DCPL-K9A02
VOLUME : IIH
SECTIOIN-IV
SCOPE OF WORK, TERMINAL POINTS & EXCLUSIONS
1.01.00 Scope of Supply
The scope of work of the bidder covered under this specification is described
here-in-under. The items which are not specifically mentioned but needed to
make the system complete and reliable for safe operation and guaranteed
performance shall also be treated as though included and the same shall be
furnished unless otherwise categorically excluded.
The bidder shall take a note that design, engineering of the entire Ash
Handling Plant envisaged in the specification is the responsibility of the bidder
himself - such design engineering essentially includes system design and
sizing of all equipment/ components.
In case of confusion/contradiction with other volumes, if any there, the bidder
is advised to seek clarification.
Quantities indicated here below are broadly indicative and for the purpose of
tendering only.
1.01.00 Bed Ash Handling System up to Common silos
1.01.01 Three crushers (one for each 135MW unit) fitted near bed ash surge hopper
of respective unit. Each crusher capacity will be 6 TPH (minimum)
1.01.02 Three vibrating screen (one for each 135MW unit) fitted near bed ash surge
hopper of respective unit. Each vibrating screen capacity will be 28 TPH
(minimum)
1.01.03 Three buffer hopper, Three feeding hopper, Three surge hopper and Total
nine/six no air lock/conveying vessel/ densoveyor vessel.
1.01.04 Adequate number of level probes.
1.01.05 Adequate number change over/switch valve/dome valve to dispose ash in
intermediate bed ash surge hopper.
1.01.06 Adequate number and suitably sized bed ash conveying pipes to dispose bed
ash to intermediate bed ash surge hopper. Bed ash carrying pipes shall
dispose bed ash to bed ash intermediate surge hopper via target box. Total
bed ash conveying capacity of ash conveying pipes of each unit shall be
([Link]) [Link]/S-IV : 1
DCPL-K9A02
28TPH (dry ash basis, minimum). Structure, fittings, instruments, valves etc as
required for smooth operation of system will be in scope of bidder.
1.1.7 One number intermediate bed ash surge hopper of 84Ton (dry ash basis or 60 minute
holding capacity whichever is higher) effective capacity. This ISH will be fitted
with two level probes (high level & high-high level sensing), adequately sized
bag filter arrangement, pressure relief valve, poke hole and maintenance door.
1.01.08 Intermediate bed ash surge hopper inside surface shall have 3mm thk SS
lining. Bed ash ISH shall be structurally supported from ground level. The
structural arrangement having multiple floors, staircase shall hold other
associated equipment as well, ensuring proper operation and maintenance
access.
1.01.09 Five numbers (three working + two standby) pneumatic conveying vessel with
inlet manual knife gate valve, expansion joint , dome valve and outlet
discharge pipe up to silo shall be provided . Each vessel shall have
discharging capacity 28TPH. These vessels shall be fitted below intermediate
bed ash surge hopper. Knife gate valves at ash conveying pipes on silo top
( as shown in tender flow diagram) and ash conveying pipe associated fittings
at silo top while disposing bed ash to silos shall also be in scope of ash
handling bidder.
1.02.00 Fly Ash System from Hoppers up to silos
1.02.01 Adequate number of air lock/conveying vessel /PD pump type stationary ash
conveying vessel etc. Capacity of vessels & corresponding accessories, pipe
etc at first and second ESP fields shall match with the ash load (considering
outage of first field and consequential ash collection in second field and
onwards). Capacity of ash conveying vessels, corresponding pipe, valves,
fittings etc at third field and onwards shall be designed considering outage of
first field.
1.02.02 Adequate number of level probes as per enclosed flow diagram.
1.02.03 Adequate number change over/switch valve/dome valve to dispose ash in
intermediate fly ash surge hopper.
1.02.04 Complete ash piping for fly ash conveying system from the hoppers to
intermediate surge hopper/silos along with necessary valves, fittings,
instruments, specialties and all accessories as required for complete system.
The ash vessel discharge pipe shall combine to number of headers to
enable the optimization of cleaning time and energy of operation.
1.02.05 One number intermediate fly ash surge hopper of 99Ton (dry ash basis or 45
minute holding capacity whichever is higher) effective capacity. This ISH fill
be fitted with two level probes (high level & high-high level sensing),
adequately sized bag filter arrangement, pressure relief valve, poke hole and
maintenance door.
([Link]) [Link]/S-IV : 2
DCPL-K9A02
Necessary fluidizing arrangement for intermediate fly ash surge hopper shall
be provided. The fluidizing air will be tapped from compressed air line
(supplied by conveying air compressor discharge header)
1.02.06 Five numbers ( three working + two standby) pneumatic conveying vessel with
inlet manual knife gate valve, expansion joint , dome valve and outlet
discharge pipe up to silo shall be provided . Each vessel shall have
discharging capacity 44TPH(minimum). These vessels shall be fitted below
intermediate fly ash surge hopper. Knife gate valves at ash conveying pipes
on silo top ( as shown in tender flow diagram) and ash conveying pipe
associated fittings at silo top while disposing bed ash to silos shall also be in
scope of ash handling bidder.
1.02.07 The respective hoppers of ESP & APH are under scope of supply of the Boiler
supplier. However, fluidizing pads with support structures, pipes, valves &
fittings etc. shall be supplied & erected inside these hoppers as desired by
system by the Ash Handling System supplier who shall carry out all necessary
modifications also.
1.02.08 Necessary adapters to match the hopper outlet flanges on one side & ash
system supplier's equipments on the other side.
1.02.09 Requisite number of level probes fitted in ESP & APH hoppers. Each ESP
hopper shall be provided with at least one level probes to ascertain hopper
empty/ low ash level condition.
1.02.10 Adequate number and adequately sized surge chute for 3X135MW units.
Each surge chute will be fitted below each APH hopper.
1.02.11 Hopper Fluidizing air system comprising two (2) no (1Working + 1Standby)
fluidizing blowers and two (2) no (1 Working and 1 Standby) of hopper
fluidizing blowers heaters for each 135MW unit to serve the ESP Hoppers of
each unit complete with suction filters cum silencers, relief valves, discharge
pressure indicators, isolating and non return valves, drive motors;
instrumentation; all necessary pipes, valves; fittings, hangers, supports ;
thermal insulation & cladding etc. Arrangement shall be provided with isolation
valves (refer corresponding flow diagram) in such a way that any heater can
be accessed by any blower as and when required. The blower with heaters
shall be preferably placed near ESP area of respective unit in a shed.
1.03.00 Conveying Air system
Five numbers (Three working + two stand by) oil free type screw
compressors shall be installed to cater to the requirement for pneumatic
conveying of fly ash and bed ash for the three units. However, bidder may
provide alternate number of oil free compressor with 50% ( minimum) stand by
to suit the system.
Complete conveying air piping from the conveying air header along with
valves, fittings, and all accessories as required for complete system. Air
([Link]) [Link]/S-IV : 3
DCPL-K9A02
receivers of suitable capacity shall be provided for individual stream
consumption.
1.04.00 SILO AND ASSOCIATED ARRANGEMENT
1.04.01 One (1) Common R.C.C. fly ash storage silo (capacity : 2000 Te) and One (1)
Common R.C.C. bed ash storage silo (capacity : 1725 Te) for three units to
store ash and allowing transport trucks to receive fly/bed ash from it. Each silo
shall be fitted with air slides (fluidizing pads), diffusion hoods at the silo bottom
and shall be complete with suitable number of pulse jet operated bag/ vent
filters followed by suitable number of vent fans; pressure relief valve ,high
level sensing RF type level probe and continuous ash level monitoring
purpose level transmitter. Each bag filter/Vent filter fitted in ash handling
system shall be designed to limit face velocity within 1.5M/min at 10%
chockage condition. Vent filter out let air ash content should not exceed
50mg/NcuM.
1.04.02 Each Bed ash silo shall have total six openings. Among these six openings,
one (1) opening duly blanked with flanges shall be kept for future bed ash
conveyance; Two (2) opening shall be for rotary Drum Conditioners cum
Unloaders for discharging conditioned ash to the trucks , One (1) opening
for telescopic spouts with scavenger fan for unloading on closed tankers and
two (2) no (1W + 1S/B) opening for bed ash disposal to the ash pond
through lean slurry system during exigency condition.
Each Fly ash silo shall have total seven openings. Among these seven
openings, one (1) opening duly blanked with flanges shall be kept for future
fly ash conveyance; One (1) opening shall be for rotary Drum Conditioners
cum Unloaders for discharging conditioned ash to the trucks, Two (2)
openings for telescopic spouts with scavenger fan for unloading on closed
tankers and three (3) no (1W +1S/B) opening for fly ash disposal to the ash
pond through lean slurry system during exigency condition.
1.03.03 Each silo shall be provided with large size access door for maintenance &
inspection purpose; level detection device for showing ash level in silo; relief
valve to handle any unusual pressure/vacuum surges inside silos; antistatic
protection (electrical) if required to prevent dust explosion.
1.03.04 Six number rotary vane feeder (fitted below two silos). Each ash unloading
capacity 180TPH( dry ash basis).
1.03.05 Three rotary dust conditioner. Each ash unloading capacity 180TPH( dry ash
basis).
1.03.06 Three Telescopic spout arrangement along with vent fan, winch and winch
motor. Each ash unloading capacity 180TPH( dry ash basis).
([Link]) [Link]/S-IV : 4
DCPL-K9A02
1.03.07 Total five (5) nos of feeder ejectors below three silos with all valves above
and jetting water connections.
1.03.08 Total five (5) nos of collector tanks/mixing tank in the remote silo area.
1.03.09 Total five (5) numbers of jet pumps( capacity @75TPH, dry ash basis) below
three collector tanks with HP water jetting connection.
1.03.10 Total five (5) no lean slurry disposal pipe line with all valves, fittings,
accessories to dispose the lean slurry in ash pond.
1.03.11 Silo utility building containing blowers, conditioning water pump and HP ash
water pump with adequate maintenance space and associated electrical
room.
1.03.12 Paving of silo unloading floor with peripheral drains leading to drain pit.
1.03.13 Silo Fluidizing Air system Comprising total three (3) silo fluidizing blowers
(one for each Silo and one common stand by) Complete with Suction filters
cum silencers, relief valves, discharge pressure indicators, isolating & non
return valves, drive motors, electric air heaters (total three ,one for each Silo
and one common stand by); all necessary pipes, valves, fittings, hangers,
supports ; thermal insulation and cladding etc. Arrangement shall be
provided with isolation valves ( refer corresponding flow diagram) in such a
way that any heater can be accessed by any blower as and when required.
1.04.00 Water system
1.04.01 Two (2) horizontal centrifugal type dust conditioning water pump (1 working +1
S/B) to provide all the dust conditioning water in Silo complex. Motor, valves,
piping, instruments etc along with the pumps are in scope of supply of vendor.
1.04.02 Two (1W + 1S/B) HP ash water pump to cater HP water requirement for
3X135MW units. Motor, valves, piping, instruments etc along with the pumps
are in scope of supply of vendor.
1.04.03 Two (1W + 1S/B) booster seal water pumps which will take their suction from
seal water header to cater seal water requirement for ash handling plant.
1.04.04 One (1) common ash water sump of R.C.C. construction near silo utility
building area. The sump shall be complete with level control instrumentation,
crossover platforms on the sump top for personnel movement.
1.04.05 Two (1W+1S/B) Recovery water pump at ash disposal area for 3X135MW
units. Motor, valves, piping, instruments etc along with the pumps are in
scope of supply of vendor.
1.04.06 Recovery water pump house
([Link]) [Link]/S-IV : 5
DCPL-K9A02
1.04.07 One (1) common recovery ash water sump of R.C.C. construction near ash
disposal area. The sump shall be complete with level control instrumentation,
crossover platforms on the sump top for personnel movement.
1.04.08 One (1) MS ERW recovery water pipe of suitable dia from Ash disposal area
to the top of silo area ash Water sump. The pipe shall follow same pipe route
as of lean slurry disposal pipe lines and shall be Complete with supports,
fittings, specialties etc. Space provision shall be kept in the pipe corridor such
that additional number of one pipe can be installed at a future date when the
need is felt.
1.05.00 Drain pumping system
Vertical, Centrifugal, single stage, semi-open or (open non-clogging) type
impeller type drain pumps to be provided in ash disposal area recovery water
sump, silo area ash water sump ,near silo area and near ESP area. In Silo
area total two no drain pumps for three units (one working and one stand by)
shall be provided. In recovery water sump total two no drain pumps for three
units (one working and one stand by) shall be provided..In ash water sump
total two no drain pumps (one working and one standby) for three units shall
be provided. Two (1W+1 S/B) drain pumps (common for three units) shall
preferably be provided at the center of ESP area of 3X135 MW units.
1.06.00 Common make up water
Water from cooling tower blow down,/ raw water from main plant, and also
decanted water from the ash dump area shall comprise the input water
sources for Ash Handling system. Various types of water are used for various
Consumers while keeping Maximum vigil on the aspect of reuse of water such
that water economy is achieved. Water from CT blow down/raw water
discharge header will be provided at one point near to ash water sump( near
silo area).Necessary piping, valves, piping , control etc beyond this point is in
scope of supply of ash handling vendor.
1.07.00 Instrument Air System
Two numbers (1 w+ 1 S/B) oil free screw compressors of suitable capacity
shall be provided along with Two numbers (1 w+ 1 S/B) refrigerant type air
drier to cater to the instrument air requirement for the five units.
Complete instrument air piping from the instrument air header along with
valves, fittings, and all accessories as required for complete system. Air
receivers of suitable capacity shall be provided for individual unit consumption,
silo area and such major consumption points. IA pipes and fittings shall be MS
galvanized. IA lines shall be properly sloped and drain trap shall be provided
at strategic locations. Reducers in IA line shall be eccentric one.
1.08.00 Cooling Water System
([Link]) [Link]/S-IV : 6
DCPL-K9A02
Cooling water required for ash handling system will be tapped from main plant
ACW header at one suitable point near compressor house (supplied by client)
and return water will be fed to return water header. Pipes, fittings, valves etc
beyond this single suction and discharge point as mentioned above to
various consumption points of ash handling system is under scope of ash
handling vendor.
1.09.00 Seal/Clarified Water System
All of the requirements will be met from clarified/ seal water supply header
(for Ash Handling system). In this context, it is to note that seal water
connection for Conditioning water pump and HP ash water pumps and
recovery water pumps are envisaged because it is assumed that recovery
water from ash disposal area settling pond will contain considerable amount
of ash/ soil contamination.
It is envisaged that there shall be two (1W + 1S/B) booster seal water pumps
which will take suction from seal water supply header (for ash handling
system) to cater the requirement of seal water at different consumption
points.
Seal/clarified water required for ash handling system will be tapped from main
plant clarified water header at one suitable point @ 1 Kg/sq cm. Pipes, fittings,
valves, necessary boosting water pumps(100% stand by) etc beyond this
single point to various consumption points of ash handling system is under
scope of ash handling vendor.
1.10.00 Hoisting Equipment ,Air Conditioning and Ventilation system
1.10.01 Semi EOT crane (hand operated LT, pendant operated CT and hoist) of
capacity 5 ton (approx) shall be provided for fly ash and bed ash common
equipment building (containing compressor, etc). If compressor room is wide
enough and one row of central column is required to be provided in the said
room to sustain width, then two semi EOT crane is envisaged in compressor
room. Similar crane 3.5(approx) ton capacity shall be installed for ash water
pump house.
Capacity of the cranes are tentative, however selection of crane capacity shall
be guided by 110% of heaviest load to be handled. Electrically operated hoist
shall be provided on top of silo. All control room shall be air conditioned with
window/ package air conditioners and is included in scope of supply of ash
handling vendor. Electrical room for MCC shall be pressurized ventilated.
Adequate ventilation fans are to be provided in the equipment building/ rooms
associated with ash handling system.
([Link]) [Link]/S-IV : 7
DCPL-K9A02
1.10.02 Suitable lifting equipment shall be provided for Crusher, Vibrating screen and
bowers( for blowers not situated in compressor house), recovery water pumps
,for drain sump pumps and at silo unloading floors.
1.11.00 Scope of Supply and Works - Additional Notes
The detailed scope of supply and work for the following sub- systems,
associated with this plant, although have not been specified in detail within
this volume shall be deemed to be included within the Main plant package and
has already been covered in detail in corresponding sections. The scope of
such work under this specification includes, but not limited to the following:
a) All Civil Work of and pertaining to the Ash Handling Plant. Ref.
Relevant part of specification.
List of Work - The scope of work shall also include complete civil
design, engineering, furnishing BOQ, furnishing of civil construction
drawings, supervision of execution of civil works. The scope shall
include supply of base plates, sole plates, foundation bolts, anchor
bolts, sleeves, steel inserts, embedments and bar bending schedules
for the associated civil works for complete ash handling system. In
this context it is to note that construction of silos, compressor building
(accommodating conveying air compressors & IA compressors),
recovery water pump house (accommodating recovery water pumps),
silo utility building (accommodating silo fluidizing blowers, HP ash
water pumps, ash conditioning water pumps, booster seal water
pumps), blower shed in ESP area, ash handling control room,
associated electrical buildings, annexed toilets, all sumps , pits , roads
and paved area in silo unloading floor along with peripheral drain ash
handling system pipe pedestal, ash handling system related pipe rack
etc are included in scope of supply of AHP vendor.
Complete construction of Ash Dyke including necessary excavation
(For details please refer to the corresponding technical specification)
b) All Structural - List of Work - Overhead Pipe racks; Work (Steel)
Structures etc. complete with stairs, galleries, platforms etc. In brief
designing, supply and erection of pipe rack shall be in Ash Handling
Vendor ‘s scope
c) All Architectural - complete design, engineering, furnishing BOQ,
furnishing of construction drawings, supervision of execution of works
for all architectural Work are in scope of supply of ash handling vendor.
Toilets, Drinking water facilities are excluded from scope of supply of
ash handling package.
d) All Electrical - For requirement of motor provided with VFD facility,
owner will provide HT/LT feeder up to incoming point of VFD system
([Link]) [Link]/S-IV : 8
DCPL-K9A02
from their HT/LT switch gear. Bidder will provide all equipment / cabling
from VFD incoming point up to drive motor.
Earthing system above fround level for earthing of equipment supplied
by bidder.
For detail specification of electrical equipment/ item please refer
relevant electrical sections enclosed with this specification.
e) All Instrument - As required and as per standard/good station Supplies
engineering practice including cables, junction boxes; instrument
hardwares and softwares, etc. . Ref. Relevant part of specification.
f) Ventilation - The ash control room and wherever PLC System & Air
equipments are placed shall be air-conditioned; All other Rooms
Conditioning System and Buildings shall be properly ventilated by
judicious selection system of equipment. Air conditioning and
ventilation for all rooms, buildings shall be in Scope of ash handling
bidder.
g) Fire Protection - As per recommendations of the fire safety System
codes available in the country and as per good engineering practice
for all Buildings installing equipment and having operator habitation.
However fire protection system shall be done by separate by fire
fighting vendor and it is not included in ash handling bidder’s scope of
supply.
.
h) Electric Overhead- As required in the Ash Handling Plant. Traction
Cranes; However electric overhead cranes shall be considered in
miscellaneous crane package and shall be excluded from scope of
supply of ash handling bidder. In this connection bidder is requested to
provide a list of crane/hoist which they consider is excluded from ash
handling packages as per the said clause and also to provide a list
crane/hoist which they consider is included in ash handling package.
i) Erection, Testing - As required and as described elsewhere.
Pre-commissioning Adherence to Safety codes/norms etc. . Ref.
Relevant part of specification.
4.12.00 Scope of Services shall include
i) Complete cleaning, protection and painting.
ii) Packing, forwarding and transportation to site including transit
insurance.
iii) Shop testing of all equipment as listed elsewhere in this specification.
([Link]) [Link]/S-IV : 9
DCPL-K9A02
iv) Unloading, storage and handling at site, leveling, grouting, erection of
plant, touch up painting at site, final check up, testing and
commissioning of all equipment and accessories of the complete plant
v) Any additional equipment and materials or work, which are not
specifically mentioned, but required to make the installation complete
in every respect shall be under the scope of the specification.
vi) For insurance clause, Bidders are advised to refer the Volume-I,
Conditions of Contract.
vii) The contractor shall arrange for necessary handling equipments, if
required, for the erection of equipments under his scope.
viii) Supervision of equipment Civil/Foundation work.
ix) Lubricants (oil/ grease) till commissioning. (i.e., till the commissioning
of the unit is over.)
x) Mandatory spares.
xi) Recommended spares
xii) Special tools and tackels
([Link]) [Link]/S-IV : 10