Tender23 1

TENDER DOCUMENTS
FOR
FREE ISSUE ITEMS FOR
PROPOSED 800 MTPD exp. upto 1600 MTPD CATTLE FEED PLANT
ON 20 HRS OPERATION BASIS.
AT Kapdivav, P.O. Chikhload, Taluka - Kapadwanj, Dist. - Kheda, Gujarat
1. Design, manufacture, supply, erection, testing and commissioning of Raw Material
(grains) Bulk Storage GI Silos - 500 MT x 8 Nos.
2. Design, manufacture, supply, erection, testing and commissioning of 4 TPH Solid Fuel
Fire Boiler Plant. – 1 No.
3. Design, manufacture, supply, erection, testing and commissioning of Mild Steel
Molasses Storage Tanks for Liquid Molasses. – 6000 MT x 2 Nos.
4. Design, supply, installation and commissioning of 500 CFM Air Compressor and
Accessories. – 2 Nos.
5. Design, Manufacture, supply, erection, testing and commissioning of SDF Dry
Transformer. – 1500 KVA x 2 Nos.
6. Design, manufacture, supply, erection, testing and commissioning of 80 MT capacity
Electronic Road Weigh Bridge. – 2 Nos.
BID REFERENCE NO: AMUL/CFF-

1/KAPDIVAV/2013
KAIRA DISTRICT CO-OPERATIVE MILK PRODUCERS’

UNION LIMITED
AMUL DAIRY, ANAND, GUJARAT-388 001
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CONTENTS
Page
SR
SECTION DESCRIPTION No.
NO
01 Section I Invitation for Bids 4

02 Section II Instructions to Bidders 7
03 Section III General Conditions of Contract 25
04 Section IV Part –I Special Conditions of Contract 39
Special Conditions of Contract for
05 Section IV Part – II 46
Erection & Commissioning
Special Conditions of Contract for
06 Section IV Part – III 63
Mechanical Works
07 Section V Technical Specifications 78
08 Sub Section – 1 Introduction 79
09 Sub Section – 2 Instructions to Bidders 82
10 Sub Section – 3 Responsibilities 86
11 Sub Section – 4 Project Management 89
12 Sub Section – 5 Technical Specification 94
13 Sub Section – 6 Deviations from Technical Requirement 254
14 Sub Section – 7 Optional Items 256
15 Sub Section – 8 Drawings Data & Documentation 258
16 Sub Section – 9 Technical Evaluation of Bid 261
17 Sub Section – 10 Performance Guarantee 263
18 Sub Section – 11 Bidders Meeting 265
19 Section VI Bidding Terms Deviation 267
20 Section VII Bid Form & Price schedule Performa 269
21 Section VIII Qualification Application 273
22 Section IX Collaborators' Authorization Form 282
2
DESCRIPTION
SR Page No.
SECTION
NO
23 Appendices 1 284
Form of BG for Performance
a) 286
Security
Form of BG Against Advance
b) 289
Payment
c) Contract Form 291
d) Proforma of Completion Certificate 292
e) Form of BG for Bid Security (EMD) 294
List of acceptable Banks for Bank
f) Guarantees From Foreign / 296
Nationalized / Scheduled Banks
24 Appendices 2 297
a) Site Layout Drawings 299
b) Spares Philosophy 301
c) Documentation Philosophy 304
3
SECTION – I
INVITATION FOR BID
4
Kaira District Co-operative Milk Producers’ Union Limited.
Amul Dairy, Anand- 388 001, Gujarat (India)
Phone: +91-2692-225473, Fax: +91-2692-225475
Invitation For Bid (IFB)
Name of CATTLE FEED

Bid Reference AMUL/CFF-1/KAPDIVAV/2013
Project FACTORY
Estimated
SN Description EMD (Rs.)
Cost (Rs)
Design, manufacture, supply, erection, testing and
1. commissioning of Raw Material (grains) Bulk Storage GI 100 Lacs 1 Lac
Silos - 500 MT x 8 Nos.
2. 100 Lacs 1 Lac
commissioning of 4 TPH Boiler Plant. – 1 No.
3. commissioning of Mild Steel Molasses Storage Tanks 1.7 Crore 1.7 Lacs
for Liquid Molasses – 6000 MT x 2 Nos.
Design, supply, installation and commissioning of 500

4. 40 Lacs Nil
CFM Air Compressor and Accessories – 2 Nos.
Design, Manufacture, supply, erection, testing and
5. commissioning of SDF Dry Transformer – 1500 KVA x 2 25 Lacs Nil
Nos.
6. commissioning of 80 MT capacity Electronic Road 30 Lacs Nil
Weigh Bridge – 2 Nos.
Duration (months) 4 Months
Start 25.4.2013, Thursday

Bidding Document Sale.
Stop 6.5.2013, Monday
Submission 6.5.2013 at 15.00 Hrs., Monday

Last Date & Time of Bid.
Tender Opening 8.5.2013 at 11.00 Hrs., Wednesday
Date of Pre Bid Meeting. 30.04.2013 at 11.00 Hrs., Tuesday

Office of:
Place of Pre-Bid Meeting General Manager (Projects & Engineering)
and Amul Dairy Road, Anand 388 001.
Tender Opening.
Phone: (02692) 225 473
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1. Eligibility Criteria
1.1 The Bidder/Bidder shall have turnover, in each of the last three years, at least equal
to the estimated cost of the job and must have executed, in the last ten years at least
a contract of similar nature and of value not less than 50% of the estimated cost of
the job. Apart from this the sole criteria will be the original key equipments
manufacturer and technical competence to execute the job of this kind. Total value
will be considered in the project including the imported machinery directly imported
by the client for the project.
2. Purchase of Bidding Document

2.1 Interested bidders may download the Tender documents free of cost from the
Website http://tender.amuldairy.com
3. Submission of Bid
3.1 The bidder who purchase the bidding document, are eligible for submission of bids in
their name only.
4. Bid Security
4.1 All bid must be accompanied by bid security (Earnest Money Deposit – EMD) in the
form specified in the bidding document. The bids not accompanied with EMD shall be
summarily rejected. The bid security shall be denominated in Indian Rupees of value
as specified and shall be in the form of Bank Guarantee from Nationalized or
Scheduled Banks or Demand draft in favour of Kaira District Co-operative Milk
Producers’ Union Ltd., payable at Anand.
The Bid security may be forfeited if
A bidder or bidder withdraw its bid during the period of bid validity specified by
the bidder/ bidder on the bid form or
In case of successful bidder/ bidder, if the bidder/ bidder fails to sign the contract.
5. Rights Reserved by KDCMPU Ltd.

5.1 KDCMPU Ltd, at its sole discretion and without assigning any reason thereof,
reserves the right to accept and / or reject the whole or part of any or all the bids
received.
6. Validity
The offer should be valid for 90 days from the date of tender opening
Managing Director
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SECTION – II
INSTRUCTION TO BIDDERS
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CONTENTS
1. COST OF BIDDING
2. CONTENTS OF BIDDING DOCUMENT
3. CLARIFICATION OF BIDDING DOCUMENT
4. AMENDMENT OF BIDDING DOCUMENT
5. PRE BID MEETING
6. LANGUAGE OF BID
7. DOCUMENTS COMPRISING THE BID
8. BID FORM
9. BID PRICES
10. PRICE ADJUSTMENT
11. BID CURRENCY
12. DOCUMENTS ESTABLISHING BIDDER’S EXPERIENCE AND

QUALIFICATIONS
13. DOCUMENTS ESTABLISHING GOODS’ CONFIRMITY TO BIDDING

DOCUMENT
14. BID SECURITY (EARNEST MONEY DEPOSIT)
15. PERIOD OF VALIDITY OF BIDS
16. FORMAT AND SIGNING OF BID
17. SEALING AND MARKING OF BIDS
18. DEADLINE FOR SUBMISSION OF BIDS
19. LATE BIDS
20. MODIFICATION AND WITHDRAWAL OF BIDS
21. OPENING OF BIDS BY PURCHASER
22. CLARIFICATION OF BIDS
23. PRELIMINARY EXAMINATION
24. EVALUATION AND COMPARISION OF BIDS
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25. CONTACTING THE PURCHASER
26. POST QUALIFICATION
27. RIGHT TO VARY QUANTITIES AT THE TIME OF AWARD
28. RIGHT TO ACCEPT ANY BID AND TO REJECT ANY OR ALL BIDS.
29. NOTIFICATION OF AWARD
30. SIGNING OF CONTRACT
31. PERFORMANCE SECURITY
32. IMPORT LICENSE
33. TURN KEY CONTRACT
34. BREAK UP PRICES
35. DELIVERY SCHEDULE OF ITEMS
36. TABLE 1 CHECK LIST OF BID SUBMISSION
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1. Cost of Bidding
1.1 The Bidder shall bear all costs associated with the preparation and submission
of its bid, and the Kaira District Co-operative Milk Producers’ Union Ltd.
hereinafter referred to as "the Purchaser", will in no case be responsible or liable
for those costs, regardless of the conduct or outcome of the bidding process.
2. Contents of Bidding Document

2.1 The goods required, bidding procedures and contract terms are
prescribed in the Bidding Document. The contents of the Bidding
Document are organized in sections as given in the Table Contents at the
beginning of this document.
2.2 The Bidder is expected to examine all instructions, forms, terms and
specifications in the Bidding Document. Failure to furnish all information
required as per the Bidding Document or submission of a bid not
substantially responsive to the Bidding Document in every respect will be
at the Bidder's risk and may result in the rejection of its bid.
3. Clarification of Bidding Document

3.1 A prospective Bidder requiring any clarification on the Bidding Document
may notify the Purchaser in writing by fax/ telex/ cable at the Purchaser's
mailing address indicated in the Invitation for Bids. The Purchaser will
respond in writing to any request for clarification on the Bidding
Document, which it receives not later than 7 days prior to the deadline for
the submission of bids prescribed by the Purchaser. Written copies of the
Purchaser's response (including an explanation of the query but without
identifying the source of inquiry) will be sent to all prospective Bidders,
which have received the Bidding Documents. However, the Bidders
cannot consider delay in receipt of clarifications, as a cause for
requesting extension in the due date of submission of the bids.
4. Amendment of Bidding Document

4.1 At any time prior to the deadline for submission of bids, the Purchaser
may, for any reason, whether at its own initiative or in response to a
clarification requested by a prospective Bidder, modify the Bidding
Document by amendment.
4.2 The amendment will be notified in writing or by email or by fax or cable to

all prospective Bidders, which have received the Bidding Documents and
will be binding on them. The amendment will be attached to the bidding
document sold subsequently.
4.3 In order to afford prospective Bidders reasonable time, in which to take

the Amendment into account in preparing their bids, the Purchaser
may, at its discretion, extend the deadline for the submission of bids.
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5. Pre Bid Meeting
The bidder or his official representative is advised to attend a pre bid
meeting which will be convened at the office of General Manager
(Projects & Engineering), Amul Dairy, Anand.
Venue of the Meeting : Office of General Manager (P&E), Amul Dairy,

Anand – 388 001, Gujarat
Date of Pre Bid Meeting : 30.04.2013
Clarifications shall be submitted to the bidders on the same day.
6. Language of Bid
6.1 The Bid prepared by the Bidder and all correspondence and documents
relating to the bid exchanged by the Bidder and the Purchaser shall be
written in the English language. Any printed literature furnished by the
Bidder may be written in another language so long as accompanied by an
English translation of its pertinent passages in which case, for the
purposes of interpretation of the bid, the English translation shall govern.
7. Documents comprising the Bid

7.1 The bid prepared by the Bidder shall comprise the following Components:
7.1.1 A Bid Form and a Price Schedule completed in accordance with Clauses
7, 8 & 9.
7.1.2 Documentary evidence established in accordance with Clause 10 that the

Bidder is qualified to perform the contract if its bid is accepted.
7.1.3 Documentary evidence established in accordance with Clause 11 that the

goods and ancillary services to be supplied by the Bidder conform to the
Bidding Document.
7.1.4 Bid security (Earnest Money Deposit) furnished in accordance with

Clause 12 along with the bid security details form.
7.1.5 A statement of deviation and exception to the provision of bidding

documents.
8. Bid Form
8.1 The Bidder shall complete the Bid Form and appropriate Price Schedule
furnished in the Bidding Document, indicating for the goods to be supplied, a
brief description of the goods, their country of origin, quantity and prices.
9. Bid Prices
9.1 The Bidder shall indicate on the appropriate Price Schedule attached to this
document the total bid prices of the goods it proposes to supply, install and
commission under the contract. To this end, the Bidders are allowed the option
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to submit bids for anyone or more packs specified in the "Schedule of
Requirement" and to offer discounts for combined packs. However, Bidders
must submit a bid for the complete requirement of goods and services specified
under each pack, failing which, such bids will not be taken into account for
evaluation& comparison and will not be considered for award.
9.2 Prices indicated on the Price Schedule shall be entered separately in the
following manner:
9.2.1 The total price is to be given for the total scope considering and without
considering EPCG benefit.
9.2.2 The price of the goods, quoted ex factory, ex showroom, ex warehouse or off
the shelf, as applicable, including all customs duties and other duties, sales and
other taxes already paid or payable on the components and raw material used in
the manufacture or assembly of goods quoted ex factory or on the previously
imported goods of foreign origin quoted ex showroom, ex warehouse or
off the shelf.
9.2.3 Any excise duty (Customs Duty, Countervailing Duty etc. for import) applicable
and payable on the goods along with tariff numbers and the details of
classification of the goods, if this contract is awarded AS A PERCENTAGE OF
EXWORKS PRICE or otherwise indicating clearly in the price schedule format
given.
9.2.4 Any sales and other taxes applicable, which will be payable on the goods if this
Contract is awarded AS A PERCENTAGE OF EX WORKS, packed including
ED PRICE or otherwise indicating clearly in the price, schedule format given.
9.2.5 Charges for packing and forwarding, inland transportation, insurance and other
local costs incidental to delivery of the goods to their destination; AS A
PERCENTAGE OF EX-WORKS PRICE or otherwise indicating clearly in the
price schedule format given.
9.2.6 The cost of installation and commissioning as described in the technical

specifications and in accordance with Special conditions of Contract with regard
to erection, testing and putting the equipment into satisfactory operations,
including successful completion of performance and guarantee tests to be
performed at the destination by Bidder and AS A PERCENTAGE OF
EX WORKS PRICE or otherwise indicating clearly in the price schedule format
given.
9.2.7 The cost of incidental services listed in Clause 7 of Special Conditions of

Contract AS PERCENTAGE OF EX WORKS PRICE or otherwise indicating
clearly in the price schedule format given.
9.3 The Bidder's separation of price components in accordance with above will be
solely for the purpose of facilitating the comparison of bids by the Purchaser and
will not in any way limit the Purchaser's right to contract on any of the terms
offered.
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9.4 Price of spare parts All the Bidders are required to submit the following details
about the spare parts, along with their bids:
9.4.1 Spare parts required for the items quoted by the Bidders, for 2 years normal
operation. The price should be part of contract.
9.4.2 Item wise prices of all the spare parts valid, for acceptance by the Purchaser
and placement of orders, for one year from the date of bid opening.
10. Price Adjustment

10.1 Price quoted by the Bidder shall be subject to adjustment during the
performance of the contract to reflect changes in the cost of labour and material
components in accordance with the procedure specified in the special conditions
of the contract. A bid submitted with a fixed price quotation will not be rejected
but the price adjustment shall be treated as zero.
11. Bid Currency

11.1 Prices shall be quoted in Indian Rupees only for the goods and services, which
the Bidder will supply if a contract is awarded against this invitation for bid. For
import, ceiling amount in respective currencies should be mentioned along with
exchange rates considered. The price adjustment shall be allowed on account of
any changes in the landed cost due to variation in the Exchange rates and / or
Customs Duty (combined effect). For arriving at the variation in landed cost, the
actual invoice value (from the foreign bidder) with bank certificate for Exchange
Rates & bill of entry for Customs Duty paid has to be submitted as supporting
documents. However, such changes shall be allowed only within the ceiling
amount quoted and within the period of the contract. The variation will be worked
out on the difference between Customs Duty rate / exchange rate mentioned in
the Bid and the actual respective rates levied during the time of actual imports
multiplied by the actual CIF value and not the ceiling value. The purchaser may
opt for importing the key machinery direct in case it is deemed fit.
But this will be as per the quoted price in the bid.
11.2 All claims shall be against the supporting documents.
12. Documents Establishing Bidder's Experience and

Qualifications
12.1 Pursuant to Clause 7 the Bidder shall furnish, as part of its bid,
documents establishing the Bidder's qualifications to perform the Contract
if its bid is accepted. The Bidder should also give information in the format
attached to the Bidding Document.
12.1.1 The documentary evidence of the Bidder's qualifications to perform
Contract if its bid is accepted, shall establish to the Purchaser's
satisfaction.
12.1.2 That in the case of a Bidder offering to supply goods and services under
the Contract which the Bidder did not manufacture or otherwise produce,
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The Bidder has been duly authorised by the goods' manufacturer or
producer to supply the goods. The bid shall include manufacturer’s
authorisation Form given in the bidding documents.
12.1.3 That the Bidder has the financial, technical and production capability
necessary to perform the Contract. To ascertain this, all bids submitted
shall include the information as per the pro forma along with qualification
application (Table 1, 2 & 3) in Appendices II.
12.1.4 Copies of original documents defining the constitution or legal status,
place of registration and principal place of business of the company or
firm partnership, etc;
12.1.5 Details of experience and past performance of the Bidder on equipment
offered and those of similar nature and those of similar nature within the
past 5 years and details of current contracts in hand and other
commitments.
12.1.6 Major items of plant and equipment available/ installed in the Bidder's
factory premises.
12.1.7 Qualification and experience of key personnel for successful execution of
the contract.
12.1.8 Reports on financial standing of the Bidder such as profit and loss
statements, balance sheets and, auditor's report of the past three years,
bankers certificates etc.
12.1.9 Information regarding any current litigation in which the Bidder is involved
12.2 Bidders who meet the criteria given above are subject to be disqualified if
they have made untrue or false representations in the forms, statements
and attachments submitted in proof of the qualification requirements or
have record of poor performance such as abandoning the work, not
properly completing the contract, inordinate delays in completion or
financial failures etc
13 . Documents Establishing Goods' Conformity to Bidding

Document
13.1 Pursuant to Clause 6 the Bidder shall furnish, as part of its bid,
documents establishing the conformity to the Bidding Document of all
goods and services, which the Bidder proposes to supply under the
Contract.
13.1.1 The documentary evidence of the goods' and services' conformity to the
Bidding Document may be in the form of literature, drawings and data,
and shall furnish:
13.1.2 A detailed description of the goods' essential technical and performance
characteristics
13.1.3 A list giving full particulars, including available sources and current prices,
of all spare parts, special tools, etc. necessary for the proper and
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continuing functioning of the goods for a period of two years, following
commencement of the goods' use by the Purchaser; and
13.1.4 A clause by clause commentary on the Purchaser's Technical
Specifications demonstrating the goods and services' substantial
responsiveness to those specifications or a statement of deviations and
exceptions to the provisions of the Technical Specifications.
13.2 The purposes of the commentary to be furnished pursuant to above, the
Bidder shall note that standards for workmanship, material and
equipment, and references to brand names or catalogue numbers
designated by the Purchaser in its Technical Specifications are intended
to be descriptive only and not restrictive. The Bidder may substitute
alternative standards, brand names and/or catalogue numbers in its bid,
provided that it demonstrates to the Purchaser's satisfaction that the
substitutions are substantially equivalent or superior to those designated
in the Technical Specifications.
14 Bid Security (Earnest Money Deposit)

14.1 Pursuant to Clause 6 the Bidder shall furnish, as part of its bid, bid
security (Earnest Money Deposit) as specified in the NIT (Notice Inviting
Tender).
14.2 The bid security is required to protect the Purchaser against the risk of
Bidder's conduct, which would warrant the security forfeiture.
14.2.1 The bid security shall be denominated in Indian Rupees of value as
specified and shall be in the form of BG or a Demand draft in favour of
Kaira District Co-operative Milk Producers’ Union Ltd., payable at Anand.
14.3 Any bid not accompanied with bid security in accordance with clause 14.1
and 14.3 above will be rejected by the purchaser as nonresponsive.
14.4 Unsuccessful Bidders' bid security will be discharged/ returned as
promptly as possible but not later than 30 days after the expiration of the
period of bid validity prescribed by the Purchaser. The successful Bidder's
bid security will be discharged upon the Bidder's executing the Contract
agreement on acceptance of the order & furnishing the performance
security, pursuant to Clause 29.
14.5 The bid security may be forfeited:
14.5.1 If a Bidder withdraws its bid during the period of bid validity specified by
the Bidder on the Bid Form; or
14.5.2 In the case of the successful Bidder, if the Bidder fails:
14.5.3 To sign the Contract in accordance with Clause 28
14.5.4 To furnish performance security in accordance with Clause 29
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15 Period of Validity of Bids
15.1 Bids shall remain valid for 90 days after the last date of submission of the
bids prescribed by the Purchaser, pursuant to Clause 16. A bid valid for a
shorter period may be rejected by the purchaser as non-responsive.
15.2 In exceptional circumstance, the Purchaser may prior to expiry of the
initial validity period, solicit the Bidders' consent to an extension of the
period of validity. The request and the responses thereto shall be made in
writing (or by cable or telex/fax). The bid security provided under Clause
12 shall also be suitably extended. A Bidder may refuse the request
without forfeiting its bid security. A Bidder granting the request will not be
required nor permitted to modify its bid.
16. Format and Signing of Bid

16.1 The Bidder shall prepare two copies of the bid, clearly marking each
"Original" and "Copy" as appropriate. In the event of any discrepancy
between them, the original shall govern.
16.2 The original and all copies of the bid shall be typed or written in indelible
ink and shall be signed by the Bidder or a person or persons duly
authorized to bind the Bidder to the Contract. Written power-of-attorney
must accompany the Bid to indicate the authorization. The person or
persons signing the bid shall initial all pages of the bid, except for
laminated printed literature.
16.3 The bid shall contain no interlineations, erasures or overwriting except as
necessary to correct errors made by the Bidder, in which case, the person
or persons signing the bid shall initial corrections.
17. Sealing and Marking of Bids

17.1 The Bidders shall seal the original and each copy of the bid in an outer
envelope, duly marking the envelopes as "original" and "copy."
17.2 All the inner and outer envelopes shall be addressed to the Purchaser
and must bear the Invitation for Bids (IFB) reference number.
17.3 All the envelopes should bear the word "DO NOT OPEN BEFORE (The
time and date of opening as specified).
17.4 The inner envelopes shall indicate the name and address of the Bidder to
enable the bid to be returned unopened in case it is declared "late."
17.5 If the outer envelope is not sealed and marked as required, the Purchaser
will assume no responsibility for the bid's misplacement or premature
opening.
A bid opened prematurely for this cause will be rejected by the Purchaser and
returned to the Bidder.
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18. Deadline for Submission of Bids
18.1 The Purchaser at the address specified must receive bids not later than
the time specified for receipt of the bids.
18.2 The Purchaser may, at its discretion, extend this deadline for the
submission of bids by amending the Bidding Document in accordance
with Clause 4 above in which case all rights and obligations of the
Purchaser and Bidders previously subject to the deadline will thereafter
be subject to the deadline as extended.
18.3 No telegraphic/ telephonic/ fax bids shall be considered. However, any
amendment sent by a telegram or a telex or fax to the bid already
submitted/received shall be considered provided it is received before the
due date and time of opening of the bids and it is confirmed in writing by
post.
19. Late Bids

19.1 Any bid received by the Purchaser after the deadline for submission of
bids prescribed by the Purchaser, pursuant of Clause 16 will be rejected
and returned unopened to the Bidder.
20. Modification and Withdrawal of Bids

20.1 The Bidder may modify or withdraw its bid after the bid's submission,
provided that written notice of the modification or withdrawal is received
by the Purchaser prior to the deadline prescribed for submission of bids.
20.2 The Bidder's modification or withdrawal notice shall be prepared, sealed,
marked and dispatched in accordance with the provisions of Clause15. A
withdrawal notice may also be sent by fax or cable but followed by a
signed confirmation copy, post marked not later than the deadline for
submission of bids.
20.3 No bid may be modified subsequent to the deadline for submission of
bids.
20.4 No bid may be withdrawn in the interval between the deadline for
submission of bids and the expiration of the period of bid validity specified
by the Bidder on the Bid Form. Withdrawal of a bid during this interval
may result in the forfeiture of the Bidder's bid security, pursuant to
Clause12.
21. Opening of Bids by Purchaser

21.1 The Purchaser will open the bids, in the presence of the Bidders'
representatives who choose to attend, at the time and date specified in
the Invitation for bids, at the office of the Amul Dairy, Anand, Gujarat
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India. The Bidders’ representatives who are present shall sign a register/
form evidencing their attendance.
21.2 The Bidders' names, bid prices, modifications, bid withdrawals and the
presence or absence of the requisite bid security and such other details
as the purchaser, at its discretion, may consider appropriate will be
announce during the opening of the bids.
22 Clarification of Bids
22.1 To assist in the examination, evaluation and comparison of bids the
Purchaser may, at its discretion, ask the Bidders for a clarification of its
bid. The request for clarification and the response shall be in writing and
no change in the price or substance of the bid shall be sought, offered or
permitted.
23 Preliminary Examination
23.1 The Purchaser will examine the bids to determine:
23.1.1 Whether they are complete,
23.1.2 Whether any computational errors have been made,
23.1.3 Whether required sureties have been furnished,
23.1.4 Whether the documents have been properly signed,
23.1.5 Whether the bids are generally in order.
23.2 Arithmetical errors will be rectified on the following basis:
23.2.1 If there is a discrepancy between the unit price and the total price that is
obtained by multiplying the unit price and quantity, the unit price shall
prevail and the total price shall be corrected. If the Bidder does not accept
the correction of the errors, its bid will be rejected. If there is a
discrepancy between words and figures, the amount in words will prevail.
23.3 Prior to the detailed evaluation, pursuant to Clause22, the Purchaser will
determine the substantial responsiveness of each bid to the Bidding
Document. For purposes of these clauses, a substantially responsive bid
is one, which conforms to all the terms and conditions of the Bidding
Document without material deviations. The Purchaser's determination of a
bid's responsiveness isto be based on the contents of the bid itself
without recourse to extrinsic evidence.
23.4 If the prices of certain components/sub assemblies/spare parts are not
included, the Purchaser will load the offer with the cost of these in
evaluation if goods/equipment/plant is functional. If the Purchaser
considers that without these the goods/equipment is not functional, then
the bid will be treated as incomplete and non responsive.
23.5 To facilitate loading incomplete bids, the highest cost of such components
offered by other Bidders or the estimated cost of such components in the
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opinion of the Purchaser or other Purchases similarly made based on
past experience shall be considered for loading incomplete bids.
23.6 Since the bid is invited for the complete job of design, supply, installation
and commissioning of the equipment/plant, the incomplete or part bids
submitted by any Bidder may not be considered for evaluation and may
be liable for rejection.
23.7 A bid determined as not substantially responsive will be rejected by the
Purchaser and may not subsequently be made responsive by the Bidder
by correction of the nonconformity.
23.8 The Purchaser may waive any minor informality or nonconformity or
irregularity in a bid, which does not constitute a material deviation,
provided such waiver, does not prejudice or affect the relative ranking of
the Bidder.
24 Evaluation and Comparison of Bids

24.1 The Purchaser will evaluate and compare the bids previously determined
to be substantially responsive, pursuant to Clause 21. No bid will be
considered if the complete requirement covered under this work is not
included in the bid.
However, the discounts offered by the Bidders, if any, will be taken into
account in the evaluation of bids so as to determine the bid offering the
lowest evaluated cost for the Purchaser in deciding award of contract/s.
24.2 The Purchaser's evaluation of a bid will include and take into account, in
the caseof goods manufactured in India or goods of foreign origin already
located inIndia, sales and other similar taxes, which will be payable on the
goods if acontract is awarded to the Bidder. Also, applicable excise duty
payable by thePurchaser will be added to the bid price for evaluation.
24.3 The comparison shall be of free delivery at site basis including unloading
and inclusive of all taxes (sales, works contract etc.) and duties (customs,
counter vailing, excise etc.) of the goods offered from within India, such
price to include all costs as well as duties and taxes paid or payable on
components &raw material incorporated in the goods as well as taxes &
duties payable on finished goods and the installation and commissioning
costs as per the provisions in the technical specification.
24.4 The Purchaser's evaluation of a bid will take into account, in addition to
the bid price and the price of incidental services, the following factors, in
the manner and to the extent indicated in this Clause 22 and in the
Technical Specifications:
24.4.1 Cost of inland transportation, insurance and other costs within India
incidental to delivery of the goods to their final destination and applicable
excise duty payable by the Purchaser;
24.4.2 Delivery schedule offered in the bid.
24.4.3 The cost of components and service;
19
24.4.4 The availability of spare parts and after sales services for the equipment
offered in the bid.
24.4.5 Deviation in payment schedule from that specified in the Special
Conditions of Contract
24.4.6 The quality and adaptability of the equipment offered.
24.4.7 The performance and productivity of the equipment offered
24.5 Pursuant to above of Clause 22, the following evaluation methods will be
followed:
24.5.1 Inland Transportation, ex-factory/ Insurance and Incidentals: For the
goods offered, the Bidders must quote separately for inland
transportation, insurance and other incidentals for delivery of goods to the
project site as stated in Clause 8.
24.5.2 Delivery Schedule: The Purchaser desires to have delivery of the goods
covered under the invitation, at the time specified in the Schedule of
Requirements. The estimated time of arrival of the goods at the project
site/ destination should be calculated for each bid after allowing for
reasonable transportation time.
24.5.3 Bidders shall state their bid price for the payment schedule outlined in the
Special Conditions of Contract. Bids will be evaluated on the basis of this
base price.
24.5.4 The goods/ plant offered shall have the guaranteed performance with
regard to the rated capacity and operating parameters specified in the
technical specifications related to Process performance and consumption
guarantees.
24.6 If it is found that any Bidder for any reason indicates impractical or
impossible data to arrive performance guarantees, such data shall be
corrected and all the calculations shall be based on the data furnished by
the highest Bidder for the purpose of comparison.
25 Contacting the Purchaser

25.1 Subject to Clause 21, no Bidder shall contact the Purchaser on any
matter relating to its bid, from the time of the bid opening to the time the
Contract is awarded.
25.2 Any effort by a Bidder to influence the Purchaser in the Purchaser's bid
evaluation, bid comparison or contract award decisions may result in the
rejection of the Bidder's bid.
26 Post Qualification
26.1 In the absence of prequalification, the Purchaser will determine to its
satisfaction whether the Bidder selected as having submitted the lowest
evaluated responsive bid is qualified to satisfactorily perform the Contract.
20
26.2 The determination will take into account the Bidder's financial, technical
and production capabilities. It will be based upon an examination of
thedocumentary evidence of the Bidder's qualifications submitted by the
Bidder,pursuant to Clause 10 as well as such other information as the
Purchaser deemsnecessary and appropriate including details of
experience and records of pastperformance.
26.3 An affirmative determination will be a prerequisite for award of the
Contract to the Bidder. A negative determination will result in rejection of
the Bidder's bid, in which event; the Purchaser will proceed to the next
lowest evaluated bid to make a similar determination of that Bidder's
capabilities to performsatisfactorily.
26.4 Subject to Clause 26, the Purchaser will award the contract to the
successful Bidder whose bid has been determined to be substantially
responsive and has been determined as the lowest evaluated bid
provided further that the Bidder is determined to be qualified to perform
the contract satisfactorily as per Clause 22 and 24.
27 Right to Vary Quantities at the Time of Award

27.1 The Purchaser reserves the right at the time of award of Contract to
increase or decrease by up to 15% (Fifteen percent) the quantity of goods
and services specified in the Schedule of Requirements without any
change in unit rates as specified in the price break .up or other terms and
conditions.
28 Right to Accept any Bid and to Reject Any or All

Bids
28.1 The Purchaser reserves the right to accept or reject any bid, and to annul
the bidding process and reject all bids at any time prior to award of
Contract, without thereby incurring any liability to the affected Bidder or
Bidders or any obligation to inform the affected Bidder or Bidders of the
grounds for the Purchaser's action.
29 Notification of Award
29.1 Prior to expiration of the period of bid validity, the Purchaser may notify
the successful Bidder in writing by registered letter or by cable or fax to
be confirmed in writing by registered letter, that its bid has been accepted.
29.2 The notification of award will constitute the formation of the Contract.
29.3 Upon the successful Bidder's acceptance of the Purchase Order and
signing of the contract agreement, the Purchaser will promptly notify each
unsuccessful Bidder and will discharge its bid security.
21
30 Signing of Contract
30.1 At the same time as the Purchaser notifies the successful Bidder that its
bid has been accepted, the Purchaser will send the Bidder the Contract
Form /Purchase Order in corporating all agreements between the parties.
30.2 Within 30 days of receipt of the Contract, the successful Bidder shall
return the duplicate copy of the Order duly signed and sealed in token of
acceptance of the order to the Purchaser.
31 Performance Security
31.1 Within 30 of the receipt of the notification of award, the successful Bidder
shall furnish the performance security in accordance with the Conditions
of Contract, in the Performance Security Form provided in the Bidding
Document or another form acceptable to the Purchaser.
31.2 Failure of the successful Bidder to comply with requirement of Clause 28
or Clause 29 shall constitute sufficient grounds for the annulment of the
award and forfeiture of the bid security, in which event the Purchaser may
make the award to the next lowest evaluated Bidder or call for new bids.
32 Import License
32.1 For the goods of foreign origin, if any, offered on CIF Mumbai Port basis,
the import license shall have to be arranged by the Purchaser and the
details of such license shall be notified to the successful bidder. In case of
goods offered from within India and for which a contact is awarded, if any
import is required the license shall be arranged by bidders themselves.
33 Turnkey Contract
33.1 All the Bidders should quote for the design, supply, installation, testing
and commissioning of equipment as detailed in this bidding document on
turn key basis within the scope specified in the technical specification.
The Purchaser shall, however, be at liberty to award the contract for the
part or whole of the work.
34 Breakup prices
34.1 All the Bidders shall furnish the cost separately for the supply and
installation/commissioning along with detailed cost break up
(item wise), which will be applicable for progressive payments. Items and
works for which no breakup price is furnished by the Bidder will not be
paid for by the Purchaser when supplied/executed and shall be deemed
covered by other break up prices. Such break up cost should be based
on ex works cost and percentage of ex works cost should be indicated
separately for packing and forwarding, sea/Air freight & Inland
22
transportation, insurance, taxes & custom duties and other incidental
charges, erection, and commissioning on percentage basis for each item.
35 Delivery Schedule of items

35.1 Bidders should submit a detailed item wise delivery schedule keeping in
view the completion period of the contract. Such items shall be grouped
under monthly Delivery schedule with total value of such items. This will
facilitate for ensuring the cash flow requirement for the project.
35.2 Material should be supplied strictly as per the time schedule mentioned in
Purchase Order. Amul has right to deduct the lump sum amount from the
final bills if delay in material supply found.
23
TABLE 1
CHECK LIST OF BID SUBMISSION
SR NO REQUIREMENT TICK (E)

1 Bid Form on your Letterhead
2 Qualification Application and Supporting
Price Schedule summary sheet and item wise break-up
3
sheet
4 Manufacturer’s Authorisation Form
5 Technical Deviation Statement Form
6 Commercial Deviation Statement Form
7 Bid Security (Earnest Money Deposit)
8 Power-of-attorney for authorised Signatory
24
SECTION - III
GENERAL CONDITIONS
OF THE CONTRACT
25
Contents
1. Definitions
2. Application
3. Definition of Country of origin
4. Standards
5. Use of Contract Documents and Information
6. Patent Rights
7. Performance Security
8. Inspection and Tests
9. Packing and Marking
10. Delivery and Documents
11. Insurance
12. Transportation
13. Incidental Services
14. Spare Parts
15. Warranty/Guarantee
16. Payment
17. Prices
18. Change Orders
19. Contract Amendment
20. Assignment
21. Sub contracts
22. Delays in the Bidder's Performance
23. Price Reduction Clause
24. Termination for Default
25. Force Majeure
26. Termination for Insolvency
27. Termination for Convenience
28. Resolution of Disputes
29. Governing Language
30. Applicable Law
31. Notices
32. Taxes and Duties
33. Right to use defective equipment
34. Income Tax and Other Taxes
35. Jurisdiction
26
1. Definitions
1.1 In this Contract, the following terms shall be interpreted as indicated:
1.2 "The Contract" means the agreement entered into between the Purchaser
and the Bidder, including all attachments and appendices thereto and all
documents incorporated by reference therein.
1.3 "The Contract Price" means the price payable to the Bidder under the
Contract for the full and proper performance of its contractual obligations.
1.4 "The Goods" means all of the equipment, machinery, and/or other
materials, which the Bidder is required to supply to the Purchaser under
the Contract.
1.5 "Services" means services ancillary to the supply of the Goods, such as
transportation and insurance, and any other incidental services, such as
installation, commissioning, provision of technical assistance, training and
other such obligations of the Bidder covered under the Contract.
1.6 "The Purchaser" means the Organization purchasing the Goods and
services and would include the term "Owner".
1.7 "The Bidder" means the individual or firm supplying the Goods and
services under this Contract would include also the terms “contractor” or
“Bidder”.
1.8 Engineer-in-charge means the Engineer designated as such or other
Engineer appointed from time to time by the Purchaser and notified in
writing to the Bidder to act as Engineer-in-charge for the purposes of
contract.
2. Application
2.1 These General Conditions shall apply to the extent that provisions in
other parts of the Contract do not supersede them.
3. Definition of Country of origin

3.1 For purpose of this Clause "origin" means the place where the Goods
were mined, grown or produced, or from which the Services are supplied.
Goods are produced when, through manufacturing, processing or
substantial and major assembling of components, a commercially
recognized new product results that is substantially different in basic
characteristics or in purpose or utility from its components. The origin of
Goods and Services is distinct from the nationality of the Bidder.
4 Standards
4.1 The Goods supplied under this Contract shall conform to the standards
mentioned in the Technical Specifications, and, when no applicable
standard is mentioned, to the latest Indian Standards.
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5 Use of Contract Documents and Information
5.1 The Bidder shall not, without the Purchaser's prior written consent,
disclose the Contract, or any provision thereof, or any specification,
plan, drawing, pattern, sample or information furnished by or on behalf of
the Purchaser in connection therewith, to any person other than a person
employed by the Bidder in the performance of the Contract. Disclosure to
any such employed person shall be made in confidence and shall extend
only so far as may be necessary for purposes of such performance.
5.2 The Bidder shall not, without the Purchaser's prior written consent, make
use of any document or information except for purposes of performing the
Contract.
5.3 Any document, other than the Contract itself, shall remain the property of
the Purchaser and shall be returned (in all copies) to the Purchaser on
completion of the Bidder's performance under the Contract if so required
by the Purchaser.
6 Patent Rights
6.1 The Bidder shall indemnify the Purchaser against all third party claims
of infringement of patent, trademark or industrial design rights arising
from use of the Goods or any part thereof.
7 Performance Security
7.1 The Bidder shall furnish performance security to the Purchaser in the
amount specified in the Special Conditions of Contract.
7.2 The proceeds of the performance security shall be payable to the
Purchaser as compensation for any loss resulting from the Bidder's
failure to complete its obligations under the Contract.
7.3 The Performance Security shall be denominated in Indian Rupees and
shall be in one of the following forms:
7.3.1 A bank guarantee issued by a Nationalized Bank in India and in the form
provided in the Bidding Document. Such bank guarantee shall be valid till
the expiry of the warranty period.
7.3.2 Demand Draft from a Nationalised Bank in favour of Kaira District Co
Operative Milk Producers’ Union Ltd. payable at Anand. No interest shall
be paid on the security deposit, which shall be retained till the completion
of the warranty period.
7.4 The performance security will be discharged by the Purchaser and
returned to the Bidder not later than 30 days following the date of
completion of the Bidder's performance obligations, including any
warranty obligations, under the Contract.
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8.1 The Purchaser or its representative shall have the right to inspect and/or
test the Goods to confirm their conformity to the Contract. The Special
Conditions of Contract and/or the Technical Specifications shall specify
what inspections and tests the Purchaser requires and where they are to
be conducted. The Purchaser shall notify the Bidder in writing of the
identity of any representatives, if retained for these purposes. Bidders
must carry out test as per guideline of purchaser at their own cost.
8.2 The inspections and tests may be conducted on the date of delivery
and/or at the Good's final destination. Where conducted on the premises
of the Bidder or its subcontractors(s), all reasonable facilities and
assistance including access to drawings and production data shall be
furnished to the inspectors at no charge to the Purchaser. In case of any
defects or deficiency notified by the Purchaser's inspection authority, the
Bidder will rectify and make good the same without delay and not proceed
with further processing of such item(s) of Goods without obtaining
approval from the inspection authority.
8.3 Should any inspected or tested Goods fail to conform to the
Specifications, the Purchaser may reject them and the Bidder shall either
replace the rejected Goods or make all alterations necessary to meet
specification requirements free of cost to the Purchaser upto the
satisfaction of Purchaser.
8.4 The Purchaser's right to inspect, test and, where necessary, reject the
Goods after the Goods' arrival at the destination shall in no way be limited
or waived by reason of the Goods having previously been inspected,
tested and passed by the Purchaser or its representative prior to the
Goods shipment from the country of origin.
8.5 Nothing in this clause shall in any way release the Bidder from any
warranty or other obligations under this Contract.
9. Packing and Marking

9.1 The Bidder shall provide such packing of the Goods as is required to
prevent their damage or deterioration during transit to their final
destination as indicated in the Contract. The packing shall be sufficient to
withstand, without limitation, rough handling during transit and exposure
to temperature, salt and precipitation during transit and open storage.
Packing case size and weights shall take into consideration, where
appropriate, the remoteness of the Goods' final destination and the
absence of heavy handling facilities at all points in transit.
9.2 The packing, marking and documents within and outside the packages
shall comply strictly with such special requirements as shall be expressly
provided for in the Contract and, subject to Clause 18, in any subsequent
instructions ordered by the Purchaser.
29
9.3 Each package shall be marked to indicate a) Name of the Bidder, b)
Details of items in the package, c) Name of the Consignee, d) Purchase
Order Number, e) Gross, net and tare weights of the item, f) Destination.

10.1 Delivery of the goods shall be made by the Bidder in accordance with the
terms specified by the Purchaser in its Schedule of Requirements and the
Special Conditions of Contract. For the purpose of the Contract, "FOB",
"C&F", "CIF", "FOR Destination", "Free delivery at site" and other
trade terms used to describe the obligations of the parties shall have the
meanings as per the common trade practices.
10.2 DRAWINGS AND QAP: Drawings & QAP to be submitted within 15 days from
date of LOI / P.O in prescribed format of Purchaser. Necessary type test reports
shall also be submitted along with the drawings in line with requirement. All
drawings and documents shall be submitted in the name of KDCMPUL(AMUL)&
PO reference shall appear in all drawings/documents/QAP/test report. Any delay
in the submission of drawings & QAP will reduce the agreed delivery period by
equal time. Bidder has to give Weight & Volume details of the packed equipment
for his scope of supply along with drawings to enable purchaser to arrange for
suitable storage at site. All drawings/ documents shall be submitted in 3 sets
(hard copy) for further submission to client. All the drawings and documents
shall also be submitted in editable soft format.
10.3 RISK PURCHASE: In the event of any failure in supplying the equipment by
stipulated delivery date or in the event of non-performance of ordered equipment
after commissioning due to design and/or manufacturing defects, purchaser
reserves the right and option to cancel the order in part or full and purchase
such cancelled equipment from elsewhere on account of and at the risk of bidder
without prejudice to other terms, conditions of this purchase order.
11. Insurance
11.1 The goods supplied under the Contract shall be fully insured in Indian
Rupees against loss or damage incidental to manufacture or acquisition,
transportation, storage and delivery in the manner specified in the Special
Conditions of Contract. Where the Purchaser requires delivery of the
Goods on free delivery at site basis; the Bidder shall arrange and pay for
marine insurance naming the Purchaser as the beneficiary. The Bidder
shall provide a copy of the insurance policy along with invoice to the
Purchaser who will make arrangements to extend the validity of the
policy, if necessary. The Bidder shall initiate and pursue claim till
settlement and promptly make arrangements for repair and/or
replacement of any damaged item/s irrespective of settlement of claim by
the underwriters.
30
12. Transportation
12.1 The Bidder is required under the Contract to deliver the Goods FOR
destination, specified in the Schedule of Requirement. Transport of the
Goods, up to the destination shall be arranged and paid for by the Bidder
and the cost thereof shall be included in the Contract Price. Where the
Bidder is required to effect delivery under any other terms, for example,
by post or to another address in the source country, the Bidder shall be
required to meet all transport and storage expenses until delivery. In all
the above cases, transportation of the Goods after delivery shall be the
responsibility of the Purchaser.
13. Incidental Services

13.1 As specified in the Special Conditions of Contract, the Bidder shall be
required to provide any or all of the following services:
13.1.1 Performance or supervision of on site assembly and/ or start up of the
supplied Goods;
13.1.2 Furnishing of a detailed operations and maintenance manual for each
appropriate unit of the supplied Goods; and manuals covering the
operation and maintenance of automation software and control systems.
13.1.3 Furnishing of tools required for assembly and/or maintenance of the
supplied goods
13.1.4 Performance or supervision or maintenance and/or repair of the supplied
Goods, for a period of time agreed by the parties, provided that this
service shall not relieve the Bidder of any warranty obligations under this
Contract an
13.1.5 Conduct of training of the Purchaser's personnel, at the Bidder's plant
and/or onsite, in assembly, start up operation, maintenance and/or
repair of the supplied Goods.
14. Spare Parts

14.1 As specified in the Special Conditions of contract, the Bidder may be
required to provide any or all of the following materials and notifications
pertaining to spare parts manufactured or distributed by the Bidder:
14.1.1 Such spare parts as the Purchaser may decide to purchase from the
Bidder, provided that this decision shall not relieve the Bidder of any
warranty obligations under the Contract; and
14.1.2 In the event of termination of production of the spare parts:
14.1.3 Advance notification to the Purchaser of the pending termination, in
sufficient time to permit the Purchaser to procure its needed
requirements; and
14.1.4 Following such termination, furnishing at no cost to the Purchaser, the
softcopies, the blueprints, drawings and specifications of the spare parts,
if and when requested.
31
14.1.5 The spares & consumables required till successful commissioning shall
be in the scope of bidder.
14.1.6 Bidder confirms the availability of spare parts required for O&M of the equipment
for a period of 10 years from the date of LOI/PO.
14.1.7 Necessary commissioning spares to be considered in bidder’s scope which may
be required during erection & commissioning of the equipment, without any extra
cost implication to purchaser. The same shall be supplied to site within 2 days
notice from purchaser.
14.1.8 Bidder has to submit spares price list, indicating complete technical
specification, Part No. / Ordering no. of OEM.
15.1 The Bidder warrants that the Goods and equipment supplied, installed
and commissioned under the Contract are new, unused, of the most
recent or current models and incorporate all recent improvements in
design and materials unless provided otherwise in the Contract. The
Bidder further warrants that the Goods supplied under this Contract shall
have no defect arising from design, materials or workmanship (except in
so far as the design or material is required by the Purchaser's
Specifications) or from any act or omission of the Bidder, that may
develop under normal use of the supplied Goods in the conditions
obtaining in the country of final destination. The Bidder also guarantees
that the Goods supplied shall perform satisfactorily as per the
designed/rated/installed capacity as provided for in the Contract. The
warranty will not cover normal wear and tear of consumables and minor
spares.
15.2 This warranty/guarantee shall remain valid for not less than 12 months
after the goods or any portion thereof as the case may be, have been
commissioned, or for not less than 18 months after the date of shipment /
dispatch, whichever period concludes later. Bidder to submit the price for
additional warranty of 18 months after expiry of above warranty period at
the time of order finalization. Any rectification/replacement of any
defective material supplied or works done during warranty period shall be
made good without any time and cost implication to purchaser. Any
repaired / modified or replaced part shall be subject to defect free
guarantee for a further period of 12 months from the date of rectification
/replacement.
15.3 The Purchaser shall promptly notify the Bidder in writing of any claims
arising under this warranty.
15.4 Upon receipt of such notice, the Bidder shall, with all reasonable speed,
repair or replace the defective Goods or parts thereof, without costs to the
Purchaser other than, where applicable, the cost of inland delivery of the
32
repaired or replaced Goods or parts from the port of entry to the final
destination.
15.5 If the Bidder, having been notified, fails to remedy the defect(s) within a
reasonable period, the Purchaser may proceed to take such remedial
action as may be necessary, at the Bidder's risk and expense and
without prejudice to any other rights which the Purchaser may have
against the Bidder under the Contract.
15.6 This warranty/guarantee shall not cover any damage/s resulting from
normal wear and tear or improper handling by the Purchaser or his
authorized representatives.
15.7 The Bidder shall guarantee the complete installation for satisfactory
performance for a minimum period of twelve months from the date of
commissioning. The Bidder at his own cost shall rectify any defect arising
out of faulty installation or use of substandard material or workmanship.
16. Payment
16.1 The method and conditions of payment to be made to the Bidder under
the Contract shall be specified in the Special Conditions of Contract.
16.2 The Bidder's request(s) for payment shall be made to the Purchaser in
writing, accompanied by an invoice describing, as appropriate, the Goods
delivered and
Services performed, and by shipping documents, submitted pursuant to
Clause 10, and fulfilments of other obligations stipulated in the Contract.
16.3 Payments shall be made promptly by the Purchaser within forty five (45)
days of submission of an invoice/claim by the Bidder and shall be in
Indian Rupees only.
17. Prices
17.1 Prices charged by the Bidder for Goods delivered and Services
performed under the Contract shall not, with the exception of price
adjustments authorized by the special conditions of the contract, vary
from the prices quoted by the Bidder in its bid and the Contract shall be
on fixed price basis. Variation due to changes in statutory levies and
exchange rates (for imported items if quoted with foreign currencies
multiplied by the exchange rates limited to the foreign currencies ceiling
quoted) shall be acceptable within the contact period.
18. Change Orders

18.1 The Purchaser may, at any time, by a written order given to the Bidder
make changes within the general scope of the Contract in any one or
more of the following:
18.1.1 Drawings, designs or specifications, where Goods to be furnished under
the Contract are to be specifically manufactured for the Purchaser
33
18.1.2 The method of shipment or packing
18.1.3 The place of delivery or
18.1.4 The Services to be provided by the Bidder.
18.2 If any such change causes an increase or decrease in the cost of, or the
time required for, the Bidder's performance of any part of the work under
the Contract, whether changed or not changed by the order, an equitable
adjustment shall be made in the Contract Price or delivery schedule, or
both, and the Contract shall accordingly be amended. Any claims by the
Bidder for adjustment under this clause must be asserted within thirty (30)
days from the date of the Bidder's receipt of the Purchaser's change
order.
19. Contract Amendment

19.1 No variation in or modification of the terms of the Contract shall be made
except by written amendment signed by the parties.
20. Assignment
20.1 The Bidder shall not assign, in whole or in part, its obligations to perform
under the Contract, except with the Purchaser's prior written consent.
21. Subcontracts
21.1 The Bidder shall notify the Purchaser in writing of all sub contracts
awarded under the Contract if not already specified in his bid. Such
notification, in his original bid or later, shall not relieve the Bidder from any
liability or obligation under the Contract.
21.2 Subcontracts must comply with the provisions of Clause 5.
22. Delays in the Bidder's Performance

22.1 Delivery of the Goods and performance of Services shall be made by the
Bidder in accordance with the time schedule specified by the Purchaser in
its Schedule of Requirements.
22.2 An unexcused delay by the Bidder in the performance of its delivery
obligations shall render the Bidder liable to any or all of the following
sanctions:
22.2.1 Forfeiture of its performance security,
22.2.2 Imposition of liquidated damages, and/or
22.2.3 Termination of the Contract for default
22.3 If at any time during performance of the Contract, the Bidder or its
subcontractor(s) should encounter conditions impeding timely delivery of
the Goods and performance of Services, the Bidder shall promptly notify
the Purchaser in writing of the fact of the delay, its likely duration and its
cause(s). As soon as practicable after receipt of the Bidder's notice, the
34
Purchaser shall evaluate the situation and may at its discretion extend the
Bidder's time for performance, in which case the extension shall be
ratified by the parties by amendment of the Contract.
23. PRICE REDUCTION CLAUSES

23.1 Subject to Clause 25, if the Bidder fails to deliver any or all of the Goods
or perform the Services within the time period(s) specified in the Contract,
the Purchaser shall, without prejudice to its other remedies under the
Contract, deduct from the Contract Price, as liquidated damages as
under:
23.1.1 For the Supply Component:
A sum equivalent to 0.5% of the contract value for each week of delay or
part thereof.
23.1.2 For the Erection and Commissioning Component:
A sum equivalent to 0.5% of the contract value for each week of delay or
part thereof beyond the time specified in the contract for the successful
completion of the plant.
The total amount so deducted as per above, shall not exceed 10 % of the
Contract value. Once the maximum is reached, the Purchaser may
consider termination of the Contract.
23.1.3 For the Supply Component : Any delay beyond the agreed date of delivery,
PRICE will be reduced at the rate of 1% per week of total contract value, subject
to maximum of 5% of the order value, without prejudice to any other terms/
conditions of this purchase order.
23.2 Any incremental taxes and levies on account of delay in performance of

the Contract by the Bidder shall be to the Bidder's account.
24. Termination for Default

24.1 The Purchaser may, without prejudice to any other remedy for breach of
contract, by written notice of default sent to the Bidder, terminate the
Contract in whole or in part:
24.1.1 If the Bidder fails to perform any other obligation(s) under the Contract or
24.1.2If the Bidder fails to deliver any or all of the Goods within the time
period(s) specified in the Contract, or any extension thereof granted by
the Purchaser pursuant to Clause 22.
24.2 In the event the Purchaser terminates the Contract in whole or in part,
pursuant to Clause 24, the Purchaser may procure, upon such terms and
in such manner, as it deems appropriate, Goods similar to those
undelivered, and the Bidder shall be liable to the Purchaser for any
excess costs for such similar Goods. However, the Bidder shall continue
performance of the Contract to the extent not terminated.
24.3 Consequent to such termination of Contract, the Purchaser shall recover
the advance paid, if any, to the Bidder along with interest @ 18% per
35
annum compounded quarterly on the last day of March, June,
September and December on the advance paid for the entire period for
which the advance was retained by the Bidder.
25. Force Majeure

25.1 Not withstanding the provisions of Clauses 22, 23 and 24, the Bidder shall
not be liable for forfeiture of its performance security, liquidated damages
or termination for default, if and to the extent that, its delay in
performance or other failure to perform its obligations under the Contract
is the result of an event of Force Majeure.
25.2 For purposes of this clause, "Force Majeure" means an event beyond the
control of the Bidder and not involving the Bidder's fault or negligence and
not foreseeable. Such events may include, but are not restricted to, acts
of the Purchaser either in its sovereign or contractual capacity, wars or
revolutions, fires, floods, epidemics, quarantine restrictions and freight
embargoes.
25.3 If a Force Majeure situation arises, the Bidder shall promptly notify the
Purchaser in writing of such condition and the cause thereof. Unless
otherwise directed by the Purchaser in writing, the Bidder shall continue
to perform its obligations under the Contract as far as is reasonably
practical, and shall seek all reasonable alternative means for performance
not prevented by the Force Majeure event.
26. Termination for Insolvency

26.1 The Purchaser may at any time terminate the Contract by giving written
notice to the Bidder, without compensation to the Bidder, if:
26.1.1 The Bidder becomes bankrupt or otherwise insolvent,
26.1.2 The Bidder being a Company is wound up voluntarily by the order of a
Court receiver, liquidator or Manager appointed on behalf of the
debenture holders or circumstances shall have arisen which entitle the
court or debenture holders to appoint a receiver, liquidator or a Manager,
provided that such termination will not prejudice or affect any right of
action or remedy which has accrued or will accrue thereafter to the
Purchaser.
27. Termination for Convenience

27.1 The Purchaser, may by written notice sent to the Bidder, terminate the
Contract, in whole or in part, at any time for its convenience. The notice of
termination shall specify that termination be for the Purchaser's
convenience, the extent to which performance of work under the Contract
is terminated, and the date upon which such termination becomes
effective.
36
27.2 The Purchaser shall purchase the Goods that are complete and ready for
dispatch within 30 days after the Bidder’s receipt of notice of termination
at the Contract terms and prices. For the remaining Goods, the Purchaser
may decide:
27.2.1 To have any portion completed and delivered at the Contract terms and
prices and/or
27.2.2 To cancel the remainder and pay to the Bidder an agreed amount for
partially completed Goods and for materials and parts previously
procured by the Bidder. Both Purchaser and Bidder shall mutually settle
all terminations as per clause 24, 25, 26 and 27.

28.1 The Purchaser and the Bidder shall make every effort to resolve amicably
by direct informal negotiation any disagreement or dispute arising
between them under or in connection with the Contract.
28.2 If, after thirty (30) days from the commencement of such informal
negotiations, the Purchaser and the Bidder have been unable to resolve
amicably a Contract dispute, either party may require that the dispute be
referred for resolution to the formal mechanisms specified in the Special
Conditions of Contract. These mechanisms may include, but are not
restricted to, conciliation mediated by a third party, adjudication in an
agreed national or international forum, and/or international arbitration.
The mechanism shall be specified in the Special Conditions of Contract.
29. Governing Language

29.1 The Contract shall be written in the language of the bid, as specified by
the Purchaser in the Instructions to Bidders. Subject to Clause 30, that
language version of the Contract shall govern its interpretation. All
correspondence and other documents pertaining to the Contract, which
are exchanged by the parties, shall be written in that same language.
30. Applicable Law

30.1 The Contract shall be interpreted in accordance with the laws of the
Union of India.
31. Notices
31.1 Any notice given by one party to the other pursuant to the Contract shall
be sent in writing or by fax / email and confirmed in writing to the address
specified for that purpose in the Special Conditions of Contract.
31.2 A notice shall be effective when delivered or on the notice's effective date,
whichever is later.
37
32. Taxes and Duties
32.1 The Bidder shall be entirely responsible for all taxes, duties, license
fees, etc. incurred until delivery of the contracted Goods to and taking
over of the works by the Purchaser. The onus of paying all the statutory
levies as per the applicable tariff heads and norms shall be on the Bidder.
33. Right to use defective equipment

33.1 If after delivery, acceptance and installation and within the guarantee and
warranty period, the operation or use of the equipment proves to be
unsatisfactory, the Purchaser shall have the right to continue to operate
or use such equipment until rectification of defects, errors or omissions by
repair or by partial or complete replacement is made without interfering
with the Purchasers' operation.
34. Income Tax and Other Taxes

34.1 The Bidder shall be liable to pay all corporate taxes, income tax and other
taxes that shall be levied according to the laws and regulations applicable
from time to time and the price bid by the Bidder shall include all such
taxes. Wherever the laws and regulations require deduction of such taxes
at the source of payment, the Purchaser shall effect such deductions from
the payment due to the Bidder. The remittance of amounts so deducted
and issuance of certificate for such deductions shall be made by the
Purchaser as per the laws and regulations in force. Nothing in the
Contract shall relieve the Bidder from his responsibility to pay any tax that
may be levied on income and profits made by the Bidder in respect of the
Contract. The Bidder's staff, personnel and labour will be liable to pay
personal income taxes in respect of such of their salaries and wages as
are chargeable under the laws and regulations for the time being in force,
and the Bidder shall perform such duties in regard to such deductions
thereof as may be imposed on him by such laws and regulations. The
Purchaser shall not, in any way, be responsible for such payments by the
Bidders' staff.
35 Jurisdiction
35.1 Settlement of any dispute out of the purchase order/ contract against this
bid shall be subject to the courts at Anand only.
38
SECTION IV - PART I
SPECIAL CONDITIONS
OF CONTRACT
39
Contents
1. Definitions
2. Performance Security
5. Insurance
6. Incidental services
7. Spare Parts
9. Payment
10. Price Adjustment
12. Notices
40
The following Special Conditions of Contract shall supplement the General
Conditions of Contract. Whenever there is a conflict, the provisions herein shall
prevail over those in the General Conditions of Contract. The corresponding
clause number of the General Conditions is indicated in parentheses:
1. Definitions (Clause 1)
1.1 The Purchaser is Kaira District Co-operative Milk Producers’ Union Limited
and would include the term "Owner"
1.2 The Bidder/Bidder is (Name of Bidder/Bidder).
1.3 Equivalency of Standards and Codes (Clause 4)
1.4 Wherever reference is made in the contract to the respective standards and
codes in accordance with which goods and materials are to be furnished, and
work is to be performed or tested, the provisions of the latest current edition or
revision of the relevant standards and codes in effect shall apply, unless
otherwise expressly set forth in the Contract. Where such standards and codes
are national in character, or relate to a particular country or region, other
authoritative standards which ensure an equal or higher quality than the
standards and codes specified will be accepted subject to the Purchaser's prior
review and written approval. Differences between the standards specified and
the proposed alternative standards must be fully described in writing by the
Bidder/Bidder and submitted to the Purchaser at least 30 days prior to the date
when the Bidder/Bidder desires the Purchaser's approval. In the event the
Purchaser determines that such proposed deviations do not ensure equal or
higher quality, the Bidder/Bidder shall comply with the standards set forth in the
documents.
2. Performance Security (Clause 7)

2.1 The Performance Security shall be in the amount of 10% of the Contract price up to sixty
days after the date of completion of performance obligations including warranty
obligations.
3. Inspection and Tests (Clause 8)

3.1 The inspection of the Goods shall be carried out to check whether the Goods are in
conformity with the technical specifications attached to the purchase order form and
shall be in line with the inspection/test procedures laid down in the Schedule of
Specifications and the Contract conditions.
4. Delivery and Documents (Clause 10)

4.1.1 For imported goods: Upon shipment, the Bidder/Bidder shall notify the
Purchaser and the Insurance Company by fax / email the full details of the
shipment including purchase order number, description of goods, quantity, the
vessel, the bill of lading number and date, port of loading, date of shipment, port
of discharge, etc. The Bidder/Bidder shall mail the following documents to the
Purchaser, with a copy to the Insurance Company:
41
4.1.2 For imported goods: Original and three copies of:
• The Bidder's invoice showing purchase order no., Goods description, quantity, unit
price, total amount;
• The negotiable, clean, on-board bill of lading marked freight prepaid and three copies of
non-negotiable bill of lading;
• Packing list identifying contents of each package;
• Insurance certificate;
• Manufacturer's/Bidder/Bidder's guarantee certificate;
• Inspection certificate, issued by the nominated inspection agency and the
Bidder/Bidder's factory inspection report; and
• Certificate for Country of origin.
• The Bidder's certificate certifying that the defects pointed out during inspection have
been rectified.
4.2 The Purchaser shall receive the above documents at least one week before
arrival of the Goods at the port and, if not received, the Bidder/Bidder will be
responsible for any consequent expenses.
4.4 For Domestic Goods: Original and three copies of:
• The Bidder's invoice showing purchase order no., Goods' description, quantity, unit
price, total amount;
• Delivery note/packing list/lorry receipt;
• Manufacturer's/Bidder/Bidder's guarantee certificate;
• Inspection Certificate issued by the nominated inspection agency, and the
Bidder/Bidder's factory inspection report;
• Excise gate pass/ Octroi receipts, wherever applicable, duly sealed indicating payments
made; and
• Any other document evidencing payment of statutory levies.
• Single MCE insurance policy shall cover the entire project.
4.5 Note: The nomenclature used for the item description in the invoice/s, packing
list/s and delivery note/s etc. should be identical to that used in the purchase
order/contract. The dispatch particulars including name of transporter, LR
Number and date should also be mentioned in the invoice/s.
4.6 Ensure that material supplied are Brand new and defect free and also to be
mentioned in Commercial Invoice.
5. Insurance (clause 11)

5.1 The marine/transit insurance shall cover an amount equal to 110% of the FOR
destination value of the goods from "warehouse to warehouse" on "All Risks"
basis including War Risks and Strike clauses valid for a period not less than 3
months after the date of arrival of Goods at final destination.
42
5.2 The Insurance charges shall be paid by successful Bidder/Bidder towards all
risks during storage, erection, testing, commissioning and up to acceptance of
the plant.
6 Incidental services (Clause 13)

6.1 The incidental services shall be provided as per the requirements outlined in the
Schedule of Specifications and as covered under Clause 3.13. The cost shall be
included in the contract price, if provided for in the scope of the Contract.
7 Spare Parts (Clause 14)

7.1 Bidder/Bidders shall carry sufficient inventories to assure ex-stock supply of consumable
essential spares considered for the plant All spare parts and components shall be
supplied as promptly as possible but in any case within three months of placement of
order.
8. Warranty/Guarantee (Clause 15)

8.1 The warranty/guarantee shall be as per provision under Clause 3.15 of General
Conditions.
9 Payment (Clause 16)

9.1 Payment for supply, installation and commissioning contracts must be as below:
9.1.1 10% advance of total contract value (Supply component )on:
(i) Acceptance of the order i.e.
a. Submission of the Duplicate copy of the order duly signed by the authorised
signatory putting stamp of the Organisation.
b. Execution of the Contract Form.
(ii) Against a bank guarantee for equivalent amount valid for 30 days beyond the
stipulated delivery (as per schedule of delivery/supply)/ completion period
¾ 20% of the Supply value on first submission of Plant layout, and P&I Diagram for
process and services.(supply)
¾ 60% progressive payment of supply value against safe receipt of goods at
site.(supply)
¾ 10% of total contract value (Supply) against submission of bank guarantee valid
for 1 year from the date of commissioning.
9.1.2 80 % of erection and commissioning value on Pro rata basis. For erection the
payment shall be made on progression of erection as per Joint Measurement
Sheet within 30 days of submission of JMS (erection and commissioning)
¾ 20% Erection & Commissioning value to be pay based on successful erection
and Commissioning.
9.2 The Bank Guarantees should be obtained from Nationalized Banks and
acceptable Foreign Banks operating in India (please refer to list given in the
Appendices I).
43
9.3 Notes:
• All Payments shall be made within 45 days from the date of submission of
Invoice.
• Payment shall be made on complete supply of an item/ group of items specified
in the Contract as per the Price Break up. No payment shall be made if supply of
an item/ group of items is incomplete.
• Bank Guarantees for advance payment shall be released not later than 30 days
after the date of delivery of all the Goods at their final destination.
• For items, which do not involve any supply and the Bidder/Bidder/ contractor has
to do only the erection and commissioning, 60% payment shall be made on
completion of erection of the items as per the break-up prices to be given in the
Purchase Order.
9.4 Third party claims, bills and invoices will not be entertained during the contract
by AMUL.
10. No rise adjustment during the project period.
11. Resolution of Disputes (Clause 28)

11.1 All disputes or differences in respect of which the decision is not final and
conclusive shall, on the initiative of either party, be referred to the adjudication of
sole Arbitrator. Within thirty days of receipt of notice from the Bidder/Bidder of
his intention to refer the dispute to arbitration, the Purchaser shall finalize a
panel of three Arbitrators and intimate the same to the Bidder. The Bidder shall
within fifteen days of receipt of this list select and confirm his acceptance to the
appointment of one from the panel as Arbitrator. If the Bidder to communicate
his selection of name, within the stipulated period, the Purchaser shall without
delay select one from the panel and appoint him as the sole Arbitrator. If the
Purchaser fails to send such a panel within thirty days, as stipulated, the
Bidder/Bidder shall send a similar panel to the Purchaser within fifteen days. The
Purchaser shall then select one from the panel and appoint him as the sole
Arbitrator within fifteen days. If the Purchaser fails to do so, the Bidder/Bidder
shall communicate to the Purchaser the name of one from the panel who shall
then be the sole Arbitrator. The appointment of sole Arbitrator so made shall be
final and conclusive.
11.2 The Arbitration shall be conducted in accordance with the provisions of the
Indian Arbitration Act, 1996 and rules there under or any statutory modifications
thereof for the time being in force. The Arbitration proceedings shall be held in
Chikhali ONLY at the time as the sole Arbitrator may decide. The decision of the
sole Arbitrator shall be final and binding upon the parties and the expenses of
the Arbitrator shall be paid as may be determined by the Arbitrator.
11.3 Performance under the Contract shall, if reasonably possible, continue during
the Arbitration proceedings and payments due to the Bidder/Bidder by the
Purchaser shall not be withheld, unless they are the subjects of the Arbitration
proceedings.
44
All awards for claims equivalent to Rupees thirty thousand or more shall be in
writing and state the reasons for the amounts awarded.
11.5 Neither party is entitled to bring a claim to Arbitration if its Arbitrator has not
been appointed within thirty days after expiration of the warranty/ guarantee
period.
12. Notices (Clause 31)

12.1 For the purpose of all the notices, the following shall be the address of the
Purchaser and Bidder.
Purchaser :
Kaira District Co- operative Milk Producers’ Union Limited.
Anand- 388 001,
Gujarat ,India Phone: +91-2692-225473, Fax: +91-2692-225475
Bidder: (address will be provided by bidder)
45
SECTION IV – PART II
SPECIAL CONDITIONS OF
CONTRACT FOR ERECTION
AND COMMISSIONING
46
Contents
1. Sufficiency Of Tender
2. Programme Of Installation & Commissioning
3. Preparation of Drawings for Approval
4. Superintendence, Team And Conduct
5. Purchaser's Instructions
6. Right Of The Purchaser
7. Bidder/Bidder’s Functions
8. Variations
9. Duties of the Bidder/Bidder Vis-a-Vis the Purchaser
10. Supply Of Tools, Tackles And Materials
11. Protection Of Plant
12. Unloading, Transportation And Inspection
13. Storage Of Equipment
14. Approvals
15. Review & Co-Ordination of Erection Work
16. Extension of Time for Completion
17. Table 1 List of Drawings required Submission
47
1. Sufficiency of Tender
1.1 The Bidder/Bidder by bidding shall be deemed to have satisfied himself as to all
the conditions and circumstances affecting the Contract Price, as to the
possibility of executing the works as shown and described in the Contract, as to
the general circumstances at the site of the works, as to the general labour
position at site and to have determined the prices accordingly.
2. Programme of Installation & Commissioning

2.1 As soon as practicable after the acceptance of the bid, the Bidder/Bidder shall
submit to the Purchaser for his approval a comprehensive programmed in the
form of PERT network/ bar chart and any other form as may be required by the
Purchaser showing the sequence of order in which the Bidder/Bidder proposes
to carry out the works including the design, manufacture, delivery to site,
erection and commissioning thereof. After submission to and approval by the
Purchaser of such programmed, the Bidder/Bidder shall adhere to the sequence
of order and method stated therein. The submission to and approval by the
Purchaser of such programmed shall not relieve the Bidder/Bidder of any of his
duties or responsibilities under the Contract. The programmed approved by the
Purchaser shall form the basis of evaluating the pace of all works to be
performed by the Bidder/Bidder. The Bidder/Bidder shall update the PERT
Network every month, submit it to the Purchaser and shall inform the Purchaser
the progress on all the activities falling on schedule for the next reporting date.
3 Preparation of Drawings for Approval

3.1 The Bidder/Bidder should visit the site to acquaint himself in respect of existing
site conditions and to know the details/information required for understanding
the nature and type of civil construction works involved in the project. The
Bidder/Bidder shall submit to the Purchaser for approval:
• Within the time given in the specification or in the program, such drawings,
samples, patterns and models as may be called for therein, and in numbers
therein required.
• During the progress of works and within such reasonable times as the Purchaser
may require such drawings of the general arrangement and details of the works
as the Purchaser may require.
3.2 Wherever necessary, the Bidder/Bidder would be provided with a set of
architectural drawings for the buildings where the erection works would be
carried out and also the equipment details/ drawings of various equipment
handed over to the Bidder/Bidder by the Purchaser.
3.3 The specifications/ conditions concerning the submission of drawings by the
Bidder/Bidder are detailed as under:
3.4 Within three weeks from the date of receipt of the order, Bidder/Bidder shall
furnish a list of all necessary drawings, which the Bidder/Bidder shall submit for
approval, identifying each drawing by a serial number and descriptive title and
expected date of submission. A brief list of drawings is given in Table 1. This list
48
shall be revised and extended if necessary, during the progress of work
depending on the nature of the contract also.
3.5 The Purchaser shall signify his approval or disapproval of all drawings or such
drawings that would affect progress of the contract as per the agreed
programmed.
3.6 The purchaser shall issue, within four weeks of time in all circumstances, any
drawing requested by the Bidder/Bidder and required to be provided by us. If the
Bidder/Bidder suffers delay and/ or incurs costs due to delay on purchaser’s part
in this regard, then the Purchaser shall take such delay into account in
determining any extension of time to which the Bidder/Bidder is entitled under
Clause 15 hereof and the Bidder/Bidder shall be paid the amount of such cost as
shall be reasonable.
3.7 P&I Drawings, Plant Layout and GA Drawings submitted for approval shall be
signed by responsible representative of Bidder/Bidder and shall be to any one of
the following sizes in accordance with Indian Standards: “A0, A1, A2, A3 and
A4”.
3.8 All drawings shall show the following particulars in the lower right hand corner in
addition to Bidder/Bidder’s name:
Name of the Purchaser Date of drawing

Project Title Drawing number
Title of drawing Space for drawing number
Scale
3.9 In addition to the information provided on drawings, each drawing shall carry a
revision number, date of revision and brief description of revision carried out.
Whenever any revision is carried out, correspondingly revision number must be
updated.
3.10 All dimensions on drawings shall be in metric units.
3.11 Drawings (three sets) submitted by the Bidder/Bidder for approval will be
checked, reviewed by the Purchaser, and comments, if any, on the same will be
conveyed to the Bidder/Bidder. It is the responsibility of the Bidder/Bidder to
incorporate correctly all the comments conveyed by the Purchaser on the
Bidder/Bidder's drawings. The drawings, which are approved with comments,
are to be re-submitted to the Purchaser for purpose of records. Such drawings
will not be checked/reviewed by the Purchaser to verify whether the
Bidder/Bidder has incorporated all the comments. If the Bidder/Bidder is unable
to incorporate any comments in the revised drawings, Bidder/Bidder shall clearly
state in his forwarding letter such non-compliance along with the valid reasons.
3.12 Drawings prepared by the Bidder/Bidder and approved by the Purchaser shall
be considered as a part of the specifications. However, the examination of the
drawings by the Purchaser shall not relieve the Bidder/Bidder of his
responsibility for engineering design, workmanship, and quality of materials,
49
warranty obligations and satisfactory performance on installation covered under
the contract.
3.13 If at any time before completion of the work, changes are made necessitating
revision of approved drawings, the Bidder/Bidder shall make such revisions and
proceed in the same routine as for the original approval.
3.14 Date of submission: In the event, the drawings submitted for approval require
many revisions amounting to redrawing of the same, and then the date of
submission of the revised drawings would be considered as the date of
submission for approval.
3.15 The Bidder/Bidder shall furnish to the Purchaser before the works are taken
over, Operating and Maintenance instructions together with Drawings of the
works as completed, in sufficient detail to enable the Purchaser to maintain,
dismantle, reassemble and adjust all parts of the works. Unless otherwise
agreed, the works shall not be considered completed for the purposes of taking
over until such instructions and drawings have been supplied to the Purchaser.
4 Superintendence, Team and Conduct

4.1 The Bidder/Bidder shall employ one or more competent representatives, whose
name or names shall have previously been communicated in writing to the
Purchaser by the Bidder/Bidder, to superintend the carrying out of the works on
the site. The said representative or if more than one shall be employed, then
one of such representatives shall be present on the site during all times, and any
orders or instructions which the Purchaser may give to the said representative of
the Bidder/Bidder shall be deemed to have given to the Bidder/Bidder. The said
representative shall have full technical capabilities and complete administrative
and financial powers to expeditiously and efficiently execute the work under the
contract.
4.2 The Bidder/Bidder shall, execute the works with due care and diligence within
the time for completion and employ Bidder/Bidder’s team comprising qualified
and experienced engineers together with adequate skilled, semi-skilled and
unskilled workmen in the site for carrying out the works. The Bidder/Bidder shall
ensure adequate workforce to keep the required pace at all times as per the
schedule of completion. Bidder/Bidder shall also ensure availability of
competent engineers during commissioning/start up, trial runs, Operation of the
plant/equipment till handing over of the plant.
4.3 The Bidder/Bidder shall furnish the details of qualifications and experience of
their senior supervisors and engineers assigned to the work site, including their
experience in supervising erection and commissioning of plant and equipment of
comparable capacity.
4.4 When the Bidder/Bidder or Bidder/Bidder's representative is not present on any
part of the work where it may be desired to give directions in the event of
emergencies, orders may be given by the Purchaser and shall be received and
observed by the supervisors or foremen who may have charge of the particular
part of the work in reference to which orders are given. Any such instructions,
50
directions or notices given by the Purchaser shall be deemed given to the
Bidder/Bidder.
4.5 The Bidder/Bidder shall furnish to the Purchaser a fortnightly labor force report
showing by classifications the number of employees engaged in the work. The
Bidder/Bidder's employment records shall include any reasonable information as
may be required by the Purchaser. The Bidder/Bidder should also display
necessary information as may be required by statutory regulations.
4.6 None of the Bidder/Bidder’s supervisors, engineers, or labourers may be
withdrawn from the work without notice to the Purchaser and further no such
withdrawals shall be made if in the opinion of the Purchaser, it will adversely
affect the required pace of progress and/or the successful completion of the
work.
4.7 The Purchaser shall be at liberty to object to any representative or person,
skilled, semi-skilled or unskilled worker employed by the Bidder/Bidder in the
execution of or otherwise about the works who shall, in the opinion of the
Purchaser, misconduct himself or be incompetent, or negligent or unsuitable,
and the Bidder/Bidder shall remove the person so objected to, upon receipt of
notice in writing from the Purchaser and shall provide in that place a competent
representative at Bidder/Bidder's own expense within a reasonable time.
4.8 In the execution of the works no persons other than the Bidder/Bidder, sub-
Bidder/Bidder and their employees shall be allowed on the site except by the
written permission of the Purchaser.
5 Purchaser's Instructions
5.1 The Purchaser may, in his absolute discretion, issue from time to time drawings
and/ or instructions, directions and clarifications, which are collectively referred
to as Purchaser's instructions in regard to:
• Any additional drawing and clarifications to exhibit or illustrate details.
• Variations or modifications of the design, quality or quantity of work or the
additions or omissions or substitution of any work.
• Any discrepancy in the drawings or between the schedule of quantities and/or
specifications.
• Removal from the site of any material brought there by the Bidder/Bidder, which
are unacceptable to the Purchaser and the substitution of any other material
thereof.
• Removal and/or re-execution of any work erected by the Bidder/Bidder, which
are unacceptable to the Purchaser.
• Dismissal from the work of any persons employed there upon who shall in the
opinion of the Purchaser, misconduct him, or be incompetent or negligent.
• Opening up for inspection of any work covered up.
• Amending and making good of any defects.
51
6 Right of the Purchaser
6.1 Right to direct works
• The Purchaser shall have the right to direct the manner in which all works under
this contract shall be conducted, in so far as it may be necessary to secure the
safe and proper progress and specified quality of the works. All work shall be
done and all materials shall be furnished to the satisfaction and approval of the
Purchaser.
• Whenever in the opinion of the Purchaser, the Bidder/Bidder has made marked
departures from the schedule of completion or when circumstances or
requirement force such a departure from the said schedule, the Purchaser, in
order to ensure compliance with the schedule, shall direct the order, pace and
method of conducting the work, which shall be adhered to by the Bidder/Bidder.
• If in the judgment of the Purchaser, it becomes necessary at any time to
accelerate the overall pace of the plant erection work, the Bidder/Bidder, when
directed by Purchaser, shall cease work at any particular point and transfer
Bidder/Bidder’s men to such other point or points and execute such works, as
may be directed by the Purchaser and at the discretion of the Purchaser.
6.2 Right to order modifications of methods and equipment
• If at any time the Bidder/Bidder's methods, materials or equipment appear to the
Purchaser to be unsafe, inefficient or inadequate for securing the safety of
workmen or the public, the quality of work or the rate of progress required, the
Purchaser may direct the Bidder/Bidder to ensure safety, and increase their
efficiency and adequacy and the Bidder/Bidder shall promptly comply with such
directives. If at any time the Bidder/Bidder's working force and equipment are
inadequate in the opinion of the Purchaser, for securing the necessary progress
as stipulated, the Bidder/Bidder shall if so directed, increase the working force
and equipment to such an extent as to give reasonable assurance of compliance
with the schedule of completion. The absence of such demands from the
Purchaser shall not relieve the Bidder/Bidder of Bidder/Bidder's obligations to
secure the quality, the safe conducting of the work and the rate of progress
required by the contract. The Bidder/Bidder alone shall be and remain liable and
responsible for the safety, efficiency and adequacy of Bidder/Bidder’s methods,
materials, working force and equipment, irrespective of whether or not the
Bidder/Bidder makes any changes as a result of any order or orders received
from the Purchaser.
6.3 Right to inspect the work
• The Purchaser’s representative shall be given full assistance in the form of the
necessary tools, instruments, equipment and qualified operators to facilitate
inspection.
• The Purchaser reserves the right to call for the original test certificates for all the
materials used in the erection work.
• In the event the Purchaser's inspection reveals poor quality of work/materials,
the Purchaser shall be at liberty to specify additional inspection procedures if
52
required, to ascertain Bidder/Bidder's compliance with the specifications of
erection work.
• Even though inspection is carried out by the Purchaser or Purchaser's
representatives, such inspection shall not, however, relieve the Bidder/Bidder of
any or all responsibilities as per the contract, nor prejudice any claim, right or
privilege which the Purchaser may have because of the use of defective or
unsatisfactory materials or bad workmanship.
7 Bidder/Bidder’s Functions
7.1 The Bidder/Bidder shall provide everything necessary for proper execution of the
works, according to the drawings, schedule of quantities and specifications
taken together whether the same may or may not be particularly shown or
described therein, provided that the same can reasonably be inferred there from
and if the Bidder/Bidder finds any discrepancy therein, Bidder/Bidder shall
immediately refer the same to the Purchaser whose decision shall be final and
binding on the Bidder/Bidder.
7.2 The Bidder/Bidder shall proceed with the work to be performed under this
contract in the best and workman like manner by engaging qualified and efficient
workers and finish the work in strict conformance with the drawings and
specifications and any changes/modifications thereof made by the Purchaser.
8 Variations
8.1 The Purchaser shall make any variation of the form, quality or quantity of the
Works or any part thereof that may, in his opinion, be necessary and for that
purpose, or if for any other reason it shall, in his opinion be desirable, he shall
have power to order the Bidder/Bidder to do and the Bidder/Bidder shall do any
of the following:
• Increase or decrease the quantity of any work included in the contract,
• Omit any such work,
• Change the character or quality or kind of any such work,
• Change the levels, lines, position and dimensions of any part of the works
• Execute additional work of any kind necessary for the completion of the works
and no such variation shall in any way vitiate or invalidate the contract, but the
value, if any, of all such variations shall be taken into account in ascertaining the
amount of the Contract price.
8.2 The Bidder/Bidder shall make no such variations without an order in writing of
the Purchaser. Provided that no order in writing shall be required for increase or
decrease in the quantity of any work where such increase or decrease is not the
result of an order given under this clause, but is the result of the quantities
exceeding or being less than those stated in the Contract/Bill of Quantities.
Provided also that if for any reason the Purchaser shall consider it desirable to
give any such order verbally, the Bidder/Bidder shall comply with such order and
any confirmation in writing of such verbal order given by the Purchaser, whether
before or after the carrying out of the order, shall be deemed to be an order in
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writing within the meaning of this clause. Provided further that if the
Bidder/Bidder shall within seven days confirm in writing to the Purchaser and the
Purchaser shall not contradict such confirmation in writing within 14 days, it shall
be deemed to be an order in writing by the Purchaser.
8.3 All extra or additional work done or work omitted by order of the Purchaser shall
be valued at the rates and prices set out in the contract if in the opinion of the
Purchaser, the same shall be applicable. If the contract does not contain any
rates or prices applicable to the extra or additional work, then suitable rates or
prices shall be agreed upon between the Purchaser and the Bidder/Bidder. Any
Extra Work, carried out by the Bidder/Bidder would be at mutually agreed cost
8.4 Provided that if the nature or amount of any omission or addition relative to the
nature or amount of the whole of the works or to any part thereof shall be such
that, in the opinion of the Purchaser, the rate or price contained in the contract
for any item of the works is, by reason of such omission or addition, rendered
unreasonable or inapplicable, then a suitable rate or price shall be agreed upon
between the Purchaser and the Bidder/Bidder. In the event of disagreement the
Purchaser shall fix such other rate or price as shall, in his opinion, be reasonable
and proper having regard to the circumstances.
8.5 Provided also that no increase or decrease mentioned above or variation of rate
or price shall be made unless, as soon after the date of the order as is
practicable and, in the case of extra or additional work, before the
commencement of the work or as soon thereafter as is practicable, notice shall
have been given in writing:
• By the Bidder/Bidder to the Purchaser of his intention to claim extra payment or a varied
rate or price, or
• By the Purchaser to the Bidder/Bidder of his intention to vary a rate or price
a. No price variation on part of quantity increase or decrease.
8.6 The Bidder/Bidder shall send to the Purchaser’s representative once in every
month an account giving particulars, as full and detailed as possible, of all claims
for any additional payment to which the Bidder/Bidder may consider himself
entitled and of all extra or additional work ordered by the Purchaser which he
has executed during the preceding month.
8.7 No final or interim claim for payment for any such work or expense will be
considered which has not been included in such particulars. Provided always
that the Purchaser shall be entitled to authorize payment to be made for any
such work or expense, notwithstanding the Bidder/Bidder's failure to comply with
this condition, if the Bidder/Bidder has, at the earliest practicable opportunity,
notified the Purchaser in writing that he intends to make a claim for such work.
8.8 The work shall be carried out as approved by the Purchaser or his authorized
representative/s from time to time, keeping in view the overall schedule of
completion of the project. The Bidder/Bidder’s job schedule must not disturb or
interfere with Purchaser’s or the other Bidder/Bidder’s schedules of day-to-day
work. The Purchaser will provide all reasonable assistance for carrying out the
jobs.
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8.9 Night work will be permitted only with prior approval of the Purchaser. The
Purchaser may also direct the Bidder/Bidder to operate extra shifts over and
above normal day shift to ensure completion of contract as per schedule.
Adequate lighting wherever required should be provided by the Bidder/Bidder at
no extra cost. The Bidder/Bidder should employ qualified electricians and
wiremen for these facilities. In case of Bidder/Bidder’s failure to provide these
facilities and personnel, the Purchaser has the right to arrange such facilities
and personnel and to charge the cost thereof to the Bidder/Bidder.
8.10 In order to enable the Purchaser to arrange for insurance of all items received at
the site including the items of supply covered under this contract, the
Bidder/Bidder shall furnish necessary details of all the equipment immediately on
its receipt at site, to the Purchaser. Any default on the part of the Bidder/Bidder
due to which any item does not get covered under the insurance of the
Purchaser; the consequential losses shall be charged to the Bidder/Bidder.
8.11 The Purchaser shall not be liable for or in respect of any damages or
compensation payable at law in respect or in consequence of any accident or
injury to any workman or other person in the employment of the Bidder/Bidder or
any sub-Bidder/Bidder, save and except an accident or injury resulting from any
act or default of the Purchaser, his agents, or servants. The Bidder/Bidder shall
indemnify and keep indemnified the Purchaser against all such damages and
compensation, save and except as aforesaid and against all claims,
proceedings, costs, charges and expenses whatsoever in respect thereof or in
relation thereto.
8.12 The Bidder/Bidder shall ensure against such liability with an insurer approved by
the Purchaser, which approval shall not be unreasonably withheld, and shall
continue such insurance during the whole of the time that any persons are
employed by him on the works shall, when required, produce to the Purchaser or
Purchaser’s representative such policy of insurance and the receipt for payment
of the current premium. Provided always that, in respect of any persons
employed by any sub-Bidder/Bidder, the Bidder/Bidder's obligations to ensure as
aforesaid under this sub-clause shall be satisfied if the sub-Bidder/Bidder shall
have insured against the liability in respect of such persons in such manner that
the Purchaser is indemnified under the policy, but the Bidder/Bidder shall require
such sub-Bidder/Bidder to produce to the Purchaser or Purchaser's
representative, when required such policy of insurance and the receipt for the
payment of the current premium.
8.13 Whenever proper execution of the work under the contract depends on the jobs
carried out by some other Bidder/Bidder, the Bidder/Bidder should inspect all
such erection and installation jobs and report to the Purchaser regarding any
defects or discrepancies. The Bidder/Bidder's failure to do so shall constitute as
acceptance of the other Bidder/Bidder's installation/jobs as fit and proper for
reception of Bidder/Bidder's works except those defects which may develop after
execution. Bidder/Bidder should also report any discrepancy between the
executed work and the drawings. The Bidder/Bidder shall extend all necessary
help/cooperation to other Bidder/Bidders working at the site in the interest of the
work.
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8.14 Bidder/Bidder shall carryout final adjustments of foundations, levelling and
dressing of foundation surfaces, bedding and grouting of anchor bolts, bedplates
etc. required for seating of equipment in proper position. The Bidder/Bidder shall
be responsible for the reference lines and proper alignment of the equipment.
However, all civil works like making cut outs in walls, floors and ceilings for
pipelines shall be done by the purchaser. Adjustment &levelling are to be carried
out by the Bidder/Bidder at no extra cost. The Purchaser shall arrange the
necessary refilling/repairs of these cut outs and pockets. The Bidder/Bidder
should arrange for laying the supports, cut outs, grouting of bolts, etc., when the
civil works are in progress, so as to avoid refilling/repair works. The Purchaser at
Bidder/Bidder’s costs shall make the damages occurring to civil and other works
good. For fixing of piping/equipment supports on wall/beams/roof floor etc.,
preferably anchor bolts shall be used by the Bidder/Bidder. Drilling of holes for
fixing anchor bolts & supply of anchor bolts is in the scope of Bidder/Bidder
without any extra cost.
8.15 The Bidder/Bidder shall keep a check on deliveries of the equipment covered in
the scope of erection work and shall advise the Purchaser well in advance
regarding possible hold-up in Bidder/Bidder's work due to the likely delay in
delivery of such equipment/components to enable him to take remedial actions.
9 Duties of the Bidder/Bidder Vis-à-Vis the Purchaser

9.1 The equipment and the items, if any, to be supplied by the Purchaser for
erection, testing and commissioning shall be as listed in the contract.
9.2 Besides the utilities/ services as specified in battery limits, Purchaser shall also
provide the following assistance/ facilities to the Bidder/Bidder for carrying out
the installation work:
• Plant building ready for installation of equipment/items.
• Necessary temporary water for carrying out the installation shall be supplied at
only one point within the project site by the Purchaser free of charge. All
necessary distribution tapings from this point onwards shall be the
Bidder/Bidder's responsibility.
• Necessary temporary power for carrying out the installation shall be arranged by
the Bidder/Bidder at Bidder/Bidder's own cost. The Purchaser on written request
by the Bidder/Bidder will issue the necessary authorization letter.
9.3 If the power is provided to you, the recovery @1% of total installation charges
will be deducted from the erection bill of the Bidder/Bidder. However, the
Bidder/Bidder shall supply all the items such as energy meter, switchgear etc.
required for getting temporary power.
9.4 The details of temporary water and power requirements shall be furnished one
month in advance by the Bidder/Bidder to enable the Purchaser to make timely
arrangement.
9.5 If the Bidder/Bidder suffers delay and/or incurs costs from failure on the part of
the purchaser to give possession of the civil works in accordance with the
mutually agreed schedule, the purchaser shall determine:
56
• Any extension of time to which the Bidder/Bidder is entitled under clause 22 of GCC
(General Conditions of Contract) and
• The amount of such costs, which shall be added to the contract price, and shall notify
the Bidder/Bidder accordingly.
10 Supply of Tools, Tackles And Materials

10.1 The Bidder/Bidder shall, at his own expense, provide all the necessary
equipment, tools and tackles, haulage power, consumables necessary for
effective execution and completion of the works during erection and
commissioning.
11 Protection of Plant
11.1 The Purchaser shall not be responsible or held liable for any damage to person
or property consequent upon the use, misuse or failure of any erection tools and
equipment used by the Bidder/Bidder or any of Bidder/Bidder's Sub-
Bidder/Bidders even though such tools and equipment may be furnished, rented
or loaned to the Bidder/Bidder or any of Bidder/Bidder’s Sub-Bidder/Bidders.
The acceptance and/or use of any such tools and equipment by the
Bidder/Bidder or Bidder/Bidder's Sub-Bidder/Bidder shall be construed to mean
that the Bidder/Bidder accepts all responsibility for and agrees to indemnify and
save the Purchaser from any and all claims for said damages resulting from the
said use, misuse or failure of such tools and equipments.
11.2 The Bidder/Bidder and Bidder/Bidder’s Sub-Bidder/Bidder shall be responsible,
during the works, for protection of work, which has been completed by other
Bidder/Bidders. Necessary care must be taken to see that the Bidder/Bidder’s
men cause no damage to the same during the course of execution of the work.
11.3 All other works completed or in progress as well as machinery and equipment
that are liable to be damaged by the Bidder/Bidder's work shall be protected by
the Bidder/Bidder and protection shall remain and be maintained until the
Purchaser directs its removal.
11.4 The Bidder/Bidder shall effectively protect from the effects of weather and from
damages or defacement and shall cover appropriately, wherever required, all the
works for their complete protection.
11.5 The Bidder/Bidder shall carry out the work without damage to any work and
property adjacent to the area of Bidder/Bidder's work to whomsoever it may
belong and without interference with the operation of existing machines or
equipment.
11.6 Adequate lighting, guarding and watching at and near all the storage handling,
fabrication, pre-assembly and erection sites for properly carrying out the work
and for safety and security shall be provided by the Bidder/Bidder at
Bidder/Bidder's cost. The Bidder/Bidder should adequately light the work area
during night time also. The Bidder/Bidder should also engage adequate
electricians/wiremen, helper etc to carry out and maintain these lighting facilities.
If the Bidder/Bidder fails in this regard, the Purchaser may provide lighting
57
facilities as he may deem necessary and charge the cost thereof to the
Bidder/Bidder.
11.7 The Bidder/Bidder shall take full responsibility for the care of the works or any
section or portions thereof until the date stated in the taking over certificate
issued in respect thereof and in case any damage or loss shall happen to any
portion of the works not taken over as aforesaid, from any cause whatsoever,
the same shall be made good by and at the sole cost of the Bidder/Bidder and to
the satisfaction of the Purchaser. The Bidder/Bidder shall also be liable for any
loss of or damage to the works occasioned by the Bidder/Bidder or the
Bidder/Bidder’s Sub-Bidder/Bidder in the course of any operations carried out by
the Bidder/Bidder or by the Bidder/Bidder’s Sub-Bidder/Bidders for the purpose
of completing any outstanding work or complying with the Bidder/Bidder's
obligations.
12 Unloading, Transportation and Inspection

12.1 The Bidder/Bidder shall be required to unload all the materials/equipment from
the carriers, those received at site after Bidder/Bidder's team arrives at
site. Bidder/Bidder shall be paid extra for unloading of the equipment being
supplied by the purchaser whereas no extra payment for unloading of the
equipment/piping shall be paid to Bidder/Bidder for the equipment being
supplied by the Bidder/Bidder. The Bidder/Bidder shall plan in advance, based
on the information received from the Purchaser, Bidder/Bidder's requirement of
various tools, tackles, jacks, cranes, sleepers etc. required to unload the
material/equipment promptly and efficiently. The Bidder/Bidder shall ensure that
adequate and all measures necessary to avoid any damage whatsoever to the
equipment at the time of unloading are taken.
12.2 Any demurrage/detention charges incurred due to the delay in unloading the
material/equipment and releasing the carriers shall be charged to the
Bidder/Bidder's account.
12.3 The Bidder/Bidder shall be responsible for the reception on site of all plant and
Bidder/Bidder's equipment delivered for the purposes of the contract.
12.4 The Bidder/Bidder shall safely transport/shift the unloaded materials/equipment
by the Bidder/Bidder to the storage area.
12.5 All the materials/equipment received by the Purchaser prior to arrival of the
Bidder/Bidder at site shall be handed over to the Bidder/Bidder and there upon
the Bidder/Bidder shall inspect the same and furnish the receipt to the
Purchaser. The manner in which the inspection shall be carried out is
enumerated below:
12.6 The materials/equipment would be carefully unpacked by opening the wooden
cases/other modes of pickings as the case may be.
12.7 Detailed inventory of various items would be prepared clearly listing out the
shortages, breakage/damages after checking the contents with respect to the
Bidder/Bidder's packing list, the Purchaser's purchase order and approved
equipment drawings. The Bidder/Bidder shall also check each & every
58
equipment for any shortage/shortcoming that may eventually create difficulty at
the time of installation or commissioning.
12.8 All the information and observations by the Bidder/Bidder shall be furnished in
the form of ÌNSPECTION REPORT' to the Purchaser with specific
mention/suggestions which in the opinion of the Bidder/Bidder should be given
due consideration and immediate necessary actions, to enable the Purchaser to
arrange repair or replacement well in time and avoid delays due to non-
availability of equipment and parts at the time of their actual need.
12.9 The inspection for all the equipment handed over to the Bidder/Bidder shall be
completed within three week's period.
12.10 The protection, safety and security of the materials so taken over from the
Purchaser shall be the responsibility of the Bidder/Bidder, until they are handed
over to the Purchaser after erection, commissioning and testing as per the terms
of the Contract.
13 Storage of Equipment
13.1 The Bidder/Bidder shall be responsible for the proper storage and maintenance
of all materials/equipment under Bidder/Bidder's custody. Bidder/Bidder shall
take all required steps to carry out frequent inspection of equipment/materials
stored as well as erected equipment until the same are taken over by the
Purchaser. The following procedure shall apply for the same.
13.2 The Bidder/Bidder’s inspector shall check stored and installed
equipment/materials to observe signs of corrosion, damage to protective coating
to parts, open ends in pipes, vessels and equipment, insulation resistance of
electrical equipment etc. The Bidder/Bidder shall immediately arrange a coat of
protective painting whenever required. A record of all observations made on
equipment, defects noticed shall be promptly communicated to the Purchaser
and Purchaser's advice taken regarding the repairs/rectification. The
Bidder/Bidder shall there upon carry out such repairs/ rectification at
Bidder/Bidder’s own cost. In case the Bidder/Bidder is not competent to carry out
such repairs/ rectification, the Purchaser reserves the right to get this done by
other competent agencies at the Bidder/Bidder's responsibility and risk and the
entire cost for the same shall be recovered from the Bidder/Bidder's bills.
13.3 The Bidder/Bidder's inspector shall also inspect and provide lubrication to the
assembled equipment. The shafts of such equipment shall be periodically
rotated to prevent rusting as well as to check freeness of the same.
13.4 The Inspector shall check for any signs of moisture or rusting in any equipment.
13.5 If the commissioning of equipment is delayed after installation of the equipment,
the Bidder/Bidder shall carry out all protective measures suggested by the
Purchaser during such period.
13.6 Adequate security measures shall be taken by the Bidder/Bidder to prevent theft
and loss of materials handed over to the Bidder/Bidder by the Purchaser. The
Bidder/Bidder shall carry out periodical inventory checks of the materials
received, stored and installed by the Bidder/Bidder and any loss noticed shall be
59
immediately reported to he Purchaser. The Bidder/Bidder shall maintain a
proper record of these inventories. The Bidder/Bidder should not sell, assign,
mortgage, hypothecate or remove equipment or materials which have been
installed or which may be necessary for completion of the work without the
written consent of the Purchaser.
13.7 Suitable grease recommended for protection of surfaces against rusting (refined
from petroleum oil with lanolin minimum (70 0C) and water in traces) shall be
applied over all equipment as required once in every six months.
13.8 All equipment shall be stored inside a closed shed or in the open depending
upon whether they are of indoor or outdoor design. The space heaters where
provided into the electrical equipment shall be kept connected with power supply
irrespective of their type of storage. Where space heaters are not provided
adequate heating with bulb is recommended. For transformers heating of oil
shall be done by giving 440 V supply and short-circuiting the LT
terminals. Frequent checks on insulation resistance are essential for all
electrical equipment and record of the inspection reports and mugger readings
shall be maintained equipment wise. Such records shall be presented to the
Purchaser whenever demanded.
13.9 All the necessary items/goods required for the Bidder/Bidder as described above
shall arrange protection and such cost shall be included in the Contract price.
13.10 If material/ Goods were found damaged during inspection, material should be
replaced on TO & FRO basis including Freight and other charges. Material are
consider as free replacement.
14 Approvals
14.1 The Bidder/Bidder shall obtain the necessary approvals of the Factory Inspector,
Boiler Inspector, Electrical Inspector, Weights & Measures Inspector, Explosive
Inspector and any other state and local authorities as may be required and the
cost of obtaining such approvals shall be included in the contract price.
14.2 The Bidder/Bidder will furnish all the necessary details, drawings, and
submission of application and proofreads to the Purchaser for verification/
signature. The Bidder/Bidder on behalf of the Purchaser shall submit the
necessary application duly filled-in, together with the prescribed fees to the
appropriate authorities. However all the actual statutory prescribed fees paid by
the Bidder/Bidder shall be reimbursed by the Purchaser upon production of the
receipt/vouchers.
14.3 Wherever necessary or required, the Bidder/Bidder shall furnish the necessary
test and/or inspection certificates etc. from the appropriate authorities as per
IBR, IER and other statutory regulations and the cost for obtaining these
certificates shall be included in the contract price.
15 Review & Co-Ordination of Erection Work

15.1 The Bidder/Bidder shall depute senior and competent personnel to attend the
site co-ordination meetings that would generally be held at the site every
60
month. The Bidder/Bidder shall take necessary action to implement the
decisions arrived at such meetings and shall also update the erection schedule.
16 Extension of Time for Completion

16.1 Should the amount of extra or additional work of any kind or any cause of
delay referred to in these conditions, or exceptional adverse climatic conditions,
or other special circumstances of any kind whatsoever which may occur, other
than through a default of the Bidder/Bidder, be such as fairly to entitle the
Bidder/Bidder to an extension of time for the completion of the works, the
Purchaser shall determine the amount of such extension and shall notify the
Bidder/Bidder accordingly. Provided that the Purchaser is not bound to take into
account any extra or additional work or other special circumstances unless the
Bidder/Bidder has within twenty eight days after such work has been
commenced, or such circumstances have arisen, or as soon thereafter as is
practicable, submitted to the Purchaser full and detailed particulars of any
extension of time to which he may consider himself entitled in order that such
submission may be investigated at the time.
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Table 1
List of Drawings required Submission
SN Drawings
1 Equipment drawings for fabricated & non fabricated items.
2 Equipment layout for production and service blocks.
3 Flow diagrams for PROCESS and various services.
4 Service piping layouts in production and service blocks.
5 Piping & ducting layout in production blocks, WHEREVER REQUIRED.
6 Electrical cable & instrument, conduit/ cable tray layout.
7 Standard Installation Drawings for Equipment.
8 Automation SCADA networking drawings, Cabling drawings etc.
9 Automation logic write-up along with logical flow network.
10 Other miscellaneous drawings as required for erection work.
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SECTION IV – PART III
SPECIAL CONDITIONS OF
CONTRACT FOR MECHANICAL
WORK
63
Contents
1. Scope
2. General Installation
3. Service Piping Installation
4. Special Instructions And Specifications
5. Insulation of Piping and Equipment
6. Interconnections of Services
7. Guidelines for Expansion Work
8. Cleaning Chemicals and Lubricants
9. Testing, Commissioning and Start Up
10. Trouble shooting during the trial period
11. Painting
12. Training of Personnel
13. Code of Practice for Painting Service Pipe Lines
Table 1 Painting of Equipment & Structural Work
Table 2 Colour Code For Pipelines as per BIS 2379 1963
Table 3 Testing Pressures for Various Pipelines
Table 4 Makes of Bought Out Item
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1 Scope
1.1 General installation i.e. positioning and installing all the production,
miscellaneous and service equipment as per approved layout drawings and as
per the contract.
1.2 Supply and installation of structural platforms and tables cross over etc.
1.3 Supply and installation of all service and product piping including ancillary items.
1.4 Insulation and cladding of piping, equipment including supply of materials.
1.5 Interconnections of services and Electrical with equipment.
1.6 Guide line for expansion work.
1.7 Clean up of work site.
1.8 Supply of all cleaning chemicals and lubricants.
1.9 Testing, commissioning and start up.
1.10 Painting including supply of paints as approved by the Purchaser.
1.11 Training of personnel.
1.12 Detailed specifications are given in the subsequent clauses.
1.13 SCOPE: The bidder’s scope shall be to design, engineering, manufacturing,
approval, testing, inspection, packing and supply of equipment, components,
accessories & spares at site in accordance with the plans, procedures,
specifications, drawings, codes & any other documents as specified by the
purchaser. Successful Commissioning of equipment at site is in bidder’s scope.
Any Item(s) not specifically mentioned/listed but are necessary for completion &
meeting satisfactory performance as per guaranteed parameters shall be
deemed to be part of Scope of Supply of the bidder & shall be supplied by the
bidder without any extra cost to bidder. F.O.R. destination, inclusive of Packing,
Forwarding and Freight. The price quoted shall remain firm for complete duration
of the order & shall not be subject to any escalation whatsoever at any time
thereafter. The Billing break-up has to be submitted by the bidder during order
finalisation. Price agreed vide this PO shall be valid for a period of 18 months
from the date of the PO.
2 General Installation
2.1 Positioning of Equipment
2.1.1 The work involves preparation of access for moving of the plant and equipment
including their fittings from the work site godown or from the place within the site
where they have been unloaded, to the place of erection, de crating and
placing on the foundation wherever required. The Purchaser shall arrange all the
civil foundations as per the manufacturer/Bidder’s drawings. The Bidder shall
place the equipment and carry out final adjustment of the foundations including
alignment and dressing of foundation surface, embedding and grouting of
anchor bolts and bedplates. The Bidder shall be responsible for obtaining correct
reference lines for the purpose of fixing the alignment of various equipments
from master benchmarks provided.
2.1.2 Tolerances shall be as specified in equipment manufacturer's drawings or as
stipulated by the Purchaser's Engineer. No equipment shall be permanently
bolted down to foundations or structure until the Bidder has checked the
alignment and witnessed by the Purchaser.
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The Bidder shall carry out minor alterations in the anchor bolts, pockets etc. At
no extra cost and set the equipment properly as per approved layout, drawings
and manufacturer’s instructions. The Bidder shall supply all the necessary
foundation/anchor bolts and bedplates if required without extra cost if these have
not been provided with main equipment.
2.1.3 The Bidder shall supply, fix and maintain, at his own cost, during the erection
work, all the necessary cantering, scaffolding, staging required not only for
proper execution and protection of the said work but also for protection of the
surrounding plant and equipment. The Bidder shall take out and remove any or
all such cantering, scaffolding, staging planking etc., as occasion shall require or
when ordered to do so and shall fully reinstate and make good all things
disturbed during execution of the work, to the satisfaction of the Purchaser. The
Bidder shall be paid no additional amount for the above.
2.2 Structural Platforms and Tables

2.2.1 Structural platforms shall be required to access to various equipment. Tables
shall be required for handling products. These platforms and tables shall be
fabricated keeping stability and other functional as well as aesthetic
requirements into consideration as approved by the Purchaser. No payment
shall be made for such facility, deemed essential for smooth operation and
safety of plant personnel.
3 Service Piping Installation

3.1 General Guidelines
3.1.1 All piping systems shall comply with the latest editions of the following
regulations wherever applicable:
3.1.1.1 Indian Boiler Regulations
3.1.1.2 Regulations of explosives inspectorate
3.1.1.3 All applicable Indian Standards
3.1.1.4 All applicable State Government/ Central Government Laws/ Acts
3.2 Scope of Supply

3.2.1 The Bidder shall supply all piping materials like pipes, fittings, flanges,
measuring instruments and all other items as shown in the P&I
diagram/specifications and schedule of quantities. All the pipes & fittings and
insulation material etc. should be of class and make as approved by the
Purchaser. The Bidder, for the class and make of all materials, must obtain prior
approval of the Purchaser. The Bidder should furnish the details of makes
selected by him, in the pro forma given in Table 5.
3.3 Scope of Piping Erection

3.3.1 The scope of erection for piping, includes all system covered in the flow
diagrams and specifications. The Bidder's work commences/ terminates at the
pipe connections with valves or flanges as specified in flow diagrams/ battery
limits.
66
3.3.2 The Bidder shall also install necessary piping and any specialties furnished with
or for equipment such as relief valves, built in bypass, primary elements for
flow measurements, control valves and on line metering equipment.
3.3.3 The Bidder shall perform necessary internal machining of pipes for installing
orifices, flow nozzles, control valves etc. The Bidder shall install all pipes, valves
and specialties being procured from other sources.
3.4 Testing of Piping

3.4.1 The Bidder shall test all piping systems including valves and specialties and
instruments as per procedure mentioned in Table 4.
3.4.2 All piping shall be internally cleaned and flushed by the Bidder after erection
in a manner suited to the service and as directed by the Purchaser.
3.4.3 For hydrostatic testing and water flushing, the Bidder shall furnish necessary
pumps, equipment, instruments and piping etc.
3.5 Other Guidelines

3.5.1 Colour code shall be used to identify pipe material. The Bidder shall be able to
identify on request all random piping prior to field fabrication.
3.5.2 The Bidder shall be responsible for the quality of welding done by them and
shall conduct tests to determine the suitability of the welding procedure by him.
3.5.3 All piping supports, guides, anchors, hangers, rollers with structural framework
shall be supplied and erected by the Bidder. The kinds of pipe supports like CI
clamps, wooden saddles, roller supports and support framework shall be as per
the design approved by the Purchaser prior to taking up the work.
3.5.4 All piping shall be suspended, guided and anchored with due regard to general
requirements and to avoid interference with other pipes, hangers, electrical
conduits and their supports, structural members and equipment and to
accommodate insulation and conform to buildings structural limitations. It is the
responsibility to the piping Bidder to avoid all interference while locating hangers
and supports.
3.5.5 Anchors and/or guides for pipelines or for other purposes shall be furnished,
when specified, for holding the pipeline in position for alignment. Hangers shall
be designed fabricated and assembled in such a manner that any movement of
the support pipes cannot disengage them.
3.5.6 All piping shall be wire brushed and purged with air blast to remove all rust,
mill scale from inner surface. The method of cleaning shall be such that no
material is left on the inner or on outer surfaces, which will affect the
serviceability of the pipes.
3.5.7 Effective precautions such as capping and sealing shall be taken to protect all
pipe ends against ingress of dirt and damage during transit or storage. The
outside of the steel pipes (black) shall be painted with two coats of red oxide
paint/heat resistant paint or as directed by the Purchaser.
3.5.8 All SHE standerds set by purchaser must be followed stricktly during installation
and commissioning of entire plant equipments
3.5.9 All Liability arrising due to accident will be born by bidder.
67
4 Special Instructions and Specifications
4.1 Steam Piping
4.1.1 Steam piping work can be classified into two categories:
4.1.1.1 High pressure steam piping when the working pressure of steam is more than
1.0 kg/cm2 (15 psi).
4.1.1.2 Low pressure steam piping when the working pressure of steam is up to 1.0
kg/cm2 (15 psi).
4.1.2 All the pipes and fittings used for high pressure steam piping work should
conform to IBR and they should be IBR certified and also to be identified with
number and mark showing that they are tested by the Boiler Inspector and
supported with duly authentic certificates to this effect. ALL HIGH PRESSURE
STEAM PIPES SHALL BE SEAMLESS TYPE, SCHEDULE 40.
4.1.3 The high pressure steam piping after installation should be hydraulically tested
in presence of the Boiler Inspector for his approval.
4.1.4 The high pressure steam piping work should also include fabrication
and installation of pressure reducing stations strictly conforming to IBR.
4.2 Other Piping

4.2.1 ALL THE PIPING FOR SOFT AND RAW WATER, H.P. AND L.P. STEAM, AIR
AND FURNACE OIL/ LSHS PIPING SHALL GENERALLY BE OF WELDED
CONSTRUCTION. Whenever welding is done for pipes of smaller size special
care should be exercised to avoid clogging of flow area with the welding
material.
5 Insulation of Piping and Equipment

5.1 Hot Insulation of Steam, Condensate & Hot Water and
Molasses Pipe Lines
5.1.1 All the steam and hot water and molasses pipelines shall be insulated with
mineral wool or equivalent of specified thickness. The insulation shall be
carried out in the following manner and should be supplied in the form of
properly required sizes.
5.1.2 Clean the surfaces to be insulated. Apply a coat of heat resistant primer and
fix glass wool/mineral wool of specified thickness, tightly to the pipes, butting all
joints and tie with lacing wire.
5.1.3 It should then be covered with GI wire netting of 20 mm x 22 SWG.
5.1.4 In case the insulation does not have the desired insulation properties, the entire
insulation will have to be redone at the Bidder's cost to give the desired
results.
5.1.5 In case of condensate return piping all the steps mentioned above shall be
executed except that thickness of the insulation shall be 25 mm.
5.2 Aluminium
5.2.1 The chilled water, glycol, ammonia, water, steam & hot water molasses lines
after insulations may be covered by aluminium.
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5.2.2 Aluminium cladding will be done with 22 gauge aluminium sheet with proper
grooves and overlaps and screwed in position with 12 mm self tapping parker
screws.
6 Interconnections of Services
6.1 The Bidder shall lay service piping and provide connections with the equipment
complying strictly with the equipment manufacturers' instructions.
6.2 The Bidder shall also carry out all the interconnecting service piping with the
various items of plant/system. The work shall be complete with capillary piping
if required and connections with instruments and controls supplied with the
equipment.
6.3 The Bidder shall also carry out electrical connections for equipment with the
control panels including equipment lighting as per the wiring diagrams of the
equipment Bidders. Connection shall be made for small electrically operated
devices on equipment installed as accessories to, or assembled with equipment.
Connections regarding instruments, float switches, limit switches, pressure
switches, thermostats and other miscellaneous equipment shall be done as per
manufacturers' drawings & instructions.
7 Guidelines for Expansion Work

7.1 Clean Up of Works Site
7.1.1 All soils, filth or other matters of an offensive nature taken out of any
trench, drain or other places shall not be deposited on the surfaces, but
shall at once be carted away by the Bidder from the site of work for
proper disposal.
7.1.2 The Bidder shall not store or place the equipment, materials or erection
tools on the drive ways and passages and shall take care that his work in
no way restricts or impedes traffic or passage of men and materials
during erection, the Bidder shall without any additional payment, at all
time keep the working and storage area used by him free from
accumulation of dust or combustible materials, waste materials rubbish
packing, wooden planks to avoid fire hazards and hindrance to other
works.
7.1.3 If the Bidder fails to comply with these requirements in spite of written
instructions from the Purchaser, the Purchaser will proceed to clear these areas
and the expenses incurred by the Purchaser in this regard shall be payable by
the Bidder. Before completion of the work, the Bidder shall remove or dispose off
in a satisfactory manner all scaffolding, temporary structures, waste and debris
and leave the promises in a condition satisfactory to the Purchaser. Any packing
materials received with the equipment shall remain as the property of the
Purchaser and may be used by the Bidder on payment of standard charges to
the Purchaser and with prior approval of the Purchaser. At the completion of his
work and before final payment, the Bidder shall remove and shall restore the site
to neat workman like conditions at his cost.
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8 Cleaning Chemicals and Lubricants
8.1 The necessary quantities of cleaning chemicals, lubricants etc., required
for the installation, commissioning, testing and start up of all the
equipment till handing over are to be supplied the Bidder and nothing
extra would be paid for these.
9 Testing, Commissioning and Start up

9.1 The Bidder shall operate, maintain and give satisfactory trial run of the
plant, for the design product satisfactorily for a minimum period of 30
days on continuous basis or as mutually agreed by
Bidder/purchaser/Purchaser of the plant at the rated output. The Bidder
should carry out all rectification of damages/defects and routine
troubleshooting during commissioning with the help of purchaser’s staff.
9.2 During this period, B idder shall incorporate/execute necessary minor
modifications during the trial period for maximizing operational efficiency.
The Bidder should also execute minor modifications as may be suggested
by the manufacturer/Purchaser, if required. The Bidder shall suggest
recommended log sheet proofread for recording necessary operating data
and pass it on to the Purchaser in proof of satisfactory rated output and
performance of the equipment/plant.
9.3 The commissioning shall also include, for all the equipments, the
following:
9.3.1 Field disassembly and assembly
9.3.2 Clean out of lubrication system including chemical cleaning wherever
required.
9.3.3 Circulation of lubricant to check flow.
9.3.4 Clean out and check out of all the service lines.
9.3.5 Check out and commissioning of instruments, equipment and plants,
filtering of transformer and other oils so that if deteriorated, they shall
attain the required properties/standards, specified tests in this regard
must be carried out by approved authorities and their satisfactory reports
submitted to the Purchaser before start up.
9.3.6 Recharging or make up filling of lubricant oil up to the desired level in the
lubrication system of individual machine.
9.3.7 Operation in empty condition to check general operation details wherever
required and wherever possible.
9.3.8 Closed loop dynamic testing with water/product wherever required.
9.3.9 Operation under load and gradual load increase to attain maximum rated
output.
70
10. Trouble shooting during the trial period
10.1 The Bidder shall demonstrate proper working of all mechanical and electrical
controls; safety and protective device, in presence of the Purchaser's engineer
and the same should be duly recorded.
10.2 After conducting testing, in case particular equipment is not working properly or
not giving rated output the Bidder will furnish a detailed report to the Purchaser
stating therein the detailed account on the performance of the equipment with
possible reasons for improper or not working of the same.
10.3 The Purchaser after receipt of report from the Bidder would take up the matter
with the manufacturers and if required would invite the representative of original
manufacturers. In case the Purchaser considers that the non-performance of
equipment is only due to inexperience of the Bidder, then the charges
incurred for the manufacturer's representative visit would be debited to
the Bidder's account.
10.4 Further, before the commencement of testing or commissioning, the Purchaser
reserves the right to invite the original manufacturer's representative at the cost
of the Bidder for start up help, assist and guide the Bidder during
commissioning in the following cases:
10.4.1 The Bidder has no previous experience of commissioning and start up of the
similar equipment.
10.4.2 The Purchaser is of the opinion that the Bidder is not capable to commission
and start up of certain specific equipment.
10.5 However, in either of the cases the manufacturer's representatives would be
called with prior information to the Bidder and the Bidder will have to extend all
co operation to such representatives in good spirit and in the interest of the
work.
10.6 After satisfactory commissioning and start up the Bidder shall keep his
representatives under whose supervision the Purchaser's staff shall be
operating and maintaining the plant and equipment for a minimum period of two
months. The Bidder's representatives should be present at all times during the
running and operation of plant and equipment. During this period the Bidder
shall ensure proper working of complete plant and equipment and attend any
works required to be done and shall also take complete responsibility for proper
operation and maintenance of the complete plant and equipment.
11. Painting
11.1 All the equipment/ machineries like motors, pumps, HT/ LT panel, transformer,
switch boards, starters, junction boxes, isolators, storage tanks, supporting
structures, pipe supports and MS/ GI pipes and all exposed and visible iron parts
included in the scope of erection/ commissioning shall be given double coat of
paint of approved shade over a double coat of anticorrosive primer
wherever necessary irrespective of the condition of original paint of equipment/
machineries/ structures/ supports. Surfaces wherever required must be properly
cleaned for scale, dirt and grease prior to painting. Spray painting is
preferably be used on all the equipment/ machineries and wherever practicable.
Suitable and necessary cleaning/ wiping of sight/ dial glasses, other
non metallic parts, flooring, walls and other surfaces which have been spoiled
by paint during painting must also be carried out by the Bidder .
71
11.2 Lettering and other markings, including capacity and flow direction markings,
shall also be carried out by the Bidder on the tanks, pipe lines, starters, motors,
isolators and wherever else necessary, as directed and as per the standard
practice of installation. ISI colour codes and colour charts as mentioned in
Table 3 & Table 2 must be adhered to.
11.3 Supply of all paints and all other materials required is included in the scope of
supply of the Bidder under this contract/order.
12. Training of Personnel

12.1 The Bidder for operating the plant as may be deputed by the Purchaser shall
train necessary staff. The personnel will be associated for the training during the
installation; testing, commissioning and start up period and the training tenure
shall be extended for a minimum period of one month from the date of
commissioning and start up.
13. Code of Practice for Painting Service Pipe Lines

13.1 On Non insulated Pipe Line & Insulated Pipeline without Aluminium
Cladding
13.1.1 Ground colour to be applied throughout the length of the pipeline.
13.1.2 Colour bands to be applied near every valve and branch connection as well as in
every room near the entry.
13.1.3 The 1st band should be 4" wide and the second band should be 1" wide.
13.1.4 On the 1st band a white arrow to be put to indicate the direction of flow.
13.1.5 The arrows should be put on the bottom of the pipelines so that the same are
visible from below in case of horizontal bank of pipes and on sides in case of
vertical bank of pipes.
13.1.6 The valves should be painted with the same colour as the ground colour of the
pipeline.
13.2 On Insulated Pipeline with Aluminium Cladding

13.2.1 Ground colour to be applied in a length of 500 mm of the pipe all round near
every valve and branch connections as well as in every room near the entry. The
complete length of the pipeline should not be painted.
13.2.2 Colour bands should be applied in the middle of every ground colour strip. The
1st colour band should be 4" wide and the second band should be 1" wide.
13.2.3 On the 1st band a white arrow is to be put to indicate the direction of flow of
the fluid.
13.2.4 The arrows should be put on the bottom of the pipelines, so that the same are
visible from below in case of horizontal bank of pipes and on sides in case of
vertical bank of pipes.
13.2.5 The valves should be painted with the same colour as the ground colour.
13.2.6 The ground colours and the colours of the 1st and 2nd colour bands have
been indicated on the enclosed list for the pipelines carrying various types of
fluids and gases. The list also indicates the shade nos. of the colours to be used.
In case the exact shade is not available, the nearest possible shade in the same
colour may be selected.
72
13.2.7 Only synthetic enamel paint should be used for the painting and band
markings on the pipelines and it should be ensured that the finish should be
glossy.
13.2.8 Where no colour bands have been recommended, only the ground colour is to
be applied as per the above procedure. If only one colour band is recommended
the same should be 4" wide and applied on the ground colour. In case of 2 nos.
colour bands, the 1st band should be 4" wide and second band 1" wide and
should be applied on the ground colour.
13.2.9 To avoid mixing of colours, it is recommended to apply the bands only after the
ground colour paint is dry and subsequently to apply the arrow only after the 1st
band paint is dry.
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Table 1
Painting of Equipment & Structural Work
SN Item Painting Shade
1 All Storage silos with outer MS Bright yellow Shade No 632 of ISI
All M.S. platforms/pipe supports/ pipe
2 Dark Admiral grey shade No.632 of ISI
bridges and any other structures
3 Water Pumps, Geared Motor of vats. Original colour
4 HT & LT panels Original colour
5 LT distribution switchboards Dark admiral grey
6 Coal Handling Equipment Black
7 Boiler Chimney & Generator Exhaust Aluminium Heat Resistant Paint
8 Air Compressor Original colour

Air Handling Unit in Laboratory including
9 Aluminium Paint
Ducting
Mixing units, buffer storage, grinding
10 Original colour
equipment
11 Sieves, coolers, pellet mill, conditioner Original colour
12 Molasses tanks Bitumen Paint
13 Conveyors and elevators Original colour
74
Table 2
Colour Code For Pipelines as per BIS 2379-1963
Ground
SN Services First Band Second Band
Colour
1 Cold Water French Blue 166 -
2 Boiler Feed Water Parrot Green -
3 Condensate Light Brown 410 -
4 Hot Water Light Brown 410 -

Sea Green 217
5 Drinking Water French Blue 166 Signal Red 37
6 Treated Water Light Orange 557 -
8 Untreated Water White -

Compressed Air
9
Sky Blue 101
10 Vacuum Black
11 Steam Silver Grey 628 Original colour
12 Diesel Brilliant 221

Light Brown
410
13 Lubricating Oil Light Grey 631
14 Drainage Black
15 Fire Hydrant PO Red
75
Table 3
Testing Pressures for Various Pipelines
Allowable
Test
Sr Test Duration of pressure
Name Pressure
No medium Test (Hour) Drop
kg/cm2
(kg/cm2)
H.P.Steam pipe
1 27 Water 1/2 0
lines
L.P.Steam pipe
2 8 Water 1/2 0
lines
3 Water pipe lines1 8 Water 1/2 0
4 Furnace oil/ LSHS 16 Water ½ 0
5 MS pipes for dairy 6 Water 1/2 0
6 Air 12 Air 8 0.1
7 Ammonia pipe lines
7a Suction 16 16 N2 24 0.2
7b Discharge 24 N2 24 0.2
Vacuum Test of Absolute

7c Vacuum 48 NIL
Ammonia Lines Zero
Molasses pipe
8 16 Water 1/2 0
lines
Engineer in charge shall provide water at available supply point from which the Bidder
shall connect temporary piping for testing water.
76
Table 4
Makes of Bought Out Items
SN Items Makes
1 Steam piping TATA / JINDAL
1a MS C class pipes (Seamless) TATA / JINDAL
1b Cast steel globe valves Forbes Marshall / AUDCO
1c Bronze globe valves Forbes Marshall / AUDCO
1d Non return valves LEADER
Pressure reducing valves, safety valves,

1e FORBES MARSHALL
expansion joints and other steam fittings.
1f Pressure & temperature gauges FORBES MARSHALL / E&H
2 Furnace oil piping/ air piping TATA / JINDAL
MS C class pipes (seamless/ ERW as

2a TATA / JINDAL
approved)
Cast steel globe/bronze globe/ Gun metal gate

2b Forbes Marshall / AUDCO
valve
2c Pressure gauges FORBES MARSHALL / E&H
3 Water piping TATA / JINDAL
3a GI `B' class pipe TATA / JINDAL
3b CI globe valve KSB/ AUDCO
3c Gun metal gate valve KSB/ AUDCO
Gun metal globe valves/ strainers/ non return

3d KSB/ AUDCO
valves
3e Water pump GRUNDFOS
LLOYDS/ BEARDSHELL
4 Insulation materials
/ RINAC
LLOYDS/ BEARDSHELL
4a Expanded polystyrene
/ RINAC
LLOYDS/ BEARDSHELL
4b Glass/ mineral wool
/ RINAC
Please select reputed established makes only. Actual supply shall be based on makes
approved by us.
77
SECTION – V
TECHNICAL SPECIFICATION
78
SECTION – V
SUB SECTION – 1
INTRODUCTION
79
1 INTRODUCTION
1.1 It is proposed to set up one 800 M Tons/day (expandable to 1600
MTPD) capacity Cattle Feed Plant at KAPADVANJ, GUJARAT for
producing concentrate feed in pellet form suitable for milk animals. But
the raw material handling capacity till it reaches the hammer mill will have
to be designed for 1600 tons of production.
1.2 The project shall be executed on single responsibility Basis and this
contract shall be covering design, supply, erection, testing &
commissioning of the entire 800 TPD Cattle Feed Plant and related
Engineering facilities.
1.3 Foundations, civil works , steam generation , air generation, water
generation, and electrical power up to the PCC Area shall be provided by
the purchaser, however bidder shall have to specify mechanical load for
civil work, required pressure and quantity of steam, Electrical power
etc.
1.4 The bidder shall be responsible for developing the conceptual
layout and flow diagram to ensure plant with optimum investment
to meet all the Quality Standard of feed as well as to fulfil the
design data and technical specification specified in the Bidding
Document within the battery limits.
1.5 As stated earlier this project will have to be executed on a single
responsibility basis and the bidder should consider the complete
work in its totality. It should be understood that any minor work which may
be necessary to achieve the rated capacity of the plant is included in
the scope of work, enough not specifically mentioned.
1.6 It is suggested that the bidder visits the site before pricing the bid.
1.7 The plant shall be designed, supplied and executed in accordance
with the prevailing and applicable
- Indian Standards
- Indian Boiler Regulations.
- Indian Electricity Rules
- Gujarat State Electricity Board (GEB)
- Chief Electrical Inspectorate of Gujarat State
- Indian Explosives Act
- Indian Factory Act
- Indian Pollution Act ( Gujarat Pollution Control Board )
- Indian Weights& Measures Act
And any other applicable Indian Act. Wherever Indian Standards are
not available/applicable the bidder shall follow International Standards.
The bidder shall be responsible for arranging approval from various
applicable Indian statutory authorities on behalf of the Purchaser.
The statutory fees shall be reimbursed by the Purchaser on production
of documentary evidence. All Liaoning expenses will be made by Bidder.
80
1.8
1.8.1 Site conditions:
Average Ambient Temperature (Deg C) : 30 Deg C
Maximum Ambient Temperature (Deg C) : 44 Deg C
Minimum Ambient Temperature (Deg C) : 18 Deg C
Relative Humidity (%): 90%
1.8.4 Project Site Address:
Kaira District Co operative Milk Producers’ Union Ltd.
Cattle Feed Factory,
Kapadivav, PO Chikhload 387 640,
Ta. Kapadvanj, Dist. Kheda.
India, Gujarat
81
SECTION – V
SUB SECTION – 2
INSTRUCTIONS TO BIDDERS
82
1. INSTRUCTIONS TO BIDDERS
1.1. This Sub Section of the tender defines the way that bidders are
required to structure the presentation of the technical section of their bids.
1.2. All technical data required by the tender is to be provided in the format
given in this Sub Section. If no format is given for any specific item the
bidder may submit bid in their format.
1.3. Any bidder not following the required bid document structure of
presenting technical data that is not in the required format is liable to be
deemed nonresponsive.
BID STRUCTURE OF TECHNICAL SECTION

1.4. The technical section of the bid is to be structured in the same order as
Tender Document. Each statement is to be numbered with the same
Sub section and paragraph number as in the Tender Document. Every
page of the technical section of the bid is to be numbered. Section
number is also indicated in every page. The general structure, therefore,
is to be as follows:
Sub
Section
Subject
1 Introduction
2 Instruction to Bidders
3 Design Basis
4 Responsibilities
5 Project Management
Scope of Supply and Technical Specification
6
(Tender Packages)
7 Battery Limits
8 Deviations from Technical Requirements
9 Optional & Additional Items
10 Drawings and Documentation
11 Criteria for Technical Evaluation of Bid
12 Process Performance and Consumption Gurantee
13 Requirement for Bidder Meeting
83
1.5. The bidder is to cover each requirement of the Tender Document by
statements, technical data and descriptive material and, in particular to
detail the following:
SUB-SECTION: 1: INTRODUCTION
The bidder is to describe his technical proposal in details, stating the
processes and systems, which he has, applies in designing the plant.
Also to highlight any special technical innovations that the bidder
proposes to include in the plant that will improve the performance, reduce
operating cost or improve product quality. The “Preamble” should
commence at the start of the process and work logically through the
process. Any such highlights should be cross referenced with the Bid
sub-Section and paragraph number to which they apply.
SUB-SECTION: 3: BASIS OF DESIGN

The bidder is required to follow the Basic of Design in the tender, and
indicate clearly where additional processes or alternative processes of
equipment are considered to be necessary or desirable to achieve
optimum plant operation efficiency, optimum product quality within the
standards specified, and optimum plant operation convenience. Under the
utilities sections quantified the peak and daily loads of each utility and
cross reference this two service load histogram data to be provided with
this bid. All calculation used to determine the capacity / ------ of equipment
/ system to be attached along with histogram.
SUB-SECTION: 4: RESPONSIBILITIES
Responsibilities of the Bidder
The bidder is required to specifically state his acceptance of
non acceptance of each clause in this sub section. Non acceptance
shall be deemed a deviation from the tender and should be mentioned in
deviations, Sub Section 8.
Responsibilities of Client
The bidder is required to state here any additional responsibilities that he
consider are to be borne by Client besides those described in the tender.
SUB-SECTION: 5: PROJECT MANAGEMENT

Time Schedule
The bidder is to state in this subsection the proposed programme of
implementation from receipt of order to commencement of product trials,
to be provided as per Sub Section 10.
84
Management Team
The bidder is to detail the make up of the management team in terms of
designation, accordance with this Sub Section of the tender. Also to
quantify the support that will be given by foreign collaborators, with
designation and man months of attendance in India and at site. This
bidder is to ensure that the following Sub Sections are fully detained
and quantify the duration and manpower supplied to each.
• Commissioning
• Product trials
• Training
SUB-SECTION: 6: SCOPE OF SUPPLY & TECH.

SPECIFICATIONS (TENDER PACKAGE)
The bidder is required to follow the sequence of the tender Document and
to make a statement on each paragraph. Do not leave any item without a
clarify statement.
SUB-SECTION: 7: BATTERY LIMITS

Battery limits for the plant are mentioned in this sub Section.
SUB-SECTION: 8: DEVIATIONS
All technical deviations are to be stated. This is mandatory, and failures
tocomply with make the bid liable to be deemed non responsive
SUB-SECTION: 9: OPTIONAL ITEMS

Items that the bidder includes in this Sub Section that are considered
by evaluation team to be essential to the satisfactory operation of the
plant, shall be included in the commercial evaluation of the bid.
SUB-SECTION: 10: DRAWINGS, DATA & DOC.

The list of drawings and technical documents required for technical
evaluation is included in Sub Section 10. These include a number of
data sheet formats to be completed by the bidder. The completion of this
format is mandatory, and failure to comply will make the bid liable to be
deemed non responsive.
85
SECTION – V
SUB SECTION – 3
RESPONSIBILITIES
86
3. RESPONSIBILITIES
3.1. BIDDER’S RESPONSIBILITIES

3.1.1. Developing the process design, complete engineering design and
ensuring best performance of individual equipment/system, for which he
shall avail the assistance of reputed specialists in their respective fields,
wherever required.
3.1.2. Performance and suitability of the total system.
3.1.3. Performance tests should be carried out by the bidder in the presence of
and to the satisfaction of Purchaser/Client's in charge.
3.1.4. Execution of the project in accordance with the prevailing Indian
Standards, Indian Boiler Regulations, Indian Electricity Rules, Indian
Explosives Act, Indian Factories ct, Indian Pollution Act and any other
Acts. Wherever Indian Standards are not available the bidder shall follow
International Standards.
3.1.5. Arranging for approvals from various statutory authorities on behalf of the
Client / Purchaser. The statutory fees shall be reimbursed by the
Client/Purchaser on production of receipts.
3.1.6. Ensuring satisfactory performance and After Sales service of
'Bought Out' items included in the scope of supply.
3.1.7. First charge of oil, lubricants and consumables. "First charge” means that
these items shall be replenished whenever and wherever required till the
successful completion of product trials and commissioning.
3.1.8. Test kits required for establishing performance parameters.
3.1.9. Necessary manpower and tools.
3.1.10. Performance guarantees with regard to the following:
3.1.10.1. Rated performance of individual equipment and complete system(s).
3.1.10.2. Product quality standards conforming to the prevailing Standards.
3.1.10.3. Consumption of utilities for individual equipment and for the complete
system.
3.1.10.4 Visual safety and operational requirement boards, indicators, markers
Bidder has to submit utility consumption date in separate sheet.
3.2. PURCHASER’S RESPONSIBILITIES

3.2.1. Details of civil design, building layout and drainage and sewage details.
3.2.2. Documents on local site conditions related to climate, access and
communications.
3.2.3. Temporary water and power supply at one point within the plant premises
during erection. Water supply will be free of cost. However for temporary
power, the bidder shall pay actual charges against supporting bills, if
availed. The bidder shall have option of making arrangements for
temporary power on its own.
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3.2.4. Lighting and domestic wiring system and internal telephone system
including the switch boards for lighting. Engineering personnel to liaison
with the bidder, Project Manager and the execution team.
3.2.5. Permanent water and power supply at the time of pre commissioning of
the plant.
3.2.6. Adequate staff including operators, supervisors and engineers for product
trials. However commission trials should be taken by bidders only.
3.2.7. All civil works including buildings, roads, cable trench, underground
condensate piping and drainage.
3.2.8. Provision of and cost of services, raw products, packaging materials &
chemicals.
3.2.9. Timely provision of personnel for training.
3.2.10. Provide open storage area only and office space during erection and
commissioning of project. The bider need to arrange the office structure.
3.2.11. Suitable Site fabrication yard
3.2.12. Lighting distribution system in RMG and FPG and non plant areas.
3.2.13. Telephone and fax on chargeable basis.
3.2.14. Payment as per agreed terms and conditions.
3.2.15. Approval of drawing within 10 days from date of submission and decision
within a week on any issue which will come up.
3.2.16. Project manager with team throughout the implementation.
3.2.17. Lightening protection system & protection against rain.
3.2.18. Readiness of Civil Building, clear civil fronts in all respects along with
necessary utilities within agreed schedule to enable commencement of
erection activities to meet the overall completion schedule.
3.2.19. Availability of required quantity of raw material for the designed product to
conduct the first run of product trials at the rated plant capacity.
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SECTION – V
SUB SECTION – 4
PROJECT MANAGEMENT
89
4. PROJECT MANAGEMENT
4.1. TIME SCHEDULE

4.1.1. The project execution shall be time bound as per the mutually agreed
time schedule. A competent execution team shall be deputed at site and
shall be headed by a Project Engineer who shall be stationed at site and
adequately experienced in Project Management of such magnitude and
type. The Project Engineer shall avail of assistance from reputed experts
in various fields who shall be directly responsible for satisfactory
execution.
4.1.2. The project staffing pattern shall be submitted before commencement of
work and should include sufficient personnel to meet the execution time
schedule.
4.2. MANAGEMENT TEAM

4.2.1. Project Manager who shall be adequately experienced in projects of
similar magnitude and type shall head a competent executive team.
Reputed experts in various fields who shall be responsible for
satisfactory execution of the project shall assist the Project Manager. He
shall be responsible for overall implementation of the project, from
commencement to final take over of the plant.
4.2.2. A Project Engineer shall be appointed for day to day operation and co-
ordination, and to ensure successful and satisfactory design,
procurement, manufacture, inspection, erection, testing and
commissioning of all the equipment/facilities/systems within the time
bound schedule.
4.2.3. The Project Manager and Project Engineer shall attend technical and
review meeting between various parties involved in the project, and
ensure implementation of all decision taken in the meetings.
4.2.4. The Project Manager shall also be responsible for detailed material
accounting at site and management of project materials and equipment
stored at site.
4.2.5. The Purchaser will nominate a Project Manger with whom the Project
Manager of the bidder shall communicate/co ordinate.
4.2.6. For smooth execution of the project, a team of Project Manager and Key
Personnel shall remain consistent throughout the execution period.
4.2.7. The Project Manager shall be fully authorized to take on spot decision
with regards to:
• Modification in layout and execution programme to suit local condition.
• To purchase essential materials from local market to avoid delays.
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4.3. APPROVAL
4.3.1. Purchaser shall give approval on technical documentation within 7
working days after submission. Amendments, which are not in the
original scope of work or due to changes in concept, shall be taken up by
the bidder as per mutually agreed rates to be decided before execution,
and shall be binding on the bidder.
4.3.2. Bidder shall obtain approval for purchase of specific makes of equipment
whose makes are not mentioned in his offer. If two or more makes of
equipment are mentioned in the form of alternatives in the approved list ,
the bidder shall select any one of the particular make from the approved
list after mutual discussions with the Purchaser.
4.4. INSPECTION
4.4.1. For indigenous items, the bidders shall invite Purchaser for inspection
and preliminary testing. Inspection may be required at various stages of
manufacture/assembly for some items. The Purchaser will arrange to
complete such inspection as maybe necessary along with clearance
within a reasonable time (7 days) from the date of intimation by the
bidder.
4.4.2. For imported items, however, the bidder shall do the inspection at his cost
and submit the necessary test certificate wherever possible.
4.5. SITE WORK AND INSTALLATION

4.5.1. Protection of electronic equipment. It is the responsibility of the bidder to
ensure that all electronic equipment and control system shall be fully
protected against hostile environment, humidity, heat and dust that will be
encountered during storage and installation.
4.5.2. Temporary power supplies. Power supply at site is normally very stable,
but the bidder is responsible to ensure that delicate electronic equipment
used during construction, such as welding machine, testing devices etc.
are protected against damage from mains supply. In the event of a major
power failure in the system, it shall be the responsibility of the bidder to
hire a diesel generator if this proves to be necessary.
4.6. COMMISSIONING
4.6.1. After satisfactory erection and testing, a competent team shall be deputed
to commission the plant and to run product trials and to establish
performance parameters.
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4.7. PRODUCT TRIAL AND PERFORMANCE GUARANTEE
4.7.1. On completion of the Commissioning period, the plant will be operated at
full capacity to the satisfaction of the Project Authority for a period of 30
days on the designed product.
4.7.2. If shut down occurs due to External Force Majeure reasons after 16 hours
of operation in any day, this shall be considered as a full day of testing. If
at less than 16 hours of operation, the trials shall be continued for an
additional full day.
4.7.3. Performance Guarantee: Performance and services consumption
Guarantees and the relevant penalties for not meeting the rated
capacities and efficiencies are covered in the tender.
4.8. TRAINING
4.8.1. Training pertaining to the use of the various process equipment in the
plant shall form an important component of Project Management.
4.8.2. Training shall be undertaken by the bidder for a period of six weeks
during which the contractor should guide and train the staff of the client in
operating the plant equipment to achieve the optimum plant efficiency and
product quality.
4.8.3. Training should commence during the commissioning period and include:
4.8.3.1. Familiarization with major equipment like Grinding, Molassing, Pelleting,
bagging etc including the operation of the computer based auto batch
weigher.
4.8.3.2. Procedure for attaining the rated output and optimum product quality.
4.8.3.3. Familiarization with the basic principles of Electronic/Electrical control
systems, if any including fault finding.
4.8.3.4. Familiarization with start up procedures, regular maintenance and
operational procedures including dismantling of machine parts,
replacement of spares/ components, preventive maintenance etc.
4.8.3.5. Condition monitoring of equipments.
4.8.4. Training shall be given to all the personnel required to operate the plant,
and their immediate Supervisors /Engineers.
4.8.5. The training schedule should be proposed by the bidder together with the
content of training programmes, their duration etc.
4.9. STAND-BY AFTER COMMISSIONING

4.9.1. Once the commissioning and warranty runs are over, the bidder shall
provide to the plant standby technical supervisory support as follows
4.9.1.1. For one month after warranty runs in which further training of the
Purchaser/Client's operating staff if required shall be done and
equipment/system still needing finer adjustment/changes shall be carried
out.
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4.9.1.2. For a week each after 4 months, 8 months and 1 year from warranty runs,
to have discussions with plant staff, to review the correctness of
operations & maintenance procedures.
4.9.2. These visits of the Bidder other than those covered under guarantee
clause, which shall be undertaken whenever required separately.
4.10. SERVICE COVER

4.10.1. In order to ensure that the efficiency of the plant is maintained at an
optimum level, a proposal to offer a service coverage for a period of two
years from the date of plant acceptance shall be given by the bidder for
the maintenance of the Auto Batch weigher and Electronic Bagging off
Weigher. The objectives of this coverage shall be:
4.10.1.1.To arrange for regular service visits by the bidder of these equipments to
inspect, service and carry out repairs if necessary and whenever there is
a breakdown/failure of the system. The frequency and duration of the
visits may be clearly specified.
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SECTION – V
SUB SECTION – 5
TECHNICAL SPECIFICATIONS
94
DESIGN, MANUFACTURE, SUPPLY,
ERECTION, TESTING AND COMM.
OF RAW MATERIAL (GRAINS)
BULK STORAGE GI SILOS.
CAP – 500 MT X 8 NOS.
95
1.0 INTRODUCTION
This section of the documents outlines the technical specifications for the
Design, Manufacture, Supply, Erection, Testing and commissioning of
raw material (grains) bulk storage silo system required for the 800 MTPD
Cattle Feed Plant (expandable up to 1600 MTPD). These technical
specifications are for the guidance of the bidders only and not intended to
bring out all the details of design and fabrication of the equipment or
equipment components. The successful Bidder shall be fully responsible
to undertake all the works involved in the design, engineering,
manufacture, supplying equipment at site including the erection, testing
and commissioning of all the equipment of bulk storage silo system for
grains. Bidders are to note that this Raw Material Bulk Storage Silo
System being offered in this quote shall be part of the overall project and
together with the main feed plant equipment. They shall be fully
responsible in the overall timely implementation of the project on Turnkey
basis, within the battery limits defined in this slice. The work being carried
out shall confirm to high standards of engineering design & workmanship.
The equipment offered shall be capable of performing in continuous
commercial operation to meet agreed performance standards and
acceptable to the purchaser/client. No exclusions of any nature are
acceptable, other than those specifically detailed in this quote document.
The bidders are required to provide all technical data/information
wherever asked for. Any quote not following the quote format structure or
provided with insufficient technical data / information / documents is liable
to be considered as non-responsive. The Purchaser/Client will interpret
the meaning of various equipment specification and drawings submitted
by the bidder and shall have the right to reject any material/equipment,
which in their opinion is not in full accordance to quote specifications.
2.0 SCOPE OF WORK
The scope of the work for this is as follows:
2.1 Design, detailed engineering, manufacturing, inspection at manufacturer’s

works, packing, forwarding, unloading, erection, testing, commissioning,
achieving rated equipment and plant capacities and handing over to
purchaser’s satisfaction of the following as given section wise in the list
below and not limited to :
A) Design and supply of:
• Raw material bulk storage silo system for grains located in project site
complete with silos. The total quantity of silo is 8 nos. and each silo
capacity is 500 ton.
B) Erection, testing and commissioning of:
• Raw material bulk storage silo system equipment. The scope includes
positioning, placement of equipment on foundation, bolting, grouting etc.
complete as per requirement.
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• Commissioning of the Raw material bulk storage silo system including
integrating with the main plant SCADA software and related
communication software.
2.2 Bidder’s scope of supply also includes supply of wear and spare parts of
their equipment for two years trouble free operation. All consumables like
Gear oils, lubricants, packing for flanged joints etc. and commissioning
spares, required if any, for installation, testing & commissioning till taking
over the plant by the purchaser shall be provided by bidder and the same
after taking over the plant shall be provided by purchaser / project
authority.
2.3 Test runs and commissioning trials including imparting training for
operation and maintenance.
Important note for Bidder:
• This is a turnkey job which will have to be executed on a single

responsibility basis. Bidder should consider the complete work in its
totality. All minor works which may be necessary to achieve the rated
capacity of the individual equipment being supplied and in turn to achieve
the rated plant capacity, is included in the scope of work, though not
specifically mentioned.
• The unit rates of items / equipment to be quoted by bidder shall include its
drive of suitable rating and shall be on FOR site basis inclusive of packing
& forwarding, insurance, freight, taxes, duties, octroi etc.
• The equipment and accessories shall be covered under the

warranty/guarantee clauses specified in quote document.
3.0 STATUTORY REQUIREMENTS
The Mechanical and Electrical design, performance and function of the

main equipment/parts and their accessories, including control and
instrumentation panels, shall comply with the latest relevant Indian
standards. Safety and other statutory regulations/ requirements shall
comply with that being followed in the country.
4.0 BATTERY LIMITS Equipment
All raw material bulk storage silo system equipment and machinery to be
supplied & erected by the bidder but not limited to the list in SOQ is in the
scope of works. All frames, foundation bolts for equipments under this
pack are also to be provided by the bidder and their grouting shall be
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arranged by the purchaser under supervision of the bidder. Bidder shall
provide equipment details including cut out drawing as per requirement.
Silo System Structure:
RCC foundation for silos and all other civil works including RCC columns,
trenches for hopper / flat bottom silos shall be provided by the Purchaser.
5.0 EXCLUSIONS
Civil Works: All civil foundations for flat bottom silos, pits and supporting
steel structure of conveyors / elevators of raw material storage silo
system shall be provided by purchaser.
RAW MATERIALS AND OTHER RESOURCES: All raw materials for

production of feed, operating staff for commercial production shall be
provided by purchaser/project authority. All consumables like gear oils,
lubricants, packing for flanged joints etc. and commissioning spares
required if any, for installation, testing & commissioning till taking over the
plant by the purchaser shall be provided by bidder and the same after
taking over the plant shall be provided by purchaser / project authority.
6.0 TECHNICAL SPECIFICATIONS OF SILO SYSTEM, ACCESSORIES.
The silos shall be of galvanized iron corrugated sheet of thickness as per

design requirement. The silo height and diameter are to be designed
according to ANSI-ASAE based on the raw material grains (like wheat,
maize, barley, bajra, jowar etc.). The average bulk density of these raw
materials may be considered as 750 kg/cum for grains.
Minimum galvanization thickness to be 450 gsm. The silos shall be

designed for wind load (highest as per historical records) and for seismic
stability as per seismic zone.
Flat bottom Silos: Shall be provided with galvanized corrugated steel

sheets, outside galvanized stiffeners, bolts, adequate no. of galvanized
supporting legs, roof, roof ladder, hand rail for roof ladder, ladders from
ground to roof eave with safety cage and one rest platform under cylinder
door, inside ladder from access door to ground floor without safety cage.
Suitable eaves close between silo cylinders a roof to prevent water entry
to be provided. Each silo has to have membrane type high, middle and
low level switch, inspection opening on roof and cylinder door. The
detailed silo specification for sheets, roof and other accessories shall be
as per details given below.
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ROOF: The roof shall be of minimum 0.8 mm thickness and of 30 deg
slope for providing optimum strength and providing low peak heights for
overhead equipment like conveyors and related equipment. Roof ribs are
to be full lapped- double or triple-rib formed for added strength. One
pieced roof panel preferred depending on diameter. Steel quality shall
conform to S 280 GD according to norm UNE-EN-10326 (2004) and
having desired tensile strength and yield point Galvanization shall be 450
gm/sq. m according to norm UNE-EN-10326 (2004). In case of large
diameter silos or wherever required structural roof with beams and purling
hot dipped galvanized and designed to support overhead equipment like
catwalks and conveyors to be provided.
If required provide a vented roof panel, which is pre-punched in order to

allow roof vents to be placed in a proper way.
Steel quality is S 280 GD according the norm UNE-EN-10326 (2004)
Overlap detail in the wave of silo roof section to give high strength &
stiffness to the roof as well as make it water tight.
Eave detail to close gap between roof and cylinder to secure the silo from
water penetration.
CORRUGATED STEEL BODY SHEET: The vertical body sheets shall be

corrugated galvanized sheet of thickness varying from 0.8 mm to 4 mm
as per design calculations. The vertical joints shall utilize automatic
punching system to assure perfect connection between them. Quality
controlled steel coils shall be used for the same of tensile strength not
less than 420N/mm2. Galvanization shall be 450gm/sq.m according to
norm UNE-EN-10326 (2004). Corrugation pitch of 76mm x 14 mm deep
preferred with useful length of sheet 1140 mm x 2400 mm. Steel quality
shall conform to S 350 GD according to norm UNE-EN-10326 (2004).
STIFFENERS: Outside positioned stiffeners to carry the vertical load of

the silo to the foundation, manufactured from high tensile steel (420
N/mm2) of thickness varying from 1.5 mm to 4mm as per design
requirements and galvanization 450gm/sqmt according to norm UNE-EN-
10326 (2004). Design shall ensure strong joints and best stability.
Stiffeners may be C channels /omega shaped of minimum 75 mm and
lengths about 1140mm or 2280 mm. Steel quality shall conform to S 350
GD according to norm UNE-EN-10326 (2004). Stiffeners same profile
section from bottom of silo to eave, as well as overlapping detail in case
of double, triple stiffeners, to secure better distribution of loads.
SEALANT: These shall be made from butyl rubber compound supplied in

strips of 4.5 mm and shall be used to fill vertical joints of body sheets and
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hopper sheet joints. The sealant of bolting holes shall be made with
special sealing washer or similar unbeatable weather seal.
BOLTING: Each bolt shall have a special sealing washer to act as

unbeatable weather seal and shall conform to DIN 933 with steel quality
8.8 or 10.9. Nuts shall conform to DIN 934 with steel quality 5.6. The
bolting shall be electrolytic galvanized and passivated (bi-chromate)
having resistance to salt water spray test according to DIN 50021-
minimum 250 hours without corrosion.
CAT WALKS: These shall be formed in two different sections each of 700
mm width including double hand rail (pipe of 32 NB GI “A” class) of 1 M
high. One section shall be used as walkway and the other for installing
the conveyor. The structure of the catwalk to be made with profiled
beams made from galvanized steel of min. 3 mm thickness. Flooring shall
be special grating and not chequered plate. Steel quality shall conform to
S 280 GD according to norm UNE-EN-10326 (2004) and galvanization
275gm/sqmt according to norm UNE-EN-10326 (2004).
AERATION SYSTEM: These are for flat bottom silos. For flat bottom silos
the aeration system shall be Y type made of special galvanized
corrugated and perforated (hole 1.5 mm dia) steel sheets with large area
covering the entire flat bottom silo. Centrifugal fan of adequate capacity
and required Water Column head shall be fitted to bottom of Y. Special
type aeration roof vents are also to be provided. The air blower shall be
activated / run automatically when the temperature of raw materials
reaches a set temperature above ambient. Dust inside the silos is to be
controlled to prevent any dust explosion.
SWEEP AUGERS: These shall be used for the grain silos with adequate
capacity of MORILLION SPIR0GYRE type or equivalent and shall include
one central steel support, electrically operated with suitable KW rating
motor, screw flight of suitable size including all supporting structure and
planetary advancing system. There should be only one motor per auger
and shall not be inside the silo. It shall be outside the silo for easy
maintenance and accessible from trench or open area.
• Industrial sweep auger for heavy duty industrial utilization of every day
and to reduce the damaging impact on grain while unloading the silo.
• Capacity minimum 40-50 tons/hour
• One single motor to be located outside and under the floor of the silo to
enable it accessible from conveyor trench for maintenance
• Auger screw to be supported along its length by a square beam to avoid
bend under the load of the product even when the silo is full.
• Water-proof bearings to avoid any damage with the dust.
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• Auger screw to be protected by a flat cover.
• ATEX Conform.
TEMPERATURE CONTROL SYSTEM: These shall consist of a

temperature control centre made up of a Pentium computer, color screen
with provision for indicating the temperature of each probe, activation and
deactivation of the probes, activation and deactivation manually the
sensors which are in the raw material depending on height of silo fill,
graphical representation of temperature charts, RS 232 interface between
PC and temp control system and to main plant SCADA system. The
temperature control system shall activate the aeration system when set
temperature is reached. Supply shall be at 220V with intrinsic safety
barrier to feed circuits placed in explosion risk zones (Zone 20 ATEX).
Sufficient number of probes with 3 or 4 sensors per probes shall be
provided for each silo. The system shall include multiplexation box for the
probes, connecting wires/ cables and supports on the silo roof for the
cables. Probes should be assembled from outside the silo for easy
maintenance.
• Temperature control system will be automatic and linked to aeration

system fans operation
• Complete automatic management of the temperature developments
and aeration fans operation (with sensor of external relative humidity and
outside temperature) from control room, historical data in numerical as
well as graphical form.
• Probes to be mounted from outside roof and dismountable also when
silo is full.
• Special support system in silo of probes to reduce load on roof.
• To minimize the traction effect of the grain on the probe sheath, it
should be made up of an inside tube of polypropylene,
wrapped/reinforced in steel wires and outside covered with a cape of
extruded polyethylene.
• The sensors to be of Thermistor NTC type
• ATEX Conform.
Important Notes:
• The foundation location of silos, layout of elevators, trenches, pits

including load details on the foundations shall have to be provided to the
purchaser to design the foundation. Foundation bolts shall be in the
scope of the bidder.
• The steel supports shall be designed for box type sections or other
economical sections, so as to reduce the overall steel requirement,
keeping the minimum safety standards as indicated.
• The silos and the supporting framework shall be designed for wind load
(highest as per historical records) and for seismic stability as per seismic
zone. Stability certificate for the silos and structure shall be submitted by
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the successful bidder. Design calculations for the silos to be shared with
purchaser without any extra cost.
• Staircase shall be suitably located so that quick approach to working

platforms and shall be 1.2 m wide with 32 mm pipe (GI “A” class) hand
railing (double braced).
• Platforms, railing shall be extended to all working equipment to facilitate

inspection, operation and maintenance.
• Elevation (all sides) drawings for the silo system showing heights of all
silos including elevators and conveyors shall be furnished to the
purchaser including the conveyor entry direct to plant intake section and
pre-weighing sections.
6.6 TECHNICAL SPECIFICATIONS FOR ERECTION, TESTING AND

COMMISSIONING
Erection, testing and commissioning is inclusive but not limited to the

following:
- Positioning of all the silo system equipment in the approved locations,

including grouting, anchoring etc as per requirement.
- Erection/Welding/Grouting into place necessary structural platforms,

walkways, hand rails etc., as per requirement.
- Name of all important machines to be written on them after final

installation but before commissioning by a painter. Necessary aero marks
and other identification by painting to be provided on piping as required.
- After installation of all equipment and completion of product piping and

connection of all utilities including electrical, each major equipment shall
be tested at no load after checking all alignments. On completion of
satisfactory no load test, section-wise testing at no load shall be carried
out. Any defect noticed during no load shall be attended to. After testing
of all sections on no load, the plant as a whole shall be tested with raw
material for trial run and ultimately commissioning the complete plant to
the satisfaction of purchaser/project authority.
6.7 ESTABLISHING PERFORMANCE GUARANTEES
On completion of supply, erection, testing and commissioning of the plant

/ equipment, the same has to be operated at full capacity continuously in
3 shifts of 8 hours basis for four weeks to the satisfaction of the
Purchaser/Project Authority, to establish performance guarantees
provided by the bidder. However, if purchaser/client is unable to provide
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operating staff for three shifts, number of days can be increased with
mutual discussions.
6.8 TRAINING
Training in the operation and maintenance of the various equipment of

the plant shall form an important component of Project Management.
Training shall be undertaken by the bidder for a period of one month
during which the contractor should guide and train the staff of the client in
operation and maintenance of the plant equipment to achieve the
optimum plant efficiency and product quality. Training should commence
during the testing/ commissioning period and shall include:
1. Familiarization with all major equipment including the operation of the

computer/PLC based auto systems.
2. Procedure for attaining the rated output and optimum product quality.
3. Familiarization with the basic principle of Electronic/Electrical control

systems, including fault finding.
4. Familiarization with start-up procedures, regular maintenance and

replacement of spares/components, preventive maintenance etc.
5. Condition monitoring of equipments.
6. Generating production and maintenance log sheets of important

equipment and systems.
Training shall be given to all the personnel required to operate the plant
equipment and their immediate Supervisors/ Engineers. The training
schedule should be proposed by the bidder together with the content of
training programmes, their duration etc.
7.0 TECHNICAL DETAILS AND DRAWINGS TO BE FURNISHED

ALONGWITH THE QUOTE
Following drawings are enclosed along with the quote:
The bidder to provide drawing/data and technical details with their quote
as specified. After commissioning and during handing over of the plant by
Bidder to Purchaser/Project Authority, the contractor to provide the
following:
• As executed final drawings and technical data of the complete plant for
operation, maintenance and permanent record in soft (in AutoCAD) and 3
sets of hard copies.
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The final software and source codes of the systems.
• A consolidated operation and maintenance manual -3 sets of the

complete plant along with operation and maintenance of each key
equipment as provided by manufacturer.
DRAWINGS
Equipment drawing: The general arrangement (GA) drawing of silo and

each associated indicating dimensions, tolerances etc., as proposed by
the bidder.
• Layout drawing The machinery and equipment layout drawing of the silo
system showing layout of the silos and other equipment.
• Catalogues The relevant catalogues, technical data sheets, drawings,

photographs etc., of each equipment/accessory being offered to be
submitted by bidder
A) TECHNICAL DATA (to be furnish by bidder) FOR SILOS:
SL
DESCRIPTION UOM
NO
I GRAIN STORAGE SILO
1 Model
2 Diameter Mtr
3 Height to Eave Mtr
4 Height to Peak Mtr
5 Volume cum
Compacted Capacity with 6%
6 MT
compaction
7 Uncompacted Capacity MT
8 Product
9 Bulk Density Kg / m3
10 No of Wall Rings Nos
11 No of sheets /Ring Nos
Wall Ring thickness from bottom to Gauge /
12
top mm
Gauge /
13 Wall ring stiffener thickness
mm
14 Wall Sheet Corrugation mm
15 Columns per wall Sheet Nos
16 Total Stiffener columns Nos
17 Wind Ring Nos
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18 Roof sloop degree
19 Roof Peak Load Capacity Kgs
20 Common bin design wind Velocity Kph
21 Snow Load Psf
22 Seismic Zone IS
23 Galvanizing g/m2
24 Roof Manhole
25 Side Wall Door on Ring
26 Aeration System
27 Comm. bin roof cap
28 Punched roof sheets, roof vent
29 Total Weight in Kgs
30 Foundation Bolts
II BIN ACCESSORIES
1 Internal Ladder
2 External Ladder
3 Base Sealer
4 Roof Hand Rail
III Temperature Monitoring System
1 Temperature Cable
2 No of probes
3 No of sensors per probe
4 Plug Box & lead wires
5 Portable Reading instrument
6 Temperature Cable support
IV AERATION SYSTEM
1 Number of Fan per Bin Nos
2 Air Flow m3/ hr
3 Static Pressure mbar
4 Fan Type
5 Power of Fan Motor HP
6 Make of Motor
7 Speed Rpm
8 Floor Type
Approx area of FB silo covered by the
9
aeration system
10 Centrifugal fan HP
Centrifugal fan capacity in cum/hr and
11
head WC
12 No of special aeration roof vents
V BIN SWEEP AUGER
1 Model
105
2 Silo Diameter M
3 Capacity Tons/Hr
Flight Specifications
4 Diameter of screw mm
5 Tube Diameter mm
6 Length of the Sweep Auger M
7 Electric Motor 1 Main drive HP
Electric Motor 2 Traction wheel HP
8 Make of Motor
9 Sheave Pulley mm
VI COMMERCIALS
1 500x8 MT Flat Bottom Silo for grains 1
2 SILO ACCESSORIES
a Ring internal ladder 1
b Ring External ladder 1
c Base Sealer 1
d Roof ladder Hand rail 1
e High level Indicator 1
f Aeration system 1
g Sweep Auger 1
h Temperature Monitoring System 1
Floor accessories Inside Silos Like GI
i 1
perforated grills, etc for trench
Automation and PLC Panel
Software to communicate all temperature data’s with centralized SCADA

PLC/PC and required cable length for connection in between Multiplexer
Card/Box & Interface card for the Silos.
Details of the automation scheme, network diagram, type & model of

PLC offered.
Technical detail of computer system with a write-up indicating equipment

details, process, controls, type of reports which can be printed. Detail of
input/output ports and other technical details of the PLC panel & hard
ware of computer systems.
8.0 TECHNICAL DETAILS AND DRAWINGS TO BE SUBMITTED AFTER

AWARD OF CONTRACT
The following shall be provided after award of contract:
106
1. The final equipment GA drawing (in both hard -3 sets and soft form) being
manufactured as per design and product specifications of purchaser
2. Final services /utilities schematic with sizes of pipe lines, valves,

insulation thickness, controls, showing all instruments and accessories
3. Final foundation foot print
4. Final electrical load details in HP/KW
5. Final control schematic of the control panel/automation
9.0 SCHEDULE OF QUANTITIES
A – SUPPLY
RAW MATERIAL STORAGE SILO SYSTEM EQUIPMENT FOR

GRAINS.
Sr. No. Description Cap Qty
FLAT BOTTOM SILO (WITH

1 500 MT 8 NOS.
IMPORTED SHEETS)
FLAT BOTTOM SILO

2 --- 8 SETS
ACCESSORY(IMPORTED)
ELECTRICALLY OPERATED
3 SWEEP AGUGER (IMPORTED) 40 TPH 8 SETS
FOR FLAT BOTTOM SILOS.
B –INSTALLATION, TESTING AND COMMISSIONING
107
RAW MATERIAL STORAGE SILO SYSTEM EQUIPMENT FOR
GRAINS.
Sr. No. Description Cap Qty
FLAT BOTTOM SILO (WITH

1 500 MT 8 NOS.
IMPORTED SHEETS)
FLAT BOTTOM SILO

2 --- 8 SETS
ACCESSORY(IMPORTED)
ELECTRICALLY OPERATED
3 SWEEP AGUGER (IMPORTED) 40 TPH 8 SETS
FOR FLAT BOTTOM SILOS.
108
ERECTION AND COMMISSIONING OF
4 TPH BOILER PLANT.
109
1.0 INTRODUCTION
Design, Manufacture, Supply, Erection, Testing and Commissioning of
the boiler system required for the 800 MTPD Cattle Feed Plant
(expandable up to 1600 MTPD). These technical specifications are for the
guidance of the bidders only and not intended to bring out all the details
of design and fabrication of the equipment or equipment components.
The successful bidder shall be fully responsible to undertake all the work
involved in the design, engineering, manufacture including the erection,
testing and commissioning of the boiler equipment’s & associated fuel &
service requirements. Bidders are to note that the boiler plant being
offered, shall be part of the overall project and together with the main feed
plant and other equipment they shall be fully responsible in the overall
timely implementation of the project on Turnkey basis, within the battery
limits defined in this slice. The work being carried out shall confirm to high
standards of engineering design & workmanship. The equipment offered
shall be capable of performing in continuous commercial operation to
meet agreed performance standards and acceptable to the
purchaser/client. No exclusions of any nature are acceptable, other than
those specifically detailed in this document. The bidders are required to
provide all technical data/information wherever asked for. The
Purchaser/Client will interpret the meaning of various equipment
specification and drawings submitted by the bidder and shall have the
right to reject any material/equipment, which in their opinion is not in full
accordance to the specifications. The entire plant should be dust free and
suitable aspiration units will be provided at all required points.
2.0 SCOPE OF WORK
The scope of the work is as follows:

achieving rated equipment and plant capacities and handing over to
purchaser’s satisfaction of the following as given section wise in the list
below and not limited to :
Part A: Design & Supply of
• 4 TPH boiler, chimney, ducting, HP steam piping & PRS. High pressure
steam generated in the boiler shall be reduced to LP steam in PRS, one
located within the Boiler House, other located in the Main plant.
• Water Piping: Insulated feed water piping drawn out from the outlet ports
of the Feed water tank to Boiler, break water tank & its water circulated
system to recover heat from the Main blow-down line’s operation.
110
• Fuel Handling System: Fuel dumped into dumping hoppers manually &
mechanically conveyed, pulverized (if necessary) before being stored in
bunkers for boiler use. The fuel handling & feeding to the Boiler shall be
automatic & based on Boiler steam pressure.
• All electrical & automation works related to the steam generation, fuel
handling, pollution control equipment with necessary hardware &
software.
• All structural works like platforms with railing, trench covers, walkways,
ladders, for operation & maintenance of the items.
The bidder shall supply one no. 4 TPH Multi-fuel (solid) fired Fluidized
Bed Combustion (FBC) type Boiler with chimney complete automated fuel
storage & handling system, Flue gas ducting, HP steam header, Pressure
Reducing Station (PRS), Ash handling system etc. It is to be noted that
one boiler shall cater to the steam demand of the entire plant. Connecting
the flue gas ducting on chimney and interconnecting the HP steam outlets
to a steam header, PRS, water supply to the Boiler etc. is included in the
scope of the bidder.
Part B: Labour job of installation, testing & commissioning of 4 TPH boiler

plant & Utility handling for Cattle Feed Plant.
The list given below of equipment is as per preliminary design of the plant
by Purchaser. The detail list of equipment & their individual capacity may
vary as per design and detailed engineering by the bidder to achieve the
minimum steam generation of suitable capacity or as specified in design
data & battery limits. If required, the bidder can break-up an item into
further detail but wherever purchaser has indicated quantity as one lot, no
further detail is required. Bidders may add additional items section wise if
these are required as per their detail engineering. These additional /
optional / alternatives items offered by the bidder will be considered
during technical evaluation of the specifications and would be subjected
to acceptance by the purchaser only through addendum of the document.
The section wise list of equipment is as follows:
2.1.1 BOILER PLANT EQUIPMENT & RELATED WORKS
The bidder shall execute the following major works as per the scope;
1. 4 TPH Boiler complete with accessories and mountings,

2. Common chimney (suitable for two boilers operation – one planned and
one future), independent ducting etc. complete.
3. Common Automatic Fuel handling up to boiler house, independent
storage & handling equipment’s.
4. Independent Pollution Control & waste heat recovery equipment’s.
111
5. Utility works including Break water tank, pipes, valves & fittings for water,
Compressed air generation & distribution for boiler operation, IMCC &
associated electrical works for Boiler & related items in the scope of
supply.
6. HP, LP steam, drain etc. piping with insulation, valves, fittings including
two PRS complete (10.5 to 3.5 kg/sq.cm (g)), one suitable for 3.0 TPH
steam throughput & other 700 kgs/hr.
7. Independent Auto Blow-down with heat recovery systems.
8. Statutory approvals for Boiler & HP steam piping, electrical, weights &
measures, Pollution Control equipment’s.
9. Complete ash handling system with required statutory approvals.
2.2 Bidder’s scope of supply also includes supply of spare parts of their
equipment for two year trouble free operation.
All consumables like Gear oils, lubricants, packing for flanged joints etc.
and commissioning spares, required if any, for installation, testing &
commissioning till taking over the plant by the purchaser shall be provided
by bidder and the same after taking over the plant shall be provided by
purchaser / project authority
2.3 Test runs and commissioning trials including imparting training for
operation and maintenance
Important note for Bidder
• The technical specification of equipment is generally based on a

particular design but bidders can supply equipment as per their design to
meet the functional requirement of equipment specified in these technical
specifications.
• The list of equipment accessories & their capacities may vary as per
design and detailed engineering by the bidder to achieve the minimum
equipment rated capacity as specified in design data & battery limits.
• If required, the bidder can break-up an item (or SET) into further detail.

totality. All minor works which may be necessary to achieve the rated
capacity of the equipment being supplied and in turn to achieve the rated
plant capacity, is included in the scope of work.
• The unit rates of items / equipment to be quoted by bidder shall include its
drive of suitable rating and shall be on FOR site basis inclusive of packing
& forwarding, insurance, freight, taxes, duties, octroi etc.
• The equipment and accessories shall be covered under the

warranty/guarantee clauses specified in document.
112
The Mechanical and Electrical design, performance and function of the
main equipment / parts and their accessories, including control and
instrumentation panels, shall comply with the latest relevant Indian
standards. Safety and other statutory regulations / requirements shall
comply with that being followed in the country. The Electrical works shall
comply with the latest Indian Electricity Rules and other statutory
regulations / requirements of power supply authorities and Chief Electrical
Inspectorate.
The steam generation plant including HP piping, PRS shall be got
approved by the Boiler inspectorate both during stage wise manufacture
till despatch and finally after installation and commissioning. Necessary
approval for the steam generation and distribution installation and the
electrical installation done by the bidder under this shall be obtained by
him from the above statutory authorities and any modifications or
changes if suggested by the authorities, the same shall be carried out by
the bidder without any additional cost. Approval certificate shall have to
be handed over to the purchaser.
4.0 BATTERY LIMITS
S. No Description Purchaser’s scope Bidder’s scope

1 Water Up to UG sump Starts from softening water plant outlet to
boiler. This includes all required piping,
instruments and pumps, electrical panels.
2 Flue Gas _ From the Boiler outlets, across pollution
control equipment, ID fans up to the
outlet of common self-supported
chimney.
3 Steam From the outlet of From the outlet of boilers through HP
the PRS to steam piping up to PRS. The steam pipe
consumption points from safety valves discharge shall be
taken outside the boiler house. All
necessary pipe fittings & accessories,
valves, expansion bends, strainers, PRV
controls, trap assembly, steam Flow
meter, pressure gauge etc., required is
included in the scope of supply. The PRS
shall be installed near the consumption
points.
4 Blow-down Blow down pit shall From Boiler through main blow-down
be provided. valve, auto-blow-down system up to
blow-down pit located outside the boiler
house.
5 Drains Blow down pit shall All other drains from Mobrey water level
be provided. controllers, level gauges, sample cock,
113
steam trap etc. shall be taken in the
trench, outside the boiler house, to blow
down pit.
6 Fuel Fuel shall be From the dump pit up to both Boiler,
unloaded at a place across automatic handling equipments
for day’s storage. with conveyors-elevators-hoppers,
bunkers etc.
7 Electricals Power shall be From the Outlet of PCC bidder scope will
provided at PCC at start. MCC, Boiler control panel, required
the substation. cables and cable trays etc and up to all
individual loads for the Boiler and
accessories. Cabling for auto blow-down
system and all instruments, flow meter,
PRVs, probes, sensors etc are covered in
the work scope. The junction box and the
electrical connection from the box up to
the aviation light fittings. The scope
includes obtaining approval for electrical
installation executed by the bidder from
the Electrical Inspectorate.
8 Earthing ___ Earthing grid from the Boiler House IMCC
to individual panels, instrument earth,
electrical loads in the Boiler house etc.
Earthing of the lightening arrestor on the
chimney is included in the scope. Earth
pit is also included
9 Foundation All civil works, indoor Necessary steel supports/cable trays etc.
related & trenches. for piping/ducting and cabling etc. is in
structural bidder’s scope. Supports for piping,
works ducting, and platform for Feed water
Tank, PRS is included in the scope. All
necessary foundation bolts/nuts,
templates for chimney & machinery etc.
are included. All the supports shall be
either from rectangular or square hollow
sections. All the supports shall be then
duly pained in approved shade. Plant
layout drawing will be provided by bidder.
10 Compresse _____ Suitable size air compressor and required
d Air piping piping with electrical and instrumentation
work will be in bidder scope.
11 Condensate Condensate from the Condensate from the PRS installed near
indirect heat the Boiler House and plant PRS, shall be
exchangers shall be taken to the Feed water tank and flash
collected & pumped steam recovery from all steam traps.
back to the Feed
water tank
deareator.
12 Flash steam _ Flash steam from the Blow down heat
recovery unit shall be taken back to Feed
114
water tank.
13 Raw All raw materials for All consumables like Gear oils, lubricants,
materials & Boiler, operating packing for flanged joints etc. and
Consumabl staff for commercial commissioning spares required if any, for
es production shall be installation, testing & commissioning till
provided by taking over the plant by the purchaser
purchaser/ project shall be provided by bidder and the same
authority. after taking over the plant shall be
provided by purchaser / project authority
14 Ash Generated ash should be transferred to
Collection the ash storage area by automatic
system.
15 Automation Integration of Central For all machines /equipments in the scope
PLC with Boiler of supply & provision to transmit data to
House Centralized PLC in Main Control room.
Required hardware for communication
with central SCADA system should be in
bidder scope.
4.1 Standby Services after commissioning:

Once the commissioning & warranty runs are completed & plant taken
over by purchaser, the bidder shall provide for standby service cover for a
period of 1 (one) year. Four visits shall be undertaken by the bidder, once
every three month for minimum two days, to assist, fine tune the
operations & suggest ways for improvement. Bidder shall suggest
solutions to problems occurring during this period.
5.0 EXCLUSIONS
Civil Works MCC/Control room shall be provided by the Purchaser. All

civil foundations for steam boilers, ash handling, dust extraction, chimney
etc., shall be provided by purchaser based on the GA drawing and
load/foundation details provided by bidder.
Other exclusions:
a) Boiler house structure, OH Tank, masonry trenches and blow down pit.
b) LP piping after PRS.
c) Power & water.
d) Fuel & other chemicals.
e) Internal lighting electrification, telephone for Boiler House.
115
6.0 TECHNICAL SPECIFICATIONS OF BOILER PLANT, FUEL HANDLING
SYSTEM & ASSOCIATED UTILITY WORKS:
6.1 FUNCTIONAL REQUIREMENTS
General Description:
Boiler is required to generate dry saturated steam for feed conditioning &
Molasses pre-heating applications in Cattle Feed plant. The boiler shall
be with adequate steam space to cater to varying steam load, depending
on process requirements.
6.2 DESIGN REQUIREMENTS
6.2.1 Boiler:
Boiler should be FBC type design, automatically controlled including fuel

handling, firing (except ash removal), tested and proven under rigorous
conditions and subject to the strictest quality control procedures. Boiler
construction shall be in accordance with the latest revision of Indian Boiler
Regulations 1950, Act 1923 applicable and in conformity with AOTC
requirements for unattended boilers. All materials used shall be approved
and tested as per relevant existing codes. All the welded joints shall be as
per code requirement.
Sr. Parameter Requirement Remarks

No
.
1 Capacity 4000 kg/hr From and at 100˚C of water
2 Net Peak steam 3000 kg/hr at 3.5 kg/sq.cm Assuming blow down and
demand condensate recovery
3 Working pressure 10.5 kg/sq.cm
4 Quantity 01 No.
5 Dryness of steam 0.98 minimum
6 Boiler design FBC type suitable for coal,
agro based pellets, rice
husk, and ground nut
shell.
7 Accessories All standard accessories FW pumps, FD, PA, ID fans,
O2 trimer with close loop
operation to control air fuel
ratio. APH pollution control
equipment etc.
6.2.2 Fuel:
The boiler should be designed to use solid Fuel (Coal or Agro-based

pellets, rice husk, ground nut shell). Ultimate analysis for coal is as under:
116
No Parameter Unit Importedcoal IndianCoal Kutch Lignite
1 Carbon % wt 62.19 48.89 40.00
2 Hydrogen % wt 3.23 2.47 2.20
3 Nitrogen % wt 1.03 0.98 1.00
4 Sulphur % wt 0.21 0.26 2.00
5 Oxygen % wt 11.86 4.56 12.8
6 Moisture % wt 10.00 9.06 32.00
Mineral Matter
7 % wt 11.48 34.18 10.00
(Ash)
8 GCV kcal/kg 5500 4100-4400 3800
For specification purpose following GCV is to be considered,

Coal - 3800 Kcal/kg.
Agro- based pellets – Between 3500 - 3800 Kcal/kg
6.2.3 Thermal efficiency:
Thermal efficiency with all agro based fuel at 50 % steam load, at 30-40
deg C ambient temperature & 60 % Relative Humidity, should be
maximum but not less than 80% with air pre-heater as per BS: 845 Part 1
indirect abbreviated heat loss method on GCV basis. However, the bidder
can offer highest possible efficiency (above 80% with a different
technology, considering the fuel as coal or agro based pellets).
6.3 SCOPE OF SUPPLY
6.3.1 Boiler:
The complete boiler having steam generating arrangement, casing,

pumps, controls, instruments, all necessary accessories should be
supplied.
• The Boiler shall be latest design with water-in-tube or water-in-shell. The
boiler shall be reliable, rugged & versatile for operation.
• The boiler shall be complete with all mountings, accessories, controls etc,
MOC SA 515/516 Gr 70 for shell, tube plates, pads, bosses etc.
• The boiler should be of modern & compact design with risers & down-
comer headers, with blow-down.
• Furnace shall comprise of adequate furnace volume & heat transfer
surface comprising tubes & connecting strips forming a membrane panel
117
to maximize heat transfer area. Equivalent design like swaged water wall
design is also acceptable.
• One pass or two pass smoke tube design acceptable, with up to 50% turn
down, without reduction in overall thermal efficiency.
• The boiler mountings, fittings, accessories shall be as per specified in
item 6.4.8.
• The ports for loading of fuel, removal of ash, primary air inlet, and
secondary air shall be optimally designed for maximum efficiency &
minimum losses.
• The boiler shall be designed and constructed to generate steam at
efficiency of more than 80% on Gross calorific valve (GCV) basis at 50 %
steam load. Efficiency shall be demonstrated as per standard BS – 845
Part 1 Indirect methods.
• The insulated cylindrical shell of the boiler shall then be cladded with 22
G aluminium sheets. A movable ladder shall be provided which can be
moved as per convenience.
• Boiler and accessories shall be mounted on a single base frame.
Individual systems such as feed water pump etc. may be on separate
base plates welded to the boiler base frame.
• 100 % radiography examination for circumferential & longitudinal seams
of shell & stress-relieving shall be executed as per IBR norms
The main boiler should be a water tube/fire tube steam boiler type,
consists of following major components:
A. Furnace
B. Radiation part,
C. A convection part with horizontal fire tube bundle (Boiler drum)
D. Combustion system
The water tube radiation part should be connected to the convection part
on the waterside with down-comers and with riser tubes on the steam
side.
A. FURNACE
The furnace should be completely integrated in the boiler: the sidewalls

and in-bed of the furnace are completely cooled by the membrane walls
of the boiler. The furnace should be built of refractory wall construction or
the membrane walls of the furnace should be partially covered by
refractory wherever exposed to flame directly. The amount of the
concrete should be however restricted to a minimum in order to minimize
the investment and the maintenance costs and to maximize boiler
availability. The design of furnace into the boiler should be such as to
control the combustion temperature and furthermore it should reduce
excessive slagging of the ashes on the sidewalls of the furnace. The
boiler should be extremely efficient for the combustion of fuels with
118
varying heating values and fuels characterized by low ash fusion
temperatures. A door should be mounted into the rear wall of the furnace
and ensure that the boiler is easily accessible. An adequate inspection
glass mounted in the rear wall shall give an inside view of the combustion
process in the furnace. All working parts of the boiler should be
accessible for ease of inspection and maintenance.
Insulation & Refractory works:
Three layer refractory lining required for the furnace. The bidder shall
undertake to execute refractory & lagging works for the furnace & shell at
site. All refractory materials shall be castable including refractory bricks;
cement firecrete etc shall be executed as per best engineering practices.
The fixing arrangement of the membrane panel for the furnace with fire
bricks, cement firecrete etc, shall be included in the scope of works.
Necessary refractory bricks, fire resistant cement shall be supplied by the
bidder. Rock wool/ Mineral wool as per IS 8183 & shall be suitable for
ambient temperature of 30 Deg C. Density shall be considered 100-120
kg/m3. Cladding shall be ribbed Al. Sheet for pressure parts & rest all
shall be plain.
B. RADIATION PART
The radiation part consists of heat transfer surface comprising tubes &
connecting strips forming a membrane panel to maximize heat transfer
area. The configuration shall incorporate 3 side water walls including the
in-bed layer to maximize the absorption of heat of combustion. The ratio
of tubes to membrane panel shall be maximum & shall not be below 55
%. The fire tubes in the furnace shall conform to BS 3059 PART 1 ERW
or seamless tubes. These tubes in the furnace shall be three side water
wall types, to give maximum heat transfer area to enable safe operation &
easy maintenance. To maximize combustion efficiency, the furnace
temperature shall be maintained between 800 to 850 Deg C. The boiler
shall operate in this range to avoid ash fusion & clinker formation. Buck
stays to be provided for membrane wall/ furnace walls.
C. BOILER DRUM
The flue gases needs to be cooled down rapidly in the fire tubes where
they pass by convection. The fire tube part should be executed as a multi
pass heat-exchanger. The large water content should be provided in the
convection drum, with a large evaporation surface along with a
modulating feed water control (Single Element Drum Level Controller)
which shall ensure in a quick response when the steam production shows
a peak load. The voluminous drum should be provided to ensure dry
steam without complicated or expensive secondary measures as steam
dryers. The flue gas velocities should be optimal chosen to reduce the
fouling of the fire tubes. Accessibility should be assured through a door(s)
the cleaning doors on the smoke box at the end of the drum. The shell
shall consist of adequately sized drum to increase the steam-water
119
interface for better steam quality & higher steam release rate. The fire
tubes shall be adequately sized (2.5” or 3”OD), to prevent choking. The
water-hold-up volume shall be maximum for the rating to meet sudden
surges in steam demand. Double hinged Access Doors required in both
front & back side for clear access to the tubes for inspection/cleaning.
D. COMBUSTION SYSTEM
The system shall comprise of spontaneous combustion of the pulverised /

palletized fuel within the furnace due to turbulence of particles, through a
single bed design. Air from the plenum chamber complete with
distribution plate with fluidizing air nozzles shall ensure proper & uniform
distribution on air for combustion. For wet or higher size fuels, provision
for over-bed feeding shall be included in the scope.
Air distributor:
Air Distributor shall distribute pre-heated air, to achieve the fluidization

velocity, & to evenly spread air in the fluidizing zone. The material of
Construction of the distribution plate shall withstand furnace temperature
without problems. The number of perforations & the geometric pattern of
the perforation shall be suitable for underfeed fuel feeding system of
pulverized coal. The distributor plate shall be thermally protected with
refractory lining, layer of bed material & in-bed tubes.
Bed Materials:
Bed materials can be a mixture of silica sand, Coal ash, limestone or

pulverized refractory with an average size of 1 mm. The depth of the bed
shall ensure optimum pressure drop & effective air velocity for good
turbulence. Generally the static bed depth shall be kept between 250-300
mm. Bed temperature control system shall be provided which shall sense
bed temperature shall cut-off or cut in fuel with indicators.
ID, FD, Booster Fan:
The Boiler shall be supplied with suitable ID, FD, Booster centrifugal fans
with air modulating dampers. Vanes of the fans shall be backward
inclined / curved. ID Fan shall preferably be installed on the floor level for
easier operation & maintenance. These units shall have common base-
frame for the fan, gearbox / chain transmission with motor mounted on
Anti-Vibration pads. Energy efficient motor (EFF1) of TEFC enclosure
with class F insulation and IP 55 protection shall be selected for the
motor. The ID fan shall be VFD controlled based on the combustion air
requirements, to maintain desired furnace draft.
The FD, ID fans should be suitable to create suitable balanced draft for
complete combustion of fuel. The ID fan capacity / head shall be selected
to compensate the pressure drop across air pre-heater & ducting length
and Pollution control equipments. Similarly the FD fan capacity / head
120
shall be selected based on pressure drop across APH, ducting length,
combustion requirements.
The Booster fan shall draw pre-heated air from the FD fan & discharge
the air across venturi to draw pulverized/pellet fuel from the Bunkers, for
spraying in the combustion zone. The duty shall ensure that sufficient fuel
is drawn out from the bunkers for Boiler duty conditions. Secondary Air, if
required, shall also be drawn from the pre-heated air from the FD fan
6.4.2 AIR PRE-HEATER:
An air pre-heater shall be designed to maximize heat recovery from flue

gas to improve overall efficiency of boiler. Heat from the Boiler flue gas
shall be used to pre-heat the ambient intake air from FD fan, before
entering the furnace and shall thus act as a heat recovery unit in the
system. The sizing shall be suitable to cater to the total air / flue gas flow
of the boiler. The unit shall be insulated , shell & tube design & provided
with dampers, necessary pressure & temperature gauges, sensors,
controls and all associated accessories etc complete to maximize heat
recovery.
6.4.3 AIR CONTROL
• The flow of primary air should be automatically regulated by pneumatic

dampers.
• The flow of secondary air should be automatically regulated by pneumatic
dampers.
• The ID fan should be controlled based on Furnace Pressure.
• The secondary regulation of Primary Air, Secondary Air & ID fan should
be done based on feedback on Oxygen feedback in the flue gas. Thus
the boiler should have Oxygen Trimming system for Primary, Secondary
and ID Fan.
6.4.4 FUEL CONVEYING & HANDLING SYSTEM
Bidder shall design a suitable automatic fuel conveying system and

storage hopper as per their design requirement. The entire conveyer will
be a closed type with hood arrangement to avoid any dust in the
surrounding environment. A suitable dust extraction system shall be
supplied.
Feeding system shall also be provided for feeding agro-based pellets, &
other bigger sized fuels, for above-bed (overfeeding) fuel feeding. The
feeder shall be a suitable type / sized feeder with pneumatic spreading
arrangement. This feeder shall also be VFD controlled, with online
weighing system. The storage bunker for fuel shall be located in the
Boiler House, near to the furnace. The dumping area of fuel shall be
located outside the Boiler house. Other associated equipments for fuel
121
handling system like, Dumping hoppers, Aspiration units for Dumping
Hoppers, inclined conveyors, bucket elevators, magnetic drum separator,
vibrating screen, crusher, recirculation elevator etc. required for fuels like
coal, agro-based pellets shall be included in the scope of the work.
Aspiration unit shall be provided for the crusher to avoid dusting and
losses.
Each Boiler shall have 1 day of fuel storage within set of bunkers
provided. The storage shall comprise of two identical bunkers of equal
capacity. A hopper below the bunkers shall have necessary stiffeners
leading to fuel conveying arrangement to the Boiler. The Bunker storage
silos shall be modular in design & suitably stiffened & Floor supported by
MS structure. It shall be possible to load any bunker from the dumping
Yard by selecting & opening the pneumatic operated gate. The pulverized
fuel / pellets feeding from the storage bunker through venturi & the spray
nozzles shall be automatic. Nozzles shall be fabricated / machined from
high quality SS 310 solid bar or CI with 3 % chromium.
The design of individual handling equipments to meet the required

handling capacity, dust extraction system & operational requirements
shall be the responsibility of the bidder.
All structural steel for supporting the handling equipments shall be in the
scope of the bidder. Operation & maintenance platforms with hand- railing
for the fuel handling system including application of primer & painting of
external structures, equipments shall be supplied, as a part of the total
work. Purchaser shall only provide for civil works for trenches, elevator
pits & pedestals for structures.
Note: Bidder shall submit a detailed scheme for the Fuel Feeding system.
The feeding system should be of multiple / single designed such that it
requires no removal / fittings / alterations while change of fuel. The
feeding system should be able to adapt to the various fuels on as it is
basis. The change of fuels should be done merely through selection of a
switch on the control panel. (Hence the change over should be fully
automatic type)
6.4.5 WATER HANDLING SYSTEM:
Raw water shall be made available in the water sump. Depending on the
water requirement for the Boiler House, Raw water shall be pumped by a
set of self-priming centrifugal pumps (1 working + 1 standby) to the
overhead water tank for storage & use.
The Overhead water tank has two 30 KL capacity compartments, one for
soft water & other for raw water. The filling of raw water from the sump to
the Overhead water Tank (Raw water) shall automatic, based on level
sensors on the tank. However, a Push Button Station (PBS) shall be
provided in the Boiler House for the filling of Overhead water tank by any
of the two raw water pumps on manual mode, if auto-operation fails.
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Control wiring for the PBS shall be drawn from the pump panel up to the
Boiler House. A multi-grade filter shall be placed on the pumping line to
remove suspended solids from raw water. The multi-grade filter (Simplex)
shall be suitable for the pumping capacity (Capacity of the Multi grade
filter to be mentioned)
Calibrated Water level indicators (SS ball float & counterweight type) shall
be provided for each of the overhead tanks & two (Three) for the
underground water sump. The overhead water tank shall be located
within 30m of the Boiler House.
Water shall be drawn from the raw tank compartment of Overhead water
tank by the softener pump, which will transfer water across softener to the
second compartment of Overhead water tank. Water shall flow by gravity
from the soft water compartment of the overhead water tank to the 20 KL
insulated Feed water Tank through the atmospheric deareator or
additional inlet port. A provision in piping shall be made to directly take
soft water from softener to feed water tank in a manual mode, through
manually operated valves.
A water circulation pump shall continuously circulate Feed water in the

feed water tank across the Atmospheric deareator for mixing flash steam
with makeup water, condensate etc.
Raw Water Pumps
Requirement:
The pumps for transferring water from underground sump to OH water
tank, for water supply for steam generation, shall be supplied.
However, the bidder shall propose suitable pumps for these items to
match the actual duty requirement.
Duty:
The pump should be single stage, Horizontal, self-priming, end suction
coupled pump. The pump shall be CI casing with Bronze impeller
capable of delivering 30,000 L/Hr at 25 MWC (Pressure drop across
MGF may also be considered) (min.) with TEFC squirrel cage, degree
of protection IP 55 induction motor suitable for 3 phase, 415 V, 50 Hz.
AC supply. A common base frame of MS channel (100 x 50 mm) with
holding down bolts shall be provided for the motor and pump. A
suitable 18 G GI sheet shroud shall be supplied & installed for each
pump for protection against external weather conditions.
The pump duty is based on approximate site locations, valve, and

system resistance and is intended as a guide to facilitate biding. The
bidder shall, before execution, verify & decide duty requirements
against actual equipment and systems. Successful bidder shall be
responsible to ensure that the selection of pumps is based on Best
Efficiency Point (BEP) parameter on pump curve, to meet actual duty
requirements, for the least connected power. Details of the proposed
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revised pump duties shall be furnished to the Purchaser, and shall be
subject to approval.
Construction:
Pumps for specific services shall meet requirements:
The type of pump shall be End suction, base plate type, not close
coupled, with C.I. casing, bronze impeller, packed gland, and shaft
sleeve. The connections shall be flanged with Casing vent and drain.
Gland shall have drainage well. The Shaft shall be supported in deep
groove ball bearings. (Vertical pumps of Grundfoss /WILO may be
considered)
General:
The rotating parts of centrifugal pumps shall be dynamically balanced,
and pump shall run at 2900 rpm. Unless otherwise specified, drives
shall be direct, through flexible couplings of appropriate type and
rating. Coupling guards shall be fitted.
Motors:
Driving motors shall have continuous ratings in TEFC enclosure, F
class insulation with IP 55 protection & suitable rated motor for the
application. Pumps and motors shall be mounted on common base
frame, with alignment locating points factory established to ensure
correct positioning of motor when mounted on site. Motor for the pump
shall be energy efficiency type, as per IS 12615 – 2004 Eff 1, as per
below details
Motor Power Efficiency (%)

KW/ (HP) 2 Pole 4 Pole
5.5 (7.5 hp) 88.5 89.2
7.5 (10 hp) 89.5 90.1
INSTALLATION:
General:
Pump shall be installed as per manufacturer’s installation drawings.
The building Contractor employed by the Purchaser will construct
pump foundations as per requirements. Bidder shall provide drawings
for approval, showing all requirements for arrangement and
positioning, including holding down bolt pockets.
Suction:
To each water pump an isolation valve with suitable pot type strainer
with SS304 mesh shall be provided. Each pump shall have an
independent suction line complete with a foot valve with strainer. The
suction pipes shall be properly supported to enable maintenance of
foot valve. Pump gland wells shall be connected drain.
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Discharge:
To each water pump a vertical swing check (wafer type), isolation
valve (butterfly) shall be provided. The common discharge header shall
have 6” Dial type pressure gauge with 65 mm butterfly valve
connection for Overhead water tank & 2 nos. 25 mm ball valve
connections (spare). Discharge header shall be properly supported
Power:
Electrical power for the pumps shall be drawn from a power panel
located near the sump, provided by the purchaser. Cable from the
panel to each pump is included in the scope of work.
MULTIGRADE FILTER
Multi-grade Filter shall be placed in the raw water pump discharge line
to the OH tank. This unit shall be placed adjacent to the Raw water
pumps on the UG water sump (Or may be near the sump if not over
the sump) & shall be suitable to meet the pump discharge
requirements with regards capacity & head. Capacity: 30 KLPH
S. No Requirement Qty
1. Vertical in construction MS pressure vessel with inlet, 1 set
outlet connection, manhole on top & bottom, media
removal port, air release connection.
2. Set of internals for the above comprising raw water 1 set
distribution system , strainer plate, strainers, supporting
stays etc.
3. Initial charge of Filter media beds 1 Lot
4. 4” Inlet and outlet pressure gauges 1 set
5. Tank shall have MS lifting lugs & be supported on heavy 1 set
duty pipe legs welded on MS base plate
Note:
• Tank shall have Torispherical dish ends & joints have to have to be tested
for 100 % radiography.
• Surface preparation of the vessel: Sand blasting followed by epoxy
painting internally and synthetic enamel painting externally.
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• Vessel shall be pressure tested at Design pressure & tested at 1.5 times
Design pressure
7. WATER SOFTENING PLANT
FUNCTIONAL REQUIREMENT
The water softener up flow type (manual) & should be capable of

delivering 200 cu.m. per regeneration of soft water. Brief requirement
is indicated below;
S. No. Description Requirement

1. Output between regeneration (OBR) 200 cu.m.
2. Minimum flow rate required 15 KLPH
3. Regeneration Manually through brine injection
The entire regeneration sequence such as opening and closing of valves,

brine injection, beginning of next regeneration etc., shall be with manually
operated diaphragm valves.
DESIGN REQUIREMENT AND SCOPE OF SUPPLY:
S. No Requirement Qty
Vertical in construction MS pressure vessel with inlet, outlet 1 set
connection Manholes on top & bottom, resin charging and

1.
withdrawal connection with supports.
Set of internals for the above comprising raw water inlet distribution 1 set
2. system/brine distributor and bottom collecting system
Brine tank of HDPE construction to store and measure salt for 1 set
3.
regeneration of the softener complete with brine level indicator.
4. Set of mild steel flanged pipe work including regeneration piping 1set
Set of manually operated cast iron diaphragm valves for normal 1 set
5.
operation and regeneration
6. Manually operated brine injector 1 No
Magnetic type Water flow meter with Digital indications of Flow & 1 No
7. totalized flow, with provision for remote display of these
parameters.
8. Inlet and outlet sample valves 1 set
Raw water pump (Vertical pump may be considered) (1 W +1 S) 2 sets
9.
with base frame to suitable to deliver 15 KLPH (the flow should be
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sufficient during the back wash cycle of softening plant) at
required head. However, the rating of pump shall be decided by
the bidder based on site conditions. The pump shall be with MS
base frame, TEFC enclosure, IP 55 protected EFF1 motor. The
pump casing, gland, stuffing box shall be Cast Iron, shaft of cast
steel, shaft sleeve & impeller of bronze.
Initial charge of ion exchange resin for the softener vessel 1 Lot
10.
4” Inlet and outlet pressure gauges 1 set

11.
4” Pressure gauge for discharge of softener pump 1 No

12.
13. Hardness test kit 1 set

Drains from the softener shall be taken to the drain within or 1 set
14. outside the building.
Tank shall have MS lifting lugs & be supported on heavy duty pipe 1 set
15.
legs welded on MS base plate
Salt dissolving tank of suitable capacity in MS with FRP coating/ Epoxy

coating should be provided.
Note:
• The operation of the softener pump (working) shall be automatic based

on water level sensors placed in the soft water OH tank. However, Push
Button Station shall be available for operation on manual mode through a
Auto/manual selector switch. There shall be selector switch for selection
of softener pump.
• Tank shall have Torispherical dish ends & joints have to be have to be
tested for 100 % radiography.
• Surface preparation of the vessel: Sand blasting followed by epoxy
painting internally and synthetic enamel painting externally.
• Vessel shall be pressure tested at Design pressure & tested at 1.5 times
Design pressure
QUALITY OF RAW WATER:
The test results of raw water are furnished as under, but water shall be
tested in a Govt. approved lab by the bidder, before finalizing type of
softener.
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Raw water Analysis Report
Source of Water Borewell
Total Hardness 147.70 mg/l
Calcium Hardness 28.77 mg/l
Magnesium Hardness 18.45 mg/l
Alkalinity 592.29 mg/l
Dissolved soilds 953 mg/l
Chlorides 207.02 mg/l
Sulphates 56.20 mg/l
Nitrates 29.66 mg/l
QUALITY OF TREATED WATER:
S. No. Parameter Value

1. pH 7 - 7.5
2. Total suspended solids < 5 ppm
3. Total Hardness < 5 ppm
FEED WATER TANK (INSULATED) (CAP.: 20,000 L)
• Functional Requirement:
The tank would be used as buffer store for boiler feed water. The tank
shall also receive plant condensate, Flash steam, makeup water & have
an arrangement to deareate feed water, before it is drawn out for boilers.
• Design Requirement & Scope of Supply:

The tank shall be designed by the successful bidder as below
requirements.
S. No Description Requirements
1. Overall dimensions Vertical (Horizontal) cylinder with conical top, but
not more than 3.5m on any side.
2. Capacity 20,000 L
3. Constructional Covered, circular cross-section, insulated with
features welded construction having GI cladding.
4. Finish All welds should be ground smooth.
5. Body The tank shall be fabricated out of MS plate of
minimum 5 mm thickness with free standing
structure having stiffener & bottom support.
6. Insulation The entire tank shall be insulated with 50 mm thick
glass wool of thermal conductivity 0.029 Kcal/hr.M
DEG.CENT. and shall be retained with chicken
wire mesh and 2 mm GI sheet as cladding.
7. Manway 600 mm dia circular MS flanged air tight manway
at top with 6 mm thick counter flange with
minimum no. of quick opening bolts - 1 no.
8. Outlet 80 mm NB flanged with butterfly valve - 2 nos.
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9. Atmospheric Suitably sized head with provision to receive cold
deareator make up water, circulated water, condensate
return (50mm) , Flash steam, automatic air vent
connection complete with immersion tube with
perforations to enable proper mixing - 1 No.
10. Additional inlet 75 mm at ¾ full level with SS 304 ball float &
butterfly isolation valve for quick fill- 1 no.
11. Overflow 80 mm NB flanged with water seal, funnel &
connected to drain line - 1 no.
12. Level Indicator Guided SS 304 float connected to counter weight by
SS stranded wire. Wire counter weight shall be
threaded to gauge board.
13. Air vent 150 mm dia(min) vent head with baffles, SS
removable wire mesh - 2 no.
14. Drain Provision with drain cup with 65 mm bend with
butterfly valve – 1 set.
15. Heating A suitable sized port with a set of properly selected
arrangement Steam injectors with flanged inlet with piston
isolation valve.
16. Temperature Suitable provision for temperature sensor, pn.
control Operated piston valve with temperature
controller for suitable for steam.
17. Makeup water Connection at deareator head with suitable level
Control probes for pn. Operated makeup water utility valve
with level controller suitable for 100 Deg C water
18. Feed Water Suitable sized provision for feed water recirculation
circulation
19. Feed water pump Low Water level probe with Alarm & tripping of feed
control water pump.
20. Lifting Adequately sized Lifting lugs ( 4 Nos.), approach
arrangement & ladder, top railing, internal MS rungs for tank
approach inspection/ maintenance shall be provided .
21. Inside painting Sand blasting followed with two coats of heat
resistant epoxy primer followed by two coats of
heat resistant epoxy paint.
22. Outside paint One coat of heat resistant primer followed with
2 coats of heat resistant synthetic enamel
paint.
Note:
• The overflow & drain lines shall be connected & extended to the nearest
drain.
• Bidder shall submit a detailed GA dimensioned drawing along with the bid
& shall obtain approval before fabrication
• Stand-off for all connections on the tank shall be at least 150 mm from
cladding.
• Structural supports, platform, Trench covers, hand railing, staircase etc
for the Feed water Tank shall be included in the scope of work & the
bidder shall include this in structural item.
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CIRCULATION PUMP:
Circulation pump shall be of suitable capacity 3 phase, mono-block

centrifugal type with EEF1; TEFC motor with B class insulation suitable
for the Feed water conditions. The pump shall have SS body, SS impeller
with mechanical seal suitable for the application & shall be mounted on a
MS base frame. The circulation line shall have suction isolation ball valve,
strainer & NRV, isolation valve, Pressure gauge on the pump discharge.
The pipeline shall be properly supported with CI clamps to avoid vibration.
(Vertical pump may be considered)
WATER PIPES, VALVES & FITTINGS
Water piping would be GI ‘B’ class pipe of suitable sizes for desired flow
rate shall be complete with reducers, bends & accessories like isolating
valves, pressure gauges, check valves, strainers, water flow meter etc. as
required. All pump discharge header shall have a 6” Dial type pressure
gauge to read pressure with isolation cock.
Pipeline shall be fabricated through manual electric arc welding process

after due end preparation. Flanged joints provided at appropriate
locations for isolation / maintenance. If the water lines are taken
underground, HDPE pipes shall be used after excavation, sand bedding
as per best industry practices. The material of the HDPE pipe shall
correspond to PE 63 as per ISO -4427 & shall meet pressure grade of
PN-6.
For water line valves for sizes 40 mm & above shall be Butterfly type with
handle, MOC of cast iron body, single piece rubber-lined body wafer type,
with EPDM/nitrile seat & shall have PN10 rating. For sizes up to 40 mm
NB cast steel body Ball valves, in 3-part construction with SS working
parts, weldable end type to be used.
9. Non-return shall be wafer type swing check valves with integral hinge pin
with rubber O ring seat for ambient water & PTFE seat for hot water and
SS working parts shall be selected & shall have PN10 (min) rating. Pot
strainer with CI body with SS304 perforated sheet strainer of suitable size
shall be provided for each pump.
Foot Valves are also to be provided for the pumps to be installed on the
sump Specifications to be mentioned
The scope of supply also includes all necessary supporting structure
required for raw & soft water piping. CI pipe clamps shall be used for
supporting water piping.
The feed water lines shall be separate for individual boilers & shall be
insulated with Glass-wool & cladded with 22 G plain Aluminium sheets.
The water flow meter shall have the same specification as steam flow
meter.
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Please note: Separate Water flow meter shall be provided in the Feed
water pump discharge line for each of the Boiler. Hence 2 Nos water flow
meters required. The Flow meter shall have remote display unit mounted
on the control panel with open protocol connectivity for data transfer to
the central MIS system.
6.4.5 ASH REMOVAL:
Bottom ash removal shall be done from the various ash points in the
Boiler & fluidizing box, bag filter, MDC etc. Damper for the fluidizing bed
shall be opened manually, depending on increase of plenum air pressure.
6.4.6 AUTOMATION:
All automation required for the automatic operation of the boiler from the
Boiler Control panel shall be included in the scope. All controls, safeties
for efficient operation of equipments in the scope of supply shall be
considered by the bidder.
Details of automation may be mentioned.
Single element drum level controller.

High pressure cut-out
High flue gas temperature cut-outs
Temperature of boiler feed water
Inlet air temperature to APH
Outlet air temp from APH
Flue gas inlet temp in APH
Flue gas outlet temp from APH
Draft of furnace
Etc
The measuring instruments for steam & water flow, temperature, fuel
utilization measurement etc., shall have local as well as remote display
indicators on Boiler control panel. The indicators on the panel shall be of
same make. However, it shall be possible to transfer important plant
performance parameters of individual boilers, to the Centralized PLC
(located in the Cattle Feed Main plant), through a universal protocol, for
totalized & current flow/consumption. These parameters are as under for
individual boilers;
1. Steam generation,
2. Water consumption,
3. Fuel consumption,
4. Energy consumption
The Boiler Control panels (MCC not the control panel) shall have energy
manager to capture, & transmit energy consumptions related to each of
the Boilers. All indications on the Boiler panels shall be digital.
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The Power panel (Motor Control Centre) shall be a standard
compartmentalized panel construction, instead of Intelligent Motor Control
Centre. All switchgears in the scope of supply shall be housed in the
MCC. The incomer shall have an Energy monitor (load manager), which
would capture overall energy utilization for the entire plant & have the
facility to transmit the data.
The incomer of the MCC shall be suitable 4 poles MCCB instead of ACB
depending on the connected electrical load. Feeders for Raw water, soft
water pumps, panel room AC & the other electrical loads in the scope of
the tender, shall be considered in the MCC.
Automation system shall include all hardware including instruments,

panels, network cabling, PLC & associated computer with software. The
system shall integrate all information from field & logically control the
operations to achieve best performance & efficiency. The PLC shall be
integratable to the Main PLC for the entire plant & shall have a universal
protocol. Automation consists of the following major requirements;
1. Fuel handling & feeding to the Boiler including VFD for the Rotary feeder
controlled by the feedback received from steam pressure transmitter. Fuel
rate measurement & display of direct efficiency is included in the scope.
2. Combustion Control system consisting of steam pressure indicator cum
controller, pressure Transmitter, PID Controller, Three way manifold,
Pneumatic actuators for FD fans, to maintain constant steam pressure &
steam quality.
3. Furnace draft control system consisting of pneumatic damper & controller
for primary air requirement, furnace draft transmitter, PID controller, VFD
for ID fan for accurate control of excess air.
4. Bed temperature control system for fuel cut–off or on with controller &
temperature indicator.
5. Online indicator & measurement of efficiency through direct method by
integrating inputs from feeder i.e. the fuel fed into the Boiler & from steam
flow meter for steam generated.
6. Online analyzer shall be installed in the Flue gas line to monitor
combustion efficiency & automatically adjust the inlet FD air quantity, PA
& ID fans for achieving complete combustion with least amount of excess
air.
7. Single element Drum control comprising of pneumatically controlled valve
for Feed water regulation into the Boiler, with the help of level transmitter
installed on Boiler Drum, including by-pass valve for the control valve,
feed water spill back line, three valve manifolds for the transmitter,
condensate pot assembly, isolation valves etc.
8. A direct efficiency monitor to record display and print the fuel feeding rate
& the steam generation rate, so as to compute the direct efficiency, S/F
ratios etc, shall be installed near the boiler. The monitor shall also pick
132
critical parameters like feed water temperature, steam pressure, flue gas
exit temperatures.
CONTROL PANEL, INCLUDING PLC AND TOUCH SCREEN HMI
A Programmable Logical Controller (PLC) to control the process. The

PLC should be mounted on a durable control panel. The visualization
system should give the operator a quick overview of the major process
values of the installation. Furthermore, it should allow showing the text-
based alarm messages. Before shipment, the control system should be
completely tested in order to have a trouble-free start-up on site. The
control system shall have the following major functions:
• Continuous monitoring of the major process values (temperatures,

oxygen level, pressures.)
• Continuous monitoring of the electrical parameters of each boiler.
• An automated process control for an optimal energy plant operation
• A continuous safety control of the equipment (and the personnel)
• Continuous alarm feedback
• SCADA system for visualization and online efficiency monitoring system
and measuring of the following parameters:
• Stack loss, Enthalpy loss etc.
• Steam Flow Trends.
• Water flow trends
• Compressed Air pressure & flow trends
• Low pressure steam in Main plant
• Draft Pressure
• Air Damper Positions
• Fuel firing rate & trends
• Steam to fuel ratios
• All trends and graphs for all other important parameters.
The control panel shall have the following
A. Power section:
1 Set Main switches and further for each motor:

Incl. a Motor Protection circuit breaker (MPCB) for SC protection
Incl. an indicator lamp for ON, OFF and trip status
Incl. Intelligent Motor protections relay (IMPR) which should include an
automatic thermal overload switch (for protection against abnormally high
current)
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B. Regulation and safety equipment:
1 Set the regulation and control of the installation shall be by a Siemens

S7-300 series / Equivalent PLC to monitor total electrical parameters
Incl. all regulation and safety equipment:
Incl. under pressure regulation, including an under pressure detector
Incl. Modulating capacity regulation
Incl. Water level controller (1 point control)
Incl. Continuous oxygen measurement and display on the control panel
Network Hardware
Ethernet cable / Fibre Optic cable – 1 Lot

Field run bus / similar bus cable – 1 Lot
ASI bus cable for valves – 1 lot
Switches – As required Interfacing Units for third party devices /
instruments etc. – 1 Lot
Remote I/Os complete with communication & power unit – 1 Lot
Hardware based security device – 1 Lot
The system shall have a redundant I/O panel power supply unit
Other hardware – as per requirement
The hardware units shall be installed inside suitable wall / rack mounted
water tight cabinets.
All other hardware/software required for communication with plant
SCADA and MIS server – 1 Lot
Accessories
All junction boxes / distribution boxes for control / instrumentation system

shall be in SS-304 / Cast Aluminium construction. Instrumentation / signal
cables / wires shall be laid in separate cable tray so as to avoid any
interference.
System Software
The system software will be based on open architecture / protocol. It shall

be latest object oriented software, which result in fully scalable system.
Original license version of the latest release of software shall be used.
The system shall use Fibre optics as backbone.
Software
This shall be based on software of open architecture / protocol. Following

minimum reports are envisaged from the system. Necessary forms to be
developed on the networked PC’s for entering the data. All the reports
shall be developed after the discussion with the customer. However,
following minimum reports are to be considered for development.
Fuel storage, feeding reports.

Boiler-wise steam generation report
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Water consumption report
Boiler-wise efficiency report
All equipment hourly log report
CONTROL PHILOSOPHY
The bidder may propose a brief control philosophy along with the
quotation. However, the control philosophy would be actually finalized
during detailed engineering.
General
All equipment, system and accessories furnished shall be from latest

proven product range of established / reputed manufacturers and shall
conform to applicable national and international standards.
The design of various control systems and related equipment shall

adhere to the principle of failsafe operation implying that loss of signal,
loss of power supply or failure of any component will not lead to
hazardous conditions / product losses, while at the same time, prevent
occurrence of false and unrelated trips.
Climatic Condition
The instruments / control system shall be suitable for environmental

conditions that are normally encountered in western part of India. All
equipment / system / sub-system etc. shall be fully tropicalized
accordingly.
Ambient Temp. 55 deg. C.
Relative humidity – 95% at <55 deg. C.
System power supply condition
For applications requiring AC power, 240 V AC, 50 Hz uninterrupted

power supply shall be made available by bidder from UPS (3 phase)
complete with a common servo stabilizer. The UPS battery bank may be
common. In case of power failure, the UPS (3 phase) should be capable
of delivering power for min. 30 minutes to control / instrumentation system
including valve actuation power. The UPS shall have a static by-pass
switch. Necessary filters should be considered to protect the system from
harmonics, which may be generated in the UPS.
12/24 V DC power supply shall be used wherever applicable for Control

System and will be derived from the UPS. Any other voltage level
required for the system shall also be the responsibility of the Bidder along
with all required hardware. DC voltage system for Main CPU & all I/O
stations / panels shall be with dual channel & kept separate for different
step downs as per requirement. Each filed I/O stations shall have
separate voltage step down / standard power converter module system
from 220V AC to duel channel 12/24 V DC to meet the requirement.
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Control & Instrument (C&I) equipment furnished shall incorporate
necessary techniques for protection against electrostatic discharge and
radio frequency interface, as per international codes and standards.
Safety earthing and C&I System earthing shall be separate. Safety earth
bus shall be connected to main plant earth pit. Separate earth pits shall
be provided for system earth bus (electronic earth). Electronic earth shall
be cabled directly to the corresponding earth bar. The earthing for
automation / C&I system shall be of copper only. All instruments shall
have clear access for maintenance, removal, lay-down, calibration etc.
The sensors & display units should be separate. All readable instruments
shall be clearly visible unassisted.
Portable SS access ladder with platform shall be provided for easy

access of instruments, valves and actuators.
All prefabricated plugged cables, power supply cable for Bidder’s System.
System Cabinet, Marshalling Cabinet and Power Supply Cabinet to fulfil

the system requirement.
Power Distribution Cabinet for extension of power supply to field

instruments.
SINGLE ELEMENT DRUM LEVEL CONTROL SYSTEM
The feed water level should be controlled through a proportional signal or

process variable (PV) coming from the drum level transmitter. This signal
is compared to a set point and the difference is a deviation value. This
signal is acted upon by the controller which generates corrective action in
the form of a proportional output. The output is then passed to the boiler
feed water valve, which then adjusts the level of feed water flow into the
boiler drum The single Element Drum Level Control System shall consist
of the following:
• Differential Pressure Transmitter

• Isolation valve
• Condensing Pot
• Control Valve
• Controller
• Piston Valves
• Piping & Hardware
6.4.7 AIR POLLUTION CONTROL EQUIPMENTS
Pollution control equipments shall be installed to meet the local pollution

Control norms (GPCB) which are as under;
Parameters Unit Levels

136
SPM level mg/Nm³ < 150
SOx mg/Nm³ 100
NOx ppm 50
However, if there are revisions on the local pollution Control norms, the
bidder shall comply with the latest applicable norms.
1) BAG FILTER (PULSE-JET TYPE)
The dusty flue gas coming out of the Boiler should be routed through the
Bag filter before they pass to the chimney.
Bag filter shall separate fly ash from the exhaust flue gases of the Boilers
to meet the pollution Control norms. The Bag filter with parallel MDC shall
be common for both Boilers (one planned and one future). The entire unit
shall be insulated with 75 mm thk mineral wool & cladded with 24 SWG
aluminium cladding. The filter material (nomex / ryton bags) shall be able
to withstand a temperature of 220 Deg C .The casing of the bag filter shall
be fabricated from 3 mm MS sheet. Perforated sheets shall be placed at
both sides of the inlet to filter courser particles. Cages for the filter shall
be made of special wires to withstand high temperature. Required no. of
hoppers shall be provided with 70 deg plate angle with access doors.
Hoppers shall end with a rotary airlock valve driven by a geared motor.
Venturi for cleaning operation of bags shall be of Cast iron MOC. Air
solenoid valves shall be operated for pulsing compressed air for bag
cleaning & shall be sequential timer controlled. Supporting structures,
hand rails, ladder for the bag filter shall be provided along with the unit.
Inlet cum by-pass damper (pneumatically operated) shall be provided to
by-pass unit at higher temperatures & during start up.
Instrumentation:
1. Hopper with thermostat controlled heater for flowability.

2. Differential pressure switch for on-demand filter bag cleaning.
3. Temperature indicator with controller for by-pass operation.
4. Sequential controller for pulsing bag for cleaning.
5. Limit switches for damper, for indication of Bag filter On-OFF position.
6. Pressure switch for control of air supply.
The unit shall come with fittings like Air pressure gauges, air filter with
drain valve arrangement, pneumatic cylinder etc.
While in operation, the emission limit for Suspended Particulate Matter
from stack shall be restricted to 150mg/ Nm3 level or latest GPCB norms.
137
In case the flue gas temperatures rise above a pre-set value. The RTD
based pneumatically operated control valve will bypass the flue gases
through the Mechanical Dust Collector.
2) MECHANICAL DUST COLLECTOR
Mechanical dust collector shall comprise of steel structure housing the

high efficiency insulated cyclone / multi-cone separator with air-tight
rotary air lock with operating handle, for efficient removal of fines from the
flue gases. The rotary airlock valve shall be driven by geared motor. The
entire unit shall be insulated. This will be installed in parallel to the Bag
filter & shall be operated in the by-pass mode of Bag filter. MDC should
consist of:
• Collection Tube
• Outlet or Discharge tube
• Inlet Guide Vanes
• Dust Discharge Boot
• The dust laden flue gases enter the MDC and then inside the collection
tube. At the entry of the collection tubes the inlet guide vanes guide the
path of the gases.
6.4.8 Boiler mountings, accessories, tools:
The boiler should have all necessary standard mounting, accessories,

and tools for safe and efficient operation of the boiler and in accordance
with the latest IBR regulations. The boiler shall have all the components
as listed below. It will be the bidder’s responsibility to indicate any
components not listed in this specification but required as per the
statutory regulations. Price considered for all such additional components
/ items shall be furnished item wise separately in their offer. It will be the
successful bidder's responsibility to provide any components / items not
appearing in the list, nor additionally listed by the bidder in their offer and
the same are found to be required as per the statutory regulations.
Successful bidder shall provide such additional components / items within
the scope of the work and no additional cost will be considered for the
same. List of the major mountings, accessories, tools to be supplied with
the boiler are;
Sr. Description Qty.

No
1 Spring loaded full lift type safety valve having a total discharge 02 sets
rate exceeding the maximum steam producing capacity of boiler
with exhaust pipe to discharge outside the boiler house.
2 Front casing and rear casing for shell with hinged door 01 set
3 Membrane panel complete with 3 side wall tubes, headers, with 01 set
end connections
4 Membrane panel drain connection 01 set
5 Combustion and setting chamber complete with bed materials 01 set
6 Plenum chamber complete with distribution plate and fuel 01 set
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materials
7 Ash removal ports, ducting with sliding gate 01 set
8 Main steam stop valve with counter flange 01 set
9 Shell blow down connection for automatic blow-down system with 01 set
necessary pipes, fittings up to blow-down pit located outside the
boiler house
10 Blow down connection for in-bed tubes with valve 01 set
11 Steam pressure gauge of minimum size 200 mm dia (IBR 01 set
certified) with siphon tube and cock.
12 Steam connection with isolating valve for fixing test pressure 01 set
gauge and for removal of air
13 Water level sight glasses with safety shields and isolating valves 02 sets
and drain valves connected to a drain line up to blow down pit
14 Magnetic water level controller (heavy duty) mobrey type for high, 02 sets
low and extra low water level alarms with isolating valve and
drain valves connected to a drain pipe up to blow down pit
15 Port for single element level controller 01 set
16 Hinged type rear access with flame observation port/fire view 01 No
glass with blue tint colour glass/plain glass
17 Access ladder, top walkway platform complete with pipe railings 01 set
18 Rigid MS base frame, MS supporting structure, lifting lugs, 01 set
saddles etc. (for shell and furnace etc.)
19 Fusible plug 01 set
20 Steam pressure switch for audio alarm and ID fan cut-off 01 No
21 Flue gas temperature sensor with indicator (digital type) 01 No
22 Boiler nameplate 01 No
23 Refractory and insulation works including fire bricks, fire cement, 01 set
lining, mineral wool insulation and cladding etc
24 Feed water pumps with discharge lines, valves and fittings to the 02 Nos
shell
25 Induces draft fan complete with gear box motor, damper, 01 set
supporting base-frame, structure
26 Forced draft fan complete with gear box motor, damper, 01 set
supporting base frame, structure
27 Booster fan for under bed fuel feeding complete with gear box 01 set
motor, damper, base frame, structure
28 Air preheater complete with controls and dampers 01 set
29 Pollution control equipment including bag filters, MDC etc. 01 set
30 Boiler controls including IMCC, control panel, direct efficiency 01 set
monitor etc.
31 Tools comprising of a set of essential tools, shovel for ash 01 set
suitable for length, set of spanners, tube cleaning burshes, etc.
32 Essential spares for 2 years normal operation 01 set
Important note: Recommended Spares for 2 year operation is included in

the scope of supply & shall be included in the costing of the Boiler. List of
essential spares & wear parts like temperature sensors, pressure gauges,
draft gauges, pneumatic cylinders, gates, geared motors, solenoid valves,
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bearing, coupling, seals, O rings, gaskets & other essential components,
with quantity, for 2 year trouble-free operation shall be attached with the
quotation. The bidders should quote their rates with the quantity break-up
for essential spares considering normal operation of the plant for two
years. All spare components shall be duly quantified and included in the
offer with price break-up for each of the spare components. Following in
brief are few essential components which are to be quoted.
a) Boiler tubes - minimum 2% of the total tubes.
b) Other accessories which are not listed above but are required for
normal functioning of the boiler for two years of operation.
It may please be noted that, any spares required during start-up and
commissioning of the boiler and all its associated equipment, the same
shall be deemed to be included in the quoted price of the steam raising
plant.
6.4.9 BOILER AUXILLARIES
1. Ducting & Equipments
FLUE GAS DUCTING

Flue gases from the Outlet of boiler shall be separately taken across
separate Air pre-heater & shall be connected to common Pollution Control
equipment.
Flue gas ducting shall be suitable to receive and convey flue gases
across the Mechanical dust collector, ID Fan from individual Boilers. MS
ducting between the chimney & Boiler shall be fabricated from MS sheet
of minimum 4 mm thickness & shall be designed for a peak flue gas
velocity of 14 to 16 m/s. fabricated ducting segments shall be welded to
each other and suitably supported within the Boiler House. The flue gas
ducting shall be insulated with 50mm thk glass wool insulation with 24 G
Al. Sheet cladding & shall be connected to the chimney though a pair of
flanges. The Main Flue gas ducting shall be connected to the pollution
Control equipment, ID fan & shall have an expansion bellow. It is
desirable to have Flue gas ducting from Boilers connected to the chimney
separately.
AIR PRE-HEATER
Air pre-heater consists of pre-heater blocks with tubes & tube sheets. The
pre-heater casing shall have stiffeners & shall be fully insulated. Suitable
erosion allowance shall be provided at entry level of pre-heater tubes.
Carbon steel tubes shall be provided in the cold suction.
AIR DUCTING
Air ducting shall be suitable to receive and convey air across the Air
preheated, FD Fan & shall be dedicated for Boiler. MS ducting between
the FD Fan & Boiler shall be fabricated from MS sheet of minimum
3.15mm thickness & shall be designed for a peak velocity of 14 to 16 m/s.
Fabricated ducting segments shall be welded to each other and suitably
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supported within the Boiler House. The flue gas ducting shall be insulated
with 50mm thk glass wool insulation with 24 G Al. Sheet cladding
Sr. No. Velocity Profile Required Velocity Profile

1 Fluidizing bed (m/s) 2.0 – 2.5 m/s
2 Furnace (m/s) 2.0 – 2.5 m/s
3 Boiler bank (m/s) 5.0 – 9.5 m/s
4 Air preheater (m/s) 9.0 – 11.0 m/s
2. Chimney
Chimney shall be suitable to receive and convey flue gases from Boiler.
Though one boiler is sufficient for the designed capacity of the feed plant
& Chimney shall be designed for conveying flue gases of both (one
planned and one future) boilers.
The chimney for the boilers shall be of self supporting type, made out of
mild steel sheets of suitable thickness. The steel plates and sections used
in construction of the chimney along with other materials such as rivets,
bolts, nuts, washers, gaskets including all consumables like welding rods
etc., should conform to the relevant IS. The corrosion allowance for
thickness (3 mm min.) of chimney should be considered for minimum of
20 years life. The chimney height shall be as per the Pollution Control
Board's regulation. The design and construction of the chimney shall be
conforming to IS: 6533 - Part 1 & 2 - 1989.
While calculating the load on the chimney the following shall be

considered:
1) Dead load considering the weights of the chimney shell and permanent
fixtures such as ladders with protection cage, platforms with railings,
baffles, helical strakes, flanges, fasteners and all accessories.
2) The imposed load of minimum 1000Kg/sq.m shall be on the sampling
platform.
3) Wind loads in accordance with the provisions contained in IS 875 (part 3)
1987. The wind load force on the ladders and other fixtures and
accessories fixed to the chimney shall also be determined and added to
the force on the chimney.
4) Earthquake loads in accordance to IS 1893: 1975. The chimney design
and the foundation design for the chimney shall be determined by
considering the maximum forces, effects and stress calculated from
combination of any of the following combinations.
• Dead load + wind load

• Dead load + earthquake load
• Dead load + load due to the lining + imposed load on service platforms +
wind load
• Dead load + load due to the lining + imposed load on service platforms +
earthquake load
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The chimney should consist of all the accessories and the minimum
requirement of few are as follows:
• Base plate with gussets plate (minimum thickness of 12 mm) and base
stool.
• Inspection door with minimum size of 500 W x 800 W shall be provided.
The door shall have handles and all associated accessories. The cut-out
made on the chimney should have stiffeners of not less than 50 x 50 x 6
mm angles welded on the periphery of the cut-out in the chimney.
• Access ladder with protection cage: The ladder should start base of the
chimney and it should be up to the top of the chimney. The ladder shall
be supported from the chimney with structural members of not less than
50 x 50 x 6 mm ISA and the ladder rung should be located at a distance
of 250 mm from the chimney. The ladder rung should be made of 20 mm
dia rod, the width of the rung should be of minimum 400mm and the
ladder step should be at a frequency of 200 mm C/C. Safety enclosure or
cage shall be provided for the ladder from 3m to the top.
• Platform for flue gas sampling and inspection: The platform width should
be not less than 800mm and should have 1000mm high railings, one
additional support shall be provided in the middle of the railings, toe guard
support shall be provided at the bottom of the railing. There should be
suitable arrangement in the platform for draining out the rain water.
Sampling port shall be provided for flue gas sample analysis as per the
PCB regulation.
• Painter's trolley.
• Conical cowl with cowl stays: The minimum cowl diameter should be 1.5
times the diameter of the top of the chimney section.
• Twin aviation lights and warning lights: Aviation obstruction light fixture
shall be made of Aluminium alloy casing with separate galleries to house
a set of two 40 watts (minimum) LED lamps. The lamp fixture shall have
suitable red domes on the galleries and the lamp fixture shall be of
reputed make. Aviation obstruction light point should be connected up to
the IP 55 grade of protection Cast aluminium junction box installed at the
base on the chimney with 3C x 2.5 sq.mm., PVC sheathed, PVC
insulated copper cable. The circuit cable shall be run on the rigid PVC
conduit, 2mm thick and shall be fixed on the chimney surface with
suitable saddles and clamps mounted on the epoxy based insulators.
• Lightening arrestor: Lightening arrestor should be of copper with minimum
5 prongs, the lightening arrestor should be connected to two earth
stations. The earthing conductor should be of size should not less than GI
25 x 6 mm / or of equivalent size and conductor material as approved by
the local statutory authorities. The earthing conductor should be mounted
on the epoxy based insulators and not directly fixed to the chimney
surface. Two earthing conductor should run parallel from the lightening
arrestor and each connected to the independent earth stations. The earth
stations in turn should be interconnected with one another.
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• The earth station should be of GI plate conductor and constructed as per
IS 3043 latest edition. The earth station should be complete with
excavation, filling with charcoal / salt, watering pipe, funnel, earthing
conductor, test link, 350x350 mm CI hinged cover with frame complete
with all masonry works.
• Flue gas inlet: Flue gas ducting is separately specified. The cut-out made
on the chimney should have stiffeners of not less than 50 x 50 x 6 mm
angles welded on the periphery of the cut-out. The opening made on the
chimney for the flue gas duct should be extended by 200 to 1000mm and
terminated on counter flanges to facilitate connection of the ducting on
the chimney.
• Helical strakes to reduce wind excited oscillations for the top 2/3rd height
of the chimney.
• Chimney bottom should be insulated up to 3 M height by 50 mm white
mineral wool followed by cladding with 3 mm MS sheet. MS sheet
cladding should be of butt welded construction.
• All MS parts of the chimney shall be given initial surface treatment
including degreasing, de-rusting etc., followed by a coat of primer. The
chimney should be finally painted with two coats of suitable heat resistant
paint.
• Foundation bolt of adequate length and diameter (min 40 mm) shall be
provided along with the anchoring channel of section ISMC 150 on the
bolt base. Template shall be provided by the successful bidder suitable
for the foundation bolts for casting the chimney foundation.
3. Support Structure, trench covers & Platform
All general purpose Structural steel shall be conform for physical &
chemical composition as per IS 2062 Grade A (of latest revision).
Nominal Dimensions of rolled steel
Shall conform to IS 808 -- for Beams, columns, Channels, Angles.
Shall conform to IS 1730 -- for Plates, strips, flats.
Shall conform to IS 3954 -- for Channel sections.
Shall conform to IS 1239 -- for pipes.
The structure shall be welded type consisting of suitable steel structure
having columns, Ì' beams, channels, angles, plates, foundation bolts etc.
Platform shall be fabricated from 5 mm thick steel chequered plates
suitably stiffened.
Necessary MS `B' class pipe NB 32 mm railing to be provided wherever
required. Complete steel structure to be painted with two coats of Red-
oxide Zinc Chromate primer and then 2 coats of synthetic enamel paint.
Note: For sections below 100mm, re-rolled sections shall be acceptable; if

they meet the respective IS with regards dimension & weight. All sections
above 100mm shall be supplied from one of the preferred makes
indicated at the end of this specification.
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4. ELECTRICALS
Electrical distribution system shall be suitable to operate, control and

maintain all the parameters required for receiving the Fuel & handling up
to Boiler and for all operations of the Boiler, to meet steam demand for
feed manufacture for the 800 MTPD Cattle Feed Plant.
Intelligent Motor Control Centre (IMCC) with required number of feeders

complete with switchgears, push buttons and indications, auto-manual
selection switches and facility to operate and control electrical motors etc.
through central control room SCADA, remote controlled push button
stations etc. as per the requirement of the plant & equipment shall be
provided for effective and safe operation of the Plant.
Power shall be made available in an outgoing feeder in the PCC located

close to the Boiler House. The successful bidder shall lay suitable cables
from the PCC up to the incomer of the IMCC, for further distribution.
The intelligent panel shall house all power feeders for both boilers, for all
equipments in the scope of supply. Apart from this the 20 % spare
feeders based on KW rating shall be provided in the panel, for other
power driven equipments located in & nearby boiler house. Power
feeders of 30 HP & above shall have a suitable capacitor connected in
parallel & shall be a part of the Power panel.
A separate PLC panel, Boiler control panel housing annunciation &

controls for boiler shall be in the supply scope. The communication
between the IMCC with PLC, Boiler Control panel, shall be through
suitable communication network cable. The bidder shall include computer
with printer, UPS, Computer furniture, split type AC for the Control room.
Required quantity of braided copper / armoured aluminium & copper

power cable, copper control cable, instrument cable, GI perforated trays,
plate type earth pit, earthing network, earthing conductors, load break
Isolators with plug & sockets / junction boxes, (or Push Button stations for
Soft starter started motors) near motors for emergency isolation and
controls, rubber mats for panels, lockable push button at each floor for
emergency stop etc. shall also be provided.
The sizes of power cables for different capacity of loads / motor rating
shall be as indicated in cable selection charts. All the power & control
cables shall be laid through perforated GI cable trays and drop conduits.
GI shrouds for all pumps & motors shall be provided wherever located
outside the buildings.
Supply & placement of electrical grade rubber mats / sock proof paint of
proper size as per the Gujarat State Electrical Inspectorate rules shall be
provided.
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Power Cables shall be braided copper conductor cable for motors of all
ratings.
All cables between the outgoing feeders in MCC and plug & socket with
isolator or junction boxes near motors shall be of copper / aluminium
conductor as above. Connection from plug & socket isolator or junction
boxes to motor junction boxes shall be with PVC insulated flexible copper
cable in suitable PVC steel ribbed conduit.
The electrical LT distribution system specification is detailed below.
INTELLIGENT MOTOR CONTROL CENTRE (IMCC)
The IMCC shall be suitable for indoor installation in the wardrobe

construction for compact configuration with provision for expansion. The
motor control centre shall be completely dust & vermin proof conforming
to IP 44 standard. The bus bar rating of each MCC shall be capable of
carrying 1.25 times of full load current of all the feeders of respective
MCC plus spare feeders’ load and future load of the plant as described in
the design basis.
The Incomer of each IMCC shall have 4 poles EDO, ACB of suitable
rating / Type with built in solid state / Microprocessor based protective
devices / relays with all accessories. Also the Incomer shall have 3-phase
4-wire energy meter with necessary Indications, Voltmeter, and Ammeter
with selector switches and CT's and phase Indication lamps. Load
Manager shall be provided in each MCC for monitoring power condition
and energy consumption through system automation being provided for
the feed plant. (Energy meter should have bus communication facility for
MIS purpose)
For Incomer of the panel, the rating of the switchgear shall be 1.25 times
of rated full load current of connected load (including spare feeders’ load
and future expansion load as described in design basis) of the panel. The
necessary feeders complete with switchgears for future expansion shall
be provided in the IMCCs as detailed in the specifications. The outgoing
cables from the MCCs in the electrical control room shall be laid in cable
trays. Cable entry & exit for all the feeders of MCC shall be from the top.
The cables going to plant equipment shall be laid in cable trays on pipe
rack.
The MCCs would receive, control & distribute electrical power at 440 V,
50 Hz AC to all electrical loads to be connected in the various sections of
the plant.
One no of 100 A TPN MCCB unit for welding receptacle shall be provided
at appropriate location.
All outgoing feeders shall have isolation facilities in the IMCC using
MPCB (or MCCB as specified). Motor feeders shall include contactors,
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overload protection through intelligent relay & necessary operating
controls. All VFD and soft starter also shall have communication facility.
All motor feeders will have Soft Starters or VFD.
Variable Frequency Drive (VFD) unit will be provided for a motor feeder
wherever speed control is required. Intelligent motor protection relay
(intelligent controller) shall have minimum 4 nos. digital inputs & 2 no.
digital outputs.
Providing & laying power cables of suitable rating and no. of runs
(considering load of future expansion) from PCC in electric substation to
IMCC under this package is included in the scope of bidder. These cables
shall be aluminium armoured cables and should be laid in
trench/underground/pipe-bridge/cable trays between PCC to Boiler House
as decided by site requirements.
The quantity of IMCC shall be as decided by the plant load requirements

and design of the bidder with the available switch board room. As
indicated above the MCCs shall have power monitoring system to be
hooked up with automation system through field bus for online monitoring
of power from operating station.
In view of no. of soft starters and VFDs, the system should have
safeguards against all harmonics. The total harmonic distortion produced
/ generated in the plant shall be analyzed and suitable harmonic filter
shall be provided as required to limit the THD within the IEC
recommended guidelines.
FUNCTIONAL REQUIREMENTS:
To receive, control and distribute electrical power at 440 V, 50 Hz, AC in

sheet steel housing and communicate real time operating parameters to
Main PLC Panel. The specifications describe the requirements for the low
voltage intelligent motor control centre (IMCC) which shall fundamentally
provide for the following:
Achieve controls through microprocessor based systems

Replace hardwiring by using network technology
Provide enhanced degree of diagnostic and protective functions.
The IMCC shall provide comprehensive protection on motors by
integrating intelligent motor protection relays (IMPR) or intelligent
protection devices (IPD) inside the switchboard. The IMCC should also
bundle the bus communication with the most common protocols found in
the industrial networks (Modbus SL / Modbus TCP / Profibus DP /
DeviceNet).
Operating temperatures -40˚ C/+75˚ C.
146
Design Requirement and Scope of Supply
(i) Statutory Requirements:

Motor Control Centre is to be manufactured / assembled as per the latest
applicable Indian Standards, Indian Electricity Rules, Indian Electricity
Act, Fire Insurance Regulations and comply with all currently applicable
statutory requirements of concerned State Electricity Inspectorate and
safety codes in the locality where the equipment will be installed and as
per the detailed specifications mentioned below. The manufacturer of the
panel must possess a type test certificate from CPRI.
The major board components and intelligent devices used in the IMCC
should be of an international company (like ABB/ Schneider/ SIEMENS/
Rockwell). The IMCC should provide the flexibility to choose different
solutions in motor protection and monitoring functions according to the
requirements of the plant.
(ii) Housing Details:
(ii-a) The switchboard shall be fabricated using pressed and shaped cold
rolled steel sections structure of adequate thickness. The sheet steel
used for panel shall be minimum 14 SWG sheet except that the partition
plates, inter-panel barriers and cubical doors may be made of 16 SWG.
The switchboard shall consist of free standing front and back open able
panels arranged to form a continuous line-up of wardrobe type cubicles of
uniform height. Cold rolled sheets shall be used for doors and front
covers. Front doors shall be hinged type with quarter turn fasteners and
bus bars and cable alleys covers shall be bolted type. Each ward robe
type cubicle shall house 8 to 9 feeders or as per design requirement of
shipping lengths.
(ii-b) Switch Board shall be extensible at both the ends by addition of vertical
sections. Ends of the bus bars shall be suitably drilled for this purpose.
Panels at extreme ends shall have openings, which shall be covered with
plates screwed to the panel. The switchboard shall be provided with
integral base frame channel painted black. The cable gland plate shall be
2.5 mm thick.
(ii-c) The switchboard shall be totally enclosed, dust, weather and vermin
proof and shall conform to degree of protection not less than IP 44 as per
IS 2147. Gaskets of durable material shall be provided all round the
perimeter of adjacent panel, panel and base frame, removable covers,
doors and other openings.
(ii-d) All hardware shall be corrosion resistant. All joints and connections
shall be made by galvanized zinc passivated or cadmium plated high
tensile strength steel bolts & nuts. Spring washers shall be provided to
secure against loosening.
(ii-e) The switchboard shall be non-draw out wardrobe type design except
for the individual ACB cubicles used if any for incoming, outgoing and bus
147
coupler. Each wardrobe shall contain 8 to 9 feeder components as per
design. The IMCC shall be suitable for indoor installation. Suitable cable
& bus bar alleys shall be provided if required. All components of the
switchboard shall generally be approachable from front. However, IMCC
can be in double front execution also if specifically asked for or is required
as per site requirements. The maximum and minimum operating handle /
push button height of any feeder shall not be more than 1900 mm or less
than 300 mm with reference to panel bottom. The total height of panel
shall not exceed 2300 mm. Supporting arrangement and saddles for
dressing of power and control cables shall be provided. Maximum
shipping length of MCC shall be 2500 mm. Each shipping section shall be
provided with suitable lifting hooks. These hooks when removed shall not
leave any opening in the board. Minimum depth of cubicle for ACB shall
be 1000 mm and minimum width of cable and bus bar alleys shall be 300
mm. Space heaters with toggle switches, fuses and thermostat shall be
provided in each cable alley. Cabinet fans with filter kits (120 mm), 2 feet
cabinet lights, protective SP MCBs and door limit switches are the other
general IMCC components to be provided.
(ii-f) Internal arc features: The switchboard should be designed to minimize

the risks of occurrence of internal arc and whenever such an arc occurs it
should prevent its effect on operators and material/equipment
surrounding the switchboard. The short-circuit withstand capacity of the
panel with bus bar and supports shall be minimum 50 KA/1 sec.
(ii-g) Painting: All metal surfaces shall be thoroughly cleaned and degreased
to remove all scales, rust, grease and dirt. Fabricated structures shall be
pickled and treated to remove any trace of acid. The under-surface shall
be prepared by applying a coat of phosphate paint and a coat of yellow
zinc chromate primer. The under surface shall be made free from all
imperfections before undertaking the final coat. After preparation of the
under surfaces, the panel shall be spray painted with final two coats of
approved shade of powder coating (RAL 7032 Siemens grey). Thickness
of powder coating shall not be less than 60 microns. The finished panels
shall be dried in stove ovens in dust free atmosphere. Panel finish shall
be free from imperfections like pin holes, orange peels, run-off paint, etc.
All unpainted steel parts shall be cadmium plated or suitably treated to
prevent rust, corrosion, etc.
(ii-h) Nameplates: Apart from panel nameplate highlighting the operating

voltage, the nameplates for all incoming & outgoing feeders shall be
provided on doors of each compartment. Nameplates shall be fixed by
screws only and not by adhesives. Engraved nameplates shall preferably
be of 3-ply (Black-White-Black) acrylic sheets or anodized aluminium.
Special danger plates shall be provided as per requirement. Lettering
sizes used in the panel shall be 5 mm or 15 mm as directed for feeders
and main inside the panels, stickers should be provided for all
components giving identification no. as per detailed wiring diagram.
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(ii-i) Cooling Fan & filter assembly, lighting of panels, heater: Each section
of the panel shall be provided with a set of cooling fan and filter assembly
and 2 feet long T5 tube light fitting operating through a door limit switch.
Each section of the panel shall also be provided with heating plate and a
suitable thermostat.
(iii) Bus bar Sizing Connection and Supports: The bus bars shall be made
from high purity & high conductivity copper. The bus bars and supports
shall be capable of withstanding the rated and short circuit current.
Minimum size of power (phase) bus bars shall not be less than 200 Amps
rating. Maximum current density permissible for Copper bus bars shall be
1.2 Amps/mm2. A suitable section earthing bus bar shall be provided in
the panel at bottom throughout the length of the panel. Provision shall be
made to connect the earthing bus bar to the plant earthing grid at two
ends. All doors shall be earthed using flexible copper connections to the
fixed frame of the switchboard. The bus bars shall be tinned to protect
against oxidation.
The bus bars shall be provided with heat shrinkable PVC insulating
sleeves of 1100 V grade. Red, Yellow and Blue colour shall be used for
phase bus bars and black colour shall be used for neutral bus bars. The
sleeves should be non-inflammable and self-extinguishing type. All joints
in main horizontal bus bars and all tap-off connections from the main
horizontal bus bars shall be suitably shrouded. Supports for bus bars
shall be made of suitable size non-hygroscopic and non-inflammable
epoxy compound SMC / DMC blocks and these should be adequate in
number so as to avoid any sag in the bus bars. The main bus bar should
be spliced at each column level in order to achieve simplicity and
flexibility in transportation, installation and maintenance. Sliding fishplates
should be used to make the connection of the copper bars between
columns.
Minimum clearance between bus bars phase to phase shall be 25 mm
and that between phases to neutral / earth shall be 20 mm.
(iv) Power Connection:

For power interconnection within the panel board: Copper flexible
conductor PVC insulated cables of adequate cross section shall be used.
However, for current rating above 100 Amps, Copper bus bar strips of
adequate rating shall be used. Minimum size of copper flexible conductor
to be used shall not be less than 4.0 mm2. Maximum flexible copper
conductor size used in the panel shall be 35 sq. mm for 100 Amps
feeders. Cable lugs / sockets of suitable size and type shall be used for
all interconnections and cable terminations.
For incoming feeders of the MCC, copper conductor cable will be used
and hence the panel is to be designed for receiving these and wherever
required cable boxes with bus bar extensions for receiving more no. of
cables, shall be provided in panel by bidder. For all aluminium to copper
connections, the copper surfaces shall be properly cleaned and supplied
with oxide inhibiting grease. Copper washers shall be used in these
terminations.
149
For all outgoing motor feeders, the suitable size terminal blocks shall be
provided in cable alleys and wiring up to these from contactors shall be
done by panel bidder. These terminal blocks shall be heavy-duty type to
withstand high starting currents. The cable entry shall be either from top
or bottom as specified in feeder details or as required for the project.
Removable gland plates of minimum12 gauge thickness shall be provided
on top / bottom of panel (as required), for cable entries. The cable alleys
shall also be totally isolated from switchgears by suitable partition plates.
To prevent accidental contacts, all junctions of interconnecting cables and
bus bars also shall be shrouded suitably using coloured PVC insulation
tape.
Standard colour code of red, yellow and blue for phases and black for
Neutral to be followed for all bus bars/conductors.
(v) Auxiliary wiring and Terminals:

Wiring for all controls, protection, metering, signalling etc. inside the
switchboard shall be done with 1100 V grey colour PVC insulated FR
copper conductors. Minimum size of these conductors shall not be less
than 1.5 mm2. However, CT circuit wiring shall be done with 2.5 mm2.
Control wiring to components fixed on doors shall be flexible type.
The complete panel would be subdivided into different sections as
required for the project. Terminal block for control wiring shall be provided
for each outgoing motor feeder in the top of the cubical. 10% spare
terminals shall always be available in each terminal block. Control wiring
up to these terminal blocks shall be done by bidder. Full depth wire ways
shall be used. Network cabling and power/control cables shall be
separated. All conductors should be terminated using compression type
cable sockets / lugs at both the ends.
Each control wiring termination shall be identified at both the ends by
PVC ferrules. The identification termination numbers should match with
those on drawings. Suitable size SP MCB instead of fuses shall be used
for tapping the power for control circuit wiring.
Control wiring for motor feeders should be such that the "green" light of
motor feeder is "ON" only when control as well as power circuit of feeders
is "ON" and it shall have its own fuse.
For all motor starter feeders, provision for control wiring to remote
ON/OFF control is to be made. The auxiliary wiring for the same shall be
brought up to terminal block in the feeder's cubicle.
(vi)-Switchgears:
(vi-1) Air Circuit Breakers (ACBs):

These shall be electrically operated, fully draw out type with built-in
microprocessor based programmable protection, and suitable for 415 V,
50 Hz supply. Microprocessor based programmable protection unit shall
have settings for overload, short circuit, instantaneous and earth fault
currents with time delay and LED indicators to show various conditions
such as Power ON, Overload, Short-circuit, Instantaneous Earth fault,
Percentage load, Self Diagnostic Test etc.
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Mechanical spring charging mechanism stored energy type shall be
provided with mechanical indicators to show 'Open', 'Closed', 'Service' &
‘Test’ positions. The circuit breaker shall be provided with mechanically
operated emergency tripping device. This device shall be available on the
front of the panel.
The control supply shall be 240 V AC. 6 NO + 6 NC auxiliary contacts

shall be provided.
The interlocks shall be as under:
It shall not be possible to plug in a closed circuit breaker or to draw out a

circuit breaker in closed position. It shall not be possible to operate a
circuit breaker unless it is in fully plugged-in, test or fully isolated position.
In test position, the breaker shall be tested without energizing the power
circuit. The ACB feeder cubical door cannot be opened when ACB is
"ON". However, it shall be possible to defeat this interlock for inspection
purpose. Closing and trip coils shall work under the following voltage
variation conditions:
Closing coils - 85 % to 110 % of rated voltage

Trip coils - 50 % to 130 % of rated voltage
For series tripping, overload, short circuit and under voltage/shunt trip
release shall be provided.
Built-in relays for overload, short circuit, instantaneous and earth fault
protection shall be provided for incoming feeders’ ACB. Suitable port like
RS 485 must be available in ACB for transferring/ communicating data
pertaining to operation parameters, to main PLC/ DCS Panel. Current
rating, short circuit current, protection relays etc. shall be as specified in
feeder details.
(vi-2) Moulded Case Circuit Breakers (MCCB):

MCCBs shall always be provided with separate rotary operating handle
mechanism with door interlocking. The MCCBs shall be of three / four
pole construction (as required in the feeder details) arranged for
simultaneous three / four pole manual closing or opening and automatic
instantaneous tripping on short circuits. MCCBs shall be provided with
adjustable type tripping device with inverse time characteristics for over
load protection.
Closing mechanism shall be quick make, quick break & trip free type.
Operating handle shall give a clear ÒN', ÒFF' & `TRIP' indications.
Control voltage for MCCB shall be 240 volts. The MCCBs shall be rated
for continuous maximum duty as specified. The rating of the MCCBs shall
be as per the feeder details.
Minimum rated breaking capacities shall be as under:
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MCCBs up to 200 Amps 35 KA
MCCBs above 200 Amps 50 KA
Note: All feeders having 3 pole MCCB shall be provided with neutral link
complete with isolating link. However, the MCCBs for incoming and non-
motor outgoing feeders shall be of 4 pole construction, unless stated
otherwise.
(vi -3) Motor Protection Circuit Breaker (MPCB):

All motors below 40 HP shall be protected by Motor Protection Circuit
Breakers (MPCB) having suitable rating thermal overload relays. These
shall be used along with contactors as specified in feeder details.
The MPCB will have motor protection tripping characteristics, current

limiting and shall have low let through energy. It shall have bi-metallic
overload protection and electromagnetic release for short circuit
protection. MPCB shall have inbuilt single phase protection and
adjustable overload settings.
In the MPCB, it shall be possible to have accessories like auxiliary
contacts, trip alarm contacts, shunt release/under voltage release, as
required for motor control and protection. MPCB shall give indication for
‘ON’/’OFF’ and tripping on fault. The breaking capacity of MPCB shall not
be less than 50 KA. MPCB shall have rotary operating mechanism with
door interlock and provision to lock it in ‘OFF’ position with a padlock.
(vi -4) Switch Disconnector fuse units:

The load break switches shall be heavy duty, air break type suitable for
continuous maximum rating with manual quick make / break mechanism.
These shall have positive isolation with positive indication of contact
separation. They shall have high short circuit making and withstanding
capacities. Breaking capacity shall correspond to AC 23A utilization
category. Mechanical interlock shall be provided to prevent opening of
door in switch 'closed' position and prevent closing of switch in door 'open'
position. However, it should be possible to defeat this arrangement for
testing purpose. Live terminals of the switch shall be shrouded.
(vi -5) Fuses:

These shall be non-deteriorating HRC cartridge link type with operation
indicator which will be visible without removing fuses for the service.
These shall be complete with moulded phenolic fuse base and cover. The
fuse base shall be so located in the modules to permit insertion of fuse
pullers and removal of fuse links without any problem. One set of fuse
pullers to cover entire range of fuses used in the panel shall also be
provided.
(vi -6) Contactors:

The rating of the power contactors shall be as required depending upon
the feeder rating indicated in the specifications and as per the feeder
details table provided in this specification below. Contactors coils shall be
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suitable for 240 volts, 50 Hz. unless otherwise specified. All contactors
shall be supplied with minimum 2 NO + 2 NC auxiliary contacts.
Additional contacts if required for interlocking etc. shall also be provided.
Minimum contactor rating for power shall be 9 Amp. All the three
contactors of Soft starter shall be of same rating. Rating of contactors
shall be based on feeder rating.
All contactors of motor starters shall be suitable for AC 3 duty unless

specified otherwise.
(vi -7) Intelligent Motor protection relays (IMPR):

Intelligent Motor protection relays (Intelligent controllers/intelligent motor
management devices) are required for motor feeders instead of bimetallic
overload relay as specified in the special requirement of this
project/approved drawings. These shall be fixed on DIN rails or on
mounting boards.
The IMPR should provide the communication ports for the connection to
the communication network. It should be easily integrated into the
communication architecture with remote information access. It shall have
minimum 4 nos. digital inputs & 2 no. digital outputs. The Thermal
overload trip shall have selectable tripping class 5, 10, 15, 20, 25, 30. The
reset shall be through manual, automatic or remote
It shall be an open communications system, which means that it shall be

directly connected to the main industrial network protocols, listed below:
- ModBus SL
- ModBus / Ethernet
- Profibus DP
- DeviceNet
The IMPR should embed the relevant network protocol in built-in (native)
mode.
The IMPR bidder should provide user-friendly software running in a

Windows environment to ease the IMPR on-relay configuration. The
software should have menus and icons for easy access to the data
required, guided navigation to go through all the data of the same function
in one screen and with a file management system.
(vi -8) Timers:

The timers shall be continuously adjustable & electronic type, suitable for
240 V, 50 Hz supply. The timers for Softstarter automatic starters shall
have time delay of 0 to 60 seconds between changeover of contacts.
(vi -9) Push Buttons (PBs):

Push buttons shall be complete with actuator and contact block and shall
be generally mounted on doors of the cubicles. Colours shall be as follow:
Stop/ open/ emergency - Red
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Start/ close - Green
It should have minimum 1 NO + 1 NC contacts. Push buttons shall
conform to IP - 65 protections against dust and water ingress.
(vi -10) Indication Lamps:

All outgoing & incoming feeders shall be provided with ‘ON’ indication
lamps. Colours shall be as under:
Phases : Red, Yellow & Blue

ON : Red
OFF : Green
TRIPPED : Yellow
Indicating lamps shall be of LED (cluster of high intensity light emitting

diodes) type, suitable for 240 V AC supply. These shall be provided with
translucent covers of red, green and amber colours as required. These
lamps shall be of minimum 22.5 mm dia. Indication lamps to be provided
for all feeders.
(vi -11) Current Transformers (CTs):

CTs shall be cast resin insulated type. Primary and secondary terminals
shall be marked indelibly. CTs shall preferably be mounted on stationery
parts. These shall be capable of withstanding momentary short circuit and
symmetrical short circuit current for 1 second and shall have a minimum
rating of 10 VA. Neutral side of CTs shall be earthed.
Protection CTs shall be of low reactance, accuracy class "5P" and an

accuracy limit factor greater than "10". Instrument CTs shall be of
accuracy class “1.0" and accuracy limit factor less than "5.0". Separate
CT's to be provided for protection and metering purpose.
(vi-12) Measuring Instruments:

These shall be of digital square pattern meters having approximate
dimensions 96 mm X 96 mm, flush mounting type. Necessary auxiliary
instruments like CTs etc. are also included in the scope of supply.
All AC meters shall be of Digital type for displaying three phases reading.
Suitable selector switch shall be provided if the digital meter does not
have provision for simultaneous display of three phase readings.
Voltmeter shall be suitable for direct line connection. Voltmeters shall be
connected through MCBs only.
Intelligent Panel Meter shall be provided with incoming feeder of the MCC
for the measurement and digital display of Multifunctional Electrical
Parameters such as voltage, current, active power, reactive power,
frequency, power factor, active energy, reactive energy, etc. Data port will
be provided to communicate all these parameters to Main PLC Panel
through suitable data bus/ signal communication cable. All motor feeders
of 15 HP and above shall be provided with ammeter. Ammeter shall also
be provided for all incoming & outgoing ACB / MCCB / switches of rating
100 A & above.
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Ammeters shall always be CT operated.
Special Requirements of the Project:
Feeder details for incoming and outgoing for this project as per battery
limit to be worked out by the bidder as per the design requirements of the
plant. All motor feeders will have SOFTSTARTER starter. Variable
Frequency Drive (VFD) Unit will be provided for a motor feeder if
specifically mentioned and required as per design requirements. Suitable
Line Chokes shall be provided in VFD feeders. Each motor feeder shall
consist of an MPCB/ MCCB, contactors (single contactor for
SOFTSTARTER and three nos. for Softstarter started motors), an IMPR
(Intelligent Motor Protection relay or intelligent controller), auxiliary relay,
start& stop pushbuttons, ON/OFF/TRIP indicating lamps and SPMCB for
control circuit protection Intelligent motor protection relay (intelligent
controller) shall have minimum 4 nos. digital inputs & 2 no. digital outputs.
If needed separate 24V DC power source (for controller only) shall be

provided from suitable rating UPS. Soft Starter must have inbuilt
protections for single phasing, phase sequence, over current, over
voltage, under voltage etc. In case of motors having embedded thermistor
winding, Soft Starters for these motor feeders should have in-built
thermistor relay.
(i) The following selection table shall be followed for motor feeders unless
otherwise specified:
Sr. 415 V Motor HP Contactor MCCB MPCB Type of

No Rating Rating Rating Starter
Amps Amp Amp
1 Up to 3 HP 9 - 9 Soft
Starter
2 5 to 10 HP 16 - 16 Soft
Starter
3 12.5 to 15 HP 25 - 25 Soft
Starter
4 20 to 25 HP - - 40 Soft
Starter
5 30 to 35 HP - - 50 Soft
Starter
6 40 HP - 63 - Soft
Starter
7 45 HP - 100 - Soft
Starter
8 50 to 60 HP - 125 - Soft
Starter
9 65 to 70 HP - 200 - Soft
Starter
10 75 to 90 HP - 200 - Soft
Starter
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11 100 to 125 HP - 250 - Soft
Starter
12 150 to 180 HP - 400 - Soft
Starter
13 200 to 250 HP - 400 - Soft
Starter
14 275 to 400 HP - 630 - Soft
Starter
For capacitor, rating of contactors / switch shall be double of rated current

of capacitor.
(ii) For incoming feeder of rating up to 630 A, 4 pole MCCB & for rating
higher than 630 A, 4 pole ACB shall be provided unless otherwise stated
in the feeder details. Each incoming feeders shall be complete with earth
leakage relay. For each incoming feeder, a microprocessor based data
logger (Multifunction meter)to be provided to indicate and store 3 phase
voltages, 3 phase current, power factor, energy consumed in KW hr and
KVAR etc.
(iii) In addition to the connected load to each IMCC, at least 20 % (based on

KW rating of the IMCC) spare outgoing feeders complete with starters
shall be provided. These spare feeders shall cover as far as possible
more or less all sizes of starters including two nos. 10 HP
SOFTSTARTER, two nos. 15 HP soft starters, two nos. 200A TPN SDF
feeder, two nos. 100 A MCCB feeders and one 63 A TPN SDF unit to be
provided for connecting welding sets.
(iv) For High electrical loads (large motors) like FD fan, Crusher, ID fan etc,
capacitors shall be placed in the IMCC & these shall be automatically
connected to the bus, once the respective feeder is put ON. Each
capacitor feeder shall have MCCB for isolation, capacitor duty contactors
for ON/OFF, start/stop pushbuttons, auto/manual toggle switches,
SPMCBs for control circuit etc.
(v) MCCB, 4 pole shall be provided (unless stated otherwise) for

outgoing feeders of rating 63 Amps and above and preferably these shall
be located at the lower portion of the panel. These feeders shall have
isolating link for neutral in case 3 pole MCCBs. These non motor feeders
are to be supplied as per the specific requirement specified for the
project.
(vi) Electrical interlocking shall be provided between various feeders as

required by the process and specified in feeder details. Interlocking will
also be provided in software programme of Main PLC Panel.
(vii) ON/OFF operation of all motor feeders shall be possible in both Auto
mode (PLC signal operation) as well as Manual mode from MCC through
selector switch. Indication for ON/OFF/TRIP for all motor feeders shall be
provided.
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(viii) If the total operating load on MCC is more than 600 kW, (including spare
feeders’ load and future expansion load as described in design basis)
MCC shall have two incoming ACB feeders (double incomer with
necessary interlocks to enable redundancy in case of cable/switch
failure). Each incoming feeder shall have independent instrumentation,
protection relays, etc.
(ix) Provision shall be made to communicate operational parameters / data

from all incoming/outgoing feeders to main PLC/ DCS Panel through
suitable data bus/ signal communication cable. Operation parameters of
motor feeders like ON/OFF status, actual current, trip status etc shall be
communicated.
Makes of Items
Sr.
Name of Items 2nd
No 1st preference
preference
1 ACB and its relays
2 Moulded case circuit breaker
3 Motor protection circuit breaker
4 Switch Dis-connector fuse unit
5 HRC fuse links
6 Miniature circuit breaker
7 Contractors
8 Starter relays
9 Electronic timers
10 Push buttons
11 Indicating lamps
12 Current transformers
13 Measuring instruments
14 PVC insulated control wires
15 PVC insulated power wires
16 Terminal blocks
17 Soft starters
18 Variable frequency drive
19 IMCC panel
(x) Bidder has to submit GA, control & power circuit drawing for approval to
purchaser before starting manufacturing of MCC. Induction motors (above
10 KW) having 3000 RPM shall require higher rating for switches, fuses,
MPCB, contactors and electronic timers due to very high starting current.
IMCC bidder to specially check this requirement from purchaser before
preparing the drawings.
(xi) Bidders should specify maximum two "makes" of the following items in
order of preference:
All the major components of an IMCC shall be of same make.
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Wherever desired distributed I/Os with Communication adaptors or linking
devices shall be installed in each shipping split or shipping section and
factory wired to each starter unit. IMCC shall be connected to remote
controller/SCADA via one network of high bandwidth. Network connection
from remote controller wherever required is to be made to the
communication adaptor/linking devices installed in each shipping unit.
However in general it is preferred that all the intelligent relays, soft
starters and VFD provided in the panels for electrical equipment shall be
interfaced to the Central PLC through open protocol communication cable
(open networks) for control action and data acquisition/diagnostic
information directly at device level. The communication protocol (bus) for
intelligent controller and packaged PLC shall be same for ease of
communication. The VFD shall be dynamically controlled from the PLC
depending on the program and feedback system from field. These VFD
shall have Battery backup and communication port. The routing of
network cables in IMCCs may be through horizontal and vertical wire
ways. However more optimized approaches such as use of Trunk lines
and drop lines isolated behind barriers or Independent, easy-connect
ports on drop lines - are preferred. These configurations would provide
independent, readily accessible ports to simplify installing, withdrawing,
relocating and adding plug-in units. The configuration is preferable to
daisy-chain architecture, in which moving or adding an MCC unit requires
interrupting the chain and disabling downstream units. The open networks
shall be such as Ethernet, Modbus, CANopen, DeviceNet and
PROFIBUS.
The specifications of the intelligent motor control relay (Intelligent
motor management relay) shall be as given below:
A) General
The motor management device should confirm to IEC 60947-4-1, 60947-
5-5 & 60947-8 for overload and thermistor protections. The device should
be suitable for operation at ambient temperature up to 60 Deg C. The
components in the main circuit (i.e. Current / Voltage measuring devices)
should have rated operation voltage of up to 690V.
The device should offer comprehensive motor management functions

including Protection, Monitoring, Control and Diagnostics functions as
detailed subsequently in this specification.
B) Construction
The motor management & control device should be of the latest
technology available. The device should be compact and preferably
modular in construction. The device should have integrated
communication port for direct link to higher level, with open protocol bus
system like profibus preferably.
The protection system should be independent / autonomous of the

automation system. i.e. Motor protection & control should continue to be
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available for operation in the event of a communication or automation
system failure.
The device should have a control voltage of either 24V DC or a wide band
control voltage from 110 to 240 V AC/DC, as applicable.
The basic unit shall have the following minimum status display
a) Device Readiness
b) Status of control supply
c) Feeder fault indication
d) Status of communication with PLC
The device shall have facility to test/reset as standard. It shall be possible

to select between manual reset (at the device) or remote reset (through
PLC/SCADA from control room). The device shall have following
minimum no. of Digital Inputs & Outputs as standard which should be
freely assignable.
4 Digital Inputs
3 Digital outputs (Potential free) Optionally, It shall be possible to expand
the no. of digital inputs / outputs, if required, using add-on modules.
C) Functional Requirements
Protection Functions
The device shall incorporate the following protection function as standard
a) Overload protection with trip class adjustable from 5 to 40.

b) The device should have an in-built Thermal Motor Model (Thermal
Memory).
c) It shall be possible to adjust the reset time after an overload.
d) Provision for connecting thermistor inputs.
e) Phase failure protection.
f) Unbalance protection with adjustable time delay.
g) Stall protection with adjustable time delay.
Monitoring Functions
The device shall incorporate the following monitoring function as

standard.
a) Over current monitoring with adjustable time delay.

b) Under current monitoring with adjustable time delay.
c) Earth fault Monitoring with adjustable time delay.
When threshold value of above settings exceed, it shall be possible to set

the type of response (Warning, Tripping, Signalling and Disable).
a) Motor Operating Hours monitoring
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b) Motor Stop time monitoring
c) No. of starts monitoring
When threshold value of above protection setting exceeds, it shall be

possible to set the type of response (Warning, Signalling and Disable)
Additionally, the following monitoring functions shall be possible as an
option and should be provided for feeders wherever specifically asked for.
a) Under voltage monitoring

b) Power factor monitoring
c) Active Power Monitoring
d) Phase sequence monitoring
e) Temperature monitoring via PT100 / PT 1000, NTC, KTY 83/84
inputs
f) Recording the curves of measured values like current, voltage, power
etc.
g) Monitoring of analog values using Analog I/O modules
Control Functions
In order to minimize the wiring & interlocks, the device shall have built-in
software logics to achieve the various control functions like
(a) Direct on line starter (SOFTSTARTER)

(b) Reversing SOFTSTARTER (SOFTSTARTER)
(c) Automatic Softstarter starter
(d) Pole changing starter
(e) Positioner
(f) Solenoid valve
The device may be chosen as per the requirement of the individual

feeders.
Logic Function Modules
The Intelligent Motor Control and Protection Device shall offer the
following in-built logic functions.
(a) Truth table
(b) Timer
(c) Counter
(d) Flashing function
(e) Flickering function
With the above functions it is envisaged to reduce the hardware in the

feeder viz. timers. The flashing/flickering functions must facilitate
multiple functionality to the same lamp - to glow constantly when the
feeder is OFF and flash on the event of a trip caused by a fault.
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Standard function blocks
The Intelligent Motor Control and Protection Device shall have standard
control function control blocks.
(a) Check back signal

(b) Test Position feedback
(c) External fault
(d) Emergency start
(e) Communication Error
(f) Testing the device including tripping of the feeder
(g) Testing the device without tripping the feeder
Diagnostics, Service & Operating Functions
The motor management system shall make available the following

diagnostics, service and operating data on the bus system for further
processing by the higher level control system. (eg. PLC/SCADA).
Operating data
The following shall be available at the PLC as part of the cyclic send data
1. Motor switching state (ON,OFF direction of rotation, right, slow fast

etc).
2. Current (maximum of the 3 phases).
The “cyclic send data” should consist of a minimum of 16 bits for

communicating status of various aspects of the feeder like current limit
exceeded, motor operating hours exceeded etc.
Diagnostic & Service data
a) The device should be capable of signalling/warning in case of overload of

115% of set current.
b) It should be possible to set “warning” or “trip” as response for current
limits exceed, unbalance in current, earth fault, operating hours exceeded
etc.
c) It should be possible to read from the device the value of last trip current.
d) In case of a device fault or a trip, the device shall send the diagnostic
data to the PLC for the user to analyse. The diagnostic information should
consist of Status information on fault type, status information on limits
exceeded, Status information on warnings, device healthiness, bus fault,
cooling down period (in case of overload fault), no. of starts, motor
operating hours etc.
e) Event log with a capacity to record last 20 events, shall be accessible
whenever required.
161
Measured Values:
The device shall by default transmit the current value (maximum of the 3
phases).
However, it shall be possible to access from the PLC other related

parameters like percentage of unbalance, power factor, current in the 3
phases, last trip current, time to trip (for a feeder undergoing overload),
cooling down period (after an overload trip), active power, apparent
power.
Optionally where power/voltage monitoring is specified the following

additional data should be available
a) Voltage in the three phases (Line-to-Line) in Volts

b) Consumed energy in kWh
c) Active Power in Watts
d) Apparent power in VA
e) Phase voltages in V
f) Power factor
g) Phase sequence
D) Configuring & Communication
The bidder shall offer standard software for configuring the device. It shall
be possible to configure a device either individually or over a
communication network. For this purpose, provision for connecting a
laptop should be available at the motor management device.
The device shall have integrated communication facility to communicate

directly on a bus system without any additional components.
The device shall be able to transmit cyclic as well as acyclic data to

higher-level automation. It shall be possible to define each bit in the cyclic
and acyclic data sent to the PLC. The data defined as cyclic shall be
fetched by master PLC in a sequential manner. i.e. one slave after other.
The critical events like tripping of device or alarm shall be sent to master
PLC on priority basis (acyclic transfer) irrespective of the slave sequence.
In order to achieve minimum response time, the device shall be capable

of transmitting data at a speed of 12Mbps, suitable for operation with
high-speed bus systems.
The following selection table shall be followed for cables of motors unless
otherwise specified:
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Minimum size of steel braided copper cable for various rating of motors (to be laid
between MCC and motors)
Motor Full load
Power cable rating (at
Sr. No Rating current Type of starter
ambient temp of 45˚ C
HP Amp.
1 0.5 1 Soft Starter suitable
2 0.75 1.3 Soft Starter Suitable
3 1 1.9 Soft Starter suitable
4 1.5 2.6 Soft Starter suitable
8 5 7.8 Soft Starter Suitable
9 7.5 11.2 Soft Starter suitable
10 10 16 Soft Starter suitable
11 12.5 19 Soft Starter suitable
14 25 34 Soft Starter Suitable
29 375 N.A Soft Starter suitable
Note: Suitable de-rating factor of cables as per manufacturer's guidelines

to be applied where more than one cables feeding to various
motors/drives are to be laid in parallel
3 phase 415 V
Aluminium conductor cable size : sqmm
motor HP
Soft Starter Soft Starter
Supply side Motor side Supply side Motor side
60 70 70 70 2 x 35
75 95 95 95 2 x 50
100 120 120 120 2 x 70
125 185 185 185 2 x 95
150 240 240 240 2 x 120
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180 - - 300 2 x 150
200 - - 2 x 150 2 x 150
250 - - 2 x 185 2 x 185
275 - - 2 x 240 2 x 240
300 - - 2 x 240 2 x 240
Note: Cables indicated above in the table shall be only armoured copper
conductor cable up to 50 HP motor. Armoured aluminium cable will be
used with concern to purchaser.
Wherever needed as per process requirements, VFDS shall be used and

these shall be clearly listed out in the offer. VFDS shall have input chokes
on line side. Load side chokes wherever required are also to be included.
ELECTRICAL ITEMS / ACCESSORIES:
Cable trays from PCC to MCCs & further distribution inside the plant,
earth pits & earth strips shall be of GI. Earthing for automation and
instrumentation shall be independent of power earthing. Earthing of
individual motors shall be provided with PVC insulated 4 sq mm copper
wire. For higher rating motors, GI earth strip of suitable cross-section
shall be provided. All Isolators, junction boxes shall be in Al. Die cast
housing or thermo-plastic construction as directed by purchaser. The
cable drops (power, control & instrument cables) from the overhead cable
trays shall be through GI conduit pipe. Necessary 11KV 12 mm thk. Full
length rubber mats should be provided for all MCCs, sub-power panels.
(i) MOTOR ISOLATORS/EMERGENCY PBS, CABLE TRAYS, CABLE

GLANDS, CONDUITS, CABLE CONNECTORS, CABLE ROUTE
MARKER, CABLE INDICATORS
(ii) LT POWER CABLES
Power cables for use on 415 V system shall be of 1100 volt grade, copper
conductor, PVC insulated, metal braided, rodent proof (up to 50 Sq.mm)
& unless otherwise specified, aluminium conductor (above 50 Sq.mm),
XLPE insulated, PVC sheathed, armoured and overall PVC sheathed
strictly as per IS : 7098 PART 1/1988.
The size of cable shall be as specified in cable selection chart. No copper
cable of size less than 2.5 sq. mm. shall be used.
(iii) LT CONTROL CABLES
Control cables for use on 415 V system shall be of 1100 volts grade,
copper conductor, PVC insulated, metal braided, Rodent proof armoured
PVC sheathed armoured and overall PVC sheathed, strictly as per IS:
1554 (Part I) - 1976. The minimum conductor diameter shall be 1.5
sq.mm.
164
(iv) EARTHING SYSTEM: Earth Pit
• Plate type earth electrode with earth pit shall be provided for this work
unless otherwise advised by site engineer due to typical site conditions.
Earthing electrode and pit shall be as per IS: 3043-1987 the latest
revision (code of practices for Earthing). Sketches for pipe and plate type
earth electrode earthing pit have to be submitted for approval. All earth
electrodes shall preferably be driven to a sufficient depth to reach
permanent moist soil.
• Earth pit centre shall be at a minimum distance of 3 M from nearest

building, unless otherwise advised. The minimum 3 M distance shall be
maintained between centres of 2 earth pits.
• Earth electrode for PLC, instrumentation earthing shall be of copper,

whereas the same for all other application (LT / MCC /Electrical panels)
shall be of GI.
• Earthing electrodes for Main plant lighting panel shall be plate type with
double earthing.
Earth Bus, Earthing Lead & Earth Wire/Strip
All electrical equipment is to be doubly earthed by connecting two-earth

strip/ wire conductor from the frame of the equipment to an earthing pit/
main earthing ring. The earthing ring will be connected via links to several
earth electrodes. The cable armoured will be earthed through the cable
glands. Conductor size for connection to various equipments shall be as
specified in the drawing or as instructed by the Engineer-in-charge.
However, the length of the branch leads from equipment to earthing grid/
ring shall not be more than 10 to 15 meters.
All hardware for earthing installation shall be hot dip galvanized. Spring
washers shall be used for all earthing connections of equipment having
vibrations.
Size of earthing lead/ wire shall be as specified in schedule of
quantities/drawings. Below Table may be considered as general
guidelines.
However, while deciding type & size of earth lead, the resistance between
the earthing system and the general mass of the earth shall be as per IS
code of practice. The earth loop impedance to any point in the electrical
system shall not be in excess of 1.0 Ω in Contract to ensure satisfactory
operation of protective devices.
G.I. wire/ Copper wire shall be connected to the equipment by providing
crimping type socket/ lug. Wherever earthing strip to be provided in cable
tray, it shall be suitably bolted on cable tray and electrically bonded to the
cable tray at regular interval.
Excavating & refilling of earth, necessary for laying underground earth
bus loops shall be the responsibility of the Bidder. Wherever earth leads/
165
strips/ wire are laid in cable trenches, these shall be firmly and suitably
cleared to the walls/ supporting steel structure on which cable is clamped.
All LT Electrical panels shall be double earthed i.e. connected to earth pit
independently and earth pit shall have GI earth plate. Earth strips for
panels shall be interconnected wherever possible.
Long runs of GI strip shall be connected at each end with lap type welding
to ensure continuity.
Sizing of earthing lead/wire
Sr. No Item Size

1 Control switches / glands Copper wire 14 SWG
Copper wire up to the cable tray
2 Motor / isolators up to 40 HP
and GI strip 25 x 3 mm
3 Motor above 50 HP up to 125 HP GI strip 40 x 3 mm
4 Motor above 125 HP GI strip 25 x 6 mm
5 Switch board / MCC GI strip 50 x 6 mm
6 Earthing main in trenches GI strip 50 x 6 mm
POWER CAPACITOR BANKS:
FUNCTIONAL REQUIREMENTS
The power capacitor banks shall be used to improve the power factor of
an electrical system. These will be placed parallel to switchgears for
motors above 30 HP in the IMCC & shall have their own switchgears for
isolation with fan cooling facility.
DESIGN REQUIREMENTS
Each basic unit is to be built up with a number of elements. These

elements shall be of two layer dielectric design (non-self-healing) using
heavy Polypropylene Film, Aluminium Foil and Capacitor Tissue Paper as
required, ensuring that total dielectric thickness is more than 14 micron.
Capacitor element must be completely sealed with epoxy resins to
provide maximum humidity protection and highest insulation. The
capacitor elements are to be given adequate outside insulation and
should be put in all welded surface treated containers. The outer surface
shall be provided with a coat of protective primer followed by two coats of
synthetic enamel paint of approved shade. The metal case shall be
equipped with porcelain bushings to permit connection between power
lines and active capacitors. The unit shall have built-in internal individual
fuses.
Externally each capacitor unit shall have two separate earthing points,
name plate confirming to the requirements of IS-2834 (amended up to
date), discharge resistances etc. Capacitor requirement shall be worked
out as per the plant load requirements by the bidder
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REMOTE CONTROL PANELS
Remote Control panels other than Boiler Control panel, essentially are
required for the following ;
1. Fuel handling, storage & feeding system.

2. Pollution Control Equipments.
Generally, these shall be floor/structure mounted type as per site

requirement. These shall be made of Al. Cast housing for wall mounting.
Front cover shall be removable type with suitable rubber gaskets to make
them dust, vermin and moisture proof & with a degree of ingress
protection for housing shall be IP - 54/55. Each feeder of station shall be
provided with name plate (white Bakelite), indication lamp, one ÒN'
(Green) push button and one 'OFF' (Red) push button with latch to
prevent accidental starting. Green and Red push buttons shall have
contact elements having 1 NO + 1 NC. Heavy duty connector to be used
in RCP for internal wiring. Indication lamps to be LED type to give bright
indication. These shall be of 22.5 mm dia and having operating voltage of
240 V AC.
These can be floor/wall mounted type and made from CRCA sheets with
suitable supporting arrangements. These can be as per the standard
design of the manufacturer of the related machine.
BOILER CONTROL PANEL:
The complete control panel shall be supplied and installed with all
instruments and components such as LED indicator type push buttons,
indicating LED with window annunciator, temperature /pressure controller,
digital temperature indicators etc. The control panel should be made from
14 Gauge CRCA sheet duly pre-treated and powder coated. It should
also have audio alarming system for all the fault condition, which should
appear, visually on annunciator window.
Major instrument controls & safeties required are:
Sr. Description of condition Control requirement

No
1 Water level control in Through mobrey level controller for
drum feed pump on-off
2 Low level in boiler Feed water pump on - visual indication
3 Extra low level in boiler ID fan cut-off with alarm, boiler trip
4 Very low level in boiler Fusible plug blow
5 High steam pressure in ID fan cut-off, alarm, boiler trip
boiler
6 Steam pressure high Safety valve lift
7 Extra low in feed water Feed water pump trips with alarm
tank
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8 TDS controller for blow Pneumatic / electrically operated
down with indicator controller for blow down valve
9 Stack temperature high Alarm and boiler trip
10 Bed temperature high Alarm and fuel feeder trip
11 Water flow measurement Water flow meter with indicator
12 Steam flow Steam flow meter with indicator
measurement
13 Direct efficiency Direct efficiency monitor
monitoring
14 Combustion control O2 trim
15 Blow down heat recovery Circulation pump operation depending
on temp of blow down inlet temp to
plate heat exchanger
16 Pressure reduction Automatically controlled through
electro-pneumatic controller.
A separate display shall be provided for monitoring Boiler efficiency with

indications of fuel consumed with steam generated.
Other Control & safety
All the legal safety measures should be taken with regard to pressure,
water level and flue gas temperature. In the scope of supply you can find
the complete list of the control and safety equipment. The following
control logic should be incorporated.
Fuel Circuit
• The fuel in the hopper should be regulated and the fuel conveyer should
be stopped and started based level of fuel in the hopper.
Fuel Flow & Air Control Coarse Control
• The fuel feeding system controlled through VFD with an interlock based
on the load on the boiler. PA motorized dampers, Secondary air
motorized dampers and the quantity of fuel.
• All primary air and secondary air motors damper motors should be
controlled through the PLC automatically with respect to the load
fluctuations on the boilers up to 30% of the rated capacity.
• O2 Trim control system – ID Fan, Primary Air Fan & Secondary Air Fan.
Safety Control
• The O2 trim should also incorporate the safety feature in which the boiler
switches off in case O2 level drops below 2.5%
Safety Interlocks
• Pressure Range for furnace pressure control. In case of positive pressure

PA & SA Fan Trip.
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• Pressure Switch in Drum – Boiler Trip in case of high pressure
• Outlet Temperature of Boiler High (set point) – Bag filters Bypass.
Auxiliary Controls for Boiler House Equipments
Fuel Circuit
• Crushed Fuel Storage Hopper Full – Crusher & Conveyer Stop
• Crushed Fuel Storage Hopper Empty – Crusher & Conveyer Start
• Boiler Trip – Conveyer Stop
CONTROL AND SAFETY EQUIPMENT HARDWARE
• 1 Pc. Regulation pressure switch

• 1 Pc. Safety pressure switch
• 1 Pc. Low water level on water level regulator (Software)
• 1 Pc. Low water level protection
• 1 Pc. Low water level protection with float
• 1 Pc. High water level protection with float
• 2 Pc. Water level gauges
• 2 Pc. Safety valves
• 1 Pc. Flue gas temperature control with digital display (for incorporation in
the control panel)
• 1 Pc. Manometer
Any other instruments/controls not mentioned but required to complete

automation requirements shall be supplied, installed & commissioned by
the successful bidder, as this is a total job requirement.
Field Instruments, Control Valves and Accessories.
General
Field Instruments shall be suitable for area in which these are located. In
general, field instruments shall be weatherproof, dust tight and corrosion
resistant with Protection Class IP-65. Field instruments shall be suitably
mounted, supported and terminated in local SS/ CA junction boxes.
Dial size for all pressure and temperature gauges shall be 150 mm and
any lower size selection specific to the application shall be subject to the
purchasers approval.
In general the minimum accuracy of the instruments shall be as below:
Electronic transmitters: ± 0.2 % of FSD

Pressure & temperature gauge: ± 1.0 % of FSD
Conductivity transmitter: ± 0.5 % of FSD
Level gauges: ± 5.mm of the reading
The repeatability of pressure, temperature, level and flow switches shall

be ± 2.0 % of FSD (minimum).
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Measuring ranges of transmitters shall be selected in such a way that
best accuracy of measured value (in the measurement range) is
achieved.
Material of construction of thermo well shall be SS 316 suitable for the
application. The cable & instrument air inlet at the instruments would have
proper protection. Instrument air tapping from header shall be of SS-304
pipe with SS-304 distributor & FRL/moisture trap etc.
All field instruments/ equipments shall be provided with stainless steel

(SS) tag plates with engraved tag no. and service description. The tag
plate shall be secured to the instrument/equipment with SS chain.
Transmitters (Temp. & Pressure): 1 Lot
The transmitters shall be provided as per requirement for utility having

best accuracy/reliability, as available in the market and the hard wired
signals (4-20 mA) shall be connected with automation system through I/O
stations. The transmitters shall have field diagnostic/configuration facility.
Proper sanitary type mounting arrangement shall be provided for

installation of the sensors in various tanks/ pipelines, suitable for the
application. The transmitters shall have separate local digital indicators as
per requirement.
Measuring ranges of transmitters shall be selected in such a way that the

rated value of the measuring variables appears at approx. 50-80% of the
span.
Accuracy of the process transmitters should be plus or minus 0.2 %

(minimum) of measured value or better.
The sensing elements and internal parts shall be constructed with AISI
316. In case of stock and corrosive fluid application, diaphragm seal type
transmitter with capillary is foreseen.
The bidder to quantify the number of such transmitters required, based on

the specification as well as functional requirement & offer accordingly.
Gauges: 1 Lot
Process gauges shall be provided for local indication on all utility lines &
tanks (as necessary).
Pressure gauge sensing element shall be Bourdon/Bellow/ Diaphragm

type in general depending upon the process condition. Direct reading
Pressure/Differential Pressure gauges shall be used of SS 316 sensing
element and AISI 304 movement material.
170
Local temperature measurement shall be done bi-metal Temperature
gauges. Temperature gauges may be direct mounted type (multi-angle)
or with SS capillary extension (at least 2 Mtrs) as per the application area.
The sensing element / bulb / capillary etc. shall be of SS 316 for

temperature gauges.
The bidder to quantify the number of such gauges required, based on the
specification as well as functional requirement & offer accordingly.
Temperature Elements: 1 Lot
All Temperature Sensors Elements shall be of Duplex type with SS 316

sheath (sanitary type). Depending on temperature ranges, Pt-100
Resistance Temperature Detector (RTD) or thermocouple shall be used.
Thermocouple / RTD heads, with chain holder, shall be of the waterproof

type, with duplex terminal block, gasketed cover and stainless steel chain.
Screwed covers shall be used.
Proper sanitary type mounting arrangement shall be provided for

installation of the sensors in various tanks/ pipelines, suitable for the
application.
The bidder to quantify the number of such elements required, based on

Process Switches: 1 Lot
Local switches for pressure, differential pressure, temperature, level,

proximities etc. shall be having best reliability & accuracy as available in
the market & provided as per requirement. The hard wired signals shall
be connected with automation system through I/O stations. The switches
shall be appropriate & suitable for the selected application. The level
switches shall be tuning fork type/Capacitance/laser beam type as
required for the application. The bidder to quantify the number of such
switches required, based on the specification as well as functional
requirement & offers the full details of the same with the quotation.
Set points shall be adjustable throughout the range. Switching differential

shall be adjustable.
Control valves: 1 Lot
Control valves of required turn down for process & utility application shall
be provided having best reliability & accuracy, as available in the market
and the hard wired signals (4-20 mA) with field configuration facility. The
CVs shall be connected with automation system through field I/O stations.
For steam application, control valves shall have extended bonnet. The
bidder to quantify the number of such control valves required, based on
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The valves shall be sanitary type for process application.
Level Transmitters: 1 Lot
Flange mounted diaphragm seal type level transmitters (or better sensor)
of sanitary design & required turn down capacity shall be used for level
measurement on tanks having best accuracy & reliability suitable for
Dairy application, as available in the market. For concentrated chemical
tanks ultrasonic LTs shall be provided.
The wetted parts shall be of SS 316 or suitable material to suit process

fluid. The sensor & electronics unit of the level transmitter should be
separate or with remote seal to avoid moisture condensation. The level
transmitters shall have separate field display (digital) unit having hard
wired signals (4-20 mA) with field diagnostic/configuration facility.
Connectivity with automation system shall be through remote I/O stations.
The wetted parts material shall be SS 316 / SS 316L or as per the
requirement of process fluid. Accuracy of LTs should be plus or minus 0.2
% of measured value or better.
The bidder to quantify the number of LTs required, based on the

specification as well as functional requirement & offer accordingly.
Variable Frequency Drives: 1 Lot
The variable frequency drives shall be smart type having field run bus
connectivity with required diagnostic features. The VFDs should be
configurable from the HMI/operating console as well as in the field. The
VFDs shall have best accuracy & reliability, as available in the market.
The bidder to quantify the number of VFDs required, based on the
specification as well as functional requirement & offer accordingly. The
VFDs shall have DC choke (inbuilt harmonic filter) apart from external AC
line filters as per requirement. In sensitive locations, RFI should be
provided to avoid any interference to adjacent electronic unit.
6.5 IMPORTANT NOTES
6.5.1 The main boiler unit shall have pressure parts consisting of fusion welded
shell, flue tube, tube plates, tubular passes, end plates, reversing
chambers, steam drier units with all associated accessories. The boiler
shall also consist of front and back smoke boxes. The firing / stoking
arrangement should be designed to have optimum volumetric heat
release rate for complete combustion. Rear access door shall also be
provided and preferably the same shall be of bolted type for easy
maintenance.
6.5.2 Insulation: Supply and application of insulation of boiler, refractory

materials, brick works are completely in the scope of bidder. All portions
of the boiler shell are to be lagged with glass wool mattress min.100 mm
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thick and density minimum 100 kg/cum to ensure a safe working
temperature. The insulation shall be retained with wire mesh.
The boiler shell is then to be covered with GI cladding of 20 SWG

thicknesses duly pre-treated before painting with two coats of heat
resistant paint. The temperature of the outer shell should not be more
than 5ºC of the ambient temperature. The main steam pipe line up to and
including non-return valve shall also be insulated by the bidder.
6.5.3 Feed Water system: Feed water line to the Boiler shall be drawn from the
outlet port of feed water tank; a common water flow meter shall be
installed on the outlet line feeding both boilers to log the water flow rate &
totalized flow. An online pH correction system shall be supplied & shall be
installed in the common for FW inlet line for both boilers.
Water flow meter
• Water flow meter vortex type, suitable for operation up to 100ºC Feed
water temperature & size as per Feed water pump flow rate. The unit
shall have local display of flow and totaliser with a provision of data
communication port for future connectivity. The meter shall have an
accuracy of +_1.0 %, & a repeatability of 0.5% of measured value &
turndown ration of 20:1. The unit shall have a separate terminal
compartment with sturdy field housing of IP67.
• The assembly shall consist of pipe reducers, flanged type isolating
valves, bypass valve, ground electrode, wires & other required
accessories on the common feed water pipeline, as per installation
directions of the meter manufacturer.
• If the unit requires 24-30 V DC supply, the necessary stabilized supply
shall be in the scope of work.
Feed water pumps : Two electrically driven multi-stage vertical type

centrifugal pumps to match the capacity of the boiler (one for duty and
one standby) shall be supplied with 4 TPH energy efficient motor (EFF1)
with ingress protection class IP 55 with TEFC motor enclosure & Class F
insulation. The pump should be capable of handling water at 100ºC
temperature and pressure above maximum discharge pressure generated
by the boiler. The class of motor insulation and number of stages of the
pump should be accordingly selected. The pumps should have SS 304
body & impellers with mechanical seals.
The pumps should be supplied with suction strainer, suction isolating

valves (butterfly/ball type). The delivery line of pumps connected to the
boiler, shall have feed check (spring loaded Disc type) valve, discharge
isolation valve (Piston type) &100mm dia. pressure gauge. Separate
delivery lines from the Feed water pumps to boiler are preferable. A
digital temperature sensor with indicator shall be provided at the suction
header of the pump, to indicate Feed water inlet temperature. A extra low
level in the feed water tank shall trip the Feed water pump with alarm.
Necessary wiring, sensor shall be in the scope of bidder.
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AUTO pH CORRECTION SYSTEM:
The system shall have a metering pump, to doze a fixed quantity of

alkaline solution into the feed water line, after checking pH online. The
system shall be complete with a mixing tank with agitator. A soft water
line shall be connected to fill water to prepare a solution of desired
concentration is included in the scope. The system shall be common for
both boiler & shall be installed on the main feeding line.
6.6 ERECTION AND COMMISSIONING:
6.6.1 The scope of work in brief includes positioning of the boiler on foundation,
connecting feed water line, steam line up to main valves, safety valve
vent line outside building, ID fan, blow down lines up to blow down pit,
electrical panel installation, power & control supply, installation &
termination to electric, double earthing of the panel and all the equipment,
fabrication of ducting as per layout, positioning of the chimney on the
foundation and making all necessary connections, completing all other
associated works.
6.6.2 The boiler should be transported by the bidder after receiving intimation
regarding readiness of the foundation. Boiler should be insured,
transported and unloaded on foundation by the bidder.
6.6.3 All mountings, fittings, accessories etc. should be installed, aligned and
piping, electrical connections etc. should be carried out as per the latest
engineering practices.
6.6.4 Necessary refractory materials, cement and insulation materials shall be

supplied and installed.
6.6.5 Chimney and ducting should be fabricated after getting the drawings
approved from the Purchaser/ Statutory Authorities.
6.6.6 For commissioning and trial run of the boiler, necessary materials for 1st
charge like lubricating oil, grease etc. shall have to be supplied by the
bidder.
6.6.7 After commissioning the boiler the following parameters are to be

established for the Boiler and recorded by the bidder.
Sr. No Parameter Instrument / Method

1 Steaming rate Steam flow meter
2 HP steam pressure Pressure gauge
3 Overall thermal efficiency Indirect method
4 Overall thermal efficiency Efficiency monitor / direct method
SPM level in flue gas after To be confirmed by bidder
5 pollution control
equipment
174
6 Fuel consumption rate From fuel feeder
Electricity consumption for Energy meter in the IMCC
7
entire plant
8 Water consumption rate Water flow meter
9 Blow down rate To be confirmed by bidder
10 Ultimate analysis of fuel Lab test
11 Proximate analysis of fuel Lab test
12 LP steam pressure Pressure sensor
13 Flue gas exit temperature Temperature indicator
14 Feed water temperature Temperature indicator
The bidder's have to specify the methodology proposed to be adopted by

them for establishing the design parameters. It will be the successful
bidder's responsibility, to provide all the necessary additional instruments
required for establishing the design parameters during testing and till the
time the results are achieved and accepted by the Purchaser.
Thereafter, the boiler should be on trial run the plant at rated capacity for
minimum four weeks, during this period training should be imparted to the
authorized operating personnel before handing over the boiler to
Purchaser / Project Authority in satisfactory working condition. Necessary
log sheet shall be maintained by the bidder during four weeks of
operation which will be signed by both the bidder’s and purchaser’s
authorized representative. The bidder shall take statutory approval for the
complete installation prior to commission the plant.
6.6.7 Cost of services for which the functioning of the boiler shall be calculated
is as follows;
Electricity Rs.6.75/- per KWH.
The working cost of the boiler with all its associated equipment shall be
as per the evaluation criteria furnished in the Quotation.
The total value of the same shall be worked out and quoted by the bidder
separately in their offer.
6.6.8 The erection and commissioning should be carried out as per general
terms and conditions of erection contract mentioned in the specification.
6.7.1 OTHER SUPPLIES
HP STEAM PIPING
Steam generated from both Boilers through the steam stop valves shall
be directed to a common HP steam header within the Boiler House. HP
steam shall be distributed to the plant across Pipe Bridge (to be provided
by purchaser) to the PRS. One PRS shall be located near or within the
Boiler House for Feed Water pre-heating & molasses pre-heating.
Necessary expansion loops, air vents, Drain trap assembly for HP piping
as per standard practices shall be included in the scope of work. All HP
pipes & fittings, PRS shall be IBR approved.
175
HP STEAM HEADER:
HP steam lines from each of the Boilers shall be terminated on a floor

supported steam header suitably located in the Boiler house at an
operation level. The size of the header shall be designed for simultaneous
operation of Boiler. Each of the incoming & outgoing lines with 2 spare
nozzles (50 mm) shall be terminated with an isolation valve. The header
shall be insulated & shall have 100 mm dia Dial type IBR approved
pressure gauge & condensate drain trap assembly.
STEAM FLOW METER:
IBR certified Steam flow meter shall be installed on the main common HP
line (before PRS) & shall be suitable for a steam throughput of 4 TPH.
Flow meter shall be vortex type with density compensation feature with
digital display of flow rate, total flow, pressure, temperature etc & shall
have communication port capable of generating analogue output.
Associated fitment for proper flow-metering shall be included in this item.
Installation of the flow meter shall be as per the OEM directives. The pipe
fittings, assembly, pipe interconnections, flanges shall be as per IBR
approved drawing with FORM III A. Necessary services like electrical
connections/compressed air etc, if required for the flow meter shall be a
part of this item. The make & model of the Flow meter to be supplied shall
be intimated in the quotation & the necessary literature/brochure shall be
submitted along with the quotation.
STEAM PRESSURE REDUCING STATION (PRS):
Steam Pressure reducing station (IBR) shall be supplied as per below

specifications and installed in the Main plant located near the pellet mills
in the main plant.
Type: Electro-pneumatic (ROBERTOR) type station assembly, (IBR

certified)
Throughput: 3000 Kgs/hr of steam. – 1 No.
Steam Pressure shall be reduced from 10.5 kg/sq.cm to 3.5 kg/sq.cm.
The PRS shall comprise of following IBR certified items;
1. Moisture separator with Drain assembly.

2. Inlet pressure gauge.
3. Inlet stop valve.
4. Strainer (with SS perforated screen).
5. Pressure Reducing valve (Electro-pneumatic type)
6. Outlet isolation valve.
7. Safety valve/valves (angle type).
8. Outlet pressure gauges.
9. Manual by-pass reduction valve.
176
The Control system of Pressure reducing valve shall have downstream
pressure sensor, P to I converter, controller, with a system for remote set-
point setting & read-out.
These pipe fittings shall be assembled on a common battery, duly

insulated & suitably supported for operation/ maintenance at operable
height. Pressure Reducing Valve shall be automatically modulated
through an electro-pneumatic system by sensing the down-stream
pressure. The pressure transmitter shall provide inputs for the controlling
of steam pressure. The pipe fittings, assembly, pipe interconnections,
flanges shall be as per IBR approved drawing with FORM III A. The entire
assembly shall be insulated (50 MM thk) & aluminium cladded as per
standard practice.
The Other PRS in Boiler House or nearby molasses day tank, shall be
Pilot operated self-acting pressure reducing station with a throughput of
700 kg/hr for the similar pressure reduction rating. Condensate from this
PRS shall be recovered & directed to the break water tank.
AUTOMATIC BLOW – DOWN CONTROL SYSTEM:
This system shall be used to automatically blow-down Boiler water in the

shell portion by sensing the conductivity & shall be dedicated for each
Boiler.
This system shall be used to inline measuring the conductivity for Boiler
water & automatically blow-down when TDS levels in Boiler water exceed
a set level. The system shall have isolating valves, pneumatically
operated control valve, non return valve, conductivity sensor of suitable
range and of material of construction SS 316, controller to control and
monitor TDS level of the boiler water, by-pass manual blow-down valve,
upstream & downstream steam piping (IBR certified) and all other
associated accessories. The entire assembly shall be insulated.
The system shall include controller installed in a panel for 4 digit

continuous digital readout of the set TDS & push button interface for
calibration & testing. Other features shall include High TDS alarm output,
automatic probe conditioner for descaling probe & automatic temperature
compensation. The pipe fittings, assembly, pipe interconnections, flanges
shall be as per IBR approved drawing with FORM III A.
BLOW – DOWN HEAT RECOVERY SYSTEM:
This system shall be used to recover heat from the Boiler blow-down
operation & shall be dedicated for the Boiler. The system shall envisage
use of the following equipments;
a) Flash vessel,
b) Ball Float trap,
c) Plate Heat Exchanger,
177
d) Break water tank (common for one planned and one future Boiler).
e) Circulation pump (common for one planned and one future Boiler).
Flash steam recovered from the flash vessel, due to intermittent blow-
down shall be connected to the Deareator head of the feed water tank.
The residual heat in the condensate shall be recovered through a suitable

capacity circulation pump by circulating break tank water. The operation
shall be controlled through a thermostat installed on the Blow-down inlet
line to the PHE. Suitable size break water tank with nozzles to receive
make –up water & discharge water to boiler feed water tank deareator
head shall be included in the scope of work. The pipe fittings, assembly,
pipe interconnections, pressure gauges, flanges shall be supplied as
required as a system. A cleaning system for PHE is included in the
scope. The circulation line shall be insulated.
INSULATION OF HP STEAM PIPING
Thermal insulation of steam lines with resin bonded mineral wool in pipe
form including cladding with 22 G Al. sheet as per IS 737-1900 (amended
as on date) should be provided.
STEAM PIPES, VALVES AND FITTINGS
Suitably supported Insulated High pressure steam lines from the outlet of
the steam stop valve/NRV from the outlet of both Boilers to header & up
to PRS, with supports, valves, standard fittings like pressure gauge, drain
trap assembly etc are included in the scope of work. The HP steam lines
shall be designed as per PRS throughput connected to them.
Necessary expansion loops shall be supplied for every 30 mts of straight

line length of piping. Expansion loops shall have drip leg with condensate
thermodynamic trap assembly, & necessary air-vents (thermostatic type)
shall be provided.
Type : Seamless Schedule 40 (IBR approved), welded type heavy duty

piping with Forged steel body & bonnet (ASTM A 105) piston type
valves/NRVs with Stainless Steel spindle & piston in flange/ screwed
execution.
Supporting: MS shoe, guide, roller support, in mild steel painted execution

generally as per specification and meeting with IBR requirements.
Accessories: Pipe sleeves, roller supports arrangement of flow

measurement at the entry point to the plant.
Pipe Insulation: 50 mm Thk insulation mineral wool, with 24 G aluminium

cladding
178
6.7.2 COMPRESSED AIR HANDLING SYSTEM:
AIR COMPRESSOR:
One number Oil free Rotary screw air compressor of suitable Free Air
Delivery (FAD) for the generation of oil-free & moisture–free Compressed
air of quality ISO 8573 -1, Class 0, suitable for pneumatically operated
instruments & other requirements for generation pressure of 7.5 kg/sq.cm
(g). This unit shall be complete with silencing canopy, intake filter & air
cooling arrangement. The compressor shall have pre-mounted electrical
cubicle to house control and monitoring system with local display. The
drive for the compressor shall be controlled through a Frequency driven
Variable Speed Drive. The motor shall be of high efficiency type with IP
55 level of protection with TEFC enclosure. The connecting Air dryer shall
be integrated with the Air compressor & shall be supplied as a single unit.
Matching capacity refrigerated Air Dryer with filters, automatic drain for
ensuring the required air quality is included in the scope. All standard
fitments required for proper functioning of the air compressor shall be
supplied along with this unit. External air receiver of minimum 1000 L (MS
tank) complete with safety valve, pressure gauge, automatic drain valve,
bypass valve is included in the scope of work. Drain from the Air receiver
shall be taken outside the building
The Flow meter shall have remote display unit mounted on the control
panel with open protocol connectivity for data transfer to the central MIS
system.
Compressed Air, fittings, tubing’s & specials for all pneumatically

instruments in the scope of supply shall be executed as per best industry
practices.
AIR RECEIVER: Capacity: 1000 litres
Function:
Air receiver shall store compressed air, help equalize pressure variation
in pipes, & prevent short cycle loading and unloading of compressor.
Design Requirement:
Receiver shall be free standing vertical tank with dished ends which shall
meet the statutory requirement of pressure vessels. Receiver shall be
designed conformity to IS 7983 and the material of construction shall
conform to the relevant IS in Mild steel. The receiver shall be complete
with safety valve, service valves, 6” pressure gauge, fusible plug, hand
holes and auto drain to remove moisture, lifting hooks, . The air receiver
shall be suitable for Design pressure of 12 Kg/sq.cm & shall pass Hydro-
test at 18 Kg/sq.cm.
179
COMPRESSED AIR PIPING AND VALVES
Heavy duty, Galvanized Steel ERW piping “C” class (shall conform to IS
1239), only welded or flanged installation, complete with SS 316 internals
ball valves, flexible metal braided hoses, PVC tubes , connectors & other
fitment, brass nipples, 4 port, 3 way Solenoid valves etc as per
requirement.
Filter-cum-regulation units shall be provided at all distribution headers

near all consumption points inside the plant. FRL units if required are to
be provided as per specific need.
Please Note: Bidder shall not consider any compressed air generation in
their scope. Only storage & distribution of compressed air shall be
considered.
6.8 TECHNICAL SPECIFICATIONS FOR UTILITIES / SERVICES
GENERAL REQUIREMENTS
The supply of pipes, valves, fittings and accessories for utilities and
services includes but not limited to that, HP and LP steam, feed water,
safeties and drains
The following may specially be noted.

1. For pipe sizing the following flow rates is to be considered.
HP Steam: 25 m/sec
Water line (suction): 1.0 mtr/sec
Water line (discharge): 2.0 mtr/sec
Compressed Air: 18 mtr/sec 2.
2. All valves for above services are to be flanged type except those below
25 mm.
3. The supply of above service pipes should be inclusive of same quality
bends, tees, flanges and with necessary gaskets, bolts, nuts etc
4. Materials for piping;
For raw water and soft water, pipes; Galvanized steel (ERW) IS
1239,3589, 3601,4736 (medium duty)
For steam lines and compressed air line: MS 'C' class pipes (ERW) IS
1239/3601/4736
Valves (all valves for steam, water, air shall be glandless type)
Service Fittings Size specifications

valves 15mm to 40mm Forged carbon steel body (A105) with SS
internals, piston valve with SW ends.
HP 50mm to 100mm Forged cast steel body (ASTM A216 WCB)
steam with SS internals piston valve (for isolation)
with flanged ends.
NRV 15 mm to 100mm Ferritic / austenitic SS body, disc and spring
180
of austenitic SS disc check valves with
heavy duty springs, wafer pattern,
sandwiched between flanges (NRV)
Valves 15 mm to 40mm Forged carbon steel body (A105) with SS
internals, piston valve with SW ends or CS
body, SS ball, special PTFE seats, 800#
with SW ends ball valves
NRV 15mm to 40 mm Ferritic / austenitic SS body, disc and spring
sandwiched between flanges (NRV)
LP
Valves 50mm to 100mm Forged cast steel body (ASTM A216 WCB)
Steam
with SS internals piston valve (for isolation)
with flanged ends.
NRV 50mm to 100mm Ferritic / austenitic SS body, disc and spring
sandwiched between flanges (NRV) or CS
body, 13%Cr trim 150#, flanged swing
check (NRV)
Valves 15mm to 40mm CS body., SS ball, PTFE seats, 800# with
SW or SCD ends ball valve
Water /
Valves 50mm to 150mm CI body 13%Cr disc, 125# wafer type
Air
butterfly
NRV All sizes CS body 13% Cr trim, wafer type check
Flanges/counter flanges shall be as per BS tables:
Table F for HP steam;

Table D for water;
Table E for air
5. Painting of pipelines with anti corrosive primer and paint of approved

shade including, lettering, marking, flow directions etc., shall be as per
specifications.
6.9 Details of the boiler plant with associated equipment:-
Sr. No Description Requirement

1 Boiler capacity Continuous water evaporation of 4 TPH
rating F&A 100˚C based on net peak
steam demand of 3000 kgs/hr @ 3.5
kgs/sqcm
2 Operating pressure 10.5 kg/sqcm (g)
3 Boiler qty 01 No.
4 Chimney Height shall be as per statutory regulation.
This shall be suitable for venting out flue
gases from 1 no of 4 TPH boiler. Design
considering one future boiler.
181
5 Chimney qty. 01 No.
6 Type of chimney MS construction, self supported and
mounted on concrete foundation outside
the boiler house.
7 Flue gas ducting From the boiler outlet port up to the
common chimney across bag filter, ID fan
etc.
8 Air ducting including FD, From FD fan, APH, PA fans up to fluidized
PA, APH bed
9 Auto blow down system Required
and heat recovery
system
10 Steam flow meter Required
11 Air preheater Required
12 Control pollution control Required
equipments like bag
filter, MDC
13 Auto pH correction Required
system
14 Automatic fuel, handling, Required
storage and feeding
system
15 PRS Required
16 Feed water tank Required
17 Water flow meter Required
Items required for establishing Boiler efficiency
The bidder should provide the following analyzer at their cost for
establishing capacity and efficiency of the boilers during trial runs. This
instrument can be taken back by the bidder after successful trials.

ALONGWITH THE QUOTATION
A) DRAWINGS
• GA drawings: The general arrangement (GA) drawing of boiler and

common chimney and drawings of associated equipment like Pollution
control equipment, dust extraction system, fuel handling & feeding system
etc., indicating dimensions, tolerances etc., as proposed by the bidder
• Layout drawing: The machinery and equipment layout drawing of the
entire steam generation system showing layout of the boilers with the
common chimney and with all accessories including panels complete.
• Service piping & Schematic: Feed water schematic piping; steam piping,
compressed air piping (including branch lines, valves, safety valves, Fuel
handling & feeding system & detailed description of automation for the
entire supply and all accessories etc., to be submitted with quotation.
• Electricals: The single line diagram showing electrical power distribution
from the panel, details of motor HPs of all the motors, cable sizes of
182
feeders to various equipment etc., to be furnished. Control wiring and
automation scheme diagrams of the relevant panel drawings to
understand the control scheme/logic is to be submitted by bidder.
• Catalogues: The relevant catalogues, technical data sheets, drawings,
photographs etc., of each equipment/accessory being offered to be
submitted by bidder.
B) EQUIPMENT
List of equipment of the steam generation plant with adequate brief
specification of each item including construction material, critical
thicknesses, and length / height / capacity, drive details, make/model etc.
A comprehensive list of essential spares for the entire supply.
C) Technical Data & details (to be furnished by the Bidder) in the following
proforma:
S. No Description Details
7.1 Boiler Details
Design code of boiler
Type of combustion system
Type of boiler (design)
Type of fuel which can be used
Type of water circulation
Type of supports / installation
Model
No. of passes
7.2 Steam generation (F&A 100˚C of water) Kg/hr
7.3 Steam quality
Max. total solids ppm
Silica ppm
Dryness fraction
7.4 Steam pressure Kg/sq.cm (g)
Safety valve-1 set pressure Kg/sq.cm (g)
Safety valve-2 set pressure Kg/sq.cm (g)
No. on steam drum (MOC/Size/Qty) Kg/sq.cm (g)
No. of dosing line (MOC/Size/Qty) Kg/sq.cm (g)
No. of pressurized water line Kg/sq.cm (g)
(MOC/Size/Qty)
No. of non pressurized water line Kg/sq.cm (g)
(MOC/Size/Qty)
Modulating pressure control range __to__Kg/sq.cm
(g)
High steam pressure alarm pressure switch Kg/sq.cm (g)
setting
7.5 Boiler thermal efficiency
Boiler eff (%) based on G.C.V of fuel at
100% load
183
Boiler eff (%) based on G.C.V of fuel at 75%
load
load
load
7.6 Boiler water concentration limits
Hardness as CaCO3 ppm
Total dissolved solids ppm
Suspended solids ppm
Alkalinity as CaCO3 ppm
pH value
Free CO2 ppm
Dissolved oxygen ppm
Silica ppm
Phosphates as PO4 ppm
Sodium sulphite as SO3 ppm
7.7 Connected/ consume electrical load No. HP
Total
Feed water pump
FD fan
Booster fan
ID fan
Bag filter unit
Mechanical dust collector
Circulation pump
Aspiration unit dumping hopper
Conveyor for crusher
Crusher
Vibrating sieve
Recirculation elevator
Elevator for bunker filling
Conveyor for bunker loading
pH correction system’s pump, agitator etc.
Any other load
7.8 Utilities consumption at maximum rated
capacity
Fuel (coal or agro based briquette) Kg/hr
Electricity KWH
Water Kg/hr
7.9 Boiler dimension
Overall dimension of boiler
Recommended size of boiler house suitable
for 01 no boiler
7.10 Mechanical details of boiler
Total heating surface area (sq.m)
Bed coil
Furnace water wall
184
Boiler bank
Air per heater
7.10.1 Tubes
OD x thickness (mm)
Qty (nos)
Material of construction
No. of passes in the shell
7.10.2 Shell
Thickness (mm)
Diameter (mtrs)
Length (mtrs)
Material of construction
Steam- water interface area
Water content at working level (cum)
7.11 Feed water and cooling water arrangement
No. of pumps
Standby water pumps
Type of pumps
NPSH required
Capacity of each pump (cum/hr at MWC
head)
Feed water temperature indicator
7.11.1 Cooling water
Cooling water qty (m3/hr)
Pressure (kg/cm2(g))
Temperature (˚C)
Quality
7.11.2 Auto pH correction system
Make of pump
Pump type
Pump capacity (l/hr)
Tank capacity (L)
7.12 Valves in water feed piping
Stop valve at pump outlet (yes/no)
Non-return valve at pump outlet (yes/no)
Pressure gauge at pump outlet (yes/no)
Pump suction side isolating valve (yes/no)
7.13 Fuel handling and feeding system
Bunker
Type
No. of bunkers per boiler
Bunker storage volume
Bunker MOC
Type of conveyor and capacity
Type of intake elevator and capacity
Type of recirculation elevator and capacity
Type and capacity of crusher
Type and capacity of vibro screen
185
Type and capacity of dust extraction system
for dumping hopper
Type and capacity of dust extraction system
of crusher
Type and capacity of distribution conveyors
Type of fuel feeding system
Type of feeders
No. of feeders
Type of feeder control (VFD or Dynadrive)
Drive rating (kW)
No. of venture
Venture MOC
No. of tight shut off dumpers in bed
7.14 Other accessories
7.14.1 Air pre-heater
Type
Tube size
Tube MOC
Sheet MOC
Flow medium – inside tube
Flow medium – outside tube
7.14.2 Draft equipment specification FD / ID / PA fan
Flow rate (m3/min)
Design head (mm WC (g))
Medium
Temperature (˚C)
Motor rating (kW)
Qty
Fan speed (rpm)
Type
7.14.3 Other items
Size of flash vessel (dia, height, port sizes)
Plate heat exchanger (H.Tr.Area) & make
MOC of plates
Circulation pump capacity, head, type
Break water tank capacity and MOC
% of BD heat after FV recoverable
Type of PRV for main plant and size
Model of PRV for main plant
Type of PRV for boiler house and size
Model of PRV for boiler house
7.15 Firing and bed arrangement
7.15.1 Furnace
Type of furnace
Volume
Firing / arrangement (manual/auto)
Water wall construction
Water wall tube size
186
Water wall tube MOC
Header size (dia-mm)
Header MOC
Strip MOC
No. of access doors
7.15.2 Fluidized bed and bed tubes
Total no. of plenum side partitions
Height of plenum chamber
MOC of nozzles
Pressure drop in the nozzle
In bed tubes size (dia x thk)
In bed tube pitching (mm)
In bed tube MOC
In bed tube header MOC
In bed header diameter
Type of fluidized bed wall construction
MOC of the furnace refractory
MOC of outer layer of the refractory
MOC of inner layer of the refractory
Type of air distribution and MOC
Mode of fuel charging
Normal fuel bed depth (static)
Expanded bed height
Furnace draft (in mmwc)
Type of refractory bricks used
Arrangement for ash removal (qty)
Recommended size of fuel for firing
7.15.3 Start up fuel / chemical / lubricant
Diesel (ltrs)
Silica sand (dry) (kg)
Charcoal for single start up (kg)
Firewood – dry (kg)
7.16 Flue gas and air
Flue gas opening size on boiler (mm)
7.16.1 Air pre-heater
Overall size
Heat transfer area
Damper provided or not
By-pass arrangement provided (yes/no)
Details of controls provided
7.16.2 Chimney
Dia at base of chimney
Dia at top of the chimney
Number of chimney sections
Dia at base of each section
Dia at top of each section
Height of each section
Total height of the chimney
187
Plate thickness at each section
Supporting arrangement
7.16.3 Flue gas ducting
Size (mm)
Length (mtrs)
Plate thickness (mm)
7.16.4 Flue gas analysis (%wt)
CO2
H2O
SO2
O2
N2
7.16.5 Flue gas analysis (%vol)
CO2
H2O
SO2
O2
N2
7.16.6 Ash analysis
Silica (SiO2)
Iron oxide (Fe2O3)
Aluminium oxide (Al2O3)
Calcium oxide (CaO)
Magnesium oxide (MgO)
Sodium oxide (NaO)
Unburnt carbon
Sulphuric trioxide (SO3)
Quantity of ash generation/ton of steam
generation
7.16.7 Temperature profile
Flue gas
Furnace temperature (˚C)
Boiler bank outlet (˚C)
Air pre heater outlet (˚C)
7.16.8 Air
Inlet air (˚C)
Outlet air after APH (˚C)
7.16.9 Water
Inlet to economizer (˚C)
Outlet of economizer (˚C)
7.16.10 Ductings
Air ducting thickness (mm)
Flue gas ducting thickness (mm)
Boiler bank and APH hopper thickness
(mm)
Plate MOC
Ducting MOC
Hoppers MOC
188
Ash silo MOC
7.16.11 Compressed air
Air compressor FAD m3/h
Type of compressor make and model
Instrument air qty
Pressure kg/cm2 (g)
Temperature
Drier make and capacity
Quality and dew point
7.16.12 Conveying air
Air qty
Pressure
Temperature
Quality
7.17 Automatic water level controls
Single element controller type (yes/no) – qty
Type of control valve provided and size
Mobrey level controller (yes/no) – qty
Alarm and signal provided for
Low level (yes/no)
High level (yes/no)
Extra low level (yes/no)
Low level signal from feed water tank
(yes/no)
7.18 Boiler mountings and fittings Qty size make
Steam stop valve
Non-return valve
Safety valve
Feed check valve
Blow down valve for shell
Blow down valve for in-bed header
Air vent valve
Water level gauge
Steam pressure gauge
Steam flow meter
Auto blow down system
7.19 Structural’s
Provision of platform for boiler (yes/no)
Provision of ladder / staircase for boiler
(yes/no)
Structural platform for pollution control
equipment
Structural works for ID, PA, FD fans
(yes/no)
7.20 Boiler losses
(break up details of losses in % to be Wood
furnished on GCV basis) briquettes
Dry stack loss
189
Sensible heat loss
Moisture in air loss
Radiation loss
Unaccounted loss
Total loss
7.21 Critical performance parameters at full load
Net effective area of heat transfer (sq.m)
Flue gas temperature / stack temp (˚C)
Excess air %
Steam to fuel ratio
Water volume (ltr)
Steam space (ltr)
Volumetric heat release (kcal/cum)
Steam generation rate (kgs/sq.m)
Electricity consumption at rated capacity
8.0 TECHNICAL DETAILS AND DRAWINGS TO BE TO BE SUBMITTED

AFTER AWARD OF CONTRACT

1. The final equipment GA drawing of boilers and common chimney being
manufactured after approval by purchaser
2. Final services / utilities schematic with sizes of pipe lines, valves,
insulation thickness, controls, showing all instruments and accessories
4. Final electrical load details in HP/KW
5. Final control schematic of the control panels, automation including the
proposed architecture showing control panels, PLC, Control station etc.
6. Final list of essential spares.
Sr. Unit
Description of equipment/item Capacity/ size Qty Total Amount
No. rate
PART (A) : DESIGN & SUPPLY OF THE FOLLOWING: Rs. Rs.
1. Solid fuel fired steam 4 TPH (Mention 1 sets
generation plant complete with the capacity) F
FD, ID, PA Fan, FW pumps & A 100 Deg C
and all associated @10.5
accessories, mountings kg/sq.cm (g)
2. MS self-supported chimney Chimney 32 m 1 set
(suited for simultaneous (min), & as per
operation of both the boilers) PCB norms
with foundation bolts including
Flue gas ducting
3. Air pre-heater with air ducting As per site 1 sets
layout
4 Pollution Control equipment --- 1 sets
including Bag filter &
190
5 Auto blow-down Control system --- 1 sets
& heat recovery system
including Flash vessel etc.
6 Automatic fuel handling, Bunker shall be 1 Lot
storage & feeding system of capacity for
one day
consumption
Fuel handling
system shall be
of capacity
such that the
one days
consumption is
handled in one
shit of 8 hours)
1 day’s
requirement
7 HP Steam flowmeter “Vortex --- 1 sets
type” with digital indicator
8 Steam Pressure Reducing
Stations (Robertor type)
8a. For throughput of 3000 kg/hr (10.5 to 3.5 1 set
kg/sq.cm)
8b. For throughput of 700 kg/hr (10.5 to 3.5 1 set
kg/sq.cm)
9. HP steam pipes, valves and As per site 1 lot
fittings , including expansion layout
loops, air vent, drain trap
assembly, steam header etc.
10. Water handling system
10a. Raw water pumps 30 KLPH, 1 sets
suitable head
10b. Multi-grade filter 30 KLPH, 1 set
suitable head
10c. Water softener with softener 15 KLPH, 200 1 set
pumps, magnetic flowmeter m3 (OBR)
10d. Feed water Tank with , 20 KL 1 No
deareator & circulation pump
10e. Water pipes, valves & fittings, ----- 1 Lot
level sensors , level controllers
etc.
10f. Water level indicators ( 2 nos ----- 4 sets
for OH tank, 2 Nos for UG
sump)
10g. Water flow meter (vortex) type --- 1 sets
with indicator
10h. Automatic pH correction system --- 1 set
191
11. Compressed Air system
11a Air compressor with dryer suitable 1
11b. Air receiver with auto-drain 1000 L 1 set
11c. Air flowmeter (vortex type) ----- 1 set
11d. Compressed Air pipes, valves & As per site 1 Lot
fittings layout
12. Structural steel platform, Trench As per site 1 Lot
covers, staircase /ladder etc layout
13. MCC, Electrical cabling, cable As per site 1 Lot
tray, panel room AC, Remote layout
Control panels, earthing
network, earth pits etc.
14 Plant Automation complete with 1 lot
Boiler Control panel, Direct
efficiency monitor, sensors,
instruments , indicators,
gauges, PID controllers etc
15 Spares for 2 years operation ----- 1 set.
16 Statutory approvals including ----- 1 Lot
submission of approved
drawings, Boiler Folder &
documents for Boiler, PRS, HP
steam piping , PCB, electrical
Insp. Etc.
PART (B) : LABOUR CHARGES FOR INSTALLATION,
TESTING, COMMISSSIONING OF THE FOLLOWING:
1. Solid fuel fired steam 4 TPH F & A 1 sets
generation plant complete with 100 Deg C
FD, ID, PA Fan, FW pumps @10.5
and all associated kg/sq.cm (g)
accessories, mountings
2. MS self-supported chimney with Chimney 32 m 1 set
foundation bolts including Flue (min), & as per
gas ducting PCB norms
3. Air pre-heater with air ducting As per site 1 sets
layout
4 Pollution Control equipment --- 1 sets
including Bag filter &
5 Auto blow-down Control system --- 1 sets
& heat recovery system
including Flash vessel etc.
6 Automatic fuel handling, 1 day’s 1 Lot
storage & feeding system requirement
7 HP Steam flowmeter “Vortex --- 1 sets
type” with digital indicator
8 Steam Pressure Reducing 1 set
Stations (Robertor type)
8a. For throughput of 3000 kg/hr (10.5 to 3.5 1 set
192
kg/sq.cm)
8b. For throughput of 700 kg/hr (10.5 to 3.5 1 set
kg/sq.cm)
9. HP steam pipes, valves and As per site 1 lot
fittings , including expansion layout
loops, air vent, drain trap
assembly, steam header etc.
10. Water handling system
10a. Raw water pumps 30 KLPH, 1 sets
suitable head
10b. Multi-grade filter 30 KLPH, 1 set
suitable head
10c. Water softener with softener 10 KLPH, 200 1 set
pump, magnetic flowmeter m3 (OBR)
10d. Feed water Tank with , 20 KL 1 No
deareator & circulation pump
10e. Water pipes, valves & fittings, ----- 1 Lot
level sensors , level controllers
etc.
10f. Water level indicators ( 2 nos ----- 4 sets
for OH tank, 2 Nos for UG
sump)
10g. Water flow meter (vortex) type --- 2 sets
with indicator
10h Automatic pH correction system --- 1 set
11.Compressed Air system

11a.Air receiver 1000 L 1 set
11b.Air flowmeter (vortex type) ----- 1 set
11c.Compressed Air pipes, valves & As per site 1 Lot
fittings layout
12. Structural steel platform, Trench As per site 1 Lot
covers, staircase /ladder etc layout
13. MCC, Electrical cabling, cable As per site 1 Lot
tray, panel room AC, Remote layout
Control panels, earthing
network, earth pits etc.
14 Plant Automation complete with 1 lot
Boiler Control panel, Direct
efficiency monitor, sensors,
instruments , indicators,
gauges, PID controllers, Panel
room AC etc
193
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Maakkeess ooff B
Boouugghhtt oouutt IItteem
mss ((N
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STEAM RAISING PLANT & ACCESSORIES

Boiler feed water pump GRUNDFOS/ SALMSON/ KSB/ B.E. PUMPS
HP / LP Steam / condensate FORBES MARSHALL/AUDCO / CRESCENT /
Valves LEADER / THERMAX / BDK /SHARP / INTERVALVE
Steam Traps & strainers SPIRAX / MAZDA / SAMSON / THERMAX
Steam Pressure Reducing

SPIRAX / MAZDA /THERMAX
Valve
Non Return Valves AUDCO / SPIRAX/ BDK / GG / INTERVALVE
Steam Pre. Red. Station JN MARSHALL (SPIRAX) / MAZDA / THERMAX
Manometer TECHNOFLOW
Steam /water/Air
E & H /ROSEMOUNT
flowmeter
Expansion bends SPIRAX MARSHALL / MAZDA / THERMAX
Pressure gauges FORBES MARSHALL/ H GURU/ FIEBIG /GLUCK
Blow down valve LEVCON/ SHARP/ LEADER / SANT/ SPIRAX
Steam relief valve SEMPELL/LEADER /FAINGER LASER
Water level indicator with drain TELEFLO/SHARP/LEADER/HAWA/ FORBES /MH
cock BROS
Automatic water level
ABB/Yokogawa
controller
Forced Draft / PrimaryP
FLAKTWOODS / NADI/ LAXMI/UNIVERSAL/ AIR
AirpInduced Draft / Primary
CONTROL
Air Fan
DANFOSS / ALCO / HANSEN / PARKER / E&H/
Pressure switches SWITZER / PYROTECH / ALTOP / GIC/ WIKA /
INDFOSS
Resin bonded mineral
LLOYD / UP TWIGA / MINWOOL / ROCKWOOL
wool
Conductivity & pH Transmitter E&H / EMERSON / YOKAGAWA
Pressure gauges FORBES MARSHALL/ H GURU/ FIEBIG/ GLUCK
Dial type thermometers FORBES MARSHALL/ H GURU/ FIEBIG/ GLUCK
Temperature sensors and
YOKOGAWA/ TATA HONEYWELL/ RADIX/
digital indicators/ controllers/
PYROTECH/ CHINO/ ENDRESS + HAUSER
recorders
VALVES , PIPES (MS & GI), FITTINGS, ACCESSORIES
Water/Air Valves ( Butterfly / SAUNDERS / AUDCO / INTERVALVE / BDK /
Ball) CRESCENT / LEADER
Non-return Valve for water
AUDCO / INTERVALVE / BDK / FORBES MARSHALL
(wafer type)
GI Pipes for water TATA / MST / JINDAL / ZENITH / SURYA ROSHNI
MS Pipes for air, steam &
TATA / JINDAL / KALYANI / MST / ISMT
condensate
NRV for Air Line INTERVALVE / AUDCO / LEADER
MISCELLANEOUS ITEMS MECHANCAL/ELECTRICAL
Geared Motor / Gear Box PBL / POWER MASTER / ELECON / RADICON/
194
SHANTHIGEAR / IC BAUER / BONFIG LOLI / EURO
DRIVES
BHARAT BIJLEE / SIEMENS / ABB / KIRLOSKAR /
Electric Motors
CROMPTON GREAVES
SIEMENS / ALLEN BRADLEY / DANFOSS / ABB /
VFD
L&T YASOKAWA
DANFOSS / L&T/ SIEMENS / ROCKWELL (ALLEN
Electronic Soft Starter
BRADLEY) / SCHNEIDER / ABB
Level Transmitter & indicator ABB
TI and TIS SELECTRON
Intelligent Motor Protection
L&T / SIEMENS / ABB / SCHNEIDER
Relay
Energy Monitor ALLEN BRADLEY / SIEMENS / ABB / L&T
Voltage / Current / Energy /
RISHABH / ENERCON
Power factor Transducer
COMPAQ/HEWLETT-PACKARD/IBM LENEVO/ DELL /
PC (Personal Computer)
ACER / HCL / WIPRO
SIEMENS / ALLEN BRADLEY / HONEYWELL/
PLC System
SCHNEIDER / L&T QUANTUM / EMERSION
L&T / MDS-LEGRAND / SIEMENS / ABB / MERLIN
MCCB, MPCB
GERIN / GE / CROMPTON GREAVES
Contactors L&T / SIEMENS / ABB / SCHNEIDER
Starter Overload Relays L&T / SIEMENS / ABB / SCHNEIDER
Timers Electronic L&T / SIEMENS / BCH / GE
Switch Fuse Units L&T / SIEMENS / ABB / SCHNEIDER / C&S/ GE
MCBs SIEMENS/ L&T-HAGER / MDS-LEGRAND / GE
Push Buttons ESBEE / SIEMENS / GE / VAISHNO / TEKNIC
Indicating Lamps L&T / SIEMENS / VAISHNO / TEKNIC
Digital Ammeter &
ANERCON / L&T / HPL SOCOMEC / MECO
Voltmeter
Analog Ammeter &
RISHABH / IMP / MECO / AE
Voltmeter
Current Transformer KAPPA / MECO / AE / IMP / INDCOIL
CCI / FORT GLOSTER / RPG ASIAN / INCAB /
LT Power Cables
FINOLEX / UNIVERSAL / NICCO
CCI / RPG ASIAN / FINOLEX / RR KABELS (UNILAY)
LT Copper Control Cables
/ FORT GLOSTER / LAPP KABEL
Signal & Instrument cable LAPP KABEL / POLYCAB / THERMOPAD
Temperature sensors / digital YOKOGAWA / CHINO / TATA HONEYWELL / RADIX
indicator / controller / recorder / PYROTECH / E & H
PVC Insulated Copper wire (
FINLOEX / RRKABEL/
for panel)
Cable Tray INDIANA / MEK / SUNRISE / SUPER / PILCO
Isolating Switches SIEMENS / L&T / ABB / SCHNEIDER / C&S
HRC fuses L&T / SIEMENS / EE / C&S
IP 55 boxes for motor
isolators, push buttons, HENSEL / HANSU
junction boxes etc.
Terminal Blocks WAGO / LAPP INDIA / CONNECT WELL / ELMEX
195
Selector Switch KAYCEE / SALZER / L&T
COMET / EX-PROTECTA / DOWELS / LAPP KABEL /
Cable Glands
BRACKO
Cable Lugs DOWELS / COMET / LAPP KABEL
Structural Steel SAIL / TISCO / RINL / IISCO / ESSAR
CARRIER / VOLTAS / BLUE STAR/ LG/ HITACHI /
Air Conditioner (Split)
GODREJ
MALDE / MEHER / KHATAU JANKAR / SIEMENS /
Power Capacitors
EPCOS/ MOMAYA.
SHAVO NORGEN / FESTO / AIRMATIC / LEGRIS /
Air lines accessories
NUCON
Auto Drain Valve ULTRA FILTER / ZANDER
TETRA PAK / APV / GEA-ECOFLEX / ISOFTC-
PHE Type Water Heater
SONDEX
196
COMMISSIONING OF 6000 MT
CAPACITY MILD STEEL MOLASSES
STORAGE TANKS FOR LIQUID
MOLASSES.
197
1.0 INTRODUCTION
This documents outlines the technical specifications for the Design,

Manufacture, Supply, Erection, Testing and commissioning of 2 Nos. Mild
Steel Bulk Storage tanks of 6000 MT capacity each for storing of liquid
molasses required for the 800 MTPD Cattle Feed Plant.
These technical specifications are for the guidance of the bidders only
and not intended to bring out all the details of design and fabrication of
the tanks. The successful bidder shall be fully responsible to undertake all
the work involved in the design, engineering, supply of sheets/plates,
structural, including the fabrication, testing and commissioning of these
Mild Steel Bulk Storage tanks of 6000 MT capacity each and their
accessories. Bidders are to note that these storage tanks being offered in
this quote shall be part of the overall project and together with the main
feed plant equipment they shall be fully responsible in the overall timely
implementation of the project on Turnkey basis, within the battery limits
defined in this slice. The work being carried out shall confirm to high
standards of engineering design & workmanship. The tanks offered shall
be capable of performing to meet agreed performance standards and
acceptable to the purchaser/client. No exclusions of any nature are
acceptable, other than those specifically detailed in this document.

provided with insufficient technical data/information/documents is liable to
be considered as non-responsive.
The Purchaser/Client will interpret the meaning of the specifications and

drawings submitted by the bidder and shall have the right to reject the
quote, if in their opinion, the same is not in full accordance to
specifications.
2.0 SCOPE OF WORK
The scope of the work for the slice is as follows:
2.1 Design, detailed engineering, supply of plates, structural etc., fabrication

at site, testing and commissioning, including calibration, painting and
handing over to purchaser’s satisfaction of the following.
A) Design and supply of
• Mild steel bulk storage tanks, two nos. of 6000 MT each which may be in
the form of plates and other structural completely welded at site with
internal supporting structure like cross bracing, king supports etc. This
includes the molasses Intermediate Tank one no. of 10MT, molasses
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pumping to the storage tanks and from the storage tanks to Intermediate
Tank. This does not include the molasses day tank at the plant, and the
distribution system to the molasses day tanks.
• External interconnecting structural platform with spiral staircase, platforms

and walkways for the Two Bulk Molasses Mild steel storage tanks
including the MS box type columns, beams, channels, angles, flats, kick
plates, staircase, and railings including chequered plates etc.
• The steam coils for both the bulk tanks & intermediate tank to be
provided. MOC of steam coils are MS C Class pipes.
B) Labour for fabrication, Erection, testing and commissioning of:
• Mild steel bulk molasses storage tanks. The scope includes site
fabrication of the tanks on the civil foundations provided by the purchaser
complete as per requirement.
• Structure complete with platform, chequered plates, ladders, walkways,

railings, steam coil etc. required for the interconnection and access for
maintenance of these Bulk Molasses storage tanks
Note: Commissioning of the Bulk molasses storage tanks is complete

only after water fill hydro test, sandblasting, painting, calibration etc.
2.1.1 STEEL BULK STORAGE TANKS FOR LIQUID MOLASSES
1. Mild Steel Molasses Storage Tank 6000 MT 2 Nos.
2. Inter Connecting Mild Steel Structural Platform, 1 Lot.

Railing with two circular rings on top, with toe guard
with 6" height
3. Molasses Transferring Pumps from Sump to Storage 4 Nos.

Tanks (Pumps with Stainless steel SS 304 covers)
4. Required valves, headers, piping, overflow line back 1 Lot

to the sump, automatic high level-low level control &
temperature control with indicator accessible to
SCADA, digital level transmitter with indicator etc
5. Mild Steel Intermediate Molasses Storage Tank 10 MT 1 No.
6. Molasses Transferring pumps from Storage Tanks to 2 Nos.

Intermediate Tank (Pumps with Stainless steel SS 304
covers)
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7. Required valves, headers, pipings, level & temp 1 No
control with digital display accessible to SCADA.
2.2 Important note for Bidder:
• The tanks have to design as per the structural requirements of product

and self load and wind, earthquake and other loading factors taken into
consideration.

totality. The tank dimensions shall be designed so as to achieve the
minimum storage capacity of each tank considering the product and its
bulk density. The viscosity of 2000 seconds red wood 1 at 20 Deg. C. and
specific gravity of molasses may be considered to be 1.4.
• The Diameter of tanks shown in the site plan is approximate. It may vary
as per the design of the bidder. Successful bidder has to supply the
equipment as per the approved equipment drawings.
• The equipment components viz. plates and support structural shall be

supplied on FOR site basis inclusive of packing & forwarding, insurance,
freight, taxes, duties, octroi etc.
• The tank complete with accessories shall be covered under the

• Bidder has to make its own arrangement for all tools, tackles, scaffolding,
welding machines and other accessories for fabricating the tank at site.
• The bidder shall make his own arrangement for the power required for
fabrication. In case the same is arranged by the purchaser, the same
shall be charged on lump sum basis at 0.5% of the whole contract value
of supply and labour. This power shall be made available at one point
within the site and bidder shall make his own arrangements for tap off
from this point.
• Water for commissioning shall be arranged free of cost by the bidder near
the tank and bidder shall make his own arrangements for tap off from this
point
• The bidder shall submit a GA drawing mentioning overall dimension,

thickness of bottom plate, top roof and various shell segments, sizes of all
nozzles, location and sizes of king posts, cross bracings, total quantity of
mild steel required for each tank etc. However, the successful bidder shall
submit the detailed fabrication drawing to the purchaser for approval prior
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to start fabrication, clearly indicating typical welding joints, width of
sheets, details of various nozzles/components etc.
The Mechanical and Structural design of these tanks shall comply with
the latest relevant Indian standards. Safety and other statutory
regulations/ requirements shall comply with that being followed in the
country.
Bidder has to submit purchased steel material test certificates to

purchaser/project authority.
Bidder shall provide the stability certificate from their structural consultant
for the structural stability of these tanks.
Calibration of tank and approval of the tanks from Excise and Weights &
Measures is part of the scope. However statutory fees paid if any, shall
be reimbursed on production of originals.
4.0 BATTERY LIMITS
The Purchaser shall provide the RCC foundation for molasses storage
steel tanks as per load details provided by the bidder. The bidder's
scope of works includes design of tanks, fabrication as per approved GA
drawing, certified by their structural consultant, supply of steel required as
per detailed fabrication drawing prepared by bidder and approved by
purchaser, fabrication of tanks on RCC foundation at site, providing all
flanged type nozzles such as inlet, outlet, drain, man hole & its cover, air
vents, over flow and float type level indicators etc., testing,
commissioning, calibration, cleaning by sand blasting and painting.
Provide inter connecting structural platform, separate staircase with
railing, top railing with toe guard, valves with counter flanges for drain,
inlet & outlet, over flow line up to molasses sump, level & temperature
control system, steam heating system, in each tank are also in the
bidder’s scope of works.
Transferring molasses from RCC pit to MS molasses storage tanks

through pump and then from outlet of molasses storage tank up to the
Intermediate tank through pumps with inlet and outlet headers shall be
provided by the bidder.
Bidder’s scope also includes arranging inspection and obtaining approval

from Excise and Weights & Measures, as required from local authorities.
Bidder shall also arrange inspection and obtain approval from their
structural consultant for structural stability of molasses storage tanks and
also from Local factory Inspector, or from other statutory bodies if
required.
Water required for testing shall be provided by purchaser in one point

inside the plant premises. Arranging water from this point to molasses
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tank and filling water into tanks shall be done by bidder. Testing of tanks
with water shall be done one by one so that same water can be used for
testing of all the tanks.
Molasses required for commercial production shall be provided by

purchaser/project authority. All consumables like packing for flanged
joints etc. and commissioning spares required if any, for installation,
testing & commissioning till taking over the plant by the purchaser shall
be provided by bidder and the same after taking over the plant shall be
provided by purchaser / project authority.
Power for fabrication
Power for fabrication shall be arranged by bidder at his own cost. In case
power is arranged by the purchaser, then recovery @ 0.5% of entire tank
contract value shall be recovered from the bidder by the purchaser.
EXCLUSIONS
All civil foundations for the tanks shall be provided by purchaser.

Molasses shall be arranged by the purchaser/project authority.
6.0 TECHNICAL SPECIFICATIONS OF INDIVIDUAL EQUIPMENT
6.1 MOLASSES STORAGE TANKS Capacity - 6000 MT (2 nos.) (Each Dia
25 Meter X 9.5 Meter Height) with steam heating coil.
Intermediate Tank Capacity: 10 MT (1 no.) (Horizontal 1.75m dia X
3 M length, 6 mm MS plate body) with steam heating coil
6.1.1 FUNCTIONAL REQUIREMENTS
These are required for storage of molasses in bulk in plants.
6.1.2 DESIGN REQUIREMENTS
• Capacity of each tank 6000 tons with Molasses specific gravity of 1.4.
Capacity of Intermediate tank: 10 tons.
• Material of construction - Mild steel structural steel as per IS 2062 Grade

A ; IS 808 for Rolled steel for beams, channels, angles; IS 1730 for
Plates, trips, flats ; IS 1239 for MS pipes.
• Tank to be fabricated at project site with welded construction on

foundation provided by purchaser.
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Molasses storage tank to be welded type, vertical and cylindrical shape,
mild steel construction, circumference/base of steel plate and having
internal steel structural members like cross bracings, central king post,
additional king post, circumferential stiffener rings etc. Each tank to be
provided with standard accessories such as spiral ladders, rung ladder
(welded inside the shell), safety railing on top with toe guard, manholes
(at bottom and top), inlet, outlet, air vents, float type level indicators,
drain, digital level transmitter with display unit accessible to SCADA. Two
adjoining tanks to be connected with working platform at top. Tanks to be
fabricated at site on civil foundation (1 M above ground). Civil foundation
shall be provided by the Purchaser. After fabrication, the tanks are to be
tested with water for leakages and then all internal surfaces are to be
cleaned by sand blasting and then provided with epoxy painting. All
outside surfaces are to be sand blasted and provided with enamel primer
and paint. After testing, all the two tanks to be calibrated.
6.1.3 SCOPE OF SUPPLY
6.1.3.1 Bottom Plate: Minimum 16 mm thick with lap joint welding with 75 mm
overlap.
6.1.3.2 Vertical Shell:
Bottom 4.50d M - Minimum 12 mm thick

Intermediate 1.50 M - Minimum 10 mm thick
Next 3.0 M - Minimum 8 mm thick
Roof plate - Minimum 6 mm thick
Double 'V' groove welding on both sides.
Steam Heating coil at the bottom of the shell (MS C class pipe 32 NB)
6.1.3.3 Roof: Conical type with 6 mm thick plates having slope of 5 degree from
horizontal.
6.1.3.4 Strengthening Structure:
• Central king post (1 no.) for roof supporting made from minimum 300 NB
MS C class pipe, with 20 mm thick 970 mm dia MS base and crown plate
at bottom and top respectively.
• Additional king posts (minimum 8 nos.) on suitable PCD made from of

100 NB MS C class pipe with 10 mm thick 70 mm dia MS base and
crown plate at bottom and top respectively.
• Circumferential stiffener rings (minimum 7 nos.) at circumferential welding

joints made from 100 x 50 mm MS channels.
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• Circumferential stiffener ring (minimum 1 no.) with full welding at
circumferential welding joint of bottom plate and shell on inner side, made
from 90 x 90 x 6 mm MS angle.
• Supporting brackets (minimum 8 nos.) at circumferential welding joint of

bottom plate and shell (outside the tank), made from 200 x 100 mm MS
channel 300 mm long.
• Curb angle (1 no.) at circumferential welding joint of roof plate and shell
(outside the tank) made from 65 x 65 x 6 mm MS angle.
• Cross bracing between shell and central king post (set of 12 nos. –
minimum 1 set) made from 75 x 40 mm MS channel.
Roof supports (minimum 18 nos.) made from 75 x 40 mm MS channels.
Vertical stiffeners for shell (minimum 8 nos.) made from 75 x 40 mm MS

channels.
6.1.3.5 Staircase
Rung ladder welded inside the shell, made from 20 mm dia MS rods.
Spiral staircase consisting of grill type steps fabricated from 20 x 5 mm

MS flat (300 x 840 mm), supporting frame from 100 x 50 mm MS
channels, railing on one side only from 32 NB MS C class pipes with two
layers of pipes, mid and top landing with MS grating fabricated from MS
flat of size 20 x 5 mm and staircase supporting pipes (6 nos.) from 32 NB
MS C class pipes.
Safety railing on top of the tank having two circular rings made from 32
NB MS C class pipe - 1.2 M high complete with vertical supports at every
30 degree angle and toe guard made of 3 mm thk.150 mm width MS
sheet welded circumferentially on railing support.
6.1.3.6 Tank Accessories
Inlet 100 NB MS C class pipe (2 nos.) with F table flange on roof of the
tank. One inlet to be closed with blind flange and for other, counter flange
to be provided.
Manhole in shell near bottom (1 no.) of 600 mm dia, made from 12 mm

thick MS plate and cover plate from 12 mm thick complete with bolts,
nuts and packing etc.
• Manhole on roof (1 no.) of 600 mm dia. made from 8 mm thick plates

complete with flanged bolted rain hat and wire mesh.
Float type level indicator complete with SS 304 float, 14 gauge SS guide
wires, pulleys, SS wire ropes (14 gauges), scale with marking in litres.
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Automatic Level control with low level & high level control, the output
compatible to SCADA for bulk tanks & Intermediate tank.
Automatic Temperature control, the output compatible to SCADA for bulk

tanks & Intermediate tank.
Automatic level transmitter with indicator & output for PLC SCADA/DCS.
Air vent at roof (minimum 8 nos.) from minimum 150 NB MS C class pipe
with arrangement of rain and insect protection.
• Drain near bottom plate (1 no.) from 150 NB MS C class pipe complete
with flanged type butterfly valve, blind flange F table, bolts, nuts and
packing.
• Outlet near bottom (2 nos.) from 150 NB MS C class pipe complete with
flanged type Butterfly valve, counter flange H table for one outlet and
blind flange of table H for 2nd outlet, bolts, nuts and packing. The
provision for 2nd outlet is meant for electronic level indicator. However,
electronic level indicator is excluded from the scope of supply.
• Steam coil for bulk tanks & intermediate tank to be made from 32 NB C
Class Pipe.
• Intermediate tank with supporting legs, level indicator & ports for the high
level & low level, with required valves.
6.1.3.7 Testing
After completion of fabrication, all jigs and fixture should be removed from
inside and outside and unnecessary welding deposit should be ground
smooth prior to painting, complete tank to be filled with water and kept for
observation for any leakage for at least 24 hours. Any leakage observed
should be plugged with welding. During testing, calibration of the tank
shall be done.
6.1.3.8 Painting
After completion of testing, the complete tank from inside and outside
shall be cleaned with wire brush and SAND BLASTING. All the inside
surface shall be cleaned after sand blasting followed with two coats of
black epoxy primer followed by black epoxy paint. The entire outside
surface after sand blasting should be painted with two coats of red oxide
primer followed by two coats of black enamel paint.
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6.1.4 REMARKS
• Bidder has to make its own arrangement for all tools, tackles,
scaffolding, welding machines and other accessories for fabricating
the tank at site.
• Bidder to follow all rules and regulation statutory requirements, workers’

compensation act for the labour force employed by them. Bidder would
be solely responsible for any injury or accident if it happens to his persons
working on project site. Bidder has to take necessary labour insurance in
this regard.
• No accommodation would be provided for staff and labour of the

Bidder at project site, however they may construct temporary hutment
at their expenses within project site after taking approval from site in
charge. The same shall have to be cleared / removed upon completion of
the job or as & when instructed by the Engineer-in-charge.
Important Notes:
• The load details on the foundations shall have to be provided to the

purchaser to design the foundation.
• The steel structure for the bulk molasses storage tanks shall be as per
the design of the bidder. The tanks shall be designed for wind load
(highest as per historical records) and for seismic stability as per
seismic zone. Stability certificate for the silos and structure shall be
submitted by the successful bidder. Design calculations for the
structure shall be shared with the purchaser and who shall suggest the
bidder, for alteration, wherever found required. Design calculations for
the tanks to be shared with purchaser without any extra cost.
• Staircase shall be suitably located so that quick approach to working

platforms and shall be 1.2m wide with 32 NB MS C class pipe hand
railing (double braced).
• Platforms, railing shall be extended to all working equipment to

facilitate inspection, operation and maintenance.
• Elevation drawings for the tanks showing heights shall be furnished to

the purchaser.

COMMISSIONING
• Erection, testing and commissioning is inclusive but not limited to the

following:
- Fabrication and welding of the complete bulk molasses storage tanks &
intermediate tank.
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- Erection / Welding / Grouting into place necessary structural platforms,
walkways, hand rails etc., as per requirement.
- Approval of the installation executed by the bidder by the factory

inspector for structural stability and safety and by excise authorities as
molasses is excisable commodity.
6.3 GENERAL REQUIREMENTS
The following may be noted in general with respect to the technical

specifications of the supply of feed milling equipment.
1. Capacities of tanks in MT are specified based on molasses specific

gravity of 1.4
2. Packing for flanged joints of machines/hoppers/bins etc. should be felt or

rubber depending on the application. Packing to be fixed with glue rather
than simple grease. .
3. Painting: The tank external shall be painted. However standard cleaning,

degreasing practice before painting shall be followed, then primer coating
before applying one coat of black synthetic enamel paint. Second coat of
black synthetic enamel paint to be provided at site before commissioning.
Supporting steel structure, transition pieces & piping etc. being fabricated
at site to be applied with corrosion resistant zinc oxide primer before
erecting/installing and then applying one coat of synthetic enamel paint
after erection.

ALONGWITH THE QUOTE
A) DRAWINGS
• Equipment drawing: The general arrangement (GA) drawing of tanks

indicating dimensions, tolerances etc., as proposed by the bidder.
• Layout drawing: The layout drawing of the bulk molasses tanks

showing layout of the silos and connecting platforms.
8.0 TECHNICAL DETAILS AND DRAWINGS TO BE SUBMITTED AFTER

AWARD OF CONTRACT
1. The final equipment GA drawing being manufactured as per design and

product specifications of purchaser
3. Final layout of the 2 tanks with connecting platform
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9.0 List of preferred Makes of Bought out Items (Not in order of
preference)
Description Makes
Structural Steel SAIL / TISCO / RINL / IISCO / ESSAR
Level Measurement E & H / Emmersion
Molasses Pumps Roto
Motors ( Eff-1)
Valves General / ABB
Filters Audco / Saunders / Rotex / Flowwell
Bend, Union, Clamps etc Filter Concept / AGS/ other well known
brand
Reputed Brand
A – SUPPLY
Sl. Description
Capacity Qty
No.
STEEL BULK STORAGE TANKS
FOR LIQUID MOLASSES
1.0 MILD STEEL MOLASSES 6000 MT 2 NOS.

STORAGE TANK (Approximate
Weight in MT to be indicated / tank.)
MILD STEEL INTERMEDIATE
TANK WITH PIPES & VALVES & all 10 MT 1 NOS
accessories.
2.0 INTER CONNECTING MILD STEEL 1 LOT.

STRUCTURAL PLATFORM, with all
accessories.
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B – INSTALLATION, TESTING AND COMMISSIONING
Sl. Description
Capacity Qty
No.
STEEL BULK STORAGE TANKS
FOR LIQUID MOLASSES
1.0 MILD STEEL MOLASSES 6000 MT 2 NOS.

STORAGE TANK
MILD STEEL INTERMEDIATE 10 MT
TANK
2.0 INTER CONNECTING & TANK TOP 1 LOT.

MILD STEEL STRUCTURAL
PLATFORM, RAILINGS & ALL
ACCESSORIES
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KAIRA DISTRICT CO-OPERATIVE
MILK PRODUCERS’ UNION LTD.,
AMUL DAIRY ROAD, ANAND 388 001.
DESIGN, SUPPLY, INSTALLATION
AND COMMISSIONING OF 500 CFM
AIR COMPRESSOR AND
ACCESSORIES.
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1.0 AIR COMPRESSOR: (cap-500 cfm) – Qty.-02 nos. (1w + 1s)
This is required for producing compressed air required for operation of

pneumatic flaps / gates and aspiration filters of feed mill, etc.
DESIGN REQUIREMENT
This shall be oil free rotary screw type two stage compressor for
generation of oil & moisture free air at suitable pressure and required free
air delivery. Compressor shall be advanced control system for capacity
control and for performance monitoring with VFD operated high efficiency
(Eff. 1) motor. It shall be complete with intake filters and all standard
accessories such as service valve, safety valve, auto drain valve,
pressure gauge, suitable drive motor & drive parts etc.
Compressor shall be provided with a pressure switch for auto operation.

The capacity of receiver shall be sufficient to meet sudden large
requirement of compressed air and to avoid frequent ON/OFF of
compressor. For removal of bulk of moisture from receivers, automatic
drain valve with solenoid etc. to be provided.
Capacity of the compressor and its drier, receiver shall be suitable to take
care of the load of compressed air for complete plant included bulk
storage silo systems and mineral mixture / premix plant.
Measurement and recording of compressed air with totalizer shall be

provided for total generation / usage. The data shall be made accessible
at the central control room. A separate vortex type flow meter shall be
provided for air consumption. The flow meter shall be with temperature /
pressure correction facility and accordingly Pressure / Temperature
transmitter would be required for the purpose. The system would be
operated, monitored & control from local panel and necessary
arrangement shall be made for taking feed back for automation interface /
MIS. FRL units shall be provided at all distribution headers near
consumption points inside the plant.
2.0 REFRIGERATED AIR DRYER:
FUNCTIONAL REQUIREMENTS
Air drier would be required to provide moisture free compressed air for
use in various equipment, controls & instruments.
DESIGN REQUIREMENT
The Air Dryer shall be refrigerated type, air cooled type and suitable
capable of handling requirement of air for complete plant at a Maximum
Pressure of 16 kg/sq cm. It shall be fitted with a suitable CFC free
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reciprocating refrigerant compressor, using R134A Gas having a
minimum pressure drop (0.35 bar) fitted with efficient compact copper
tube in tube heat exchanger, with counter flow pattern, heat exchangers
fully encapsulated with PUF insulation all housed under insulated box.
The compressor shall deliver air quality of +3 deg C PDP all housed in a
sound reducing enclosure needing no foundation.
Operating conditions Desired Maximum
Inlet Temperature 45 º C 60 º C
Ambient temperature 40 º C 50 º C
Inlet pressure 7bar (gauge) 16bar (gauge)
Pressure Dew Point 3ºC NIL
Capacity of the compressor drier shall be suitable to take care of the load of
compressed air for complete plant included bulk storage silo systems, by pass
protein plant and mineral mixture plant.
SCOPE OF SUPPLY
The Air drier should be provided with the following:
• Air inlet connection
• Air outlet connection
• Air inlet strainer
• Cyclone condensate separator
• Pressure dew point meter
• Air-drying unit insulating block housing Air-to-Air heat exchanger, air to

refrigerant heat exchanger/evaporator, cyclone condensate separator,
liquid separator, refrigerant distributor, refrigeration injection restrictor.
• Condensate trap with automatic discharge
• Manual drain valve for condensate & auto drain valve (timer based)
• Water cooled condenser
• Safety switch, High & Low pressure
• Liquid refrigerant dryer
• Liquid shut off valve
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• Liquid refrigerant receiver
• Liquid separator
• Sight glass with moisture indicator
• Refrigerant expansion valve
• Refrigerant circuit access connection
• Hose, automatic condensate discharge
3.0 AIR RECEIVER: (cap-6 cum)
Air receiver shall store compressed air, help equalize pressure variation
in pipes, & prevent short cycle loading and unloading of compressor.
DESIGN REQUIREMENT
Receiver shall be vertical type with dished ends and shall meet the
statutory requirement of pressure vessels. Receiver shall be designed
conforming to IS 7983 and the material of construction shall conform to
the relevant IS in mild steel. Capacity of the receiver shall be suitable to
take care of the load of compressed air for complete plant included bulk
storage silo systems and mineral mixture / premix plant. The receiver
shall be complete with safety valve, service valves, pressure gauge,
fusible plug, hand holes, automatic moisture separator and drain valve
(Timer based) to remove moisture. The air receiver shall be designed for
Design pressure of 12 Kg/sq.cm & should be Hydro-tested at 18
Kg/sq.cm.
4.0 GENERAL CONDITIONS:
(4.1) Bidder shall nominate an experienced engineer who shall be responsible

for activities of supply and installation in office and site. The services of
the Project Engineer shall be ensured for the day to day operations and
coordination to ensure successful and satisfactory design, procurement,
manufacture, inspection, erection, testing and commissioning of all the
equipment/facilities/systems within the time-bound schedule.
(4.2) The purchaser shall also nominate a Project In-charge with whom the
bidder shall communicate / coordinate. The purchaser shall also post a
Site Engineer at project site for supervision and coordination with Site
Engineer of the bidder.
(4.3) Bidder shall obtain approval for purchase of specific makes of equipment
whose makes are not mentioned in his document. If two or more makes
of the same equipment are mentioned in the form of alternatives, the
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bidder shall seek approval for choosing one make over another. All the
detailed design calculations regarding the selection of equipment sizes,
system types, etc. shall be submitted to Purchaser / Client for their
specific observation and record whenever asked for.
(4.4) The bidder’s Project Engineer will provide to the purchaser’s Project In-
charge with progress reports which clearly indicate the actual Vs planned
progress and the new likely completion date of supply, erection and
commissioning of the equipment.
(4.5) For indigenous items, the bidder shall invite Purchaser / Client for
inspection and preliminary testing. The inspection may be required at
various stages of manufacture / assembly for some items. For imported
items, the purchaser has right to inspect the equipment at manufacturer’s
works prior to dispatch. However, bidder shall do the inspection and
submit the necessary test certificate.
The Project / Site Engineer of bidder shall be fully authorized to take on

the spot decision with regard to:
a) Modification in layout and execution programmed to suit local

conditions.
b) To purchase essential materials from local market to avoid delays.
(4.6) For smooth execution of the project, the bidder’s team consists of Project
Engineer, Site Engineer and key Personnel shall remain consistent
throughout the execution period.
(4.7) After satisfactory erection and testing, competent commissioning team

shall be deputed to establish the performance parameters for a specific
period.
5.0 TESTING AND COMMISSIONING:
After installation of all equipment and completion of piping and connection

of all utilities equipment shall be tested at no load after checking all
alignments. On completion of satisfactory no load test, the plant as a
whole shall be tested with full load to the satisfaction of purchaser/project
authority.
6.0 ESTABLISHING PERFORMANCE GUARANTEES:
On completion of supply, erection, testing and commissioning of the

equipment, the same has to be operated at full capacity continuously in 3
shifts of 8 hours basis for seven days to the satisfaction of the Purchaser /
Project Authority, to establish performance guarantees provided by the
bidder. However, if purchaser / client are unable to provide operating staff
for three shifts, number of days can be increased with mutual
discussions.
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7.0 TRAINING
Training in the operation and maintenance of the equipment shall form an

important component of Project Management. Training shall be
undertaken by the bidder for a period of one month during which the
bidder should guide and train the staff of the purchaser in operation and
maintenance of the equipment to achieve the optimum plant efficiency
and product quality.
Training should commence during the testing / commissioning period and

shall include:
1. Familiarization with all major/minor components of equipment including

the operation of the computer / PLC based auto systems.
2. Procedure for attaining the rated output and optimum product quality.
3. Familiarization with the basic principle of Electronic / Electrical control

systems, including fault finding.
4. Familiarization with start-up procedures, regular maintenance and

replacement of spares / components, preventive maintenance etc.
5. Condition monitoring of equipments.
6. Generating production and maintenance log sheets of important

equipment and systems.
Training shall be given to all the personnel required to operate the plant
equipment and their immediate Supervisors / Engineers. The training
schedule should be proposed by the bidder together with the content of
training, their duration etc.
8.0 STANDBY SERVICES AFTER COMMISSIONING:
Once the commissioning and warranty runs are over and the plant is
taken over by Purchaser / Project Authority, the bidder of the machine
shall provide to the plant standby technical supervisory support as
follows:
• For one month after warranty runs in which further training of the
Purchaser / Project Authority’s operating staff shall be done and
equipment / system still needing finer adjustment / changes shall be
carried out.
• For a week each after 4 months, 8 months and 1 year from warranty runs,
to have discussions with plant staff and assistance to review the
correctness of operations / maintenance procedures and necessary
corrections.
• These visits of the Bidder are other than those covered under guarantee /
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warranty clause which shall be undertaken whenever required separately.
9.0 LIST OF DRAWINGS AND DOCUMENTS
The bidder to provide drawing / data and technical details with their quote
as specified.
After commissioning and during handing over of the plant by Bidder to

Purchaser / Project Authority, the bidder to provide the following:
• As executed final drawings and technical data of the complete

equipment/machine for operation, maintenance and permanent record in
soft (in AUTO CAD) and 3 sets of hard copies.
• The final software and source codes of the systems.
• A consolidated operation and maintenance manual -3 sets of the

complete equipment/machine along with operation and maintenance of
each key components as provided by manufacturer.
10.0 PERFORMANCE GUARANTEES:
If the equipment / machine or any part thereof does not give the offered
process performance, capacities and consumption guarantees as
confirmed in design data and technical data given by bidder during the
commissioning, suitable recovery shall be made by purchaser from
bidder’s bill.
217
ERECTION, TESTING AND
COMMISSIONING OF SDF DRY
TRANSFORMER.
218
1.0 CODE & STANDARDS:
• All equipment and material shall be designed manufactured and tested in

accordance with the latest applicable Indian Standard. IEC standard and CBIP
manuals except where modified and / or supplemented this specification.
• Equipment and material confirming to any other standard, which ensures equal
or better quality, may be accepted. In such case copies of English version of the
standard adopted shall be submitted.
• The electrical installation shall meet the requirement of Indian Electricity Rules
as amended up to date, relevant IS code of practice and Indian electricity act. In
addition other rules of regulations applicable to the work shall be followed in
case any discrepancy the most stringent and restrictive one shall be binding.
• The Transformer offered shall in general comply with the latest issues including
amendments of the following Indian standards but not restricted to it.
Title I.S. Equiv. I.E.C. standard
Distribution Transformer IS:2026 IEC:60076 IEC:60616

Dry Type Power Transformer IS:11171 |EC:60726 IEC:60905
Thermal evaluation & Classification of IS:1271 ---
electrical insulation
Fittings and accessories for Distribution IS:3639 ---

Transformer
Code of practice for installation and IS:10028 ---

maintenance of Transformers
Ready mixed paint, air drying Red oxide, IS:2074 ---

Zinc Chrome, Priming
Colour for ready mix paints IS:5 ---

Enamel synthetic, exterior IS:2932 ---
a)Undercoating
Dimension'of porcelaing transformer bushing IS:3347 ---
for use in very heavily polluted atmosphere
Indian Electricity Rules 1956 ---

Indian Electricity Act 1910 ---
219
2.0.0 DESIGN CRITERIA
11 kV/433 volt distribution transformer shall be installed at outdoor substation
location along the ring mains 11 kv feeder system in MGVCL Supply area. The
11 kv HV winding would be connected to VCB of the ring mains unit at
substation through 11 kv (E) grade XLPE cable. LV winding feeds the 8/10 /12
way distribution panels or L.T. A.C.B./M.C.B. through 1.1 kV 1/C, 400/500 mm2
XLPE cables.
The transfo rmers shall be installed in hot, humid tropical atmosphere. All
equipment accessories and wiring shall be provided with tropical finish to
prevent fungus growth.
The transformers shall be capable of continuous operation of rated output under
the operating conditions of voltage and frequency variations as per statutory
limits governed by relevant Indian Standard and Indian Electricity Rules, 1956
with latest amendments in force.
The transformer shall conform to best engineering practice.
The design material construction shall be such that to secure reliability,
economy, safe and convenient operation and shall include all specified or
unspecified incidental items necessary for similar equipment for convenient
working in every respect.
The transformers shall be capable of withstanding the short circuit stresses due
to terminal fault between phase to phase and phase to ground on one winding
with full voltage maintained on the other windings for a minimum period of three-
seconds.
The transformers shall be free from annoying hum or vibration. The design shall
be such as not to cause any undesirable interference with radio or
communication circuits.
SPECIFIC REQUIREMENT:
Requirement:
11000/433 Volt Dry type 400, 630, 750, 1000, 1500, 2000 & 2500 kVA ANAN
cooled double wound, core type suitable for installation at indoor-outdoor for
ground mounting, all live parts completely enclosed except where specified for
L.V. terminals.
Voltage Ratio:
No load voltage 11000/433 volts within tolerance as stipulated in IS: 2026.
Rating:
The transformer shall have a continuous rating as specified at any of the
specified tapping position and with the maximum temperature rise specified. The
rated KVA shall be the product of the rated voltage in kV, the corresponding
rated current and the phase factor 1.73. When the transformer is operated with
the rated primary voltage applied to the terminals of the primary winding, the
apparent power (RVA) at the terminals of the secondary winding, when carrying
the rated secondary current differs from rated kVA by an amount corresponding
to the regulation of the transformer and is the product of the actual secondary
voltage, the rated secondary current and phase factor 1.73.
Place of installation:
Outdoor in a basement of a building / closed substation building with limited
ventilation.
220
System:
11000 volts A.C. supply, on H.V. side and 433 Volts on L.V. side with variations,
as per statutory variation governed by relevant Indian Standard and Indian
Electricity Rules, 1956 with latest amendments in force. The 11 kv neutral and
L.V. neutral is. earthed solidly at each transformer substation. The transformers
will be connected in a system consisting of both overhead and underground
mains (both on HV and LV sides)
Temperature Rise :
The maximum temperature rise [90°C for class H Insulation] of the transformer
above the cooling air temperature, shall not exceed the limit indicated in table 4
of 18:11171 (latest amendment) when tested in accordance with clause No.10 of
18:11171 considering ambient temperature, not exceeding 40°C daily average
or 50''C maximum.
Type of Load:
The transformers will be used to supply a mixed power and lighting load-which
may not always balance. Plant will be equipped with soft starters and VFD”S for
all equipements.
Overloads:
The transformers shall be suitable for carrying overload within temperature rise
indicated in the
Connections:
H.V. Delta and L.V. Star connected with neutral brought out on the secondary
side for connection to earth; Vector group DYn11 of IS:2026.
Tapping:
Each transformer shall be provided with adjustable tapping such as to provided
or a voltage adjustment on H.V. from +5.0% to -5.0% of rated voltage of 11000
volts in 4 equal steps (5 position) to obtain rated voltage of 433 volts on LV side.
The normal tap position is 3. The tapping shall be suitable to change on H.V.
side by links provided for this purpose.Transformer should be equiped with
OLTC and High efficiency Voltage stabilizer.
Overall Dimension:
The overall dimensions of the transformer shall not exceed the following:
Length Width Height •

400 kVA 1700 1750 1850
630 kVA 1900 1750 1850
750 Kva 2000 1800 2200
1000 kVA 2200 2100 2400
1500 Kva 2460 2200 2600
2000 Kva 2750 2250 2600
2500 KVA 3000 2300 2650
221
Enclosure (Housing):
Outdoor Application: Enclosure for outdoor type transformer shall be
constructed using suitable M.S. Steel sheet of thickness not less than 2mm. The
enclosure shall be finished both internally and externally with weather resistant
paints. The enclosure shall have perforated sheets & Louvers at suitable
height/locations for easy air circulation. The Ingress Protection class for Outdoor
type transformer shall be IP-,45 or better, & Enclosure Top & Bottom sheet
thickness shall be min. 4mm. In Enclosure, approach window for Tap-links,
cable termination & marshalling box door shall be only to be design for closing-
opening arrangement. All other windows are to be. Closed. The Top î Bottom
cover shall have a slop to avoid water logging, but the slop shall be away from
sides of cable termination.
Indoor Application: Enclosure for indoor type transformer shall be constructed
using suitable M.S. Steel sheet of thickness not less than 2mm. The enclosure
shall be finished both internally and externally with weather resistant paints. The
enclosure shall have perforated sheets & Louvers at suitable height/locations foe
easy air circulation.
General: Door / Window hinge arrangement shall be from Door hinges to be
connected from Top & Bottom side to the main panel/pillar body making door
non-removable. Hinges shall be of Mild Steel material with tight-fit brass tube of
suitable dimensions.
Cleaning & Painting:
All steel surfaces shall be thoroughly cleaned by sand blasting or chemical
agents, as required to produce a smooth surface free of scales, grease and rust.
Surface Pre-Treatment:
Seven tank paint surface pre-treatment shall be followed. The pre-treatment
process shall include following procedure...
a) Degreasing
b) Water rinse,
c) Acid cleaning (de-rusting treatment)
d) Water rinse,
e) Surface activation,
f) Phosphating, (The Phosphating process shall be an accelerated process as

per relevant IS).
g) Water rinse,
h) Passivation
Powder Coating: The surface to be given coating of Siemens-Grey (RAL-7032).

The powder coating shall be as per IS: 13871. The material used shall be
Grade-A: Glossy Finish Polyester based powder coating the thickness of powder
coating shall be MIn. 80 microns. The type of paint shall be rust resisting +
weather resisting by nature, as per IS: 2932 specially recommended for
transformer use.
• The paints shall be carefully selected to withstand tropical heat rain, effect of
proximity to the sea etc. The paint shall not scale off or crinkle or be removed by
abrasion due to normal handling.
222
• Sufficient quantity of touch up paint shall be furnished for application after
installation at site.
• If it is considered necessary, the transformer may be given a further coating at
site by the owner. The Bidder shall therefore indicate the type and quality of the
paint with full specification for this purpose.
• Special care shall be taken by the manufacturer to ensure against rusting of
nuts, bolts (to be of S.S material) and fittings during operation. All bushings and
current carrying parts shall be cleaned property after final painting.
Cable Boxes:
• Both H.V. & L.V. Bus-bars and cable termination arrangement shall be provided
within main transformer enclosure without projection.
• The H.V. "bus-bare shall be of sufficient dimensions, for termination of one
APLySTY/A2XWY 11 kv 3/C X 240 mm2 Aluminium conductor cable. The
dimensional details & rating of the bus-bar shall be stated & shall be adequate
for carrying the rated current. In any case the size of the bus-bars shall not be
less than 50 X 6 mm. adequate arrangement shall be provided for supporting the
H.V. cable. The material of connecting bus shall be tinned copper.
• The dimensional details & rating of the LT. bus-bar shall be stated & shall be
strictly as per following table for different ratings.
Trans Rating (KVA) Phase / Neutral Cu Bus bar size mm

(considering 50° temp rise )
400 / 630 / 750 Phase 80 x 12mm

Neutral 50 x 10mm
1000 Phase 80 x 12mm
Neutral 50 x 10mm
1500 Phase 130x12 mm
Neutral 80 x 10mm
2000 Phase 2nos. 120 x 12mm
Neutral 2 nos. 80 x 10 mm
2500 Phase 2nos. 160 x 12mm
Neutral 2nos. 100 x 10mm
For entry of 1.1 kV 1/C 400/500 mm2 XLPE cable, adequate number of holes
shall be provided on the bottom plate of the enclosure for respective transformer
sizes as mentioned in clause: 3.14.6. This portion of the bottom plate shall be of
detachable type. To support the L.T. cable, suitable non-ferrous (AL), supports
with clamping arrangement shall be provided. The support shall be designed &
fixed in such a way as to ensure that the L.V. cables are exactly vertical with
respect to the bus-bar. The material of connecting bus shall be Tinned copper.
Sufficient clearances shall be maintained between the individual bus-bars.
The H.V. & L.V. bus-bar support insulators shall have creep age corresponding
to very heavily polluted atmosphere.
223
Also cable lugs with knurling on inside surface (for better crimping) shall be
provided on L.V. side [dimensions of 400mm2 size lug: - Total lug length=205mm
(75+130), Lug inside dia.=29mm, Lug outer dia.=39mm] suitable for 1.1 kV 1/C
X 400/500mm2 XLPE cable Termination arrangement to suit 1/C X 400/500mm2
XLPE cable connection as follows
Transformer Per Phase Neutral (nos.) Total (nos.)

(nos.)
400 kVA 2 2 8
630 kVA 3 2 11
750 kVA 3 2 11
1000KVA 4 2 14
l500kVA 6 3 21
2000 kVA 8 4 28
2500 KVA 10 5 35
Suitable copper or brass coupling plate mounted vertically shall be provided on

each L.V. terminal for connecting lugs. L.T. extension bus-bars shall be checked
for proper finish before assembly.
Both H.V. & L.V. bushing (Epoxy-Resin-cast) shall have creep age
corresponding to very heavily polluted atmosphere.
Clamping of leads:
All leads from the coils to the terminals shall be suitably clamped to prevent
snagging and fouling with other parts and the tank/enclosure.
Phase Marking & Danger Plate: Phase markings in fluorescent paint on small
non-corrodible metallic tags shall be permanently fixed for H.V. and L.V sides.
Phase markings tags shall be properly fixed with proper alignment. Danger
plates shall be provided on the H.V & LV sides, mentioning the Corresponding
Voltages.
Core and Coil

The core shall be built up with high grade, non-aging, low loss, high
permeability, grain oriented, cold-rolled silicon steel laminations especially
suitable for core material. The grade of, core lamination shall be premium grade
M-OH 'or better quality with thickness of 0.23mm. The transformer shall be so
designed as to have minimum humming noise. The percentage harmonic
potentials with the maximum flux density under any conditions shall be such that
capacitors connected in the system shall not be overloaded.
The coils shall be manufactured from electrolytic copper conductor and fully
insulated for rated voltage by class F or above insulation.
The coils shall be manufactured from electrolytic copper conductor and fully
insulated for rated voltage. Copper for winding shall be purchased from 'Original
Copper Manufacturer'. HT Winding shall be Disc/spiral/cross over type. The L.T.
224
winding shall be cross over coil type or Foil type for 400, 630, 750 kVA,
1000,1500, 2000,2500 kVA rating.
Insulating material shall be of proven design. The insulating materials shall be
class "F" or above specified as per IS 1271 with latest amendments, thereto.
Coils shall be so insulated that impulse and power frequency voltage stresses
are minimum. Due consideration shall also be given to the fact that the
transformers will be connected at the end of 11 kv and 0.4-33 kV overloaded
feeders, in a lightning prevalent area.
All leads from the windings to the terminal board and bushings shall be rigidly
supported to prevent injury from vibration or short circuit stresses. Guide tube
shall be used wherever practicable.
The core and coil assembly shall be securely fixed in "position so that no shifting
or deformation occurs during movement of transformer. The core and coil
assembly shall be capable of withstanding without injury, the thermal and
mechanical effects of short circuit at the terminals of any winding as per IS:2026
with latest amendments thereto.
All nut-Bolts used in transformer assembly shall be of Special steels (S.S.) only
except for frame-parts + core assembly where at critical locations specially
designed Nut-bolts of wooden-like-material if required.
Losses:
The reference temperature to which the Load loss, Impedance voltage and short
circuit impedance are to be corrected shall be the maximum winding
temperature rise { 90°C } as given in table-4 of 18:11171, above ambient
temperature {40°C}, not exceeding 40°C daily average or 50°C maximum. The
transformer losses at respective temp. rise { 90°C }as per relevant insulation
class and at normal tap without any positive tolerance shall be as under:
Transformer No-Load Max. Max. Guaranteed Total loss

Load Loss at 130°C Max.
400 kVA 0.90 kW 3.40 kW 4.30 kW
630 kVA 1.20kW 5.40 kW 6.60 kW
750 RVA 1.40RW 6.00 kW 7.40 kW
1000kVA 2.20 kW 8.60 kW 10.80 kW
1500kVA 3.20 KW 11.50kW 14.70 kW
2000 kVA 3.56 kW 15.25kW 18.81 kW
2500 KVA 4.05 kW 17.00kW 21.05RW
Note:
Other factors being equal, due consideration shall be Qiven to offers of
transformer with lesser Guaranteed Losses.
The Guaranteed losses at principle tap are to be corrected at 130°C i.e. the
maximum winding temperature rise { 90°C } as given in table-4 of 13:11171,
above ambient temperature, not exceeding 40°C daily average or 50°C max.
225
as detailed in spec. This corrected Load losses in any case shall not exceed
the max. Guaranteed losses detailed in above table.
In the event of order, each losses specified as above will be binding on the
bidder and, any unit which exceeds these losses shall be rejected.
Parallel Operation: All the above transformers shall be designed to operate in
parallel with each other and with previous units, if any supplied by the tenderer
within limits, stipulated in IS: 2026. They may be also required to operate in
parallel with other standard transformers supplied by well known manufacturers,
in use in our system, details of which will be furnished with the tender.
Noise: The Contractor shall take special precautions to ensure that the noise
and vibration level does not exceed which is obtained in good modern practice.
Impedance Volts: The impedance value at any tap shall be as per clause:
4.00.00 of this specification subject to tolerance as specified in IS:2026. The
value of the impedance volts at each tapping over the specified range shall be
specified in the bid.
Regulation: The regulation to be corrected, shall be the maximum winding
temperature rise as given in table-4 of 13:11171, above ambient temperature at
full load at unity and 0.8 power factor subject to the usual tolerance as per
IS:2026 shall be specified in the bid.
Insulation Level (Impulse voltage): The distribution transformer shall be
designed so that they are capable of withstanding impulse voltages as per
Miscellaneous:
C.T's with accessories : C.T's of rating as specified below are to be provided,
mounted on the Transformer L.T side. C.T. shall be mounted on L.T. Bushing &
supported by bakelite sheet of 8 mm thickness affixed to main tank by nut-bolt
arrangement. It shall be possible to replace these C.T.s by removing fixing nuts
of bakelite sheets, after removal of L.T. cable from bus bar, without disturbing
L.T. Bushings.
Sr Particulars All Ratings

1 Current Ratio As given below
2 Class of Accuracy 0.5
3 Burden 15 VA
4 Type Resin cast Ring type Suitable for
Outdoor use
Rating 400kV 630kVA 750kVA 1000kVA 1500kVA 2000kVA 2500kVA

C.T. 600/5 1000/5 1200/5 1500/5 2500/5 3000/5 3500/5
Current
Ratio A
The Secondary Terminals of the C.T's shall be individually v/ired, using 4.0mm2
flexible copper wires (with colour coding, ferrules at both ends) up to a Terminal
block housed inside a scalable M.S. Box of size 10X16 inches. Terminal block
shall be provided with C.T. shorting-opening link facility independent of external
226
wire loop i.e. Elmex-connector with Drop-in Link arrangement. The M.S Box
housing this Terminal Block shall be located inside the Transformer enclosure,
fixed at a suitable height. M. S. Box door access & closing-opening shall be
possible from outside without opening the transformer enclosure. The three
phase voltages also are to be tapped from the L.T bus bar and wired up to the
terminal block. The M.S box shall be provided with 14 nos. of 4.0 sq mm
terminals for termination of current and voltage circuits. The box shall be
provided with 2 nos. of knock-outs at the bottom, suitable for glanding 10 Core,
4.0mm2 cables (32mmdia. G2 size gland). Suitable provisions shall be made for
supporting these cables. The wiring of the Current and Voltage circuits inside the
Transformer enclosure shall be through conduits made of heat resistant and
insulating material. The C.T secondary shall be covered with scalable transport
covers.
C.T., V.T. wiring diagram shall be submitted for approval & once approved shall
be labelled on the inside of marshalling box door. The door hinges shall be of
reversible type & door-locking knob shall be of good quality with proper threads
& washer arrangement.
As detailed in this specification each distribution transformer shall be provided
with necessary power cable Glands, Lugs and all other miscellaneous materials
required for assembly, installation and maintenance. Required spare items as
detailed in the specification shall also be supplied. Additional; items which bidder
feels necessary for assembly, installation and maintenance shall also be
supplied with each power transformer without any extra cost.
4.00.0 RATINGS AND REQUIREMENTS
Requirements All ratings

4.01.0 Service Outdoor/Indoor, Step down
4.02.0 Type Dry Type
4.03.0 Cooling system ANAN
4.04.0 No. of Phases 3
4.05.0 No. of winding per phase 2
4.06.0 Rated output (MVA) With ANAN cooling HV/LV
a) 400 kVA 0.40 / 0.40
b) 630 kVA 0.63/0.63
c) 750 kVA 0.75/0.75
d) 1000KVA 1.0/ 1.0
e) 1500kVA 1.5/1.5
f) 2000 kVA 2.0/2.0
g) 2500 kVA 2.5/2.5
4.07.0 Rated voltage in KV (Line to Line ) HV-11 kv, LV-0.433 kV

4.08.0 Rated frequency 50 Hz
4.09.0 Temperature rise above 40°C avg. 50°C max.
4.09.1 In winding by resistance 90°C or below.
227
4.10.0 Guaranteed losses at normal tap position Asperclause:3.18.0
without any +ve tolerance
4.10.1 No Load loss (kW) As per clause:3.18.0
4.10.2 Full Load loss (kW) As per clause:3.18.0
4.10.3 Total loss (kW) Asp er clause:3.18.0
4.11.0 Insulation level
4.11.1 H.V. (kV)lmpulse
4.11.2 L.V. (kV) -
4.12.0 Vector Group Dyn11
4.13.0 Parallel operation Yes
4.14.0 Type of taps provided Off Load full capacity Tapping
4.15.0 Taps provided on H.V. winding
4.16.0 Range of taps +5.0% to -5.0% in steps of
•f 2.5% (4 steps, 5 position)
4.17.0 Method of Tap Change control OLTC
4.17.1 Manual load Yes "Off Circuit'
4.18.0 Percentage impedance at 130° C Full MVA base (ANAN rating)

4.75% with tolerance as per
• 400/630kVA, 750kVA, lOOOkVA
IS:2026
• 1500kVA,2000kVA.2500kVA
6.00% with tolerance as per
IS:2026
4.19.0 System earthing

4.19.1 H.V. Solidly earthed
4.19.2 L.V. Solidly earthed
4.20.0 Terminal arrangement
4.20.1 H.V. Cable box suitable for Heat
shrinkable termination by
APLySTY/A2XWY, 11 kv, 3c x
240 mm2 . PILC/XLPE cable
4.20.2 L.V. 1.1 kV. 1/C x 400/500 mm' Al.
XLPE cable. 4 Nos of cable
termination / phase
arrangement as per
31 0
4.20.3 L.V. Neutral 1.1 kV, 1/C x 400/500 mm' Al.
XLPE cable. 2 Nos of cable
termination / neutral
arrangement as per
4.21.0 Transformer-bushing voltage class a) 11 kv class 1 .Ok V class
H.V. (RV) b) L.V. (kV)
4.22.0 System fault level a) H.V. side b) L.V. 500MVA(11 kv)
side
4.23.0 Short circuit withstand capability duration 3 sec.
228
4.24.0 Overall dimensions without any positive As per clause:3.11.0
tolerance
4.25.0 L.T. side C.T. ratings
4.25.1 Current Ratio As per clause:3,24.0
4.25.2 Class of Accuracy 0.5
4.25.3 Burden 15 VA
4.25.4 Type Resin cast ring type for
5.0.0 FITTINGS & ACCESSORIES

5.1.0 The following accessories conforming 11 kv/0.433 kV distribution transformer.
5.2.0 Two earthing terminals with copper lugs. The lugs shall be provided in such a
way that they shall not obstruct the movements of rollers. The ear thing
continuity for all the connected equipments shall be properly done.
5.3.0 Two lifting lugs for complete transformer as well as enclosure.
5.4.0 Off circuit tapping links suitable for changing tap position arid having 100Amp,
125Amp & 150Amp continuous current rating shall be supplied for up to 1500
rating, 2000 & 2500 kVA distribution transformer respectively. Taping links shall
be suitably marked for Tap positions. Bidders shall submit with the bid, technical
catalogue for the same.
5.5.0 Four plain rollers fitting so that the transformer can suitably moved in any
direction along with roller direction changing and locking facility shall be
provided.
5.6.0 Rating plate and diagram plate of durable non-corroding metal giving information
as required under IS.-2026. Rating plate shall also include Transformer Actual
%Z, No-Load Loss & Full-Load Loss along with details like Purchase Order
Number, date. The name plate marking shall be done with
Fluorescent colour. Each equipment shall carry individual name-plate with
proper instructions & affixed with screws.
Presimeasure/Bestc-Bell/Pecon make winding Temp Indicator-scanner shall
have 100mm diameter dial/digital indication & shall have resalable maximum
reading pointer and a set of Skid with Haulage lugs
Surge arrestors shall be connected at Transformer Primary termination end, to
protect transformer winding from H.V. switching surges.
Marshalling box & Exhaust fan control cubicle:
Exhaust fan to be provided if mentioned in Purchase Order copy. However cost
may be quoted separately in tender enquiry.
A Sheet steel, weatherproof, Out door type Marshalling Box & Fan control
cubicle shall be supplied. The minimum thickness of sheet steel shall be 2.5mm.
Glass window shall be provided on the door in front of winding temperature
indicator. The interior and exterior of the cubicle shall be cleaned and painted up
to primer and filler coats. The cubicle shall be painted internally with at least two
coats of epoxy white paints to enhance illumination. The marshalling box shall
comprise of the following
• independently adjustable trip and Exhaust fan actuation contacts.
• Associated fuses and links pertaining to marshalling box.
229
• Air breaks contactors for main supply - L&T/Siemens.
• Air breaks contactor separate for each exhaust fans.
• Single phase power plugs industrial type.
• On & Off controlling switches for exhaust fan L&T/Siemens make.
• Exhaust fan "ON" indicating lamps.
• HRC fuses & neutral links of English Electric make only.
Two numbers of 415V, 1 phase, 450mm size, completely weather proof & fire
proof, outdoor type, GEC Make Exhaust fan shall be provided in the metal
enclosure. Fan shall be wired for automatic operation at a pre-set tap winding
temperature. Each fan shall be individually protected by a HRC fuse.
6.0.0 TESTS:
6.1.0 Routine Tests: Following tests shall constitute the routine test.
6.1.1 All transformers to be supplied shall be subjected to routine tests as per IS.-
2026 & ls: 11171. All results obtained during the tests shall be furnished to the
purchaser in triplicate for approval/comments.
6.1.2 Pressure Test: After assembly each core shall be pressure tested for one
minute at 4 kV Ac between all bolts, side plates, structural steel works. & the
core.
6.1.3 Excitation loss & current measurements shall be made at 90 %, 100 % & 110 %
of the rated voltage.
6.1.4 Load loss measurements shall also be carried out.
6.2.0 Type Tests: Following type tests shall be conducted on first unit of transformer
fiym a recognized laboratory e.g. ERDA/CPRI. for each size & kVA rating of
transformer under offer in accordance with relevant standard.
6.2.1 The temperature rise test shall be carried out on first unit in accordance with
latest IS: 2026/Pt-2 & 18:11171. The temperature-rise test shall be carried out
by applying losses corresponding to the maximum loss tap. For this purpose no
load losses and load losses shall be measured in following manner.
1) No load losses 'shall be measured by either applying to the secondary
terminals, a voltage of 110% of rated secondary voltage or the voltage induced
in the transformer when delivering 11 kv output at full load at 0.9 power factor.
2) Load losses (including stray losses) shall be measured for every tap and full
load secondary current.
6.2.2 Highest values of no load losses and load losses shall be applied while carrying
out temperature rise test.
6.2.3 Temperature rise so obtained shall not exceed values as stated in relevant
clause of this specification.
6.2.4 The transformer shall be designed to withstand impulse voltage of 75 RV(peak)
with 1.2/50 micro second wave on the high voltage winding. If identical units
have been tested in the past for type test, it shall be sufficient if the bidder
furnishes test certificates for such tests along with the tender.
6.2.5 For existing bidder type test certificate as per clause 6.5.1. shall be submitted
with the offer or to be carried out if mentioned in purchase order copy. For new
bidder/new vendor the type test is mandatory on first unit of our transformer.
6.2.6 Cost of such tests, if extra, shall be quoted separately.
230
6.3.0 Miscellaneous:
6.3.1 All components parts and auxiliary equipment such as bushings, tap-links, C.T.S
etc. shall be routine tested as per relevant Indian Standards. Test certificate
shall be submitted for purchaser's approval along with transformer test
certificate.
6.3.2 The manufacturer shall have the necessary laboratory grade instruments and
equipment for carrying out all routine and type tests and get these calibrated at
frequent intervals.
6.3.3 The transformers (including tap-links) shall be capable of withstanding without
damage the thermal and mechanical effects of short circuits at the terminals of
any winding or the periods as provided by latest IS:2026/Part1. The
manufacturer shall supply the calculation for short circuits ;in case required by
purchaser.
6.3.4 Every transformer received at BSES shall be routine tested at BSES testing
works and obtained results shall be binding for rejection or acceptance of units.
In case the losses measured are more than guaranteed values units may be
rejected or accepted with penalty as loss capitalization formula as specified
earlier in this specification. Purchaser's decision shall be final in this regard.
6.4.0 Test Witness:

6.4.1 All Routine test as per clause:6.1.0 & Type test as per clause:6.2.0 shall be
performed in presence of Owner's representative if so desired by the Owner.
The Contractor shall give at least fifteen (15) days advance notice of the date
when the tests are to be carried out.
6.4.2 In process Inspection call : Manufacturer shall submit process-wise
manufacturing schedule along with dates. The in-process inspection call shall be
submitted minimum 15 days advance. Inspection may be carried out by owner’s
representative is so desired.
6.5.0 Test Certificates:

6.5.1 Certificates for Type Tests: "The manufacturer shall produce the latest test
certificate for type test from a recognized laboratory e.g. ERDA/CPRI for each
size & RVA rating of transformer under offer. Type test certificate shall be
considered valid for 5 years from the date of test performed on the equipment.
6.5.2 Certified reports of all the tests carried out at the works shall be furnished in
three (3) copies for approval of the Owner.
6.5.3 In addition following test cert. shall be furnished for approval in the form of a
bind-report..
1) E.C. grade Copper used for winding (original copper manufactures test cert.)
2) Lamination stamping used in core-building (original' manufactures test cert.)
6.5.4 Units shall be dispatched from bidder's works only after written permission from
the Owner.
6.5.5 Once the delivery of all the transformer is complete, Bidder shall submit one
additional copy of tests report for the transformer in the form of a booklet.
231
7.0.0 SPECIAL TOOLS AND TACKLES & RECOMMENDED SPARES
7.1.0 Tools & Tackles
7.1.1 The bidder shall tabulate the item wise list of special tools being furnished by
him for the installation, commissioning operation and maintenance of the
distribution transformers whose total cost has been indicated in Price schedule
in Annexure.
7.2.0 Recommended Spares
7.2.1 The bidder shall give itemized list along with unit rates for recommended spares
for three (3) year operation and maintenance of trouble free service of the
transformers being supplied by him covering the following but not restricted to
following items only.
Sr Description Qty
1. 11 kv HV bushing with metal parts if used in the design (3 Nos. for 6 sets
all 3 phase)
2. LV side bushing (3 Nos. for all 3 phases) With metal part & gaskets 12 sets
3. Off circuit Tap Links ( each phase) 1 No.
DOCUMENTS COMPRISING THE BID:

The Bidder shall complete the bid .proposal sheets inclusive of copy of the
specification duly filled- in with compliance status, engineering drawings, quality.
& operational manuals etc. indicating the material to be supplied, a brief
description of the .goods, their quantity and prices. In absence of these
documents, the offer shall be considered incomplete & may be rejected.
DRAWINGS, DATA AND MANUALS

Drawings, Data & Manuals shall be submitted with the bid.
Successful bidder shall submit 3 set of drawings for Purchaser's scrutiny and
approval. It is expected that drawings for approval be submitted within 15 days
from date of receipt of Purchase Order Copy. Purchaser shall return one set of
approved drawings to successful Bidder. Successful Bidder shall collect all sets
of drawings which shall have revision numbers prior to revision number indicated
on approved drawings.
Following Drawings shall be submitted for approval.
a) Final technical particulars,
b) Final Bill of material,
c) Dimensional general arrangement drawing showing disposition of various
fittings.
d) Foundation plan and loading,
e) Rating & diagram plate,
f) Terminal arrangements.
g) Drawings of major components like H.V.. L.V. phase and L.V. Neutral bushing
etc.
232
h) Detailed drawing indicating arrangement of clamping with respect to L.V. bus
bars, C.T. mounting, to clarify L.V. cables shall be exactly vertical.
i) Terminal box & wiring diagram for C.T./V.T. terminal box.
J) Detailed drawing for roller assembly indicating operation of direction changing
facility.
Transport/shipping dimensions with weights, wheel base detail un-tanking height
etc.
Flow diagram of the cooling system showing the number of cooling banks, fans,
pumps, valves etc.
Any other relevant drawing or data necessary for satisfactory installation,
operation and maintenance.
Bidder shall submit 5 sets of Approved drawing complete with Bill of material,
Operation & maintenance manual for purchaser's reference. One additional copy
containing Routine/Type test certificates of all transformers under current
Purchase order in the form of Booklet to Planning dept after delivery is complete.
1 set of Approved drawing complete with Bill of material, Operation &
maintenance manual, in Soft Copy format to Planning dept.
To be submitted with the Bid

1..1 Bill of materials
1..2 Type test reports for the Transformer of the type and rating offered.
1..3 Type test reports for protective & auxiliary relays, meters, switches etc. of the
type and rating offered.
1..4 Type test certificate /report offered shall be considered valid for 5 years from the
date of test performed on the equipment / material.
1..5 Cross sectional dimensional drawings for the transformer indicating details of
every compartment.
INSTRUCTION MANUALS
1..6 The manual shall clearly indicate the installation method, check-up and tests to
be carried out before commissioning of the equipment.
The Bidder may note that the drawings, data and manuals listed herein are
minimum requirements only. The Bidder shall ensure that all other necessary
write-ups, curves and information required to fully describe the equipment are
submitted with his bid.
GUARANTEE
The Bidder shall guarantee that the material supplied by shall be new and in
accordance with Bid document and shall be free from defect in material and
workmanship.
The Company's representative shall have full power to reject any of the
materials or works, which may prove defective in manufacture, poor
workmanship or performance both before the delivery and up to a period of sixty
(120) from the date of bringing the equipment's into use, the Bidder shall
forthwith replace such rejected material or works to the reasonable satisfaction
of. the Company's representative al his own cost.
233
REPLACEMENT OF DEFECTIVE PARTS & MATERIALS
The bidder shall make good at his own expense all defects due to faulty design,
material or workmanship, which may develop under proper use during a period
of from the date on which the equipment's are delivered or (120) month after
bringing the equipment into commercial use whichever is earlier.
ENCL:
Sr Particulars
1 Annexure as per attached sheet Annexure 1
234
ANNEXURE 2
DEVIATION SHEET (TECHNICAL & COMMERCIAL)
If the proposal has got any deviation from the Technical and Commercial
specifications, the bidder shall tabulate these deviations clause in the schedule.
Add more sheets if required.
_________________________________________________________(Bidder's
name)
Clause No. Deviations.
A) Technical NLL quoted are 2200

watts & LL 8600 watts
235
GUARANTEED TECHNICAL PARTICULARS FOR DISTRIBUTION
TRANSFORMER
ANNEXURE1
The bidder shall fill up Technical Particular of Distribution Transformer in the
following format
Sr. No. Description Specified / offered Rating \ KVA
1.0 General
1.1 Make
1.2 Type
1.3 Reference Standard
2.0 Rating
2.1 Rated output with ON AN cooling (KVA)

2.2 Type of cooling
2.3 .Rated Voltage (KV)

a) H.V. b) L.V.
2.4 Rated Current (Amps.)
a) H.V. b) L.V.
2.5 Guaranteed No Load current @ 100%
rated voltage
a) H.V b) L.V.
2.6. Guaranteed No Load current @ 110%
rated voltage
c) H.V d) L.V.
2.7 No. of Phases
2.8 No. of coil windings per phase
2.9 Type of coil winding

2.10 Rated Frequency (HZ)
2.11 Vector Group Reference
2.12 Trans suitable for Fault Level on H.V. side

3.0 Temperature
3.1 Reference ambient temperature (Deg.C)
3.2 Temperature rise over reference Ambient
a) Winding by resistance (Deg.C)
3.3 Maximum continuous overloading capacity
236
4.0 Tappings
4.1 Type
4.2 Capacity
4.3 Range-Steps x% variation
4.4 Tap provided on 11 v windings
4.5 Details of Tapings
Tap Position
1
2
3 Normal
4
5
4.6 Off Load tap links
a) Operating Voltage (Kv)
b) Rated current (Amp)
c)Type
d) Reference Standard
e) Number of Poles
f) Defined features provided (Please
5.0 Impedance at principal tap rated
5.1 Impedance
5.2 Reactance
5.3 Resistance
5.4 Zero Sequence impedance
a) H.V.
b) L.V.
5.5 Resistance of the winding @130°C
a) H.V.
b)LV.
6.0 Guaranteed Losses at principal tap full
6.1 No Lad losses (kW)
6.2 Load Loss (kw)
6.3 Total Losses (kw)
6.4 No Load loss at maximum permissible
6.5 Total Exhaust fan losses
7.0 Efficiency
7.1 Efficiency at 130 Deg.C and unity power
a) at 110% load
b) at 100% load
237
c) at 80% load
d) at 60% load 1
e) at 40% load
F ) at 20% load
7.2 Efficiency (0} 130 Deg.C and 0.8%
powerfactor lag%
; a) at 110% load
b) at 100% load
c) at 80% load
d) at 60% load
e) at 40% load
f) at 20% load
7.3 Maximum efficiency (%)
7.4 Load and power factor at which it occurs
8.0 Regulation
8.1 Regulation at full load @ 130 Deg.C
a) at Unity power factor
b) at 0.8 Power factory lagging
8.2 Regulation at 110% load @ 130 Deg.C
a) at Unity power factor
b) at 0.8 Power factor lagging
9.0 No load current (Amps)
9.1 At 100% voltage
a) H.V.
b) L.V.
9.2 At 110% voltage
a) H.V.
b) L.V.
10.0 Maximum flux density (Lines/Cm2)
10.1 At 100% rated voltage
10.2 AT 110% rated voltage
11.0 Maximum current density Amps / cm2
11.1 H.V. winding
11.2 LV. winding
12.0 Withstand time and current as multiple
12.1 Three phase dead short circuit at Terminal
12.2 Single phase short circuit at terminal with
13.0 Cooling System
13.1 Type of Cool inn
238
13.2 No. of Cooling exhaust fans
15.0 Core
15.1 Type/Core/or Shell
15.2 Core Material
15.3 Thickness of Lamination (mm)
15.4 Insulation of lamination (mm)
15.5 Equivalent cross section are (mm2)
16.0 Coils
16.1 Type of Coils
a) H.V.
b) L.V.
16.2 Conductor material
16.3 Gauge/area of cross section of conductor
a) H.V.
b) L.V.
16.4 Insulating material
a) H.V. Turn
b) L.V. Turn
c) L.V. Core
d) HV – LV
16.5 Insulating material thickness (mm)
a) H.V. Turn
b) L.V. Turn
c) L.V. Core
d) HV-LV
17.0 Minimum design clearance (mm)
17.1 HV to earth in air
17.3 LV to earth in air
17.5 Between HV & LV in air
17.7 Top winding and Yoke
17.8 Bottom wimSmg and Yoke
18.0 Transformer impulse level
18.1 HV Winding
18.2 LV Winding
20.0 Bushing
20.1 Make
20.2 Type
20.3 Reference Standard
20.4 Voltage Class (KV) (HV/LV)
20.5 Creep age distance factor (mm/KV)
239
20.6 Weight (Kg)
20.7 Free Space required for bushing removal
21.0 Terminal Connections
21.1 HV
21.2 LV
21.3 LV Neutral
21.4 L. T. Side C. T. Details:
1. Current Ration
2. Class of Accuracy
3. Burden
4. Type
22.0 Accessories
22.1 Each transformer furnished with fittings
and accessories as per Clause No. 5.0.0
(Please attach separate sheet giving
details)
22.2 Whether Surge Arrestor provided on H V

termination?
23.0 Painting: as per clause:

24.0 WTI Temperature-indicator-scanner
24.1 Details for make, catalog, manual
25.0 Overall Dimensions
25.1 Length (mm)
25.2 Breadth (mm)
25.3 Height (mm)
26.0 Enclosure
26.1 Material
26.2 Thickness of sides (mm)
26.3 Thickness of bottom(mm)
26.4 Thickness of Top Cover (mm) min.
26.5 Degree of Ingress Protection
27.0 Weight Data Kg
27.1 Core
27.2 Frame parts
27.3 Total Winding
27.4 Core and frame
27.5 Tank Kg
27.6 Core windings, tanks, oil etc. but
240
27.5 Tank Kg
27.6 Core windings, tanks, oil etc. but
27.7 Total Weight Kg
27.0 Shipping Data
27.1 Weight of heaviest package (Kg)
27.2 Dimensions of largest package (L x B x H)
28.0 Tests
28.1 Routine tests as per 18:2026, IS:11171
28.5 Core bolt withstand voltage for 1 minute
28.6 Type Test quoted: a) Temperature rise
29.0 C.T.'s with all accessories as per
241
GUARANTEE
The Bidder shall guarantee that the material supplied shall be new and in
accordance with Bid document and shall be free from defect in material and
workmanship.
For Unitized Substation Enclosure & Transformer: The material shall be
guaranteed for the period of 10(Ten) calendar years commencing immediately
after the satisfactory completion of installation and commissioning. In case
measured losses exceed the specified losses; amount calculated from loss
capitalization formula shall be deducted from final payment. In this situation
purchaser's decision whether to reject the equipment or accept the '"equipment
with penalty as per loss capitalization shall be final. For the purpose of
evaluation of loses, losses of the transformers measured at BSES testing
laboratory shall be final.
Technical Specification
CODE & STANDARDS:

All equipment and material shall be designed manufactured and tested in
accordance with the latest applicable Indian Standard. IEC standard and CBIP
manuals except where modified and / or supplemented this specification.
Equipment, and material confirming to any other standard which ensures equal
or better quality may be accepted. In such case copies of English version of the
standard adopted shall be submitted.
The electrical installation shall met the requirement of Indian Electricity Rules as
amended up to date relevant IS code of practice and Indian electricity act. In
addition other rules of regulations applicable to the work shall be followed in
case any discrepancy the most stringent and restrictive one shall be binding.
The Unitized Sub-station offered shall in general comply with the latest issues
including amendments of the following standards but not restricted to it.
Title Indian Standards
High Voltage Low Voltage Pre-Fabricated Substation IEC:1330
11 kv Switchgear cubicles IS:13118, 1S:3427,

IEC:694. IEC:298
Ring main unit 11 kv grade IS:9920, IEC:265
Code of practice for selection, installation and maintenance IS:10118

of Switchgear
Distribution Transformer IS: 2026
Dry Type Power Transformer IS:11171 1-
Thermal evaluation & Classification of electrical insulation IS: 1271
Fittings and accessories for Distribution Transformer IS:3639
242
Code of practice for installation and maintenance of IS: 10028
Transformers
Ready mixed paint, air drying Red oxide, Zinc Chrome, IS:2074
Priming
Colour for ready mix paints IS:5
Enamel synthetic, exterior a)Undercoating b) finishing IS:2932
Dimension of porcelain transformer bushing for use in very IS:3347

heavily polluted atmosphere
L.T. Fuseboard Panel 1S:5039
Indian Electricity Rules 1956
Indian Electricity Act 1910
DESIGN CRITERIA
o Unitized Sub-station consisting of 11 kv Non-Ext RMU + Transformer + L.T.
Fuseboard Panel with all connection accessories, fitting & auxiliary equipment in
an
o Enclosure to supply Low-voltage energy from high-voltage system as detailed in
this specification. The complete unit shall be installed on a substation plinth
(base) as Outdoor substation located at very congested places along the ring
main 11KV feeder system in BSES supply area . 11 kv Wing Isolator controls
incoming-outgoing feeder cables of the 11 kv distribution system. Oil fuse switch
shall be used to control and isolate the llkV/433V Distribution transformer. The
transformer L.T. side shall be connected to L.T. Fuse-board Panel. The
connection cables to consumer shall be taken out from the fuse-board panel.
o The prefabricated-unitized substation shall be designed for a) Compactness, b)
fast installation, c) maintenance free operation, d) safety for worker/operator &
public.
o The Switchgear and component thereof shall be capable of withstanding the
mechanical and thermal stresses of short circuit listed in ratings and
requirements clause without any damage or deterioration of the materials.
o For continues operation at specified ratings temperature rise of the various
switchgear components shall be limited to permissible values stipulated in the
relevant standard and / or this specification.
Service Conditions:
The equipment offered shall be suitable for continuous satisfactory operation in
tropical area of Mumbai in close proximity to sea with its high humidity and
following prevailing climatic conditions.
A Average Grade Salt laden.

Atmosphere
B Ambient Air Temperature: Highest 45° C, Average 35° C
243
C Relative humidity 95% Maximum
D Rainfall 3000 mm Concentrated in 4 months
E Basic wind speed as 44m/sec.

IS:875
F Seismic Zone 3
Enclosure:
The Enclosure, High Voltage switchgear-control gear, Low Voltage switchgear-
control gear & Transformer of the Unitized substation shall be designed to be
used under normal outdoor service condition as mentioned in IEC:694. The
following factors shall also be taken in to account while designing substation T.'
"w"
a) Rapid Temperature changes,
b) Solar radiations
c) The ambient air may be polluted by dust, smoke, corrosive gas, vapour or
salt.
d) Account shall be taken of the presence of condensation or precipitations,
SPECIFIC REQUIREMENT
The main components of a prefabricated-unitized substation are Transformer,
High^ voltage switchgear-control gear. Low-voltage switchgear-control gear,
corresponding "interconnections" (cable, flexible-bus bar) & auxiliary equipment.
The components shall be enclosed, by either common enclosure or by an
assembly of enclosure. All the components shall comply with their relevant
IS/IEC standards.
Ratings:
Description Unit Value
Rated Voltage / Operating Voltage kV rms 22
Rated frequency & Number of phases Hz & nos. 50 & 3
Rated maximum power of substation kVA 1000
Rated Ingress protection class of Enclosure IP: IP-.54 or

better
HV Insulation Level
Rated withstand voltage at power frequency of 50 Hz kV rms 28
Rated Impulse withstand Voltage kV peak 75
244
HV Network & Busbar
Rated current Amp 1300
Rated short time withstand current kA rms / Isec 13.4
Making capacity for switch-disconnector & earthing kA peak 33.4

switches
Breaking capacity of Isolators (rated full load) A 1300
LV Network & Busbar
Voltage V 400
Rated current (max load current) A 1300
Number of phases Nos. 3 P+ IN
245
ERECTION, TESTING AND
COMMISSIONING OF 80 MT
CAPACITY ELECTRONIC WEIGH-
BRIDGE.
246
1.0 INTRODUCTION
Design, Manufacture, Supply, Erection, Testing and commissioning of 2
Nos. Electronic Road Weigh Bridges of 80 MT capacity each required for
the 800 MTPD Cattle Feed Plant (expandable up to 1600 MTPD).
These technical specifications are for the guidance of the bidders only
and not intended to bring out all the details of design and fabrication of
the equipment or equipment components. The successful Bidder shall be
fully responsible to undertake all the work involved in the design,
engineering, manufacture including the erection, testing and
commissioning of these Electronic road weigh bridges and their
accessories. Bidders are to note that weigh bridges being offered in this
quote shall be part of the overall project and together with the main feed
plant and other equipment they shall be fully responsible in the overall
timely implementation of the project on Turnkey basis, within the battery
limits defined in this slice. The work being carried out shall confirm to high
standards of engineering design & workmanship. The equipment offered
shall be capable of performing in continuous commercial operation to
meet agreed performance standards and acceptable to the
purchaser/client. No exclusions of any nature are acceptable, other than
those specifically detailed in this document

provided with insufficient technical data/information/documents is liable to
be considered as non-responsive.
The Purchaser/Client will interpret the meaning of various equipment

specification and drawings submitted by the bidder and shall have the
right to reject any material/equipment, which in their opinion is not in full
accordance to tender specifications.
2.0 SCOPE OF WORK
The scope of the work for the slice is as follows:

including calibration and stamping and handing over to purchaser’s
satisfaction of the following
A) Design and supply of

• Two nos. Electronic Road Weigh Bridges complete with required
supporting structures and platform. This does not include the associated
civil works.
247
B) Erection, testing and commissioning of:
• Electronic Road Weigh Bridges complete with required supporting

structures and platform.
• Erection of associated electronic hardware like load cells, load
converters, computers, UPS, etc including weigh software.
• Commissioning of the Electronic Road Weigh Bridges complete after
testing, painting, calibration of the weigh scale etc.
2.1.1 ELECTRONIC ROAD WEIGH BRIDGES
LORRY WEIGH BRIDGE ( ELECTRONIC ) WITH 80 MT 2 NOS

ASSOCIATED STRUCTURALS AND PLATFORM
ELECTRONIC SENSING AND RECORDING 1 LOT.
EQUIPMENT INCLUDING LOAD CELLS, COMPUTER
HARDWARE AND SOFTWARE
2.2 Important note for Bidder –

totality
• The location and size of the weigh bridges shown in the site plan are
approximate. It may vary as per the design of the bidder. Successful
bidder has to supply the weigh bridge as per the approved drawings
• The equipment shall be supplied on FOR site basis inclusive of packing &
forwarding, insurance, freight, taxes, duties, octroi etc.
• The weigh bridges with accessories shall be covered under the
• Bidder has to make its own arrangement for all tools, tackles for lifting,
welding and other accessories for positioning and fabricating the
platform/accessories if any at site including arranging manpower required
for the same
• The bidder shall submit a GA drawing mentioning overall dimension,
sizes of structures etc. However, the successful bidder shall submit the
detailed final weigh bridge drawing to the purchaser for approval prior to
start of fabrication.
Weigh Bridge shall comply with the latest relevant Indian standards.
248
Safety and other statutory regulations/ requirements shall comply with
that being followed in the country.
Calibration of weigh bridges from Weights & Measures is part of the

scope. However statutory fees paid if any, shall be reimbursed on
production of originals.
4.0 BATTERY LIMITS
The Purchaser shall provide the RCC foundation for weigh bridges as per
load details provided by the bidder. The bidder's scope of works includes
design of weigh bridge platform, fabrication as per approved GA drawing,
supply of steel required as per detailed fabrication drawing prepared by
bidder and approved by purchaser, testing, commissioning, calibration,
cleaning and painting..
Bidder’s scope also includes arranging inspection and obtaining approval

from Weights & Measures, as required from local authorities.
Test weights required for testing, commissioning and calibration shall be

provided by bidder himself.
All commissioning spares required if any, for installation, testing &

commissioning till taking over the plant by the purchaser shall be provided
by bidder and the same after taking over the plant shall be provided by
purchaser / project authority.
Power for fabrication
Power for fabrication shall be arranged by bidder at his own cost. In case
power is arranged by the purchaser, then recovery @ 0.5% of entire order
value shall be recovered from the bidder by the purchaser.
5.0 EXCLUSIONS
All civil foundations for the weighbridge including ramps and civil works
shall be provided by purchaser
6.0 TECHNICAL SPECIFICATIONS OF INDIVIDUAL EQUIPMENT
6.1 ELECTRONIC ROAD WEIGH BRIDGE (PIT LESS TYPE)
These road weigh bridges are used for weighing of different raw materials
and finished products in trucks etc. The weight shall be digitally displayed
on the Digitiser/computer and also on a Jumbo Digital display for the
viewing of the truck driver. Suitable output for connection to central data
memorizing and processing unit to be provided. The weigh bridge should
be of electronic type with electronic sensing and indication and consist of
249
a microprocessor based controller with an Intel dual core PC (minimum)
along with,
1. The Platform shall be designed for maximum axle load of 32 T. The Steel
Platform shall be of size 18 M X 3 M of primarily welded design having
longitudinal and transverse bumper stops. The deck shall be of minimum
8mm thick plate and should be constructed in modular design, fully
welded, constrainer less, fully floating with longitudinal and lateral bumper
assembly, with minimum 2mm thick anti skid grippers spread across the
plate area. Only single section rolled beams without splice joints or Butt
welding shall be used. Three/four transverse load carrying
members/transoms shall be provided. Longitudinal deck modules bolted
to top of platform using high tensile bolts. Platform plates are to be
provided with welded anti skid strips. The structural steel MOC shall
confirm to IS 2062 and make of structural steel shall be as per approved
makes. The test certificates from manufacturer shall be furnished.
Detailed design calculations to be provided. Tubular painted side railings
on MS bracket along both sides of deck as guide for drivers. Surface
preparation of platform with structure through sand blasting, painting with
red oxide primer and finally epoxy finish paints.
2. Load cells (8 nos. of 30T each) of resistive strain gauge compression

type, hermetically sealed, dust, vermin and water proof with minimum IP
68. Accuracy shall be min 5000 OIML and zero balance/Readability 1% of
rated output. Repeatability shall be 0.01% of full scale and combined
error not more than 0.02% of rated output. Free motion Load cell
Mountings to cancel the effects of horizontal forces on the load cells due
to vehicle motion. Junction box and Screen cables from load cells/junction
box to digitiser.
3. Advanced Microprocessor controlled DIGITISER. Communication shall be

possible to main plant SCADA software through open
protocol/communication bus aided through RS 232 or 20mA serial as
standard. The inbuilt programme to have provision for print out of tickets
giving vehicle Number, date, time net weight, gross weight, tare weight,
product name and storing minimum 1000 tare and cumulative weights.
The digitiser shall work on 230 V AC- 50 Hz. The key pad should be
numeric and use heavy duty tactile keys / membrane keys. Display Unit
shall have minimum12.7 mm 2x7 digits vacuum fluorescent read outs.
4. IBM compatible computer preferable Pentium/Intel dual core or later

processor with TFT/LCD COLOUR MONITOR, Key board, Mouse and
other accessories to store data. The computer shall work as a data base
for the weighments made. Free windows based software for access,
display and print out of data in desired format is included in the scope of
the contract.
5. 132 col. dot matrix printer
6 Suitable rated UPS for computer.
250
7. Control panel arrangement to draw off the UPS supply.
8. Jumbo display unit. One additional out door type electronic weight display
unit (min. 100 mm wide letter size)
9 Surge protection of load cells/Digitiser and complete earthing of platform

and load cells with appropriate size earth conductor
Special note:
• The bidder shall arrange for inspection and stamping of the weigh bridge
by local weights and measures authorities. The fees for stamping if any
will be reimbursed to the bidder for documentary proof.
• Separate independent Cu earth pits shall be provided for weigh bridge
load cell and instrumentation by the bidder
• MS nosing angle/channels for Ramp edges shall be supplied and erected
by the bidder.
• The load details on the foundations shall have to be provided to the
purchaser to design the foundation.
• The steel structure for the weigh bridges shall be as per the design of the
bidder.
• Proper facility for inspection, operation and maintenance of structural,
members, load cells etc are to be provided by the bidder.

COMMISSIONING
• Erection, testing and commissioning is inclusive but not limited to the

following:
• Assembly of the factory fabricated modular weigh bridge at site.
• Erection/Welding/Grouting into place necessary plates, hand rails etc., as

per requirement.
• Approval of the installation executed by the bidder by the weights and

measure department for accuracy
• Testing and commissioning procedure have been detailed separately
6.3 GENERAL REQUIREMENTS
Painting: The Road weigh bridge structure (external and internal) shall
be painted. However standard cleaning, degreasing sandblasting practice
before painting shall be followed, then primer coating before applying one
coat of black synthetic epoxy paint. Second coat of synthetic epoxy paint
to be provided at site during erection and commissioning. Supporting
steel structure etc. being fabricated at site to be applied with corrosion
251
resistant zinc oxide primer before erecting/installing and then applying
two coats of synthetic epoxy paint after erection.

ALONGWITH THE QUOTE
A) DRAWINGS
Equipment drawing: The general arrangement (GA) drawing of weigh

bridges indicating dimensions, tolerances etc., as proposed by the bidder
layout drawing: The layout drawing showing layout of the both weigh
bridges and room including layout of the PC with monitors and other
displays to be provided
Earthing layout: The earthing layout proposed for both weigh bridges
and room including layout of the earth pits and earth conductors to be
provided
B) Other details
Thickness of deck plate
Type of load cells
Load cell type
Readability in Kgs
Accuracy of load cells
8.0 TECHNICAL DETAILS AND DRAWINGS TO BE TO BE SUBMITTED

AFTER AWARD OF CONTRACT
The final equipment GA drawing of weigh bridge being manufactured
Final foundation foot print
Final layout for the weigh bridges and room including layout of the PC
with monitors etc
The final earthing layout of the both weigh bridges and room including
layout of the earth pits and earth conductors to be provided
252
9.0 List of preferred Makes of Bought out Items (Not in order of
preference)
Description Makes
Electronic Weigh Bridge (Pit METTLER TOLEDO / SARTORIUS / ESSAE-
less) DIGITRONICS / AVERY.
Structural steel SAIL / TISCO / RINL / IISCO / ESSAR
A – SUPPLY
Sl. Description Capacity Qty
No.
1.0 LORRY WEIGH BRIDGE ( 80 MT 2 NOS

ELECTRONIC ) WITH
ASSOCIATED STRUCTURALS
AND PLATFORM
2.0 ELECTRONIC SENSING AND 1 LOT.
RECORDING EQUIPMENT
INCLUDING LOAD CELLS,
COMPUTER HARDWARE AND
SOFTWARE
B –INSTALLATION, TESTING AND COMMISSIONING
Sl. Description Capacity Qty

No.
1.0 LORRY WEIGH BRIDGE ( 80 MT 2 NOS

ELECTRONIC ) WITH
ASSOCIATED STRUCTURALS
AND PLATFORM
2.0 ELECTRONIC SENSING AND 1 LOT.
RECORDING EQUIPMENT
INCLUDING LOAD CELLS,
COMPUTER HARDWARE AND
SOFTWARE
253
SECTION – V
SUB SECTION – 6
TECHNICL DEVIATIONS
254
6. DEVIATION FROM TECHNICAL REQUIREMENT
6.1. This tender document provides guidelines for the processes and
equipment to be used in tender package and the "basis of design" and
the "standards and specifications", define the qualitative parameters
against which equipment will be required to perform.
6.2. It is incumbent on bidder to provide a fully detailed list of equipment and
services, which they intend to provide a fully execute the contract inline
with the tender document.
6.3. At various points in the tender the purchaser has stated that alternative
processes or alternative equipment will be considered. The bidder as part
of the bid document shall provide the fully detailed list of such
alternatives, together with a consider rationale for employing such
alternatives.
6.4. Items, which deviate from the tender proposal, shall be as per design
specification of the bidder and shall be treated as a deviation from the text
of this tender document. Deviated item should fulfil the minimum
performance parameters as specified in the tender.
6.5. This tender does not allow bidders to make exclusions from any part of
tender packages for which they bid, and an incomplete list of equipment
or an incomplete schedule of services to be provided would be
considered as a nonresponsive bid.
Table 3
Technical Deviation Statement Form
Sr. No Clause Reference Deviation Remarks
(Justification)
Above are the particulars of deviations from the requirements of the

tender specifications. The technical specifications furnished in the bidding
document shall prevail over those of any other document forming a part of
our bid, except only to the extent of deviations furnished in this statement.
Date
Signature of Authorised Signatory of Bidder/Bidder
NOTE: Where there is no deviation, the statementshould be returned duly signed

with an endorsement indicating "No Deviations".
255
SECTION – V
SUB SECTION – 7
OPTIONAL ITEMS
256
7. OPTIONAL ITEMS
7.1. All items mentioned in the tender packages or in the basis of design as
optional items shall be quoted on the basis of equipment of the systems
that are supplied "ready to pipe in ". The price for such items shall include
supply, installation, commissioning and connections including all
necessary piping, fitting, instrumentation, controls, utilities etc.
7.2. The entire system shall be designed with all provisions to include the
optional items in such a way that no major changes would be required in
the system. The provision shall be made in the system irrespective of
whether these additional items are supplied or not. The specifications of
optional items shall be the same as that of similar items mentioned in
tender.
7.3. The cost of optional items shall not be included in the calculation of total
bid price. In the event that the purchaser, for supply, selects optional
items, the quoted price for the optional item shall include all incidental
costs of installing that item as part of the contract.
257
SECTION – V
SUB SECTION – 8
DRAWINGS, DATA AND
DOCUMENTS.
258
8. LIST OF DRAWINGS AND DOCUMENTS:
8.1. Following drawings are enclosed along with the tender:
8.1.1. Flow Diagram
8.1.2. Overall site plan. Bidders to consider the site plan of the purchaser.
8.2. The following drawings shall be enclosed with the offer by the bidder
8.2.1. Proposed machinery layout (plan) for the cattle feed plant, floor wise
including the sectional elevations showing the major equipment/feed
piping. The drawing should also show staircase, platforms, walkways,
ladders etc. and other details.
8.2.2. Product flow diagram including production equipment, service and
production piping.
8.2.3. All drawings, data, histograms, etc provided by bidder shall be in soft
copy format. Documents shall be in Microsoft word or excel. Drawings
shall be in AutoCAD format.
8.2.4. The bid shall include general arrangement drawings for the individual
equipment along with equipment specifications.
NOTES:
Bidders may note that if successful, fabrication drawings of all equipment
irrespective of whether stated separately or not shall be got approved by
Client before fabrication.
8.2.5. Charts:
8.2.5.1.The following charts shall be enclosed along with the offer by all the
Bidders :
8.2.5.1.1. Plant utilization chart for services ( HISTOGRAMS).
8.2.5.1.2. Electrical Load diagram for on 24 hours basis.
8.2.5.1.3. Hourly equipment wise service consumption data on 24 hours basis
for steam, air etc.
8.2.5.1.4. Bar chart for Project execution including personnel training programme.
8.2.5.1.5. PERT chart.(Bar Chart/ Pert chart to be given after the PO has
been Finalised)
8.2.9. Service consumption schedules for connected average and peak loads
for all the equipments. The services to be considered are :
8.2.9.1. Steam : in kgs/hr.
8.2.9.2. Compressed air : in N.cu.m./min.
8.2.9.3. Power: in KWH.
8.2.10. Category wise staff requirement for various production and utility
sections of the plant on shift basis and daily basis.
8.2.11. Literature covering general and technical information for all equipment
covered within the scope of the tender including relevant pages of
operation and maintenance manuals.
8.2.12. List of spare parts with quantity, to be quoted on two years inventory
basis along with price break up.
259
10.2.13. Any other equipment/item which is not mentioned above but is required as per
description in the text shall also be provided.
10.2.14. Any other equipment/item that the Bidder feels is necessary shall also be
provided.
10.2.15. All makes purchased by bidder if successful shall be approved by client first
and then only procurement of such items shall be done.
260
SECTION – V
SUB SECTION – 9
TECHNICAL EVALUATION OF
BIDS.
261
9. TECHNICAL EVALUATION OF BIDS
9.1. The purchaser will evaluate and compare the technical merits of the bids based
on the information supplied by the bidders taking into account the following
factors.
9.1.1. Suitability of the process with regard to ultimate product quality conforming to
the standards specified in this section of the tender.
9.1.2. Specifications of individual equipments as well as the system as a whole for
material of construction, throughput, operating parameters, level of automation,
extra features, latest design, ease of maintenance etc.
9.1.3. Energy efficiency of individual equipment and system as a whole.
9.1.4. Completeness of submitted bid with respect to all information, data, details and
documents asked for.
9.1.5. The evaluation of the tender will be on a lump sum basis and the unit rates
asked for will be operable only for any additions/deletions.
262
SECTION – V
SUB SECTION – 10
PROCESS PERFORMANCE
AND GUARANTEE.
263
10. PROCESS PERFORMANCE & CONSUMPTION
GUARANTEE
10.1. If the plant or any part thereof does not give the agreed process
performance and consumption guarantees during the warranty period due
to reasons attributable to the bidder, the action shall be as below
10.1.1. EQUIPMENT PERFORMANCE.

10.1.1.1. The satisfactory performance for the equipment/ production plant (the
bidding Package) will be considered achieved if the plant operates
above 98% of the rated capacity declared by the bidder in the bid
documents.
10.1.1.2. If performance is between 95% and 98% of rated capacity, penalty will
be calculated at 2% of Rs value of the contract per 1% of shortfall.
10.1.1.3. If performance is below 95% the bidder will be required to upgrade the
plant or replace the plant to comply with the above performance
criteria. Otherwise the plant will be deemed unacceptable. All given
utility consumption to be inline.
10.1.2. SERVICE REQUIREMENTS

12.1.2.1. If measured demand of service in any bidding package of the plant is
less than 102% of the consumption declared by the bidder, the buyer
will accept that service requirements guarantees have been achieved.
12.1.2.2. If the requirement of any services of the plant is between 102% and
105% of the declared demand, penalty will be charged at 2% for every
1% rise in consumption for each of the services which falls in this
category of excessive demand. For the purpose of this calculation, only
the main services, steam, power, and compressed air will be
considered.
12.1.2.3. If the measured demand for services and energy is above 105%, the
bidder will be required to upgrade the plant or replace the plant to
comply with the declared performance criteria. Otherwise the plant will
be deemed unacceptable.
12.1.3. MAXIMUM LIABILITY

12.1.3.1. The maximum liability of bidders on all counts of penalties including
above, Liquidated Damages clause and other liabilities of any kind
shall not exceed 10% of Contract value over and above the liquidated
damage clause.
264
SECTION – V
SUB SECTION – 11
BIDDERS MEETING.
265
11. BIDDERS MEETINGS
11.1. Details of the proposed pre bid meeting are contained in instruction to
bidders section II. This will be a general meeting at which all purchasers
of the tender document may attend.
11.2. Bidders may also request technical discussions with the KDCMPUL /
clients project team before the tender closing date. Subjects for
discussion at the technical meeting may include:
• Project management
• Technical clarifications
• Scope of supply
• Concept of the design
• Processes
• Equipment designs
• Equipment bidders
• Automation
• Plant management
• Quality control
• Existing equipment to be utilized in the job
• Battery limits
• Acceptable alternatives
• Equipment bidders
This will be the only opportunity for bidders to discuss the project in detail
with KDCMPUL before the commercial bid opening, and all technical
matters should be resolved at meetings.
266
SECTION – VI
BIDDING TERMS DEVIATIONS.
267
Bidding Terms Deviation Statement Form
Sr. Clause Deviation Remarks
No Referen (Justification)
Above are the particulars of deviations from the requirements of the tender
specifications. The technical specifications furnished in the bidding document shall
prevail over those of any other document forming a part of our bid, except only to the
extent of deviations furnished in this statement
Date
Signature of Authorised Signatory of Bidder/Bidder
NOTE: Where there is no deviation, the statement should be returned duly signed
with an endorsement indicating "No Deviations".
268
SECTION – VII
BID FORM AND PRICE
SCHEDULE FORM.
269
BID FORM & PRICE SCHEDULE
(To be furnished in the letterhead of the company)
Date
To ,
Dear Sirs,
Sub:
Ref:
Having examined the Bidding Documents, including the Addendum ________we, the
undersigned, offer to supply and / or supply and deliver Goods and Services
including installation and commissioning as detailed in the price schedule, in
conformity with the said Bidding Documents including the technical specifications
and drawings (except to the extent of deviation statement furnished in our bid) and
the Conditions of Contract as mentioned in or referred to therein for the sum of:
or such other sums as may be ascertained in accordance with the Schedule of

Prices attached herewith and made part of this bid and the said conditions.
We accept all the conditions of the Bidding Document in this Bid Form and this
acceptance shall prevail over any other conditions, if any, given in our Bid.
We undertake, if our bid is accepted, to commence and complete delivery of all the
Goods and Services as specified in the Schedule of Requirements of the Bid
Document, from the date of receipt of your purchase Order/Notification of Award.
If our bid is accepted we will obtain the bank guarantee as per the conditions of the
Contract for the due performance of the Contract.
We agree to abide by this bid for the period of 90 days from the date fixed for bid
opening and it shall remain binding upon us and may be accepted any time before
the expiration of that period.
Until a formal contract is prepared and executed, this bid, together with your written
acceptance thereof and your Purchase Order / Notification of Award of Contract
(NOAC), shall constitute a binding Contract between us.
We understand that you are not bound to accept the lowest or any bid you may
receive. Dated this day of 2013.
Duly authorized to sign bid for and on behalf of Name of witness:
270
Price Schedule Form
Summary Sheet
Sr. No Summary Heads Amount
1 2 3
1 Total Ex factory, Packed
2 Total Excise Duty
3 Total Sales Tax/ WCT
4 Transportation
5 Insurance
6 Total Supply Price delivered at ite
(1+2+3+4+5)
7 Total Installation & Commissioning
10 Service Cover
11 Spares for 2 years of normal operations
Total Bid Price (6+7+8+9+10+11)
Notes:
1 Bid must be submitted strictly as per this pro forma (Summary
Sheet and items break up sheet)
2 Amount against Sr. No 1 to 3 & 7 must be the total worked out
in items break up sheet
3 Please quote charges for transportation (Sr. no 4) and
insurance (Sr. no 5) as a percent of ex factory, packed (Sr.
No 1)
Signature of Authorized Signatory of Bidder/Bidder
271
ITEMWISE PRICE BREAK-UP SHEET
CEILING ON
WHICH
NSTALLATION
INLAND EXCHANGE
&
#EX-WORKS Packed FREIGHT & RATE & CUSTOM TOTAL
COMMISSIONIN
INSURANCE DUTIES
G
ITEM VARIATION
QTY
S.NO. UNIT DESCRIPTI APPLICABLE
.
ON
C&F
CURREN (16=6+8+
UNITPRICE TOTAL % Value VALU % Value
CY 12)
E
(8=6*7 (12=6*1
(1) (2) (3) (4) (5) (6=2 * 5) (7) (9) (10) (11)
) 1)
TOTAL
# Inclusive of Custom Duty, Excise Duty & Sales tax / WCT( In Words Rupees ------------ only )
272
SECTION – VIII
QUALIFICATION APPLICATION
273
Qualification Application Form
You must submit this form (Table 2 and 3), duly filled in, along with the supporting as
per following checklist given in Table
Table 1
Checklist for Supporting
Supporting Required Please (√)
Latest Balance sheet filed with (Name of Authority) on
(Date)
Latest Profit & Loss Statement from (date) to (date)
filed ith (Name of Authority) on (date).
Audited copies 1of annual accounts and P & L account
of past 3 years
Certificate of Financial Soundness from Bankers of
dder/Bidders
Income Tax Clearance Certificate (Latest)
Sales Tax Clearance Certificate (Latest)
Details of Income Tax Registration
Details of Sales Tax Registration
Organization Chart
Annual Report of last three years
----------------------------------------
Indigenous Bidder/Bidders must attach copy of accounts audited under section 44
AB of Income Tax Act. Incase the accounts need not be audited, a Charted
Accountant or Manager of a Nationalized Bank should attest theinformation in this
statement.
274
Table 2
Financial Soundness
General Information
Name
Address
Phones
Mobile
Fax
E mail
Contact
Personnel
with designation
Financial Information
Sr. No Description Value(Rs)
In Bank
Cash
1 In Hand
Balance
Total
Gross
2 Fixed Assets
Net
Inventories
Current
3 Others
Assets
Total
Bank Cash Credit
Sundry creditors
Sundry creditors
Provisions
Current
4 Contingent Liabilities
Liabilities
(including claims
not acknowledged, please
specify)
Total
Share capital
Free reserves
5 Capital
Other reserves (please
specify)
6 Term loans from financial institutions and banks
275
7 Working capital
8 Net worth
Debtors and More than 6 months
9 advances Less than 6 months
considered good
Significant Financial Ratios
Sr. No Ratio Definition Value
1 Current Current Assets to Current Liabilities
(Cash + temporary investment held in
2 Acid Test lieu of cash + current receivable) /
current liabilities
3 Solvency Total Liability to Net Worth
Net Profit before Tax Sr.
Sr. No Period
1 Current period
2 During the last Financial Year
3 During the year before last Financial Year
Financial Arrangements
Sr. No Resources Amount
1 Own
2 Bank Credits
3 Others (Specify)
276
Sales
Value of orders to be executed/
anticipated Sales
Sr. No Category of Customers
Current Next Financial
Year
1 Government Department
2 Commercial
3 Others
Total
Annual Turnover
Sr. No Financial Year (Please begin with current
year)
1
2
3
4
5
6
Rate Contracts for the items to be supplied
Sr. No Organization Items Valid till
1 Directorate General of Supplies &
Disposal,
Government of India.
National Cooperative Consumers’
2
Federation of India Ltd
3 KendriyaBhandar
Central Equipment Stores
Purchase
4
Organization for State
Governments
5 GCMMF
6 Others
277
Table 3
Technical Competency
Classifications
Sr. No Category Please (√)
1 Manufacturer
2 Clearing & Forwarding
Agent
3 Stockist
4 Wholesale Dealer
5 Authorized Reseller
6 Authorized Service Agent
7 Retailer
8 Trader
9 Others (please specify)
Details on Plant
Sr. No Plant Details
1 Location
2 Description
3 Type
4 Size of building
5 Is property on lease or free hold?
If on lease, indicate date of
6
expiry of ease in each case.
7 Others (please specify)
278
Plant Facilities
Sr. No Facilities Ans Remark
1 Space available for manufacturing (in m2)
2 Space available for storage (in m2)
3 Space available for inspection (in m2)
4 Are buildings fire resistant? (Y/N)
5 Are premises approved by Municipal fire
Department? (Y/N)
6 Are buildings under Municipal fire protection?
(Y/N)
7 Are power & fuel supply adequate to meet
production requirements? (Y/N)
8 Are adequate transportation facilities available?
(Y/N)
9 Are safety measures adequate for performance
of proposed
contract? (Y/N)
10 Is adequate material handling equipment
available? (Y/N)
Testing Facilities
Sr. No Facilities
1 List testing equipment available
2 Give details of tests to be carried out on items offered.
3 Details of the testing organizations available.
Quality Control Organization
Sr. No Quality Control Method Response
1 Are goods offered subject to Batch Test, Random
Sampling or full 100% test for quality?
2 Are tests carried out by factory employees or by
a separate testing agency?
3 Are independent Quality Control Organization
checks made and certificates issued?
279
Manufacturing Capacity
Units Manufactured
Description of
Sr. No Capacity
Equipment
Current year Last Year 2nd last year
Personnel/ Organization
Sr. No Personnel in Numbers in levels
1 Production Managerial Supervisory Skilled Workmen
2 Marketing
Installation and
3
commissioning
4 Service
5 Spare parts
6 Administrative
Service Centre nearest to our site location
Location
Phone no
Sr. No Information required on Details
1 Number of skilled employees
2 Number of unskilled employees
3 Number of engineering employees
4 Number of administrative employees
5 List of special repair/ workshop facility available
6 The storage space available for spare parts (in m2)

7 Value of minimum stock of spares available at all the service
centres in respective currency
8 List of the models/ types of equipment serviced by the Centre in
last 2 years
280
References
Sr. No Name of
Address, Telephone, Fax, Contact Person
Organization
1
2
List of components usually subcontracted
1
2
Workload for the current and forth coming financial year on quarterly basis
Sr. No Financial Year Quarterly Workload as % of Total Capacity
1 Current Financial I ll lll lV
Year
2 Next Financial Year
List of major projects of similar size and nature previously executed
Sr. No Name of Project Year of Year of Capacity/
the client award completion Products Value
(Curre
ncy)
1
2
3
4
Type of equipment manufactured and supplied (M & S) during last 2 years
Sr. No Equipment Capacity Qty Projects On Hand Order Qty
1
2
3
Names of two buyers to whom similar equipment are supplied, installed and
commissioned in the past and towhom reference may be made by the KDCMPUL
regarding the Bidder/Bidder’s technical and delivery ability:
Type of equipment manufactured, supplied, installed and commissioned (MSIC)
Sr. No Equipment Capacity Qty Projects On Hand Order Qty
1
2
3
4
Schedules for furnishing technical data and certified drawings after receipt of
orders
1
2
Number of weeks required for preparing a bid proposal
281
SECTION – IX
COLLABORATOR’S
AUTHORISATION.
282
Collaborators' Authorisation Form
Reference Dated
Managing Director
Kaira District Co operative Milk Producers’ Union Limited.
Amul Dairy
Anand – 388 001
Gujarat
Dear Sir,
Bid Reference: KD/CF/T M/2012 13/001
We, (Name of the Collaborator), an established and reputable bidder of Technology

and goods (Name of Technology & Goods ) do hereby authorize (Name and address
of Agents) to bid, negotiate and include the contract with you against Bid
Reference: KD/CF/T M/2012-13/001 for the above technology & goods supplied by
us.
No company or firm or individual other than (Name of your sole agent/ distributor)
are authorized to bid, negotiate and conclude the contract in regard to this business
against this specific Bid. (Strike out this, if not applicable)
We hereby extend our full guarantee and, warranty for the technology and goods
offered for supply against this invitation for bid by the above firm.
Yours faithfully,
(NAME)
For and on behalf of
(Name of Manufacturers)Note:
This letter of authority should be on the Letterhead of the Collaborators' concern and
should be
signed by a person competent and having the power of attorney to bind the Bidder.
283
APPENDICS – I
284
Contents
1. Form of BG for Performance Security
2. Form of BG for Advance Payment
3. Contract Form
4. Pro forma of Completion Certificate
5. Form of BG for Bid Security (EMD)
6. List of acceptable Banks for Bank Guarantees from
Foreign / National Bank
285
Form of BG for Performance Security
(On the Non Judicial Stamp Paper as per the Stamp Act of State
Government)
Bank Guarantee Number Date:

This deed of performance guarantee made this ________ day of 20 (Two
thousand __) by (Name and address of the Bank) (herein referred to as the Bank)
which expression shall unless repugnant to the context and meaning thereof
includes its legal representatives, successors and assignees and the Kaira District
Co operative Milk Producers’ Union Limited.(hereinafter referred to as the
KDCMPUL) which expression shall unless repugnant to the context and meaning
thereof include its legal representative, successors and assignees.
Whereas, KDCMPUL /its clients has awarded a Contract and Purchase Order
bearing Number __ dated _____ on (Name and address of the party) (hereinafter
referred to as the `Bidder/Bidder’) for the supply/ supply and erection and
commissioning of __. And whereas, the Bidder/Bidder has agreed to submit a
performance guarantee in the form of a Bank Guarantee to the KDCMPUL in terms
and conditions of the Bidding Document and the Contract which will be kept valid up
to __ calendar months from the date of Bank Guarantee (the period should be till
end of warranty period). And whereas, the Bank and its duly constituted agent and
officer has already read and understood the contract made between the KDCMPUL
and the Bidder / Bidder.
In consideration of the KDCMPUL having agreed to award the contract/purchase
order on theBidder/Bidder, we, (name of the Bank), do hereby guarantee, undertake,
promise and agree to with the KDCMPUL, its legal representatives, successors and
assignees that the within named (name of the bidder/Bidder) their legal
representatives and assignees will faithfully perform and fulfil everything within the
Bidding Document and the Contract/Purchase order on their part to be performed or
fulfilled, at the time (time being the essence of the contract) and in the manner
therein provided, do all obligations there under and we further undertake and
guarantee to make payment to the KDCMPUL of Rs _ (Rupees __ only) being the
10% of the contract value, without any demur in case the Bidder/Bidder, their legal
representatives and assignees do not faithfully perform and fulfill everything within
the Bidding Document and the Contract/Purchase order on their part to be performed
or fulfilled, at the time and in the manner therein provided and do not wilfully and
promptly do all obligations there under.
In case, the Bidder/Bidder fails to perform or fulfil the Contract/ Purchase Order as
per the terms and conditions agreed upon, the KDCMPUL is entitled to demand an
amount equal to 10% of the Contract value from the Bidder/Bidder and the demand
made by the KDCMPUL by itself will be conclusive evidence and proof that the
Bidder/Bidder has failed to perform or fulfill his obligations and neither the
286
Bidder/Bidder nor the Bank will be entitled to raise any dispute regarding the reasons
for the failure of performance or fulfilment, on any ground.
We, (name of the Bank), do hereby undertake to pay an amount equal to 10% of the
order value, being the amount due and payable under this guarantee without any
demur, merely on a demand from the KDCMPUL which has to be served on us
before the expiry date of Bank Guarantee i.e. / / stating that the amount
claimed is due by way of non performance of the contractual obligations as
aforesaid by the Bidder/Bidder or by reason of the Bidder/Bidder's failure to perform
the said contractual commitments/Purchase Order, any such demand made on the
Bank shall be conclusive as regards the amount due and payable by the Bank under
this guarantee. However, our liability under this guarantee shall be restricted to an
amount not exceeding Rs (Rupees _ only) being the amount equal to 10% of the
total order value.
We, (name of the Bank), further, agree that the performance guarantee herein
contained shall remain in full force and effect for a period of calendar months
from the date of Bank guarantee (the period should be till end of warranty period)
and till the KDCMPUL certifies that the terms and conditions of the said contract/
purchase order have been fully and properly carried out by the said Bidder/Bidder
and accordingly discharge the guarantee, unless a demand or claim under this
guarantee is made on us in writing by the KDCMPUL on or before _ , we shall be
discharged from all liabilities under this performance guarantee thereafter.
We, (name of the Bank), further agree with the KDCMPUL that the KDCMPUL shall
have the fullest liberty without our consent and without affecting in any manner our
obligations hereunder to vary any of the terms and conditions of the said Bidding
Document and the Contract/Purchase order or to extend the time of performance by
the said Bidder/Bidder from time to time or postpone for any time or from time to time
and any of the power exercisable by the KDCMPUL against the Bidder/Bidder and to
forebear or enforce any of the terms and conditions relating to the said Bidding
Document and the Contract/Purchase Order and we shall not be relieved from our
liability by reason of any such variation, or extension being granted to the said
Bidder/Bidder, or for any forbearance, act or omission on the part of the KDCMPUL
to the said Bidder/Bidder by any such matter or thing whatsoever which under
the law relating to sureties would but for this provision have effect of so relieving us.
This guarantee shall be in addition to and without prejudice to any other securities or
remedies which the KDCMPUL may have or hereafter possess in respect of the
goods supplied or intended to be supplied and the KDCMPUL shall be under no
obligation to marshal in favour of the Bank any such securities or funds or asset that
the KDCMPUL may be entitled to receiving or have a claim upon and the KDCMPUL
at its absolute discretion may vary, exchange, renew, modify or refuse to complete to
enforce or assign any security or instrument.
The Bank agrees that the amount hereby guaranteed shall be due and payable to
the KDCMPUL on serving us with a notice before expiry of bank guarantee, requiring
287
the payment of the amount and such notice shall be deemed to have been served on
the Bank either by actual delivery thereof to the Bank or by dispatch thereof to the
Bank by Registered Post at the address of the Bank.
In order to give full effect to the provisions of this guarantee the Bank hereby waives
all rights inconsistent with the above provisions and which the Bank might otherwise
as a guarantor be entitled to claim and enforce.
We, __, undertake to renew the Bank Guarantee provided the request for the
Bidder/Bidder before the expiry of Bank Guarantee makes renewal.
We, __, (Name of the bank) lastly undertake not to revoke this guarantee during its
currency except with the previous consent of the KDCMPUL in writing and the
guarantee shall be a continuous and irrevocable guarantee up to a sum of Rs __
(Rupees __ only).
Notwithstanding anything stated herein before: (i) our liability under this guarantee is
restricted to Rs __ (Rupees _ only) (ii) The Bank Guarantee shall remain in force till
__/__/20__ and (iii) The Bank is liable to pay the guarantee amount or any part
thereof under this Bank Guarantee only if the KDCMPUL serves upon the bank a
written claim or demand on or before __.
Signature
Seal
Code Number
Place: Date:
Notes:
Bidder/Bidders should ensure that the bankers, before submission of the bank
guarantees,
put seal and code number of the signatory.
Stamp paper is not required in case of foreign Bidder/Bidders.
The value of stamp duty should be as per latest stamp act of local state government
where the bank guarantee issued.
288
Form of BG against Advance Payment
(On the Non Judicial Stamp Paper as per the Stamp Act of State
Government)
Bank Guarantee Number Date:
In consideration of the Kaira District Co operative Milk Producers’ Union
Limited. hereinafter
called `KDCMPUL’) having agreed to grant an advance of Rs _ Rupees only) to M/s
___ (hereinafter called the said Bidder/Bidder) under the terms and conditions of an
contract/purchase order Number __ dated _ made between the KDCMPUL and M/s
_ for the supply/ supply, erection and commissioning (hereinafter called the `said
contract/purchase order') on production of a Bank Guarantee for Rs _ (Rupees _
only). We __ (hereinafter called `the Bank') do hereby undertake to pay the
KDCMPUL an amount not exceeding Rs _ (Rupees ____ only) against any loss/
damage caused to or suffered would be caused or suffered by the KDCMPUL by
reason of any breach by the said Bidder/Bidder(s) of any of the terms and conditions
contained in the said contract/ purchase order.
We, ___, do hereby undertake to pay the amounts due and payable under this
guarantee without any demur merely on a demand from the KDCMPUL which has to
be served on us before the expiry date of Bank Guarantee i.e. __ stating that the
amount claimed is due by waymof loss or damage caused to or would be caused to
or suffered by the KDCMPUL by reasons of any breach by the said Bidder/Bidder(s)
of any of the terms and conditions contained in the contract/purchase order or by
reasons of the Bidder/Bidder(s) failure to perform the said contract/purchase order,
any such demand made on the Bank shall be conclusive as regards the amount due
and payable by the Bank under this guarantee shall be restricted to an amount not
exceeding Rs _ (Rupees __ only).
We, __, further agree that the guarantee herein contained shall remain in full force
and effect during the period that would be taken for the performance of the said
contract/ purchase order and that it shall continue to be enforceable till all the dues
of the KDCMPUL, under, or by virtue of the said contract/purchase order have been
fully paid and it’s claims satisfied or discharged or till the KDCMPUL certifies that the
terms and conditions of the said contract/Purchase Order have been fully and
properly carried out by the said Bidder/Bidder(s) and accordingly discharge the
guarantee unless a demand or claim under this guarantee made on us in writing on
or before _ , we shall be discharged from all liability under this guarantee thereafter.
We, ___, further agree with the KDCMPUL that the KDCMPUL shall have the fullest
liberty without our consent and without affecting in any manner our obligation
hereunder to vary any of the terms and conditions of the said contract/Purchase
Order to extend time of performance by the said bidder/Bidder from time to time or
to postpone for any time or from time to time any of the power exercisable by the
KDCMPUL against the said Bidder/Bidder and to forbear or enforce any of the terms
and conditions relating to the said contract/Purchase Order and weshall not be
289
relieved from our liability by reason of any such variation, or extension or for any
forbearance, act of omission on the part of the KDCMPUL or any indulgence by the
KDCMPUL to the said Bidder/Bidder or by any such matter or thing whatsoever
which under the law relating to sureties would but for this provision have effect of so
relieving us.
The Bank agrees that the amount hereby guaranteed shall be due and payable to
the KDCMPUL on serving us with a notice before expiry of Bank Guarantee requiring
the payment of the amount and such notice shall be deemed to have been served on
the Bank either by actual delivery thereof to the Bank or by dispatch thereof to the
Bank by registered post at the address of the Bank.
We, ___, lastly undertake not to revoke this guarantee during its currency except
with the previous consent of the KDCMPUL in writing.
We, __, undertake to renew the Bank Guarantee provided the request for the said
Bidder/Bidder before the expiry of Bank Guarantee makes renewal.
Notwithstanding anything stated herein before: (i) our liability under this Bank
guarantee is restricted to Rs.__ (Rupees __ only) (ii) The Bank Guarantee shall
remain in force till _____20____ and (iii) The Bank is liable to pay the guarantee
amount or any part thereof under this Bank Guarantee only if the KDCMPUL serves
upon the bank a written claim or demand on or before ______.
Signature
Seal
Code Number
Place: Date:
Notes:
Bidder/Bidders should ensure that the bankers, before submission of the bank
guarantees, put seal and code number of the signatory.
The value of stamp duty should be as per latest stamp act of local state government
where the bank guarantee is issued.
290
Contract Form
(On the Non Judicial Stamp Paper as per the Stamp Act of State Government)
THIS AGREEMENT made the __ day of __ 2012 between Kaira District
Co operative Milk Producers’ Union Limited., Anand 388 001, (hereinafter “the
purchaser”) of the one part and __
(hereinafter “the Bidder/Bidder”) of the other part.
WHEREAS the Purchaser is desirous that certain goods and ancillary services
should be provided by the Bidder/Bidder, viz (brief description of goods and services)
and has accepted a bid submitted by the Bidder/Bidder in response to the
Purchaser’s Bidding Document Reference KD/CF/T M/2012 13/001 for the supply
of those goods and services in the sum of Rs _ (Rupees ___) (hereinafter “the
contract price”).
NOW THIS AGREEMENT WITNESSETH AS FOLLOWS:
In this agreement words and expressions shall have the same meaning as in the
Terms and Conditions mentioned in Section III and Section IV and in other sections
in the above referred Bidding Document. The following documents shall be deemed
to form, read and construe as part of this agreement:
• The offer and the price schedule submitted by the Bidder/Bidder and as accepted
by the purchaser;
• The schedule of requirement/ list of items and the technical specifications in the
above referred Bidding Document;
• The terms and conditions in the above referred Bidding Document;
• The Purchaser’s purchase order Number _________ dated In consideration of the
payments to be made by the Purchaser to the Bidder/Bidder as hereinafter
mentioned, the Bidder/Bidder hereby covenants with the Purchase to provide the
goods and services and to remedy defects therein in conformity in all respects with
the provisions of the Purchaser’s purchase Order and Bidding Document.
The Purchaser hereby covenants to pay the Bidder/Bidder in consideration of the
provision of the goods and services and the remedying of defects therein, the
contract price or such other sum as may become payable under the provisions of the
purchase order at the times and in the manner prescribed in the Purchase order and
bidding document.
IN WITNESS whereof the parties hereto have caused this agreement to be executed
in accordance with their respective laws the day and year first above written.
Signed, sealed and delivered by the authorized signatory for the Purchaser) In the
presence of:
1.
2.
Signed, sealed and delivered by the authorized signatory for the Bidder/Bidder) In
the presence of:
1.
2.
291
Pro forma of Completion Certificate
(To be issued by the purchaser after successful commissioning of the supplied goods)
Reference Date
Subject: Certificate of commissioning of supplied goods/ PLANT

This is to certify that the plant section as detailed below has been received in good
condition along with all the standard and special accessories (subject to short supply
mentioned) in accordance with the Contract/ Specifications. The same has been
installed and commissioned. The Performance Test has been done to our entire
satisfaction and operators have been trained to operate the plant. The bidder/Bidder
has fulfilled his contractual obligations satisfactorily (subject to unfulfilled obligations
mentioned)
Completion Certificate
Sr. No. Item Description
1 Contract Number & Dated
2 Description of the plant
3 Quantity
4 Bill of Lading/ AWB (for Import Contract)/ LR/
RR &Dated
5 Name of the vessel/ transporters
6 Consignment Note Number & Dated
7 Name of the consignee
8 Name of the consignee
Details of short supply and recoveries to be made

Sr. No. Description Amount to be recovered
1
2
Details of unfulfilled contractual obligations
Sr. No. Description Amount to be recovered
1
2
Explanatory Notes for filling up the certificates on contractual obligations of the

Bidder/Bidder
• Bidder/Bidder has adhered to the time schedule specified in the contract in
dispatching the documents/ drawings pursuant to technical specifications.
• Bidder/Bidder has installed and commissioned the plant in time (within the period
specified in thecontract) from the date of the intimation by the Purchaser in respect
of the installation and commissioning of the units.
292
• Training of personnel as per contractual obligation by the Bidder/Bidder has been
done.
• In the event of documents having not been supplied or installation and
commissioning of the plant have been delayed on account of the Bidder/Bidder, the
extent of delay should always be mentioned.
293
Form of Bank Guarantee for Bid Security
(On Non Judicial Stamp Paper as per the Stamp Act of Local State Government)
Bank Guarantee Number: Date:

This Deed of Guarantee made this ____ day of 20 ____(two thousand and )
by (Name and the address of the bank), hereinafter referred to as the Bank, which
shall unless repugnant to the context and the meaning thereof include its legal
representatives, successors and assignees and the Kaira District Co operative
Milk Producers’ Union Limited (hereinafter referred to as the KDCMPUL) which
expression shall unless repugnant to the context and meaning thereof include its
legal representatives, successors and assignees.
Whereas the KDCMPUL has invited Bids for the design, supply, installation &
commissioning of 600 MTPD Cattle Feed Plant, by the Invitation to bid number
KD/CF/T M/2012 13/001. AND WHEREAS (Name and Address of the
Bidder/Bidder) who having submitted their bids (hereinafter referred to as the
Bidder/Bidder) and have agreed to deposit to the KDCMPUL an amount indicated in
the Invitation to bid as per the terms and conditions of the Bidding Documents. AND
WHEREAS the KDCMPUL is also willing to accept a Bank guarantee in lieu of
payment by demand draft of an amount equivalent to the amount of Bid security
required to be deposited by the Bidder/Bidder to the KDCMPUL and the guarantee
shall be kept valid for 60 days after the day of the opening of the bids.
In consideration of the KDCMPUL having agreed to consider the Bid proposals
having submitted by the Bidder/Bidder without depositing the amount of Bid security
and against this Bank guarantee, we (name and address of the Bank) hereby
undertake and guarantee to make payment to the KDCMPUL the amount of Bid
security or any part thereof not deposited by the Bidder/Bidder to the KDCMPUL at
any time (time being the essence of the Contract) when the KDCMPUL asks for the
same as per the terms and the conditions of the Bidding Document within 60 days
from the date of opening of bids.
The Bank further undertakes not to revoke this guarantee during its currency except
with the previous consent of the KDCMPUL in writing and the guarantee shall be
continuous and irrevocable guarantee up to a sum of Rs _ (Rupees _ only) provided
always that any indulgence or forbearance on the part of the KDCMPUL to the said
Bidder/Bidder, with or without the consent of the Bank shall not prejudice or restrict
remedies against the bank nor shall the same in any event be a ground of defence
by the Bank
against the KDCMPUL.
In case the KDCMPUL puts forth a demand in writing on the Bank for the payment of
amount full or in part against this bank guarantee, the Bank will consider without
demur that such demand by itself is a conclusive evidence and proof that the
Bidder/Bidder has failed incomplying with the terms and conditions stipulated by the
KDCMPUL in its Bidding Document and payment will be made to the KDCMPUL
294
without raising any disputes regarding the reasons for such failure on the part of the
Bidder/Bidder.
The Bank shall not be discharged or released from this guarantee by any
arrangement between the Bidder/Bidder and the KDCMPUL with or without the
consent of the bank or any alterations in the obligations of the parties or by an
indulgence, forbearance shown by the KDCMPUL to the Bidder/Bidder.
This guarantee shall be in addition to and without prejudice to any other securities or
remedies which the KDCMPUL may have or hereafter possess against the
Bidder/Bidder and the KDCMPUL shall be under no obligations to marshal in favour
of the Bank any such securities or fund or asset that the KDCMPUL at its absolute
discretion may vary, exchange, renew, modify or refuse to complete or enforce or
assign any security or instrument. The Bank agrees that the amount hereby
guaranteed shall be due and payable to the KDCMPUL on serving us with a notice
before expiry of Bank Guarantee requiring the payment of the amount and such
notice shall be deemed to have been served on the Bank either by actual delivery
thereof to the Bank or by dispatch thereof to the Bank by Registered Post at the
address of the Bank.
In order to give full effect to the provisions of this guarantee the Bank thereby waives
all rights inconsistent with the above provisions and which the Bank might otherwise
as a guarantor be entitled to claim and enforce.
The guarantee shall remain in force until _ and the bank undertakes to renew the
Bank Guarantee provided the Bidder/Bidder before the expiry of Bank Guarantee
makes the request.
Notwithstanding anything stated herein before: (i) our liability under this guarantee is
restricted to Rs _ (Rupees _ only) (ii) The Bank Guarantee shall remain in force till _
20 _ and (iii) The Bank is liable to pay the guarantee amount or any part thereof
under this Bank Guarantee only if the KDCMPUL serves upon the bank a written
claim or demand on or before _.
Place: SIGNATURE
Seal Code Number.
Note:
Bidder/Bidders should ensure that the banker before submission of the bank
guarantees puts the seal and code number of signatory.
The value of stamp duty should be as per latest stamp act local state government
from where the bank guarantee issued.
295
Bank Guarantees from Foreign and Scheduled Banks
Bank Guarantee from all nationalized banks is acceptable. Other than the
Nationalized Banks, BGs from the following banks shall also be acceptable:
1. Scheduled Banks:
• IDBI Bank
• ICICI Bank
• AXIS Bank
• HDFC Bank
296
APPENDICES – ll
297
Contents
1. Site survey plan.

2. Spares Philosophy
3. Documentation Philosophy
298
SITE PLAN
299
SPARES REQUIREMENT
300
All bidders are required to follow and consider the following Mandatory spares
philosophy atthe time of submitting the bid prices.
Sr. Items Spares required
no.
01 Instrumentation items
a) Instruments including sensors / 20% or minimum one number of each
transducers, transmitters, type, make, model number and range
solenoid valves / coils, air filter whichever is higher
regulators, RTD, proximity
switches, gauges, process/utility
switches, instrument
configuration etc.
b) Control Valves 5% or minimum one number of
following items for each type, model,
make, size etc whichever is higher.
• Diaphragm
• Body Gasket
• Packing set
c) DCS/PLC/PLC control system • 5% or minimum one number of each
type of following whichever is higher
o Analog I/O card
o Digital I/O card
o Power supply module
o Interface card
o Operating panel display
d) Pneumatic Valves 10% or minimum one number of
make, size etc. whichever is higher
• Sealing kit
• 2 way SOV
• 3 way SOV
• Limit / Proximity switches
• Cable connectors
e) Actuated valves 10% or minimum one number of
make, size etc. whichever is higher
• Spare kit for valves
• Spare kit for actuator
02 Electrical Items
a) Electrical Switch gear items like Spares for 2 years of normal
fuses, MCBs, Contactors etc. operation as per OEM
recommendation.
03 Mechanical Items
301
a) Pumps & Motors 10% or minimum one number of
following items whichever is higher.
• Bearing sets
• O ring set
• Gasket set
• Oil seals
• Coupling keys
• Mechanical seal set
302
DOCUMENTATION
REQUIREMENT
303
1. Documentation Requirement
1.1. Following minimum documentation is envisaged to be submitted by the
Bidder at time of detailed engineering for review, information or approval
and as a final As Built Drawing after ccommissioning of the plant.
1.1.1. Drawings:
1.1.1.1. Plant P&IDs Drawings.
1.1.1.2. Utility Generation and Distribution P&IDs.
1.1.1.3. Plant & Utility Equipment Layout.
1.1.1.4. GA Drawing of Plant & Utility equipment along the details of Point
load and foundation details.
1.1.1.5. GA drawings of fabricated equipments.
1.1.1.6. Plant O&M Manual (Inclusive of Process as well as utility) with all trip
settings, interlock details etc.
1.1.1.7. Plant Commissioning Manual (Inclusive of Process as well as utility)
1.1.1.8. O&M Manual of Individual Equipment supplied by OEM.
1.1.1.9. Piping layout (Process and Utility)
1.1.1.10. Electrical & Instrumentation Drawings
1.1.1.10.1. Panel location drawings
1.1.1.10.2. Cable tray layout drawings
1.1.1.10.3. Earth pit location layout
1.1.1.10.4. Communication cable layout
1.1.1.10.5. Instrument Index
1.1.1.10.6. Process Logic write up
1.1.1.10.7. DCS/PLC / PLC Graphics and colour scheme
1.1.1.10.8. Process and Utility Interlock details with Trip and alarm setting
details.
1.1.2. Order / Purchase specifications:
1.1.2.1. Each Purchase / Ordered specifications shall have following as
minimum:
1.1.2.1.1. item description
1.1.2.1.2. Bidder name and contact details
1.1.2.1.3. Project details
1.1.2.1.4. Design Basis
1.1.2.1.5. Specification of ordered items
1.1.2.1.6. Datasheet (Showing Make & Model number of the item along with
make and model number of accessories ordered, Service catered,
Point of installation, specific requirements, if any, etc.)
1.1.2.1.7. Approved QAP
1.1.2.1.8. Product catalogue of the selected model giving the brief technical
specifications and model decoding details.
1.1.2.1.9. GA drawings
1.1.2.1.10. BOQ with makes for Packages and Panels.
304
1.1.2.1.11. Panel wiring details for Packages, MCC, PCC, APFC, DCS/PLC, HT
panel, DG set etc.
1.1.2.1.12. Sizing calculations
1.1.3. Further to above all original documents pertaing to inspection as per
approved QAP shall be handed over with the running invoices.
1.1.4. All the above drawings shall be submitted in six sets as Hard copy and
One set as editable soft copies (AutoCAD, PDF, Excel sheet, MS word
etc.)
305

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BID REFERENCE NO: AMUL/CFF-

KAIRA DISTRICT CO-OPERATIVE MILK PRODUCERS’

01 Section I Invitation for Bids 4

Invitation For Bid (IFB)

Name of CATTLE FEED

Design, supply, installation and commissioning of 500

Duration (months) 4 Months

Start 25.4.2013, Thursday

Submission 6.5.2013 at 15.00 Hrs., Monday

Date of Pre Bid Meeting. 30.04.2013 at 11.00 Hrs., Tuesday

2. Purchase of Bidding Document

The Bid security may be forfeited if

5. Rights Reserved by KDCMPU Ltd.

2. CONTENTS OF BIDDING DOCUMENT

3. CLARIFICATION OF BIDDING DOCUMENT

4. AMENDMENT OF BIDDING DOCUMENT

5. PRE BID MEETING

7. DOCUMENTS COMPRISING THE BID

10. PRICE ADJUSTMENT

11. BID CURRENCY

12. DOCUMENTS ESTABLISHING BIDDER’S EXPERIENCE AND

13. DOCUMENTS ESTABLISHING GOODS’ CONFIRMITY TO BIDDING

14. BID SECURITY (EARNEST MONEY DEPOSIT)

15. PERIOD OF VALIDITY OF BIDS

16. FORMAT AND SIGNING OF BID

17. SEALING AND MARKING OF BIDS

18. DEADLINE FOR SUBMISSION OF BIDS

19. LATE BIDS

20. MODIFICATION AND WITHDRAWAL OF BIDS

21. OPENING OF BIDS BY PURCHASER

22. CLARIFICATION OF BIDS

23. PRELIMINARY EXAMINATION

24. EVALUATION AND COMPARISION OF BIDS

26. POST QUALIFICATION

27. RIGHT TO VARY QUANTITIES AT THE TIME OF AWARD

29. NOTIFICATION OF AWARD

30. SIGNING OF CONTRACT

31. PERFORMANCE SECURITY

32. IMPORT LICENSE

33. TURN KEY CONTRACT

34. BREAK UP PRICES

35. DELIVERY SCHEDULE OF ITEMS

36. TABLE 1 CHECK LIST OF BID SUBMISSION

2. Contents of Bidding Document

3. Clarification of Bidding Document

4. Amendment of Bidding Document

4.2 The amendment will be notified in writing or by email or by fax or cable to

4.3 In order to afford prospective Bidders reasonable time, in which to take

Venue of the Meeting : Office of General Manager (P&E), Amul Dairy,

Date of Pre Bid Meeting : 30.04.2013

Clarifications shall be submitted to the bidders on the same day.

7. Documents comprising the Bid

7.1.2 Documentary evidence established in accordance with Clause 10 that the

7.1.3 Documentary evidence established in accordance with Clause 11 that the

7.1.4 Bid security (Earnest Money Deposit) furnished in accordance with

7.1.5 A statement of deviation and exception to the provision of bidding

9.2.6 The cost of installation and commissioning as described in the technical

9.2.7 The cost of incidental services listed in Clause 7 of Special Conditions of

10. Price Adjustment

11. Bid Currency

But this will be as per the quoted price in the bid.