
j.
k.
l.
m. n.
o. p. q.
Specification3 450 mlc <2m 300 lph Electrical motor, Std. 3 phase, 415 VAC, 50 Hz., squirrel case induction motor, with VFD operation 8 Quantity 2 Nos ( 1W + 1S ) . All components subjected to pumps discharge pressure shall be designed for at least 45 kg/cm2(g). Those components exposed to suction pressure shall be designed for at least 10 kg/cm2(g). The materials of the main pump components shall comply with the requirements of appropriate ASTM Standards. The cylinder block, suction, discharge connections shall be stainless steel (SS 316L) or better. Material for all other parts will be at the discretion of the manufacturer but shall be subject to approval by Purchaser. The cylinder block shall be provided with replaceable liner or bushings. The liner and plunger material shall be corrosion and wear resistance and the combination shall not gall. Lubrication of the plunger packing shall be with pumped fluid only. The plunger packing and crankcase sealing arrangements shall be such that there will be no contamination of the pumped fluid or its leakage with oil or grease. The pump shall be provided with a plunger leakage collection arrangement which does not expose the pumped fluid leakage to pump room or crank case atmosphere. Preferred arrangement is triple packing with the interspace between the adjacent packings and the first (primary) interspace connected to the pump suction while the second (secondary) interspace provided for leak off connection. All liquid and valves shall be readily accessible for maintenance. All valves shall have renewable seats designed for easy replacement. To prevent galling, the difference in hardness between valves and seats shall be at least 30 BHN. Sufficient free area through valves shall be kept to restrict liquid velocities below lm/sec. at design capacity. Inlet and outlet connections shall be flanged conforming to ANSI B 16.5 and rating suitable for the pressure specified Antifriction bearing life rating shall be computed in accordance with ANSI B for a rating life of 60,000 hours. Each pump-motor unit shall have its own lubrication system. The system shall be such that no dismantling of any part of the unit is necessary to replenish or replace the lubricant. For a unit using a pressure lubrication system, a pressure switch, to the approval of the Purchaser, shall be provided for sensing the lubricating oil pressure. Pressure indication shall also be provided. Bearings shall give satisfactory service when lubricating oil is added or / changed at intervals of not less than 6 months operation. Crank case or packing box vents shall be protected with a mesh filter. Pumps shall carry name plates with the following information. Sr. no. 1 2
Item Discharge head Pump NPSH Flow Rate Drive
Information Tag no. Serial no. 55 | P a g e
IIT Bombay Tender Number – 201601548 Sr. no. Information 3 Model no. 4 Size 5 Capacity and pressure 6 Max. operating temperature r. Materials i. Materials for pressure casings and major internal parts in contact with the liquid shall be specified by the vendor and shall be subject to purchaser's approval. Unless otherwise specified, ASTM A 193 Gr B8M material shall be used for bolting of liquid and pressure joints. ii. Unless otherwise specified, small internal parts such as screws, nuts, keys, lock washers and pins shall be of the material equal to in corrosion resistance to valves. iii. Name plates, rotation arrow plates etc. shall be AISI 304 stainless steel, attached by pins and similar material. s. Pulsation Suppression Devices i. The details of the pulsation suppression device shall be furnished by the vendor. ii. Unless otherwise specified, pulsation suppression devices shall be designed in such a way as to give amplitude of pulsation within the limits of + 3% of mean. The pulsation suppression devices shall be chosen to suit operating pressure. iii. The pulsation suppression device and gas charging assembly shall be supplied by the vendor along with necessary instruction for maintenance and use. The supply shall include all the required interconnecting parts & components. t. Relief valve i. Relief valves shall be as per ASME Sec. VIII Div-1. ii. Unless otherwise specified relief valve, for packed plunger pump shall be furnished by the vendor and shall be mounted on pump discharge flange or manifold. The relief valve setting pressure shall be equal to the rated discharge pressure of 45 Kg/cm2. Relief valve shall be single coil type and shall be of a reputed make. iii. Material of construction of relief valve shall be stainless steel (SS 316 L) iv. End connection of relief valve shall be flanged type and shall be connected to discharge to suction side. v. Relief valve shall be selected to pass 100% rated capacity of pump when fully open and to limit accumulation pressure to 110% of rated discharge pressure. u. Maintenance i. The design shall be such that maintenance can be performed by persons with those skills and tools normally available in modern power plants. Any special tools shall be supplied by the Bidder. ii. All units of same design supplied to this specification shall be interchangeable for installation purposes and all spare parts shall be suitable for installation in any of the units. v. Threaded Fasteners
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IIT Bombay Tender Number – 201601548 i.
v.
Threaded fasteners shall conform to IS0 metric threads or ANSI B 1.1 and shall be provided with corrosion resistant positive locking devices. Frictional locking devices shall not be used. w. Balance and Vibration i. The unit shall be designed to operate with a minimum of vibration. Any vibration isolation equipment required in the pump base assembly shall be indicated. Supplier shall also indicate the guaranteed maximum vibration level for the Unit under normal operating conditions, at both high and low pressure levels indicated in para. 5.16. 11 x. Electric Motor Drivers i. The motor brake horse power provided shall be at least 10% higher than the I maximum horse power (including gear and coupling losses) required for the rated capacity of the pump. y. Base Plate i. Common base plate for the pumps and driver along with bolts with nuts shall be provided by Vendor. ii. Base plate shall have a raised tip to contain stuffing box leakages. iii. The pump shall be mounted on a trolley such that the pump shall be moved to location as and when required and connected to suction and discharge piping using flexible metallic hoses. iv. Base plate shall have sufficient strength and rigidity to take the worst combination of pressure, torque and connected piping induced loads, and horizontal loads. The details of the pump base and bolts shall be subject to purchaser's approval. Inspection and Testing a. Inspection i. The bidder shall be responsible and provide for and perform all the inspection and testing specified herein. The inspection and testing shall be conducted in a manner satisfactory to and shall be subject to the approval of the Purchaser. The Purchaser / Purchaser's representative shall have access to all bidder's / sub-vendor's plants where manufacture or testing of equipment is in progress. Bidder shall provide the Purchaser with advance notification of the tests specified as witness tests. All materials designated as in conformance with an ASTM Standard shall be tested as required by such standard. Proof in the form of certified test reports or mill certificates that the required tests have been carried out at the source will be acceptable, but if these are not available, these tests shall be performed by the Bidder. ii.
Liquid Penetration inspection The first and last passes of all pressure containing welds, all external and accessible internal surfaces of the pressure bearing parts, the rotating and reciprocating parts, after final machining and before assembly, shall be inspected by a Liquid penetration method.
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IIT Bombay Tender Number – 201601548 Magnetic particle inspection shall be in conformity with ASTM E 109 or ASTM E 13 B. Any suitable method specified therein is acceptable. Demagnetization is required. Castings showing defects greater than those shown in ASTM E 125 of the degree listed below are not acceptable. Sr. no. 1 2 3 4
Type Degree I & V, (linear discontinuity end All indications porosity) removed II (Shrinkage) 1 III (Inclusions) 1 IV (Internal Chills) 1
to
be
Liquid penetration inspection shall be in conformity with ASTM E 165. The temperature of the part shall be between 50°F and 100°F. Penetrant and developer shall be removed on completion of inspection. The cleaning agent as well as the penetrant and developer shall not contain halogens and sulphur. Any indication of defects on any of the components inspected by dye penetrant inspection will not be acceptable. iii.
Radiographic Inspection: All pressure containing castings shall be fully radiographed in accordance with ASME Pressure Vessel Code Section VIII Div.1 and shall meet the requirements specified therein. All welds in pressure containing parts shall be fully radiographed in accordance with ASME pressure vessel code section VIII Div.1.
b. Tests Pumps and pump driver's unit shall be tested for the following: i.
Hydrostatic Test Pressure containing parts including auxiliaries shall be tested hydrostatically with liquid at a minimum of 1.5 times the pressure specified. Tests shall be continued for a sufficient period of time to permit complete examination of parts under pressure, but not less than 30 minutes.
ii.
General Performance Test The Pump shall be subjected to a performance test in accordance with the Standards of the Hydraulic Institute Test code for power Pumps, Section VIII - PP. The tests shall be performed using ordinary water at a temperature not in excess of (110°F) 43.5"C. For the purpose of this test each pump shall be connected to its own motor. The pump flow, power input to the motor, and the pump efficiency shall be determined over a range of total head from zero to at least maximum rated head. The Bidder shall submit test curves showing 58 | P a g e
IIT Bombay Tender Number – 201601548 Total Head, efficiency, brake horsepower and volumetric efficiency plotted as ordinates on the same sheet with pump capacity as abscissa. After the pump performance curves have been determined the pump shall be run continuously for 24 hours at rated head using ordinary water. A plunger leakage test shall be carried out during this run with the primary seal leakage cavity at atmospheric pressure. The leakage shall not exceed the value stated in the Tender as "the normal leak rate" to be expected. Vibration readings at suitable points shall be recorded during the test. The leakage through secondary seal cavity shall be measured with primary seal cavity maintained at a minimum pressure of 0.5 Kg/cm2g. iii.
Strip Test After the performance test, the liquid end shall be stripped off, to check for its wear and workmanship. Shafts under packing shall be checked for any abnormal rubbing and wear.
iv.
NPSH Test Vendor shall perform the test to verify NPSH required for each pump.
c. Inspection or Test Failure i. In the event the equipment or any part thereof fails to meet inspection or test requirements specified herein, the bidder shall notify the Purchaser or his authorized representative. The bidder shall obtain permission from the Purchaser before repair or subsequent use of such equipment or part. If the repairs including redesign, are likely to affect the results of tests of work previously completed, appropriate re-inspection and re-testing shall be conducted. vi.
vii.
Finish a. All exterior unfinished carbon steel surfaces shall be coated with a rust preventive primer followed by two coats of PU paint subjected to the approval of the Purchaser or his authorized agency. The colour shall be grey corresponding to shade No. 693 of IS5. Drawings and documents a. The bidder shall submit following documents for seeking approval of the supply of the pump i. Outline dimensioned drawing of the assembled unit including motor, indicating trolley and mounting details. ii. Cross sectional view of the unit showing clearly all working parts. iii. Catalogues / Technical data sheets giving in sufficient detail the constructional, operational and maintenance features. iv. Sub-vendor data sheets duly filled in and signed by the vendor. b. Subsequent to approval for supply, bidder shall submit the following documents for approval. i. Six copies each of certified dimensional outline drawings, cross sectional and assembly drawings including parts list & drawing giving trolley details. c. After completion, the bidder shall submit 4 copies of the following: 59 | P a g e
IIT Bombay Tender Number – 201601548 i. ii. iii. iv. v.
As built drawings. All test certificates for major pressure retaining parts. Performance test reports All relevant catalogues for proprietary items. Instruction manual which shall cover installation, operation and maintenance procedures. It shall also include recommended spare parts with replacement schedule, lubrication requirements and recommended lubricant etc.
Please refer datasheet C530/ME/DS/A4/312 for more details. Centrifugal pump Scope This specification covers the design, material, construction features, manufacture, inspection, testing the performance at the Vendor’s/Sub-Vendor’s Works and delivery to site of Horizontal Centrifugal Pumps. Codes and standards The design, material, construction, manufacture inspection and performance testing of Horizontal Centrifugal Pumps shall comply with all currently applicable statutes, regulations and safety codes in the locality where the Equipment will be installed. Nothing in these specifications shall be construed to relieve the Vendor of this responsibility. The Equipment supplied shall comply with the latest applicable Indian Standards listed below. Other National Standards are acceptable, if they are established to be equal or superior to the Indian Standards. List of Applicable Standards Sr. no.
Heater no.
Mounting equipment
1
IS : 1520
Horizontal Centrifugal Pumps for clear cold fresh water.
2
IS : 5120
Technical requirements of roto dynamic special purpose pumps.
3
API : 610
Centrifugal pumps for general refinery service.
4
IS : 5639
Pumps Handling Chemicals & corrosion liquids.
5
IS : 5659
Pumps for process water.
6
HIS
Hydraulic Institute Standards, USA
7
ASTM-1-165-65
Standards Methods for Liquid Penetration Inspection.
In case of any contradiction with aforesaid standards and the stipulations as per the technical specifications as specified hereinafter the stipulations of the technical specifications shall prevail. Design requirements 1. The Pump shall be capable of developing the required total head at rated capacity for continuous operation. Also the pumps shall be capable of being operated to give satisfactory performance at any point on the HQ characteristics curve over the operating 60 | P a g e
IIT Bombay Tender Number – 201601548 range of 40% to 120% of the duty point. The maximum efficiency of pump shall be preferably be within +/- 10% of the rated design flow as indicated in the data sheets. 2. The total head capacity curve shall be continuously rising from the operating point towards shut-off without any zone of instability and with a minimum shut-off head of 15% more than the design head. 3. Pumps shall run smoothly without undue noise and vibration. Peak to peak vibration limits shall be restricted to the following values during operation. Speed
Antifriction Bearing
Sleeve Bearing
1500 rpm and below
75.0 micron
75.0 micron
4. The noise level shall not exceed 85 dB. Overall sound pressure level reference 0.0002 microbar (the standard pressure reference for air sound measurement) at a distance of 1 M from the equipment. 5. The pumps shall be capable of starting with discharge valve fully open and close condition. Motors shall be selected to suit to the above requirements. Continuous Motor rating (at 50 ⁰C ambient) shall be at least ten percent (10%) above the maximum load demand of the pump in the entire operating range to take care of the system frequency variation and no case less than the maximum power requirement at any condition of the entire characteristic curve of the pump. 6. The kW rating of the drive unit shall be based on continuously driving the connected equipment for the conditions specified. However, in cases where parallel operation of the pumps is specified, the actual motor rating is to be selected by the Bidder considering overloading of the pumps in the event of tripping of operating pump(s). 7. Pumps shall be so designed that pump impellers and other accessories of the pumps are not damaged due to flow reversal. Design construction Design and construction of various components of the pumps shall conform to the following general specifications. For material of construction of the components, data sheets shall be referred to.
1. Pump Casing a. Pump casing shall have axially or radially split type construction. The casing shall be designed to withstand the maximum shut-off pressure developed by the pump at the pumping temperature.
b. Pump casing shall be provided with a vent connection and piping with fittings & valves. Casing drain as required shall be provided complete with drain valves, piping and plugs. It shall be provided with a connection for suction and discharge pressure gauge as standard feature. It shall be structurally sound to provide housing for the pump assembly and shall be designed hydraulically to minimum radial load at part load operation.
2. Impeller a. Impeller shall be closed, semi-closed or open type, and it shall be designed in 61 | P a g e
IIT Bombay Tender Number – 201601548 conformance with the detailed analysis of the liquid being handled.
b. The impeller shall be secured to the shaft, and shall be retained against circumferential movement by keying, pinning or lock rings. On pumps with overhung shaft, impellers shall be secured to the shaft by a lockout or cap screw which tightness in the direction of normal rotation.
3. Impeller/Casing Wearing Rings a. Replaceable type wearing rings shall be provided at suitable locations of pumps. Suitable method of locking the wearing ring shall be used. Wearing rings shall be provided in pump casing and/or impeller as per manufacturer’s standard practice.
4. Shaft a. The critical speed shall be well away from the operating speed and in no case less than 130% of the rated speed.
b. The shaft shall be ground and polished to final dimensions and shall be adequately sized to withstand all stresses from rotor weight, hydraulic loads, vibration and torques coming in during operation.
5. Shaft Sleeves a. Renewable type fine finished shaft sleeves shall be provided at the stuffing boxes/mechanical seals. Length of the shaft sleeves must extend beyond the outer faces of gland packing of seal end plates so as to distinguish between the leakage between shaft and shaft sleeve and that past the seals/gland.
b. Shaft sleeve shall be fastened to the shaft to prevent any leakage or loosening. Shaft and shaft sleeve assembly should ensure concentric rotation.
6. Bearings a. Heavy duty bearings, adequately designed for the type of service specified in the enclosed pump data sheet and for long, trouble free operation shall be furnished
b. The bearings offered shall be capable of taking both the radial and axial thrust coming into play during operation. In case, sleeve bearings are offered additional thrust bearings shall be provided. Antifriction bearings of standard type, if provided, shall be selected for a minimum life 16,000 hrs. of continuous operation at maximum axial and radial loads and rated speed.
c. Proper lubricating arrangement for the bearings shall be provided. The design shall be such that the bearing lubricating element does not contaminate the liquid pumped. Where there is a possibility of liquid entering the bearings suitable arrangement in the form of deflectors or any other suitable arrangement must be provided ahead of bearings assembly.
d. Bearings shall be easily accessible without disturbing the pump assembly. A drain plug shall be provided at the bottom of each bearings housing.
7. Stuffing Boxes
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IIT Bombay Tender Number – 201601548
a. Stuffing box design should permit replacement of packing without removing any part other than the gland.
b. Stuffing boxes of packed ring construction type shall be provided wherever specified. Packed ring stuffing boxes shall be properly lubricated and sealed as per service requirements and manufacturer’s standards. If external gland sealing is required, it shall be done from the pump discharge. The Bidder shall provide the necessary piping valves, fittings etc. for the gland sealing connection.
8. Mechanical Seals Wherever specified in pump data sheet, mechanical seals shall be provided. Unless otherwise recommended by the tenderer, mechanical seals shall be of single type with either sliding gasket or bellows between the axially moving face and shaft sleeves or any other suitable type. The sealing faces should be highly lapped surfaces of materials known for their low frictional coefficient and resistance to corrosion against the liquid being pumped.
9. Pump Shaft Motor Shaft Coupling The pump and motor shafts shall be connected with an adequately sized flexible coupling of proven design with a spacer to facilitate dismantling of the pump without disturbing the motor. Necessary coupling guards shall also be provided.
10. Base Plate A common base plate mounting both for the pump and motor shall be provided. The base plate shall be fabricated steel and of rigid construction, suitably ribbed and reinforced. Base plate and pump supports shall be so constructed and the piping unit so mounted as to minimize misalignment caused by mechanical forces such as normal piping strain, internal differential thermal expansion and hydraulic piping thrust. Suitable drain troughs and drip lip shall be provided.
11. Assembly and Dismantling Assembly and dismantling of each pump with drive motor shall be possible without disturbing the grouting base plate or alignment.
12. Drive Motor (Prime Mover) The kW rating of the drive shall be based on continuously driving the connected equipment for the conditions specified. In case, where parallel operation of the pumps are specified, the actual motor rating is to be selected by the tenderer considering overloading of the pumps in the event of tripping of operating pumps. Testing The manufacturer shall conduct all tests required to ensure that the equipment furnished shall conform to the requirements of this specification and in compliance with the requirement of applicable Codes and Standards. The particulars of the proposed tests shall be submitted to the DEC/ IITB for approval before conducting the tests. a. Hydrostatic Tests
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IIT Bombay Tender Number – 201601548 All pressure parts shall be hydraulically tested at 200% of pump rated head or at 150% shut off head whichever is higher. The test pressure shall be maintained for 1/2 hr. and no leakage shall be permitted. While arriving at the above pressure, the maximum suction head specified in Data Sheet shall be taken into account. b. Performance Tests The bidder shall furnish manufacturer’s test certificates c. Mechanical Balancing All rotating components of the pumps shall be statically balanced. In addition to static balancing, rotating components of the pumps shall be balanced dynamically at or near the operating speed. Tenderer shall furnish acceptance norm for this test. d. Visual Inspection Pumps shall be offered for visual inspection by the bidder before shipment. The components of the pumps shall not be painted before inspection. e. NPSH Test NPSH test shall be conducted with water as medium if required. NPSH shall not be mandatory in case type test certificates are furnished for the similar rating of pumps. f.
Noise and Vibration Measurement Noise and vibration shall be measured during the performance testing at shop as well as during the site test. i. The noise level shall not exceed 85 dBA. Noise level measurement will be made as per applicable internationally acceptable standard. The measurement shall be carried out with calibrated integrating sound level meter meeting the requirement of IEC:651 or BS:5969 or IS:9779. Sound pressure level will be measured all around the pump and motor set at a distance of one meter from the nearest surface of the machine and at a height of 1.5 m from the floor level. A minimum of six (6) points should be covered for measurement. The measurement shall be done with a slow response on the A-weighted scale. The average of the A-Weighted sound pressure measurements expressed in decibels to a reference 0.0002 microbars shall not exceed the specified value. ii. The tests shall be carried out on the machine operating at rated speed and as near as possible to the rated power. Corrections for background noise and correction on account of test environment will be considered in line with applicable standard. For this purpose, all the additional data required should necessarily be collected during the test. iii. Vibration check will also be done as per HIS. Vibration would be checked at thrust bearing locations on horizontal, radial and vertical direction. The acceptance limits would be as per HIS. The instrument used would be IRD 308 or equivalent with velocity pick-up. Vibration limits to be specified as per the speed of the pump. 64 | P a g e
IIT Bombay Tender Number – 201601548 g. Material Test Certificate i. Material of the various pump components shall be tested in accordance with the relevant standards. Test certificates for these shall be furnished for IITB / DEC’s approval. ii. Where stage inspection is desired by IITB / DEC / TPI all material test certificates shall be correlated and verified with the actual material used for construction before starting fabrication by IITB / DEC / TPI’s inspector who will stamp the material. In case mill test certificate for the material are not available, the supplier shall carry out physical and chemical tests at his own cost from a testing agency, approved by IITB / DEC, as per the requirement of specified material standard. The sample for physical and chemical testing shall be drawn up in presence of IITB / DEC / TPI’s inspector who shall also witness the testing. h. Non Destructive Testing i. UT shall be carried out on shafts of diameter more than 50 mm. ii. DP tests shall be carried out on shaft and impeller. iii. No weld repair shall be allowed on cast iron. i.
Field Testing i. After installation, the pumps offered shall be operated to prove satisfactory performance as individual equipment as well as a system run. If the performance at site is found not to the requirements then the equipment shall be rectified or replaced by the bidder, at no extra cost to the IITB. The procedure of the above testing will be mutually agreed between the DEC / IITB and the bidder. Noise and vibration tests shall also be repeated at site. ii. Based on observation of the trial operation, if modifications and repairs are necessary, the same shall be carried out by the bidder to the full satisfaction of the engineer in charge and then the performance and guarantee tests to be repeated at site as per relevant clauses of the specification.
Electrical heaters Sr. no. Heater no. 1 2 3 4 5 6
EH-01 EH-02 EH-03 EH-04 EH-05 EH-06
Mounting equipment Thermocline tank Evaporator Preheater Receiver start-up Receiver testing Receiver testing
Rating heater 4 kW 15 kW 15 kW 15 kW 40 kW 40 kW
/ Qty 16 1 1 5 7 1
Total heat duty 4 kW 15 kW 15 kW 75 kW 280 kW 40 kW
1. The equipment shall comply with the latest edition of Indian Standards / IEC / BS / VDE / IEEEE / NEMA or equivalent. In case of imported equipment, standards of the country of origin, if equivalent / stringent than applicable Indian standards, shall be applicable. 65 | P a g e
IIT Bombay Tender Number – 201601548 2. The equipment shall also conform to the provisions of Indian Electricity Rules and other statutory regulations currently in force. 3. The electrical heater and panel shall also comply to the requirements of licensor’s specifications, if any. 4. The offered equipment shall be brand new and shall be of proven track record. 5. The heaters and panels shall be suitable for installation and operation in environment as per the geographic location of the site and the equipment, their positions and surroundings and the tower structure etc. as shown in the drawing and details with this tender. 6. Design basis: a. The heaters and panels shall be designed to provide continuous operation at rated output, at the specified process conditions. b. Over temperature protection shall be provided. c. Suitable controls shall be provided to enable maintenance of the heaters. 7. Power supply : a. Power supply shall be 415 VAC, TPN, 50 Hz, 8. Safety: a. All components shall be designed to provide a maximum degree of safety during all operating conditions, inspection and maintenance with proper clearance between various components and devices. The heaters shall be located as per the details and shall be designed to withstand prevailing environmental conditions. 9. Construction: a. 4 kW, Thermocline tank heaters, 16 no.s EH-01: Heater assembly, consisting of 3 elements, each of 1.33 kW, made out of 10.5 mm diameter incoloy-800 tube, brazed to 65mm NB x 15mm thick S.S.304 flange, length – 900 mm, cold – 150 mm, stand off - 250mm. b. 15 kW, evaporator heater EH-02: Heater assembly consisting of 3 nos. elements, each of 5 kW, made out of 16 mm diameter incoloy-800 tubes, brazed to 80 mm NB, 600 class, S.S. 304 flange, length of element below flange - 1500 mm, stand-off - 200 mm. c. 15 kW, water preheater EH-03: Heater assembly consisting of 3 nos. elements, each of 5 kW, made out of 16 mm diameter incoloy-800 tubes, brazed to 80 mm NB, 600 class, S.S. 304 flange, length of element below flange - 1500 mm, stand-off - 250 mm. The heater shall be mounted inside 80 NB pipe for inline heater EH-03 as per GA drawing attached with the tender.
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IIT Bombay Tender Number – 201601548 d. 15 kW, Receiver heaters, 5 no.s, EH-04: Heater assembly consisting of 3 nos. of elements, each of 5 kW, made out of 16 mm diameter incoloy-800 tube, brazed to 80mm NB, 150 class S.S.304 flange, length of element – 2500 mm, the elements will be supported by baffles and stud. The assembly will have safety thermocouple. The heaters shall have a loose fit cap at top which shall remain at the cut-out in the receiver cavity wall to prevent convection heat loss. The cap will fit on the top of the heater and will be carried up as the heaters rise in the cavity for daily startup heating of the receiver coils. e. 40 kW, Receiver testing heaters EH-05, 7 no.s & EH-06, 1 no.: Heater assembly consisting of 15 nos. of elements, each of 2.666 kW, made out of 8 mm diameter incoloy-800 tube, brazed to 250mm NB, 150 class S.S.304 flange, length of element – 2500 mm, the elements will be supported by baffles and stud. The assembly will have safety thermocouple. Heaters EH-05 will have reflectors made of SS 316, buffed and polished on the inside subtending an angle of 150º at the centre of the heater. These heaters EH-05 and EH-06 shall be dismantled and removed along with their panel from site and handed over as directed by the site in-charge by the bidder after successful testing of the molten salt loop. f.
Heater elements i.
Heater elements shall be constructed of 80Ni, 20 Cr resistance wire surrounded by MgO powder.
ii.
The heater elements shall be protected against over-temperature.
g. Enclosures / Terminal boxes / panel i.
The enclosures / terminal boxes shall be suitable for the site conditions and other relevant information provided in this tender.
ii.
The enclosures / terminal boxes shall have a minimum ingress protection rating of IP-55. Separate earth terminals shall be provided inside and outside.
iii.
Panel shall be free standing, constructed of sheet steel, powder coated, equivalent to IP-55, with lockable hinged doors, with sufficient component spacing to allow cooling and provided with cooling fans, if required.
iv.
Panels shall be bottom cable entry only.
h. Inspection and testing : i.
Heaters: Following electrical tests shall be carried out 1. High voltage test 2. Insulation resistance test of heaters to earth 3. continuity test on each phase of the heater
ii.
Panels / terminal boxes 1. Insulation resistance test
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IIT Bombay Tender Number – 201601548 2. Electrical continuity test iii.
Site acceptance testing: A full load test of heaters in its service conditions shall be carried out to confirm the design output. In addition, interfaces with other connected systems shall be tested with particular emphasis on controls and protection.
Please refer data sheet C530/EE/DS/A4/413 Piping, valves and fittings on molten salt lines, steam lines and feed water line The scope of work shall be read in conjunction with other parts of this document. The scope of work of bidder shall include the following: Piping work (molten salt, feed water and steam piping, instrument air, cooling water, etc.) 1. Procurement, supply, shop & field fabrication, testing, painting (non-insulated piping) and erection and commissioning of piping, installation of specialty items including supply and erection of following materials but not limited to the same. a. Pipes (All sizes and schedules) b. Flanges (All sizes, types and Pressure ratings) c. Fittings (All sizes, types and schedules) d. Valves (All sizes, types and ratings) e. Gaskets (All sizes, types and ratings) f. Studs, Nuts or M/c Bolts (all types) g. Specialty items like MOV, Control valves etc. h. Installation of traps, strainers, sample coolers etc. 2. Procurement, supply, fabrication and erection, painting etc. of pipe supports like shoes, clamps including bolting materials, saddles, guides, dummy pipes, stops, anchors, clips, cradles, hangers, turn buckles, springs used in clamps for pulsating/ vibrating lines, spring washers, supporting fixtures, brackets, cantilevers, struts, tee-posts, including erection of spring supports, expansion bellows, steam and condensate manifolds and sway braces. Bare pipes of all sizes shall be supported with corrosion pad or pad and shoe on pipe rack / sleepers. 3. Site Fabrication of piping items. a. Fabrication of piping specials like special radius bends, reducers, miters, etc. b. Fabrication of plain and threaded nipples from pipes as required during erection. c. Fabrication of swage nipples as and when required. d. Fabrication of odd angle elbows like 60°, 30°, or any other angle from 90°/45° elbow as and when required. e. Fabrication of flanges, reducing flanges, blind flanges, spectacle blinds, crosses, jump overs etc. as and when required. f. Fabrication of circular pipe for steam rings, utility lines at all levels and elevations. g. Fabrication of stub in connections with or without reinforcement. h. Grinding of edges of pipes, fittings, flanges, etc. to match mating edges of uneven / different thickness wherever required as per specifications including beveling of plain end pipes. i. Threading of all small bore piping as per piping material specifications. j. Drilling on blind flange for inserting / joining small bore lines.
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IIT Bombay Tender Number – 201601548
4. 5. 6.
7. 8.
9.
10.
11. 12.
13. 14. 15. 16.
17. 18.
k. Fabrication and welding of reinforcement pads at branch pipe locations wherever required. Modifications like providing additional cleats for extension of stem of valve, locking arrangement of valves, providing chain operation facility etc. as and when required. Obtaining approval from statutory authority (IBR), for drawings prepared by consultant / suppliers / bidders required as per instructions of Engineer-in-charge. As-built marking of Isometrics, bill of materials & supporting details of lines up to and including 1½" related to instruments & pump flushing / cooling, purging, pump vents, drains & Non IBR lines and lines specified as field routed within the unit battery limit including subsequent approval from Engineer-in-charge as and when required is in bidder’s scope of work. Non-destructive examination / testing as per Job Specification for Non-Destructive Examination Requirements of Piping Specification. Fabrication and erection of small structures for pipe supports and valve operation / attending some instruments etc., providing brackets from structures for pipe supports, modification / extension of platforms, providing additional platforms / ladders for improving / providing accessibility, including supply of necessary materials. Providing insert plates with anchor fasteners in concrete structures / paved floors and repair of platform gratings around pipe openings and providing suitable members for support under the platform grating. Materials required for above are in bidder’s scope of supply. Flushing and testing of all piping systems as per standard requirements for inspection, flushing and testing of piping systems. The accessories required for blinding the line like flange, blind flange, gasket (all sizes, type and rating), stud-bolts, flexible hoses etc. are to be arranged by the bidder. During flushing the discharged water / air shall be drained / routed as directed by the Engineer In-Charge. Hydraulic bolt tensioning & torqueing shall be performed on flange joints as per the standard requirements Wherever piping class breaks of high pressure / low pressure are involved, the highpressure circuit shall be tested up to piping class spec. break and the low-pressure circuit shall be tested up to the nearest flange of high-pressure piping. Providing stiffeners for all small bore (1.5” and below) branches. Materials required for above are in Bidder’s scope of supply. Internal grinding of welds of orifice flanges to render smooth surface. Fabrication of saddles for supports from bidder supplied carbon steel & stainless steel plates. All piping must have high point vents and low point drains. All process drains, vents and bleeds used and required for plant operation shall be in accordance with P&IDs. ¾” NB maximum or line size if line size is less than ¾” NB size, valve high point vent and low point drains are to be provided for all systems for hydrostatic / pneumatic testing / flushing. Bidder shall prepare welding specifications for all weld joints where dissimilar welding will be performed, and obtain approval from DEC. Supply and application of primer including surface preparation to piping, pipe supports and structural steel work for pipe supports as per specification and instructions of Engineer-in-charge.
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IIT Bombay Tender Number – 201601548 19. Any other incidental / intermediate / ancillary or any enabling work not specifically mentioned in any specification but required to complete the work. 20. Providing marked up As-built GADs / Isometrics of all lines under the scope of this tender. All As-built drawings shall be approved by the Engineer in–Charge and shall be supplied in CDs and Hard Copies. Silencer for steam vent The silencer shall be for the following parameters: Sr. no. 1 2
Parameter Medium Service
3
Upstream temperature Steam flow rate (max) Downstream noise level
4 5
Value Superheated steam Discharge of steam to atmosphere at the end of steam discharge piping after main outlet steam valve pressure, 40 bara, 425 ⁰C 500 kg/hr. < 85 dB at 1.5 m distance /
1. Scope: Includes design, engineering, procurement, manufacturing, supply, inspection, packing, insurance, transport, loading, unloading, storage, erection, testing and commissioning along with all spares, etc. complete. 2. The silencer shall be inclusive of inlet nozzle, support brackets, lifting lugs, drain nozzle, weather cowl with bird screen, manufacturer’s name plate etc. complete 3. The Vent Silencer shall be designed to bring down the noise level to 85±4 dBA at 1.5m distance at a directivity of 360 degree from the existing noise level in free field conditions. The noise reduction shall be demonstrated at the time of commissioning and handover. 4. The bidder shall submit detailed design drawings and noise calculations for approval prior to fabrication in triplicate. 5. The external surface of the vent silencer shall be sand blasted and painted with 3 coats of HR aluminium paint. 6. The bidder shall submit as-built drawings in triplicate.
Instrument air plant 1. Purpose Instrument air system consisting of screw / reciprocating air compressor, desiccant type air dryer and pre filter is required to supply dry and filtered air with minimal oil content. 2. Main specification The instrument air system shall consist of following items, with specifications given against each. Ambient parameters shall be considered for Greater Noida, Uttar Pradesh. a. Air compressor i. An independent Air Compressor unit capable of continuously supplying compressed air to the machine, powered by a 3 phase A.C. electric motor of suitable rating and complete with
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IIT Bombay Tender Number – 201601548 a. Receiver Tank (conforming to ASME Norms), made of IS 2062, fitted with Safety Valves, pressure gauge, and drain valve. b. Pressure Relief Valve, c. Automatic Pressure Switch, d. Suction Filter, e. Oil Sight Glass, f. Drain Valve, g. Starter for the motor ii. iii.
Air delivery: 150 SCFM or more Working pressure at outlet of Integrated Desiccant Type Air Dryer: 7.5 Kg/cm2. iv. Receiver Air tank capacity: 500 litres minimum. v. Compressor shall be designed for continuous duty. vi. Maximum noise level of compressor should be < 67 dB (A) at normal load condition, one meter away from the machine / enclosure. b. Adsorption type air dryer: The Instrument air unit should have an adsorption type Air Dryer i. Moisture Trap (with automatic and manual drain). ii. The unit shall provide and stable pressure dew point ( -15 C to -20 C) & avoid freezing during extended un-load run operation. iii. Air dryer should be able to deliver compressed air from the machine according to ISO – 8573-1 having the following parameters of air:
iv.
a. Solid particles / dust:
Class – 1
b. Humidity:
Class – 3
c. Oil content:
Class – 2
Purge loss shall be stated.
c. Downstream filters i. General purpose pre-filter - A suitable and efficient Pre Filter for Compressor Unit as per the requirement mentioned above for oil & other foreign particles removal from air. d. Control Panel: Control panel for monitoring continuously & accurately (through microprocessor based Regulator and Electronic Controller) the data and for controlling the performance through feedback to the operator and interlocking arrangements. Built in protection systems, inclusive of the following, should be provided for safe and fool proof operation of the complete compressor system. i. ii. iii. iv.
Phase sequence protection relay, Phase failure protection relay, Motor overload Trip, High Air / Oil Discharge Temperature Trip. 71 | P a g e
IIT Bombay Tender Number – 201601548 v. vi. vii. viii.
3.0.
4.0
Protection against starting on load, Suitable for controlling the compressor operation locally, remotely or via. Local Area Network. Maintenance schedule display and alerts Usage statistics
e. All accessories to meet the specification and make the unit operable at site shall be provided by the bidder with permanent arrangement as required. Spares and consumables Bidder shall supply 4 sets of all filters (air and oil), compressor oil for 2 years of continuous operation (@ 24 hr. / day basis. Bidder shall also include 2 years comprehensive maintenance contract with the OEM. Complete list of spares & consumables (inclusive of the following spares & consumables) is to be provided, giving individual item’s part identification no, its application, life (in hrs of use), recommended quantity and unit cost. Other requirements
a. Safety feature should be incorporated for safety of operator and the machine. b. Anti-vibration mountings should be provided on the compressor frame for vibration isolation from Screw element, Motor and Oil Separator Tank. c. Documentation: Three sets of Operation and Maintenance Manuals documents are to be supplied along with the unit with detailed electrical drawings ( SLD and CWD ). d. Guarantee: Bidder shall provide full and complete guarantee from the OEM for two years trouble free performance from date of successful commissioning / final acceptance. e. Civil work: Bidder shall submit civil foundation drawings from OEM. f. Space requirement: Bidder shall submit GA drawing of the package and indicating space requirement for installation and maintenance of the package. g. Notes: a. Technical literature and catalogues of the offered package unit shall be submitted in advance. b. Compressor performance is measured according to ISO 1217, 4th Edition, and Annex. C. Tolerances are applicable. c. Operating Sound Level: Operating sound levels for machines equipped with recommended standard motors and enclosures are guaranteed +/-3 dB(A) according to Pneurop/Cagi PN8NTC2, tolerance: 3 dB(A). h. Training: Bidder shall arrange for operation and maintenance training to client / site personnel for handover. The training shall be duly documented. Motorised hoists The design of electric hoists shall be compact modular type, reliable and have proven quality. Only reputed makes shall be offered. The requirement is as below:
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IIT Bombay Tender Number – 201601548 Sr. No.
Description
1
5 Te for receiver maintenance, outdoor, elevation 1 141.6m
2
2 Te for pumps etc., indoor, elevation 125.6m
3
2 Te for cleaning mechanism without trolley, indoor, 1 in parking area for cleaning mechanism, ground floor
Design specification for electric hoists Sr. no. Item
Qty.
1
Specification / description
1.
Number of hoist
As per table above
2.
Type of hoist
Standard Electric hoist
3.
Duty of the hoist
Class II
4.
Capacity
as per table above
5.
Height of the Lift
as per equipment details
6.
Hoisting speed
as per manufacturer’s standard
7.
Traversing speed
as per manufacturer’s standard
8.
Head Room (Distance between bottom ≤ 500 mm ( preferred ) of monorail & hook top most position)
9.
Method of operation
Push button pendant suspended at the bottom. ( hang with suitable chain )
10.
Electric Supply
A.C. 415V 3∅
11.
Monorail size
As per details in structural drawings
12.
Length of Travel
As per details in structural drawings
Material of construction All materials used shall be of sound quality and shall conform to latest relevant standards as given below, Sr. no. 1. 2. 3.
Item Steel Plates High Tensile Bolts Hooks and Clevises
4. 5.
Steel Pinions Steel Shafts and Axles
Specification / description IS-2062, Grade B BS-970 (EN-24) or IS equivalent IS-1875 Class 3A and IS-3815, BS-482 & BS2903 BS-970 (EN-24) or IS equivalent BS-970 (EN-8) or IS equivalent
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IIT Bombay Tender Number – 201601548 Sr. no. 6. 7. 8. 9. 10. 11. 12.
Item Pins and Screws Steel Castings Iron Castings Steel Forging Hoisting rope Monorails Wheels
Specification / description BS-970 (EN-8) or IS equivalent IS-1030 (Gr-II) IS-210 (Grade 4 or better) IS-2004, class-III (carbon % 0.25 - 0.35.) IS 2266 (Steel Core) IS-3443, 50C12 En-9 forged
Design requirements 1. General design requirements for electric hoists: The hoist shall be as per latest IS-3938 & IS-807 and of class-II duty (In-door / Outdoor service) type, rigid and shall have adequate margins to give excellent performance, safety arrangements for preventing overloading, over stressing on hoist component. The hoist design shall be modular construction for easy maintenance. All efforts shall be made to make the hoist as compact as possible. a. Design requirements: Mechanical i. Gear train: In order to ensure smooth operation & long life of gear train all gear transmission shall be achieved from accurate machine cut spur gears at each stage. The gears shall run in totally enclosed oil bath giving positive splash lubrication to all gears & bearing. All gears in gear train shall be anti-friction bearing mounted. ii. Bearings: All supported / gears / shaft / wheels shall be mounted on the antifriction ball / roller bearings. For wheel, bearings shall of spherical roller type and for hook block thrust ball bearings shall be used. The bearings shall be SKF / FAG only. The test certificate for the bearing from the manufacturer shall be provided. iii. Rope drum: The rope drum shall be of carbon steel fabricated seamless construction, having spiral grooves machined to suit wire rope. The rope drum shall be Ultrasonic tested. The drum shall have dimensions to meet IS: 3938. (In order to make hoist compact higher diameter drums may be used). The revolution of rope drum shall be on self-aligning ball bearings, which ensures smooth running. iv. Rope guide: A rope guide completely encircling the drum shall be provided so that the rope shall be held in its grooves at all times and cannot get uncoiled even when the rope is unloaded. Or any other suitable means for rope guiding so that the verticality of the wire rope to be maintained within 1: 12. v. Wire rope: Extra flexible long durable steel wire rope with an appropriate factor of safety shall be used, which ensures long life. Replacement of wire of wire rope shall be very easy. vi. Runner wheels: The runner wheels shall be mounted on ball bearings. The trolley drive assembly shall be attached to one of the runner angles and can be adjusted to suit various joist sizes. vii. Bottom block assembly: The forged hook conforms to IS: 3815 and shall be supported on a thrust bearing, allowing the load to swivel freely. Provision shall
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IIT Bombay Tender Number – 201601548 be made to lock the swivelling of hook as & when required. Sheaves shall be provided with guards to retain the rope in position. viii. Frame: The frame, which supports the load shall consist of steel side plates and steel runner plates of adequate section. The gear train and electrical control gear shall be attached to the side plate and shall be housed inside separate fabricated steel covers. A gasket shall be provided between cover and side plate for oil sealing. ix. Lubrication: The gears and bearings shall run in oil bath. The positive constant splash lubrication to gears and bearings shall be ensured for faster heat dissipation, smoother operation and longer life. The provision shall be made for lubricating oil level indicator. b. Design requirements: Electrical i. Feeders for Electric Hoists: One-point supply to each hoist shall be provided from the PMCC. Further distribution shall be in Bidder’s scope. This shall include local starter panel, push button station, other control, cables, cable trays and other consumables required for satisfactory commissioning. ii. Motors All motors shall conform to latest IS 12615 and either of Siemens, Bharat Bijlee, Crompton Greaves makes only. Drives for travel of the hoist as well as hoist shall comprise of totally enclosed, fan cooled (IP55) squirrel cage induction motors suitable for operating on a 415 V, 3 phase, 50 Hz AC electrical supply. The hoisting motor shall be foot-mounted type. The motors used shall be special hoist duty type (S4 duty) with CDF 1.5, and dual speed double winding suitable for frequent starting, reversing and braking. The motors should operate satisfactorily for voltage variation of ±10% & frequency variation of ±5%. The testing of motor for type & routine test shall be carried out. Test for noise and variation measurement also shall be carried out. iii.
Hoist brake The hoist motor shall be fitted with an electro-magnetic brake designed and built to arrest and hold safely the full load capacity of the hoist. The brake shall be connected across the motor terminals for fail safe features. The brake shall be easily accessible for its setting. The brake shall be rated for half an hour continuous operating and for 150 % load capacities and shall be suitable for selected class of duty cycles. The brake shall be of reputed make like BCH / Speed O control / Electro-mag makes.
iv.
Controls and control system The hoist shall be designed to operate by push button pendant station. The push button pendant shall be suspended along with steel link chain in order to avoid stretch on control pendant wire. The push button pendant and control cabinet shall be of light weight design. The control panel consists of contactors, Overload Relays, Single Phase Protection devices, transformer, rectifier and fuse etc. shall be provided on the hoist body 75 | P a g e
IIT Bombay Tender Number – 201601548 itself with suitable dust and weatherproof cover. The control panel shall be easily accessible on hoist. All control equipment shall be suitable for operating on control voltage 110 V AC to ensure safety to operator. A separate isolator switch shall be provided by supplier for the electric supply to control system and shall be of AC-24 duty. Stop, start and directional changes shall be accomplished by reversing magnetic contactors by push buttons operating a control circuit. In all cases the push button shall be spring loaded and shall return to off positions when released. They shall be suitably interlocked such that the push buttons of two reverse motions (e.g. hoist up & down etc.) cannot be simultaneously operated. Contactors & overload relays: All contactors, overload relays shall be of reputed company (Siemens, Telemechanic) make and rated to permit 150 switching operations per hour. Overload relays with built in SPP (Single Phase Protection System) shall be considered. Wherever designed the reversing contactors shall be provided with electrical and mechanical interlocks between forward and reverse contactors. The contactors shall be provided with a three element, positive acting, ambient temperature compensated, time lagged, hand reset type thermal overload relays with adjustable setting to suit the rated motor current. Resetting of the relay shall be feasible from front door of the panel. The contactors shall be AC4 duty only. v.
MCCBs/MPCBs: All MPCBs/MCCBs shall be of reputed make like and shall conform to IEC 60947. All switchgear components shall be of ABB/Siemens/Schneider/L&T.
vi.
Cables: a. All cable shall be of 1.1 KV grade and control panel wiring shall be of insulated and sheathed copper conductors for control circuit wiring. b. Conductor section of main power circuit cables shall be selected taking into consideration simultaneous operation of the hoist and trolley. The minimum cross section of copper conductor wire/cable for power and control circuit shall be 2.5 mm2 & 1.5 mm2 respectively. c. Limit switch: A limit switches shall be provided for hoisting and trolley travel operation in order to restrict the motion at both extreme ends. For hoisting rotary as well as gravity type limit switch shall be provided.
Painting All surfaces shall be cleaned thoroughly, preferably by sand blasting. All oils and greases shall be removed prior to painting. Two shop coats of primer shall be provided at the supplier’s works followed up two final epoxy coats.
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IIT Bombay Tender Number – 201601548 Spares and maintenance tools 1. Spares: The supply shall include necessary spares for 3 years trouble free service. 2. Maintenance tools: The supply shall include the required maintenance tools for the hoist. Documentation 1. All material and routine test certificates 2. Operating and maintenance manuals 3. Guarantee / Warranty document LP, HP dosing system: Refer data sheet C530/UT/DS/A4/601 Technical Requirements 1. The equipment shall meet the duty requirements and performance parameters as specified. 2. The equipment shall be designed for outdoor and unprotected location. 3. Dosing Tank a.
Tank shall be designed and fabricated as per the requirements of process data sheet.
4. Dosing Pumps a.
Pumps shall be designed, manufactured and tested in accordance with API-675.
b.
Pumps shall be with suitable speed control to enable variable rate of dosing.
c.
All coupling, gears and exposed rotating parts shall be provided with adequate guards of non-sparking type.
d.
Strainers shall be provided before inlet of the pumps.
e.
Pump shall be supplied with calibration pot. The upper graduation level of calibration pot shall be lower or equal to the maximum liquid level in the tank. The vent of the pot shall be with valve and kept inverted ‘U’.
5. Structural Skid a.
Complete dosing package shall be mounted on a single structural skid suitable for single lift.
b.
The skid shall be designed and built to ensure that all the equipment along-with accessories, panel and piping are mounted suitably for convenient operation/maintenance.
c.
All the components of the system shall be mounted on the skid, fully assembled, piped with inlet and outlet piping terminated at the skid edge with appropriately rated flanges.
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IIT Bombay Tender Number – 201601548 6. All electrical devices shall meet the requirements of the area classification and electrical specification attached elsewhere in the bid. The instrumentation for the skid shall be provided. 7. Interconnecting piping material specifications of the assembly shall be suitable. Bidder to note that only SS piping shall be used. 8. Inspection and Testing a.
All equipment shall be subjected to inspection and testing at Vendor’s works by purchaser/ his authorized inspection agency.
b.
Manufacturer’s Quality Assurance (QA) plans shall be submitted for Purchaser’s approval before taking up manufacturing.
c.
Fittings, valves, instruments etc. shall be duly tested and manufacturer’s test certificates shall be furnished.
d.
All the pressure vessels shall be hydrostatically tested and inspected. The total skid shall be hydro-tested at applicable pressure.
e.
Any or all the tests, at Purchaser’s option, shall be witnessed by Purchaser/ his authorized inspection agency. However, such inspection shall be regarded as checkup and in no way absolve the Bidder of his responsibility.
Thermal Insulation 1. General Requirements Thermal insulation shall be provided mainly for the following reasons. a. Conservation of heat and maintenance of temperature as per design cycle. b. Personnel protection c. Insulation thickness as mentioned shall be provided. 2. Technical Requirements a. All Insulating materials, accessories and protective covering shall be non-sulfurous, incombustible, low chloride content, chemically rot-proof, non-hygroscopic and shall be guaranteed to withstand continuously and without deterioration the maximum temperature to which they will be subjected under the specified conditions. b. The use of insulation of finishing materials containing asbestos in any form is not permitted. The insulation compound shall not contain any substance detrimental to health. c. Insulation mattress / section shall be supplied in thickness of 25, 40, 50 and 75 mm. Insulation of higher thickness shall be made up in multiple layers using mattress/slabs of thickness specified above. However, if the required thickness is not achieved, the mattress/slabs in increment of 5mm shall be acceptable. The minimum thickness shall not be less than 25 mm, the number of layers shall be minimum and the innermost layer shall be the thickest. d. The durability and adherence of insulation layer on the bottom of the equipment is of particular importance, therefore, special attention shall be paid to this when the insulation is designed and applied.
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IIT Bombay Tender Number – 201601548 e. Special fire protection measures shall be taken for the steam lines running in the immediate vicinity of oil lines. The sheet metal jacketing shall be made oil proof by inserting self-adhesive flexible tapes. f. Rock wool insulation mattress shall be of long fibered rock processed into fibrous form bonded with a binder. No kind of slag wool inclusion is acceptable. g. Clean water shall be used in mixing insulating or covering components. Care shall be taken that brackish or salt water is not used for this purpose. h. All insulation shall conform to the quality requirements laid down below and test certificates on samples from the lot to be supplied shall be furnished to the Purchaser for approval. i. The use of asbestos in any form for insulation and elsewhere is not permitted. j. The thermal conductivity of the insulating material to be considered for the design of thickness of insulation shall be the maximum value as per the relevant standard to which the material belongs. 3. Material of insulation a. Insulation wool: Insulation wool Sr. no.
Particular
Type # 1
Type # 2
1
Material
Lightly resin bonded mineral Resin bonded mineral ( rock ) ( rock ) wool wool pre-formed pipe sections/ blocks
2
Apparent density
100 kg/m³ for temp. 60 - 400 140-150 kg/m³ ⁰C 150 kg/m³ for above 400 ⁰C
3
Material IS: 8183 standard & testing code
IS: 9842
4
Applicable Piping system & equipment Piping system of 350 NB and service with operating temp. range below with temp. in range of 60of 60 - 650 ⁰C 400o C
b. Cladding material: Cladding material for all insulated surfaces. equipment, piping etc. confirming to ASTM B 209-1060 temper H-14 or IS-737 Gr.19000/H2 shall be provided as follows,
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IIT Bombay Tender Number – 201601548 Cladding material Sr. no. Insulation dia.
With lightly mattresses For dia of insulated 18 swg surfaces of 450 mm & above and for flat surface For dia of insulated 20 swg surfaces less than of 450 mm.
1 2
bonded With preformed pipe sections 20 swg
c. Binding and lacing wires Binding and lacing wires Sr. no. Temperature 1 Upto 400 ⁰C. 2 Above 400 ⁰C.
Material Galvanised steel Stainless steel
Thickness 20 swg 20 swg
d. Straps, bands, screws, wire mesh: i. ii. iii. iv. v.
Materials of straps and bends shall be as under: Bands shall be 20 mm wide and 0.6 mm thick c) For securing aluminium sheathing material, stainless steel or anodized aluminium bands shall be used. Screws shall be of stainless steel, self-tapping type. Hexagonal wire mesh shall be conforming to following: Hexagonal wire mesh Sr. no. Temperature 1 Upto 400 ⁰C. 2 Above 400 ⁰C.
Material Galvanized steel Stainless steel
Thickness 20 swg 20 swg
e. Bonding agent
f.
i.
Shall be alkali silicate based, formulated with surface drying additives-self setting.
ii.
Shall be suitable for temperature applications upto 900 ⁰C.
iii.
Shall be non-corrosive, nontoxic and non-inflammable.
iv.
Shall be free from unreacted matter.
v.
Shall not require internal, or external drying; thus eliminating requirement of steam heating. Others accessories The bidder shall also provide other accessories such as ceramic boards, sealants and washers as required within the quoted price.
4. Application Procedure for Thermal Insulation and Refractories a.
General 80 | P a g e
IIT Bombay Tender Number – 201601548
b.
c.
i.
All surfaces to be insulated shall be cleaned of all foreign materials such as dirt, grease, paint residue, loose scale and rust etc., and shall be dry before the application of insulation.
ii.
Before applying the insulation, the bidder shall check that all instrument tapping, clamps, lugs and other connections on the surface to be insulated have been properly installed as per the relevant erection drawing.
iii.
Firm anchoring shall be welded onto the pads/strips already provided on the body of the casings/ equipment. Pads/strips in addition to those already provided shall be attached only with the approval from purchaser.
iv.
All flanged joints shall be insulated only after the final tightening and testing.
Installation on valves and fittings i.
All valves, fittings and specialties shall be insulated with the same type and thickness of insulation as specified for the connected piping with the special provisions and or exceptions as given below.
ii.
All valves and flanges shall be provided with removable box type of insulation covered with box fabricated from aluminium sheets of thickness same as the connected pipe cladding. Adjoining pipe insulation shall be bevelled back to permit removal bolts and nuts or bands. The portion of the valve which cannot be covered by box type insulation shall be filled by loose insulating material of packing density at least equal to that of the insulating material of adjoining pipe. The insulation for valves/flanges shall be applied after the finishing has been applied over the connected piping. The cladding shall be applied in such a manner that the bonnet flange can be exposed easily without disturbing the complete insulation and cladding.
iii.
For expansion joints the insulation, wherever applicable, shall be applied in such a way that it does not hinder the functioning of the joint.
iv.
Safety valves shall be suitably insulated.
Installation on piping i.
All vertical pipes shall be provided with the suitable insulation supports to prevent collapsing/crushing of insulation due to its self-weight. Support rings shall be provided at a spacing of 3 metres on all vertical piping with a vertical length of 4 meter or above.
ii.
Longitudinal joints of insulation mattresses sections of horizontal piping shall be on the bottom or at the sides of the pipe.
iii.
When more than one layer of insulation mattress/section is required on piping the circumferential joints on adjacent layers shall be staggered by at least 150 mm and longitudinal joints shall be staggered by at least 50 mm.
iv.
Mattress type insulation shall be formed to fit the pipe and applied with the mattress edges drawn together at the longitudinal joints and secured by lacing wire. Pipe section insulation shall be fitted on pipe using binding wires.
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IIT Bombay Tender Number – 201601548
d.
v.
Where insulation is applied in two or more layers each layer of mattress shall be backed with hexagonal wire mesh. For the first layer of insulation and in case of single layer insulation, hexagonal wire mesh shall be provided on both the surface of the mattress. For pipe sections, the preformed sections shall be held in place by binding wires without any wire mesh.
vi.
The ends of all wire loops shall be firmly twisted together with pliers, bent over and carefully pressed into the surface of the insulation. Any gap in the insulation shall be filled with loose mineral wool or finishing cement.
vii.
Insulation mattress/section ends shall be terminated at a sufficient distance from the flanges to facilitate removal of bolts.
viii.
The insulation shall be held in place by fastening over with binding wire for insulation surface with diameter upto and including 550 mm and with metal bends for insulation surfaces with diameter over 550 mm. The fastening shall be done at intervals of 250 mm except where specified otherwise. The ends of the binding wires shall be hooked and embedded in the insulation. The straps shall be mechanically stretched and fastened with metallic clamping seals of the same materials as the strap.
ix.
Insulation for application on bends and elbows shall be cut into mitred segments, sufficiently short to form a reasonably smooth internal surface. After the application of insulation material in place, insulating cement shall be applied as required to obtain a smooth surface.
x.
Weather hoods shall be provided for insulated piping passing through floors/walls.
xi.
All pipe attachments coming on horizontal pipes, inclined pipes and bends shall be insulated along with pipe such that there will be no insulation applied to hanger rod and the component connecting hanger rod to pipe attachment. All pipe attachments exposed to weather shall be provided with weather proof.
xii.
Upstream of all drain lines and the lines connected to steam traps, shall be insulated upto and including first isolating valve for heat conservation. Rest of such lines such as downstream of the drain valves, traps etc. and other lines such as safety valve discharges, vents, etc. shall be insulated for personnel protection.
Installation on equipment i.
Insulation applied to the equipment shall be reinforced with hexagonal wire mesh. One layer of wire mesh shall be provided on the equipment surface prior to application of insulation.
ii.
Installation on horizontal cylindrical vessel/tanks (including heaters, heat exchanger etc.). a.
All the surfaces of insulation layers, applied on horizontal cylindrical vessels shall be securely fastened by bands upto vessel/tank outer
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IIT Bombay Tender Number – 201601548 diameter of 150 mm and below. Where vessel/tank outer diameter exceeds 1500 mm, binding wire passing through insulation clips provided both longitudinally and circumferentially at 500 mm centers shall be used. Gaps in the insulation shall be filled with loose mineral wool and finished with finishing cement so as to obtain a smooth surface for the application of cladding. The bidder shall provide support ribs/lugs on the surface of the vessel/tank as necessary. The bidder shall obtain the approval of the 'Purchaser' and the equipment supplier's field engineering representative before performing any welding on equipment. The bidder shall perform any heat treatment requirement as per recommendation of equipment supplier. iii.
Installation on vertical cylindrical vessel/ tanks (including flash tanks etc.): a.
All vertical vessels/tanks shall be provided with support rings/ribs with other necessary framework to take up the weight of the insulation prior to heat treatment. The bidder shall obtain the approval of the 'Purchaser' and the equipment supplier's field engineering representative before performing any welding on equipment. The bidder shall perform any heat treatment requirement as per recommendation of equipment supplier.
b.
The mattresses shall be held in position by means of 9 SWG steel wire nails, the nails being 25 mm longer than the thickness of insulation to be applied. After the mattresses have been placed over the nails, the nails shall be bent and embedded in the insulation. Alternatively, wire loops may be tack welded at 250-mm centers to hold the insulation in place.
iv.
Installation of cladding a.
All insulation shall be protected by means of an outer covering of aluminum sheathing. All insulation/cladding joints shall be sealed and made effectively weather and waterproof. All flat surfaces shall be given suitable slope to prevent collection of pools of water on the cladding surface. All sheathing shall be protected internally by the application of two coats of bitumastic paint.
b.
All longitudinal joints shall have a minimum overlap of 50 mm and shall be located at 45 deg. or more below the horizontal for horizontal equipment. Joints shall be made with cheese headed self tapping galvanized steel screws at 150 mm centers.
c.
All circumferential joints shall have a minimum overlap of 100 mm and shall be held in position by stainless steel or anodized aluminium bands, stretched and clamped.
d.
Removable box type cladding for valves and flanges shall be fitted on the connected pipe cladding, with bands.
e.
Aluminum cladding shall not come directly into contact with either the equipment surface or with the supporting arrangement on the
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IIT Bombay Tender Number – 201601548 equipment surface. To this end, adequate layers of 3 mm thick ceramic board shall be provided between the cladding and any supporting arrangement equipment surface, and fitted with self-tapping screws/metal bands, as applicable. f.
For bends, fittings etc. the cladding shall be provided in segments as to ensure a smooth finish of the cladding.
g.
For cladding on vertical pipes/equipment, provision for load take up shall be made at every 2 to 4 meters along pipe/equipment axis.
h.
All joints shall be sealed with acrylic emulsion weather barrier.
i.
Galvanic corrosion shall be prevented by carefully avoiding permanent contact of aluminum cladding with copper, copper alloys, tin, lead, nickel or nickel alloys including Monel metal.
v.
Testing and guarantees a.
All tests, as per the applicable material standards and as specified shall be carried out in accordance with the methods prescribed. Purchaser shall have the right to witness any or all of the tests conducted by the bidder at the shop or laboratory.
b.
The Bidder shall guarantee that if on actual measurement the specified maximum insulation surface temperatures are exceeded, the bidder shall either replace the insulation with a superior material or provide additional insulation thickness at no extra cost.
Suggested makes / suppliers Sr. no. Item(s)
Makes / suppliers
1
Molten Salt pumps
Auro Pumps, Process Pumps (I) Pvt. Ltd, Flowserve, Ensival Moret, equivalent
2
Boiler feed water pumps
Dampf Kolben, Positive Metering, Hironisha Systems, equivalent
3
Centrifugal pumps
KSB, Kirloskar, Crompton. equivalent
Motors
Siemens, Crompton, Kirloskar, ABB, Hindustan, equivalent
4
Electrical heaters
Rashmi Heaters, Pune, Lakshmi Electrical, Navbharat Electrical, equivalent
5
Valves
Belloseal Valves, Valvola Corporation, Flow Serve, Uniklinger, KSB, equivalent.
6
Steam Silencers
Trustwell Engineers, Anpam Engineering, Acoustics India, Decimin Control, equivalent
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IIT Bombay Tender Number – 201601548 Sr. no.
Item(s)
Makes / suppliers
7
Instrument Air packages
Aditi Engineers, Elgi Equipments, Ingersoll Rand, equivalent
8
Dosing systems
Metapow / Ravi Industries / NM Enterprise, equivalent
9
Mineral wool insulation
Lloyd Insulations, Rockwool India, Minwool Rock Fibres, Goenka Rockwool (India) Pvt. Ltd., NGP Industries Ltd., equivalent
10
Ceramic insulation
Murugappa Morgan, Unifrax India Pvt. Ltd., Varsha Refractories, equivalent
11
PLC and components
Allen Bradley
12
Salt
Enesoon, BASF, equivalent, SQM
13
Structural steel
Please refer Technical specifications – Structural Steel work.
14
Electrical items
Please refer Technical specifications – Electrical work.
Coastal
Chemical,
Haifa,
B. Technical specification - Structural Steel work SCOPE: This specification covers the general requirements for supply of steel material, where specified, fabrication and delivery at site of structural and miscellaneous steelwork. APPLICABLE CODES AND SPECIFICATIONS: 1. Materials: a. IS: 226/2062 -Structural Steel (Standard Quality). b. IS: 808 -Rolled Steel Beam, Channel and Angle Sections. c. IS:814 -Specifications for Covered Electrodes for Metal Arc Welding for Structural Steel. d. IS: 1161 -Specification for Steel Tubes for structural purpose. e. IS:2074 -Ready Mixed Paint, Red Oxide Zinc Chromate and Priming. f. IS: 823 -Code of Procedure for manual metal arc welding of mild steel. g. IS: 919 -Recommendations for limits & fits for engineering (Part I & II). 2. Codes of practice: a. IS: 800 b. IS: 816
-Code of Practice for Construction in Steel. -Code of Practice for use of Metal Arc Welding for General Construction in mild steel. 3. All steel to be supplied by the bidder:
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IIT Bombay Tender Number – 201601548 a. The BIDDER shall furnish to the DEC duplicate copies of all mill orders covering the material ordered by him for this project and the test reports received from the Mills for the Engineer’s check and information. b. It is not the intention of the IITB / DEC that all the steel materials to be supplied by the BIDDER for the work shall be specifically purchased from the rolling mills. The Bidder’s stock material may be used, provided he satisfactorily demonstrates, the specified grade and quality by furnishing test certificates. IITB / DEC shall have the right to test random samples from the steel materials proposed to be used for work, by the BIDDER at the Bidder’s cost. all steel materials supplied by the BIDDER shall be in sound condition, of recent manufacture, free from defects, loose mill scale, slag intrusions laminations, pitting, flaky rust, etc. and be of full weight and/or thickness specified. The lengths/sizes of steel sections and plates shall be as supplied by the steel mills. c. Unidentified stock material may be used, only with the prior permission from DEC in writing, for short sections of minor importance or for small unimportant works and connections where, in the opinion of IITB / DEC, the quality of such materials would not adversely affect the strength and/or durability of the structure. IITB / DEC may also permit use of such materials for other works, if adequate random samples taken out and tested demonstrate conformity with specification and requirement for the work for which these materials are proposed to be carried out to the requirement for this work. He is, however, not to commence plumbing, water supply and drainage work unless drawings for such work or parts thereof are officially released as "Released for Construction". revisions to drawings and any new drawings made to include additional work by the BIDDER shall be considered as part of this specification and contract. Bidder shall be responsible for obtaining approval of the drawings from local authorities, if required, and he shall not be entitled for any extra payment on this account. 4. Substitutions: a. Wherever the BIDDER, in order to accommodate his/other materials in stock, desires to substitute structural steel or plates for the sizes shown on drawings, such substitutions shall be made only after authorization in writing is given by IITB / DEC. b. The ENGINEER may also direct the substitution to be made, when he considers that such substitutions are necessary. 5. Drawings prepared by DEC: a. Checked and approved design drawings will be furnished to the BIDDER for execution of the work and these shall form a part of this specification. The BIDDER shall study these drawings, when made available, in detail for all information contained therein, which pertains to, and is required for his work. Bidder shall also prepare fabrication drawings showing all details as required for fabrication work& submit the same to DEC for approval prior to starting the work. The drawings shall be approved & returned to the bidder within 20 days from the day of receipt of the same. Discrepancies, if any, shall be brought tithe notice of DEC. b. IITB / DEC reserves the right to make changes. Revisions to drawings, even after release of shop drawings, are very likely to be made to reflect additional data/details received and more updated requirements. Revisions to drawings and any new drawings made which include additional work required to be carried out by the 86 | P a g e
IIT Bombay Tender Number – 201601548 BIDDER shall be considered part of this specification and contract and IITB / DEC shall entertain no extra claims on this account. c. Unless otherwise specified, the drawings and specifications are intended to include everything obviously requisite and necessary for the proper and entire completion of the work and the job shall be carried out accordingly for completeness as required and as directed by IITB / DEC. 6. Fabrication a. General: All workmanship and finish shall conform to IS: 800. all materials shall be finished straight as per the tolerance limits as specified. A holes and edges shall be free of burrs. Shearing and chipping shall be neatly and accurately done and all portion of work exposed to view shall be neatly and accurately done and finished. Material in the shop shall be kept clean and shall be protected from weather. b. Connections: i. Shop connections shall be effected either by welding, or bolting, as specified on the drawings. Bolts shall be in accordance with specifications. ii. However standard M.S. bolts conforming to IS:1363 may be used for field connections for light members such as purlins, girts, staircase stringers, hand railings, landings beams, etc. iii. Where necessary, tapered washers or flat washers or spring washers shall be used with bolts. The length of the bolt shall be such that at least one thread of the bolt project beyond the nut. iv. In all cases where bearing is critical, the unthreaded bolt shall bear on the members assembled. A washer of required thickness maybe provided to exclude the threads from the bearing thickness, if a longer grip bolt has to be used for this purpose. v. A connections and splices shall be designed for full strength of members or loads indicated, unless otherwise approved. Column splices shall be designed for the full tensile strength of the minimum cross-section at the splice. vi. A members likely to collect rain water shall have drain holes provided. vii. Not more than one shop splice shall be provided to make up the full length of a member. c. Straightening: Rolled material, before being worked, shall be straightened. If straightening or flattening is necessary, it shall be done by methods that will not injure the material. Long plates shall be straightened by passing through a mangle or levelling rolls and structural shapes by the use of mechanical or hydraulic bar/section straightening machines. Heating and/or forging shall not be resorted to without the prior approval of DEC in writing. d. Cutting: i. Cutting may be carried out by shearing, cropping, sawing or machine flame cutting, if permitted by the ENGINEER. all re-entrant corners shall be shaped notch free to a radius of at least 12 mm. Sheared or cropped edges shall be dressed to a neat workman like finish flame and shall be free from distortion and burrs. The cutting machine flame cut edges shall be removed.
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IIT Bombay Tender Number – 201601548 ii.
Hand flame cutting shall be undertaken only if so permitted by IITB / DEC and shall be carried out by an expert in such work. Hand flame out edges shall be ground smooth and straight. iii. Edge planning of sheared, cropped or gas cut edges is not intended unless the sheared, cropped or gas cut edges are such as to warrant it or is specifically called for. e. Punching and drilling: i. Holes in secondary members such as purlins, girts, lacing bars, etc., may be punched full size through material not over 12 mm thick. Holes must be clean cut, without burr or ragged edges. Holes for all other connections shall be drilled accurately and the burrs removed effectively. Where several parts are to be connected to very close tolerance, such parts shall first be assembled tightly clamped together and drilled through. ii. Sub-punching maybe permitted before assembly, provided the holes are punched 3 mm smaller in diameter than the required size and reamed after assembly to the full diameter. The thickness of materials punched shall not exceed 16mm. iii. When batch-drilling is carried out in one operation through two or more separable parts, these parts shall be separated after drilling and the burrs removed. iv. Holes for turned and fitted bolts shall be drilled to slightly smaller diameter and reamed to a diameter of the shank or barrel subject to H 8 tolerance specified in IS: 919. v. Where reamed members are taken apart for shipping or handling, the respective pieces reamed together shall be so marked that they may be reassembled in the same position in the final setting up. No interchange of reamed parts will be permitted. Poor matching, over-drilling, and orality in holes shall be a cause for rejection. Burning holes with gas is strictly prohibited. f. Welding: i. Electrodes for shielded-arc manual welds shall comply with the requirement of IS: 814 and shall be of approved make only. Approved makes are Advani Oerlikon, D&H & ESAB. ii. The Electrodes for manual arc welding shall be suitable for use in the position and type of work, as laid down in the above specifications and type of work, and as recommended by the manufacturers. Electrodes classification group 1 and 2 as given in IS:814 shall be used for welding steel conforming to IS:226. iii. Welding plant and accessories shall have capacity adequate for the welding procedures laid down and shall satisfy appropriate standards and be of approved make and quality. The BIDDER shall maintain all welding plants in working order. All the electrical plant in connection with the welding operation shall be properly and adequately earthed and adequate means of measuring the current shall be provided. iv. All weld shall be made only by welders and welding operators who have been properly trained and previously qualified by tests and to perform the type of work required as prescribed in the relevant applicable standards. v. All welds shall be free from defects like blow holes, slag inclusions, lack of penetration, undercutting, cracks etc. All welds shall be cleaned of slag or flexed
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IIT Bombay Tender Number – 201601548
vi.
vii.
viii.
ix.
x.
xi.
xii.
xiii.
xiv. xv.
show uniform sections, smoothness of weld metal, feather edges without overlap and freedom from porosity. Fusion faces and surfaces adjacent to the joint for a distance of at least 50 mm on either side shall be absolutely free from grease, paint, loose scales, moisture or any other substance which might interfere with welding or adversely affect the quality of the weld. Joint surfaces shall be smooth, uniform and from fins, tears, laminations, etc. Preparations of fusion faces shall be done in accordance with the approved fabrication drawings by shearing, chipping, machining or machine flame cutting except that shearing shall not be used for thickness over 8 mm. Members to be joined by fillet welding shall be brought and held as close together as possible and in no event shall be separated by more than 6 mm. If the separation is 1.5 mm or greater, the fillet weld size shall be increased by the amount of separation. This shall only apply in the case of continuous welds. The fit-up of joints at contact surfaces which are not completely sealed by welds shall be close enough to exclude water after painting. The separation between facing surfaces of lap joints and butt joints with backing plate shall not exceed 1.5 mm. Abutting parts to be butt welded shall be carefully aligned and the correct root gap maintained throughout the welding operation. Misalignments greater than 25 percent of the thickness of the thinner plate, or 3 mm, whichever is smaller shall be corrected and in making the correction the parts shall not be drawn into a slope sharper than 2 degrees (1 in 27.5) Prequalified welding procedures recommended by appropriate welding standards and know to provide satisfactory weld shall be followed. For nonstandards procedures, qualifications, tests etc. as prescribed in IS: 823 shall be made to verify the adequacy of the procedures. Welding procedures shall be prepared by the BIDDER and submitted to DEC for approval before start of welding. This shall include all details of welding procedure with reference to provisions of IS: 823 and IS:4353, latest. Approval of the welding procedure by IITB / DEC shall not absolve the BIDDER of his responsibility for correct and sound welding without undue distortion in the finished structure. No welding shall be done when the surface of the member is wet nor during periods of high wind, unless the welding operator and work are properly protected. In joints connected by fillet welds, the minimum sizes of single fillet welds or first runs and minimum full sizes of fillet welds shall conform to the requirements of IS: 816 and IS: 823. Fillet weld larger than 8 mm shall be made with two or more passes. A complete penetration butt weld made by manual arc welding, except when produced with the air of backing material or welding in flat position, from both sides in square-edge material not over 8 mm. thick with root opening not less than one-half the thickness of the thinner part joined, shall have the root of the initial layer gouged out on the back side before welding is started from that side, and shall be so welded as to secure sound metal and complete fusion throughout the entire cross section.
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IIT Bombay Tender Number – 201601548 xvi.
Each layer of all multiple layer welds, except root and surface runs, may be moderately peened with light blows from a blunt tool. Care shall be exercised to prevent scaling or flaking of weld and base metal from over peening. xvii. Inspection of welds: All welds shall be inspected for flaws by any of the methods described under clause "TEST OF WELDS" the choice of the method adopted shall be determined by DEC. xviii. The BIDDER shall include the costs of carrying out the tests in the cost of structural steel work itself. xix. The correction of defective welds shall be carried out as directed by DEC without damaging the parent metal. When a crack in the weld is removed, magnetic particle inspection or any other equally positive means as prescribed by DEC shall be used to ensure that the whole of the crack and material upto 25mm. beyond each end of the crack has been removed. Cost of all such test and operations incidental to correction shall be to the Bidder’s account. g. Tolerances: The dimensional and weight tolerance for rolled shaped shall be in accordance with IS: 852. The acceptable limits for straightness (slope and camber) for rolled or fabricated members are: Struts and columns -L/1000 or 10 mm. whichever is smaller. For all other members not primarily L/500 or 15 mm in compression such as purlins, whichever is girts, bracing and the web members of smaller trusses and latticed girders. Where `L' is the length of finished members of such lesser length as DEC may specify. h. Material testing: Even if mill tests reports are available for any steel materials the same shall be got tested by the BIDDER to IITB / DEC’s satisfaction to demonstrate conformity with the relevant specification at a lab approved by DEC. i.
Dimensions, workmanship & cleanliness: Members shall be inspected at all stages of fabrication and assembly to verify that dimensions, tolerances, alignment, surface finish and painting are in accordance with the requirements shown on the approved shop drawings.
j.
Drilling holes for other works: Holes in members required for installing equipment or steel furnished by other manufactures or other bidders shall be drilled at no extra cost to IITB / DEC, in the Bidder’s shop as part of this contract, the information for which will be supplied by the IITB / DEC/ before fabrication of the steel.
k. Handrails: i. Handrails shall be provided on open sides of platform, stairways and around all opening as shown on drawings. Handrails shall be of standard weight mild steel pipe of flush welded construction, ground smooth, provided with double rail, top 90 | P a g e
IIT Bombay Tender Number – 201601548
ii.
iii.
rail about 1 metre above platform level and pipe posts spaced as shown on drawings. Smooth uniform curves and bends shall be provided at stair return and also wherever required/specified. Posts connected to curb plates shall have a neat closure at the bottom and 6 mm thick plate neatly welded to posts for attachments to curb plate. all necessary fittings including inner dowels at splices, brackets, bolts, bends, flanges and chains, where required shall be furnished by the BIDDER. Open ends of the pipe posts shall be plugged and welded. A minimum radius of 3 times the pipe diameter shall be provided at all points of direction change in the handrail. The rate quoted for handrails shall be per running metre of complete handrails including posts, fitting, etc. It shall be clearly understood that individual lengths of runners, posts, etc. will not be measured for purposes of payment.
CHEQUERED PLATE: Chequered plates used shall be as shown on drawings. Chequered plate shall be fixed by8 mm. diameter cadmium plated MS. screws with counter sunk heads at a maximum spacing of 400 mm. Members supporting the chequered plate shall have matching holes tapped in them. The chequered plate pattern shall be approved by DEC. Chequered plates may also be required to be welded to the structural steel framing. The decision in this regard will be given by the IITB / DEC. l.
Marking of members: i. After checking and inspection, all members shall be marked for identification during erection. This mark shall correspond to distinguishing marks on approved erection drawings and shall legibly be painted and stamped there on. The erection mark shall be stamped with metal dye with figures at least 20 mm high and to such optimum depth to be clearly visible, even after a member is galvanized. ii. All erection marks shall be on the outer surface of all sections and near one end, but clear of bolt hole. The markings shall be so stamped that they are easily discernible when sorting out members. The stamped marking shall be encircled boldly by a distinguishable paint to facilitate easy identification. iii. Erection marks on like pieces shall be at identical locations. Members having lengths of 7.0 M or more shall have the erection mark at both ends. iv. In addition, colour code marking, wherever specified, shall be clearly painted on the member in the manner specified. v. Separate colour code or identification marks, shall be adopted for members fabricated from steel supplied by the IITB / DEC and the BIDDER. m. Errors: Any error in shop work which prevents proper assembling and fitting up of parts in the field by moderate use of drift pins or moderate amount of reaming will be classified by DEC as defective workmanship. all charges incurred by IITB either directly or indirectly because of the poor workmanship will be deducted from the amount due to the BIDDER before payments made. The amount of such deduction will consist of the sum total of the costs labour direct or indirect, material, plant, 91 | P a g e
IIT Bombay Tender Number – 201601548 transportation, equipment rental and overhead expenses. In case IITB / DEC choose to reject the material because of poor workmanship, the cost of all handling and returning of the material to the BIDDER, if he so desires, shall entirely be to Bidder’s account. all the replacement materials shall conform to the same specification as for the original materials, & shall be supplied free and in all such cases, the cost of handling, transport and delivery to site shall be borne by the BIDDER. n. Painting: i. All fabricated steel material, except those galvanized, shall receive protective paint coating. ii. The surface of steelwork to be painted shall be thoroughly cleaned of all loose mill scale, rust, grease, dirt and other foreign matter by hand tool cleaning, power tool cleaning, flame cleaning or sand/shot blasting as specified and as directed. In power brushing, sufficient care shall be exercised not to burnish mill scale to a slick finish to which paint may not adhere properly. iii. The paint treatment specified shall be applied either by brushing or spraying on the thoroughly cleaned and dry surface. Airless spraying shall be done if so specified. Surfaces inaccessible after assembly shall receive an additional coat of the specified paint prior to assembly. iv. Paint shall be stirred frequently to keep the pigment in suspension. all paint delivered to the fabrication shop shall be ready mixed in original sealed containers as packed by the paint manufacturers and no thinners shall be permitted. No painting shall be done in frosty/foggy weather or when the humidity is high enough to cause condensation on the surface to be painted. Paint shall not be applied when the temperature of the surface to be painted is 50 deg centigrade or higher. o. Method of measurement: i. For the purpose of payment, the weight of the actual, completed structures shall be calculated from the approved drawings for different items of work. The BIDDER shall submit to the IITB / DEC relevant materialist containing weight of each item. ii. Bolts, washers & nuts shall not be taken into account in calculating the weight of the completed structure. The rates of structural to include the weight of Nuts, bolts & washers etc. No allowances will be permitted for galvanizing, welding or for rolling margins. One ton for the purpose of payment shall mean ONE METRIC TON i.e. 1000 kg. iii. The weight of all member made out of standard rolled sections such as beam, channels, angles, etc. shall be based on the standard IS book weight of the member, without deducting for holes, notches, bevel cuts, etc. Where a component consist of a cut joint or channels, the full weight of the rolled section shall be considered, only if more than half the depth of the section is used. Otherwise only half the section unit weight shall be considered for calculation of the weight of the component. Deductions shall be made in the weight of gussets/plates for skew cuts and notches of 900 sq.cm. or larger.
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IIT Bombay Tender Number – 201601548 iv. v.
For gussets/plates used in trusses, bracings columns, beams, etc. the area shall be that of the minimum circumscribing rectangle, except as stated in 11.3 above. The weight of any built-up member shall be separated into the weight of each component.
p. Structural steel work in tubes: i. Scope: This specification covers the specific technical requirements for the following. ii. Supply, inspection, and testing at site of tubular structural steelwork. iii. Fabrication, erection and testing at steelwork. iv. Supply, erection and testing of materials: Materials for tubular steelwork supplied by BIDDER shall conform to IS: 1161. The class of tubes shall be as specified on drawing / BOQ. all materials shall be free from injurious defects. v. Fabrication erection and testing of tubular steelwork: a. The supply and erection of tubular steelwork shall include inspection, delivery at site, cleaning, cutting, aligning welding connecting and installing a tubular steelwork in position as shown on drawing and as directed by Engineer. b. Wherever tubes of different thickness are to be butt welded the necessary bevelling c. shall be carried out by the BIDDER at no extra cost to the IITB / DEC. d. The BIDDER shall be supplied with the drawings for tubular steelwork connections. The tubes shall be cut to the exact shape and welded properly. The thickness of the weld shall be as specified on drawing. Welded joint shall be ground smooth. vi. Welding: a. Tack welds used in assembling tubes shall be made by qualified welder, or shall be removed. Tack welds which are not to be removed shall be made with an electrode which is the same as or equivalent to the electrode be used for the first pass. b. All welds shall be full penetration, homogenous with no voids. Any cracks or blowholes that appear on the surface of joint shall be removed by chipping c. All stipulations for welding work as mentioned in this specification (para 6.6) shall apply for the welding of tubular steelwork, in addition to that mentioned above. d. Prior to commencement of welding, welder qualification test shall be taken After the welder is approved than & than he can proceed with the welding. e. When the end of a tube is not automatically sealed by virtue of its connection by welding to another member, the end shall be properly and completely sealed. Before sealing, the inside of the tubes should be dryland free from loose scale. q. Storing and handling i. Storage of structures shall be preferably be done in such a manner that erection sequence is not affected. ii. While storing, care shall be taken so that structures do not come in direct contact with the earth surface and accumulated water. Girders, beams, 93 | P a g e
IIT Bombay Tender Number – 201601548
r.
columns etc. shall be placed and stored in such a manner that during rain, no accumulation of water on the structures takes place. iii. Stacking of the structures shall be done in such a way that, erection marks are visible easily and handling does not become difficult. Wherever required, wooden sleepers / grilles may be used. iv. Handling and storage of materials shall be as per IS:7969-1975, ensuring Watch and Ward, Safety, Inventory control. Galvanising:
Wherever specified, spray galvanising shall be carried out as per specifications below: Sr. no. A 1 2 3 4 5
Aspect
Specification Sand blasting ( NACE No. 10 /SP10 ) According to IS : 13229-1991, Min Zinc 98.5% Molten Zinc spray Within 4 hrs of sand blasting in dry weather 85 Micron ( Minimum )
6
Surface preparation Quality of Zinc Method of application Spray interval Dry film thickness of zinc coating at any point on the steel surface Overall quality of HDG
B
Tests & Inspection
C
Documentation
Zinc coatings shall be uniform, adherent, reasonably smooth and free from imperfections such as flux, ash, bare patches, black spots, pimples, lumpiness and runs, rust stains, bulky white deposits as per IS 2629 practice Zinc purity and quality report. Uniformity of coating DFT measurement on various sections/parts As per tests and inspection
List of recommended makes / manufacturers for steel General: The makes and manufactures shall be preferably from the following list. In case some of the items not available in the market or some of the particular products are not producing by the following manufacturer or in case of change in trade name etc. equivalent makes or redesignated product shall be used conforming to the specific IS codes with the prior approval of IITB / consultant. In case of some items not covered in this list like fasteners, fixtures etc. may be procured form the market conforming to IS codes with test certificates and prior approval from the IITB / consultant. Sr. no.
Item
Manufacturer
1
Structural Steel
SAIL, RINL, Tata Steel, JINDAL, ESSAR or as approved by IITB / DEC
2
Electrodes
ADOR ( Advani Oerlikon ), D & H, ESAB or equivalent approved manufacturers as approved by IITB / DEC
3
Paint
BERGER, SHALIMAR, AKZONOBEL, SIGMA Coating, 94 | P a g e
IIT Bombay Tender Number – 201601548 ASIAN PAINTS, Grand Polycoat Or As Approved By IITB / DEC
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IIT Bombay Tender Number – 201601548
C. Technical specifications for instrumentation work. Instrumentation work - General 1. Definitions a. SCADA Supervisory Control & Data Acquisition System b. PLCProgrammable Logic Controller c. First block valve First block valve shall mean the valve / valves that are mounted directly on equipment, columns, vessels, pipe, standpipe etc. and shall be operated to isolate the instrument and connected instrument piping from the above items. d. Supports Supports shall mean the MS angles, flats, channels that are generally provided to support the main cable ways, cable ducts, junction boxes, angle trays, perforated trays, instrument piping, signal tubing, instrument air supply lines etc., at specified intervals from the structures, concrete columns etc., to keep all items firmly secured against vibration, warping, bending etc. 2. General conditions a. The bidder shall during the execution of his work use exclusively new material to the standards laid down in this or any supplementary documents given thereafter. Any inconsistency or ambiguity in the design documentation supplied by IITB shall be resolved by the "Engineer In-charge" before work commences. b. The bidder shall carry out the work in accordance with the standards listed herein and in accordance with any local statutory regulations and supplementary documentation. c. The bidder shall instruct his staff, skilled and semi-skilled on the standards required by the IITB and shall ensure that only competent staff handle or work on the instrument system. 3. Workmanship, tidiness & safety a. The bidder shall not allow rubbish & scrap materials from his operations to lay about the site. Such rubbish & scrap shall be collected daily and be deposited at a place approved by the "Engineer In-charge". b. No dangerous or noxious wastes products, chemicals or materials shall be disposed of on the site without approval of "Engineer In-charge". c. The bidder shall be responsible for protecting installed equipment from damage & pilferage, and shall ensure that all covers, caps, screws and weather protection, etc. are replaced at the end of each working day. d. Only the best trade practices are to be used, and all work must be done to the satisfaction of the "Engineer In-charge" who should be consulted on any point requiring clarifications. The Bidder is free to suggest to the "Engineer In-charge" alternative methods for the execution of the work where this would result in improvement. e. Upon completion of the work, the bidder shall promptly remove his equipment and return to the relevant place any unused materials supplied by the "Engineer In-charge". Finally the bidder must clear the site of all rubbish and scrap deposited by him to the satisfaction of the "Engineer In-charge". f. The bidder shall ensure that adequate precautions are taken during use and storage of pressure bottles. Bottles left unattended to shall be isolated at the main stop valve.
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IIT Bombay Tender Number – 201601548 g. The bidder shall prepare a comprehensive bar chart programmed for carrying out the installation before the commencement of the actual work. h. The bidder shall submit before commencement of the actual work, a comprehensive list of tools, tackles, and test equipment which will be employed by him for carrying out the installation. 4. Standards a. The instrumentation installation and calibration works shall be carried out generally in accordance with various latest editions of international standards ( IS, ISO, API, ANSI) in instrumentation listed below but not limited to the following i. API-RP-551 on "Process Measurement Instrumentation". ii. "International Society of Automation (ISA)" Standards Library for Measurement and Control: Guidelines for Quality, Safety & Productivity. iii. Manufacturer's standards and Practices.
5. Bidder’s scope of work a. The Scope of work includes complete instrumentation installation, calibration, testing & providing commissioning & startup assistance & making “AS BUILT “ drawing markups. b. The bidder shall have full knowledge of all applicable Local regulations & laws & all specific rules applicable at site. c. The instrumentation installation work covers various jobs listed under the "Schedule of Quantities". However, to ensure proper execution and completeness of instrumentation works any or all of the following shall also form the part of the scope and shall be covered in the quoted rates. d. Fabrication of pipe nipples, including threading wherever required. e. Filling of seal pots with filling liquids as per instructions from "Engineer Incharge". f. Seal welding of screwed fittings as required by standards. g. Laying of cables from Junction box located at the battery limit to field in the cable Tray on the pipe rack, branch cable trays, up to field instruments / local panels etc. including glanding termination on both sides. For underground cables (if any) the scope includes excavation, sand filling, brick laying and back filling & glanding termination on both sides. h. Connection of purging devices for instruments as per drawings. i. Minor civil works like chipping of pavement and grouting on the pavements the instrument panels / supports / stanchions and chipping, refilling and finishing of the pavement for conduits. j. Sealing of cables / tube entries into the control panels after laying and testing of all tubes, cables etc. k. Rotation of control valve bonnet wherever required. l. Reversing the action of control valves either by replacement of springs, accessories or in positioner wherever required. m. Painting of all structural supports for trays, pipes, junction boxes, instruments, ducts, trays etc., as per agreed painting specification.
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IIT Bombay Tender Number – 201601548 n. Identification with approved colour of paint the instruments / impulse lines manifold connected with alarm / trip circuit. Also, punching of tag numbers on items shall be carried out as per instructions of "Engineer In-charge". o. Coordination with mechanical and other sub-bidders for proper installation of line / vessels / equipment mounted instruments like control valves, on-off valves, orifice assemblies, level transmitters, level gauges other type flow meters, safety & thermal relief valves & any other type of line / vessel mounted instruments which are not covered above, which involve removal of instruments, disconnection of tubes / cables, reconnection for alignment and proper installation etc. Drilling holes on all panels, shut down cabinets, power supply cabinets, control panels, pneumatic enclosures, junction box etc., for cables / glands. p. Grounding of shield of all shielded cables to respective instrument earth bus provided in the JB / local panel. q. Laying and termination at both ends between instrument earth buses provided in JB / local panel to instrument earth pit provided by others. r. Supply of all types of consumables required for the execution of the job. s. Submission of monthly material appropriation statements for cables, tubing, piping materials fittings, indicating the quantity issued and expended in standard performances. Bidder should build up his own site office and material storage facility within the compound. t. Preparation and submission of "as built" drawings (marked up copies) as required. u. Start-up and commissioning assistance. v. Submission of final material appropriation statements for all the materials issued by the IITB. w. Where requested by the IITB / "Engineer In-charge" or his authorized representatives, all or any of the works detailed above and works as per "Schedule of Quantities" shall also be performed on package units, local panels / cabinets / gauge board installed by package units or by others. x. Sealing of safety valves / switches with standard lead seals after final setting in the presence of Engineer In-charge. y. Installation and termination of tubing, cables etc., for analyzers (if any) & its accessories like sample coolers etc. z. Bidder shall remove instruments installed in package skid for calibration. After calibration instrument shall be installed back with related tubing & wiring. aa. Bidder shall dismantle limit switch, solenoid valve, positioner, Air filter regulator from control valve/ On-Off valve, tag it properly prior to control valve / On-Off valve shall install back after clearance from the Engineer in-Charge. bb. Any other work not mentioned above, but required for the proper execution of the works. cc. Bidder to specify direct & indirect work hours rate in the quotation with breakup. dd. Installation of PLC system cabinets, SCADA PC Stations ee. Grounding of Junction boxes / cabinets will be done by electricians ff. All package instruments, Junction boxes & local panel (LCP) are pre-installed & pre-wired by respective package vendors up to skid installed JB or panel. 98 | P a g e
IIT Bombay Tender Number – 201601548 gg. Supply, Laying & termination of home-run cabling between instrument junction boxes to control system &/or Package Vendor Junction boxes / LCP to control system. 6. Bidder’s scope of supply a. The Scope of supply of Bidder includes instrument tubes & fittings, instrument cable tray with cover plate, cable duct if any, air manifolds, condensate pots, canopies & steel, all the consumables required to execute the work at site & the material listed under Clause 17 below. 7. Installation of instruments a. Each instrument or item of equipment, to be installed by the bidder shall be inspected visually for any damage. The Bidder shall then take it from where it is stored, lift it into position and ensure it is levelled, plumbed and firmly secured. The bidder shall be responsible for transporting equipment to be installed by him from the stores to the place of installation. b. The bidder shall responsible for all material until acceptance by the Client after completion of job. Care shall be taken by bidder to protect from damage, deterioration due to atmosphere & weather condition. The bidder shall properly maintain a Register of material. The register shall be available to the Client as & when required. c. Throughout the construction period, instruments shall be adequately protected where necessary, by covering with plastic bags of an approved type. The bidder shall supply and fit these bags as required. d. Instruments shall not be bracketed directly off process lines except where specified by the "Engineer In-charge". e. Local mounted instruments shall be bracketed, mounted in sub-panels or placed on a suitable pedestal. They shall wherever necessary, be secured to the nearest suitable firm steelwork or masonry in a manner prescribed by the "Engineer Incharge"; wherever possible instruments shall be located so that they are protected from damage by passing or falling objects. f. Local instruments with the exception of those on lines and vessels shall be mounted with the centre line at approximately 1.5 metre above platform or floor in a position accessible for operation and maintenance. g. Handrails shall not be used for supporting instruments without prior approval from the "Engineer In-charge". h. Instruments shall be installed in strict accordance with the appropriate hook-up diagrams or as per the Manufacturer's recommendations, wherever hook-up diagrams are not available. The bidder is not permitted to deviate from these diagrams without prior written approval by the Engineer In-charge. 8. Impulse piping / tubing a. General i. Instrument piping & tubing to be installed can be classified in the following categories: a. Air supply & transmission piping / tubing b. Instrument process impulse piping / tubing ii. Pipes / Tubes shall be bent using pipe / tube benders; any hot bending will be totally rejected. These shall be cut using pipe / tube cutting device. Hot cutting will not be allowed. 99 | P a g e
IIT Bombay Tender Number – 201601548 iii.
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Pipes or tubes installed, but not connected, shall have the ends closed in an approved fashion to prevent the entry of foreign material; e.g. for a period of up to one-week adhesive tape may be used, for a longer period caps or plugs shall be used. Where instrument pipes / tubing are run parallel to each other, joints should be systematically staggered & neatly offset. All threaded joints shall be jointed with Teflon tape and no other pipe jointing compound shall be used except on high temperature service where graphite sealing compounds shall be used. Where compression fittings are used, fittings shall be installed in strict accordance with manufacturer's recommendation. Where stainless steel compression fittings are used, the Bidder must ensure that stainless steel nuts and olives are fitted unless otherwise specified by the "Engineer In-charge". Any discrepancies between the materials / fittings specified and the materials / fittings provided shall be brought to the notice of the "Engineer In-charge" without delay. The number of joints in the pipework shall be kept to a minimum consistent with good practice. Sufficient flexibility shall be provided in meter leads, air supply and tubing lines to allow for movement (e.g. expansion) of the lines or equipment to which connected.
b. Air supply & transmission piping / tubing i. Horizontal runs of pipes & tubes shall have pipes / tubes laid vertically one above the other as far as possible and shall be run with the minimum number of changes of direction consistent with good practice and neat appearances. ii. All pneumatic signal tubing shall be cleaned by blowing thru' with filtered air before connection to Instruments. iii. Single core tubing shall be run in such a manner as to give the maximum protection against mechanical damage. iv. Where permanent enclosure trunking or conduits, etc. are left with space for tubes to be pulled in at some future date, a galvanized draw wire of adequate size shall be left in the enclosure. c. Instrument process impulse piping / tubing i. All impulse piping / tubing shall in general be run with a slope of not less than 1 in 10 unless otherwise specified. The slope of the impulse pipework shall be down from the tapping point for liquids, steam and condensable and up from the tapping point for gas service unless special provisions are made for venting and draining. ii. Special attention shall be given to the correct sitting of vents and drains to ensure that they are at the highest or lowest points of the piping run. iii. Impulse lines shall be kept as short as possible consistent with good practice. iv. Threading of pipe/ nipple shall be done by bidder as specified in Instruments Hookups.
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IIT Bombay Tender Number – 201601548 v.
vi. 9.
Stainless steel piping shall be joined by compression fittings, socket welding flanges or by screwed connections depending upon the piping specification for the project. This will be shown on the instrument hook-up drawing. Handrails must not be used to support instrument lines Piping and tubing supports
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Piping and tubing shall be adequately supported wherever possible to prevent any mechanical damage. Angle iron or fabricated cable trays shall be used for continuously supporting four or more copper, SS, plastic tubes and the tubes shall be secured to the tray at not more than 500 mm intervals. Three or four tubes may in certain cases be secured by appropriate clips at not more than 500 mm intervals to mild steel strip (not less than 16 SWG/1.6mm) or laid in small section angle bar; such routes must be approved by the Engineer In-charge. Capillaries of filled systems shall be run independently of all other lines and shall be continuously supported using mild steel angle with clips at not more than 500 mm intervals. Support trays shall be run with the breadth of the tray in a horizontal / vertical plane. Where the engineer agrees that the tray must be run with the breadth horizontal, the tray must be provided with additional supports to prevent sagging. Conduit may be used to replace cable tray under certain circumstances. In such cases, the trunking, etc. shall be supported to the satisfaction of the "Engineer In-charge". Instrument cable installation
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The bidder must ensure that wherever an electrical specification is issued the appropriate sections shall be read in conjunction with this specification and any omissions or ambiguities should be resolved by the Engineer In-charge. The cable installation drawings and documentation provided by the "Engineer In-charge" will normally specify or incorporate regulations for the elimination of electrical noise pick-up. However, the following general rules apply. Parallel runs of instrument cables and power cables should be avoided but where parallel runs must be made cable spacings specified in the documentation must be maintained. Where instrument and power cables cross in close proximity the cross shall be made at the right angles. Thermocouple cables shall be run completely independently of other instrument cables with a minimum separation and with cross over at right angles. Multi-core / multi-pair cables shall not be bent to radius less than the manufacturer's recommendations.
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IIT Bombay Tender Number – 201601548 vii.
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Multi-core / multi-pair cables shall be cut after the exact site measurements are taken between ends and the cable drum shall be selected before cutting the lengths to avoid any wastage. Where cables are run through pipes, the entry and exit shall be smooth and free from burrs. Cables must be pulled into such pipes in a way that ensures there is no damage to the cable. Joints shall only be made at terminals in instruments or approved equipment. No intermediate joints shall be made on cable tray or in conduit. Cables must be run in accordance with the design documentation. All copper cables shall be terminated at junction boxes and instruments by proper glanding. The panel wiring connections shall be done in an approved manner by qualified electrician. Where conduit terminates at a cabinet, terminals box trunking or ducting, it shall be secured lock-nutted, brushed and ferruled in an approved manner. Sharp edges shall be removed and conduit not otherwise connected shall be terminated in smooth brushes. Clips and saddles securing to steel work or tray shall be metal, preferably aluminium / Hot Dip Galvanized (GI); clips shall be spaced at 500mm intervals. Conduit shall not be fixed by hook bolts unless agreed by the "Engineer Incharge". Where hook bolts are used they shall be supplied by the bidder from a manufactured source and not performed at site. Conduit junction boxes shall be provided at distances not exceeding three random lengths of 3 meters, not more than two right angle bends occurring in one pull. All cables shall be identified close to their termination point by cable number as per cable schedule / junction box schedule. PVC ferrule / S.S. tag plate shall be used and these identification tags shall be securely fastened to the cables.
Instrument cable duct / tray i.
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The GI Ladder / Perforated cable trays shall be properly supported at a regular interval of maximum 1.5 meter from insert plates or steel structures. Wherever insert plates are not available supports on concrete structures & ceiling shall be fixed with minimum 10mm diameter expansion bolts. Angle supports for perforated trays shall be fabricated from 50 mm x 50 mm x 6 mm MS angles as a minimum. All supports shall be cut with hacksaw only. Any work executed by gas cutting for making holes or cutting pieces will be totally rejected. Free ends of angle supports shall not have sharp edges and shall be properly rounded off. Perforated GI trays shall be used for branch cables from the main Cable Ladders/Trays. Width of trays shall be as per Schedule of Quantity. Trays shall be laid generally as per site conditions with the approval of Engineer-InCharge.
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IIT Bombay Tender Number – 201601548 12.
Painting i. ii. iii.
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All the supports / Structural Steel shall be painted as per painting specifications detailed below All ferrous materials for brackets and supports and other materials not already protected in an approved way shall be cleaned and primed before erection with primer as per painting specifications specific to the project. All the supports / Structural Steel installed by the bidder shall be painted as agreed with Engineer in-charge.
d. Identification of lines and instruments i. All site mounted instrument, junction boxes, air header isolation valves, tubing and wiring terminations shall be labeled or tagged in a manner approved by the Engineer In-charge. ii. The Engineer In-charge will provide a table of the label details for labels. iii. All cable terminations shall be identified by ferrules (cross). 13.
Testing i. ii. iii. iv.
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All the necessary test equipment for performing the following tests shall be provided by the bidder. The bidder shall furnish a list of test and calibration equipment that will be provided by him. All pneumatic signal lines shall be disconnected and blown through with instrument air for 15 minutes to remove traces of oil, dust and moisture. All instrument air mains shall be isolated from the instrument and pressurized pneumatically, 1.5 times maximum working pressure and isolated from the source of pressure. The pressure shall not fall by more than 0.1 kg / cm² in ten minutes. All thermocouple, electric and electronic instrument wiring shall be tested for resistance between conductors and earth and for insulation between conductors with a potential not less than 500V D.C. These tests shall be carried out with all conductors disconnected except from the test instruments. The resistance shall not be less than 10 mega ohms. Electrical continuity of cable armoring or braiding, conduits and any associated flexible tubing, earthing conductor and / or equipment enclosures are to be checked. Correct operation of all alarms and function of interlocks shall be checked. The written results of all tests in duplicate for retention by the IITB / Engineer In-charge shall be approved by the "Engineer In-charge". The bidder is responsible for supplying the necessary test equipment and reasonable evidence of the satisfactory condition of this shall be provided, if required. All errors or faulty workmanship discovered during this testing or during subsequent testing and commissioning shall be corrected by the bidder at his cost. 103 | P a g e
IIT Bombay Tender Number – 201601548 xi. 14.
All test results shall be recorded in the approved formats. Calibration
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All test equipment used for calibration shall have the approval of Agency approved by above mentioned authorities. On demand, calibration certificates shall be submitted to "Engineer In-charge". All instruments shall be calibrated strictly as per manufacturer's instructions prior to installation. The scope of calibration includes all field and control room instruments of all types namely, pneumatic, electronics, electrical, etc. Bidder shall use his own oil free instrument air compressor for calibration purposes. Calibration Procedure for different items is outlined below. However, the detailed procedure shall be submitted to Engineer In-charge for approval before proceeding with calibration. All pressure and differential pressure transmitters shall be calibrated to the settings as per Instrument data / specification sheets and instruction of Engineer In-charge. Pressure instruments shall be loop checked by applying impulse to the instrument using instrument air regulator and standard gauge or using portable hydro pump and standard gauge. All thermocouple receiver instruments shall be calibrated by generating millivolt signals suitable for span and type of thermocouple specified. Receiver instruments and controllers shall be calibrated and aligned using test hook-up as per instructions from manufacturer's / Engineer In-charge. Pressure gauges and pressure transmitters shall be calibrated at 0%, 25%, 50%, 75% & 100% and vice versa of range using dead weight tester. DP transmitters shall be calibrated at 0%, 25%, 50%, 75% & 100% and vice versa of range using mercury, water column manometers and / standard gauges / squeeze bulb / regulator. Temperature gauges shall be calibrated with thermo-oil baths at 0%, 25%, 50%, 75% and 100% and vice versa of range. Control valves and positioner shall be checked for hysteresis and linearity and calibrated for rated strokes. Prior to calibration, valves shall be cleaned externally. The stem is then lubricated if required, and stroked few times to extreme positions of plug to ensure that movement is free from friction. The valve shall then be calibrated for rated stroke and linearity also. Subsequently the valves shall be checked for hysteresis to the accuracy of 1% FS with positioner and 5% FS without positioner. Stroke speed has to be evaluated for all trip / shutdown valves. All calibration readings shall be recorded in the agreed formats and submitted to Engineer In-charge for approval. Where significant deviations from specifications are obtained, the matter shall be brought to the immediate notice of the Engineer In-charge for corrective actions. The bidder shall clearly state in his offer the complete list of calibration and test equipment along with the range, accuracy and quantity which he proposes to use for this job.
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IIT Bombay Tender Number – 201601548 xv. xvi.
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All on-off valves to be tested with operating the solenoid valves for on-off action and limit switch actuation. All safety valves shall be tested for mentioned Cold Differential Set Pressure (CDSP) with suitable test bench & fluid. Loop test
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Loop test shall be performed after calibration of all instruments and leak test of signal lines. Loop tests are conducted to check the functional performance of all elements comprising the loop, thereby ensuring proper connections and operations. Bidder should bring all the field cable and terminate in the Junction box located in the field & further termination to the system cabinet inside the equipment room. Bidder shall assist the system vendor in the loop testing, Before proceeding for loop tests the calibration results of individual elements shall be recorded and approval obtained from "Engineer In-charge" for correctness of installation, measurements and calibration results. Loop testing for all control loops shall be generally simulation of process conditions and shall fix points namely 0%, 25%, 50%, 75% and 100% of full scale inputs. Detailed procedure shall be submitted to "Engineer In-charge" for approval before proceeding with the loop testing. In case of shutdown system field / receiver pressure switches are simulated for abnormality by disconnecting the wires at terminal and function of all associated systems are checked. After the loop test is complete, the bidder shall connect back any terminations and connections removed for loop test inside the battery limit. A loop shall be considered as handed over only after measurements in that particular loop are complete and certified by "Engineer In-charge", in addition to loop sheets being duly filled in all respects and approved and accepted by "Engineer In-charge" and the IITB. In case of loops in which certain instruments of the loops are calibrated by other agency, loop testing shall be performed in coordination with the agency involved. Any defect in the calibration of the instruments, same shall be rectified to the satisfaction of the "Engineer In-charge". However, defect in calibration of the instruments in the scope of other agency; same shall be rectified by the agency involved. After the calibration has been rechecked by other agency / agencies the loop checking would be performed to the satisfaction of "Engineer In-charge", and this part covers under the scope of the contract. Final certified loop sheets shall be submitted in number of copies as agreed with Engineer In-charge.
1Installation drawings i.
Installation drawings / documents will be furnished to the bidder after award of contract. These generally will include:
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IIT Bombay Tender Number – 201601548 ii.
iii. iv. v. vi. 16.
Instrument Location Plan drawings, showing information like indicative position of field instruments, junction boxes, indicative routes of cables, main ducts / cable trays. Cable Schedules, Instrument Junction Box Schedules, Junction Box Wiring Diagrams Individual Instrument Specifications / Data sheets. Bill of Materials. Installation Standards / Hook-ups. Drawings and documents to be provided by bidder
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Filling and submission of Test Reports & Forms. The drawings for materials that is included in his scope of supply and installation. Two sets of layout drawings, hook ups, interconnection diagrams, cable schedules etc., duly incorporating the changes / modification carried out during the course of execution of works, as built markups. All materials to be supplied by the bidder at his own cost
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The procurement and supply in sequence and at the appropriate time of all materials and consumables shall be entirely the bidder's responsibility and his rates for execution shall be inclusive for all these items. They are as follows but not limited to them. All industrial gases like oxygen, acetylene or inert gases, compressed air and all types of electrodes, brazing rods, flux etc. for welding purposes, with necessary facilities for testing the welded joints. Teflon tape and other pipe jointing compounds for threads and material for sealing of cable entries to control room, local panels, insulation tapes, sealing compounds for conduit fittings. Bolts and nuts for supports, U-bolts with nuts, clamps for tubes and pipes, anchor bolts for panels, expansion bolts (pinch anchor / Rawl bolts) for various sizes for fixing to concrete structures. Paints, primers and solvents. Plastic sleeve ferrules for identification of tubes / wires at panel junction boxes. All materials for minor civil works like grouting etc. All accessories for electrical wiring like cable lugs, ferrules for identification etc. Spool pieces and blinds for testing, wherever required. Nozzle cleaning wires. Any other item not specified, but required for the completion of the job. Note: The bidder shall submit in sealed packets all samples of all consumables like bolts, nuts, lubricants, ferrules, lugs etc. for approval from Engineer Incharge which form the standards for installation work.
e. Schedule of rates 106 | P a g e
IIT Bombay Tender Number – 201601548 Schedule of rates shall be furnished in the appropriate formats as issued specific to the Project. Refer – Schedule of quantities – Instrumentation work i. Preamble to schedule of rates i prices (sor) a. The Schedule of Rates Prices (SOR) shall be read in conjunction with the drawings, the Conditions of Contract and the Specifications as these documents are jointly explanatory and descriptive of the works included in the Contract. Any interpretation of the scope of work, made from SOR or Technical Specification in isolation shall not be valid for any extra claims. b. The quantities of work and material in Schedule of Rates Prices (SOR) are not to be considered as limiting or exceeding the amount of work to be done and material to be supplied by the Bidder. The quantities in the Schedule of Rates Prices (SOR) are an estimate of the amount of work. c. General directions and descriptions of work and materials given elsewhere in the Contract documents are not necessarily repeated in the Schedule of Rates Prices (SOR). Reference is to be made to the other documents for information and guidance. d. A price or rate in figures is to be entered against each item in the Bills of Quantities, against which quantities are in SOR. e. The prices and rates inserted in the Schedule of Rates Prices (SOR) are to be the full inclusive value of the work described under the various items, including all cost and expenses which may be required for preliminary and for the completion of the work described, together with all cost and obligations set forth or implied in the Conditions of Contract, the Specifications and the Drawings. f. The rates quoted shall include supply of all the materials by the Bidder Viz. Cement, sand, bricks, structural steel, consumables like welding rods, gases, insulation material, ferrules, etc. and nothing whatsoever will be supplied by the IITB except stated in the Scope of Supply g. The Bidder shall note that the Structural Steel materials shall be procured from approved manufacturers' only. Prior approval shall be obtained for procurement from Engineer in-charge. h. IITB reserves the right to cancel/ delete/ curtail any item or group of work if necessary. Such a step shall not be construed as reason for changing the rates. i. Quoted painting rates shall include the colour coding and lettering on the equipment as per project specification. j. Quoted rates shall include preparation of AS BUILT Drawings & Final Field documentation etc. for all the site activities which will be submitted by the bidder in required number of copies to the IITB. Editable soft copy of all the documents shall be part of as-built documentation. ii.
Inclusions to be considered in unit rates a. In general activities involving checking/adjustments (e.g. limit switches on valves, timer settings, checking solenoid valve operation, checking annunciations/operation of indicating and mimic lamps etc.) which shall be carried out during loop checking, no separate unit rates shall be 107 | P a g e
IIT Bombay Tender Number – 201601548
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applicable and the same shall be deemed to be a part of loop checking. All loop checking shall be done by actual simulation like operating final control element from PLC/SCADA, applying actuating pressure to the field sensors / transmitters (as per range set) etc. and response reporting to SCADA, PLC as Range, alarm, Set value, trip value, cross ferruling, open loop resistance / voltage etc. shall be recorded tag-wise as a part of loop checking activity. Format for loop checking and cross-ferruling shall be followed by bidder based on joint agreement at site with the DEC and IITB concern for Instrumentation work. Supply of consumables as required, shall be built into the unit rates. No separate rates shall be paid for supply of such items. These include items like welding and filler rods, argon/nitrogen, required for welding; sealants like PTFE tape, M-seal etc. used in impulse lines; ferrules, lugs, Insulation/polyester tapes, cable sealing compounds, tagging etc. used in cable laying and terminations; oxygen and acetylene required for gas cutting; primer and final paint required in painting; polyethylene bags, thermocouple required for protecting the instruments; and so on. Unit rates quoted for supply of materials shall be inclusive of Inspection, documentation, all taxes/levies, packing, forwarding and transport charges, handling charges of the bidder etc. Supply charges for structural steel include charges for required fasteners like nut bolts etc. (except for Anchor fasteners for which separate rates are applicable). Weight of these fasteners will not be considered for measurement and no separate charges for installation of fasteners are applicable. For structural steel, unit rates of installation shall include surface preparation (shot blasting), all fabrication and installation, including welding, supporting, painting, etc. For canopies of field instruments, local panels and junction boxes, etc., the unit rate of for fabrication + installation shall be quoted per sq. meter based on 3 mm MS plates, duly painted and including all fasteners as required. Canopy shall be of galvanized material. Coating / thickness of galvanizing to be of 66 Micron. Unit rates for cable laying/Installation shall include: laying of cables in trays/ducts/conduits/angles, dressing, clamping, tagging, glanding, termination with lugs, ferruling, continuity checks and meggering. Materials like Clamps, fasteners (bolts, nuts, washers etc. ), ferrules, lugs, tag plates, and Green insulating Sleeves for cable screen etc. are included in unit rates cable laying/installation. For cables laid in conduits: sealing of conduit ends or intermediate joints with sealant (including supply of sealant) is also included in unit rate of cable laying/installation. Unit rate for fibre optic cable installation shall include cost of termination and installation of converter (any special equipment required and skilled manpower required for these terminations shall be arranged by bidder and cost for the same shall be included in unit rate of fibre optic cable laying/installation)” Unit rates for cable conduit laying shall include intermediate fittings, pull boxes, making necessary threading with die/taps, termination, sealing of 108 | P a g e
IIT Bombay Tender Number – 201601548
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o.
p.
joints with sealant etc. Unit rate of supply of conduit includes clamping/supporting material like "U" bolts, packing material required to avoid galvanic corrosion etc. Supply of clamping material like self-clamps, U bolts (and other fasteners), packing material for avoiding galvanic corrosion etc. shall be included in unit rates of installation. For welded impulse pipes the unit rates of installation shall also include the necessary charges for checks including supply of DP test material. Unit rates for installation of RTDs and T/C shall include checking of sensor for short Circuit /open circuit and insulation failure, prior to installation. No other checking activity is envisaged. For all instruments with capillaries, unit rates for installation shall include laying, dressing, clamping of the capillary. Supply of necessary clamping/supporting material shall be included in unit rates of installation. Unit rates for panel mounted instruments shall include mounting of instruments and bins using clamps, termination of tubing/wiring (lugging wherever required), ferruling, dressing of wires, clamping using binding straps, flushing of tubing etc. For alarm annunciators no separate rate shall be given for checking operation of the annunciator. The same shall be considered part of loop checking. Unit rate for calibration of instruments, control valves, safety valves shall include cost of Consumables required (e.g. compressed air, Nitrogen etc.). Unit rates for installation of following instruments/equipment shall include the supply of fasteners, Tag Plates as required: i. Power Distribution Boxes, Local Panels, Control Cabinets/Panels. ii. Pressure, DP, Temperature Transmitter, Switches, Temperature Elements. iii. Air Filter Regulators, Solenoid Valves. iv. Transducers / Transmitters / Converters v. Back of Panel Instruments, Relays, Contactors etc. vi. Junction Boxes. vii. Auto/Manual or Push Button Stations, Hooters, Flashing Lights, etc. viii. Remote mounted Pressure Gauges. ix. DP Gauges and Pressure Gauges with capillaries. x. Purge Rota meters with DP Regulator and Air Filter Regulator. For items not covered in the tender but required to be installed/calibrated, rates of similar Items in the tender shall be taken for approval prior to start of execution and billing. If the same is not possible rates shall be derived from available rates after mutually discussed and agreed upon with IITB. Installation rate for all items in Schedule of Rates (SOR) shall include, all machinery, tools and tackle required for shifting of respective items from stores to place of installation, receiving, handling, unloading, unpacking, checking for damage/ short supply and informing IITB, replacement of damaged parts, assembly of all loose items, preservation of all items, 109 | P a g e
IIT Bombay Tender Number – 201601548
q. r. s. t. u.
v.
f.
transporting equipment, instrument etc. from IITB’s storage point or any other location within the project site to location of installation / calibration. This shall also include following Levelling, aligning, grouting, bolting, minor civil work including chipping & then doing finishing work, etc. Cleaning either mechanically or manually Inspection & Testing as per Site testing & inspection formats. Required Documentation as per specification & site requirements. Unit rate / price quoted for supply of all instrument & erection, bulk items shall include the required detail engineering, vendor's drawing checking, third party inspection, documentation charges and all associated jobs. Rates for all the items of Schedule of Rates include all cost involved for the performance of the completed item considering all parts of the offer document. In case any activity though specifically not covered in description of item under 'Schedule of Rates' but is required to complete the work which could be reasonably implied/ informed from the consent of Offer Document, the cost for carrying out such activity of work shall be deemed to be included in the item rate.
Quality assurance The Bidder shall maintain an effective quality system. A concise description of the Bidder’s system and its proposed application to the scope of work, including references where applicable to a quality manual or similar authorized company document, is required with the quotation. A List of documents, in dossier form, shall be retained as evidence or proof that the product or service supplied complies with specific requirements. A quality plan, indicating the verification activities that will be applied in order to achieve the required quality will be required to be submitted for approval
Technical specifications of various instrumentation items Please refer annexures as below Document ref :
Rev.
Document content
C530/I&C/IN/A4/501
R0
Instrument Index
C530/I&C/IN/A4/502
R0
Cable Schedule
C530/I&C/IN/A3/503
R0
Control System I/O List
C530/I&C/SP/A4/504
P0
Specification for Pressure and DP Transmitter
C530/I&C/SP/A4/505
P0
Specification for Temperature Transmitter
C530/I&C/SP/A4/506
R0
Flow Element (Wedge type)
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IIT Bombay Tender Number – 201601548 Document ref :
Rev.
Document content
C530/I&C/SP/A4/508
R0
Specification for Pressure gauge
C530/I&C/SP/A4/509
R0
Specification for Dial Thermometer
C530/I&C/SP/A4/510
R0
Specification for Level Switch
C530/I&C/SP/A4/511
R0
Specification for Level gauge
C530/I&C/SP/A4/512
R0
Specification for Multipoint Temperature Element
C530/I&C/SP/A4/513
P0
Specification for Globe type control valve
C530/I&C/SP/A4/514
P0
Specification for On-Off valve
C530/I&C/SP/A4/515
P0
Specification for Safety Relief Valve
C530/I&C/SP/A4/516
R0
Specification for Instrument cable
C530/I&C/SP/A4/517
R0
Specification for Instrument Junction Box
C530/I&C/SP/A4/518
R0
Specification for Instrument Cable Gland
C530/I&C/SP/A4/519
R0
Specification for Instrument Cable Tray
C530/I&C/SP/A4/520
R0
Specification for Instrument Tubing and
C530/I&C/SP/A4/521
P0
Solenoid valve
C530/I&C/SP/A4/522
R0
Vortex Flowmeter Datasheet
C530/I&C/SP/A4/523
R0
Rotameter Datasheet - Molten Salt
C530/I&C/SP/A4/524
R0
Specification for PLC based Control System
C530/I&C/SP/A4/525
R0
Specification for Instrument Installation Contract
C530/I&C/LD/A3/527
R0
Cause & Effect Charts
C530/I&C/WD/A3/526
R0
Loop Wiring Diagram
D. Technical specification – Electrical work Scope: This document describes the scope of supply, installation, testing & commissioning of complete electrical system and defines guidelines for the design of electrical system for this project. System parameters: Distribution Voltages shall be as per table given below: Equipment
System Voltage
No. Of phases &
Grounding
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IIT Bombay Tender Number – 201601548 Frequency 3 Ph. loads like Motors, 415V Heaters etc.
3 PH, 50HZ
Grounded
1 Ph. loads
230V
1 PH, 50HZ
Grounded
PLC
230V
1 PH, 50HZ
Grounded
Electrical scope of supply Scope includes supply of following equipment & material: Sr. No.
Description
Qty.
Specification clause
1
PMCC
1 no.
C530/EE/SP4/407
2
Feeder Pillar
1 no.
C530/EE/SP4/407
3
Lighting DB
1 no.
C530/EE/SP4/407
3
AC Induction motors
1 lot
C530/EE/L4/410
4
UPS
1 lot
C530/EE/L4/408
5
Electrical Cables
1 lot
C530/EE/SP/A4/411
6
Local control stations
1 lot
C530/EE/SP/A4/411
7
Earthing Material
1 lot
C530/EE/SP/A4/411
8
Erection material like Cable terminations, 1 lot cable trays, cable ties etc.
C530/EE/SP/A4/411
Codes and standards: The design of electrical system and the installation shall be in accordance with the relevant Indian Standards, IEC Standards, CEA guidelines, Indian Electricity Act & rules and Local Rules and Regulations. Standard
Title
IS 2147
Degrees of protection provided by enclosures for low voltage switchgear and control gear
IS 3427
Code of practice for installation and maintenance of switchgear
IS 8623
Low-Voltage Switchgear and Control gear Assemblies
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IIT Bombay Tender Number – 201601548 Standard
Title
IS 10118
Code of Practice for Selection, Installation and Maintenance of Switchgear and Control gear
IS 12021
Control Transformers for Switchgear and Control gear for Voltages Not Exceeding1 000 VAC. - Specification (First Revision)
IS/IEC 60715
Dimensions of low-voltage switchgear and control gear - Standardized mounting on rails of mechanical support of electrical devices in switchgear and control gear installations
IS/IEC 60947
Low-voltage Switchgear and Control gear
IS 900
Code of practice for installation and maintenance of induction motors
IS 1231
Dimensions of Three-phase Foot-mounted Induction Motors
IS 2223
Dimensions of flange mounted ac induction motors
IS 4029
Guide for Testing Three Phase Induction Motors
IS/IEC 60034 : Rotating electrical machines : Part 1 Rating and performance Part 1 IS/IEC 60034 : Rotating electrical machines : Part 5 Degrees of protection provided by the Part 5 integral design of rotating electrical machines (IP CODE) - Classification IS/IEC 60034 : Rotating electrical machines : Part 8 Terminal markings and direction of Part 8 rotation IS 12615
Permissible limits of noise level for rotating electrical machine
IEC 62040
Uninterruptible power systems (UPS)
IS 3043
Code of Practice for Earthing
IS 2309
Code of Practice for Protection of Buildings and Allied Structure against Lighting
IS 732
Code of Practice for Electrical Wiring Installation
IS 9537
Conduit for Electrical Installations: Rigid Plan Conduits of Insulating Materials
IS 5831
PVC insulation and sheath of electric cables
IS 3975
Mild steel wires, formed wires and tapes for armouring of cables
IS 7098 : Part 1
Cross-linked polyethylene insulated PVC sheathed cables: Part 1 For working voltage up to and including 1 100 V
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IIT Bombay Tender Number – 201601548 Standard
Title
IS 8130
Conductors for Insulated Electric Cables and Flexible Cords
IS 1554 : Part 1
PVC insulated (heavy duty) electric cables: Part 1 For working voltages upto and including 1 100 V Central Electricity Authority Regulations
General 1. Bidder shall carry out Supply and Electrical Installation work as per various parts of these documents in an approved manner in required time schedule. Responsibility lies with the Bidder for the proper execution of the erection work according to the existing laws and by-laws. Bidder shall conform in all respects to the requirements of local and other statutory authorities, issue of notice, as and when required by them All materials are in Bidder’s scope of supply and shall comply with all currently applicable IS and IEC Standards. 2. Bidder shall furnish all the equipment drawings for client’s approval before manufacturing. Manufacturing shall be done as per drawings approved for manufacturing. Any deviations w.r.t specification/tender shall be highlighted clearly by the bidder along with the bid (see deviations clause). 3. All the items/equipment as specified in this specification are minimum requirement for this package for tendering purpose; any more equipment, material, device or system if required for completeness of this package as well as for safe & smooth operation and good engineering practice, are included in scope of bidder without any cost or time implication. 4. If any equipment supplied by the bidder fails at site during erection, commissioning or service (within guarantee period), the vendor shall repair and put back into successful operation the failed equipment within the time frame and procedure of repair agreed with the purchaser depending on nature of failure at no extra cost to the purchaser. 5. Bidder shall carryout the installation in accordance with construction drawings, manufacturer’s drawings/manual’s installation instructions and as per specific instructions of Engineer In-Charge and as per various parts of this tender document. 6. Sufficient sets of tools and tackles shall be available at site for smooth execution of the job 7. All meters and testing equipment shall be calibrated by authorized testing and calibrating agencies. All meters and testing equipment shall be calibrated every six months. Brief specification for supply items 1. Electrical Cable Please refer specification C530/EE/SP/A4/411 Quantities of cables shall be supplied shall be as per electrical cable scheduleC530/EE/CS/A4/406. 2. Summary of Electrical cables Please refer schedule C530/EE/SP/A4/411
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IIT Bombay Tender Number – 201601548 3. Cable terminations Unarmoured cables shall be terminated by single compression type cable glands & armoured cable shall be terminated by double compression cable gland. 4. Summary of cable glands Please refer schedule C530/EE/SP/A4/411 5. Summary of cable lugs Please refer schedule C530/EE/SP/A4/411 6. GI cable trays Cable tray shall be GI perforated type. 7. Local control stations Local control stations with stay put type STOP push button & spring return type start push button shall be provided for each motor. Quantity as per present load list -8 nos. 8. Welding receptacles 415V, 63A TPNE, interlocked welding receptacles- 2nos. shall be supplied 9. Light fixtures Following light fixtures suitable for 230V, 1ph supply shall be provided. For details refer Lighting layout-C530/EL/GA/A1/405. Preferred make of light fixtures: Philips/Wipro/Crompton 10. Lighting junction boxes 4 way, Industrial, suitable for 3C 2.5 sq.mm Cu cable- 10 nos. shall be provided. 11. GI lighting pole GI lighting pole suitable for LED street light poles to be mounted on wall or column to be provided by bidder 60mm dia pipe type P1 suitable for mounting on handrail as per lighting layout: -7 nos. 60mm dia pipe type P2 suitable for mounting on wall or structural column as per lighting layout: -7 nos. 12. Switchboxes Decorative type switchboxes with 5A sockets & 20 A sockets shall be provided in Control room & MCC room. 13. Earthing Material 115 | P a g e
IIT Bombay Tender Number – 201601548 a. Earth Pit 3000mm long, 40 mm dia GI pipe electrode shall be provided in the chamber as per IS3043. b. BOQ of earthing material i. Safety equipment, antiskid mats, danger sign boards as required shall be provided by the bidder. ii. Electrical Installation iii. Panel installation iv. All panels shall be installed as described in respective specification. All supporting material & hardware shall be in the bidder’s scope. 14. Cable Installation Cable routes and mode of installation shall be generally be as shown in the construction drawings. Cable shall be secured using cable ties. Multicore cables laid on cable trays shall be tied individually with nylon tie at each rung or by 25 x 3 mm Aluminium clamps of every 1.0 m interval on horizontal run and at every 600 mm interval on vertical run. Cables routed on Walls / Structures shall be cleated with GI spacers and saddles at every 300 mm interval. GI spacer for cleating shall be 3 mm thick and saddles shall be minimum 2mm thick (8X35mm). The spacer shall be tightly fixed on walls using PVC plugs and GI screws 15. Earthing Installation a. Location of earth pits shall be decided such that fouling with column footings/rafts is avoided. It should be located at minimum 1000 mm from the boundary of building. The earth pits shall not be within a distance of 1500 mm from hot places which may have hot/damp discharges. b. All connections of earthing conductor shall be welded or bolted with appropriate hardware. In case of Cu earthing conductor the same shall be brazed or bolted with cadmium hardware. Contact surfaces shall be free from scale, paint, enamel, grease, rust or dirt. Cables used as earth conductor shall be connected by crimping type lugs. c. Earthing connections above the ground to equipment earthing pads/terminals shall be bolted type. Connections buried in earth/concrete shall be welded/brazed type. d. The pieces to be welded shall be held by pressure clamp and then welding/brazing operation shall be carried. This is to ensure good contact joint. The joints shall be cooled naturally to its ambient. If it is Galvanized Aluminium conductor, bituminous paint shall be applied at joint. 16. Lighting Installation Lighting luminaries shall be mounted as per mounting type indicated in the layout drawing and as detailed in installation standards. Fabrication of supports for luminaries shall be done as per installation standards. All hardware required for installation of lighting system shall be supplied by bidder. 17. Reference documents attached: a. Electrical Load list: C530/EL/LL/A4/401 116 | P a g e
IIT Bombay Tender Number – 201601548 b. Electrical Cable Schedule: C530/EL/CS/A4/406 18. Technical specifications of electrical motors a. Refer data sheet - C530/EE/SP/A4/410 19. Technical specifications of UPS a. Refer data sheet - C530/EE/SP/A4/408 b. Bidder shall submit GA, SLD & BOM. Manufacturing can be taken up once the panel drawings are approved by client for construction. c. This specification indicates minimum requirement for the equipment, any other equipment, components required for satisfactory operation shall be included by bidder in his scope. d. Bidder shall include commissioning spares & 2 years maintenance spares in the scope. 20. Technical specifications of Low voltage Switchgear panel a. Refer data sheet C530/EE/SP/A4/407 b. Bidder shall submit GA, SLD & BOM along with offer. Manufacturing can be taken up once the panel drawings are approved by client for construction. c. This specification indicates minimum requirement for the equipment, any other equipment, components required for satisfactory operation shall be included by bidder in his scope. d. Bidder shall include commissioning spares & 2 years maintenance spares in the scope. Note: Make of Switchgear components shall be Siemens / L&T/ Schneider.
E. Technical specifications of Molten Salt, selective coating and heat transfer compound Specification of molten salt Sr. No. Description 1
2
Specification
Composition
Mixture ( premixed ) of sodium and potassium based nitrate and nitrite salts
Proportion – NaNO3 : KNO3
59.5 + 1% : 40.5 + 1%
Impurities, max permissible
Vendor to state actual
Chlorides
0.05 % + 0.002%
Sulphates
0.01 % + 0.001%
Carbonates
0.02% + 0.002%
Nitrites
0.001 % + 0.0002%
Moisture
VTS
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IIT Bombay Tender Number – 201601548 Sr. No.
Description
Specification
Other
Nil
Anti-caking agent
Nil ( strictly not permissible )
3
Solidus, Liquidus temperatures
VTS
4
Physical properties
a
Solid
i
Bulk density
ii
Particle size
iii
Melting point
⁰C
VTS
iii
Specific heat
kcal/kg ⁰C
VTS
iv
Latent heat of fusion
kcal/kg
VTS
b
Liquid
i
Average specific heat
kcal/kg ⁰C
VTS
ii
Density
kg/m3
VTS
iii
Viscosity
cP
VTS
iv
Thermal conductivity
kcal/hr m ⁰C
VTS
v
Heat transfer coefficient
kcal/hr m2 ⁰C
VTS
5
Documents
a
MSDS
Vendor to provide
b
Test certificates
Vendor to provide TCs for properties as per respective ASTM standard, Tests shall have been carried in an internationally reputed laboratory or manufacturer’s laboratory with traceability of test equipment and calibrations to international standards
6
Other
a
Pack size
kg/m3
VTS ( required ~ 1950 + 50 ) Vendor to provide sieve analysis
Salt shall be supplied in 25 kg packs
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IIT Bombay Tender Number – 201601548 Sr. No.
Description
Specification
b
Packing quality
Sea worthy
Specifications of selective coating: Sr.no. Item / parameter
Specification
1
Description
2 3
Colour Solar absorptivity
Selective coating with high solar absorptivity and low thermal emissivity and capable of withstanding high temperatures Black ≥ 0.95
4
Maximum temperature
800 °C
5
Quantity
6
Life
7 8
Thinner Cleaning agents
8
Suggested makes
3 gallons 2 gallons are sufficient for coating. Balance 1 gallon is to cover wastage during applying the paint The paint at the time of application should be under recommended shelf life from shipping date and in sealed condition Xylene, if required Trichloroethane, methyl ethyl ketone(butanone) or suitable industrial solvents Pyromark 2500 - Tempil
Selective coating application procedure: a. Degrease all surfaces to be painted with trichloroethane b. Grit blast surfaces using 60 – 120 mesh garnet abrasive (or sand blasting) i. Position the nozzle nearly perpendicular to the surface and use a continuous motion to obtain a uniform, lightly roughened surface; a single-pass withminimum-overspray method is recommended ii. Remove excess grit/sand using clean, oil-free compressed air c. Re-clean all blasted surfaces using trichloroethane d. Mix Pyromark 2500 for ~20 minutes prior to use e. Before painting, solvent clean the surface with methyl ethyl ketone; allow surface to air dry. Application in rain and dew should be avoided. f. Apply paint using spray techniques to obtain a wet film thickness sufficient to yield a dry film thickness of ~50μm. i. Apply paint in only a single layer g. Air dry 18 hours 119 | P a g e
IIT Bombay Tender Number – 201601548 h. Heat the coils as per the heating rate given below (maximum heating rate of 10°C per minute when possible) i. Heat to 120°C, hold for ~2 hours ii. Heat to 250°C, hold for ~2 hours iii. Heat to 540°C, hold for ~1 hour iv. Heat to 700 °C, hold for 1 hour Specifications of heat transfer compound: Sr.no. Item / parameter
a. b.
c. d. e. f.
g.
1
Description
2 3 4
Maximum exposure temperature Quantity Life
5
Suggested makes
Specification
Heat transfer compound or cement to enhance heat transfer between molten salt pipe and steam tracing tubes Should have high thermal stability and bonding capability and strength Should resist thermal and mechanical shocks 590 °C 12 gallons The heat transfer compound at the time of application should be under recommended shelf life from shipping date and in sealed condition T99 - Thermon
Application procedure: The heat transfer compound must be applied on surfaces of traced valves, instrument bodies and molten salt pipes and their surfaces must be prepared prior to application. Oil, grease, dirt, rust scale etc. if any on the surfaces must be removed. The use of solvents and emulsions along with scraping, chipping and wire brushing are some of the common pre-treatment techniques for steel surfaces that can be used. If the heat transfer is water soluble, application in rain and dew should be avoided. Primer should not be used on surfaces coated with heat transfer compound The steam tracing tube should be surrounded by the heat transfer compound filled inside inside stainless steel channels. Galvanized channels should not be used. The heat transfer compound should be hand trowelled to fill steel channels. The channels should be securely tightened with steel wires or bands on the applied surface. (Please refer illustrative figure below) The heat transfer compound, accessories such as channels, tie wires or bands to be used and application procedure adopted by the bidder has to be approved from DEC and IITB
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IIT Bombay Tender Number – 201601548
6.2 Technical Deviations: 1. Any deviation or variation from the scope, requirement and/or intent of this specification shall be clearly defined under Deviation Schedules of the relevant Bid forms irrespective of the fact that such deviations/ variations may be standard practice or a possible interpretation of the specification by the Bidder. 2. Except for those deviations/ variations covered under Deviation Schedules which are accepted by the IITB / DEC before the award of the Contract, it will be the responsibility of the bidder to fully meet the intent and the requirements of the specification within the quoted price. 3. Before submitting his bid, the bidder should inspect and examine the site and its surroundings and should satisfy himself in all respects. No consequent extra claims on any misunderstanding or otherwise shall be allowed by the Employer. 4. In case of any conflicts / contradiction among various sections / annexure / chapters / appendices / tender drawings of bid documents, the same shall be referred to the Employer for clarifications whose decision shall be final and binding. No extra claims shall be allowed on this account. 5. If there is any deviation in the work as felt necessary by the Client (IITB) & communicated so officially then this will be charged at the rate previously quoted in the price bid. Maximum 5% of the Purchase Order (PO) Value will be allowed for rise in the cost due to deviations
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Section – 7: Price bid
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IIT Bombay Tender Number – 201601548
7.1 Price bid Table
Description of Item & Specification
Procurement, Fabrication, Supply, Erection and Commissioning of High Temperature Molten Salt Loop with Central Receiver, Molten Salt Storage, Heat Exchangers and Allied Works
Qty & Units
Total Price (in Rs.)
VAT , WCT, Service Tax & other taxes / charges if any please specify details (%/ in Rs.)
Total Price (in Rs.)
1 No.
1. The bidder should quote the price on the total price basis for the scope mentioned in scope of work, materials, tools & tackles, manufacturing, fabrication, transportation, construction, facilitation of intermittent & final inspection, including statutory payments and compliances as applicable for and arising from the work ( no cost will be borne by NTPC / IITB / DEC ), manpower, travel, boarding & lodging, construction and potable water for labour, own and DEC / Client personnel, temporary power arrangements etc. for the entire duration of the contract including extension, if any, thereof. 2. The bidder is required to provide item rates in Cost Drivers Details vide separate sheet. 3. Bidder is requested to visit the site before bidding to inspect the site and its surroundings and ascertain and satisfy himself in all respects to understand the site and surroundings, the development necessary by way of site clearing, filling, drainage, access roads, fences, sheds, material required for temporary and / or construction power and water, permits and procedures etc. to estimate all costs related to the work. No extra claims of any nature on any misunderstanding or otherwise shall be allowed. The site visit shall be conducted entirely at bidder’s cost.
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IIT Bombay Tender Number – 201601548 Validity - The bidder shall hold the bid valid for 180 days from the date of submission of quotation/tender. Delivery period ..........................days
PAN No:............................................................................................ VAT/TIN Registration No:....................................................... Signature: ...................................................................................... Place: Name:.................................................................................. Date: Business Address:.......................................................... Affix Rubber Stamp:..................................................................
Note: Price Bid and Cost Drivers Details should be submitted in given format only. For additional information / extra items above format may be typed and used.
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IIT Bombay Tender Number – 201601548
7.2 Payment schedule Procurement, Construction and Commissioning (PCC) Contract for “Procurement, supply, construction, fabrication, erection, testing and commissioning of High Temperature Molten Salt Loop with Central Receiver, Molten Salt Storage, Heat Exchangers and allied works” shall be a Total Price of Tender Contract. Bidder shall ascertain all work item quantities in conformity to Tender Drawings and quote Total Price Bidder shall also furnish Item Rates and amount against all “Cost Driver Items of Price Bid”. This shall form basis to arrive at compensation towards additional work ordered / reduction for deleted work, if any. PCC Contractor can raise one invoice per two calendar month, as per Delivery / Site Activity Linked Payment Schedule. Note: No invoice will be considered against incomplete work.
Sr. No.
Key Deliverables
Payment (%)
Delivery in Weeks from PO Date
1
Supply of pipes, pipe fittings, valves
6%
8
2
Pumps, dosing systems, steam silencer, all tanks
6%
12
3
Supply of instruments, PLC, SCADA
8%
12
4
Supply of salt
5%
12
5
Receiver with coils, thermocline tank, heat exchangers, vent pot
6%
16
6
Supply of electrical items including electrical heaters
21%
16
7
Supply of control valves and instrument air package
5%
18
8
Supply of spares
5%
24
9
Complete erection of equipment, piping and insulation, electrical, instrumentation
18%
25
10
Testing and commissioning of complete system
10%
30
11
Project handover
10%
32
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IIT Bombay Tender Number – 201601548
The bidder should quote period of Delivery from PO Date for Key Deliverables Listed so as to fit within an overall delivery period not exceeding 32 weeks from the date of Letter of intent / PO whichever is earlier. The overall delivery period shall be inclusive of design, procurement, fabrication, construction, erection, testing, pre commissioning, commissioning, documentation, training etc. complete.
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IIT Bombay Tender Number – 201601548
7.3 Cost drivers A. Schedule of quantities - Structural steel work Sr. No.
Item Description
1
Procurement and supply of structural steel as per drawings and details, consisting of plates, rolled steel sections such as channels, angles, rods / pipes / tubes etc., straightening of the steel if required, fabrication of steel structures, as per drawings, loading, transportation, unloading and delivery at erection site of all fabricated structures, erection, alignment and welding of all structures true to line, level, plumb and dimension including rectification if any splicing, site assembly all as per technical specifications, drawings and instruction of the Engineer-in-Charge including painting as per specifications. painting
a
Structural steel for pipe supports, frames, miscellaneous supports etc. 300
kg
Structural steel for miscellaneous equipment platforms, ladders, supports etc. 8
MT
Supply and fixing of nickel plated anchor fasteners, nuts bolts etc. 100
kg
Structural steel for receiver support
MT
a 2 3
Qty
4
Unit
Unit Rate
Amount
Rs.
Rs.
Unit Rate
Amount
Rs.
Rs.
TOTAL =
B. Schedule of quantities – Piping & Mechanical work Sr. No.
Item Description
1
Procurement, supply, transport, lifting, installation, testing ( including PMI ), installation, commissioning of heliostat receiver assembly, SR 01, consisting of 2 large coils, 3 small coils, header, inlet and outlet piping, all of A213 TP 316 Ti tubes, socket weld joints, 100% radiography, cavity lining, insulation of mineral wool and
Qty
Unit
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IIT Bombay Tender Number – 201601548
Sr. No.
Item Description
Qty
Unit
a Coils, 1,100 mm OD
2
No.
b Coils, 700 mm OD
3
No.
c Receiver header, tube 19mm OD x 2 thk, ~10.35m long with approx. 10 bends, 3 Tee joints, 5 nos joints to coils, 4m portion outside receiver insulated to 200mm thk as per insulation schedule 1
No.
d Receiver housing with insulation, supports etc
1
No.
Procurement, supply, transport, installation, testing (including PMI), installation, commissioning of Molten Salt storage tank (Thermocline tank, TCS-01) including supports, insulation, etc. complete. 1
No.
Unit Rate
Amount
Rs.
Rs.
ceramic fibres, outer encasing, opening for heaters, supports for coils etc. complete, comprising below items, coating of receiver coils with selective coating
2
3
Design, procurement, supply, transport, testing (including PMI), installation, commissioning of molten Salt – steam heat exchangers including insulation etc.
a
Preheater, PH-01
1
no.
b
Evaporator, E-01
1
no
c
Superheater, SH-01
1
no.
4
Procurement, supply, installation, testing, commissioning of molten salt pumps as per specifications.
a
Charging circuit molten salt pump, MSP-1
1
no
b
Discharge circuit salt pump, MSP-2
1
no
5
Procurement, supply, installation, testing, commissioning of water pumps as per details and specifications. 1
no.
128 | P a g e
IIT Bombay Tender Number – 201601548
Sr. No.
Item Description
a
Boiler feed water pumps, FWP-1 & FWP-2, triplex, plunger pumps 2
no
DM water transfer pump, P9402, centrifugal, CS construction 1
no
Cooling water circulation centrifugal, CS construction
1
no
b c
Qty
pump,
Unit
Amount
Rs.
Rs.
P9403,
6
Procurement, supply, transport, testing ( including PMI ), installation, painting ( for uninsulated piping ), commissioning of piping ( pipes, pipe fittings, valves pipe supports fixtures excluding structural steel, etc. ) including insulation as per details and drg
a
CS, SA 106 Gr. B, Seamless, Sch. 40, including fittings A105, 3000# below 40 NB, else fittings seamless Sch. 40, gaskets shall be 2.5 thk, spiral wound SS 304, graphite filled, outer ring CS, inner ring SS 304, mfg. std. B16.20
i
15 NB
150
m.
ii
20 NB
18
m
iii
25 NB
54
m
iv
40 NB
Q.R.
m
v
50 NB
24
m
b
SA-312 TP 321 seamless, Sch. 40, including fittings SS 321, 3000#, gaskets shall be 2.5 thk, spiral wound SS 316, graphite filled, outer ring CS, inner ring SS 316, mfg. std. B16.20
i
15 NB
40
m.
ii
20 NB
Q.R4.
m
iii
25 NB
120
m
iv
40 NB
12
m
4
Unit Rate
Q.R. means quote rate. Cost should not be added in the bid. Unit rate is asked for future requirements, if any 129 | P a g e
IIT Bombay Tender Number – 201601548
Sr. No.
Item Description
Qty
Unit
c
Alloy steel, A335, P91, Seamless Sch. 40, including fittings forged P91, 3000# below 40 NB, else seamless Sch. 40, gaskets shall be 2.5 thk, spiral wound SS 304, graphite filled, outer ring CS, inner ring SS 304, mfg. std. B16.20
i
15 NB
18
m.
ii
20 NB
Q.R.
m
iii
25 NB
120
m
iv
40 NB
Q.R.
m
v
50 NB
Q.R.
m
d
CS, IS 1239, Class C, hot dip galvanised including fittings CS seamless Sch. 40, ring gaskets shall be non-asbestos, 3 mm thk
i
15 NB
120
m.
ii
20 NB
420
m
iii
25 NB
180
m
iv
40 NB
6
m
v
50 NB
6
m
vi
25 NB for cooling coils
100
m
e
CPVC, Sch 40. IS 1239, Class C, including fittings seamless Sch. 40, ring gaskets shall be nonasbestos, 3 mm thk
i
15 NB
6
m.
ii
20 NB
Q.R.
m
iii
25 NB
54
m
iv
40 NB
12
m
v
50 NB
6
m
vi
200 NB
6
m
Unit Rate
Amount
Rs.
Rs.
130 | P a g e
IIT Bombay Tender Number – 201601548
Sr. No.
Item Description
Qty
Unit
f
UPVC, Class 4, IS 4985 / equi., including fittings of equivalent rating, ring gaskets shall be nonasbestos, 3 mm thk
i
15 NB
12
m.
ii
20 NB
Q.R.
m
iii
25 NB
180
m
iv
40 NB
6
m
v
50 NB
6
m
g
Steam tracing, ASTM 213, TP 304, seamless tube, 8mm OD x 1mm thk., including socket weld fittings A182 SS304, 3000#. 150
m.
Copper cooling piping, ASTM B 88, Type L, Hardness F 40, 99.9% copper, including fittings, brazing / soldering, compression fittings etc. complete. 120
m.
Metallic Expansion bellows for IA, 15 NB, sch. 40, flanged ASA 150 #, 150 long.
No.
h
7 8
Procurement, supply, installation, insulation, testing and commissioning of valves with end fittings etc. complete
a
Forged Globe Valve for Steam, 15 NB
4
Tag nos : HV9107, HV9108, HV9110, HV9111, HV9112, HV9113, HV9115, HV9116, HV9117, HV9117, HV9118, HV9119, HV9123, HV9125, HV9137, HV9141, HV9142, HV9143 17 b
d
Amount
Rs.
Rs.
nos.
Forged Globe Valve for Steam, Size 25 NB Tag nos : HV9109, HV9114, HV9120, HV9121
c
Unit Rate
4
nos.
Tag nos : NRV9104, NRV9106, NRV9107
3
nos.
Non slam check valve for Steam, Size 25NB
1
nos.
Non slam check valve for Steam Size, 15NB
131 | P a g e
IIT Bombay Tender Number – 201601548
Sr. No.
Item Description
Qty
Unit
2
no.
2
no.
1
no.
2
no.
1
no.
Unit Rate
Amount
Rs.
Rs.
Tag nos. : NRV9105 e
Steam Trap, Size 15NB Tag nos. : ST9101, ST9102
f
Solenoid valve, Size 15 NB Tag no. : SV-9205 / 9206
g
Safety relief valve, Size 15 NB Tag no. : PSV-9101
h
Safety relief valve, Size VTS Tag no. : PSV-9102 A/B
i
Safety relief valve, Size VTS Tag no. : PSV-9103
j
Globe Valve - Molten Salt Service, Size 15NB Tag no : HV9001, HV9002, HV9003, HV9004, HV9005, HV9006, HV9007, HV9010, HV9011, HV9012, HV9013, HV9014, HV9016, HV9017, HV9018, HV9019, HV9020 17
k
Globe Valve - Molten Salt Line, Size 25NB Tag no : HV9008, HV9009, HV9015, HV9021
l
o
nos.
3
nos.
1
no.
Pressure relief Valve – Instrument air, Size 25NB Tag no. : OPRV9001
n
4
Non slam check valve – Molten Salt Size, 25NB Tag no. : NRV9001, NRV9003,
m
nos.
Ball Valve for Hot Water, Size 15NB Tag no : HV9103, HV9104, HV9124, HV9126, HV9128, HV9129, HV9130, HV9131, HV9132, HV9133, HV9134, HV9135, HV9136, HV9139, HV9140 16
nos.
Ball Valve for Hot Water, Size 20NB
nos.
4
132 | P a g e
IIT Bombay Tender Number – 201601548
Sr. No.
Item Description
Qty
Unit
1
no.
2
nos.
2
nos.
2
nos.
Tag no : HV9423, HV9424, HV9425, HV9426, HV9427 5
nos.
Unit Rate
Amount
Rs.
Rs.
Tag no : HV9101, HV9102, HV9105, HV9106 p
Ball Valve for Hot Water, Size 50NB Tag no : HV9127
q
Non slam check valve – Hot Water Line, Size 15NB Tag no. : NRV9103, NRV9108
r
Non slam check valve – Hot Water Line, Size 20NB Tag no. : NRV9101, NRV9102
s
Y type Strainer – Hot Water Line, Size 20NB Tag No.: STR9101, STR9102
t
u
Carbon Steel Ball Valve – Cooling Water Line, Size 25NB
Non slam check valve – Cooling Water Line, Size 25NB Tag no. : NRV9402
v
1
no.
1
no.
10
nos.
True Union Ball Check Valve (CPVC), Size 25NB Tag no. : NRV9401
x
no.
Y type Strainer – Cooling Water Line, Size 20NB Tag No. : STR9402
w
1
CPVC Ball Valve, Size 15NB Tag no : HV9406, HV9407, HV9408, HV9409, HV9410, HV9411, HV9418, HV9419, HV9420, HV9422
z
CPVC Ball Valve, Size 25NB Tag no : HV9402, HV9404, HV9405, HV9412, HV9415, HV9416, HV9417 7
nos.
133 | P a g e
IIT Bombay Tender Number – 201601548
Sr. No.
Item Description
aa
CPVC Ball Valve, Size 40NB Tag no : HV9443, HV9414
ab
1
no.
3
nos.
1
no.
1
no.
1
no.
4
nos.
2
nos.
1
no.
2
no.
Procurement, fabrication, supply, installation, insulation, testing, commissioning, of Vent pot as per details and specifications 1
No.
Globe type Control Valve, Size 25 NB Tag no : PV-9004, PV-9005, PV-9105, TV-9005
ai
On-Off Ball Valve, Size 15 NB Tag no : XV-9201, XV-9202
aj
On-Off Ball Valve, Size 25 NB Tag no : BV-9107
ak
CS butterfly valves, Sixe 200 NB Tag no : HV9403, HV9413
9
nos.
Globe type Control Valve, Size 40 NB Tag no : PV-9002
ah
Rs.
Globe type Control Valve, Size 15 NB Tag no : FV-9001, FV-9002, FV-9101, LV-9106, LV9101, PV-9204, TV-9101, TV-9105 8
ag
Rs.
UPVC Ball Valve – Raw Water Line, Size 40NB Tag no : HV9438
af
nos.
Amount
UPVC Ball Valve – Raw Water Line, Size 25NB Tag no : HV9442
ae
4
Unit Rate
UPVC Ball Valve – Raw Water Line, Size 15NB Tag no : HV9439,HV9440,HV9441
ad
Unit
Y type Strainer (CPVC), Size 40NB Tag No.: STR9404
ac
Qty
134 | P a g e
IIT Bombay Tender Number – 201601548
Sr. No.
Item Description
10
Procurement, fabrication, supply, assembly, installation, testing and commissioning of mechanism consisting of gears, pulleys, sprockets, chains, roper, supports, shafts, bearings, hooks, anchors, D-shackles etc. complete for operating dummy receiver platform 500
kg
Procurement, fabrication, supply, assembly, installation, testing and commissioning of mechanism for receiver heaters with motorised winch as per design and details. 1
No.
Design, procurement, supply, installation, insulation, testing, commissioning of steam silencer as per details and specifications. 1
No.
Design, procurement, supply, installation, testing, commissioning of instrument air plant in acoustic enclosure including air receiver, auto-drain valve, drain piping, etc. complete as per details and specifications. 1
no.
Design, procurement, supply, installation, testing, commissioning of skid mounted dosing system with motorized stirrer, dosing pump, tank with instrumentation including control panel etc. complete as per details and specifications. 1
no.
a
HP boiler feed water dosing system, DT-01, DP-01
1
no.
b
Same as above by LP dosing system, DT-02, DP-02
1
no.
15
Procurement, supply, installation, testing, commissioning of sample cooler for evaporator. 1
no.
Procurement, supply, assembly, installation, testing, commissioning of 80 kW cooling system using radiator including skid, fan, panel etc. complete. 1
no.
11
12
13
14
16
17
Procurement, supply, assembly, installation, testing, commissioning of electrical hoists as per details and specifications
a
for receiver maintenance, 5 MT
Qty
1
Unit
Unit Rate
Amount
Rs.
Rs.
no.
135 | P a g e
IIT Bombay Tender Number – 201601548
Sr. No.
Item Description
Qty
Unit
b
for salt pumps maintenance, 2 MT
1
no.
c
for workshop, 2 MT
1
no.
18
Procurement, supply, erection, testing, commissioning of 10 cum HDPE tanks T9402, T9403, with manhole, covers, drain, vent etc. complete
a
10 cum HDPE tanks T9402, T9403,
2
no.
b
5 cum HDPE tanks, T 9401
1
no.
c
200 ltr MS insulated cooling water tank T9405
1
no.
Water meter, class B, as per pipe size, for water measurement for dosing, numeric counter, totaliser 2
no.
Procurement, supply, erection of heavy duty slotted angle rack for stores, 4m H x 2.7mW x 600mm x 3 nos, shelves of 2.5mm thk, all members powder coated, UDL load 100 kg/900 width, including installation etc. complete with aluminium access ladder 1
no.
19
Unit Rate
Amount
Rs.
Rs.
Unit Rate
Amount
Rs.
Rs.
Total
C. Schedule of quantities – Electrical work
Sr. No.
Item Description
1
Design, procurement, supply, testing installation, commissioning of LV Switchgear Panels as per specifications C530/EE/SP/A4/407
a
PMCC
Qty
Unit
1
No.
136 | P a g e
IIT Bombay Tender Number – 201601548
Sr. No.
Item Description
Qty
Unit
b
Feeder Pillar
1
No.
c
PDB
1
No.
2
Supply, installation, testing, commissioning of UPS and Batteries as per specifications C530/EE/SP/A4/408 1
LS
Supply, installation, testing, commissioning of AC Motors as per specifications C530/EE/SP/A4/410, along with pumps 1
LS
3
4
Supply, installation, testing, commissioning of electrical cables as per specifications C530/EE/SP/A4/411
a
3C x2.5 sq.mm Cu, XLPE insulated armoured cable
625
m
b
3C x10 sq.mm Al, XLPE insulated armoured cable
QR
m
c
3.5C x35 sq.mm Al, XLPE insulated armoured cable 600
m
d
3.5C x50 sq.mm Al, XLPE insulated armoured cable QR
m
e
3.5C x150 sq.mm Al, XLPE insulated armoured cable QR
m
3.5C x240 sq.mm Al, XLPE insulated armoured cable QR
m
3.5C x300 sq.mm Al, XLPE insulated armoured cable 50
m
h
4C x2.5 sq.mm Cu, XLPE insulated armoured cable
m
i
4C x10 sq. sq.mm Al, XLPE insulated armoured cable 500
m
5C x 2.5 sq. sq.mm Cu, XLPE insulated armoured cable
350
m
f g
i
1100
5
Earthing Material
a
8 swg GI wire
100
m
b
25 x 3 GI earth Strip
100
m
Unit Rate
Amount
Rs.
Rs.
137 | P a g e
IIT Bombay Tender Number – 201601548
Sr. No.
Item Description
Qty
Unit
c
50 x 6 GI earth Strip
120
m
d
75 x 10 GI earth Strip
200
m
e
8 swg GI wire
80
m
f
3000 mm long, 40 mm dia. GI pipe electrode with chamber 4 GI perforated Cable trays
a
50 mm wide, 25mm height, 2 m thick GI perforated cable tray 30
m
150 mm wide, 50mm height, 2 m thick GI ladder cable tray 50
m
300 mm wide, 100mm height, 2 m thick GI ladder cable tray 80
m
600 mm wide, 100mm height, 2.5 m thick GI ladder cable tray 60
m
c d
7
Double compression type cable glands for following sizes
a
3C x2.5 sq.mm Cu, XLPE insulated armoured cable
200
Nos.
b
3C x10 sq.mm Al, XLPE insulated armoured cable
QR
Nos.
c
3.5C x35 sq.mm Al, XLPE insulated armoured cable 20
Nos.
d
3.5C x50 sq.mm Al, XLPE insulated armoured cable QR
Nos.
e
3.5C x150 sq.mm Al, XLPE insulated armoured cable QR
Nos.
3.5C x240 sq.mm Al, XLPE insulated armoured cable QR
Nos.
3.5C x300 sq.mm Al, XLPE insulated armoured cable 4
Nos.
j
4C x2.5 sq.mm Cu, XLPE insulated armoured cable
70
Nos.
k
4C x 6 sq. sq.mm Al, XLPE insulated armoured cable 22
Nos.
f i
Amount
Rs.
Rs.
Nos.
6
b
Unit Rate
138 | P a g e
IIT Bombay Tender Number – 201601548
Sr. No.
Item Description
Qty
l
5C x 2.5 sq. sq.mm Al, XLPE insulated armoured cable 24
Unit
Amount
Rs.
Rs.
Nos.
8
Cable lugs
a
2.5 sq.mm Cu,
1050
Nos.
2.5 sq.mm Al
90
Nos.
b
10 sq.mm Al
QR
Nos.
c
16 sq.mm Al
20
Nos.
d
25 sq.mm Al
QR
Nos.
e
35 sq.mm Al
60
Nos.
f
50 sq.mm Al
QR
Nos.
g
70 sq.mm Al
QR
Nos.
h
150 sq.mm Al
4
Nos.
i
120 sq.mm Al
QR
Nos.
j
240 sq.mm Al
QR
Nos.
k
300 sq.mm Al
12
Nos.
9
Local Control stations
a
LCS with 1 no. Start +1 no. STOP push buttons for DOL & VFD motors 7
Nos.
LCS for 2 nos.Start + 1 no. STOP push buttons for RDOL motors 3
Nos.
10
415V, 63A TPNE welding receptacles
2
Nos.
11
Light Fixtures
a
31W LED square light fixtures for recessed mounted on false ceiling 8
Nos.
b
40W LED batten for indoor rooms
17
Nos.
c
70W LED Flood light fixtures for area lighting
QR
Nos.
b
Unit Rate
139 | P a g e
IIT Bombay Tender Number – 201601548
Sr. No.
Item Description
d
35W LED street light fixtures for periphery lighting 14
Nos.
12
4 way, Industrial Lighting junction boxes
Nos.
13
GI lighting pole
a
60mm dia pipe type P1 suitable for mounting on handrail as per lighting layout 7
No.
60mm dia pipe type P2 suitable for mounting on wall or structural column as per lighting layout 7
Nos.
14
Switchboxes
1
LS
15
Safety equipment, antiskid mats, danger sign boards 1
LS
b
Qty
10
Unit
16
Design, procurement, supply, transport, testing, installation, commissioning of electrical heater assemblies with safety panels, etc. complete
a
Electrical heater assembly, 16 x 4 kW = 64 kW in thermocline tank, EH-01 1
No.
Electrical heater assembly, 15 kW in evaporator heat exchanger, EH-02. 1
No.
Electrical heater assembly, 15 kW inline electrical water heater, EH-03. 1
No.
Electrical heater assembly, 5 x 15 kW for receiver, EH-04. 1
No.
Electrical heater assembly, 7 x 40 kW = 280 kW, for receiver testing with reflectors, including dismantling and removal of the same and plugging the openings of the receiver as per details, EH-05 1
No.
Electrical heater assembly, 1 x 40 kW = 40 kW, for receiver testing without reflectors, including dismantling and removal of the same and plugging the openings of the receiver as per details, EH-06 1
No.
b c d e
e
Unit Rate
Amount
Rs.
Rs.
Total
140 | P a g e
IIT Bombay Tender Number – 201601548
Sr. No.
Item Description
Qty
Unit
Unit Rate
Amount
Rs.
Rs.
141 | P a g e
IIT Bombay Tender Number – 201601548
D. Schedule of quantities – Instrumentation work Sr. No.
Description
1.0
Inline instruments
1.1
Control valves – globe type
1.1.1
Size = 1/2"
1.1.2
Size = 1"
1.1.3
Size = 1-1/2”
1.2
On-off valves – ball type
1.2.1
Size = 1/2"
1.2.2
Size = 1"
1.3
Safety/thermal relief valves
1.3.1
3/4" x 1"
Installation Qty
Unit UR
Total
6
No s
N/ A
6
No.
1
2
Calibration Loop check
Total
N/A
*
*
N/A
N/A
N/ A
N/A
*
*
N/A
N/A
No.
N/ A
N/A
*
*
N/A
N/A
No s
N/ A
N/A
*
*
N/A
N/A
1
No.
N/ A
N/A
*
*
N/A
N/A
3
No s.
N/ A
*
*
N/A
N/A
N/ A
Total
Grand total
UR
N/A
UR
& Supervision of installation Supply
N/A
Remarks
142 | P a g e
IIT Bombay Tender Number – 201601548 Sr. No.
Description
Installation Qty
Unit UR
N/ A
Total
UR
Total
N/A
N/ A
N/A
*
*
N/A
N/A
N/ A
N/A
*
*
N/A
N/A
*
*
N/A
N/A
1.4.1
Vortex flow meter - 1/2"
2
No s.
1.4.2
Wedge type - 1/2" with spool piece 2
No s.
N/ A
N/A
2
No s
N/ A
N/A
2.0
Off-line field instruments
2.1
Pressure transmitters ( remote seal diaphragm with capillary ) process conn.: 2" or 3" ANSI 150# 3
No s.
Pressure transmitters with threaded connection, process conn.: 1/2" NPT 2
No s.
2.2
Grand total
UR
Flow elements -
1.5.1
& Supervision of installation Supply
Total
1.4
1.5
Calibration Loop check
Remarks
Solenoid valves Size = 1/2"
2" Pipe mounting
143 | P a g e
IIT Bombay Tender Number – 201601548 Sr. No.
Description
Installation Qty
2.3
2.4
2.5
2.6
2.7
Unit UR
Flow ( DP type ) transmitters ( remote seal diaphragm with capillary ) process conn.: 2" or 3" ANSI 150# 2
No s.
Level ( Bubbler DP type ) transmitters with threaded connection process conn.: 1/2" NPT with purge meter & DP relay 1
No.
Level ( DP type ) transmitters with threaded connection process conn.: 1/2" NPT 3
No s.
Float and tape level indicator, SS 316 tape, float, guide ropes, pulley, SS 304 dead weight, GI protection conduit, Epoxy / PU coated aluminium enclosure with digital roller display. 2
No s.
Pressure gauge process connection: 2" 150#, RF ( diaphragm seal direct mount type ) 6
No s.
Total
Calibration Loop check UR
Total
& Supervision of installation Supply UR
Grand total
Remarks
Total
Bracket/Wa ll mounting
144 | P a g e
IIT Bombay Tender Number – 201601548 Sr. No.
Description
Installation Qty
2.8
Unit UR
Pressure gauge – process connection: 1/2" NPT threaded 9
No.
2.9
Temperature transmitters ( 2" pipe mounted ) 14
No s.
2.10
Bimetal temperature gauge local mounted with screwed thermowell 1
No s.
K-Type thermocouple with screwed thermowell – connection size - 1/2" NPT 13
No s.
K-Type thermocouple, skin type with incoloy sheath for receiver 3
No s.
K-Type type
8
No s.
6
No.
2.11
2.12
2.13
thermocouple,
skin
2.14
Float type level switch
2.15
Level gauge ( magnetic / reflex type )
Total
Calibration Loop check UR
Total
& Supervision of installation Supply UR
Grand total
Remarks
Total
2" Pipe mounting
145 | P a g e
IIT Bombay Tender Number – 201601548 Sr. No.
Description
Installation
UR
Total
No s.
N/ A
N/A
5
No s.
N/ A
N/A
2.16
Multi-point temperature element assembly with transmitters
2.16.1
K-type thermocouple, 10 point Type for thermocline tank 4
No s.
2.16.2
K-type thermocouple, 10 point skin Type for receiver 1
No s.
2.17
Water meter, class B, 40 NB 1
No s.
1
No s.
2.15.1 2.15.2
2.18
3.0
CC distance - 1500 mm CC distance - 1000 mm
Qty
Unit UR
3
Supply of HART calibrator
Total
Calibration Loop check
& Supervision of installation Supply UR
Grand total
Remarks
Total
Bracket/Wa ll mounting
Control room mounted system components -
146 | P a g e
IIT Bombay Tender Number – 201601548 Sr. No.
Description
Installation Qty
3.1.1
3.1.2
Unit UR
UR
Total
N/A
N/A
PLC, cabinet with Ethernet switch - Floor mounted type, 800 x 800 x 2100 mm ( W x D x H ) ( supply & fabrication of base plate frame by contractor ), software and software development etc. complete 1
No.
N/ A
SCADA station - desktop PC ( 2 Nos. ) with printer, Ethernet switch, software and software development etc. complete 1
Set
N/ A
4.0
Instrumentation work in package equipment
4.1
Dosing systems pump control panel 2
4.2
Instrument air
4.2.1
Pressure gauge
4.2.2
Total
Calibration Loop check
& Supervision of installation Supply UR
Remarks
Total
No s.
N/A
2
No s.
N/A
N/A
1
No s.
N/A
N/A
Safety relief valve
Grand total
N/A
147 | P a g e
IIT Bombay Tender Number – 201601548 Sr. No.
4.2.3 4.2.4
Description
Installation Qty
Unit UR
1
No s.
1
No s.
9
No s.
Pressure regulating valve Blanketing valve
Total
Calibration Loop check
& Supervision of installation Supply
UR
Total
UR
Total
N/ A
N/A
N/A
N/A
Grand total
Remarks
Instrument installation material 5.0
Junction boxes
5.1
JB for 6 pair signal cable ( 24 terminals )
6.0
Instrument signal & alarm cables ( Bidder's job includes laying, dressing, clamping, glanding, ferruling, testing ( meggering, continuity & loop checking ) and termination of cables at both ends including supply of materials such as ferrules, crimping lugs and clamps etc.
6.1
signal cable - 1pair x 1.5 sqmm, shielded & armoured cable, outer sheath PVC ( grey ) 500
Mtr s
N/ A
N/A
N/A
N/A
RTD signal cable - 1TRIAD X 1.5 sqmm, shielded & 100
Mtr s
N/ A
N/A
N/A
N/A
6.2
148 | P a g e
IIT Bombay Tender Number – 201601548 Sr. No.
Description
Installation Qty
Unit UR
Total
Calibration Loop check
& Supervision of installation Supply
UR
Total
UR
Total
Grand total
Remarks
armoured cable, outer sheath PVC ( grey ) 6.3
6.4
6.5
6.6
6.7
K-type thermocouple signal cable - 1pair x 1.5 sqmm, 100 shielded & armoured cable, outer sheath PVC ( yellow )
Mtr s
N/ A
N/A
N/A
N/A
signal cable - 6 pair x 1.5 sqmm individual and overall shielded 200 & armoured cable, outer sheath PVC ( grey)
Mtr s
N/ A
N/A
N/A
N/A
signal cable -12 pair x 1.5 sqmm individual and overall 200 shielded & armoured cable, outer sheath PVC (grey)
Mtr s
N/ A
N/A
N/A
N/A
signal cable -12 pair x 1.5 sqmm individual and overall 200 shielded & armoured cable, outer sheath PVC (grey)
Mtr s
N/ A
N/A
N/A
N/A
Power cable - 3 Core X 1.5 sqmm, shielded & armoured 200 cable, outer sheath PVC (black)
Mtr s
N/ A
N/A
N/A
N/A
149 | P a g e
IIT Bombay Tender Number – 201601548 Sr. No.
Description
Installation Qty
6.8 6.9
Unit UR
Total
Calibration Loop check
& Supervision of installation Supply
UR
Total
UR
Total
Ethernet cable - CAT5, 4 Pair x 0.5 sqmm, 100
Mtr s
N/ A
N/A
N/A
N/A
Fibre optic cable – 6 core
Mtr s
N/ A
N/A
N/A
N/A
100
Grand total
Remarks
7.0
Cable glands ( Rate of installation shall be included in Cable Laying rate) - Weatherproof SS 316 double compression type with check nut for Mxx glands ( all cable gland make : Cosmos / Comet / EX-Protecta). all cable glands shall be provided with PVC shrouds / gland hood
7.1
Cable Gland 1/2" Instrument side )
7.2 7.3
7.4
NPT
50
No s.
N/ A
N/A
N/A
N/A
40
No s.
N/ A
N/A
N/A
N/A
Cable Gland M40 - suitable for 6 pair x 1.5 sqmm ( cable overall OD-20-23 mm ) 10
No s.
N/ A
N/A
N/A
N/A
Cable Gland M40- suitable for 12 pair x 1.5 sqmm ( cable overall OD-26-30 mm ) 10
No s.
N/ A
N/A
N/A
N/A
Cable Gland M20 ( JB side )
(
150 | P a g e
IIT Bombay Tender Number – 201601548 Sr. No.
Description
Installation Qty
7.5
7.6
Unit UR
Total
Calibration Loop check
& Supervision of installation Supply
UR
Total
UR
Total
Cable Gland M40- suitable for 12 pair x 1.5 sqmm ( cable overall OD-26-30 mm ) Thermocouple cable 15
No s.
N/ A
N/A
N/A
N/A
Cable Gland M20 - suitable for 3 CORE X 1.5 sqmm ( cable overall OD-30-33 mm ) 10
No s.
N/ A
N/A
N/A
N/A
Grand total
Remarks
8.0
Impulse tubing / piping/ sample tubing ( Tube laying rate includes the installation of tube fitting, valve & other accessories )
8.1
Seamless tube - SS316 : 12 mm OD X 1.5mm thick 200
Mtr s
N/ A
N/A
N/A
N/A
Male connector - SS316 : 1/2" NPT(M) X 12 mm OD, 3000# 100
No s.
N/ A
N/A
N/A
N/A
Tube tee - SS316 : 12 mm OD, 3000# 12
No s.
N/ A
N/A
N/A
N/A
Nipple - SS316 : 1/2" NPT X 100 mm long, Sch-80S 25
No s.
N/ A
N/A
N/A
N/A
Pipe Tee (equal)-3000# SS316 : 1/2" NPT (F)
No s.
N/ A
N/A
N/A
N/A
8.2
8.3
8.4
8.5
12
Part impulse tubing
of
151 | P a g e
IIT Bombay Tender Number – 201601548 Sr. No.
Description
Installation Qty
8.6
8.7
8.8
8.9
8.10
Unit UR
Total
Calibration Loop check
& Supervision of installation Supply
UR
Total
UR
Total
Plug - SS316 : 1/2" NPT (M), 3000# 35
No s.
N/ A
N/A
N/A
N/A
Globe valve - SS316 : 1/2" NPT (F), 800# 10
No s.
N/ A
N/A
N/A
N/A
Globe valve (IBR certified) SS316 : 1/2" NPT (F), 800# 4
No s.
N/ A
N/A
N/A
N/A
Condensate pot with vent plug ( 4" Size with 3 x 1/2" NPT (F) ) IBR certified complete assembly suitable for design pressure & temp. 40 BARG & 425 ⁰C. MOC -SS316 4
No s.
N/ A
N/A
N/A
N/A
Tubing union - SS316 : 12 mm OD, 3000# 15
No s.
N/ A
N/A
N/A
N/A
9.0
Pneumatic tubing ( tube laying rate includes the installation of tube fitting, valve & other accessories )
9.1
12mm OD X 1mm thk seamless SS 316 tube 120
Mtr s
N/ A
N/A
N/A
Grand total
Remarks
N/A
152 | P a g e
IIT Bombay Tender Number – 201601548 Sr. No.
Description
Installation Qty
9.2 9.3
Unit UR
Total
Calibration Loop check
& Supervision of installation Supply
UR
Total
UR
Total
1/2" NPT (M) x 6mm OD SS 316 make connector, 3000# 8
No s.
N/ A
N/A
N/A
N/A
Tubing union 6mm OD, SS 316, 3000# 4
No s.
N/ A
N/A
N/A
N/A
10.0
Cable trays: ** ( Refer Note-2 )
10.1
Ladder trays - GI Collar 100 mm thickness 4mm
10.1.1
150 mm wide ( Ladder type), 4mm thick U/R
Mtr s.
N/A N/A
N/A
N/A
300 mm wide ( ladder type), 4mm thick U/R
Mtr s.
N/A N/A
N/A
N/A
10.1.2 10.2
Perforated trays - GI
10.2.1
50 mm wide ( Perforated type), 4mm thick U/R
Mtr s.
N/A N/A
N/A
N/A
100 mm wide ( Perforated type ), 4mm thick U/R
Mtr s.
N/A N/A
N/A
N/A
10.2.2
Grand total
Remarks
Part signal tubing
of
153 | P a g e
IIT Bombay Tender Number – 201601548 Sr. No.
Description
Installation Qty
Unit UR
Total
Calibration Loop check UR
Total
& Supervision of installation Supply UR
Total
10.3
150mm wide Tray fittings, 4mm thick
10.3.1
150mm wide 90 deg. horizontal bend, R=300 mm U/R
No s.
N/A N/A
N/A
N/A
150mm wide 90 deg. vertical outside bend, R=300 mm U/R
No s.
N/A N/A
N/A
N/A
No s.
N/A N/A
N/A
N/A
No s.
N/A N/A
N/A
N/A
No s.
N/A N/A
N/A
N/A
10.3.2 10.4
300mm wide Tray fittings, 4mm thick
10.4.1
300mm wide 90 deg. horizontal bend, R=300 mm U/R
10.5
100mm wide Tray fittings, 4mm thick ( Perforated )
10.5.1
100mm wide 90 deg. horizontal bend, R=300 mm U/R
10.6
50mm wide Tray fittings, 4mm thick ( Perforated )
10.6.1
50mm wide 90 deg. horizontal bend, R=300 mm U/R
Grand total
Remarks
154 | P a g e
IIT Bombay Tender Number – 201601548 Sr. No.
Description
Installation Qty
10.7
10.8
11.0 11.1 11.2 11.3
Unit UR
Total
Calibration Loop check UR
Total
& Supervision of installation Supply UR
Total
Coupler plates (3mm thk.) of suitable size for FRP trays along with SS hardware ( for ladder tray, total 4nos. of coupler plates required for joining 2 trays) U/R
No s.
N/A N/A
N/A
N/A
Coupler plates (4mm thk.) of suitable size for FRP trays along with SS hardware ( for perforated tray, total 2nos. of coupler plates required for joining 2 trays) U/R
No s.
N/A N/A
N/A
N/A
Grand total
Remarks
Structural steel for supports - painting of structural steel including supply of paint and providing 3 coats of paints ( 1 coat primer and 2 coats finished ) for all structural works to be included in the scope of bidder. (refer typical mounting drawings) ISMC 100 x50, 1600 LG
U/R
Kgs .
N/A N/A
N/A
N/A
Base plate 250 x 250 6 thk
U/R
Kgs .
N/A N/A
N/A
N/A
ISA 65 x 65x 6 thk.
U/R
Kgs .
N/A N/A
N/A
N/A
As required
155 | P a g e
IIT Bombay Tender Number – 201601548 Sr. No.
11.4 11.5 11.6
11.7
11.8
11.9 11.10 11.11
Description
Installation Qty
Unit UR
Gusset plate 70 x 140 x 6 thk.
U/R
Kgs .
Earth bar Flat 50 x 6Thk, 50LG
U/R
Kgs .
Total
Calibration Loop check UR
Total
& Supervision of installation Supply UR
Total
N/A N/A
N/A
N/A
N/A N/A
N/A
N/A
Pipe (ERW), 2" NB, MS for instrument supports, 1400 long U/R
No s.
N/A N/A
N/A
N/A
Pipe (ERW), 2" NB, MS for instrument supports, 2000 Long U/R
No s.
N/A N/A
N/A
N/A
Pipe (ERW), 2" NB, MS for instrument supports, 2500 Long U/R
No s.
N/A N/A
N/A
N/A
U/R
No s.
N/A N/A
N/A
N/A
Anchor fasteners / bolts, M10, 40 mm Long U/R
No s.
N/A N/A
N/A
N/A
Plate 150 x 150 x 10 thk.
Kgs .
N/A N/A
N/A
N/A
Top plate 52.5 Dia 6 thk.
U/R
Grand total
Remarks
156 | P a g e
IIT Bombay Tender Number – 201601548 Sr. No.
11.12 11.13
12.0
Description
Plate 150 x 150 x 6 thk. Gusset plate 200 x 110 x 6 thk.
Installation Qty
Unit UR
U/R
Kgs .
U/R
Kgs .
Total
Calibration Loop check UR
Total
& Supervision of installation Supply UR
Total
N/A N/A
N/A
N/A
N/A N/A
N/A
N/A
Grand total
Remarks
FRP canopies FRP with UV stabilised, fire retardant properties, mounting of box - 2" pipe mount with SS hardware, colour - grey
12.1 12.2
13.0
FRP canopies for transmitters ( 4mm thick) U/R
No s.
N/A
N/A
N/A
N/A
FRP canopies for junction boxes / control boxes ( 4mm thick) U/R
No s.
N/A
N/A
N/A
N/A
Unit rates for supply of labour– Including all statutory dues and charges, food, accommodation, sanitary, potable water etc. arrangements etc. complete on per man-day basis of 10 hr. shift.
as required
(Including Tools, Accessories and Consumables like Teflon Tape etc.)
157 | P a g e
IIT Bombay Tender Number – 201601548 Sr. No.
Description
Installation Qty
Unit UR
Calibration Loop check
& Supervision of installation Supply
Total
UR
Total
UR
Total
Grand total
13.1
Instrument technician
N/A
N/A
N/A
N/A
N/A
N/A
13.2
Electrician
N/A
N/A
N/A
N/A
N/A
N/A
13.3
Instrument fitter
N/A
N/A
N/A
N/A
N/A
N/A
13.4
Welder
N/A
N/A
N/A
N/A
N/A
N/A
13.5
Helper
N/A
N/A
N/A
N/A
N/A
N/A
13.6
Supervisor
N/A
N/A
N/A
N/A
N/A
N/A
14.0
Information for the estimation of loop checking and interlock checking :- (Effort Cost to be included in various activities mentioned above) PLC I/O Count -
14.1
Analog inputs / outputs
73
no.
14.2
Digital inputs
8
no.
14.3
Digital outputs
8
no.
14.4
RTD / Thermocouple inputs
140
no.
15.0
Consumables & miscellaneous items ( Supply Cost to be included in various activities mentioned above) - quantity as required
Remarks
158 | P a g e
IIT Bombay Tender Number – 201601548 Sr. No.
Description
Installation Qty
Unit UR
Total
Calibration Loop check
& Supervision of installation Supply
UR
Total
UR
Total
15.1
Cutting gases
N/A
N/A
N/A
N/A
15.2
Welding electrodes
N/A
N/A
N/A
N/A
15.3
Soldering/ brazing materials
N/A
N/A
N/A
N/A
15.4
Sealing materials / Teflon tapes
N/A
N/A
N/A
N/A
15.5
Clamps/ cable & wire binders, crimping lugs for wires & earth wires
N/A
N/A
N/A
N/A
15.6
Nuts & bolts (SS) for fixing junction boxes, cable trays
N/A
N/A
N/A
N/A
15.7
Marking ferrules
N/A
N/A
N/A
N/A
15.8
Other items as required
N/A
N/A
N/A
N/A
16.0
Details of testing
16.1
Control valves - Leakage test of pneumatic connections.
Grand total
Remarks
159 | P a g e
IIT Bombay Tender Number – 201601548 Sr. No.
Description
Installation Qty
Unit UR
Total
Calibration Loop check UR
Total
& Supervision of installation Supply UR
Grand total
Remarks
Total
16.2
On / off valves – Functional checks and leakage test of pneumatic connections
16.3
Temperature elements:Testing of resistance / voltage change with temperature.
16.4
Pressure & differential pressure transmitter calibration check & functional check.
17.0
Painting of structural items (Instrument tray supports, stanchion, JB frames, air manifold frames etc.)---- 2 coats of primer with 2 coats epoxy paint, surface preparation with wire brush, shade of epoxy will be informed by site. TOTAL Bidder shall terminate field cables in system cabinets, shall coordinate with other for loop checking
Note:
Cable trays shall be required with coupler plates for 45 deg & 90 deg vertical inside & outside as well as for horizontal bends. Bidder to consider the cost in the cable tray rates for ladder & perforated cable trays along with nuts & bolt as required. The quantities mentioned for cables, cable tray & associated fittings, structural steel are based on instrument location plans/ tray layout plant. Bidder to verify the site condition & crosscheck the quantity as required before supplying.
160 | P a g e
IIT Bombay Tender Number – 201601548
161 | P a g e
IIT Bombay Tender Number – 201601548
E. Schedule of quantities – Molten Salt, selective coating and heat transfer compound Sr. No.
Item Description
1
Molten salt
1 .1
Procurement and supply to site and storage thereof at site until directed to use, molten salt as per specification and approval in suitable pack such as to properly maintain the salt properties as per specifications. 20
MT
Lifting, shifting, transport of the salt from storage to molten salt storage tank and unloading the salt into the molten salt storage tank as directed with all required precautions to avoid any contamination of the salt during the entire process. Disposal of the molten salt packaging outside the premises will be the vendor’s responsibility. This process may be intermittent and may be carried out over several days as directed by engineer incharge. 1
LS
1.2
1.3 1.3.1 1.3.2
Qty
Unit
Unit Rate
Amount
Rs.
Rs.
Labour supply rate for salt handling other than that covered in the above items unskilled labour supervisor
UR
manhr
UR
manhr
gal
2
Selective coating
2.1
Selective coating
3
2.2
Thinner(xylene)
As required
2.3
Trichloroethane, methyl ethyl ketone(butanone)
As required
3
Heat transfer compound
3.1
Heat transfer compound/cement
12
Gal
162 | P a g e
IIT Bombay Tender Number – 201601548
Sr. No.
Item Description
3.2
Stainless steel channels flexible width = 51mm; height = 25 mm; length = 1.2m 25
No.
3.3
Stainless steel channels width = 30 mm; height= 21 mm; length = 1.2m 150
No.
3.4
Stainless steel banding
120
m
3.5
Stainless steel tie wire
200
m
Qty
Unit
Qty
Unit
Unit Rate
Amount
Rs.
Rs.
Unit Rate
Amount
Rs.
Rs.
F. Schedule of quantities – Spares Sr. No.
Item Description
1
Reference Item B.1, receiver coils
a
receiver coil, 1,100 mm OD, inlet 0.5m outside receiver, outlet 800mm long 2
no.
receiver coil, 700 mm ODl, inlet 500mm long, outlet 0.5m outside receiver 1
no.
b 2
Spares for MSP1
a
Impeller, SS316L
1
No.
b
Stuffing box sleeve, hard faced, SS316L
1
No.
c
Stuffing box bush, hard faced, SS316L
1
No.
d
Spider sleeve, SS316L
3
No.
e
Spider bush, SS316L
3
No.
f
Gasket set, graphite
1
Set
g
Hardware set
1
Set
h
Pump, motor bearing set
1
Set
i
Coupling, Disco Flex
1
No.
163 | P a g e
IIT Bombay Tender Number – 201601548
Sr. No.
Item Description
Qty
Unit
j
Shaft, SS 316
1
No.
3
Spares for MSP2
a
Impeller, SS316L
1
No.
b
Stuffing box sleeve, hard faced, SS316L
1
No.
c
Stuffing box bush, hard faced, SS316L
1
No.
d
Spider sleeve, SS316L
3
No.
e
Spider bush, SS316L
3
No.
f
Gasket set, graphite
1
Set
g
Hardware set
1
Set
h
Pump, motor bearing set
1
Set
i
Coupling, Disc-o-flex
1
No.
j
Shaft, SS 316
1
No.
4
Spares for FWP-1, FWP-2
a
Plunger, SS316L
3
No.
b
Stuffing box packing
3
set
c
Drive Belt
4
No.
d
NRV, SS 304
1
set
e
Pump, motor bearing set
1
Set
f
Drive chain with locks, in lieu of c
2
set
g
Gear oil
5
ltr
5
Spares for DM water pump
a
Impeller, CS
1
No.
b
Stuffing box packing
2
No.
c
Pump, motor bearing set
1
Set
d
coupling elastomer
3
No.
Unit Rate
Amount
Rs.
Rs.
164 | P a g e
IIT Bombay Tender Number – 201601548
Sr. No.
Item Description
6
Spares for cooling water circulation pump
a
Qty
Unit
Impeller, CS
1
No.
b
Stuffing box packing
2
No.
c
Pump, motor bearing set
1
Set
d
coupling elastomer
3
No.
e
Spider bush, SS316L
3
No.
Unit Rate
Amount
Rs.
Rs.
Common Spare pump for DM water and cooling water 7
Spare valves
a
Same as B.8.a
2
No.
b
Same as B.8.b
1
No.
c
Same as B.8.c
1
Set
d
Same as B.8.d
1
No.
e
Same as B.8.e
1
No.
f
coil, spring and seat for B.8.f
2
set
g
spring, disc and seat for B.8.g
1
set
h
spring, disc and seat for B.8.h
1
set
i
spring, disc and seat for B.8.i
1
set
j
Same as B.8.j
2
No.
k
Same as B.8.k
1
No.
l
Discs and spring for B.8.l
1
set
m
spring, disc and seat for B.8.m
1
set
n
Seats and seals for B.8.n
2
set
o
Seats and seals for B.8.o
1
set
p
Seats and seals for B.8.p
1
set
165 | P a g e
IIT Bombay Tender Number – 201601548
Sr. No.
Item Description
Qty
Unit
q
spring, disc and seat for B.8.q
1
set
r
spring, disc and seat for B.8.r
1
Set
8
Spares for instrument air plant
a
inlet, outlet air and oil filters
4
set
b
Compressor oil
20
ltr.
c
Belts
2
Set
d
Auto drain valve
1
No.
e
Spider bush, SS316L
3
No.
9
LP & HP dosing system, each
a
filters
4
set
b
Discharge pump
1
No.
c
Belts
2
Set
d
Auto drain valve
1
No.
e
Spider bush, SS316L
3
No.
10
Radiator based cooling system
a
inlet, outlet hoses with hose clamps etc.
1
set
b
fan impeller with motor
1
No.
11
Electric hoists
a
3 years operation and maintenance spares
1
set
12
Instrumentation system
a
PLC, Digital input module, of each type
1
No
b
PLC, Digital output module, of each type
1
No.
c
PLC, Analog input module, of each type
1
No.
d
PLC, Analog output module, of each type
1
No.
Unit Rate
Amount
Rs.
Rs.
166 | P a g e
IIT Bombay Tender Number – 201601548
Sr. No. e
Item Description
Qty
Unit
Amplifier Card for pressure/ DP transmitter of each type 1
No.
Amplifier Card for temperature transmitter of each type 1
No.
Integral LCD Display unit ( minimum 1 no. of each type ) 2
No.
O-rings for Electronic Transmitters ( minimum 2 nos. of each type ) 10
No.
i
SPDT Switch for Level Switch
1
No.
j
Multipoint Thermocouple Element
1
set.
k
Pressure Gauge
1
No.
l
Rotameter of each type & range
1
No.
m
Thermocouple Element
1
No.
n
Receiver thermocouple elements
2
sets
o
Fuse Links, Packet of 10 nos. of each type & rating
1
Pkt
p
Lamps, Push Buttons & Selector Switches of each type 1
No.
f g h
of each type & range
of each type
13
Electrical items
a
Cable compression type cable glands for following sizes, 10% of each type and size or 6 nos. whichever is more 1
Lot
Light Fixtures, 10% of each type and size or 1 no. whichever is more 1
Lot
b c
Switchgear etc.
i
Contactors of all types and ratings, 10% of each total qty or 1 no. each whichever is more
ii
1
LS
MCCBs, MCBs of all types and ratings, 10% of each total qty or 1 no. of each whichever is more 1
LS.
Unit Rate
Amount
Rs.
Rs.
167 | P a g e
IIT Bombay Tender Number – 201601548
Sr. No. iii iv v
Item Description
Qty
Unit
Relays of all types and ratings, 10% of each total qty or 1 no. of each whichever is more
1
LS.
LED lamps, Switches, pushbuttons, 10% of each total qty or 1 no. of each whichever is more
1
LS.
CTs of each types and ratings, 10% of each total qty or 3 nos whichever is more. 1
LS.
d
Meters, testers
i
Auto-ranging digital clamp meter –Meco Model : 3600 - 1200A DC & 1000A AC(TRMS), 3¾ Digit 3999 Counts, 40 Segment Bargraph, Auto Ranging, Peak hold, Max, Zero, Data hold functions, APO, accessories or equivalent 2
No.
Auto-ranging Digital Multimeters – TRMS Super & all accessories 4-1/2 Digits 20,000 Counts or equivalent 2
No.
Multifunction process calibrator, Meco model 333 and all accessories or equivalent 2
No.
Digital Earth Tester, Meco Model : DET 2016 with all accessories or equivalent 2
No.
Battery meter – Meco BM 63 with all accessories or equivalent 2
No.
Veerobot TLS-SLD-SLDR-77, Soldron 50W, Soldering Kit, 1 x 50W Original Soldron Soldering Iron in VEEROBOT branded box, 1 x Solder Stand, 1 x 50 Gram Solder Wire, 1 x White High Quality Flux, complete 2
No.
e
UPS spares as per OEM recommendation
1
LS
14
General Consumables
a
Multi-purpose Grease 2, Balmer Laurie
1
kg
b
Cotton hosiery waste, 50 kg bags
100
kg
c
Cotton yarn waste, white, 50 kg bags
100
kg
d
Hydrazine Hydrate, 35% in 25 kg packs
1500
kg
ii
iii iv v vi
Unit Rate
Amount
Rs.
Rs.
168 | P a g e
IIT Bombay Tender Number – 201601548
Sr. No.
Item Description
Qty
Unit
e
TSP, Assay > 98%, P2O5 content > 17.5%
1
kg
15
Digital water hardness tester, accuracy
2
No.
16
Hand operated , hydraulic Pallet Truck 2.5 Ton capacity, steel powder coated, with heavy duty polymer castor wheels, 2 nos brake wheels 1
No.
17
Heavy duty, handheld industrial platform ( 72cm x 48cm ) trolley, steel powder coated, 5” heavy duty polymer castor wheels, 150 kg load, 2 nos brake wheels
18
Supreme 515 x 310 x 200 mm Premium Plastic BIN-50, or equivalent
19 20
21
22 23
25
Unit Rate
Amount
Rs.
Rs.
No.
Supreme Plastic Pallet SIM 1210120 PDD LW 1200x1000x125 mm, or equivalent 5
No.
Electronic weighing balance 1000gm x 0.1g, autozero, auto-taring, auto standby, LED display, 100g beaker. 1
No.
Electronic heavy duty platform weighscale stainless steel construction, 100kg x 10g. LED display 1
No.
Polyester, 3 Mtrs, 2 Ton, Double Ply Webbing Slings Flat Belt 2
No.
4’ x 2’ table, steel structure with laminated plywood top, reclinable, fabric covered cushioned chairs with PU arms-rest and castors, for stores etc. 3
No.
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Section – 8: Annexures
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Annexure 1: Drawing list
Sr No.
Document No.
Rev. Document Title
1
C530/PI/PFD/A3/001
R0
Process Flow Diagram
2
C530/PI/GA/A0/005
R0
Piping Layout
3
C530/PI/GA/A1/006
R0
Piping Layout - Section
4
C530/GEN/SK/A1/011
P0
Receiver Heater Assembly Schematic
5
C530/PI/PID/A1/012
R0
P & ID For Raw Water & DM Water For Molten Salt Loop
6
C530/GEN/SK/A4/015
R0
Schematic for Steam Tracing of Molten Salt Line
7
C530/ST/GA/A1/202
R0
G.A & Fabrication details of Pipe supports
8
C530/ME/GA/A1/304
R0
G.A. of Fabrication Details of superheater
9
C530/ME/GA/A1/305 Sheet-1
R0
G.A. of Fabrication Details of Evaporator
10
C530/ME/GA/A1/305 Sheet-2
R0
Fabrication Details of Evaporator
11
C530/ME/GA/A1/306
R0
G.A. of Fabrication Details of Preheater
12
C530/ME/GA/A1/307
R0
Vent Pot
13
C530/ME/FB/A1/308
R0
G.A. of Receiver Structural
14
C530/ME/GA/A1/309 Sheet 1 of 2
P0
Receiver Tower Equipment Layout
15
C530/ME/GA/A1/309 Sheet 2 of 2
P0
Receiver section
16
C530/ME/GA/A4/314
R0
Fabrication details of Feed Water Tank
17
C530/ME/GA/A1/321
P0
Receiver heater mechanism
18
C530/EL/SLD/A1/402
R0
Single Line Diagram for molten salt loop
19
C530/EL/GA/A1/403
R0
Cable Tray Layout
20
C530/EL/GA/A2/404
R0
Earthing Layout
21
C530/EL/GA/A1/405
R0
Lighting Layout
Tower
Equipment
Layout
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Sr No.
Document No.
Rev. Document Title
22
C530/EE/GA/A4/414
R0
Electrical Preheater
23
C530/I&C/HD/A4/528 sheet 1 of 14
R0
Process & Air Hook-up Diagrams for flow transmitter wedge element + DP TX
24
C530/I&C/HD/A4/528 sheet 2 of 14
R0
Process & Air Hook-up Diagrams for level transmitter, bubble type.
25
C530/I&C/HD/A4/528 sheet 3 of 14
R0
Process & Air Hook-up Diagrams for level transmitter diaphragm seal
26
C530/I&C/HD/A4/528 sheet 4 of 14
R0
Process & Air Hook-up Diagrams for level transmitter diaphragm seal
27
C530/I&C/HD/A4/528 sheet 5 of 14
R0
Process & Air Hook-up Diagrams for level transmitter diaphragm seal
28
C530/I&C/HD/A4/528 sheet 6 of 14
R0
Process & Air Hook-up Diagrams for pressure transmitter diaphragm seal
29
C530/I&C/HD/A4/528 sheet 7 of 14
R0
Process & Air Hook-up Diagrams for Pressure transmitters steam service
30
C530/I&C/HD/A4/528 sheet 8 of 14
R0
Process & Air Hook-up Diagrams for pressure transmitters gas service
31
C530/I&C/HD/A4/528 sheet 9 of 14
R0
Process & Air Hook-up Diagrams for pressure gauge with diaphragm seal
32
C530/I&C/HD/A4/528 sheet 10 of 14 R0
Process & Air Hook-up Diagrams for pressure gauge with snubber
33
C530/I&C/HD/A4/528 sheet 11 of 14 R0
Process & Air Hook-up Diagrams for pressure gauge with syphon
34
C530/I&C/HD/A4/528 sheet 12 of 14 R0
Process & Air Hook-up Diagrams for pressure gauge
35
C530/I&C/HD/A4/528 sheet 13 of 14 R0
Process & Air Hook-up Diagrams for E/P positioner control valve
36
C530/I&C/HD/A4/528 sheet 14 of 14 R0
Process & Air Hook-up Diagrams for ONOFF Valve
37
C530/I&C/LD/A4/529
Instrument Location Plan and Cable tray Layout
R0
Heater
Assembly
before
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Annexure 2: Document List Sr. No. Document No.
Rev. Document Title
1
C530/PI/DS/A4/018
P0
Specification for Globe Valve for Steam
2
C530/PI/DS/A4/019
P0
Specification for Non slam check valve for Steam
3
C530/PI/DS/A4/020
P0
Specification for Steam Trap
4
C530/PI/MTO/A4/021
R0
Piping MTO
5
C530/GEN/DS/A4/022
P0
Technical specifications of Molten Salt
6
C530/PI/DS/A4/023
R0
Water Meter
7
C530/PI/DS/A4/024
P0
Specification for Carbon Steel Ball Valve Cooling water line
8
C530/PI/DS/A4/025
P0
Specification for Non slam check valve – Cooling Water Line
9
C530/PI/DS/A4/026
P0
Specification for Y type Strainer – Cooling Water Line
10
C530/PI/DS/A4/027
P0
Specification for True Union Ball Check Valve (CPVC)
11
C530/PI/DS/A4/028
P0
Specification for CPVC Ball Valve
12
C530/PI/DS/A4/029
P0
Specification for Y type Strainer (CPVC)
13
C530/PI/DS/A4/030
P0
Specification for UPVC Ball Valve - Raw water Line
14
C530/PI/DS/A4/031
P0
Specification for Y type Strainer (CPVC) – Soft Water
15
C530/PI/DS/A4/032
P0
Specification for Float valve – Soft water Line
16
C530/PI/DS/A4/033
P0
Specification for UPVC Ball Valve – Soft Water Line
17
C530/PI/DS/A4/034
P0
Specification for Non slam check valve – UPVC
18
C530/PI/DS/A4/035
P0
Specification for Ball Valve for Hot Water
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Sr. No. Document No.
Rev. Document Title
19
C530/PI/DS/A4/036
P0
Specification for Non slam check valve – Hot Water Line
20
C530/PI/DS/A4/037
P0
Specification for Y type Strainer – Hot Water Line
21
C530/PI/DS/A4/038
P0
Specification for Globe Valve - Molten Salt Line
22
C530/PI/DS/A4/039
P0
Specification for Non slam check valve – Molten Salt
23
C530/PI/DS/A4/040
P0
Specification for Pressure relief Valve – Molten salt
24
C530/ME/DS/A4/310
P0
Specification Molten Salt Pump for Cold Circuit
25
C530/ME/DS/A4/311
P0
Specification Molten Salt Pump for Hot Circuit
26
C530/ME/DS/A4/312
P0
Specification of Boiler feed water pumps
27
C530/ME/DS/A4/313
P0
Specification of Cooling water pumps
28
C530/EL/LL/A4/401
R0
Electrical load list
29
C530/EE/CS/A4/406
R0
Cable Schedule
30
C530/EE/SP/A4/407
R0
Technical specification for MCC / Electrical Control Panel / Distribution Boards/ Battery, Inverter and Power pack
31
C530/EE/SP/A4/408
R0
Technical specification for UPS & Battery
32
C530/EE/SP/A4/410
R0
Technical Specification for AC Motors
33
C530/EE/SP/A4/411
R0
Technical specification for supply of Bulk & Erection material including cable, earthing, lighting, cable trays, glands, lugs
34
C530/EE/DS/A4/413
R0
Technical Datasheet for Electrical Heater
35
C530/I&C/IN/A4/501
R0
Instrument Index
36
C530/I&C/IN/A4/502
R0
Cable Schedule
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Sr. No. Document No.
Rev. Document Title
37
C530/I&C/IN/A3/503
R0
Control System I/O List
38
C530/I&C/SP/A4/504
P0
Specification Transmitter
39
C530/I&C/SP/A4/505
P0
Specification for Temperature Transmitter
40
C530/I&C/SP/A4/506
R0
Flow Element (Wedge type)
41
C530/I&C/SP/A4/508
R0
Specification for Pressure gauge
42
C530/I&C/SP/A4/509
R0
Specification for Dial Thermometer
43
C530/I&C/SP/A4/510
R0
Specification for Level Switch
44
C530/I&C/SP/A4/511
R0
Specification for Level gauge
45
C530/I&C/SP/A4/512
R0
Specification for Multipoint Temperature Element
46
C530/I&C/SP/A4/513
P0
Specification for Globe type control valve
47
C530/I&C/SP/A4/514
P0
Specification for On-Off valve
48
C530/I&C/SP/A4/515
P0
Specification for Safety Relief Valve
49
C530/I&C/SP/A4/516
R0
Specification for Instrument cable
50
C530/I&C/SP/A4/517
R0
Specification for Instrument Junction Box
51
C530/I&C/SP/A4/518
R0
Specification for Instrument Cable Gland
52
C530/I&C/SP/A4/519
R0
Specification for Instrument Cable Tray
53
C530/I&C/SP/A4/520
R0
Specification for Instrument Tubing and
54
C530/I&C/SP/A4/521
P0
Solenoid valve
55
C530/I&C/SP/A4/522
R0
Vortex Flowmeter Datasheet
56
C530/I&C/SP/A4/523
R0
Rotameter Datasheet - Molten Salt
57
C530/I&C/SP/A4/524
R0
Specification for PLC based Control System
58
C530/I&C/SP/A4/525
R0
Specification for Instrument Installation Contract
59
C530/I&C/LD/A3/527
R0
Cause & Effect Charts
for
Pressure
and
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DP
IIT Bombay Tender Number – 201601548
Sr. No. Document No.
Rev. Document Title
60
C530/I&C/WD/A3/526
R0
Loop Wiring Diagram
61
C530/UT/DS/A4/601
R0
Data Sheet for Dosing System
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Annexure 3: Deviation Statement Form Following are the Technical deviations and variations from the Technical specifications S. No.
Item
Statement of deviations/variations
The following are the particulars of the deviations from the requirements of the tender document terms and conditions: S. No.
Item
Statement of deviations/variations
These deviations and variations are exhaustive. Except these deviations and variations, the entire work shall be performed as per your specifications and documents.
Signature of bidder Date Note:
The technical compliance/deviation should be supported by relevant technical literature. If specification in Superior/inferior than asked for the enquiry, it should be clearly brought out in the justification. If the bidder offers more than one model, then the technical compliance statement must be enclosed for each and every model separately.
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Annexure 4: Integrity pact
(To be printed on Supplier's letterhead) INTEGRITY PACT General This pre-bid pre-contract Agreement hereinafter called the Integrity Pact is made on ............................ day of the month of .................................. , between, on one hand, the President of India acting through Joint Registrar, Materials Management Division of Indian Institute of Technology, Bombay hereinafter called the “BUYER” of the First Part and M/s.......................................................................................................represented by Shri ...............................................................,Director /Chief Executive Officer/ General Manager hereinafter called the “BIDDER/Seller” of the Second Part.
WHEREAS the BUYER proposes to procure ................................................................................................. (Name of the Stores/Equipment/Item) and the BIDDER/Seller is willing to offer/has offered the stores and WHEREAS the BIDDER is a private company/public company/Government undertaking/partnership/registered export agency, constituted in accordance with the relevant law in the matter and the BUYER is an Autonomous Body/Department of the Government of India performing its functions on behalf of the President of India.
NOW, THEREFORE, to avoid all forms of corruption by following a system that is fair, transparent and free from any influence/prejudiced dealings prior to, during and subsequent to the currency of the contract to be entered into with a view to :-Enabling the BUYER to obtain the desired said stores / equipment at a competitive price in conformity with the defined specifications by avoiding the high cost and the distortionary impact of corruption on public procurement, and Enabling BIDDERs to abstain from bribing or indulging in any corrupt practice in order to secure the contract by providing assurance to them that their competitors will also abstain from bribing and other corrupt practices and the BUYER will commit to prevent corruption, in any form, by its officials by following transparent procedures. The parties hereto hereby agree to enter into this Integrity Pact and agree as follows:
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Commitments of the BUYER 1.1 The BUYER undertakes that no official of the BUYER, connected directly or indirectly with the contract will demand, take a promise for or accept, directly or through intermediaries, any bribe, consideration, gift, reward, favour or any material or immaterial benefit or any other advantage from the BIDDER, either for themselves or for any person, organization or third party related to the contract in exchange for an advantage in the bidding process, bid evaluation, contracting or implementation process related to the Contract. 1.2 The BUYER will, during the pre-contract stage, treat all BIDDERs alike, and will provide to all BIDDERs the same information and will not provide any such information to any particular BIDDER which could afford an advantage to that particular BIDDER in comparison to other BIDDERs. 1.3 All the officials of the Buyer will report to the appropriate Government office any attempted or completed breaches of the above commitments as well as any substantial suspicion of such a breach.
1. In case any such preceding misconduct on the part of such official (s) is reported by the BIDDER to the BUYER, with full and verifiable facts and the same is prima facie found to be correct by the BUYER, necessary disciplinary proceedings, or any other action as deemed fit, including criminal proceedings may be initiated by the BUYER and such a person shall be debarred from further dealings related to the contract process. In such a case while an enquiry is being conducted by the BUYER the proceedings under the contract would not be stalled. Commitments of BIDDERs: 2. The BIDDER commits itself to take all measures necessary to prevent corrupt practices, unfair means and illegal activities during any stage of its bid or during any pre-contract or post-contract stage in order to secure the contract or in furtherance to secure it and in particular commit itself to the following: 3.1. The BIDDER will not offer, directly or through intermediaries, any bribe, consideration, gift, reward, favour, any material or immaterial benefit or other advantage, commission, fees, brokerage or inducement to any official of the BUYER, connected directly or indirectly with the bidding process, or to any person, organization or third party related to the contract in exchange for any
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advantage in the bidding, evaluation, contracting and implementation of the Contract. 3.2. The BIDDER further undertakes that it has not given, offered or promised to give, directly or indirectly any bribe, gift, consideration, reward, favour, any material or immaterial benefit or other advantage, commission, fees, brokerage or inducement to any official of the BUYER or otherwise in procuring the Contract or forbearing to do or having done any act in relation to the obtaining or execution of the Contract or any other Contract with the Government for showing or forbearing to show favour or disfavour to any person in relation to the Contract or any other Contract with the Government. 3.3. BIDDERs shall disclose the name and address of agents and representatives and Indian BIDDERs shall disclose their foreign principals or associates. 3.4. BIDDERs shall disclose the payments to be made by them to agents / brokers or any other intermediary, in connection with this bid/contract. 3.5. The BIDDER further confirms and declares to the BUYER that the BIDDER is the original manufacturer/ integrator/ authorized government sponsored export entity of the defense stores and has not engaged any individual or firm or company whether Indian or foreign to intercede, facilitate or in any way to recommend to the BUYER, or any of its functionaries, whether officially or unofficially to the award of the contract to the BIDDER, nor has any amount been paid, promised or intended to be paid to any such individual, firm or company in respect of any such intercession, facilitation or recommendation. 3.6. The BIDDER, either while presenting the bid or during pre-contract negotiations or before signing the contract, shall disclose any payments he has made, is committed to or intends to make to officials of the BUYER or their family members, agents, brokers or any other intermediaries in connection with the contract and the details of services agreed upon for such payments. 3.7. The BIDDER will not collude with other parties interested in the contract to impair the transparency, fairness and progress of the bidding process, bid evaluation, contracting and implementation of the contract. 3.8. The BIDDER will not accept any advantage in exchange for any corrupt practice, unfair means and illegal activities. 3.9. The BIDDER shall not use improperly, for purposes of competition or personal gain, or pass on to others, any information provided by the BUYER as part of the business relationship, regarding plans, technical proposals and business details, including information contained in any electronic data carrier. The BIDDER also 180 | P a g e
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undertakes to exercise due and adequate care lest any such information is divulged. 3.10. The BIDDER commits to refrain from giving any complaint directly or through any other manner without supporting it with full and verifiable facts. 3.11. The BIDDER shall not instigate or cause to instigate any third person to commit any of the actions mentioned above. 3.12. If the BIDDER or any employee of the BIDDER or any person acting on behalf of the BIDDER, either directly or indirectly, is a relative of any of the officers of the BUYER, or alternatively, if any relative of an officer of the BUYER has financial interest/stake in the BIDDER's firm, the same shall be disclosed by the BIDDER at the time of filing of tender. The term relative for this purpose would be as defined in Section 6 of the Companies Act 1956. 3.13. The BIDDER shall not lend to or borrow any money from or enter into any monetary dealings or transactions, directly or indirectly, with any employee of the BUYER.
4. Previous Transgression 4.1. The BIDDER declares that no previous transgression occurred in the last three years immediately before signing of this Integrity Pact, with any other company in any country in respect of any corrupt practices envisaged hereunder or with any Public Sector Enterprise in India or any Government Department in India that could justify BIDDER's exclusion from the tender process. 4.2. The BIDDER agrees that if it makes incorrect statement on this subject, BIDDER can be disqualified from the tender process or the contract, if already awarded, can be terminated for such reason. 5. Earnest Money Deposit 5.1. Earnest Money Deposit is mandatory to be enclosed in the tender. 5.2. While submitting bid, the BIDDER shall deposit an amount mentioned in tender document as Earnest Money, with the IIT Bombay through the following instruments: 181 | P a g e
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A confirmed Bank Guarantee by an Indian Nationalized Bank promising payment of the guaranteed sum to the BUYER on demand within three working days without any demur whatsoever and without seeking any reasons whatsoever. The demand for payment by the IIT Bombay shall be treated as conclusive proof of payment. The Earnest Money shall be valid upto a period of 180 days or the complete conclusion of the contractual obligations to the complete satisfaction of both the BIDDER and the BUYER whichever is later.
No interest shall be payable by the BUYER to the BIDDER on Earnest Money for the period of its currency.
If successful bidder fails to submit the Performance Guarantee Bond within 30 days from the date of placing of Purchase Order then purchase order will be canceled and EMD will be forfeited.
If there is any difficulty in submitting Bank Guarantee then Demand draft can be submitted in the favour of 'The Registrar, IIT Bombay' payable at Mumbai.
Return of EMD: In case of successful BIDDER, EMD in the form of Bank guarantee will be returned within 30 days from the date of submission of Performance Guarantee Bond.
For unsuccessful bidder, Bank Guarantee will be returned within 30 days from the date of placing the Purchase Order.
In case of Demand Draft, amount of EMD will be returned within 60 days from the date of placing the purchase order.
6. SECURITY DEPOSIT /PERFORMANCE GUARANTEE: 6.1. Performance Guarantee Bond is mandatory. 6.2. Successful tenderer/ bidder should submit performance guarantee as prescribed above to be sent to Joint Registrar, Materials management Division, IIT Bombay on or before 15 days from the due date of issue of order acknowledgment. The PGB to
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be furnished in the form of bank guarantee as per proforma or annexure of the tender documents, for an amount covering 10 % of the purchase order value.
The Performance Guarantee should be established in favour of “Registrar, IIT Bombay”. PBG to be established through any of the National Banks (whether situated at Mumbai or outstation) with a clause to enforce the same on their local branch of Mumbai or any scheduled bank (other than national bank) situated at Mumbai. Bonds issued by co-operative banks will not be accepted.
Performance Guarantee Bond shall be for the due and faithfully performance of the contract and shall remain binding, notwithstanding such variations, alterations for extensions of time as may be made, given, conceded or agreed to between the successful tenderer and the purchaser under the terms & conditions of acceptance to the tender.
The successful tenderer is entirely responsible for due performance of the contract in letter and spirit and all other documents referred to in the acceptance of tenders.
The PBG shall be kept valid during the period of contract and shall continue to be enforceable for a period of two years or upto warranty period whichever is later from the date of order acknowledge. In case PBG needs extensions upto extension period then supplier shall initiate extensions to PBG one month prior to expiry of PBG.
For successful suppliers, if PBG is not submitted within 15 days from the date of Order Acknowledgement, then the Purchase Order will be cancelled with forfeiting of EMD.
No interest shall be payable by the buyer to the Bidder on PBG.
7. Sanctions for Violations 7.1. Any breach of the aforesaid provisions by the BIDDER or any one employed by it or acting on its behalf (whether with or without the knowledge of the BIDDER) shall entitle the BUYER to take all or any one of the following actions, wherever required: -
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i.
To immediately call off the pre-contract negotiations without assigning any reason or giving any compensation to the BIDDER. However, the proceedings with the other BIDDER(s) would continue.
ii.
The Earnest Money Deposit (in pre-contract stage) and/or Security Deposit/Performance Bond (after the contract is signed) shall stand forfeited either fully or partially, as decided by the BUYER and the BUYER shall not be required to assign any reason therefore.
iii.
To immediately cancel the contract, if already signed without giving any compensation to the BIDDER.
iv.
To recover all sums already paid by the BUYER, and in case of an Indian BIDDER with interest thereon at 2% higher than the prevailing Prime Lending Rate of State Bank of India, while in case of a BIDDER from a country other than India with interest thereon at 2% higher than the LIBOR. If any outstanding payment is due to the BIDDER from the BUYER in connection with any other contract for any other stores, such outstanding payment could also be utilized to recover the aforesaid sum and interest.
v.
To encash the advance bank guarantee and performance bond/warranty bond, if furnished by the BIDDER, in order to recover the payments, already made by the BUYER, along with interest.
vi.
To cancel all or any other Contracts with the BIDDER. The BIDDER shall be liable to pay compensation for any loss or damage to the BUYER resulting from such cancellation/rescission and the BUYER shall be entitled to deduct the amount so payable from the money(s) due to the BIDDER.
vii.
To debar the BIDDER from participating in future bidding processes of the Government of India for a minimum period of two years, which may be further extended at the discretion of the BUYER.
viii.
To recover all sums paid in violation of this pact by the BIDDER(s) to any middleman or agent or broker with a view to securing the contract.
ix.
In cases where irrevocable Letters of Credit have been received in respect of any contract signed by the BUYER with the BIDDER, the same shall not be opened.
x.
Forfeiture of Performance Bond in case of a decision by the BUYER to forfeit the same without assigning any reason for imposing sanction for violation of this Pact. 184 | P a g e
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7.2. The BUYER will be entitled to take all or any of the actions mentioned at para 7.1(i) to (x) of this Pact also on the Commission by the BIDDER or any one employed by it or acting on its behalf (whether with or without the knowledge of the BIDDER), of an offence as defined in Chapter IX of the Indian Penal code, 1860 or Prevention of Corruption Act 1988 or any other statute enacted for prevention of corruption. 7.3. The decision of the BUYER to the effect that a breach of the provisions of this Pact has been committed by the BIDDER shall be final and conclusive on the BIDDER. However, the BIDDER can approach the independent Monitor(s) appointed for the purposes of this Pact.
8. Fall Clause
8.1. The BIDDER undertakes that it has not supplied/is not supplying similar product/systems or subsystems at a price lower than that offered in the present bid in respect of any other Ministry/ Department of the Government of India or PSU and if it is found at any stage that similar product/system or sub-system was supplied by the BIDDER to any other Ministry/Department of the Government of India or PSU at a lower price, then that very price, with due allowance for elapsed time, will be applicable to the present case and the difference in the cost would be refunded by the BIDDER to the BUYER, if the contract has already been concluded. 9. Independent monitors
9.1. The BUYER has appointed Independent Monitors (hereinafter referred to as Monitors) for this Pact in consultation with the Central Vigilance Commission (Chief Vigilance Officer, Indian Institute of Technology, Bombay). 9.2. The task of the Monitor shall be to review independently and objectively, whether and to what extent the parties comply with the obligations under this Pact. 9.3. The Monitor shall not be subject to instructions by the representatives of the parties and performs their functions neutrally and independently. 9.4. Both the parties accept that the Monitor have the right to access all the documents relating to the project/procurement, including minutes of the meetings. 185 | P a g e
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9.5. As soon as the Monitor notices, or believes to notice, a violation of this Pact, he will so inform the Authority designated by the BUYER. 9.6. The BIDDER(s) accepts that the Monitor has the right to access without restriction to all Project documentation of the BUYER including that provided by the BIDDER. The BIDDER will also grant the Monitor, upon his request and demonstration of a valid interest, unrestricted and unconditional access to his project documentation. The same is applicable to Subcontractors. The Monitor shall be under contractual obligation to treat the information and documents of the BIDDER/Subcontractor(s) with confidentiality. 9.7. The BUYER will provide to the Monitor sufficient information about all meetings among the parties related to the Project provided such meetings could have an impact on the contractual relations between the parties. The parties will offer to the Monitor the option to participate in such meetings. 9.8. The Monitor will submit a written report to the designated Authority of BUYER/ Secretary in the Department/within 8 to 10 weeks from the date of reference or intimation to him by the BUYER / BIDDER and, should the occasion arise, submit proposals for correcting problematic situations.
10. Facilitation of Investigation In case of any allegation of violation of any provisions of this Pact or payment of commission, the BUYER or its agencies shall be entitled to examine all the documents including the Books of Accounts of the BIDDER and the BIDDER shall provide necessary information & documents in English and shall extend all possible help for the purpose of such examination. 11. Law and Place of Jurisdiction This Pact is subject to Indian Law. The place of performance and Jurisdiction is the Seat of the BUYER. 12. Other Legal Actions The actions stipulated in this Integrity Pact are without prejudice to any other legal action that may follow in accordance with the provisions of the extant law in force relating to any civil or criminal proceedings. 13. Validity 186 | P a g e
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13.1 The validity of this Integrity Pact shall be from date of its signing and extend upto 5 years or the complete execution of the contract to the satisfaction of both the BUYER and the BIDDER/ Seller, including warranty period, whichever is later. In case BIDDER is unsuccessful, this Integrity Pact shall expire after six months from the date of the signing of the contract. 13.2 Should one or several provisions of this Pact turn out to be invalid, the remainder of this Pact remains valid. In this case, the parties will strive to come to an agreement to their original intentions.
14. The Parties hereby sign this Integrity Pact.
BUYER
BIDDER
Joint Registrar (MMD), IIT Bombay
Signature with seal
Date & Place:
Date & Place:
Witness
Witness
1. _______________________ (Indenter)
1. _________________________
2. ______________________ ______________________
2.______________________ _____________________
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Annexure 5: Format for earnest money deposit/bid bond (To be typed on Non-judicial stamp paper of the value of Indian Rupees of One Hundred) (to be established through any of the nationalized banks (whether situated at Mumbai or outstation) with a clause to enforce the same on their local branch at Mumbai or any scheduled bank (other than nationalised bank) situated at Mumbai. Bonds issued by cooperative banks are not accepted)
LETTER OF GUARANTEE To, Registrar, Indian Institute of Technology, Powai, Mumbai -400076 IN ACCORDANCE WITH YOUR TENDER No:................... dated.................. for supply of ….............................., M/s. ............................. (hereinafter called the “Bidder”) having its Registered Office at …........................, wish to participate in the said bid for the supply ….................................................... as an irrevocable Bank Guarantee against Earnest Money Deposit for an amount of Rs. …................... (Rupees...............................) valid up to …............ (180 days from the date of issue of Bank Guarantee), is required to be submitted by the bidder as a condition precedent for participating in the said bid, which amount is liable to be forfeited by the Purchaser on (1) the withdrawal or revision of the offer by the bidder within the validity period, (2) Non acceptance of the Letter of Indent / Purchase order by the Bidder when issued within the validity period, (3) failure to execute the contract as per contractual terms and condition with in the contractual delivery period and (4) on the happening of any contingencies mentioned in the bid documents.
During the validity of this Bank Guarantee: We, ….......................(Bank name) having its registered Office at ….......................guarantee and undertake to pay immediately on first demand by …................................... the amount of Rs................... (Rupees………………………….) without any reservation, protest, demur and recourse. Any such demand made by the IIT Bombay shall be conclusive and recourse. Any such demand made by the purchaser shall be binding on the Bank irrespective of any dispute or difference raised by the Bidder. The Guarantee shall be irrevocable and shall remain valid up to …............(180 days from the date of issue of Bank Guarantee) If any further extension is required, the same shall be extended to such required period on receiving instruction form the Bidder, on whose behalf the is Guarantee is issued. Notwithstanding anything contained herein:
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Our liability under this Bank Guarantee shall not exceed (Rupees..........................). This Bank Guarantee shall be valid up to …...........................................(date). We are liable to pay the guaranteed amount or any part thereof under this Bank Guarantee only and only if you serve upon us a written claim or before …............ (date). This Bank further agrees that the claims if any, against this Bank Guarantee shall be enforceable at our branch office at ................................... situated at .............................. (Address of local branch).
Yours Truly Signature and seal of the guarantor: Name of Bank: Address: Date:
Instruction to Bank: Bank should note that on expiry of Bond Period, the Original Bond will not be returned to the Bank. Bank is requested to take appropriate necessary action on or after expiry of bond period.
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Annexure 6: Format for performance bank guarantee FORMAT FOR PERFORMANCE GUARANTEE BOND (To be typed on Non judicial stamp paper of the value of Indian Rupees of One Hundred) (To be established through any of the national banks (whether situated at Mumbai or outstation) with a clause to enforce the same on their local branch at Mumbai or any scheduled bank (other than nationalised bank) situated at Mumbai. Bonds issued by cooperative banks are not accepted.) To, Registrar, Indian Institute of Technology, Powai, Mumbai -400076 LETTER OF GUARANTEE WHEREAS Indian Institute of Technology, Bombay (Buyer) have invited Tenders vide Tender No............................... dated.....................................................................for purchase of ........................................................ AND WHEREAS the said tender document requires that any eligible successful tenderer (seller) wishing to supply the equipment / machinery,etc. in response thereto shall establish an irrevocable Performance Guarantee Bond in favour of “Registrar, Indian Institute of Technology, Bombay” in the form of Bank Guarantee for Rs ................................ (10% (ten percent) of the order value) and valid till two year from the date of issue of Performance Guarantee Bond may be submitted within 30 (Thirty) days from the date of Acceptance as a successful bidder. NOW THIS BANK HEREBY GUARANTEES that in the event of the said tenderer (seller) failing to abide by any of the conditions referred in tender document / purchase order / performance of the equipment / machinery, etc. this Bank shall pay to Indian Institute of Technology, Bombay on demand and without protest or demur Rs ........................ (Rupees......................................) This Bank further agrees that the decision of Indian Institute of Technology, Bombay (Buyer) as to whether the said Tenderer (Seller) has committed a breach of any of the conditions referred in tender document / purchase order shall be final and binding. We .......................................... (Name of the Bank & branch) hereby further agree that the Guarantee herein contained shall not be affected by any change in the constitution of the Tenderer (Seller) and/ or Indian Institute of Technology, Bombay (Buyer). Notwithstanding anything contained herein: 1. Our liability under this Bank Guarantee shall not exceed Rs. ......................... (Indian 190 | P a g e
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Rupees ..................................... only). 2. This Bank Guarantee shall be valid up to .................... (date) and 3. We are liable to pay the guaranteed amount or any part thereof under this bank guarantee only and only if IIT Bombay serve upon us a written claim or demand on or before.......................... (date) This Bank further agrees that the claims if any, against this Bank Guarantee shall be enforceable at our branch office at ........................................ situated at .............................. (Address of local branch). Yours Truly Signature and seal of the guarantor: Name of Bank: Address: Date: Instruction to Bank: Bank should note that on expiry of Bond Period, the Original Bond will not be returned to the Bank. Bank is requested to take appropriate necessary action on or after expiry of bond period. Submitted Earnest Money Deposit will be treated as null and void after acceptance of Performance Bank Guarantee by IIT Bombay.
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Annexure 7: Format for deviations/exclusions schedule
Format for Deviations / Exclusions schedule Proposal Ref No. and Date Name and Address To, Indian Institute of Technology Bombay Department of Energy Science and Engineering Sub : IIT-B Tender Ref : Dear Sir, We declare that the following are the only deviations, variations and exceptions / exclusions to the supply, services terms and conditions as outlined in your Bidding Documents. The Schedule has been filled in accordance with the Bidding Documents. Except these deviations, subject to the approval and acceptance by IIT-B, the entire work shall be performed as per your requirements and bidding documents. Further, we agree that additional conditions, if any found elsewhere in the offer other than those stated below, save that pertaining to any rebates / discounts offered, shall not be given effect to : Sr. No
Clause No.
Page No.
Statement deviation & variation exclusion
of Statement of deviation & variation / exclusion / Cost of withdrawal of deviation & variation / exclusion
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Notes: 1. The bidder may use additional sheets of like size and format, if required 2. The technical compliance/deviation should be supported by relevant technical literature. 3. If specification in Superior/inferior than asked for the enquiry, it should be clearly brought out in the justification. 4. If the bidder offers more than one model, then the technical compliance statement must be enclosed for each and every model separately.
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Annexure 8: Previous supply order format Name of the Firm ___________________________________
Order placed by (Full address of Purchaser)
Order No. and Date
Description Value and quantity of of ordered Order equipment
Date of completion of delivery as per contract
Remarks indicating reasons for late delivery, if any and justification for price difference of their supply order & those quoted to us
Has the Equipment being installed satisfactorily (Attach a Certificate from the Purchaser/ Consigner)
Contact Person along with Teleph one No., Fax No. and email address
Signature and Seal of the Manufacturer / Bidder ________________________ Place: _____________________ Date: _____________________
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Annexure 9: Checklist
Checklist The following items must be checked before the Bid is submitted: 1. Envelope “1” Technical Bid a) Demand Draft of Rs.500/- (Rs. Five Hundred only) towards cost of Bid document b) Bank Guarantee for Rs. 7,40,000 /-- (Rs. Seven Lakh forty thousand only) towards Earnest Money Deposit. c) INTEGRITY PACT as per format d) Eligibility Criteria & prequalification Criteria Responses (each pages duly sealed and signed by the authorized signatory) e) Copy of this tender document duly sealed and signed by the authorized signatory on every pages. f) Technical Bid responses g) The bidder has to submit in writing that he has indeed visited, inspected and examined the site and its surrounding. (on Company Letter Head)
2. Envelope “2” a) Price Bid/commercial bid: i. Price bid table ii. Cost drivers Your quotation must be submitted in two envelopes Technical Bid (Envelope 1) and Price Bid/commercial bid (Envelope 2) superscribing on both the envelopes the Tender no. and the due date and both these sealed covers are to be put in a bigger cover which should also be sealed and duly superscribed with our Tender No. & Due Date.
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