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r0 Proposal of Gree Tophill Lars - Ehi Rev1
r0 Proposal of Gree Tophill Lars - Ehi Rev1
2014
BUDGETARY PROPOSAL
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Lars Enviro Pvt. Ltd. 2014
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g2’s
Contents
Technical Proposal
I. Basic Design Data
II. Performance Guarantee
III. Treatment Scheme
IV. Process Description
V. Utility Requirements (GREE Scope )
VI. Battery Limits for Lars
VII. Brief Specification of LESAR Reactor
VIII. Lars Scope of Work
IX. PT. Energi Hijau Investama Scope of Work
X. Gree Scope of Work
XI. List of Supply Items (Lars Scope)
XII. List of Civil Units (PT. Energi Hijau Investama Scope)
Commercial Proposal
I. Price
II. Estimated Cost of Work ( Client Scope)
III. Manner of Payment
IV. Mode of Payments
V. Delivery
VI. Validity
VII. Warranty
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Project Notes
plant.
We have designed few units considering future expansion such as
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Technical Proposal
Characteristics of raw wastewater considered for designing the Biogas Plant (LESAR) are
as follows:
Key Converted
Sr. Items Parameters Unit Values / Adopted Unit
(90 Percentile) for design
1 Flow 2600 m3/d 2600 m3/d
2 pH 6.7 - 6.7 -
3 CODt 29.08 kg/m3 29080 mg/L
4 Assumed BOD 14.54 kg/m3 14540 mg/L
5 TSS 11.44 kg/m3 11440 mg/L
6 VSS 11.29 kg/m3 11290 mg/L
7 SO4 62.5 g/m3 62.5 mg/L
8 TP 122.1 g/m3 122.1 mg/L
9 TKN 582.4 g/m3 582.4 mg/L
10 O&G 152.7 g/m3 152.7 mg/L
Deg
11 Assumed Temp Not Given in Enq
36 – 39 C
It is assumed that the effluent does not contain any inhibitory substance for the
biological process. It is also assumed that all other parameters are within acceptable
limits prescribed by the concerned Pollution Controlling authority.
Characteristics of pulp (wet cake) considered for designing the Biogas Plant (LESAR) are
as follows:
Pulp
Note – To treat above quantity of wet cake / pulp, we have proposed 2 nos. of
Bio-digesters ( LESAR).
It is assumed that the Pulp does not contain any inhibitory substance for the biological
process. It is also assumed that all other parameters are within acceptable limits
prescribed by the concerned Pollution Controlling authority.
When the plant is subjected to above mentioned parameters, it shall give following
performance at steady state.
COD Removal - 90 ± 5 %
BOD Removal - 95 ± 5 %
pH - > 7.0
When the plant is subjected to above mentioned parameters, it shall give following
performance at steady state.
Biogas Qty - Approx. 26000 m3/day ± 5 % @ designed
Load (Approx. 1.8 - 2 m3/KG of VS
Reduced)
Wetcake (pulp).
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The foundation shall be suitably designed based on local soil type. The floating
type / foundation ensuring equal settlement is the most preferred type of
foundation.
Reactor will be fabricated at site using mild steel plates and structural members
confirming to relevant grades as per internationally accepted codes.
The inside of the reactor shall be sand blasted and painted using chlorinated
rubber paint as per standard specifications.
Reactor outside shall be wire brushed, cleaned / commercial sandblasted and
painted by synthetic enamel or aluminum paint as per client’s preference.
In LESAR reactor the raw waste is introduced from top of the reactor. The
recycled sludge is also introduced from the top of the reactor. This mixed liquor
travels downward through the central shaft. In this central shaft, agitator
provides adequate mixing of raw waste and recycled sludge. From central shaft
liquor enters reactor near bottom of tank.
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The reactor content outside central shaft is kept well mixed with set of agitators
located equidistant along the circumference of the reactor. This constant
agitation helps to maintain active, bacteria in suspension. These bacteria utilize
organic matter present in wastewater and produce biogas.
The solids are separated from the outlet of reactor in Lamella Clarifier and
returned to the system by recirculation pumps. This recirculation of settled solids
helps to maintain adequate population of active bacteria inside reactor.
The reactor is provided with following accessories to ensure efficient performance
and safety of the reactor:
Pressure breaker and Vacuum breaker, in case pressure goes out of operating
range.
Flare stack to flare the biogas generated in case it is not used.
Gas flow meter for recording the quantity of gas generated.
The treated effluent of LESAR reactor is discharged from the top of reactor to
utilize head available.
The biogas produced by anaerobic digestion inside the reactor is collected from reactor
roof. Biogas is then transferred to floating type gas holder (Approx. 884 m3). Gas
holder is fitted with all essential safety equipment such as breather valve, flame
arrestor etc. Biogas is then conveyed to blower for further utilization in boiler or biogas
engines.
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Cassava pulp shall be taken to hopper with the help of loaders. Screw mix pumps will
be provided to transfer the pulp to feed sump / mixing tank. Slurry from mixing tank
shall be then feed to the digester.
The foundation shall be suitably designed based on local soil type. The floating
type / foundation ensuring equal settlement is the most preferred type of
foundation.
Reactor will be fabricated at site using mild steel plates and structural members
confirming to relevant grades as per internationally accepted codes.
The inside of the reactor shall be sand blasted and painted using chlorinated
rubber paint as per standard specifications.
Reactor outside shall be wire brushed, cleaned / commercial sandblasted and
painted by synthetic enamel or aluminum paint as per client’s preference.
In LESAR reactor the raw waste is introduced from top of the reactor. The
recycled sludge is also introduced from the top of the reactor. This mixed liquor
travels downward through the central shaft. In this central shaft, agitator
provides adequate mixing of raw waste and recycled sludge. From central shaft
liquor enters reactor near bottom of tank.
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The reactor content outside central shaft is kept well mixed with set of agitators
located equidistant along the circumference of the reactor. This constant
agitation helps to maintain active, bacteria in suspension. These bacteria utilize
organic matter present in wastewater and produce biogas.
The solids are separated from the outlet of reactor in collection tank and returned
to the system by recirculation pumps. This recirculation of settled solids helps to
maintain adequate population of active bacteria inside reactor.
The reactor is provided with following accessories to ensure efficient performance
and safety of the reactor:
Pressure breaker and Vacuum breaker, in case pressure goes out of operating
range.
Flare stack to flare the biogas generated in case it is not used.
Gas flow meter for recording the quantity of gas generated.
The biogas produced by anaerobic digestion inside the reactor is collected from reactor
roof. Biogas is then transferred to floating type gas holder (Common for wastewater &
cake). Gas holder is fitted with all essential safety equipment such as breather valve,
flame arrestor etc. Biogas is then conveyed to blower for further utilization in boiler or
biogas engines.
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Collection Tank:
Treated slurry from digester shall be then enters in to this tank for separation of solids
and liquid. The tank is a hopper bottom tank. In this tank solids get settled at the
hopper. Sludge from the hopper is re circulated back to the anaerobic digester while
balanced is sent to the dewatering system.
Dewatering system:
Slurry shall be then feed to dewatering system for separation of solid and liquid. The
filtrate shall be then collected at the filtrate tank. The filtrate shall be then transferred
to hopper for makeup water.
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Design Details
1. Maximum KG COD / Day for LESAR Digesters. 75608
2. No. of LESAR Digester. 1 no.
3. Liquid Volume of LESAR Digester. Approx. 15122 m3
4. Total Tonnage Approx. 401 MT 2.5%
5. Top Entry Agitator for LESAR Digester. 1 no.
6. Side entry Agitators for LESAR Digester. 5 nos.
7. Total Lamella Clarifier Packs 1 Lot.
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Description
Design & Detail Engineering for Biogas plant (CSTR).
Load data & GA drawings for civil units.
Details Structural design, fabrication & construction drawings for LESAR digester.
Supply of all electromechanical equipments and critical equipments mentioned in
clause no. X.
Detailed specifications of piping, valves, MCC panel, Cable rating, cable routing,
earthing details.
Supply of all piping and valves within Battery Limit.
Supply of Electrical items such as MCC Panel PBS, Cabling etc.
Procurement of steel plates and structural members as per our drawings and
specifications.
Supervision of Fabrication, Erection, Installation, Testing, Seeding &
Commissioning of the Biogas plant for 180 days at free of cost. More than 180
days on chargeable basis as mentioned in this offer.
To & From Air Tickets from India to Indonesia
Lodging & boarding (Food) expenses during commissioning & supervision of works.
Training to client’s staff for 10 days during commissioning.
Providing Laboratory Manual & Operational manual.
Supply and erection of all ladder, railing, stair case, insert plates, insert pipes, puddle
flanges, manhole necks, etc. during civil construction.
All local works like. Fabrication, Erection, Installation of equipments, Piping, Valves, etc
supplied from India and its testing at site.
Supply of paint material, surface preparation & painting work as per Lars specifications.
Manpower, Water & Power for construction of plant.
Local conveyance like Airport pickup & Drop facilities.
To arrange for and bear the cost associated for mandatory inspection with third party
inspection to the biogas facility.
Liasoning with any statutory authority / seeking permission from local authority for
carrying out work, if any.
Assistance for visa & other formalities for LEPL personal.
Custom clearance inside Indonesia and its shifting till site for material supplied from
India and any documents required for transporting goods to site.
Biogas piping and burning system in boiler, Blower Room etc.
Loading / Unloading, Handling, Safe storage of the materials and labour hutment at
site.
Land development, area leveling, site cleaning, wood / tree cutting, etc.
Temporary piping and pumping arrangement for hydraulic testing
Description
Any inspection if required need to be carried out by Client before dispatch from our
works.
Operational Manpower, Water & Power for operation of plant.
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Supporting the contractor to any statutory authority / seeking permission from local
authority for carrying out work, if any.
Any other works not specifically mentioned above.
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Quantity 1 Lot
Make Waree / ITEC
9 Pressure Gauges For Gas Flow
Type Diaphragm
Quantity 1 Lot
Make Waree / ITEC
10 Manometer
Type Glass 'U' Tube
Quantity 1 no.
Make Veksler/BVK
11 Temperature Indicator
Quantity 1 No.
Make Forbes Marshall
12 Temperature Gauges
Quantity Lot
Make Waree / ITEC
13 Top Entry Agitator
KW Approx. 11.2 KW
Quantity 1 no.
Make Gladwin
14 Side Entry Agitator
Angle Fixed
KW Approx. 5.5 KW
Quantity 5 nos.
Make Gladwin
15 Lamella Clarifier Packs
MOC FRP Plate 2.5 mm thickness
Quantity 1 Lot
16 Liquid level Indicator for Flare Stack
Quantity 1 no.
17 Biogas Blower with Motor (Common for present, expansion + cake)
Type Twin lobe, Root Type
MOC CI with 2% NI impregnation
KW Approx. 75 KW
Flow Approx. 3000 m3/hr @ 3500- 4000 mmwc
Quantity 2 nos. [1W + 1 SB]
Make Kay / PPI / Airvac / Everest
18 Biogas Flow Meter
Type Vortex
Flow 0 - 3000 m3/hr
Quantity 1 no.
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29 Interconnection Piping
Quantity 1 Lot
MOC of pipes
Reactor Feed Line Feed line in SS 304 – Schedule 5
Other Pipes MS Class 'C' / HDPE 6 Kg/cm2
HDPE – All HDPE pipes shall be underground
pipes.
Make TATA / Astral / Prakash Surya / Jindal
30 Valves
Quantity 1 Lot
MOC of Valves
Feed Line Butterfly valves – CI SS,
Other Valves on piping Butterfly valves - CI CI , Ball Valves – CI SS,
Check Valves – CI CF8M
Make of valves Intervalve / CoFlow / Delvalve
31 Electrical Items
MCC panel 1 no., ABB / Siemens / L&T
Cables Qty 1 Lot
Cable Make Polycab / Gloster
Motor Make Kirloskar / ABB / Siemens
Earthing material 1 Lot
Other Electrical Specifications as per Annexure - 2
2 Screw Pumps
Qty 4 nos. [2W + 2SB]
3 Mixer in Mixing Tank
Qty 1 no.
4 Caustic Dosing System
Qty 1 no.
5 Pressure & Vacuum Breaker (Safety Devise)
No. One each (Total 2 nos. for 1diegster)
6 Flame Arrestor
Qty 2 nos.
7 Liquid Flow Meter on LESAR Feed line
No. 2 nos.
8 Pressure Gauges For Liquid Flow
No. 1 Lot
9 Pressure Gauges For Gas Flow
No. 1 Lot
10 Manometer
No. 2 nos.
11 Moisture Trap
Qty 2 nos.
12 Temperature Gauge
Qty 1 Lot
13 Agitators for Digesters
Top Entry Agitators
No 1 Lot
Side Entry Agitators
No 1 Lot
14 Liquid level Indicator for Flare Stack
Qty 2 nos.
15 Flare Stack (Local/Site Fabricated)
Qty 2 nos. Manually Ignited
16 Mixer In Collection Tank
Qty 1 no.
17 Screw Pumps @ collection Tank
Qty 2 nos. [1W + 1SB]
18 Dewatering Unit
No 1 no.
19 Pumps for backwash near Dewatering Unit
Qty 2 nos. [1W + 1SB]
20 Filtrate Transfer Pumps
Qty 2 nos. [1W + 1SB]
21 Pumps at Intermediate Sump
Qty 2 nos. [1W + 1SB]
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22 Dosing System
Qty 1 no.
23 Gas Flow Meter
No. 1 no. for Each Digester
24 Steel Plates & Structural Steel
Quantity Approx. 274 MT ± 2.5 %
25 Pre-Fabricated Items
Quantity 1 Lot
26 Piping
No. 1 Lot
27 Valves
No. 1 Lot
28 Electrical Items
No. 1 Lot
Other terms & conditions as per Annexure -2
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LESAR reactor
2 foundation 1 RCC 34.2 - - - 916
Gas Holder
3 Container 1 RCC 13.7 - - 6 884
4 Sludge Sump 1 RCC 5.8 - - 3 80
Centrifuge 1 RCC / - 3 2 - 6
Building Brick
5 Masonry
Lamella / RCC / Suitable -
Degassifier PCC
6 Foundation
Foundations for 1 RCC / Lot -
Equipments PCC
pumps, flare, pipe
7 supports
Biogas Blower 1 Brick 2 3 6
8 Room Masonry
MCC / Laboratory 1 RCC / - 4 3 12
Brick
9 Masonry
All dimensions are in mtr.
Dimensions may change after detailed engineering.
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Filtrate Sump
4 1 RCC 4.6 - - 3 49
Intermediate Sump
1 RCC 2.5 1.5 7
Fan Screw Separator 1 RCC / Brick - 3 2 - 6
5 Building Masonry
Foundations for 1 RCC / PCC Lot -
Equipments pumps,
6 flare,
Weighing Room 1 Brick Suitable to weigh 230 MT Cake 12
7 Masonry
MCC / Laboratory 1 RCC / Brick - 4 3 12
8 Masonry
All dimensions are in mtr.
Dimensions may change after detailed engineering.
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Commercial Proposal
I. Budgetary Price:
The price mentioned above is exclusive of all taxes and duties in Indonesia.
We have considered maximum 180 days supervision of our engineer at free of cost,
above 180 days we shall charge you per diem charges of $ 250 (US Dollar Two
Hundred Fifty Only) per person per day.
1 USD = 62 INR
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The estimated cost of work in local partner scope like civil works, Paint supply and
Painting work, Erection, Fabrication , Installation and other local works required for
Biogas Plant shall be approx. USD 1,800,000 (US Dollar One Million Eight
Hundred Thousands Only).
The estimated cost of work in local partner scope like civil works, Paint supply and
Painting work, Erection, Fabrication , Installation and other local works required for
Biogas Plant shall be approx. USD 650,000 (US Dollar Six Hundred Fifty
Thousands Only).
The price mentioned above is exclusive of all taxes and duties in Indonesia.
The above prices are indicative figures which refer to Indian Rate and tentative liquid
volumes / area of the civil units in the offer will be confirmed at detail design stage.
Client need to pay Lars Enviro for design, know-how, equipment supplies, guidance for
commissioning and training as specified in the contract, the following percentage of the
contract price.
1.1 100 % of the contract value through irrevocable, transferable, divisible and
confirmed letter of credit in four of Lars Enviro Pvt. Ltd by a 1 st class
international bank out which :
1.1.1 30 % of the contract value as an advance is required to be
remitted on submission of proforma Invoice for 30 % Advance to
Lars Enviro Pvt. Ltd.
1.1.2 70 % will be paid by the buyer against submission of shipping
documents. Lars Enviro Banker should be able to negotiate the
L/C on Lars Enviro’s behalf.
It is essential for 2nd party [buyer] to obtain necessary clearance and authorization from
the competent authorities in their country regarding setting up of plant. The buyer has
to ensure that mode of payment of advance and the letter of credit or any other
financial instruments to be established, mutually agreeable by both the bankers located
in the buyer’s and seller’s country for the purpose.
V. Delivery:
LESAR Digester shall be ready for commissioning within 10 months from date of
techno-commercially cleared purchase order along with advance and handing over the
dully hydro tested civil works.
Delivery is subjected to
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VI. Validity:
The offer is valid for a period of 30 days, from the date of submission.
VII. Warranty:
All mechanical equipments supplied by Lars shall be under warranty for 12 months from
the date of supply.
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Annexure - 1
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Annexure - 2
MCC panel shall be fully compartmentalized and free standing floor mounting.
Maximum height of panel shall be 2.1 mtr and depth of compartment 400 mm.
Double front type panel shall be provided if no of feeders are more. Painting
shall be Epoxy based powder coating (RAL 7032). Thickness of panel shall be
16 SWG. Panel to be provided with Neoprene gaskets. Cable entry shall be
from the bottom as a standard feature. Top cable entry may be provided, if
required. Each starter of MCC will consist of :
1. Contactor
2. Overload Relay
3. ON / Trip indication.
5. Motor rating above 11.0 KW, Star Delta starter will be provided.
6. Incomer of MCC will be: MCCB (Moulded Case Circuit breaker) shall be
provided to incomer cable.
B) Earthing
Earthing would be done using G.I. pipe rods as per I.S. standards. G.I.
conductor earthing will be done for all electrical equipment and noncurrent
carrying metallic structures / tanks. G.I. conductors will be used for lightning
protection, connected directly to separate earth pit.
Push button station will be provided near the motor wherever required with
lock and key system. Flameproof push button station (as per IS 2148) will be
provided for flameproof section and non-flameproof push button station (as per
IS 2147) will be provided for non-flameproof section.
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D) Cable Laying
G I open type cable trays will be provided for indoor application. Cables will be
buried in trenches for outdoor cables.
E) Erection Material
F) Motor Cover
G) Internal Wire
H) Miscellaneous Details
MOC of bus bar shall be Aluminium with heat shrinkable PVC sleeves
with colour code of red, yellow, blue for phase identifications
No capacitor/CVT shall be provided in the panel.
10 % spare feeders subjected to maximum of 3 nos. shall be provided
without switchgears.
No additional NO/NC contact shall be provided for PLC provision.
All meters shall be digital type.
Thickness of gland shall be 3mm.
I) Power & Control Cables
KW
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Annexure - 3
PERFORMANCE TEST
The trial runs will be conducted for a continuous period of 72 hours. If designed
organic / hydraulic load is not available upon reaching stabilized state, trial runs
shall be conducted at ‘available load’ which shall not be exceeding either the
designed organic load or designed hydraulic load in any case.
Influent and Waste Water sample values of different parameters will be based
on average of daily values determined from a composite sampling. The
performance test shall be started with a 3 days’ notice to Client after reaching
steady state. Client shall ensure uninterrupted supply of raw Waste Water
conforming to the inlet design conditions and all utilities including power,
chemicals, manpower etc. during stabilization/ commissioning period prior to
test runs and also during trial runs. If trial runs cannot be conducted due to
reasons attributable to client within 6 months from the date of hydraulic testing
or within 3 months from the date of seeding, the plant will be deemed to be
taken over by the client and the related payments, if any shall be released
immediately along with handover certificate.
Upon successful completion of trial runs, client shall formally take over the plant
and issue a performance cum handover certificate.
The commissioning for the purpose this order would mean seeding of the plant
and smooth running of all equipments.
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Annexure - 4
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161 SAB Miller (Pals Breweries, Aurangabad : Phase II) I 600 Maharashtra
162 SAB Miller (Rochees Breweries, Nimrana) I 1400 Rajasthan
163 SAB Miller (Malabar unit, Kerla I 300 Keral
164 SAB Miller India Ltd. (Pals unit, Aurangabad) I 625 Maharashtra
165 SAB Miller India Ltd. (Fosters unit, Aurangabad) I 500 Maharashtra
166 Saikrupa Sakhar Karkhana Ltd. I 500 Maharashtra
167 Sagar Industries & sugars Ltd. I 550 Maharashtra
168 Satish Sugars Ltd. I 450 Karnataka
169 Satish Sugars Ltd. I 850 Karnataka
170 Satish Sugars Ltd. I 450 Karnataka
171 SCM Sugars Ltd. I 600 Karnataka
172 SCM Sugars Ltd. (NSL Sugar) I 800 Karnataka
173 Sevanagala Sugar Industries Ltd. I 300 Export
174 Shakti Sugars Ltd. I 1000 Tamil Nadu
175 Shree Distillery Pvt. Ltd., I 225 Export
176 Shri Prabhulingeshwar Sugars & Chemicals Ltd. I 1250 Karnataka
177 Siddapur Distilleries Ltd. I 550 Karnataka
178 SNJ Breweries Pvt. Ltd. I 1200 Maharashtra
179 Sovereign Distillery Ltd. (USL) I 820 Karnataka
180 Specta Technology Solutions Pvt. Ltd. (Sikkim) I 275 Sikkim
181 SVK Milk Producers Pvt. Ltd. I 100 Maharashtra
182 Synergy Biorefineries Pvt. Ltd. I 647 Andhra Pradesh
183 The Andhra Petrochemicals Ltd. I 72 Andhra Pradesh
184 The Andhra Sugars Ltd, Bhimadolu I 225 Andhra Pradesh
185 The Andhra Sugars Ltd, Tanaku I 950 Andhra Pradesh
186 The Andhra Sugars Ltd,Taduvai I 300 Andhra Pradesh
187 The Crown Beer Internationals Pvt.Ltd. I 750 Andhra Pradesh
188 The Crown Beer Internationals Pvt.Ltd. I 1250 Andhra Pradesh
189 The Jeypore Sugar company Ltd. I 1000 Andhra Pradesh
190 The Jeypore Sugar company Ltd. II 1000 Andhra Pradesh
191 The Saswad Mali sugar Factory Ltd. I 350 Maharashtra
192 The Ugar Sugars Works Ltd. I 360 Karnataka
193 The Union Paper Mill I 1800 Export
194 Thiru Arooran Sugars Limited, I 360 Tamil Nadu
195 Thiru Arooran Sugars Limited, II 360 Tamil Nadu
196 Thiru Arooran Sugars Ltd., [Ambika Sugars] I 0 Tamil Nadu
197 Thiru Arooran Sugars Ltd., [Ambika Sugars] II 1400 Tamil Nadu
198 Tilaknagar Industries Ltd. I 250 Maharashtra
199 Trident Sugar Ltd. I 600 Tamil Nadu
200 Turkish Sugar Factory, (Erzurum) I 3600 Export
201 Turkish Sugar Factory, (Eskisehir) I 4800 Export
202 Turkish Sugar Factory, (Kastamonu) I 3600 Export
203 Turkish Sugar Factory, (Kayseri) I 6000 Export
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