DESIGN, SUPPLY, ERECTION, TESTING AND ... · Web viewQuality Assurance Plan shall be strictly in...

DESIGN , SUPPLY , ERECTION , TESTING AND COMMISSIONING

OF ROTARY VACUUM DRIER ( RVD) OF 4000 LTRS CAPACITY AND

ITS SUBSYSTEMS

Satish Dhawan Space Centre SHARIndian Space Research Organization

Sriharikota -524 124, A.P

Rotary Vacuum Dryer and subsystems SDSC SHAR, ISRO

PREPARATION OF BIDS- INFORMATION TO BIDDERS

1.1. VALIDITY OF OFFERBid shall remain valid for acceptance for a period of 4 (Four) months from the due date of submission of

the Bid. The Supplier shall not be entitled during the said period to revoke or cancel his Bid or to vary the

Bid except and to the extent required by Purchaser and communicated in writing. Bid shall be revalidated

for extended period as required by Purchaser in writing. In such cases, unless otherwise specified, it is

understood that validity is sought and provided without varying either the quoted price or any other terms

and conditions of Bid finalized till that time.

1.2. COST OF BIDDINGAll direct and indirect costs associated with the preparation and submission of Bid (including clarification

meetings and site visit, if any), shall be to Supplier's account and the Purchaser will in no case be

responsible or liable for those costs, regardless of the conduct or outcome of the Bid process.

1.3. SCHEDULE OF PRICESThe schedule of prices shall be read in conjunction with all the sections of proposal document. For

lumpsum contract, the lumpsum prices quoted by the Supplier shall be firm and fixed for the completion of

the work, unless stated otherwise. The price must be filled in the online bid with the ‘Schedule of Prices’.

The price bid format is given in Annexure – IV.

1.4. DOCUMENTS COMPRISING THE BIDPART – I TECHNICAL AND UNPRICED COMMERCIAL PART

Technical bid shall be submitted online in the format ‘documents solicited from the vendor’ and the

following documents shall be attached along with the technical bid. If sufficient space is not available for on

line submission, the same in hard copy form shall be send to Department by courier/ post to reach before

the tender opening date, failing which the on-line bid will not be considered for evaluation. No attachment

with price information shall be attached along with the technical bid.

i. Submission of bid letter along with one set of proposal document duly signed and stamped as token

of acceptance.

ii. All the annexures and scope enclosed in proposal (section -2) duly filled, signed and sealed.

iii. Unpriced copy of schedule of prices with all other commercial terms and conditions duly filled (Prices

to be kept blank), signed and stamped.

iv. Data sheets for all the equipment & checklists enclosed in proposal duly filled, signed, & stamped.

(Annexure-I, section-2).

v. Technical details, equipment general arrangement drawings with part list, catalogue, layout drawings,

P & I diagram, catalogues etc as applicable and any other drawing, document as mentioned in the

proposal.

vi. Audited balance sheet including profit and loss account for the last three financial years showing

annual turnover.

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vii. Latest income tax clearance certificate.

viii. Latest solvency certificate from a scheduled bank.

ix. List of projects in hand & completed during the last 3 financial years indicating the name of client,

contact person, contract value, nature of work, work completed, work balance, name of Consultant,

month & year of commencement & completion etc.

x. Schedule Bar chart.

xi. Execution Plan.

xii. Any other relevant document, Supplier desires to submit.

xiii. The bidder shall furnish a list of all critical items / sub-assemblies along with offer which are bought

out by the bidder and proposed to be used , along with necessary details such as manufacturer’s

name, brand, model no etc

PART – II PRICED COMMERCIAL BID Commercial bid shall be filled in on line ‘price bid format’ and no scanned copy should be attached along

with the technical bid. No deviations, terms and conditions, assumptions, conditions, discounts etc. shall be

stipulated in price bid. Purchaser will not take cognizance of any such statement and may at their discretion

reject such bids.

2. BID EVALUATION2.1. Vendor shall submit the details in vendor evaluation criteria mentioned in Annexure-III in their technical

and un-priced commercial bid to evaluate the same.

2.2. The offer shall be for complete scope of work as specified in tender document. Part/Spilt offer is NOT

acceptable.

2.3. During evaluation, purchaser may request Supplier for any clarification on the bid upon additional

documents which is to be complied with; otherwise offer will be deemed incomplete.

2.4. Techno-commercial discussion shall be arranged with Supplier, if needed. Supplier shall depute his

authorized representatives for attending discussions. The representatives attending the discussions shall

produce authorization from his organization to attend the discussion and sign minutes of meeting on

behalf of his organization if required. The authorized representative must be competent and empowered

to settle/decide on all technical and commercial issues.

2.5. The complete scope of work is defined in the Proposal document. Only those Suppliers who undertake

total responsibility for the complete scope of work as defined in the Proposal document shall be

considered.

2.6. In case Bid does not fully comply with the requirement of Proposal document and the Supplier stipulates

deviations to the clauses of the proposal in Schedule of deviations , Annexure -V, which are unacceptable

to the Purchaser, the Bid will be rejected.

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2.7. Performance of Supplier on similar works executed/ under execution shall be taken into consideration

before selecting the Supplier for opening his price bid.

2.8. Purchaser reserves right to visit client’s site for verification/validation.

2.9. The time schedule for completion is given in the Proposal document. Supplier is required to confirm the

completion period unconditionally.

2.10. Purchaser reserves the right to accept a bid other than a lowest and to accept or reject any bid in full or

part without assigning any reasons. Such decisions by the Purchaser shall bear no liability on the

Purchaser whatsoever consequent upon such decision.

2.11. Purchaser shall not be obliged to furnish any information / clarification to unsuccessful Suppliers as

regards to non-acceptance of their Bids.

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Section – 1General Terms and Conditions of

Contract

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GENERAL TERMS AND CONDITIONS OF CONTRACT

1 INTRODUCTIONSDSC SHAR invites tenders in sealed covers from reputed firms with proven ability for DESIGN, SUPPLY, ERECTION, TESTING AND COMMISSIONING OF ROTARY VACUUM DRYER OF 4000 LTRS. CAPACITY AND ITS SUB SYSTEMS AS PER TECHNICAL SPECIFICATIONS for SDSC SHAR, Sriharikota.”

2 SCOPE OF WORK AND TECHNICAL SPECIFICATIONS

The scope of work is given below and technical specifications are given in the enclosure to this document. The general terms and conditions are given below.

The details of scope of work:1. Detailed design/scheme shall be submitted to the Department and any suggestion or

modifications shall be incorporate. Clearance shall be obtained before realization.

2. Realization of the system as per the technical specifications and approval of the Department

3. Required handling systems for transportation and erection at site.

4. Submission of detailed work break-up structure with schedules and resources.

5. Supplier shall carry out inspection at identified stages and the copies of such reports after inspection shall be forwarded to Purchaser. The original copies of certificates shall be submitted along with other documents at the time of acceptance testing.

6. Supply of List of essential spare as per this document. Any other critical spare not mentioned in list has to be suggested by the supplier. The supplier has to ensure the supply of all essential spares and material for trouble free operation of the equipment for ten years. The scope of the work is not limited to the above but also includes all the requirements for the fully functioning the system and to meet all the requirements regardless of whether they are explicitly mentioned or not.

7. Acceptance tests are to be worked out in mutual consultation with Department.

3. WORKS UNDER PURCHASER’S SCOPEi. Overall layout of equipment and sub systems and its dimension.

ii. Design Review and clearance: The design report will be subjected to the review by Purchaser experts committee.

iii. Approval of Quality Assurance Planiv. Clearance for manufacture of interfaces v. Stage inspections or third party inspection.

vi. Pre-delivery / dispatch inspection.vii. Inspection of fully commissioned system.

viii. Supply of PLC , SCADA based Control systems and CCTV systems.

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4. SUPPLIER’s OBLIGATIONS & FUNCTIONS4.1 SPECIFICATIONS AND DRAWINGS

The Supplier shall execute the works in compliance with the provisions of CONTRACT,

engineering practices and code requirements.

4.2 APPROVAL OF TECHNICAL DOCUMENTS / DRAWINGSSupplier shall prepare and submit the following Documents to SDSC SHAR from the award of Purchase order for clearance.

4.2.1 Party shall produce the schedule of drawings and documents to be submitted for review, approval and information with submission date.

4.2.2 Party shall produce the configuration drawings for SHAR approval.

4.2.3 Party shall convey Quality Assurance Plan (QAP). The QAP shall list down various stages of inspection and inspection agency namely supplier quality Control agency & 3rd party inspection agency, if engaged. Elaborate Quality Assurance Plan (QAP) is to be prepared& furnished for review & approval.

4.2.4 Detailed equipment list, design details and bill of materials.4.2.5 General arrangement (GA) drawings shall be submitted for approval.

4.2.6 Instrument data sheets and mounting sketches for erection and bill of materials. Measurement Sensors mounting details shall be provided in detail.

4.2.7 Instrument list & Sensor details with Makes and Model Nos. 4.2.8 Cable Schedule and Interconnection Schedule.

4.2.9 Electrical wiring diagrams showing interlocks, controls, wiring sizes, rating of each electrical component etc. and logic diagrams.

4.2.10 Dimensioned general arrangement and section drawings of switchgear panel.4.2.11 Detailed description of operating sequence and control and interlock system.

4.2.12 No activity shall be executed unless Purchaser’s approval is obtained. The above documents / drawings shall be submitted in a format approved by Purchaser. Quality Assurance Plan shall be strictly in accordance with Quality Control Manual and Formats to be provided after the award of CONTRACT.

4.3 DESIGN & SUPPLY OF ROTARY VACUUM DRYER AND ITS SUBSYSTEMS.

4.3.1 Design, Supply, Testing, erection, Integration and commissioning of Rotary Vacuum Dryer of 4000 ltrs. Capacity and its sub systems shall be as per Section 2.

4.3.2 Any item which may not have been specifically mentioned herein but are needed to complete the equipment / system shall also be treated as included and the same shall also be supplied and erected at no extra cost, unless otherwise specifically excluded as indicated.

4.3.3 All these goods or material shall be supplied or used shall be new and of first quality. Where imported or partly imported goods or material are offered or intended to be used, the fact must be specifically stated and brought to the notice of Purchaser.

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4.4 INSPECTION AND TESTING4.4.1 As per the procedures detailed in Section 2.

4.4.2 The supplier shall identify and inform various stages of inspection including sub systems, components and bought out items etc., to SDSC SHAR. The approved QAP shall be followed during course of Supply, Erection & Testing.

4.4.3 Purchaser reserves the right to inspect all phases of Supplier’s operations through its representatives and/or third party inspection agency approved by the Purchaser. Therefore it is the responsibility of the supplier to provide the necessary support for the inspection agency and get the works inspected at all stages of work as identified in quality assurance plan. The presence or absence of a Purchaser’s representative does not relieve the Supplier of the responsibility for quality control in all phases of the work. In the event that any of the work being done by the Supplier or any Sub-Supplier is found by Purchaser’s representatives to be unsatisfactory or not in accordance with the drawings, procedures, specifications and standards, upon verbal notice of such discrepancy or deficiency, the Supplier shall take immediate steps to revise the work in a manner to conform to the relevant drawings, procedures and specifications. The Supplier shall carry out required supervision and inspection as per Quality Assurance Plan and furnish all assistance required by the Purchaser in carrying out inspection work during this phase.

4.4.4 The authorized inspectors of the purchaser shall have access to the premises of the supplier and its sub-contractors at all reasonable times. All the equipment, instruments, tools that are necessary for the inspection shall be provided by the supplier on demand by purchaser’s own inspectors or a third party authorized by purchaser. Inspection by purchaser’s own inspectors or by third party authorized by purchaser shall not absolve the responsibility of the supplier from proper performance of the system and from the guarantee/warranty clauses stipulated in the contract.

4.4.5 Pre – delivery Inspection: As per the procedures detailed in Section 2.

4.5 DELIVERY AND STORAGE 4.5.1 Dispatch Instructions given in the Contract shall be strictly followed. Failure to

comply with the instructions may result in delay in payment apart from imposing any other charges as may be deemed to fit.

4.5.2 The Supplier shall be responsible for transporting all the equipment to site, unloading and storage. No equipment shall be delivered without obtaining dispatch clearance from Purchaser. All the equipment shall be properly packed to avoid any damage during transportation / handling / storage.

4.5.3 Party shall undertake the responsibility of the system and its components during transportation to Sriharikota and during erection, testing and commissioning of the same at suitable location identified by SDSC, SHAR and until handing over the system to SDSC, SHAR after its acceptance.

4.6 INSTALLATION4.6.1 Supplier’s staff shall include adequate number of competent erection engineers

with proven experience on similar works to supervise the erection works and

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sufficient skilled, unskilled and semiskilled labour to ensure completion of work in time.

4.6.2 Supplier’s erection staff shall arrive at site on date agreed by Purchaser. Prior to proceeding to work, Supplier shall however, first ensure that required/sufficient part of his supply has arrived at site.

4.6.3 Certain material handling equipment are available with purchaser and the same shall be extended free of cost for carrying out unloading and erection at purchaser’s site. However party shall convey the list of material handling equipment needed for the above purpose. If the required material handling equipment is found unavailable, the supplier shall has to arrange the same by its own.

4.6.4 Erection of equipment may be phased in such a manner so as not to obstruct the work being done by Other Suppliers and / or operating staff that may be present at that time.

4.6.5 During erection, Purchaser’s engineer will visit site from time to time with or without Supplier’s engineer to establish conformity of the work with specification. Any deviations, deficiencies or evidence of unsatisfactory workmanship shall be corrected as instructed by Purchaser.

4.6.6 Supplier shall carry out work in a true professional manner and strictly adhere to the approved drawings. Any damage caused by Supplier during erection to new or existing building shall be made good at no extra cost to Purchaser.

4.6.7 Supplier shall provide the list of spares required for hassle-free operation of the equipment with cost and probable suppliers. Any special tooling used during erection and commissioning is to be supplied at the time of hand-over without any additional cost.

4.7 RECORDS4.7.1 Supplier shall maintain records pertaining to the quality of erection work in a

format approved by Purchaser. Whenever erection work is complete, Supplier shall offer erected equipment for inspection to Purchaser’s engineer who along with Supplier’s engineer will sign such records on acceptance.

4.7.2 The complete project, right from component level till the complete system performance tested including sub – assembly shall be properly documented with drawing, configuration drawings, Test certificate etc.

4.7.3 There shall be time to time submission of information /clearance / approval by the purchaser and all comments shall be duly incorporated.

4.7.4 All such drawing will become part of PRODUCTION MASTER FILE which shall also contain as built drawing, Final Erection, Testing & Commissioning report done at site. 5 copies of PRODUCTION MASTER FILE shall be supplied.

4.8 EQUIPMENT ERECTION4.8.1 Supplier shall carry out the works in accordance with the specific instructions given

on the approved drawings/ documents or as directed by Purchaser.

4.8.2 Supplier shall take utmost care while handling instruments, delicate equipment, panels etc., and protect all such equipment on erection.

4.9 DRAWINGS AND O&M MANUALS4.9.1 Supplier shall submit 5 hard copies & 3 soft copies of all the

approved drawings incorporating any modification / changes made

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during the execution of CONTRACT. All these drawings shall be marked as ‘As Built’.

4.9.2 Supplier shall submit 5 hard & 3 soft copies of the following documents.4.9.2.1 Operations manual of the machine.4.9.2.2 Programs manual.4.9.2.3 Maintenance manual with drawings, circuit diagrams,

interfacing instructions, trouble shooting and maintenance instructions and spares list with source of supply.4.9.2.4 Submission of the drawings and manuals shall be a

precondition for releasing of any final payment due to Supplier.4.9.2.5 Manuals and mounting instructions for all the Sensors, transmitters, Load cells and control valves.

4.10 TRAININGSupplier shall organize training for purchaser authorized persons by covering operation and maintenance of the machine, comprehensive programming at supplier’s premises prior to dispatch as described in detailed in Section 2.

5. SCHEDULE OF PRICE 5.1 The quoted price shall include all costs of “DESIGN, SUPPLY, ERECTION, TESTING

AND COMMISSIONING OF ROTARY VACUUM DRYER OF 4000 LTRS. CAPACITY AND ITS SUB SYSTEMS AS PER TECHNICAL SPECIFICATIONS”. Shop floor testing, packing, forwarding, transport to site, unloading, storage, all risk coverage, erection, commissioning, training, testing & evaluation of equipment including any other cost for proper and complete execution of the CONTRACT.

5.2 CONTRACT prices shall also include all third party inspection, travelling expenses, living expenses, salaries, overtime, benefit and any other compensation for engineers, supervisors, skilled, semiskilled workmen, watch and ward staff, laborer and other staff employed by the Supplier, cost of tools and tackles required for erection and other consumable material required, and all taxes, duties, and levies as applicable on the date of submission of bid.

5.3 Price shall be firm & fixed.5.4 The taxes applicable for supply and erection & commissioning shall be

indicated separately in terms of percentage in the price bid. If the offers submitted by the suppliers are silent on taxes, it will be presumed that quoted rates are inclusive of taxes & duties and no claim in this regard will be entertained later.

6 DELIVERY TERMS6.1 The rate quoted shall be on FOR SDSC SHAR, Sriharikota basis.

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6.2 In case of foreign suppliers the prices shall be quoted on CIP, SRIHARIKOTA basis. Supplier is responsible for clearing the consignment, transport of equipment to destination and erection & commissioning at site and all the necessary works till the equipment is commissioned and accepted by Purchaser.

7 MODE OF PAYMENT7.1 Supplier can submit the banker details and payments will be made

through Electronic Clearance System (ECS). 7.2 In case foreign suppliers LC will be established for supply portion and

erection & commissioning portion separately. The agency commission shall be paid in Indian Rupee based on the suppliers authorization. Any other mode of payment shall be stipulated by the tenderer.

8 TERMS OF PAYMENTSOur standard payment term is 100% within 30 days after receipt and acceptance of individual items at SDSC SHAR.

9 DELIVERY SCHEDULESupplier shall follow the following schedule for executing the contract

S. No Mile Stone Expected date of completion

T1 Letter of Intent / Purchase order date T

T2 Submission of Configuration and G.A. Drawings T1+ 5 weeks

T3 Date of clearance of Configuration and G.A. Drawings T2+ 3 weeks

T4 Submission of final drawings T3 + 2 weeks

T5 Submission of fully configured system for pre delivery inspection at party’s site T4 + 24 weeks

T6 Installation, Testing & Commissioning T5 +6 weeks

Tentative foundation details of the equipment such as areas where civil works are to be commenced for the foundation in the building plan, depth of foundation required for each of the item shall be submitted by the party with in three weeks from the date of receiving the purchase order. The party shall submit detailed foundation design, layout drawings and other civil requirements along with the Configuration and GA drawings.

10 Earnest Money Deposit (EMD)The Earnest Money Deposit(EMD) of Rs100000/- (Rupees One Lakh Only), refundable (Without interest), should be necessarily accompanied with the Technical Bid of the agency in the form of Demand Draft/Pay Order/Banker's Cheque drawn in favour of Accounts Officer, SDSC SHAR ,Sriharikota failing which the tender shall be rejected summarily.The details of DD/PO/BC towards EMD shall be entered in the online bid at appropriate places and the instrument shall be sent to Department before

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the tender opening date. In case, if the instrument is not received in time, the offer will not be considered.The EMD in respect of the agencies which do not qualify the Technical Bid (First Stage)/Financial Bid (Second competitive stage) shall be returned to them without any interest. However, the EMD in respect of the successful tenderer shall be adjusted towards the Security

11 RISK COVERAGEDepartment will not pay any insurance taken by the supplier. The Supplier shall include the cost of comprehensive risk coverage at his own cost covering the value of equipment including transportation to the site from manufacturer’s works, storage at site, fabrication, erection, testing and commissioning at site. The period of such coverage shall be up to contractual completion period or any extension granted by Purchaser thereof.

12 SECURITY DEPOSIT 12.1 The supplier whose tender is accepted will be required to furnish by way of

Security Deposit for the due fulfillment of the contract such a sum as will amount to 10 % of the contract price of the work awarded in the form of Bank Guarantee valid till the satisfactory execution of the contract and acceptance.

12.2 The security deposit (bearing no interest) shall be held by the Purchaser as security till satisfactory completion, testing and handing over of all the system and for the due performance of all suppliers’ obligations under the contract as per delivery period or extension granted thereof by the Purchaser.

12.3 Within 10 days from the date of receipt of Letter of Intent, supplier shall deposit the security deposit to the Accounts officer, Satish Dhawan Space Centre SHAR, Sriharikota as detailed above by any of the following modes.

(a) By a crossed demand draft in favor of Accounts officer, SatishDhawan Space Centre SHAR drawn on SBI and payable at Sriharikota.

(b) By an acceptance bank guarantee. The bank guarantee shall be from a reputed international/nationalized/schedule bank.

12.4 In case of breach of contract, the Security deposit shall stand forfeited in addition to other relief available to the Purchaser under this contract.

13 PACKING AND FORWARDING13.1 The Supplier shall arrange to have all the material suitably packed as per

the standards & statutes and as specified in the contract. Unless otherwise provided for in the contract, all containers (including packing cases, boxes, tins, drums, and wrappings) used by the Supplier shall be non-returnable.

13.2 All packing and transport charges, transit handling costs, transit risk coverage and transport fees of agents employed at the place of delivery or elsewhere, shall be deemed included in the price to be paid to the Supplier.

14 WARRANTY The supplier shall provide twelve months warranty for the entire system for a defect liability, after final official handing over. During this period supplier has to provide and adhere to the following:

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14.1 This period shall include maintenance, replacement of defective/failed parts at free of cost.

14.2 Supplier has to attend to unlimited breakdown calls.14.3 Purchaser will not provide any transport/accommodation for this purpose.14.4 Upon oral or written notification of defects in or malfunctioning of the goods

during the warranty period which require corrective action, Supplier shall send the necessary personnel to job site to supervise and assume responsibility for repairs and/or replacement, if necessary, of the defective goods or material at his own cost. If Supplier does not, within seven (7) days after receipt of notification, take steps to correct the breach, Purchaser may do so at the cost and expense of Supplier. Supplier shall reimburse Purchaser all expenses incurred by Purchaser to repair or replace malfunctioning or non-conforming goods.

14.5 Where defects items are replaced by new ones, the full warranty period stipulated in the contract shall apply to such replacement items as from the date of their delivery.

15 GUARANTEES:The Supplier shall guarantee that the equipments furnished by him are in conformance with the requirement of the specifications. Goods covered by the contract shall be free from defects in design, materials or workmanship for a period of twelve months from the date of successful commissioning & acceptance by Purchaser.

16 PERFORMANCE BANK GUARANTEE The supplier shall guarantee for the performance of the contract by providing bank guarantee in favour of the Purchaser for an amount equivalent to 10 %( ten percent) of the total value of this contract valid till the warranty period of the contract. The performance bank guarantee shall be submitted by the supplier with in fifteen days from the date of accepting the equipment as per the CONTRACT. The format for the performance bank guarantee shall be obtained from Purchaser.

17 DISCLOSURE AND USE OF INFORMATION BY THE SUPPLIERSupplier shall take all necessary steps to ensure that the requirements of the contract or any specification, plan, drawing, pattern, sample or information supplied by, or on behalf of, the Purchaser in connection therewith shall not be disclosed to any person other than a person employed or engaged by the Supplier, whether under sub-contract or otherwise, for the performance of the contract.

18 APPLICABLE LAW AND JURISDICTIONThe laws of India shall govern this contract for the time being in force. The Courts of Andhra Pradesh, India only shall have jurisdiction to be with and decide any legal matters or disputes what so ever arising out of the contract.

19 FORCE MAJEUREShould a part or whole work covered under this agreement be delayed due to reasons of Force Majeure which shall include legal lockouts, strikes, riots, civil commotion, fire accident, quarantines, epidemic, acts of God and Government, embargoes, the completion period for work, equipment referred to in this agreement shall be extended by a period not in excess

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of the duration of such Force Majeure. The occurrence shall be notified by either party within reasonable time.

20 SAFETY AND SECURITYSupplier shall follow the safety regulations / codes or safety instructions issued by PURCHASER and shall take necessary measures at his own cost. The contractor personnel have to undergo security checks by security force i.e. CISF. All the working personnel shall comply with code of conduct during their stay inside the SHAR campus.

21 GENERAL21.1 SITE DETAIL

21.1.1 The indented “ Rotary Vacuum Dryer and its sub systems ” is to be erected inside a facility in SDSC SHAR, Sriharikota, The place ”Sriharikota” is 20 km East of Sullurupeta (nearest town ) which is 80 km North of Chennai, Tamilnadu, INDIA.

21.1.2 SDSC SHAR, Sriharikota is prohibited place. Hence, no contractor, working personnel will be allowed to stay and they have to be accommodated in Sullurupeta by his own arrangement.

21.1.3 The contractor may have to transport working personnel on day to day basis by his own arrangement. Location of the site is worked out to be 32km(Approx.) from Sullurupeta.

21.2 POWER SUPPLYElectrical power provided by the purchaser during installation is NOT chargeable subjected to availability & approval. Reasonable quality of normal power will be made available at one point (415V, 3 phase, 50 Hz). However, onward distribution shall be done by the supplier. All electrical installation by the supplier shall be as per safety regulation & standard and will be subjected to purchaser inspection & approval.

21.3 WORK RULESGenerally, NO work shall be carried out during night or public holidays unless a written permission is obtained from Purchaser.

21.4 SITE CLEARANCEUpon completion of work, Supplier shall remove all his equipment and material from the site within one month or time mutually agreed. Supplier at all times shall keep site in clean condition and remove all unwanted material at regular intervals. In case supplier fails to remove all his equipment and material within the mutually agreed time it is deemed that Purchaser will arrange to remove the same at the supplier’s cost besides imposing penalty for failure.

21.5 ACCOMMODATION Very limited accommodation may be provided by Purchaser to senior supervisory staff of the Supplier on chargeable basis subject to availability. Supplier shall make his own arrangement for accommodation & canteen facility for all its staff, technicians, labor & workers. Transportation shall be arranged by Supplier at his own expenses for entire staff.

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21.6 MEDICAL FACILITIESNo medical facilities will be provided by Purchaser at site for Supplier's site personnel. Supplier shall make his own arrangement at his own expenses for medical facilities for site personnel.

21.7 WORK PROGRAMMEThe supplier along with proposal shall give a preliminary programme schedule for executing the contract as per the scope of work. Upon award, supplier shall prepare a detailed programme schedule for review / approval by Purchaser. Supplier as per exigencies of work shall revise and update programme periodically. Monthly progress review meeting will be conducted alternatively at purchaser / supplier site

21.8 SUB-CONTRACTS21.8.1 Whole of the work shall not be subcontracted. 21.8.2 The portion of the work for which the supplier is not expert,

shall be sub -contracted to proven / reputed OEM in that field. Such sub- contract if any shall be given with prior approval of the purchaser including choice of subcontractor.

21.9 CHANGES AND MODIFICATION TO SPECIFICATIONS, DESIGNS, DRAWINGS AND QUALITATIVE / QUANTITATIVE REQUIREMENTS.21.9.1 Supplier shall obtain approval for the designs and drawings

from the Purchaser before initiating the action for procurement / fabrication.

21.9.2 Change in make/model for bought item is NOT allowed unless approved by purchaser.

21.9.3 Purchaser is free to modify the designs or drawings during design review. Party has to carry out one time modifications at each stage without any extra cost and obtains the approval from Purchaser.

21.9.4 Any amendment to the contract, which may be necessary in this respect, will be established within a reasonable time in the form of an Amendment to Contract to be signed by both parties.

21.10 CANCELLATION The Purchaser shall have the right at any time to cancel a contract either wholly or in part by giving one month written notice. From the time of receipt of the written notice the Supplier shall undertake to observe the instructions of the Purchaser as to the winding up of the contract both on his own part and on the part of his sub-suppliers.In the event of such cancellation, the Purchaser shall unless otherwise specified in the contract, only pays.

- In the case of a fixed-cost contract for the supply of equipment or material. The contractual value of items delivered and accepted under the contract before receipt of notification of cancellation, or to be accepted under the special conditions of cancellation.

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Section – 2 Technical Specifications of RVD

4000 ltrs, and its subsystems

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2.1 Introduction

Ammonium Perchlorate (AP) is used as oxidizer in propellant. AP is explosive and hygroscopic. In order to reduce the moisture content of AP, it is heated and dried under vacuum using a rotary double cone vacuum dryer (RVD). AP fine powder is loaded in to the Rotary Vacuum Drier (RVD) and heated to the required temperature (70 ± 5 OC) by using the hot water circulation inside the RVD jacket. The hot water tank is located in service room and hot water is pumped to RVD jacket by using the centrifugal pump and the approximate distance from hot water tank to RVD is ~ 25-35 meters. The temperature of the water in hot water tank shall be maintained at 70 ± 5OC. The time required to heat the AP inside RVD using the hot water circulation is 45 to 60 min. The temperature inside the hot water tank is controlled by using suitable temperature controller and is monitored and controlled from control room, ~ 90-100 meters away from the service room. After completion of the heating cycle, vacuum , with Heating cycle continuing , is applied to RVD by using the vacuum pump available in service room. Vacuum of 200-300 mm Hg shall be maintained in RVD by using the suitable controls at vacuum pump and same shall be monitored and controlled from control room. The vacuum cycle is 15 to 30 min. After completion of heating ( water circulation) + vacuum cycle, RVD is purged using Nitrogen (N2) gas to break the vacuum. It shall be operated from control room as well as locally. After completion of heating cycle and vacuum cycle, a sample is collected from RVD and sent for lab for moisture analysis. Alumina (anti caking agent) is a very fine powder and added to the AP fine inside RVD by opening top lid. The AP fine is blended with Alumina by using RVD simply by rotating for a period of 30 to 45 min. After completion of blending cycle, the material is unloaded from RVD into a flexible container by pneumatic butterfly valve with manual override. The valve shall be operated from the remote control room and status of the valve need to be interfaced with the PLC and SCADA using suitable sensors like micro switches / proximity sensors. The valve shall be ATEX approved. RVD is multi walled chamber. The outermost jacket is packed with insulation material. The inner most jacket is for circulation of heating medium. The chamber host material to be dried.

2.2 General:a. The material to be handled is AP. AP is an oxidizer and hazardous and hence any

mechanism that causes friction, excessive heating and contamination shall be strictly avoided.

b. The equipment shall be designed to dry AP under vacuum using hot water as heating medium circulated in a Rotary vacuum drier, addition of aluminum oxide to dried AP and blend them.

c. All AP contact parts shall be made of SS304. Equipment and supporting system in Hazardous Bay shall conform to Zone I, Group IIA, IIB,T4 temp classification .Either Flameproof (Ex-d) or Intrinsically safe system as applicable shall be used .

d. The drying operation is carried out remotely and suitable design shall be made to execute the same.

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2.3 System Readiness:

a. RVD chamber will be washed with water and allowed to dry. The chamber will be inspected for any abnormalities.

b. The no-load trial run will be carried out to test functionality of hot water tank, water pumps, vacuum pumps, RVD drive system and control &monitoring system elements.

c. Necessary interlocks will be checked. All relevant data (Input voltage, current levels, RVD motor RPM, RVD shaft RPM, current values of RVD motor, vacuum pump, hot water pumps etc) will be measured / monitored from control room.

2.4 AP Drying:

AP is received in a trailer or platform truck to the facility. Using a crane it is lifted to top of the Rotary Vacuum drier (RVD) platform. After ensuring that the bottom outlet valve of RVD is closed properly, the AP received in flexible intermediate bulk container (FIBC) is unloaded completely into RVD chamber through its bottom discharge sprout. The top inlet lid of RVD will be closed. The RVD inlet closed status shall be monitored at the control room through proximity sensors. The area will be vacated and further operations till end are unmanned only.

The hot water at 70 -75OC from hot water tank located in service room, is circulated through heating jacket of RVD using centrifugal pumps. The RVD is rotated at 5-7 RPM to allow material attain ~72OC. The heating cycle is 60 to 90 min. All the parameters are monitored and recorded in control room. All operations will be carried out remotely from control room. After completion of heating cycle, vacuum is applied to the material to remove moisture. The vacuum (~ 200 to 300 mm Hg) is generated using vacuum pumps located in service room. Necessary controls are provided to maintain a vacuum of 200 to 300 mm Hg for a period of 15 – 30 min. The vacuum cycle is also monitored and controlled form control room.

After completion of vacuum cycle, Vacuum in the RVD is released using nitrogen gas. A sample will be collected through the top inlet lid. Pre-weighed anti-caking agent, Aluminum oxide, will be added to the chamber containing dried AP. The top inlet lid will be closed and blending will be carried out at 5-7 RPM for ~30 min.

At the end of blending cycle, material will be unloaded to SS container or FIBC through bottom outlet valve of RVD.

2.4.1 Details of materials to be handled:1. Ammonium Perchlorate:

a. UN Number :UN 1442b. Average Particle Size : 330 -360 μm – Coarse Grade

45-55 μm – Fine Gradec. Bulk Density :1.2 gm/cm3 Coarse Grade

0.6 gm/cm3 Fine Grade

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AP (Undried) in FIBC / AP fine

Unloaded material into RVD Chamber

Heating cycle

Vacuum Cycle

Unloading of Material

Process Flow chart

Blending Cycle

Alumina (Anti caking agent)


d. Hardness of Material : 2-3 on Mohs Scalee. Maximum qty of material : 1500 kg (fine grade) or 3000 kg (coarse grade)f. Moisture content of material before drying : Maximum-0.1 % g. Moisture content of material after drying : Maximum – 0.01 % -0.02 %

2. Aluminum Oxide:a. Average Particle size : Max. 10 μmb. Max Quantity : 5 kg (Will be added to AP)c. Type : White free flowing powder. It is also as abrasive. d. Bulk density : 0.8 gm/cm3.

3. The process flow chart is given below:

d. Working, Operational Sequence, Control Philosophy and Interlocks

2.5 Working of AP Drying System:a. Ammonium perchlorate is loaded into the RVD followed by heating cycle and vacuum

cycle to remove moisture.b. The dried material is blend to prevent caking. c. The operational sequence of drying and blending process is in detailed in next sectiond. Rotary vacuum drier (RVD) has one top inlet lid and one bottom outlet valve.e. RVD is supported on a frame and positioned on platform at height ~ 3 meters above

ground level. RVD be driven using an electric motor and the drive unit.

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f. Ammonium perchlorate is an oxidizer and hazardous and should not be exposed to friction, impact, high temperature and contamination.

2.6 Standard operational sequence:a. No load trial is carried out before loading the material for 15-30 min to verify

functionality of circulation pumps, vacuum pumps and RVD drive. All the functional parameters will be monitored from control room and shall be recorded.

b. The water level in hot water tank is verified and if the level is found less water will be filled till mark automatically.

c. The water in hot water tank is heated to 75OC using On/Off control of heater banks and necessary controls are operated or monitored from control room

d. The chamber of RVD will be inspected visually and the bottom discharge valve is closed properly.

e. Ground AP (Un-dried) is received from previous process facility in FIBC.f. The un-dried ground AP is lifted by using crane and is loaded into RVD chamber

through top inlet lid manually.g. The top inlet lid will be closed once all the material is unloaded into RVD

chamber.h. The bay will be vacated and all further operations till end are unmanned only. i. Circulation of hot water is initiated followed by rotation of RVD chamber.j. After the completion of heating cycle for pre-defined duration, vacuum pump

will be operated to the chamber to remove moisture.k. Vacuum will be released with nitrogen after pre-defined duration of vacuum

cycle.l. A sample will be collected.m. Aluminum oxide is added to chamber. n. Blending cycle commences for pre-defined durationo. Material will be unloaded after blending cycle through bottom discharge valve

into FIBC.

2.7 Scope of supplier

This section covers the general requirements for design of system, supply of materials, preparation of detailed drawings, manufacture, testing & inspection at contractor’s works, packing, forwarding, transportation, transit insurance, unloading at site, erection, testing & commissioning of Rotary Vacuum Drier and its subsystems as per specifications in this section, enclosed data sheets, drawings & other documents as in table 1 to 11 in Annexure – I.

2.7.1 Design, testing, supply, erection and commissioning of Rotary vacuum drier and its subsystem as per given specification. The scope includes supply and installation of all necessary equipment, instrumentation and electrical components in RVD bay and service room.

2.7.2 Supply, mounting, testing and commissioning of process equipment, sensors, transmitter as per the specifications given in this document for drying and blending of oxidizer.

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2.7.3 Any other equipment/ parts/ components, which are not mentioned in specification but required for smooth operation of the system shall be considered included and to be supplied and installed without additional cost. The list of such equipment/ parts/ components shall be submitted for department approval. Any other equipment/ parts/ components that are suggested by vendor as optional for safe and smooth running of system may be submitted along with offer.

2.7.4 An iMCC as per the detailed specification is to be realized, the iMCC shall be fabricated and assembled by a panel manufacturer from the authorized panel manufacturer specified in the list. The supplier should engage the panel manufacturer, obtain and submit GA drawing, Power drawing, control drawing and get it approved by department. The panel should undergo functional tests, HV test, Dielecric strength and other qualification tests as per standards at Panel manufacturers site in presence of department engineer and necessary test certificate shall be issued. The panel dimensions shall be suitable for the earmarked place.

2.7.5 The control and data acquisition of RVD and sub systems is through PLC & SCADA and is in a third party’s scope which will be realized in a later stage. The PLC envisaged for this automation is dual redundant with criss cross configuration. The iMCC motor management system should use PROFINET Protocol and all feeder elements including VFD drive should be configured suitable to this dual redundant configuration. All feeder currents, speed(VFD), on/off/trip status, On/Off commands ,run status, feeder protection (EL, SC, OC, winding temp) should be communicated through Ethernet cable. Ethernet cable (main & redundant -2 runs) should be laid from iMCC to control room with sufficient cable length. Ethernet Cables (CAT-6) shall be brought up to Instrumentation System Marshalling Chamber with proper identification. Termination at Instrumentation System Marshalling Chamber is not in the scope of the supplier. It will be taken up to control room via fiber optic cable. Fiber optic cable works is not in the scope of the supplier.

However individual feeders in iMCC should be controllable locally from iMCC pushbutton stations at service room apart from provision in control room with PLC mode and even without availability of PLC & SCADA system. This may be achieved by local intelligent module programming or through a small PLC incorporated in iMCC panel. The local iMCC push button control shall be possible without availability of PLC & SCADA system This local operation should have enable/disable provision with removable key.2.7.6 A laptop with iMCC codes for each feeder, Simocode ES licensed software,

drive software, drive parameters with suitable communication cables and interfaces to monitor and modify motor management system configuration and drive parameters. In case PLC is used PLC licensed software and code also to be provided in the laptop.

2.7.7 Authorized M/S Siemens Motor management systems Engineer and drive engineer ABB/SIEMENS shall be deputed for integrating iMCC with SCADA & PLC as per automation system requirements. They should carry out all required SIMOCODE configuration & Drive parameterization and

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demonstrate necessary iMCC functionality and protective features. They should also be available for first live trial process operation of the system after integration with SCADA&PLC automation systems. Party shall be available during interface/ Commissioning of PLC/SCADA System to ensure the full functionality of the system as per user requirement.

2.7.8 All the piping to and from the RVD to necessary equipment is suppliers scope. The size, material and thickness of piping shall be approved by department.

2.7.9 The hot water system should be redundant and switch over from one to other mechanically. Necessary redundancy and switching over system shall be incorporated.

2.7.10 The supply of PLC and SCADA based control system and CCTV systems for remote monitoring of process operation is not in the scope of the supplier

2.7.11 Necessary pipe laying works like clamping is under supplier’s scope. Submission of necessary GA drawings, piping layout, wiring diagram, panel drawings etc after award of contract to department and obtaining approval before commencement of fabrication is in scope of supplier.

2.7.12 Party shall submit project execution plan along with their offer, detailing the methodology of contract execution.

2.7.13 Factory Acceptance tests (FAT) & Site Acceptance tests (SAT) to meet the design specifications & functional requirements.

2.7.14 Power wiring :

Power wiring with suitable rating armoured cables as per load requirements shall be provided. The cable make shall be as per list provided in the document. The power wiring shall be carried out for the following

1. PCC to IMCC (Incomer)2. IMCC to RVD motor & other loads (Vacuum Pump, Water pump, Heater banks) at

Service room.

The cables shall comply with LT voltage level 1100V, Armoured with XLPE insulation as per IS: 7098. The minimum size of cable shall be 2.5 sq. mm copper conductor for all power wiring. All feeders shall be with copper conductor cables. The power wiring shall be carried out with necessary saddles, clamps, cable tags, glands, etc. The termination of flame proof stations @ RVD room shall be with Double Compression Glands.

2.7.15 Cable Laying:

a. Power, Control and Communication cables shall be laid in trenches and cable trays as applicable.

b. Medium voltage and control cable shall be separated from each other by adequate spacing or by running through trenches or cable trays.

c. The lengths indicated in the cables schedule are only approximate. The contractor shall ascertain the exact length of cable for a particular feeder by measuring at site.

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All cable routes shall be carefully measured and cables cut to the required lengths, leaving sufficient lengths for the terminations of the cable at both ends.

d. Cable shall be laid in RCC trench (underground trench) or in surface tray. RCC ground level Trench will be provided by department & internal required cable Tray mounting is in scope of the supplier. Cable installation shall be provided minimum cable bending radii as recommended by manufacturer.

e. Cable installation shall be provided minimum cable bending radii as recommended by manufacturer.

f. Cables shall be nearly arranged in the trenches/trays in such a manner that criss-crossing is avoided and final take off to the motor/switchgear is facilitated.

g. All cables shall be identified close to their termination point by cable tags.

2.7.16 Termination:

a. All PVC Cables up to 1.1KV grade shall be terminated at the equipment by means of Double compression type Flame proof cable glands suitable for the cable size wherever flameproof items are terminated.

b. Where copper to aluminium connections are made, necessary bimetallic washers shall be used.

c. In case of control cables all cores shall be identified at both ends by their terminal numbers by means of PVC ferrules for core size. Wire numbers shall be as per schematic wiring/inter-connection diagram. All unused spare cores of control cables shall be nearly bunched and ferruled with cable tag at both ends, for future use. All spare cores shall be terminated in TB.

d. Contractor shall drill holes for fixing glands wherever necessary. Gland plate shall be of used wherever more number of cables are terminated. Gland plate shall be of non-magnetic material/aluminium sheet in case of single core cables. All unused cable entries on equipment/panels shall be plugged or sealed.

e. The cable shall be terminated at electrical equipment/switchboard through glands of proper size.

2.7.17 Before energising, the insulation resistance of every circuit shall be measured from phase to phase, phase to neutral and from phase/neutral to earth. The approximate cable length requirements are listed in below mentioned table.

2.7.18 Control wiring:

The control wiring shall be armored with minimum copper conductor size of 1.5 sq. mm of XLPE/PVC insulation, voltage grade 650V/1100V as per IS: 1554/7098. The control wiring shall consist of following:

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a. Master Emergency OFF at Control room shall be hardwired with IMCC MCCB trip circuit.

b. RVD ON/OFF local push button station at RVD room.c. iMCC to Control room

The control cable requirements to meet various interfacing field elements are specified below. The details are indicative and vender shall meet extra cable requirements in case of requirement.

Cable scedule Cable type Anticipated Length

1 PCC to IMCC (Incomer) Armoured XLPE insulated 3 ½ C 95Sq.mm copper cable 25 m

2 IMCC to RVD motor Armoured XLPE insulated 3 ½ C 50Sq.mm copper cable 25 m

3 IMCC to Vacuum Pump, at Service room.

Armoured XLPE insulated 3 ½ C 25Sq.mm copper cable 25 m

4 IMCC to Water pump, at Service room.

Armoured XLPE insulated 3 ½ C 16Sq.mm copper cable 25 m

5 Control room to iMCC (Emergency off)

Armoured control cable 12 pair 1.5sq.mm copper cable 100 m

6 RVD room to iMCC (Emergency off)


7 RVD room to iMCC (Local RVD on/ off)


8 iMCC to Control room Armoured control cable 24 pair 1.5sq.mm copper cable 100 m

9 iMCC to Control room Profinet cable(2 runs) 200 m

2.7.19 INSTRUMENTATION SYSTEM FOR RVD :

a) The vendor has to supply suitable sensors / transducers to monitor the various parameters mentioned in Technical Specification.

b) The mounting of all sensors, transmitters, control valves etc. at the required locations to monitor various process parameters is in the scope of the suppliers. The mounting details of the sensors shall be provided with P&ID during design review phase.

c) Mounting of all sensors / transducers / Instruments by selecting suitable mounting arrangement, piping, fittings required between equipment and routing of Sensor/transmitter cables(with ferrules for proper identification) via concealed cable trays up to Marshalling chamber is in the scope of the supplier. Terminations are not in the scope of the supplier. All sensor / transmitter cables shall be minimum of 25m

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length. However actual length has to be arrived at by considering the cable routing plan.

d) All the sensors, transmitters and actuators shall be ATEX approved/ intrinsically safe to suit the environment of the process. All sensors/transmitters are to be 24V DC loop powered. The supplier has to provide calibration certificates and ATEX/intrinsic safe certificate from standard agencies for all supplied items.

e) An absolute angular encoder has to be provided to sense the angular position of RVD during rotation

f) Humidity transmitter shall be provided to measure the humidity and temperature of RVD bay. All transmitters shall be with PROFIBUS-PA interface wherever available. If PROFIBUS-PA interface is not available it shall be 4-20mA loop powered SMART transmitters. All transmitters shall be with local display. They shall be mounted at accessible locations. All control sensors are to be provided with redundancy. All control valves are to be provided with redundancy and manual override.

g) The internal temperature of RVD is to be monitored via J-type ungrounded twin thermocouple with stainless steel sheathing. Multiple numbers of sensors shall be provided over a suitable fixed mounting arrangement inside RVD. The number of sensors shall be specified along with mounting details during design review phase.

h) All manual valves shall be provided with proximity sensors / Limit switches to get the OPEN/CLOSE STATUS. All control valves (other than solenoid valves) are to be provided with manual override option.

i) Any other sensors/ equipment/ components, which are not mentioned in specification but required for monitoring / control operation of the system shall be considered included and to be supplied and installed without additional cost.

j) List of parameters to be monitored is given below along with required makes of sensors are specified below. Minimum of 20 % spares has to be provided for each type of sensor. The supply of any of the item with Makes other than those specified in the list requires approval from the purchaser.

k) Since the control system is planned with redundancy at I/O level itself, there shall

main and redundant sensors for each parameter to be monitored.

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2.8

2.9

2.8 Quality Acceptance Plan

Supplier has to submit the following Quality Acceptance Plan (QAP) and provide necessary documents/ records whenever necessary for approval of department, prior to commencement of works. A detailed execution plan shall be submitted by supplier in concurrence of QAP for department approval. Any deviations shall be reported in written format immediately.

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Sl No: Parameter Sensor Make

1Water tank water level – Main & Redundant Level Transmitter

ROSEMOUNT with PROFIBUS PA

2Water tank inlet supply open/close with status Solenoid Valve with micro switch ASCO NUMATICS

3 Temperature Sensors Pt100 Duplex Class A 4 wire RTDROSEMOUNT/NAGMAN/OMEGA

4 Water flow sensor inlet Main & Redundant Capacitive Type Proximity Sensor P&F / ifm

5 Water flow sensor outlet Main & Redundant Capacitive Type Proximity Sensor P&F / ifm

6

Water inlet valve open / close status Main & Redundant Inductive Proximity Sensor P&F / ifm

7

Water outlet valve open / close status Main & Redundant Inductive Proximity Sensor P&F / ifm

8RVD inlet closed status Main & Redundant Inductive Proximity Sensor P&F / ifm

9Vacuum Control Valve Main & Redundant Solenoid Valve with microswitch ASCO NUMATICS

10

Vacuum line isolation valve on / off status Main & Redundant Solenoid Valve with microswitch ASCO NUMATICS

11 RVD RPM sensor Inductive Proximity Sensor P&F12 RVD position sensor Absolute encoder P&F / ifm

13

Control Valve to admit nitrogen for vacuum breaking Solenoid Valve with microswitch ASCO NUMATICS

14 Temperature Transmitters ROSEMOUNT with Profibus PA15 Vacuum Transmitters ROSEMOUNT with Profibus PA16 Thermocouple OMEGA, J type, twin sensor


2.9 Factory Acceptance Tests (FAT)

Factory Acceptance Tests (FAT) will be carried out by department personnel at your site before dispatch of material to SDSC SHAR. It is supplier responsibility to carry out FAT to department satisfaction and obtain clearance for dispatch.

1. Dimensional checks of RVD chamber, support structure and other subsystems as necessary in concurrence with approved GA drawings.

2. Inspection of RVD chamber3. Leak test and pressure test of RVD jacket and other pressure tests reports of RVD.

Pressure test shall be carried out in compliance to IS2825. 4. Measurement of current and IR value for all motors.5. Functional and interlock checks of electrical systems.6. The panel should undergo functional tests, HV test, Dielecric strength and other

qualification tests as per standards at Panel manufacturers works in presence of department engineer.

7. Verification of following documentsa) Flame proof certificate of all the electrical components to be housed in RVD bay

area complying IS 2148 and issued by approved agencies like CMRI.b) All motor routine test certificates as per IS 325c) RVD shell and jacket thickness design details and load calculations.d) Material test certificates.e) Dimension measurement certificates of all couplings like gears, belts, pulleys etc.f) Radiography test certificates.g) DP test reports.h) Calibration certificate for sensors and transducersi) Panel test certificate for HV & dielectric test

8. Quality control test which shall be carried out to assure quality of all components.9. Complete trial assembly of setup and examining of interfaces, gaps, intactness etc of

system. 10. Functional testing of Rotary vacuum drier. A no-load trial shall be carried out at 5 RPM

of Rotary Vacuum drier shaft for 3 Hours and data shall be logged and presented to department. Another no-load trial shall be carried out at 7 RPM of rotary vacuum drier shaft for 3 Hours. All data like voltage and current value, bearing temperature, vibration details, noise level etc. shall be logged and presented to department.

11. A load trial (3000 kg .i.e. 1.25 times of 2400 kg) shall be carried out with dummy material with working capacity of the RVD at 5-7 RPM of Rotary Vacuum drier shaft for 6 Hours and data shall be logged and presented to purchaser. All data like voltage and current value, bearing temperature, vibration details, noise level etc. shall be logged and presented to department.

12. After the contractor has performed the tests satisfactorily, the contractor shall perform tests on the control panel to be witnessed by Department as per approved QAP. Contractor shall notify the Department at least one week prior to Factory Acceptance Test.

13. All instruments shall have calibration certificates from approved test house, valid for minimum 1 year.

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14. All the Sensors/Transmitters which are to be mounted in RVD bay has to be provided with ATEX /intrinsic safe certification from a renowned agency.

15. High voltage test & IR measurement of all panels as per standard practice.16. Cable test certificates shall be furnished.17. Visual check of all instruments, sensors, transmitters etc., 18. High voltage test as per relevant IS standard. 19. Measurement sensors mounting location & cable routing upto marshalling chamber

checks.20. Functional testing. This shall include the simulation of each item in the Control Panel

supplied & wired by the Supplier and achieving the functional requirements as called for in the specifications. Checking of hardwire logic in the Control Panels shall be carried out.

21. After the Contractor has performed the tests satisfactorily, the Contractor shall perform tests on the Control Panel to be witnessed as per approved QAP. Contractor shall notify to the department at least one week prior to Factory Acceptance Test.

22. All test certificates for testing instruments shall have calibration certificates from approved test house, valid for minimum 6 months.

2.10 Site Acceptance Tests (SAT)

After successful completion of FAT, material shall be dispatched to SDSC SHAR, unloaded, stored and installed. After successful installation of all systems at site, the site acceptance tests includes the following:

1. Physical verification of Rotary vacuum drier and its subsystem for any damages and their interfacing. All equipment shall be properly grounded using suitable GI/ Aluminum strips, GI/Copper strips of appropriate size.

2. No load trial of system including checks for abnormal running, interlocks verification and control systems. All parameters of operation shall be recorded as per department defined format. Any abnormalities found shall be reported and rectified.

3. Live trials with Ammonium Perchlorate. All parameters shall be recorded and reported. Any abnormalities shall be reported and rectified. System qualification includes obtaining qualified dried product.

4. Physical verification of RVD and its subsystems for any damages and interfacing after no-load and live trial.

5. Measurement of current and IR value for all motors.6. Functional and interlock checks of electrical systems.7. The supplier has to ensure proper interfacing of all sensors / transmitters / iMCC with

Data Acquisition and Control System.8. Interlocks Checking and Remote Operation through SCADA Console.9. Establishing communication from IMCC/drive to SCADA. This part will be executed after

erection of PLC/SCADA system by the department. Party shall provide provision for all the motor currents along with their status to SCADA.

10. Submission of installation report11. VVVF drive parameterization shall be carried out in consultation with dept. personnel.12. Drive software back up shall be provided in both hard copy and soft copy.

2.11 Training and Documentation

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2.11.1Training for department personnel, regarding operation, maintenance and troubleshooting of system

2.11.2 Three engineers from department shall be trained in VVVF drive & Motor management system from drive manufacturer and Motor management system supplier.

2.11.3 Contractor shall provide soft copies (3 nos.) and hard copies (5 nos.) of the catalogues, and manuals of all the components and systems and as built circuit diagrams. Supplier shall provide 5 no’s of lubrication and maintenance documents, list of spare with order number.

2.11.4 Soft copy & hardcopy of drive parameterization shall be provided.2.11.5 Manual and software for VFD drive shall be provided.2.11.6 3 engineers shall be trained in VVVF drive system.2.11.7 Soft copy of simocode programming and drive parameters in CD/DVD shall be provided.

2.12 Department Scope:

2.12.1 Building and cable trenches2.12.2 Supply of PLC & SCADA for remote monitoring and control operations2.12.3 CCTV System

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RVD and sub systems shall including the following :

1. Rotary vacuum drier of 4000 lts capacity2. iMCC for RVD and subsystems3. VVVF Drive system for RVD4. Coupling system for drive and RVD5. Hot water tank with heater elements, switch gear unit. & controlling elements 6. Hot water tank instrumentation elements like level transmitter, temperature sensors etc.7. Water circulation pumps8. Vacuum Pumps & controlling elements9. Flameproof push button stations10. Necessary piping, ducting and cabling.11. All sensors and field instruments specified in the document such as RTD, thermocouple,

Proximity sensors, Temperature Transmitters, Pressure Transmitters, humidity sensors, control valves etc. as specified in the technical specification with 30% spare.

12. Mounting of all sensors / transducers / Instruments by selecting suitable mounting arrangement, piping, fittings required between equipment and Sensor/transmitter up to Marshalling chamber.

13. One set of spare for hassle free operation for minimum period of 10 years. 14. Flame proof termination of all cables in Rotary Vacuum drier Bay using flame proof glands. 15. Proper grounding and earthing of equipment.

16. Suitable top lid and bottom valve for RVD17. Nitrogen purging system for vacuum breaking.18. Necessary rotary unions for hot water and vacuum pumps.19. Necessary traps/ cyclones/Dust filters to prevent any oil or contaminants reaching RVD chamber

or AP from reaching exit.20. Inching mechanism for better positioning of RVD

Detailed technical specifications of above is mentioned in subsequent sections / tables : (Table 1 to 11)

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Annexure - I

Technical Specifications

Table 1Specifications of Rotary Vacuum Drier

Description Essential Specification Compliance (Yes/ No)

Quantity : 1 NoLocation : IndoorMaterial to be dried : Ammonium PerchlorateUN Number : AP Coarse : UN1442

AP Fine : UN 0402Average Particle size : AP Coarse : 330 – 360 microns

AP Fine : 45 – 55 micronsGross capacity : 4000 ltrsMaximum quantity of material to be loaded in RVD for drying

: 3000 kg of AP Coarse ~1500 kg of AP Fine

Density of material : 1.95 gm/cm3.Bulk density : AP Coarse: 1.2 gm/cm3.

AP Fine : 0.6 gm/cm3.Heating cycle per batch : 60 min (Minimum). To be specified by supplier

along with calculations.Vacuum cycle per batch : 15 min (Minimum). To be specified by supplier

along with calculations.Working volume : 2400 lts (Minimum)Size of RVD total : Max. 5.6 (l) x 2.4 (b) x 3.2 (h) m RVD shaft RPM : 5 – 7 Type : Double cone, Double shell, water jacket typeOperating temperature of RVD

: 20 to 80 deg C

Design temperature of RVD : 10 to 100 deg C or to be specifiedOperating pressure of RVD : 50 torr to Max. 1 ksc gaugeDesign pressure of RVD : 50 torr to 3 ksc or to be mentioned by supplierOperating pressure in jacket : Max 3.0 kscDesign pressure of jacket : Max 3.75 ksc or to be specified as per the pressure

vessel design Operating temperature in jacket

: 20 to 95 deg C

Design temperature in jacket : 10 to 120 deg C or to be specifiedSafety valve in jacketed water line at appropriate place:

: 1.1 times of operating pressure or to be specified

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Thickness of shell (inner most part )

: To be specified

Thickness of jacket (middle part)

: To be specified

Thickness of insulation cover (outermost part)

: To be specified

RVD bowl details : : Middle cylinder , top cone and bottom cone dimensions are to be specified. Inlet port size shall be min of 600 mm and outlet port shall be min 300 mm

RVD bowl internal baffles Baffles shall be welded with weld pads and runs centrally to the RVD body, at a helical pitch. Baffles help to break the cascading fall of the material and aids mixing/blending. No. of baffles : To be specified

Vacuum arm and size : Details shall be provided and to be avoided the cantilever bending to vacuum pipe. Height shall be designed on the basis of 70% occupancy

Discharge valve : pneumatic operated butterfly valve with manual override shall be provided.

RVD body finish : Details shall be provided for inner surface & outer surface. (Internal : electro polish & External :min. 180 grits )

Jacket details : Details of the jacket pipe lines and flow path of water inside the jacket shall be provided.

De-scaling of jacket pipe lines : suitable de-scaling provision and procedure shall be provided

Insulation details : Hot, MOC & thickness to be specified. The outside temperature of RVD shall not be more than 30OC

Jacket nozzle : details shall be provided for drain out of waterInterconnecting pipe lines : Details shall be provided for all pipe lines for

vacuum , hot water lines etc and MOC : SS-304. Suitable insulation shall be provided for hot water lines.

Weight of components To be specified by supplier for individual componentsMOC of RVD chamber SS304 / SS 316MOC of RVD Jacket SS304 / SS 316MOC of Insulation Jacket SS304 / SS 316RVD Shaft details EN19 or better with chrome plating for corrosion

resistance and hardness shall be not less than 55 (HRC)

Drying temperature for material

: 72 ± 2deg C

Half cone of bottom conical Maximum 45O with vertical

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portionMinimum distance between two pedestals

Min. 2500 mm

Height of RVD (From top of inlet lid to bottom of the pedestal)

Max. 3200 mm

Drive assembly for RVD : Detailed drive assembly shall be specified including the following design details:1. Motor details :2. Gear box details :3. Chain details:4. Sprocket details:5. RVD shaft drive details:6. Mounting details:7. Other details and load calculations for arrived

HP:8. Drive shaft details and load calculations :

SHAFT seals : Shaft seals for dry mechanical seal , vacuum and hot water details shall be provided

Support frame : Details shall be provided for support frame for the drive unit and covering all the seals etc.

Cyclone separator : Cyclone separator details shall be provided Receiver : Receiver details shall be provided in vacuum line for

trapping the dust and moisture Additional feature required There should be provision to measure temperature of

material inside the chamber online, without affecting the conformance to Zone I, Group IIA, IIB hazardous area operation. Suitable design should be made and submitted to department for approval prior to commencement of work.

Monitoring Parameters (Digital)

1. RVD Inlet Water Temperature2. RVD Outlet Water Temperature3. RVD inside material Temperature4. RVD Vacuum5. RVD Bearings temperature6. RVD RPM ( to be measured by RPM sensor at the

shaft)7. RVD jacket pressure8. Hot water line pressure9. Angular position of RVD10. RVD motor line currents 11. RVD motor ON/OFF/TRIP status12. Other parameters as suggested by supplier for

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monitoring health of equipment

Table 2Specifications of Drive system for RVD

Compliance (Yes/ No)

An Electric Motor (flame proof) with suitable gear system is to be designed for rotating the RVD.

The motor should be 1500 rpm (syn) with suitable gear to achieve 5-7 rpm at shaft.

The Electric motor is powered through VVVF drive for fine end rpm control however the operating frequency of drive should be kept above 40Hz for 5-7rpm at shaft.

The motor capacity should be selected such that only 80% of rated current (or less) should flow at full load.

Specification of motor & gear is given belowDescription Essential Specification Compliance

(Yes/ No)Quantity 1 No

ELECTRIC MOTOR SPECIFICATIONMake Kirloskar/Crompton Greaves/Bharat Bijili/ CEMP/

MarathonRPM 1500 RPM(SYN)Power transmission mode

Gear box with sprockets and chain

Motor capacity The motor capacity should be selected such that motor shall draw only 80% of rated current at full load. Design calculations to be submitted towards arrival of motor power rating and approval to be obtained.

Motor type Flameproof induction motorOperating Voltage 415 V ± 10 %, 3 PhaseOperating Frequency 50 Hz ± 5 % Hazardous zone operation

Ex Proof, Zone I, Group IIA, Group IIB compatible

Duty class ContinuousProtection IP 65 or betterTemperature classification

T4 or better

Insulation class F and temperature rise limited to class BThermistor/KTY84 Sensor Two nos. embedded in windings to monitor winding

temperature and trip system upon high winding temperature. KTY84 is preferable

Connector Armoured copper conductor cable terminated using double compression flameproof gland

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Remarks Voltage rise time shall be more than 0.1µs, Peak insulation voltage minimum 1400 VSuitable for VFD operation considering factors like voltage rise time, peak insulation voltage and bearing currents caused by VFD. The motor shall be suitable inverter duty operations.

MECHANICAL SPECIFICATIONRPM 5-7 RPM at shaft endPower transmission mode

Gear box with sprockets and chain. Gear box Make: Shanti/ Elecon

Table 3Specifications of VFD for RVD Motor


Quantity 2 No’s (working + spare)Make ABB / SiemensMain voltage 380-480 V ± 10 %, 3 PhaseInput Frequency 48-63 HzOutput rating One size higher standard Drive rating of selected motor full

load ratingOverload capacity 150 % for 60 sec Digital inputs 6 No’s programmable (minimum)Analog inputs 2 No’s programmable (0-10 V, 0-20 mA, and -10 to +10 V)

(minimum)Relay outputs 3 No’s programmable (minimum)Analog outputs 2 No’s programmable (0-20 mA) (minimum)Safety guidelines IEC 61800Ambient Temperature

50 Deg C

communication Profinet or other protocol with Profinet converter Choke or filter Choke/Filter of suitable rating to limit THD as per IEEE519protections Protection against input/output phase loss/phase short circuit,

under/over voltage ,di/dt, inverter protection, heat sink protection etc.,

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Table 4Specifications of Vacuum Pumps


These vacuum pumps are electrically driven vacuum pumps with following specifications


Quantity 2 No’s (working + spare). Both shall be connected, to have a live & redundant pump on-line. Make: Toshniwal/ Edwards

MECHANICAL SPECIFICATIONCapacity To be designed by supplier according to requirementUltimate pressure 50 Torr.Water vapour tolerance

To be furnished by supplier

ELECTRICAL SPECIFICATIONMotor 3 phase Induction motor as per IS:325 or equivalent IEC

standard, Class F insulation,S1 dutyMotor Make Crompton/ kirloskar/ Siemens / ABB / Bharat Bijlee or OEM

own make edwardsMonitoring parameters

Pump motor currents and status(ON/OFF/TRIP)

Table 5Specifications of Hot water Pumps


These hot water pumps are electrically driven pumps with following specifications The pump and motor capacity should be selected such that it shall draw only 80%

of rated current (or less) at full load.Description Essential Specification Compliance

(Yes/ No)Quantity 2 Nos (working + spare). Both shall be connected to have a

live& redundant pump on-lineELECTRICAL SPECIFICATIONCapacity To be designed by supplier according to requirement (The

pump and motor capacity should be selected such that it shall draw only 80% of rated current (or less) at full load).

Motor 3 phase Induction motor as per IS:325 or equivalent IEC standard

Motor Make Siemens/ ABB/ Kirloskar/ Bharat Bijlee/ Crompton or OEM own make like Beacon

Operating voltage 415 V ± 10% 3 Phase

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Operating Frequency

50 Hz ± 5%

Insulation Class F with temperature rise limited to Class BProtection IP 54 or betterDuty S1MECHANICAL SPECIFICATIONType Centrifugal Monoblock, cast iron impeller with mechanical seal Insulation Class F with temperature rise limited to Class BPumping Medium Hot water (65 – 75OC)Head & capacity Min 30 m & as per design requirementOperating temperature

70 – 85 OC

Table 6Specifications of Hot water tank


These Hot water tank consists of water tank and heater banks (along with associated electricals) as in the following specificationsDescription Essential Specification Compliance

(Yes/ No)Mechanical SpecsQuantity 2 Nos (working + spare). Both shall be connected to have a live

& redundant tank on-lineCapacity Minimum 1500 ltsMOC MS with corrosion resistant and scale resistant coatingsTarget temperature 72 ± 3OC at inlet and outlet Electrical SpecsNo of heating elements

54 kw : 6kw (standard immersion heater working on 230V ac) x3heaters each for bank 1 , bank 2 &bank3

Heater control Triple bank, on/off control for Bank 1, bank2 and thyristor control for bank 3. Thyristor Make : AEI and with communication card to interface with SCADA

Water level control Automatic water level controller using level sensorConnection There shall be a local power distribution board mounted on

Tank outer wall consisting of three numbers of MCB ( one for each heater) & one ELCB for each bank (total 9 MCBs and 3 ELCB) with Bus bar arrangement in star 4 wire configuration for both heater banks. There will be one heater in each phase and Neutral in each bank . Teflon wires or suitable heat resistance wires shall be used for terminating heaters from Bus bar in local DB.

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Additional Features The tank shall be provided with level sensor/float switch and to be interlocked with heaters. There shall be a provision of water softener in the incoming water line to the hot water tank.

Hot water tank insulation

Hot water tank insulation shall be provided as per the standard given for RVD or to be specified

Pipeline arrangement

Pipeline arrangement shall be made to facilitate recirculation to tank and RVD. Piping Drawings shall be submitted for approval of department.

Monitoring parameters

1. Hot water tank Temperature2. Water Level in Tank3. Control of water flow into the tank

Table 7Pipe lines and valves


Quantity Pipe lines for hot water tank and RVD jacket and pipe lines from vacuum pump to RVD. Wherever necessary bypass pipeline with manually operated valve shall be provided to ensure smooth maintenance of electrically operated components.

Length Based on position of hot water tank and vacuum pump. Approximately 100 to 150 meter length

MOC SS-304Insulation Hot water lines shall be suitably insulated for hot mediumValves Flanged Valves shall be provided in hot water lines and vacuum

lines of make BDK / L & T Analog gauges Analog gauges shall be provided for temperature measurement

of hot water at RVD inlet and outlet and also vacuum measurement apart from digital sensors. Analog gauge also shall be provided to measure the hot water line pressure apart from digital sensor.

Testing Standard Pressure Test: IS2825Flanges & Joints: IS131589, Class 150, SORF

Additional Remarks All the necessary pipe welding, fabrication and erection, DP testing, screws, bolts, clamps, mounting brackets, tools, consumables, etc is scope of supplier. Material test certificates shall be provided. All the hot water lines shall be thermally insulated using pre-formed Rockwool pipe insulation material of minimum 1 inch thickness. Aluminum cladding with screws shall be provided over the insulation. Compressed Asbestos

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Fibre (CAF) gasket of 3 mm minimum thickness shall be used for flange joints

Table 8Specifications of Intelligent Motor Control Centre


The iMCC should be with following feeders with compartmentalized cubicles separated from each other, with bus bars and bottom cable entry

Construction a) iMCC shall be floor mounting, free standing, totally enclosed and dust, damp and vermin proof.

b) MCC enclosure shall have minimum degree of protection - IP 52 (as per IS 2147).

c) Sheet steel used for fabrication shall be cold rolled, cold annealed. Minimum thickness of various members shall be as follows :- Base frame / Channel / Gland plate : 3 mm Load Bearing Members / Doors : 2 mm Internal Partitions : 1.6 mm

d) Construction shall be rigid and robust. All steel work shall be flawless and have a smooth finish. Stiffener shall be provided where required for sufficient rigidity.

e) Clearance between phases and between phase and earthing as well as the insulation levels shall be in accordance with relevant standard.

f) Hooks shall be provided for lifting the MCC. g) Panel should have undergone 7 tank process, powder

coated with Siemens grey colour RAL7028. Cable Entry is bottom entry.

h) All feeders to be housed in separate compartments. i) Busbars shall be of high conductivity electrolytic

copper or aluminium, suitable for carrying the rated and short time current without overheating. Busbars shall be adequately supported on insulators to withstand dynamic stresses due to short circuits.

j) MCCB’s shall be 3 pole or 4 pole conforming to as IS-13947 (Part 2). MCCB’s shall have thermal over current and magnetic short-circuit adjustable releases.

k) Contactors shall be magnetic, air break type generally as per IS 13947 Part-4 suitable for Type 2 co-ordination.

l) All power contactors shall be rated for 125% of feeder full load current. Minimum rating shall be not less than 9

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Amps.m) All control wiring inside the MCC shall be carried out with

1100 / 650 V Grade PVC insulated wires of grey colour. n) Minimum size of conductor for power circuits shall be

4.00 sq. mm copper.o) Front operated.p) Height of panel should not be more than 2.0 meters.

Make : RittalIncomer feeder Motorised MCCB with adjustable short circuit, earth fault and

overload.PAC meter with Profinet connectivity for local display and remote data logging.

Outgoing feeder 1 RVD feeder: VVVF drive (detailed specification for drive given in table-3) with input and output filters and suitably rated MCCB for the feeder. AOP (Advanced operator panel) of drive should be mounted on cubicle door of panel.

Outgoing feeder 2 RVD feeder (redundant): VVVF drive (detailed specification for drive given in table-3) with input and output filters and suitably rated MCCB for the feeder. AOP (Advanced operator panel) of drive should be mounted on cubicle door of panel.Out going will be connected only when feeder 1 fails

Outgoing feeder 3Vacuum pump1

Suitably rated MCCB with adjustable short circuit, earth fault and overload protection, DOL starter for motors of vacuum pump. In case of dual motor configuration DOL configuration for individual motor shall be provided.

Outgoing feeder 4Vacuum pump2

Suitably rated MCCB with adjustable short circuit, earth fault and overload protection, DOL starter (or starters) for motors of vacuum pump. In case of dual motor configuration DOL configuration for individual motor shall be provided.

Outgoing feeder 5Hot water Pump1

Suitably rated MCCB with adjustable short circuit, earth fault and overload protection, DOL starter for motor of water pump.

Outgoing feeder 6Hot water Pump2

Suitably rated MCCB with adjustable short circuit, earth fault and overload protection, DOL starter for motor of water pump.

Outgoing feeder 7Heater bank1

Suitably rated MCCB with adjustable short circuit, earth fault and overload protection, Contactor for Heater bank 1 ON/OFF

Outgoing feeder 8Heater bank2

Suitably rated MCCB with adjustable short circuit, earth fault and overload protection, Contactor for Heater bank 2 ON/OFF

Outgoing feeder 9Heater bank 3

Suitably rated MCCB with adjustable short circuit, earth fault and overload protection. Thyristor controller 18kw(or higher),working on 415V+/-10%, 50Hz +/-3% 3ph AC supply, three legged, suitable to control three Nos of 6Kw(230V) heaters connected in star configuration (3ph-N), with panel mounted operator panel,

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Make AEG only. Contactor for Heater bank 3 ON/OFF in case of Thyristor controller breakdown or maintenance bypass with a selector switch mounted on panel to select Thyristor/ Contactor

Ratings 1) All MCCB rating should be selected based on maximum current possible with 20% margin. Ics for incomer 50kA(min) and outgoing feeders 35kA(min)

2) All contactors should be selected such that one step higher rating than the rating based on maximum current flow.

3) Bus bars shall be copper or aluminium with tinned end connection area rating should be with 80% cushion.

4) Cables minimum 4 Sqmm copper cable with 80% cushion.

Motor management system

The Intelligent motor management system should be of M/S Siemens make SIMOCODE PRO V model and shall consist of necessary current/voltage measuring modules, basic units, operator panel with display unit for each motor feeder ,monitoring of motor winding temp at two levels (trip & warning level) from NTC/KTY 84 temperature sensors embedded in winding ,ground fault monitoring, current & voltage monitoring etc. The communication protocol should be with Profinet only. Drive and Thyristor controller should have Profinet interface or suitable converter to convert to profinet protocol to be provided.

Motor winding temperature

trip /monitoring requirements

The PTC/ KTY 84 temperature sensor shall also be interfaced with motor winding temp relay with display of motor winding temp apart from trip arrangement from motor management temp module. The requirement to have two independent chain of motor winding monitoring/trip mechanism is to meet hazardous area safety guide lines for mandatory requirement of trip mechanism when Flame proof motor is driven by VFD to limit surface temperature not exceeding T4 temp class .

Control requirements

The systems control and data acquisition is through PLC & SCADA and is in a third parties scope which will be realized later. The PLC envisaged for this automation is dual redundant with criss cross configuration. The iMCC should use PROFINET Protocol and all feeder elements including VFD drive should be configured suitable to this dual redundant configuration. All feeder currents , speed(VFD), on/off/trip status, On/Off commands ,run status , feeder protection (EL,SC,OC,winding temp) should be communicated through profinet cable . Ethernet cable (main & redundant -2 runs) should be laid from iMCC to control room with sufficient extra length. Ethernet

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Cables (CAT-6) shall be brought up to Instrumentation System Marshalling Chamber. However individual feeders in iMCC should be controllable locally from iMCC pushbutton stations at service room apart from control room PLC mode and even without availability of PLC & SCADA system. This may be achieved by local intelligent module programming or through a small PLC incorporated in iMCC panel. This local operation should have enable/disable provision with removable key. The OLR’s in all feeders to be directly wired to PLC inputs , this is in addition to the overload protection provided by iMCC. All OLR NC contacts to be wired up to marshalling box for this purpose.All controls in Hazardous area such as RVD on/off , emergency off are to be interfaced to iMCC through intrinsic safe barriers of P&F make. These intrinsic safe barriers to be provided where ever required. Local pushbuttons stations in metal enclosure to be provided where ever required and to be interfaced through above IS barriers.

Marshalling cubicle Profinet cable and remote control connections wires should be terminated at instrumentation marshalling cubicle with proper cable identification and ferrules.

Test & Acceptance The panel should be designed, manufactured and tested in accordance with IS 8623(Pt1), IS 13947(Pt4/Sec1) and as per the above specifications. Type tests and routine tests shall be conducted in accordance with IS 8623(Pt1) and certificates in this regard should be provided. The panel should undergo functional tests , Insulation test with 500 volts megger, before and after H.V. test.

H.V. test on power and control circuits / components (2 KV for one minute) and other qualification tests as per standards at Panel manufacturers works in presence of department engineer.

Design approval Party to submit GA drawing, Power drawing, , including selection of switchgear ratings, control drawing ,Motor management scheme, bill of material and get it approved by department before fabrication.

Remarks Communication between IMCC and SCADA is not in the scope of the party. However party should participate during interfaces with SCADA and shall provide necessary solution during commissioning.

iMCC M/S Siemens , M/S KasaAnlagen, Chennai , M/S

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manufacturers Chemincontrols, PondicheryNote: Any Panel Manufacturer with experience of iMCC fabrication ,in this case proof of experience (iMCC with more than 6 Feeders and rating above 400A ) to be furnished

Flameproof Push button stations

Three flameproof push button station with lockable button shall be positioned each one at feed platform, discharge platform of RVD and Bay area. Make: Baliga/FCG/ FEPL

Table 9Specifications of Power and control cables


Type Armoured copper conductorSize Power cable – 4mm2.

Control cable – 2.5mm2.Insulation FRLS suitable for LT insulation class 1100 V XLPE insulation

IS:7098 sheath are of HR PVC / FRLS / LSZHMake HAVELL/ POLYCAB/ FINOLEX/ LAPP/ INCAB/ CCI/ RPG/

TORRENT/ GLOSTER/ UNIVERSAL/ HVPL/ RALLISON

Table No: 10Specification of RPM Sensors


Quantity 1 NosMake Pepperl & FuchsType Namur induction proximity switch along with suitable

frequency to current converter, current repeater, current to voltage converter and necessary subsystems

Model No NCB8-18GM40-NO-VI along with all of its accessories & Necessary cable from RPM Sensor to P&F Frequency to current converter in panel. Supply of P&F Freq to Current Converter is in the scope of Supplier.

Hazardous zone operation

Flame proof, Zone I, Group IIA, Group IIB compatible

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Table No. 11Grounding and Earthing


System Grounding and Earthing

Grounding of panels, junction boxes, power distribution boards & field instruments shall be as per Grounding Scheme.Separate instrument signal and body earthing shall be provided for each field instrument. Single point earthing configuration shall be followed for the cable shields i.e. all data and control cables shields shall to be grounded at one end only to avoid ground loop.Control Panels shall be provided with a safety ground bus & system ground bus made of copper securely fixed along the inside base of the panels. These buses shall be typically of 25 mm wide and 6 mm thick of copper. The safety ground bus shall be properly secured to the plant safety earthing. All metallic cases/frames of relays, instruments, other panel mounted equipment shall be connected to the safety ground bus and shields & drain wires of signal/control cables shall be connected to the system ground bus by independent copper wires of not less than 2.5 sq. mm. The system ground bus shall be electrically isolated from AC mains earthing bus. The insulation colour code for earthing wires should be green with yellow bands.There should be different earths for Instrumentation and Electrical equipment.All motors and panels shall be provided with double earthing with suitable earth strip or wire as applicable.

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Annexure - II

List of sparesEquipment Description Compliance

(Yes/ No)Mechanical systems 1. RVD Drive Bearings – 1 No

2. RVD Drive chain sprockets – 1 No3. RVD Drive chain – 1 No4. RVD Drive gear box – 1 No5. RVD Chamber discharge butterfly valve – 2 Nos6. RVD chamber inlet lid – 2 Nos7. Mechanical seal of water line – 1 No8. Mechanical seal of vacuum line – 1 NoOther spares recommended by supplier

Electrical Systems 1. One VFD with preloaded software for RVD motor.2. One set of Switch gears incomer MCCB, OLR, Contactor

etc3. RPM Sensors – 1 Nos4. One set each of Frequency to current converter, current

to voltage converter 5. One Flame proof push button station as a spare for each

one installed6. One flame proof motor for RVD. 7. Current measurement module -1 (each type)8. Voltage measurement module – 1 (each type)9. Basic unit- 1 (each type)

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Annexure - III

VENDOR EVALUATYION CRITERIA

The pre-Qualification criteria shall be filled by supplier, duly signed and submitted along with technical bid for review by purchaser.

Sl. No CRITERIA

Vendor Compliance(YES*/NO)

1 Tenderer shall have at least 10 years of experience in the field of design, supply and erection & commissioning of Rotary Vacuum Dryer and its sub systems for drying of hazardous materials. Tenderer shall submit the documentary proof of previous order along with quotations

2 Should have Configured, Designed, Manufactured and Erected & Commissioned Rotary Vacuum dryer and its subsystems with minimum drying capacity of 2000 ltrs during last 10 years. Proof to be enclosed.

3 Copies of the completion certificate/performance certificate and contact details from your client organization to whom similar size of the Rotary Vacuum Dryer and its subsystems shall be furnished. Performance demonstration of similar kind of machine supplied by tenderer at client site shall be arranged.Department reserve right to evaluate vendor & its sub contractor capability to supply indented RVD and its sub systems to this tender specification and reject, if not capable

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Annexure – IV

Schedule of Prices

S. No Description Unit

Cost

(in Rs/foreign currency as applicable.)

1

DESIGN, SUPPLY, ERECTION, TESTING AND COMMISSIONING OF RVD OF 4000 ltr. CAPACITY AND ITS SUB SYSTEMS (Without Spares and AMC).

Lump sum

1.1 VAT/CST on items in S.No.1 %

2Packing forwarding and Transportation charges for total system

Lump sum

2.1 Service tax on Item in S. no.2 %

3Installation, Testing and Commissioning charges for

one machineLump sum

3.1 Service Tax on Item in S.No.3 %

Total Cost (Sum of S.No. 1+1.1+2+2.1 + 3+3.1)

4.Cost of Spares (Listed in Annexure II of technical

specifications)Lump sum

4.1. VAT/CST on items in S.No.4 %

Total Cost (sum of S.No 4 +4.1) of system

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Annexure –VEXCEPTIONS AND DEVIATIONS

In line with Proposal Document, Bidder may stipulate Exceptions and deviations to the Proposal conditions if considered unavoidable.

SL.NO

Reference in Specification Dept. Spécification Offered

Spécification DEVIATION

PAGE NO

CLAUSE NO

NOTE :

Only deviations are to be written in this Annexure – V.

Any deviations taken by the Bidder to the stipulations of the Proposal document shall be brought out strictly as per this format and enclosed along with the bid.

Any deviations not brought out as per this Proforma (Annexure – V) and written elsewhere in the Proposal document shall not be recognized and the same is treated as null and void.

Any willful attempt by the Tenderer to camouflage the deviations by giving them in the covering letter or in any other documents that are enclosed may render the Bid itself non-responsive.

(SIGNATURE OF BIDDER)

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