volume i technical enquiry specs - nbppl · 8 erection conditions of contract 20 9 ... operation...

ASH HANDLING SYSTEM

FGUTPP STAGE‐IV (1X500 MW) AT UNCHAHAR

DOCUMENT NUMBER

Customer : NTPC Ltd NBPPL‐004‐102‐26‐P1M‐A

NBPPL‐004‐102‐26‐P1M‐A Rev. No.: 00

VOLUME-I TECHNICAL ENQUIRY SPECIFICATION

Dated : 16.01.2015

VOLUME-I TECHNICAL ENQUIRY SPECIFICATION FOR

ASH HANDLING SYSTEM PACKAGE FOR

1 X 500 MW UNCHAHAR THERMAL POWER PROJECT

VOLUME I NBPPL-004-102-26-P1M-A

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CONTENTS Sl. No. Description Page No.

1 PRE‐QUALIFICATION CRITERIA FOR THE PACKAGE

4

2 PROJECT INFORMATION 4

3 SCOPE OF SUPPLY 4

4 DESIGN BASIS/INPUTS 11

5 SYSTEMS DESCRIPTION 13

6 TECHNICAL DOCUMENTS AND DRAWINGS 18

7 INSPECTION AND TESTING 19

8 ERECTION CONDITIONS OF CONTRACT 20

9 SUPERVISION OF CIVIL WORKS AT SITE 20

10 SITE ACTIVITIES 20

11 OPERATION AND MAINTENANCE 21

12 TOOLS & TACKLES, COMMISSIONING SPARES

26

13 OPERATION & MAINTENANCE MANUAL

26

14 LIST OF FORMATS / ENCLOSURES

27

15 SCOPE OF ELECTRICS

29

16 SCOPE OF C&I 32

17 LD for Short fall in Aux. Power Consumption Performance 37

18 Bid Evaluation Criteria Corresponding to Aux. Power Consumption 38

19 Criteria for Evaluation and comparison of bids corresponding to Aux. Power. 40

20 CONSTRUCTION FACILITIES 41

21 TERMINAL POINTS

44

22 CIVIL AND STRUCTURAL SCOPE 45

23 EXCLUSIONS

50


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24 ANNEXURE‐A‐TECHNICAL PQR

51

25 FORMATS/ ENCLOSURES ATTACHED 52‐96


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1. PRE-QUALIFICATION CRITERIA

As per Annexure –I attached at the end of this specifications.

2. PROJECT INFORMATION:

Feroze Gandhi Unchahar Thermal Power Station (FGUTPP) Stage-I (2X210MW) was

implemented by UPRVN. Further, it was taken over by NTPC Ltd. and thereafter NTPC

implemented Stage-II (2X210MW) & Stage-III (1X210MW).

The present expansion proposal is for setting up of a Coal based FGUTPP STAGE-IV

(1x500 MW) to be owned by NTPC Ltd. The NTPC BHEL Power Project Private Limited

(NBPPL) is the prime contractor of this project.

The FGUTPP (1X500MW) is located in Raebareli district of Uttar Pradesh. It is bounded by

villages khanpur, Faridpur and khaliqpur khurd. Mustafabad town is located at a distance of

about 3 Kms from plant.

Unchahar railway station on Allahabad- Raebareli board gauge (BG) section of Northern

railway (NR) is 2 KMs away. The nearest airport is located at Lucknow at a distance of

approximately 110 Km from the project site.

The latitude and longitude of Site are 25◦54' 50” to 81◦19' 50” respectively.

MECHANICAL SYSTEM AND EQUIPMENT

3. SCOPE of Supply

3.1 The scope of work comprises turnkey supply, erection and commissioning of complete mechanical, electrical and C&I works of ash handling system for One (1) nos. boiler, of 500 MW nominal rating and their associated electrostatic precipitators, as specified and defined in this specification.

3.2 The scope of work shall include the design, engineering, manufacture, shop fabrication, assembly, testing and inspection at manufacturer’s works, type testing wherever applicable, packing, ocean shipment, custom clearance, port clearance and handling,


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inland transportation, delivery at site, unloading, handling, storage and in plant transportation at site, complete services of erection including erection supervision and site testing, inspection, storage, erection and commissioning, final paining at site, trail run, performance guarantee testing and handing over of Ash handling system of 1X500 MW FGUTPP Stage – IV to NBPPL/NTPC, for one (1) no. boiler, of 500 MW nominal rating and their associated electrostatic precipitators, as defined in this specification. The scope shall also include design, engineering including preparation of complete BOQ (required for construction purpose) for the whole civil, structural job required for this AHP. Bidder shall be solely responsible for submission and getting the drawings /Data sheets/QAP/ FQAP/Commissioning procedures /O&M manual/PG test procedure/Testing procedures approved from NTPC in time and shall plan the activities.

3.3 The equipment and materials to be supplied by the Contractor shall form a fully comprehensive Ash handling system. The equipment and services as detailed in all sections of the bidding documents and as shown on the tender drawings shall be within the scope of supply of the Contractor. Any items though not specifically mentioned but which are required to make the plant complete in all respects for its safe, efficient, reliable and trouble free operation shall also be taken to be included, and the same shall be supplied and erected by the Contractor, unless they are specifically excluded.

3.4 The work shall consist of mechanical and electrical work and equipment, all associated structural and architectural works, Control and Instrumentation equipment, mechanical services and pipe work and electrical services associated with this ash handling system, the principal features of this system being:

I. A wet ash conveying system for ash collected in the boiler furnaces, economiser hoppers and air pre-heater hoppers, including treatment system of Bottom ash hopper overflow water.

II. A dry fly ash conveying system for the ash collected in electrostatic precipitators collection hoppers.

III. A dry fly ash transportation and storage system including dry fly ash storage silos for Road/Rail.

IV. Bottom ash, air preheater hopper ash and economizer/duct hopper ash slurry disposal system.

V. Ash slurry disposal system for ash collected in ESP hoppers.

VI. Ash water supply system.

Notwithstanding the scope mentioned for various sub-systems in the following paragraphs, it is the responsibility of the contractor to carry out complete job on turnkey basis and integrate the sub systems with each other.


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Complete detail engineering drawings, calculations, preparation of bill of materials (for

civil, mechanical, electrics and C&I), selection of components etc shall be subject to

approval by NBPPL/NTPC during detailed engineering.

Successful bidder shall take prior approval from NBPPL/NTPC while placing the E&C

contract order for this package to a sub-contractor. NBPPL/NTPC reserves the right to

disapprove any such E&C contractor which NBPPL/NTPC deems not fit for executing

E&C of this contract.

Bidder’s brief scope also includes the following

1. Structural design, detail engineering, for all sub structures and super structures for entire

AHP shall be in the scope of bidder. Bidder shall also design the Bottom Ash Hopper

area foundation with provision of Piles under the Foundations. The Piles should be of

either 600 mm or 760 mm diameter only and length will be specified by NBPPL

afterwards.

2. All structural design, detail engineering along with architectural designs for all MCC

rooms, control rooms, pump house, compressor houses/ vacuum pump houses silos, silo

utility buildings, pipe pedestals, slurry trenches, pipe trestle, all Pipe racks (wherever Ash

Handling Package pipes are laid) including pipe racks from ESP to Silos etc shall be in

the scope of bidder.

3. The design, manufacture, inspection and testing of the equipment’s shall comply with all

the currently applicable statutes, regulations and safety codes in the locality where the

equipment is to be installed and shall also confirm to the latest edition of Indian and other

international standards and codes. Nothing in this specification shall be construed to

relieve the contractor of the required statutory responsibility. In case of any conflict &

ambiguity in the standard to be followed the decision of the NBPPL/customer shall be

final and binding.


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4. The Contractor 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.

5. In case of any ambiguity, conflict in the standard & specification &/or interpretation of

clauses in this enquiry spec. and its enclosures the decision of NBPPL shall be final and

binding and any change due to this shall have no price implication on NBPPL and shall

have to be absorbed by successful bidder.

6. Bidder shall provide the bill of materials, BOQ/Schedule of Quantities for the complete

civil job required for Ash Handling System and ensure the correctness of all civil design

and detail drawings which shall be the input for execution of civil works by NBPPL’s

civil contractor. Any issues like cutting/chipping of floors, beams shall not be permitted.

Any additional civil works arising from missed out things in civil drawings prepared by

bidder like pedestals, foundations, etc. shall be constructed by the bidder without any cost

implication to NBPPL and by engaging its own resources.

7. Design, Supply and E& C of Refractory in Bottom ash hopper shall be in Bidder scope.

8. Design, supply and E&C of Air compressors for Ash conveying system along with

associated valves, receiver, piping shall be in the scope of supply & E&C as per the

specifications.

9. Design, supply and E&C of Instrument Air compressors for instruments in AHP along

with associated valves, receiver, piping shall be in the scope of supply & E&C as per the

specifications.

10. Design, supply and E&C of EOT cranes, Under slung cranes, hoists etc. for maintenance

of all equipments supplied by bidder at various areas like pump houses, compressor

houses, vacuum pump houses, switchgear rooms, individual equipments etc shall be in

the scope of bidder as per the NTPC technical specifications.


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11. Design, supply and E&C of Cooling tower and its associated piping as required for

closed loop cooling water system for ash handling equipments shall be in the scope of

bidders supply and E&C. (if required)

12. Design, supply and E&C of Complete Ventilation system and air conditioning system

MCC rooms, switchgear rooms, control rooms, pump houses, silo utility building

etc.shall also be in bidder’s scope of work and supply.

13. Design, supply and E&C of complete service water system, drinking water (potable

water) system and Equipment cooling water system shall also be in bidder’s scope of

work and supply. The terminal points for Service water and Potable water piping are

provided in the terminal points section. Entire distribution network for service water and

potable water piping with in AHP area shall be in the scope of bidder supply and works.

14. Cleaning shall be done immediately at each front of any debris produced by the bidder

during E&C.

15. Rust prevention after inspection at shop floor before dispatch shall be in bidder’s scope.

16. Pipe racks required for ash Handling System shall be provided by NBPPL. However,

design & engineering of the said pipe racks shall be in the bidder’s scope.

17. Provision of any temporary supports/platforms required for E& C of mech. Equipment /

items shall be in the scope of bidder.

18. Necessary provisions shall be considered in the equipment/ items/ systems which are in

bidder’s scope for integrating with other equipments/ systems/ items which are part of

other contractor’s scope.

19. All motor alignment with drive system, supply of base frames, its bolts etc. shall be in

bidder’s scope.


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20. All Material of construction for all equipment shall be subject to NBPPL/NTPC approval

during detail engineering.

21. Consumables like lubricants, oils, grease etc for initial flushing, first fill and initial

operation with topping up to handing over. Special tools and tackles, as required,

commissioning spares, supply & application of rust preventive paints at shop floor and at

site after erection as applicable for the equipment / system shall be in the scope of bidder.

22. Bidder to note that all sub-vendors for the package shall be subject to NTPC approval in

the event of order.

23. Bidder to adhere to NTPC technical specifications for all civil, mechanical, Electrical and

C&I design for complete AHP.

24. System integration and PG test of entire AHP, until final handing over and written

confirmation from NBPPL/NTPC shall be in bidder’s scope.

25. Bidder to adhere to all NTPC technical specifications, quality assurance plan etc attached

with this tender enquiry.

26. Bidder shall furnish the L-2 project schedule indicating various milestones along with the

bid in line with completion schedule provided in the Tender document. Each successful

bidder shall furnish the L-3 project schedule in line with the L-2 schedule after award of

the contract.

27. Bidder to extend all help and documentary support for compliance and addressing any

statutory issues raised by NTPC/NBPPL which pertains to the area / work under bidder’s

scope.

28. Bidder shall submit the signed and stamped copy of all the pages which constitutes this

technical enquiry specification signed by authorized signatory to avoid any ambiguity in

scope understanding & the scope division as a technical offer during bidding.


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29. Bidder to note “no deviation” from the enclosed NTPC bid document and the pre-bid

MOM, amendments and clarifications shall be acceptable unless and until written

approval from customer NTPC/ NBPPL has been accorded. Bidder shall submit a signed

copy of NBPPL’s tender documents as technical offer along with the bid without any

deviations.

30. Quality of effluent outgoing from the plant shall conform to latest norms of Environment

Pollution Control.

31. The layout of various water/slurry piping for the Ash Handling System shall ensure that

all valves are located so as to be at conveniently accessible positions. Otherwise suitable

access/maintenance platforms shall be provided for valves/field instruments under the

bidder’s scope

32. All pads, shims plates, resilient pads of neoprene rubber etc. is in bidder’s scope.

33. Facilities for carrying out online and off-line maintenance of Ash Handling System and

auxiliaries shall be provided. In general, this should include adequate handling

equipment, working space, platforms and safety devices.

34. Maintenance platform as per Technical Specification with handrails and access ladders

shall be provided below all hoppers.

35. Inspection windows shall be provided at suitable locations.

36. Supply of grouting cement and grouting of all mechanical equipment / items and its

drives. Grouting of all the bases of equipments, minor chipping & make up of pedestals /

pockets shall be in scope of Bidder. NBPPL / NBPPL’s civil contractors shall provide

only the foundation pockets for pedestals (wherever necessary) as per civil foundation

drawings.


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37. Bidder shall make their own arrangements well in advance for heavy erection equipment

like bigger cranes, hydras, pay loaders, etc. that are required for lifting, shifting &

erection of equipment.

38. Mandatory spares shall be supplied as per the spares list furnished in the relevant

section, for equipment applicable to the bidder.

39. Breaking of wall/brick cladding and re-doing it for associating any mechanical, electrical,

C& I work portion shall be in bidder’s scope.

40. Bidder to note that AHP fronts during erection will be given in a staggered manner. So,

Bidder has to consider and envisage mobilization of all resources required, including

manpower, in the shortest possible time during E&C at site. For this, the successful

bidder has to consider advance resource planning so that E&C by the successful bidder is

not delayed.

41. All other items though not explicitly mentioned above but required for the

completeness of the Ash Handling system in Mechanical, Electrical & Civil scope &

works in this specification shall also be in Bidder’s scope of supply & works. \

4. DESIGN BASIS/INPUTS.

As per Ash collection data the following percentages of Ash collection is considered for system sizing.

S.No. Description Percentage Ash Qty.(TPH) Worst Coal

Temp. in Deg C

No. of Hoppers

1 Bottom Ash 25% 46.5 1040 2 2 Economizer Ash 5% 9.3 340 4 3 Air Preheater-

PAPH 5% 9.3 150 4

4 Air Preheater- SAPH

5% 9.3 150 4

5 ESP 90% 167.4 150 144


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ASH COLLECTION DATA Considering % Ash at BMCR as per drawings 1450-

001R-SGTR-PVC-V-505 REV 01

ESP field wise ash collection data shall be as per the drawing no: 1450-001R-SGRN-PVM-W-023 R00

The total water requirement in the ash water tank requirement shall be restricted

to 1250 m3/hr.

Out of which 230 m3/hr shall be available from CW blow down. Bidder has to design, supply, erect and commission Ash water make up pumps restricting to 1020 m3/hr along with all necessary drives, electrical, instrumentation items including vibration Monitoring systems & sensors. Flow and Head of Ash Water make up Pump to be considered as 1020 m³/hr and 45 MWC respectively. Expander and companion flange shall be in AHP Bidder Scope. Pump discharge line to be considered as 450 NB. Bidder to keep AHP Make Up water pump drive motor rating below 200KW.

The total DM cooling Water (DMCW) requirement for Air compressor cooling

water shall be restricted to 285 m3/hr. Design Inlet Temperature of DMCW is 38degC, Supply pressure at Terminal Point is 6.0kg/cm2(g), Pressure drop considered across AHP compressors is 10MWC.

Note to Bidders

1. NBPPL reserves the right to request for any additional information and also reserves the

right to reject the proposal of any bidder, if in the opinion of NBPPL, qualification data

is incomplete or the bidder is found not qualified to satisfactorily perform the works.

2. The bid shall be complete in all respects and shall necessarily contain but not limited to

Technical description, Technical data sheets of equipment and systems, Schematic

diagrams, System Process & Instrumentation Diagrams (P&ID), Guarantee declaration

schedules. Spares shall meet the project scope and technical specification requirement.


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3. The bid shall also include Price schedules, Bidder's Qualifications, Eligibility and

Conformity of the facilities, list of special Tools & Tackles. Sub-Vendors proposed by

the bidder shall also be indicated.

4. Bidder shall provide details of important conditions, Deviations (with respect to

Technical Specifications) if any, local representatives, deemed export benefits, Erection

Tools & Plants, Bought Out Items, Quality Assurance programme, Project Schedule

with Milestone Schedule and Additional Information if any.

5. NBPPL reserves the right of demanding any additional information and clarification

from the Bidder after submission of his bid for examination and evaluation of bid, in

which case, the Bidder shall furnish the same.

6. In the interest of the Bidder, a site visit by the bidder is mandatory, to familiarize

himself with the site conditions and understand entire job requirement for, local

environment conditions and facilities available inside & outside the plant before

submitting the offer. Bidder shall understand limitations/ constraints and decide the

optimal route based on the location of the buildings etc.

7. The system shall generally be as per the drawings & specification requirement in the

enclosed specification.

5. SYSTEMS DESCRIPTION

5.1. BOTTOM ASH HANDLING:

Scope under this specification for bottom ash handling system starts from the boiler furnace bottom to the disposal of Bottom ash slurry into the slurry sump of Bottom ash slurry pump house and from bottom ash slurry pump house up to ash dyke consisting of any one of the two alternatives: -

The bidder may offer any one of the alternatives specified below:-

ALTERNATIVE – I


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Double V- type water impounded hopper and jet pumps for intermittent removal of

bottom ash. All detailed technical requirements for the specified system shall be in line

with NTPC Technical specifications as specified in Vol – IIA of the Technical Specs.

ALTERNATIVE – II

Dry type bottom ash hopper and submerged scrapper chain conveyor system with BA

slurry transportation pumps for continuous removal of bottom ash.

All detailed technical requirements for the specified system shall be in line with NTPC

Technical specifications as specified in Vol – IIA of the Technical Specs.

5.2. FLY ASH HANDLING SYSTEM: Scope under this specification for dry fly ash conveying system starts from electrostatic

precipitator ash collection hoppers and primary & secondary air pre heater hoppers outlet

onwards and consist of the following :-

FLY ASH EXTRACTION SYSTEM:

For FLY ash extraction, two alternatives are specified. The bidder may offer any one

of the alternatives specified.

ALTERNATIVE – I

Vacuum system using vacuum pumps for extraction of ash from each ESP hopper up

to buffer hoppers. All detailed technical requirements for the specified system shall be

in line with NTPC Technical specifications as specified in Vol – IIA of the Technical

Specs.

ALTERNATIVE – II

Pressure extraction system for ash extraction from ESP hoppers up to buffer hoppers.



5.3. FLY ASH TRANSPORTATION SYSTEM:

Fly Ash transportation system for conveying fly ash from buffer hoppers up to storage


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silos.



5.4. ECONOMISER & AIR PREHEATER ASH HANDLING SYSTEM:

Ash collected in economiser, primary air pre heater and secondary air pre heater

hoppers shall be collected in the flushing equipments placed beneath through vertical

pipes.

1. In case submerged scrapper chain conveyor system, the slurry from flushing

equipments shall be conveyed via trenches to the sump of bottom ash slurry

transportation pump house from where it shall be pumped continuously to sump of

combined ash slurry pump house along with bottom ash.

2. In case of water impounded hopper system, the slurry from flushing equipments shall

be led to economiser & air pre heater slurry trench, which in turn shall be connected to

ESP fly ash slurry trench.



5.5. INSTRUMENT AIR SYSTEM:

Instrument air requirement for the entire ash handling System shall be catered by 2 nos.

(1W+1S) instrument air compressor which shall be in the scope of bidder.

The complete distribution system for instrument air throughout ASH handling System

including piping, fittings, valves, expansion bellows, supports, etc. shall be in the scope of

bidder.




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5.6. ASH SLURRY DISPOSAL SYSTEM:

1. JET PUMP SYSTEM:

Four (4) nos. Disposal streams with horizontal ash slurry disposal pumps in ash slurry

disposal pump house along with MS pipelines, alloy CI/basalt lined fittings etc. for

disposal of combined bottom ash and fly ash slurry. Slurry disposal piping inside ash

slurry pump house and in culvert/trench shall be MS basalt lined. The pump motor sets

shall be complete with variable speed hydraulic couplings for first stage pumps in ash

slurry pump house and fixed belt drive arrangement for subsequent stages.

2. SCC SYSTEM:

Three (3) nos. Disposal streams with horizontal ash slurry disposal pumps in ash slurry

disposal pump house along with MS pipelines, alloy CI/basalt lined fittings etc. for

disposal of combined bottom ash and fly ash slurry. Slurry disposal piping inside ash

slurry pump house and in culvert/trench shall be MS basalt lined. The pump motor sets

shall be complete with variable speed hydraulic couplings for first stage pumps in ash

slurry pump house and fixed belt drive arrangement for subsequent stages.

All detailed technical requirements for the specified system shall be in line with NTPC Technical specifications as specified in Vol – IIA of the Technical Specs.

The ash slurry disposal shall be to ARKHA ASH DYKE which is approximately 12km from proposed ash slurry pump house location. The ultimate height of dyke shall be RL 120m. Static head for slurry disposal pump shall be decided during detailed engineering based on trip level of Ash slurry sump.

5.7. FLY ASH STORAGE AND UNLOADING SYSTEM:

Two (2) no. Fly ash storage silos, each of 750 MT capacity , complete with aeration

system, bag filter cleaning system, dry ash un loader (1 no. Per silo), conditioned ash

unloaded (1 no. Per silo) for unloading the ash into closed and open trucks

respectively.


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Three (3) nos. Silo aeration blowers (2 working +1 standby) along with drives, heater,

piping and accessories.



5.8. COMMON WATER SYSTEM:

The water requirement for the ash handling system shall be met through various water

pumps as per NTPC detailed technical specifications.

ASH WATER MAKE UP PUMPS shall be in the scope of bidder.

The ash water make up water requirement shall be limited to 1250 m3/hr.

Out of which 230 m3/hr shall be available from CW blow down. Bidder has to design,

supply, erect and commission Ash water make up pumps restricting to 1020 m3/hr along

with all necessary drives, electrical and instrumentation items.

2X100% (One s/b + one in operation) ASH WATER MAKE UP PUMPS (vertical

Wet-pit type.) shall be installed in the existing make up water pump house.



5.9. MISCELLANEOUS:

The following miscellaneous items shall be in the scope of bidder.

1. Under slung /EOT crane/ Electric/ manual hoists in AHP building.


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2. Ventilation system for MCC rooms, AHP building and toilets.

3. Split Air conditioners for AHP control room and silo utility control room.

4. FRP cooling tower with pump and accessories for compressor cooling water system.

(if required).


Technical specifications.

6. TECHNICAL DOCUMENTS AND DRAWINGS:

1. Bidder shall furnish the following details in their technical offer.

a) System capacities and all equipment ratings as per their scope of supply. b) Motor ratings of all equipments Guaranteed power consumption details, BA and

FA Slurry balance & Water balance (mainly HP water requirement). c) Total water consumption (Consumptive & Non-consumptive) per shift.

2. Bidder to submit the Master Drawing List (MDL) at the time of Kick of meeting in

Post award stage. All drawing and data sheet are to be submitted in standard sheets

having approved title blocks. NTPC’s and NBPPL’s name has to be incorporated in

all the drawings.

3. As far as possible, first angle projection shall be followed.

4. Drawing shall be generally in A3 size. However, if inevitable, the size shall be A0,

A1, and A2.

5. Drawing shall be complete. Incomplete drawing shall not be accepted.

6. All drawings submitted shall indicate the type, size, arrangement, weight of each

component, breakdown for packing and shipping, the external connections, fixing

arrangements required, the dimensions required for installation with other equipment

and material, clearances required between various portions of the equipment and any

other information that is relevant or requested for.

7. Free hand drawing, lettering, overwriting etc., shall be totally avoided and the same


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shall be stenciled in ink.

8. The drawings mentioned for approval are to be submitted for approval. If drawings

are approved with comments, then the same shall be resubmitted after incorporating

the comments.

9. Test certificates shall invariably consist of details such as Nameplate data, projects

and NTPC’s name.

10. Test certificates shall be strictly in A4 size

11. Records of test results / readings etc., made during internal testing shall be available

during testing/ inspection in customer’s presence.

12. All drawings and test certificates etc., shall be marked as “CERTIFIED” and signed

by the competent authority on the Bidder’s side.

7. INSPECTION AND TESTING:

1. Bidder shall give 15 days’ advance written notice of equipment being ready for

testing. Such tests shall be to bidder’s account. The customer / Inspector, unless the

witnessing of the tests is virtually waived, will attend such tests within 15 days of the

date on which the equipment is notified as being ready.

2. Type & routine test report / certificates shall include details of standard to which the

tests are performed, test parameters, acceptance criteria, test set up etc. used during

the testing along with the test piece details / rating and the detailed test record and

final test result.

3. All inspection, measuring and test equipment used by the contractor shall be

calibrated periodically. Bidder shall maintain all relevant records of periodic

calibration, instrument identification, and shall provide for inspection by bidder

wherever asked specifically; bidder shall calibrate measuring / testing equipment in

the presence of employer.


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4. The details of the checks to be carried out for various components (MQP) are to be

submitted within one month from the date of Purchase order by bidder for customer

approval. However, some indicative checks on different items are mentioned

elsewhere in the tender specification which should necessarily form part of the

Quality Assurance Plan to be agreed with the customer.

8. ERECTION CONDITIONS OF CONTRACT: Bidder to note that AHP fronts during erection will be given in a staggered manner.

So, Bidder has to consider and envisage mobilization of all resources required,

including manpower, in a shortest possible time during execution time. For this

bidder has to consider advance resource planning so that erection by the successful

bidder is not delayed. Also refer relevant section of the tender specification.

9. SUPERVISION OF CIVIL WORKS AT SITE: Complete design of the civil and structural works pertaining to the AHP system

and getting the same approved from the Owner shall be in the bidder's scope.

Bidder shall be responsible to ensure correct implementation of their design of

civil and structural works at site through the contractor engaged by NBPPL for

the work, in order to suit the civil &structural works for equipment erection

requirement.

Joint inspection protocol for the same has to be made along with the NBPPL's

civil agency.

10. SITE ACTIVITIES:

10.1. All site activities like unloading, receipt, storage, preservation at site, security &

handling material, taking delivery of employer’s supplied materials from

employer’s stores, civil/structural & architectural works in the bidder’s scope,


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erection and commissioning, trial run & PG test, handing over to customer the

complete System shall be in bidder’s scope.

10.2. Bidder has to construct his site office , open storage yard and closed storage yard

10.3. For supervision of erection, commissioning, trial run & PG test, Bidder shall depute

continuously experienced manpower till handing over of the systems to the

customer.

11. OPERATION AND MAINTENANCE TILL HANDING OVER: 11.1. Scope of work for operation & Maintenance of the System:

11.1.1. The bidder shall be responsible to carry out the “round the clock trouble free

operation” of the complete Ash Handling System (DCS based) related to the

unit .

11.1.2. Operation and maintenance of the items supplied by the bidder during above

mentioned period in the scope of bidder.

11.1.3. All consumables (gasket, rope, diesel, rustoline, waste cloth, lapping paste,

jute, emery papers, welding electrodes, grinding wheel, hacksaw-blade,

cutting gas, Electric items like Insulation Tape, Lugs, Fuses ,Push Buttons,

Electrical contact cleaner etc.) required shall be in the scope of the bidder.

11.1.4. All tools, tackles, viz. chain pulley block, pulling & lifting equipment,

Trolley, Crane, Hydra, Truck, Trailer, winch, wire rope, grinding machine,

sling, D-shackle, Coupler etc. including precision measuring instruments,

welding machine & single phase portable welding machine that may be

essential to execute the job shall be arranged by the bidder at no extra cost to

NBPPL. Portable diesel generator machine will have to be arranged by the

bidder for carrying out maintenance job outside the plant where power

supply could not be arranged by NBPPL.


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11.1.5. For electrical job, Megger (1 no.), Multimeter (02 nos.), Clamp meter (1

no.), Tester and screw driver set (02 nos.), Spanners/Plyers/Small tools kit (1

set)/Crimping tools for power and control cables/ cutter (2 nos.)/ wire

stripper (2 nos.)/Blower to be arranged by the bidder at no extra cost to

NBPPL.

11.1.6. Necessary shifting of materials, spares, equipments etc. from store to work

site and unserviceable materials from work site to store/yard, is to be done

by the bidder at their own cost.

11.1.7. The bidder must have adequate resources to undertake routine, preventive

maintenance jobs of AHP. They should have adequate resources to mobilize

the site for carrying out three to four jobs simultaneously without any delay.

11.1.8. Bidder has to compulsorily maintain log book for the O & M staff engaged

for O&M jobs and submit to Engineer in charge.

11.1.9. In case bidder does not engage required O& M staff with tools and tackles as

specified in the specification, O& M staff shall be engaged by NBPPL at

their risk and cost on monthly basis for a minimum period of 12 months and

actual amount incurred with overheads @ 15% shall be debited from the

bidder’s bills.

Additional responsibility of the bidder:

The bidder shall also be responsible for following operational activities:

1. Top up of oil/grease/lubricant as required during operation of plant shall be done

by the bidder.

2. Eco Hoppers, APH Hoppers & ESP Hoppers are to be ensured empty round the

clock. In case of outage of ESP field due to accumulated ash in the ESP Hoppers, it

will be the responsibility of the contractor to arrange evacuation of ash from the

ESP Hoppers so that generation of the unit does not get affected.

3. Bottom ash removal through feed gates/jet pumps of Bottom ash Hoppers to be


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carried out in each shift during coal firing of the boiler.

4. Removal of erection/technological waste which may come along with ash from

BAH, ECO, APH, and ESP hoppers during the operation of the plant shall be done

by the bidder. Cleaning of ash from BAH seal trough, from BAH ground floor

area, APH hopper area, Economizer Hopper area, ESP area, ISH area and Silo area

on regular basis and disposal of the same at specified location as directed by

NBPPL.

5. The bidder should remove all the technical waste including ash in AHP area after

each maintenance and operational activities to keep the place clean and according

to the satisfaction of NBPPL Engineer in charge within 3(three) days after

completion of work, failing which NBPPL will get the cleaning done at the risk

and cost of the bidder.

6. In case there is choking due to formation of clinker in running condition of the

Boiler, utmost effort is to be given to remove those clinkers. Necessary Safety

arrangement as deemed fit is to be undertaken in course of removing clinkers.

Poking at Bottom Ash Hopper and above to dislodge clinkers as and when

required.

7. The bidder shall be vigilant and take necessary measure to prevent overflow from

slurry sumps, BAOF sump, seal water tank, ash water tank, recovery water tanks,

drain sumps etc. to avoid discharge to the nearby drain.

8. The bidder shall do the servicing of field instruments like

Limit/Pressure/Temperature /Level switches, Pressure/Temperature/Level Gauges,

Solenoid valves, Cylinders, Air filters.

9. To maintain the daily log book for shift wise plant operations which will include

activities e.g. complete evacuation of fly-ash hoppers, BA Hopper, Eco. & APH

Hoppers. A copy of observation and recording of salient operational readings of

the unit to be submitted by the bidder to the Engineer-in-charge of NBPPL for


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record and further processing.

10. Housekeeping: Cleaning of all equipment and housekeeping to be carried out

dedicatedly in total Ash Plant area and its office premises.

11. All routine, preventive, predictive and breakdown maintenance of equipments of

Ash Handling System in bidder scope.

12. Removal of all types of choking in nozzles, pipes in ash disposal system.

13. In case of dumping of ash from the hoppers on the floor the same has to be

cleaned. The ash has to be transported to the specified place by the bidder as per

the instruction of the Engineer-in-charge.

14. Fabrication and erection of platform/extra support for AHP area if felt necessary

during operation and maintenance of the System has to be done by the bidder.

Materials like channels, beam, angle etc as required shall be arranged.

15. Leakages/Spillages/Debris etc. generated on account of repairs during operation

and maintenance of the System at various locations in the ash handling system has

to be collected, cleaned and disposed at designated area as marked by NBPPL.

16. Transportation of new pipes, spares, equipments from stores to site including

loading, unloading and return the damaged pipes, spares, equipments to the

designated place in the store in scope of bidder.

17. To maintain the daily Maintenance log book in which details of overhauling /

breakdown / maintenance of any equipment including replacement of spares /

components to be recorded. Recording of any abnormality of equipments,

malfunctioning of system of the AHP also to be noted in the Log book and

informed to the Engineer-in-charge of NBPPL for initiating immediate corrective

action by the contractor.

18. Daily surveillance of all the running disposal lines (dry &wet) for any leakage etc.

and the status is to be reported to the Engineer-in-charge of NBPPL.

11.2. MANPOWER REQUIREMENT:


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1. The bidder shall take approval from Engineer-in charge of NBPPL by submitting

organization Chart of O&M staff for this site clearly indicating man power

deployment with their educational background& experience with supporting

documents.

2. EPF provisions for the workers shall be made by the bidder as per rule. Relevant

documents regarding EPF for the workers of the bidder shall be submitted to the

concerned authority before commencement of work.

3. The bidder shall be solely and wholly responsible for safety and security of workers

engaged in the job and the NBPPL property. In case of any accident the contractor

shall pay proper compensation to the workers as per workmen’s compensation act

and repair/replace NBPPL property at their own cost & arrangement. The bidder

shall also make adequate provision of insurance for their workers at their own cost

to cover them against the risk of accident.

4. The bidder and their workers engaged in the job shall follow all safety rules at the

time of execution of work. It shall be responsibility of the bidder to supply all safety

equipment as necessary to its O&M staff.

5. The bidder shall comply with all laws, rules & regulations of the land including but

not limited to, i) Labour rules & Acts, ii) Factories Act, iii) Minimum wages Act,

IV) Payment of Wages Act, v) Bonus Act, vi) EPF rules, vii) Contract Labour

(Regulation & Abolition)Act as in vogue or comes in to vogue from time to time.

NBPPL will be kept indemnified against any claim arising out of non-compliance of

such Acts/rules.

6. NBPPL shall not be responsible in matters of employment of workers engaged in

the job at any point of time. The bidder shall be fully responsible for his workers


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with regard to terms of employment of services. NBPPL shall not be held

responsible in any manner, whatsoever, in respect of workers engaged by the

contractor for carrying out the works at site. Regarding engagement of workers

preference should be given towards experienced and competent workers with

bonafide testimonials.

7. Beyond general shift if any trouble/breakdown occurs in the System, Maintenance

team must reach the plant without any delay along with Engineer/Site In charge.

8. If any additional manpower is required during O&M whatsoever under the scope of

contract the same shall be made available by bidder in time within the cost. To cater

the need of time bound maintenance jobs, the bidder shall depute additional

manpower without any cost implication to NBPPL.

9. During execution of work if any personnel is found not suitable for the job or his

presence inside powerhouse premises is felt undesirable, the personnel has to be

replaced within 15 days.

10. NBPPL will not be responsible for payment towards idle labour charges.

12. TOOLS & TACKLES, COMMISSIONING SPARES:

Lifting lugs, eye bolts, etc.

Each equipment shall be provided with suitable lifting attachments, supports, lifting lugs, eye bolts, etc. to facilitate maintenance.

12.01 The Contractor’s supply shall also include all miscellaneous items eg. first fill of lubricants, special tools and tackles etc. that are necessary to ensure safe and reliable operation of the plant during start up, continuous running, shut down and emergency conditions, even if these are not explicitly mentioned in this specification.

12.02 The contractor shall be responsible for making all connections at terminal points and for supplying any necessary jointing material, connectors, nuts, bolts, etc.

12.03 Mandatory spares shall be supplied as per the list enclosed in Mandatory Spares Section.


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13. OPERATION & MAINTENANCE MANUAL:

O & M manual shall contain the following.

1. Principle of operation of the equipment.

2. Details of preventive / repair maintenance for equipment and accessories used.

3. Details about the general specifications, design capacities of equipment, their

function.

4. Equipment Bidder’s address, telephone nos., contacts person details to be

furnished.

5. Required Dismantling devices, tools etc.

6. List of DO’s and DO NOT's.

7. Test certificates.

8. All drawings.

9. Calculations.

10. Storage and erection instructions.

11. Proper procedures & sequence of operation.

12. Details of consumable.

Note:

a) All manual shall be supplied in proper bound books or in folders, preferably

in A4 size.

b) Prospective Bidder will submit the regular progress reports for self

manufactured& their bought out items equipment ordering /manufacturing

status, drawings status once in fifteen days.

14. LIST OF FORMATS/ ENCLOSURES:

Following Formats/ enclosures attached is an integral part of this technical


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enquiry and must be dully filled, signed and stamped and submitted along with

the offer:

1. Boiler Ash collection Data drawing 1450-001R-SGTR-PVC-V-505 R 01

2. ESP Field wise ash collection data drawing 1450-001-SGRN-PVM-W-023

R00

3. Format for Joint deed of undertaking FORM-13D.

4. Past performance format Attachment - 3F

5. Format for Manufacturing capability and Plant loading of Bidder and sub

Vendor Attachment - 3D.

6. Format for Equipment guaranteed capacity/head Attachment 10B

7. Present Order Book Position for Ash Handling System Attachment – 3E


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15. SCOPE OF ELECTRICS FOR AHP PACKAGE VENDOR:

The Bidder scope shall include design, manufacture, engineering, inspection & testing at supplier's works, packing, forwarding to site, unloading, erection, testing & commissioning of the Electrical equipment / system and works indicated in this chapter or in line with NTPC Technical specifications as specified in Vol – IIA of the Technical Specs. The Electrical scope shall be as described briefly in the following clauses but not limited to it.

Painting

The painting of all electrical equipment shall be epoxy based with suitable additives. The thickness of finish coat shall be minimum 50 microns (with minimum total DFT of 100 microns).However in case electrostatic process of painting is offered for any electrical equipment, minimum paint thickness of 50 microns shall be acceptable for finish coat. The Contractor shall furnish the complete painting details during detailed engineering stage.

SCOPE MATRIX BETWEEN NBPPL AND BIDDER

SL. NO.

DETAILS SUPPLY E & C REMARKS

1

Transformers (Indoor/Outdoor)11kV/3.45 and 3.3kV/0.433V

Bidder Bidder

1. 11kV power supply from HT board of NBPPL to transformer I/C Panel along with cable tray and accessories shall be in the scope of NBPPL.

2. Control cable between 11kV switchgear (NBPPL) and Transformer I/C panel is in NBPPL Scope.

2 3.3kV Switchgears Bidder Bidder

3 415V Switchgear (PCC/PMCC, MCC)

Bidder Bidder .

4 Local Push button station, JBs and Local control panels

Bidder Bidder

5

Power cables, control cables and screened control cables as required

Bidder

Bidder

6 Any special type of cable like Bidder Bidder


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compensating, co-axial, prefab, MICC, optical fibre etc

7 Cable trays, accessories & cable tray supporting system

Bidder Bidder

Civil works of RCC cable trench along with insert plates as per the approved drawings provided by bidder during detailed Engg. Shall in the scope of NBPPL civil contractor throughout AHP. Cable trays, cable tray supporting structures and accessories shall be in bidders scope of supply and E&C.

8 Cable glands and lugs for equipments

Bidder Bidder

9 Equipment grounding & lightning protection

Bidder Bidder

Material and sizes shall be as per specification and subject to NTPC approval during detailed engineering stage.

10 Below grade grounding Bidder Bidder

Connection with main plant Earth mat shall be in bidder scope as per NTPC approval during detailed engineering stage

11 LT/HT motors with base plate and foundation hardware

Bidder Bidder Make shall be subject to NTPC approval at contract stage.

12 Lighting (Illumination)system Bidder Bidder

13

Any other equipment/material/ service required for completeness of AHP but not specified above.

Bidder Bidder

14

Engineering activities during detailed engineering stage, including those listed below.

a. Electrical load data submission in NBPPL/NTPC format

b. Electrical equipment

Bidder -

1. Documents shall be submitted as per approved project schedule of NBPPL/NTPC.

2. Vendor shall be responsible for necessary coordination with NBPPL/NTPC for


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GA drawings and layout drawings

c. Cable trench/tray layout drawings

d. Control cable schedules showing routing details.

e. Grounding and lightning protection system layouts

f. Cable termination/interconnection details (diagram)/cable block diagram (HT/LT)

required engineering interfacing during contract stage.

3. Any approval required from electrical inspection authority for electrical equipment shall be arranged by bidder.

NOTES: 1. Sub-Vendor List provided for Electrical Equipments/items is indicative only and it

requires prior approval from NBPPL/NTPC before finalising the sub-vendor. 2. All QAPs shall be subject to approval of NTPC after award of contract without any

price implication to NBPPL. If bidders have any reference QAP of NTPC projects then same shall be applicable. QAP attached with specification is for reference only.

Design, supply, transportation, loading/unloading at site, receipt, storage, security, transportation to erection location, Erection, Testing & Commissioning of the following electrical items as per NTPC Specifications required for the completion of AHP package but not limited to shall be in the scope of successful bidder.

1. Transformers (Outdoor & Indoor)(11KV/3.45kV and 3.3kV/0.433kV)

2. HT Switchgears

3. HT switchgear protections, control and metering equipments.HT

Cables

4. LT switch gears

5. LT cables

6. HT Motors

7. LT Motors

8. Medium voltage bus ducts

9. LT bus ducts

10. Cabling, Earthing& Lightning Protection

11. Station Lighting (respect to AHP)


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12. Fire Proof cable Penetration Sealing system

13. Battery.

14. Battery charger

15. Electrical Actuators with integral starters

16. LT control cables

17. Screened Control Cables

18. Local Control Panels for HT and LT Motors, other equipments.

19. Earthing Protection System. 20. LPBS , JBS(CJB& PJB) & power distribution boards (PDB)

21. Instruments/field devices/ other equipments.

ELECTRICAL GENERAL:

The following electrical items for the completion of entire AHP package shall also be

in the bidder’s scope of supply, testing and E& C with respect to the NTPC technical

specifications.

1. Minimum rear space for local panels and distribution boards shall be sufficient from

the nearest obstruction. Cabling shall be done clearing any interference between

collars, greasing points and dust collection. There shall be minimum headroom

below runoff cable trays.

2. Local control panels requiring operator’s attention shall not be located in dust prone

areas. Local panels in each area shall be housed in a dust proof cabin to minimize

dust nuisance.

3. Cable schedule shall be prepared by the bidder and shall furnish during detailed

engineering stage.

4. If speed control is required for any of the drives, drive panel for the same shall be in

the scope (supply and E&C) of bidder.

16. SCOPE OF C&I FOR AHP PACKAGE VENDOR:


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GENERAL

The Contractor shall provide all Instrumentation systems, accessories and associated equipment, which are included in Contractor’s scope, in a fully operational condition acceptable to the Employer. The Contractor shall also provide all material, equipment and services which may not be specifically stated in the specifications but are required for completeness of the equipment/systems furnished by the Contractor and for meeting the intent and requirements of these specifications. The work shall be consistent with modern power plant practices and shall be in compliance with all applicable codes, standards, guidelines and safety requirements in force on the date of award of the contract.

All detailed technical requirements for the specified system shall be in line with

NTPC Technical specifications as specified in Vol – IIA of the Technical Specs.

a) All the Instruments as indicated in enclosed flow schemes/diagrams/relevant

tender drawings/ BOQ & corresponding Mechanical sections meeting redundancy

and other requirements specified under technical specifications are to be

provided as a minimum.

b) All Instruments which are Integral to equipment like pumps, motors etc., which

are not indicated in enclosed P & IDs but required for control, monitoring and

operation of the equipment/plant/ Systems are to be provided. All the instruments

shall be provided by the Contractor to meet actual system requirements subject

to Employer’s approval.

c) Further, all the instruments which are required to implement the control

philosophy as specified in corresponding Mechanical sections shall be provided

by the Contractor, within the quoted lump sum price.

d) For temperature elements being supplied by bidder, temperature transmitters

shall be provided by the bidder. These temperature transmitters shall be mounted

in junction boxes, supplied by the bidder. Suitable arrangement / accessories

shall be provided by the bidder for mounting the Temp. Transmitters in these

Junction boxes.


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PROCESS CONNECTION & PIPING

Process connection and piping including all impulse piping, pneumatic piping/tubing, valves, valve manifolds, fittings and all other accessories required for proper installation & completeness of impulse piping system and air supply system, as stipulated in Vol – IIA of the Technical Specs.

INSTRUMENTATION CABLES, POWER SUPPLY CABLES & ACCESSORIES,

CONTROL SYSTEM:-



SCOPE MATRIX BETWEEN NBPPL AND BIDDER

SL. NO.

DETAILS SUPPLY E & C REMARKS

1 DDCMIS PANEL NBPPL NBPPL

1. Instrument cables, signal cables from DDCMIS panel (AHP control room) to main control room shall be in the scope of NBPPL.

2 UPS NBPPL NBPPL 1.Power supply from UPS to the DDCMIS panels shall be in NBPPL scope

3 Instrument cables (signal, communication cables etc.)

Bidder Bidder .

4 Measuring instruments Bidder Bidder

5 Control desk, LVS and panels

NBPPL NBPPL

6 Furniture of control room

NBPPL NBPPL

7 RIO Panels (If any) NBPPL NBPPL 1. Instrument cables, signal

cables from RIO panels to DDCMIS panel (AHP


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control room and main control room) shall be in the scope of NBPPL.

8

Any other equipment/material/ service required for completeness of AHP but not specified above.

Bidder Bidder

NOTES:

1. Make of all C&I / Electrical equipments/items supplied shall be reputed make & shall be subject to approval of NBPPL/NTPC before finalising on them.

2. All Operation philosophy and QAP’s shall be subject to approval of NTPC after award of contract without any price implication to NBPPL. If bidders have any reference QAP of NTPC projects then same shall be applicable. QAP attached with specification is for reference only.

Design, supply, transportation, loading/unloading at site, receipt, storage, security,

transportation to erection location, Erection &Commissioning of the following electrical

items for the completion of AHP package but not limited to shall be in the scope of

successful bidder.

1. Measuring instruments (Primary and Secondary)

2. Electrical power supply system

3. Instrumentation and Power supply cables

4. Type test requirements.

5. Instruments/field devices/ other equipments.

6. Instrument Cables

7. Vibration Monitoring System including sensors.

C&I GENERAL:

1. Equipment PLC specifications, Hook up, Interface between Equipment PLC and

Main plant DCS shall be as per NTPC specifications


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2. Input – output signal cabling for PLC and field instruments or Local Control

Stations or Junction box up to Marshalling Cubicle (DDSMIS) in control room is

included in bidder’s scope. Cabling includes supply of cable, cable trays, supports,

glands, lugs, tags, ferrules, laying and termination up to JB.

3. For successful implementation of control system-DDCMIS based (Employer’s

scope), the bidder shall furnish Control philosophy/write-up, I/O list, drive list,

termination details and all other details/drawings/data/information which shall be

used for preparation of logic diagrams for controls, interlock and protection of

Bidder’s equipment. Any other data as might be required by Employer during

detailed engineering stage shall also be forwarded without any cost repercussions.

Bidder shall depute his engineer to customer office for approval of above

documents. Bidder shall provide full support during FAT and commissioning of

DDCMIS System.

4. Bidder shall furnish termination details for all I/Os to be connected to Employer’s

RIO/control system cabinets as per philosophy approved by Employer during detail

engineering stage. The format and exact details by biddershall be approved by

employer during detail engineering. While preparing I/O list and drive list during

detail engineering bidder shall obtain details of exact DDCMIS/RIO configuration

from employer and include details of the same in these lists to be furnished by

bidder. Bidder shall depute his engineer to NTPC, Noida for approval of above

documents.

5. All the instruments / equipments including vibration monitoring system, sensors,

transmitters, transducers, temperature elements, switches etc. which are required to

implement the control philosophy as specified in technical specification for overall

AHP package shall be in the bidder’s scope of supply and E&C.

6. Temperature transmitters are also to be supplied by bidder for the temperature

elements supplied by bidder (Motor RTDs). These temperature transmitters shall be

mounted in junction boxes, supplied by bidder. The instrumentation


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cables/thermocouples extension cables up to temperature transmitters and from

junction boxes to control rooms shall also be in bidders scope of supply and E&C.

7. Temperature elements shall be suitably grouped depending on physical locations and

shall be connected to the JBs in which temperature transmitters are mounted.. The

arrangement of temperature transmitters in junction boxes and location of junction

boxes will be discussed and finalised during detail engineering.

8. JBs shall be strategically located in each area to enable usage of multi core cables to

DDCMIS. Cables and Cabling of all field devices up to JB (JB in bidder scope) and

from JB to marshalling cubicle (DDCMIS) in control room shall also be in bidders

scope of supply and E&C.

Type test reports shall be submitted as per NTPC specification wherever applicable. In case of non-availability of type test reports for the similar rating/type, bidder shall conduct the type test at no extra cost to NBPPL.

9. Technical specification shall be followed without any deviation for all equipments

design, testing, supply and E & C.

10. Cable schedule shall be prepared by the Bidder and shall furnish during detailed

engineering stage.

11. Cabling between supplied equipments to Junction Boxes/Local Panels including

supply of cables, cable trays, supports, accessories like glands, lugs, laying and

termination is in Bidder’s scope.

12. Supply and erection of all JBs (Power &Control) and Local control panels

connected with mechanical equipments and instruments (wherever required) shall be

in AHP Bidder scope.

17. Liquidated Damages for Short fall in Auxiliary Power Consumption Performance:


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The bidder shall guarantee the Auxiliary power consumption for this package apart

from other performance of the packages as mentioned in Volume IIA Technical

Specifications.

The Successful bidder shall demonstrate the above guarantees during performance

testing at site.

The employer may accept the equipment after levying LD as below:

Guarantee Rate of Liquidated

Damages (LD)

Acceptable shortfall with

LD

Liquidated Damages for increase of every KW of Power Consumption at motor terminals for each of equipment over the Guaranteed value in the Contract (as determined at shop for each equipment)

US $ 4646 (US dollar four thousand six hundred and forty six only) per 1 KW increase in Auxiliary Power consumption

(+) 1% of the guaranteed auxiliary power consumption

However, if the demonstrated guarantee continue to be more than (+) 1 % of

guaranteed auxiliary power consumption value, the employer may at his discretion

reject the equipment and recover the payment already made or accept the equipment

only after levying LD against the contractor.

For Equipments the test results of one equipment shall be evaluated and the liquidated

damages for deficiency in guaranteed parameters shall be assessed by multiplying the

number of working equipments with the Liquidated Damages (L.D) figure for the

tested equipment and shall be levied.

Notes:

a. If the contract currency is other than U.S dollars, then the liquidated damages

shall be in equivalent amount in contract currency based on Bill selling exchange

rate of State bank of India prevailing on the date of award of contract 05-08-2013


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Contractor’s aggregate liability to pay liquidated damages for failure to attain the

functional guarantee shall not exceed twenty five percent (25%) of the contract price.

18. Bid Evaluation Criteria corresponding to Aux. Power: The bids received shall be evaluated for power consumption at inlet to the motors, in

respect to drives specified (working drives only Viz. Not the standby), for the purpose

of price comparisons as briefed below:

The Bid evaluation shall be done at the rate as specified in Datasheets per one (1) KW

Power consumption, per working equipment as follows:

Ps = Sum (Pi X Di) + TL

Where

Ps = Guaranteed Auxiliary Power Consumption for Ash Handling System

Pi = Power Consumed by each equipment wise in ash handling system as per below

Di= Duty Factor to be considered for each equipment wise in ash handling system

TL= Losses of Transformers supplied by bidder based on works test reports.

List of drives with corresponding weight age factors thereof for which power

consumption is to be guaranteed is as follows:

S.No Drive Weight age Factor

1 Bottom Ash crushers 0.3125 for jet pump system & 1.0 for

submerged scrapper conveyor system

2 Bottom Ash H.P water Pumps 0.625 for jet Pump system & 1.0 for

submerged scrapper chain conveyor

system.

3 Bottom Ash L.P Ash water Pumps 1.0

4 Fly ash water pumps 1.0

5 Bottom Ash slurry Transportation pumps 1.0


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6 Submerged scrapper chain conveyor 1.0

7 1. Fly ash conveying air compressors

with air drying plant (ADP)

1.0

2. Fly ash conveying vacuum pumps 1.0

3. Transport air compressors with air

drying plant.

0.5

8 BA hopper cooling water over flow pumps 1.0

9 Ash slurry disposal pumps

a. With SCC for Bottom ash 1.0

b. With jet pump system for bottom ash 1.0 for continuously operating pump

and0.3125 for intermittently operating

pump.

10 Seal/Cooling water pumps 1.0

11 Instrument air compressor with air drying

plant

1.0

12 Ash water Make up pumps 1.0

The Power consumed by each drive for arriving at benchmark power for bid

evaluation shall be as indicated in datasheets of respective equipments.

No Advantage shall be given to the bidder for Aux. Power quoted lower than the

benchmark values given in cl. No. 19, considering the bid evaluation efficiencies for

pumps/equipments and motor as indicated in Datasheets. However the bids shall be

evaluated as mentioned in clause 19 if the Aux. Power quoted are higher than the

benchmark values.

19. Criteria for Evaluation and comparison of bids corresponding to Aux. power:

The bidder’s proposal shall be evaluated as per following:

The Lump sum price (including all freight, taxes & duties etc,) offered by the bidders

for the entire scope (including mandatory spares) shall be taken as base price.


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Dated : 16.01.2015

The bench mark auxiliary power consumption for Ash handling system package are as

below:

b. Jet pump system : 3800 KW

c. Scrapper chain Conveyor system : 3200 KW

Loading for deficiencies will be as follows:

In case auxiliary power consumption quoted by the bidder is more than the

benchmark auxiliary power value mentioned above (calculated as per formula given

in clause 18.0), then the difference in auxiliary power consumption shall be multiplied

by an amount of US $ 4646 per KW and loaded.

The price for evaluation shall be the sum of following prices and loading:

a) Total lump sum price (including freight, taxes & duties etc.) for entire scope

(including mandatory spares).

b) All costs on account of loading as described above.

The sum of a) & b) shall be called as the “Total Evaluated Price (TEP)” of bidder.

The lowest of the Total Evaluated Price (TEP) of the bids shall be considered as

lowest bidder (L1).

All bidders shall invariably furnish Guaranteed Auxiliary Power Consumption in

Kw for evaluation of bid.

20. CONSTRUCTION FACILITIES:

A. Land

1. Depending upon the availability, Land for contractor’s office, storage and other

facilities will be allocated with certain time frame and to the extent available/

considered necessary. The contractor has to plan and use the existing land inside the

project premise considering the use of land by other civil /mechanical/ electrical

contractors and the storage of plant machineries and materials the existing land shall

be shared by all erections agencies.


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2. The contractor will be responsible for handing back all lands, as handed over to him

by EMPLOYER/Customer.

3. Area within plant premises for fabrication, office, storage area etc. for construction

purpose shall be provided as per availability free of cost.

B. Construction of temporary office, stores etc.

The contractor shall arrange at his own cost cleaning of area allotted, construction of his

temporary office, stores, cement godown (if required) etc. and also the watch and ward of

all the above. Materials required for the same shall be provided by contractor at his own

cost.

C. Electricity

1. Contractor shall have to deploy the DG sets for carrying out the tender works.

However electricity (for construction purpose only) may be provided free of cost at

customers single point source subject to availability. Bidders have to make his own

distribution arrangement to draw electricity.

2. Contractor will have to procure & install general illumination system during

construction right from start of his work. This system will include temporary pole

lighting, portable lighting towers with DG back-up for different floors/working areas

for execution of the work & safety of workmen till the permanent illumination system

is established, within the quoted rate. The illumination should be such that minimum

illumination requirement as specified by Indian standards for general illumination is

maintained.

3. Supply of electricity shall be governed by Indian Electricity Act and Installation Rules

and other Rules and Regulation as applicable. The contractor shall ensure usage of


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electricity in an efficient manner and the same may be audited by EMPLOYER time

to time. In case of any major deviation from normally accepted norms is observed,

EMPLOYER will reserve the right to impose penalty as deemed fit for such cases.

4. Demobilization of the facilities after completion of works shall be in Contractors

scope.

5. The bidder shall have to provide earth leakage circuit breaker at each point wherever

human operated electrical devices/ T&Ps are deployed.

6. The power supply will be from the available grid. EMPLOYER shall not be

responsible for any inconvenience or delay caused due to any interruption of power

supply/ variation in voltage level and no compensation for delay in work can be

claimed by the contractor due to such non-supply on the grounds of idle labour,

machinery or any other grounds.

7. The contractor should ensure that the work in critical areas is not held up in the event

of power breakdown. In the event of breakdown in the electric supply, if the progress

of work is hampered, it will be the responsibility of the contractor to step up the

progress of work after restoration of electric supply so that overall progress of work is

not affected.

D. Water

1. Contractor has to make his own arrangement for construction and drinking water by

resorting to the methods like bore well, water tankers etc. Necessary network for

construction & drinking water system shall be done by the bidder at his own cost.

Contractor is to get the construction water tested and approved by the customer at his

own cost.

2. Contractor should arrange on their own, drinking water in their labour colony.

3. Contractor will have to arrange for storage of water to meet the day-to-day

requirement.


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Dated : 16.01.2015

21. TERMINAL POINTS:

S.No: ITEM DESCRIPTION TERMINAL POINT

1 Bottom Ash Outlet of furnace bottom hopper with SS seal

plates, drip meshes.

2 Economiser Ash Outlet flange of duct hoppers below Economiser

3 Primary & Secondary Air Pre

heater Ash Outlet flange of duct hoppers below AHPs

4 ESP Ash Outlet flange of dust hoppers below ESP

5 Ash water make up piping 13B+72, 12A+20 (As per NBPPLP&Id)

6 Service water 13B+72, 12A+92 (As per NBPPLP&Id)

7 Potable water 13B+72, 12A+92 (As per NBPPLP&Id)

8 Equipment cooling water/DM

cooling Water (limited to 285m3/hr)

Supply and return piping at 13A+55, 12B+70.

9 Ash water make up piping

Make up Pump piping from Ash water make-up pump outlet to coordinate 13B+72, 12A+20 is in NBPPL scope. Further piping to Ash water tank is in Bidders scope. Refer P&Id of plant water system attached with technical specification.

10 Ash slurry pipeline Up to Arkha Ash dyke (Approx. 12 kms)

11 11 kV power supply 11kV Switch board at HT switchgear room (Near

TG area)


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NBPPL‐004‐102‐26‐P1M‐A Rev. No.: 00


Dated : 16.01.2015

22. CIVIL AND STRUCTURAL SCOPE :

S. No. Job / Area Responsibility for Design & Drawing

Responsibility & Scope of Supply

Responsibility of Supervision/ Checking

Responsibility & Scope of Fixing, Erection & Commissioning

A Bottom and Economiser Ash Slurry System

A.1

Structural steel works for Bottom Ash Hopper along with its platform and stair case .Supporting structural steel works for water, slurry & instrument air pipes in Boiler area, handrails, Chequered plates, Gratings etc. Grouting for equipment foundation, BAH Foundation and BA panel foundation.

AHP vendor

AHP vendor

AHP vendor

AHP vendor

A.2 Structural Steel works, gratings, handrails for BA Overflow Sump

AHP vendor AHP vendor AHP vendor AHP vendor

A.3

Foundations for bottom ash hopper columns, clinker grinder drive, slurry pipe thrust blocks, air water convertor tank, overflow sump and drain sump including foundation bolts and insert plates as applicable.

AHP vendor NBPPL AHP vendor /

NBPPL NBPPL

A.4

Structural Steel works, gratings, chequered plate, handrails, insert plates etc. for Access/ maintenance Platform for ECO / APH / hopper equipments insert plates as per approved



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drawing.

A.5

Civil Foundation for above Clause A.4 including routing work, foundation bolts, insert plates as applicable


NBPPL NBPPL

B Ash Slurry Disposal and Ash water System

B.1

Ash Slurry Pump House, Ash Water pump House, MCC rooms including Control room, cable spreader room, cable trenches, seal water tank, ash water tank, ash slurry sump, drain sump, access/ maintenance platforms inside/outside building including reinforcement steel, cement, roof truss, deck sheet, crane girder, walkways, handrails, gratings, monorails for hoists in the above buildings & structures including grouting works (excluding equipment bolts grouting), foundation bolts, insert plates as applicable.


NBPPL NBPPL

B.2

Equipment foundation for water and slurry pumps, slurry pipe thrust blocks, slurry pipe pedestals, insert plates, trench/drain covers as per approved drawing


NBPPL NBPPL

B.3 Pipe Sleeves, puddle joints, overflow pipes, vent pipes for tanks and sumps

AHP vendor AHP vendor AHP vendor /

NBPPL NBPPL

B.4 RCC Pipe pedestals(excl structural works above


NBPPL NBPPL


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pedestals to maintain levels if any required as per site requirement) for ash slurry disposal piping from ash slurry pump house to ash dyke

B.5

Structural works above the pedestals to maintain levels if any required as per site requirement of RCC pipe pedestals as per B.4

AHP vendor AHP Vendor AHP vendor AHP vendor

C Fly Ash Conveying System from APH, Duct, ESP & Ash hoppers to Buffer hopper

C.1

Wherever only Ash vessels, Cables, local control panel, junction boxes, Ash Pipes, Ash-Water pipes i.e. ( only for Ash Handling System ) are to be supported, Structural steel works including Trestles, insert plates, grating, handrails, chequered plates, in boiler area, ESP area and chimney area up to Ash Slurry / Ash Water /Raw Water Pump Houses.


C.2

Structural steel works for FAE(Buffer Hoppers) towers along with staircase, grating, handrails, and chequered plates


C.3 Civil foundations for FAE (Buffer Hoppers) towers.


NBPPL NBPPL

C.4

Compressor house building, foundation for cooling towers, foundation of compressors, blowers, heaters, Air dryers,


NBPPL NBPPL


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cooling tower, cooling water pumps and air receivers, access, maintenance platforms inside / outside building including reinforcement steel, cement, roof truss, deck sheet, crane girder, walkways, handrails, gratings, monorails for hoists in the above buildings and structures.

D Main Fly ash silo area

D.1

Silo supporting columns foundations, foundations for silo stair case, MCC room, cable spreader room, covered sheds for Blowers & heaters, cable trenches, including reinforcement steel, cement, roof truss, deck sheet, walkways, handrails, gratings, monorails for hoists, Foundation of Weigh Bridge and its foundation.


NBPPL NBPPL

D.2

Access/ maintenance platforms for Mechanical Equipments &Valves, Supporting structural steel works for Ash, water, air, slurry & instrument air pipes in and around ISH and Silo.



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D.3

Silo Utility Building, Ash conditioner water sump, Drain sump, Drains, Access/ maintenance platforms inside/outside building including reinforcement steel, cement, roof truss, deck sheet, crane girder, walkways, handrails, gratings, monorails for hoists in the above buildings & structures including grouting works, foundation bolts, insert plates as applicable.


NBPPL NBPPL

D.4 Main Silo and its connecting platforms at unloading and top level, Staircase for Silo


E AHP Pipe rack and Pedestals cum cable Rack

E.1 Foundation of pipe rack & fixing of foundation bolts


NBPPL NBPPL

E.2

Structural steel works of Pipe rack including gratings, handrails, chequered plates and grouting works

AHP vendor NBPPL AHP vendor/

NBPPL NBPPL

E.2 Foundation of pipe pedestals, insert plates AHP vendor NBPPL

AHP vendor/NBPP

L NBPPL

E.3 Pipe clamps and grouting of pockets on pedestals AHP vendor AHP vendor AHP vendor AHP vendor

F Miscellaneous

F.1

Foundation Bolts for mechanical equipments in all AHP Area and grouting of pockets and base of equipments.



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F.2 Alloy/CI liners all along the sluice trenches all along the ash handling plant (if any)


F.3

Service water and drinking water arrangement with required pipes and valves for ash handling buildings from terminal point to water tank for Compressor house, Silo utility building and Recovery water pump house.


ADDITIONAL NOTES:

1. Estimated Bill of quantities for Civil & structural works as per detail scope of works, execution at site to be furnished by the bidder.

2. Equipment orientation for structures like BA hopper, detail fabrication drawings have to be submitted by successful bidder for review / comments by NBPPL/ NTPC before release for manufacturing.

3. During detail engineering, General arrangement drawings to be submitted for first review / approval along with approved Mechanical GA drawings.

4. Wherever required in the absence of inserts plates etc. HILTI make or any other approved anchor fasteners supply & fixing to be included in the scope of bidder.

5. The pile cut off level at -7.0 mtr for Boiler columns mkd S2L, S3L, S7L, S8L and S9L to meet the ash collection sump requirement. Consequently, Bottom of raft for ash collection sump shall be EL (-4.5 Mtr) w.r.to considered pile cutoff level of EL (-7.0 Mtr).Bidder to take care of the same while designing the bottom ash system.

23. EXCLUSIONS:

1. The installation of Piles for bottom ash hopper shall be excluded.

2. Station lighting for roads along AHP System..

3. DDCMIS panels (including UPS, battery and battery charger required for DDCMIS

panel), Control desk, LVS, RIO panel, Marshalling Cubicle (DDCMIS) and

Furniture’s for main control room.

4. EPABX & Public Address System.

5. Complete Fire detection and Protection system.


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Dated : 16.01.2015

ANNEXURE- I

Refer NIT for PRE-QUALIFICATION CRITERIA FOR THIS PACKAGE


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Project : NBPPL / FGUTPP - STAGE IV, Unchahar – 1 x 500 MW

Engineer : SKD/BS/JLJ TITLE : ASH COLLECTION DATA FOR BOILER

Reviewer : AVR NTPC Drg No. : 1450-001R-SGTR-PVC-V-505

Approver : MA/SCS Sheet 2 of 2 Rev 01

ASH COLLECTION DATA AT BMCR

1. Fuel and ash quantities:

Design Coal Worst Coal Best Coal

Coal fired at 100% BMCR t/hr 361 411 299

Ash in coal % 40.39 45.26 38.19

Ash generated t/hr 145.8 186.0 114.2

2. Ash distribution data -t/h (BMCR)

Furnace Bottom Ash 25 % 36.5 46.5 28.6

Economiser Ash 5 % 7.3 9.3 5.7

Air Preheater - PAH 5 % 7.3 9.3 5.7

- SAH 5 % 7.3 9.3 5.7

ESP ash 90 % 131.2 167.4 102.8

3. Sieve analysis of fly ash (% by weight)

Less than 10 microns 32

10 - 20 microns 24

20 - 30 microns 14

30 - 40 microns 10

Greater than 40 microns 20

Additional Information

Description Temp. OC

Pressure

mmwc

No. of

Hoppers

Elevation of

Hopper

bottom m

Furnace Bottom Ash 1040 -40 * *

Economiser Ash/Flue gas duct Ash 340 -100 * *

Air Preheater Ash (Primary) 150 -225 * *

Air Preheater Ash (Secondary) 150 -225 * *

ESP Ash 150 -270 * *

* Refer GA / Duct Drawings


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Customer No:R552.

Project: NBPPL Feroze Gandhi Unchahar TPP Stage-IV (1X500MW) Ash Distribution Data in Various Fields of ESP Hopper

Rev:00 / Date: 07.07.2014 Page No:2/9

REQUIREMENTS OF ASH HANDLING SYSTEM FOR ESP ((AASSHH CCOOLLLLEECCTTIIOONN RRAATTEESS FFOORR AASSHH HHAANNDDLLIINNGG SSYYSSTTEEMM DDEESSIIGGNN OONNLLYY))

The Electrostatic Precipitators are installed after the Air-pre heater collects the maximum amount of fly

ash from the dust laden flue gas in a boiler circuit and is stored temporally in the ash hoppers. These fly

ash have to be removed from the hoppers by installing fly ash removal system.

In order to ensure that most efficient and economical design for the fly ash removal system, it is of utmost

importance that certain major points are to be brought to the notice of those responsible for the

specifications and the design of fly ash handling equipment.

There are 4 electrostatic precipitators of size FAA - 9 X 45M - 2 X 92 150 - 2 per boiler. Each

ESP is provided with 4 hoppers arrangement across the flow directions. Each ESP is provided with 36

numbers of hoppers. These ash hoppers are located directly beneath the fields and receive the fly ash

dislodged from the collecting electrode and emitting system. The hoppers are of pyramidal shape with an

outlet opening size of 400X400 mm and are designed to have a valley angle of not less than 60 Deg. This

valley angle is provided to ensure free flow of fly ash. For free flow of ash it is recommended to set the

hopper heater temperature at 120 Deg C during normal operation of ESP.

Hopper heaters are provided to avoid condensation of water vapor on the inside surface of the hopper.

The ash handling system supplier shall ensure a gas-tight joint at hopper outlet to avoid admission of

moisture into the hopper wall and interfere with the free flow of ash inside the ash hoppers.

One of the important factors to be considered while specifying the ash disposal system is the pattern of

ash collection in ash hoppers along the flue gas path. The rapping of the collecting electrodes and emitting

electrodes are intermittent and are programmed by microprocessor based rapper controller. This

intermittent operation of rapping mechanism is essential from the point of view of operation of the

precipitators. Sufficient collection of fly ash on the collecting plates must be permitted so that at the time

of rapping, the collected dust shears off the collecting electrodes and falls into the hoppers in the form of

large agglomerates thereby minimizing the rapping losses.


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Customer No:R552.


Rev:00 / Date: 07.07.2014 Page No:3/9

Ash Collection Rate at Design Condition :

The ESP is designed with one field out of service at ESP Design Point. Regarding the patterns of ash

collection at different field availability conditions are tabulated below.

Case-I: The ash collection rate is furnished for 8 working fields considering the first field is in OFF

condition. This is because the ESP is designed with one field out of service.(Details furnished in Table-1)

Case-II: The ash collection rate is furnished for 7 working fields considering the first field is OFF and

second field is OUT of service condition. This is because at some time any one field in addition to the

Case-I might occur. (Details furnished in Table-2)

Case-III: The ash collection rate is furnished for 8 working fields considering the last field is in OFF

condition. This is another variant of Case-I.(Details furnished in Table-3)

Case-IV: The ash collection rate is furnished for all 9 working fields considering all fields are in service

for information purpose. (Details furnished in Table-4)


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Customer No:R552.


Rev:00 / Date: 07.07.2014 Page No:4/9

(TABLE – 1)

CASE – I Pattern of Ash Collection Rate In Different Hoppers Considering 8 Fields Working And First Field In Off Condition (At ESP Design Point Condition) Field

Sl.

no

Work

ing

Field

No

Stage

Efficiency

%

Rapping

Frequency

Raps/hr

Period of

Collection

(minutes)

Ash

Collection

per rap

(Kg/Rap)

Ash collection

Per hopper

(Kg/hr)

No. of

hoppers per

field in a

row

Ash

collection

per ESP

(kg/hr)

1 OFF

2 1 70.0 15 4 438.17 6572.55 4 26290

3 2 18.388 10 6 172.65 1726.5 4 6906

4 3 6.858 6 10 107.33 643.98 4 2576

5 4 2.765 4 15 64.88 259.52 4 1038

6 5 1.148 3 20 35.92 107.76 4 431

7 6 0.480 2 30 22.5 45 4 180

8 7 0.205 1 60 19.25 19.25 4 77

9 8 0.086 1 60 8 8 4 32

Total (kg) 37530

Total ash entering in one ESP per hour, in kg 37556

Total ash collected in one ESP per hour, kg 37530


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Customer No:R552.


Rev:00 / Date: 07.07.2014 Page No:5/9

(TABLE – 2 )

CASE – II Pattern Of Ash Collection Rate In Different Hoppers When The First Field Is Off And Second Field Out Of Service Condition (At ESP Design Point) Field

Sl.

no

Work

ing

Field

No

Stage

Efficiency

%

Rapping

Frequency

Raps/hr

Period of

Collection

(minutes)

Ash

Collection per

Rap

(Kg/Rap)

Ash

collection

Per hopper

(Kg/hr)

No. of

hoppers

per field

in a row

Ash

collection

per ESP

(kg/hr)

1 OFF

2 OUT OF SERVICE

3 1 70.0 15 4 438.17 6572.55 4 26290

4 2 18.388 10 6 172.65 1726.5 4 6906

5 3 6.858 6 10 107.33 643.98 4 2576

6 4 2.765 4 15 64.88 259.52 4 1038

7 5 1.148 3 20 35.92 107.76 4 431

8 6 0.480 2 30 22.5 45 4 180

9 7 0.205 1 60 19.25 19.25 4 77

Total (kgs) 37498


Total ash collected in one ESP per hour, kg 37498


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Customer No:R552.


Rev:00 / Date: 07.07.2014 Page No:6/9

(TABLE – 3 )

CASE – III Pattern Of Ash Collection Rate In Different Hoppers Considering Last Field Off Condition (At ESP Design Point Condition) Field

Sl.

no

Work

ing

Field

No

Stage

Efficiency

%

Rapping

Frequency

Raps/hr

Period of

Collection

(minutes)

Ash

Collection

per Rap

(Kg/Rap)

Ash

collection

Per hopper

(Kg/hr)

No. of

hoppers per

field in a row

Ash

collection

per ESP

(kg/hr)

1 1 70.0 15 4 438.17 6572.55 4 26290

2 2 18.388 10 6 172.65 1726.5 4 6906

3 3 6.858 6 10 107.33 643.98 4 2576

4 4 2.765 4 15 64.88 259.52 4 1038

5 5 1.148 3 20 35.92 107.76 4 431

6 6 0.480 2 30 22.5 45 4 180

7 7 0.205 1 60 19.25 19.25 4 77

8 8 0.086 1 60 8 8 4 32

9 OFF

Total (kg) 37530


Total ash collected in one ESP, kg/hr 37530


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Customer No:R552.


Rev:00 / Date: 07.07.2014 Page No:7/9

(TABLE – 4 )

CASE – IV Pattern Of Ash Collection Rate In Different Hoppers Considering all fields in service (At ESP Design Point Condition) for information purpose. Field

Sl.

no

Work

ing

Field

No

Stage

Efficiency

%

Rapping

Frequency

Raps/hr

Period of

Collection

(minutes)

Ash

Collection

per Rap

(Kg/Rap)

Ash

collection

Per hopper

(Kg/hr)

No. of

hoppers per

field in a row

Ash

collection

per ESP

(kg/hr)

1 1 70.0 15 4 438.17 6572.55 4 26290

2 2 18.388 10 6 172.65 1726.5 4 6906

3 3 6.858 6 10 107.33 643.98 4 2576

4 4 2.765 4 15 64.88 259.52 4 1038

5 5 1.148 3 20 35.92 107.76 4 431

6 6 0.480 2 30 22.5 45 4 180

7 7 0.205 1 60 19.25 19.25 4 77

8 8 0.086 1 60 8 8 4 32

9 9 0.025 0.5 120 4.5 2.25 4 9

Total (kg) 37539


Total ash collected in one ESP, kg/hr 37539


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Customer No:R552.


Rev:00 / Date: 07.07.2014 Page No:8/9

Ash collection Pattern:

It may be noted that in the first working field 438.17 kg of ash is dislodged by rapping, in one minute.

The second rapping takes place only after (period of collection – 1) 3 minutes and again raps off 438.17

kg of ash. In case the first working field is rendered ineffective due to certain problems, the second

working field which was earlier collecting ash at the rate of 172.65 kg/rap will now be collecting 438.17

kg/rap just like the first field. The same logic is applicable for the subsequent fields in series as indicated

in the Table.

The ash handling system shall have to cope with sudden surges in the pattern of ash collection in the

hoppers. There shall not be any reduction in ash evacuation capacity of hoppers subsequent to first field

hoppers for the reason explained above.

In case, the capacity of ash handling is inadequate, it will lead to frequent choking and undue build–up of

ash in the hoppers, ultimately resulting in tripping of the fields of electrostatic precipitator.

Therefore it is imperative that these factors are taken into consideration while specifying the ash handling

system for the electrostatic precipitator.

Table 1-4 shows that the ash evacuation capacity of the first 3 fields shall be same.

However, in practice, there will be natural collection of ash when the fields are switched off depending

upon the particle size. If the first field is off, it is expected that, the natural collection would be around

20% and if the first two fields are off, it would be around 25%. Though the fields are off, there will be

rapping in operation. Therefore, the ash handling system should work even when the fields are switched

off.


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Customer No:R552.


Rev:00 / Date: 07.07.2014 Page No:9/9

NOTE

1. The above data to be used for designing the ash handling system purpose.

2 The ESP ash collection rates furnished above are for ONE ESP ONLY and the same values shall

be considered for other THREE ESPs also.

3 The predicted values of ash collection data at different hoppers is based on design point

condition. However, while designing ash-handling system, suitable margins for the ash handling

system operation and maintenance has to be considered over and above the data indicated above.

4 It may be noted that for maintaining flow ability of ash, stainless steel lining is provided at the

bottom portion of the hopper. Space provision of 400 X 400 mm is envisaged in each hopper on

two opposite sides for installation of fluidizer pad. Kindly note that for hoppers of stainless steel

lining 360X360 mm size inside the hopper will be cut at works before dispatch. Hopper wall 5 to

8 mm thick shall be cut open at site suitably by Ash handling vendor/executing agencies during

installation of fluidizer pad.

5 It is recommended to evacuate the ash hoppers periodically and it may please be noted that the

accumulation of ash beyond the permitted level of ESP hoppers may, not only affect the ESP

performance due to damage / misalignment of ESP internals but also may lead to structural

failure because of overloading of ash.


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ATTACHMENT - 3F Page L\ A h

EPC PACKAGE FOR FEROZE GANDHI UNCHAHAR THERMAL POWER PROJECT STAGE-IV (1x500 MW)

BID DOCUMENT NO. CS-1450-001-9 (Past Performance Data)

Sub-vendor's Name and Address : 7b Employer's Name & Address

Details of Similar Plant & Equipment (Ash Handling system) Commissioned/Supplied in last ten years : .............................................................................................................................................................................. Sl. client . . Date of Unit Date of Supply Date of Erection, Order Reason for No. Name & order size & Completion Testing & Commissioning Value Delay (if

Address No. of ----------------------.--- applicable) Units Sche- Actual Schedule Actual

dule .............................................................................................................................................................................

................................................................ ....................................................................................

Date : I .......................................... (Signature) (Printed Name) ...................... .. ........

Place : .................................... / (Designation)

& (Common Seal) .................................. , Note : 1. The above attachment shall be filled up by the bidder. e.3

2. Continuation sheets of like size and format may be used as per Bidder's requirement and shall be annexed to vl this Attachment. w

rP. .............. ...... Signature of authorized signatory .. #a.


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ATTACHMENT - 3D Page 1 of 19

EPC PACKAGE FOR FEROZE GANDHI UNCHAHAR THERMAL POWER PROJECT STAGE-IV (1x500 MW)

BID DOCUMENT NO. CS-1450-001-9 (Details of manufacturing capacities and plant loading of the Bidder

. . and Sub-contractor)

.'Bidder's Name and :Address : To Employer's Name & Address

We hereby furnish below the details of our installed manufacturing capacities (in MWIMT) and work in hand to establish spare capacity for completion of work under this Package. -----------------------------IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIILLLLLLLLLLLLLLLLLLLLLL

Item 2010-2011. 2011 - 2012 2012 - 2013 2013 - 2014 2014-2015 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - - . -. . . . . . . . . . . . . . . . . . . . -. . . . . . . . -. . . . . . . . . . . . . . -. . . . -. -. -. . *. . . . . . -. . . Bidder's Sub Bidder's Sub Bidder's Sub Bidder's Sub Bidder's Sub Shop Con- Shop Con- Shop Con- Shop Con- Shop Con-

t iac- trac- trac- trac- trac- tor's tor's tor's tor's tor's

. . shop. shop shop shop ............................................................................................................................................................................. I. Applicable for SG

A Production Capacity as installed

1' Steam generator &'auxiliaries

2. High Pressure and and .:

critical steam piping

3 Coal Pulverisers

4. ESP

5 Mill Reject HBndling Sysiem

6. Other EOT Cranes & hoisting equipment

\;"P *..-,A Signature of authorized signatory ......................... <3~2


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item 2010-201 1 2011 -2012 2012 - 2013 2013 - 2014 2014-2015 . - - - - - - - - - . . - . . . . . . . . . . . . . . - - - - - - - - - - . . . . . . . . . . . . . - . - - - - - - . - - . . - . . . . . . . . . . . . . . . . . . . . . . . . . . -. -. . - - - . - - - - - - - - - - - - - - - - - - - - - - . . - - . - . - - - . . - - - - - - - . . - Bidder's Sub Bidder's . Sub Bidder's Sub Bidder's Sub Bidder's Sub Shop Con- Shop Con- Shop Con- Shop Con- Shop Con-

trac- trac- trac- trac- trac- tor's tor's tor's tor's tor's shop shop shop shop

------------------------------------------------------------------------------------------------------*---"------------------------------------------------------------------

C. Balance Capacity Available

D. Orders Expected

E Work Load Expected for this Contract

F. Shortfall, if any

G Alternative arrange. ments to make up for this shortfall


B Firm Orders in Hand Upto


D. Orders Expected

E Work Load Expected for this Contract

F. Shortfall, if any

Signature of author~zed signatory VOLUME I NBPPL-004-102-26-P1M-A

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............................................................................................................................................................................. Item 2010-201 1 2011 - 2012 2012 - 2013 2013 - 2014 2014-2015

................................................................................................................................................ Bidder's Sub Bidder's Sub Bidder's Sub Bidder's Sub Bidder's Sub Shop Can- Shop Con- Shop Con- Shop Con- Shop Con-

trac- trac- trac- trac- trac- tor's tor's tor's tor's tor's shop shop shop shop

............................................................................................................................................................................. G Alternative arrange-

ments to make up for this shortfall

V. COAL HANDLING P U N T


6 Firm Orders in Hand Upto


D. Orders Expected

E Work Load Expect id for this Contract

F. Shortfall, i f any , .

G Alternative arrangements to make up for t h ~ s shortfall

VI. FUEL OIL HANLDING PLANT


Signature of authorized ,signatory ............ .. ........ . .


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0 0 '0 G 3 p. 9 ,"' . , 3 c; a_, -. ....i' " . -.., 3 . .A.

m - - . - ...- rage LU OT + I

To [Employer's Name & Address]

of the system equipments furnished by us under the Package are guaranteed. We meeting the guaranteed figures, you may at your discretion reject the equipmentlsys-

Nos. ;working for Nos, standby for Guaranteed Parameters of all uriits all units each equipment

Capacity, each Head, each Irn3/hr\ IhA\AlP\ \..""' I \ " a " * " , - -.---

ED CAPACITYIHEAD . .

- - - - - - -- - - - - -

L - - - - - - - -

- - - -

LP Seal water pumps - - - (ii) HP Seal water pumps - , -- - -

Signature of authorized signatory ....................... VOLUME I NBPPL-004-102-26-P1M-A

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(+, , "-. - " . - .. w ..,' , ,' . , (A _ I!

ATTACHMENT - 106 Page 22 of 27

.......................................... ... Nos. standby for Guaranteed Parameters of for all units each equipment

- TPH for each SSC

- TPH for each Jet pump

- TPH for each clinker grinder.

- TPH for each clinker grinder.

............................. TPH

............................. TPH

- deg.C at 1 ata pressure

- m3/hr, at - kgIcm2 (g) inlet pressure and - deg.C inlet temp.

! rized signatory ......................... VOLUME I NBPPL-004-102-26-P1M-A

of 70

,- (-, ". p _I_ I. _ ,.._ . . \ , . .-," Q + - . .J . , . - . . I !

ATTACHMENT - 108 Page 23 of 27

-.-- * * ----- Nos. working for Nos. standby for Guaranteed Parameters of for all units for all units each equipment ---

i - m3/hr. at - kglcm2 (g) inlet pressure and - deg.C inlet temp.

TR -

(-) - deg.C at lata pressure

- m3/hr. at - kg/cm2(g) inlet pressure & - deg.C inlet temp.

b) Outlet conditions

iii) Tonnage of refrigeration (TR)

t outlet of ADP

ii) Handling rate of air

Signature of authorized signatory .......................

- m3/hr. at - kg/cm2(g) outlet pressure & - deg.C outlet temp.

TR.

(-) - deg.C at lata pressure

- m3/hr. at - Kg/cmZ (g) discharge pressure.


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ATTACHMENT - 3E Page 4 of 44

EPC PACKAGE FCIR FEROZE GANDHI UNCHAHAR THERMAL POWER PROJECT STAGE-IV (1x500 MW)

BID DOCUMENT NO. CS-1450-001-9 (Present Order Book Pos~tion for Ash Handl~ng System)

Sub-vendor's Name and Address : To Employer's Name & Address

List of Orders received i n last five years & present status. ............................................................................................................................................................................. SI. Client Order No. of Date of Present Status % work Completion of Completion of Reason No. Value Units & Order -. --. --. --. . --. --. --. -- completed supply Erection testing for deiay

Unit size Sch- Actual/ Engg.1 --. -- --. - --. -- --. -. - & commissioning (if any) ............................ edule Expec- Manufact.. Sch- ~ ~ t ~ ~ l /

ted uringl edule Expec- Sch- Actual/ Erection ted eduie Expected

.............................................................................................................................................................................

. . Date :

Place

(Signature) ................................................. lid. (Printed Name) .........................................

(Designation) ............................................. ....................................... 1 (Common Seal)

Note : 1. The' above attachment shall be filled up by the bidder. 2 . Continuation sheets of like size and format may be used as per Bidder's requirement and shall be annexed to

this '~ttachment. CJ

Signature of authorized signatory ........... .... VOLUME I NBPPL-004-102-26-P1M-A

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