WHRB Tender Specification Document · WHRB Tender Specification Document Page 2 of 26 2. Design...

WHRB Tender Specification Document

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Tender Specification Document

Title of the work: Design, Fabrication, Inspection, Testing, Supply, Erection & Commissioning of Waste Heat Recovery Boiler

Part I: Technical Specifications

1.0 Purpose: Waste Heat Recovery Boiler (WHRB) is meant for generating steam from waste heat of

process at the CNA/N2O4 production plant, Propellant Complex, Rasayani

1.1 SCOPE OF WORK

i) The scope of work involves Design, Fabrication, Inspection, Testing, Supply,

Erection & Commissioning of Waste Heat Recovery Boiler (WHRB). ii) The intended WHRB is proposed to be a one – to – one replacement of existing unit

in the operational CNA / N2O4 plant. Hence the new unit has to be dimensionally correct

and performance shall match the requirements of the existing unit.

iii) In the technical bid, bidder shall enclose the copies of design reports of similar

work carried out earlier to ascertain the bidder’s design capabilities.

iv) If any advanced features based on the modern improvements in Design are to be implemented mainly to address the operating conditions (as mentioned

under 2.4 of this document), the same shall also be proposed in the technical bid.

v) The successful bidder shall submit detailed design calculations to Purchaser

before fabrication. vi) Mechanical Design shall be approved by IBR

vii) Overall dimensions and nozzle details shall be as per attached drawing. This

drawing is only meant to indicate the dimensions of the existing unit.

viii) The detailed fabrication drawing as per approved design of new unit and having

outer dimensions equal to existing unit shall be proposed by the successful bidder.

ix) Fabrication shall be taken up only after the drawing approval from the purchaser.

Fabrication drawings and plan shall also be approved by IBR Authority.

x) The detailed specifications are as per this tender specification document for

Design, Fabrication, Inspection, Testing, Supply, Erection & Commissioning of Waste

Heat Recovery Boiler to Propellant complex, Rasayani, ISRO (PCRI), Govt. of India,

Dist.; Raigad, Maharashtra PIN-410207. xi) The scope of work also includes the removal of existing Waste Heat Recovery Boiler from the plant. The bidder shall arrange necessary equipments & resources to execute the removal of existing Waste Heat Recovery Boiler. The schedule of

these works for execution shall be discussed with the purchaser and to be finalized before dispatch of the new unit to PCRI.

xii) Quantity Required – 01 Unit


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2. Design Inputs:

Technical Data

2.1

Type Waste heat Recovery Boiler is of Horizontal Cylindrical type with Welded

Dished ends with adequate number of tubes (shell and tube heat exchanger)

2.2 Design &

Construc

tion

a. Code for WHB design shall be ASME SECTION VIII DIV 1; TEMA - B and as per IBR with latest editions of all these standards / codes

2.3 b. Allowable Stress: As per code.

c. Design data for WHRB

Shell side Tube side

Operating fluid Water / Steam Nitric Oxide gas

Flow rate 2540 + 5 kg/hrs 8337 + 5 kg/hrs

Operating temperature (o C), In/Out 218/218 + 5 Deg. C 840 /240 + 5 Deg. C

Design Pressure kg/cm sq.(g), In/Out 22 / 22 - 0.015 / -0.031

Design Pressure kg/cm sq.(g) 25 -0.05

Design temperature (o C)

• Generally decided based on IBR

rules

As per IBR rules

350 Deg. C preferred

Hydraulic test pressure (Kg/ cm2 (g)) At 37.5 ksc – Shell side

At -0.075 ksc – Tube side

Joint efficiency 0.9

Radiography 100%

Corrosion allowance (mm) 1.5 1.0

Heat treatment (PWHT)

Stress Relieving as per UCS 56 of ASME

sec VIII div. 1 code

Yes NIL

Number of passes 1 1

Wind Load 150 kg/sq. metre

Insulation 80 mm thick, Rockwool (Density:

100kg/mm2)

Earthquake factor 0.04

2.4 Operating Conditions: • During Burner Light Up (happens

every 3rd / 4th day) the temperature of

the process gas in burner section raises

steeply from 570C to 8400C within 20

minutes.


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Technical Data

• WHRB is at ambient temperature

before startup. Hence, before the

burner light up preheating of WHRB is

being done by injecting steam to WHRB

and burner basket to raise the

temperature from ambient to about

1000C.

2.5 Engineering Data of existing WHRB • Surface Area: 197m2

• Heat exchanged: 1245000 kcal/hr

• Mean temperature difference

corrected: 1610C

• Overall Heat transfer coefficient: 42

kcal/m2 hr 0C

• Empty Weight:6950 kgs

• Weight with full of water:9950 kgs

2.6 Material selection • Proposed materials are as per Table-1.

However, designer may propose

superior alternative materials, if any, in

the technical bid itself for the

consideration of the purchaser along

with separate proposal in the

commercial offer.


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Table-1

Proposed Material Specifications for Waste Heat Recovery Boiler

Sl

No Components

Material as per following codes

& standards of ASTM / IS

1 Shell plate SA 515 Gr 60 /70 or SA285 Gr C or

SA 516 Gr 60 /70

2 Tube Sheet SA 515 Gr 60

3 Tube A 179

4 Baffle Plate IS 2002 Gr B / SA285 Gr C

5 Pad plate for lug support SA 516 Gr 60

6 Stud and Nuts A193GrB7/A194Gr2H

7 Gaskets As per Drawing / Design

8 Gusset for lug support IS 2002 Gr B

9 TOP Plate IS 2002 Gr B

10 Gusset plate IS 2002 Gr B

11 All nozzle flanges, Blind flange A 105

12 All Nozzle neck A 106 Gr B

13 Anchor bolt IS226

14 Slide plate IS226

15 Stiffeners IS 2002 Gr B

16 R.F PAD for nozzles SA 516 Gr 60

17 Baffles IS 2002 Gr B

18 Carbon content of all welded parts shall be less than 0.22%

Additional Requirements of Material selection, Design, Fabrication & Testing

2.7 The raw materials for tubes and tubesheets shall be produced by electric arc melting

process.

2.8 Autogenous welding process: Only automatic TIG is acceptable by orbital welding

machine

2.9 WHRB consists of LHS & RHS tubesheets in which tube holes are to be drilled in a circular

pitch. Each hole shall be provided with two inside grooves at a distance of 10mm & 20mm

from the inner face of tubesheets for additional longitudinal load resistance of tubes.

2.10 The tubes shall be rolled & seal welded to tubesheets at both the ends.

2.11 The strength rolling (7-10% thinning) of tubes is carried out during which expanded

tubes grips inside the grooves. This arrangement also acts as a mechanical seal for

arresting the entry of water into the gap between the tube OD & tubesheet hole. Thus,

deep crevices are eliminated in the design by strength rolling of tubes in the tubesheets.

2.12 Face grooves are machined with tight tolerances on face of each hole on the tubesheet

which provides a thinner section for seal/lip welding to get the desired weld profile. This

also helps in minimizing the heat input required for seal welding and makes a perfect

fusion of the base materials (tube & tubesheet).

2.13 Even though conventional heat exchanger tube to tubesheet joints are executed first by

welding and then rolling, WHRB tube to tubesheet joints are proposed first by rolling by

using mechanical tube expanders and then single pass seal welding by automatic pulsed

TIG welding process without addition of filler wire.


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2.14 This is to avoid probable stresses induced in the welds during tube expansion step which

may result in subsequent failure of the weld joints during transient WHRB operating

conditions.

2.15 The automatic welding process ensures repeatability & consistency in quality of tube to

tubesheet weld joints.

2.16 The process parameters of welding like pre - purge time, up slope, speed of welding, down

slope, post purge time. The weld quality with respect to shape and soundness shall be

controlled by process parameters.

2.17 Tube to tubesheet seal welding shall be carried out by autogenous pulsed TIG process

after rolling. The seal weld is subjected for visual examination and fluorescent LPE as per

ASTM E-165 type-1, method C for examination of lack of fusion at the edge of hole in the

tubesheet, surface pores, cavities, cracks etc.

2.18 Tubes to be expanded before and after tube to tube-sheet welding.

2.19 Tube Pitch is to be considered as triangular pitch.

2.20 Baffle are to be considered for tube support, care should be taken for water circulation.

2.21 Construction and workmanship to be followed as per IBR / ASME requirements.

2.22 WELDING Welding shall be carried out by autogenous pulsed TIG process after rolling only. Orbital welding

machine shall be used.

2.19 RADIOGRAPHY and DP TESTS:

i) Radiography : Spot – 10% + all T joints. All welds shall be DP tested. The dye used

for Dye-penetrant test shall not have chlorides more than 50 PPM (Preferable

brands: Magnaflux / Checkmate).

ii) Radiographs have to be carried out using x-ray Source with a sensitivity of 2-2T as

per ASME sec V.

2.20 HEAT TREATMENT: Heat treatment (PWHT): Stress Relieving as per UCS 56 of ASME sec VIII div. 1 code at

5930C with a hold time of 1 hr. shall be carried out for shell only.

2.21 NOZZLES: As per drawing

i) All nozzles to shell welds (Root & Final run) shall be examined by DP test.

ii) All nozzles fabricated from plates shall be 100% radio graphed.

2.22 TESTING: A) Testing of materials: As per IBR Authority.

1. All materials used shall be tested as per Code in the Reputed Govt. approved

testing labs before fabrication.

2. The plates/pipes/tubes used for construction of Equipment shall also be ensured free from any lamination and manufacturing defects by

100% ultrasonic testing as per Practice ASTM A-435.


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3. Material Test certificates shall be furnished to purchaser for approval

before start of fabrication.

B) Hydraulic Pressure Test: i) Hydraulic test is to be conducted for shell side of WHRB. The test pressure shall

be as per design code and same shall be carried-out in the presence of IBR

Authority & purchaser. Clean potable water with chloride content less than 25

PPM, shall be used for hydro testing.

ii) After the final hydraulic pressure test, the vessel has to be degreased and painted. iii) The cleaning is to be carried out for both inside and outside surfaces of the

Equipment.

C) Pneumatic Leak Test: After Hydro test, pneumatic test for both the sides (shell & tube) of WHRB shall

be carried out individually with suitable closures using dry Nitrogen gas with dew point of minus 40 Deg. C or better and leak check with soap solution.

2.23 QAP to be prepared prior to fabrication and testing and shall be submitted to the IBR

Authority/ Purchaser for approval. During the course of fabrication, different stages of

inspection are to be identified. At every stage, purchaser’s clearance has to be obtained.

2.24 The fabrication shall be carried out using tested and qualified materials only.

2.25 Equipment shall be provided with nozzles as indicated in the drawing.

2.26 The proposed QAP is as per Annexure - I

2.27 The recommended cleaning procedure to be followed for the fabricated equipment shall be

as per Annexure – II

2.28 The bidder shall fill the proforma as per Annexure- III and submit along with technical offer.

2.29 Special Conditions

a. The waste heat Recovery Boiler shall be fabricated under the inspection of IBR

Authority.

b. At the time of submitting technical bid, party shall quote the names of IBR

authority that will be engaged during the course of entire work.

c. At the time of submitting technical bid, party shall attach documentary evidence

indicating IBR approval of the fabrication shop.

d. If the bidder is not a manufacturer, then bidder shall attach Authorized dealer

certificate or a valid partnership agreement or technical collaboration agreement

or authorized designer – business relationship agreement between designer &

fabrication agency along with technical bid.

e. Bidder shall enclose his/her credentials demonstrating Design Capabilities of

Waste Heat Recovery Boiler or similar IBR inspected heat exchanger or equivalent

equipment in the form of earlier works executed with the documentary evidence.


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f. PCRI reserves the right to reject any of the offers at technical/financial stage, if the

same is not meeting the specifications without any future communication.

g. Detailed technical offer shall be submitted by the bidder under the “Vendor

Solicited Documents” section on our e-procurement portal elaborating proposed

design scheme, major heat transfer calculations, important technical parameters,

etc.

h. IBR Authority Inspection charges for both at Manufacture’s site as well as

purchaser’s erection site shall be quoted in the price bid. (Charges will be paid

against submission of documentary evidence. The charges will be paid “on actuals”

or quoted price, whichever is lower)

i. Annexure – VII shall be filled as part of specifications compliance while submitting

the offer in On-line mode.

3.0 PART-II GENERAL CONDITIONS OF SUPPLY

3.1 Submission of drawings to the purchaser for approval prior to taking up fabrication.

a. Bidder shall prepare detailed fabrication drawings and submit to Purchaser / IBR

authority within 2-3 weeks of placing the order.

b. In case of any clarifications, the supplier shall contact purchaser through e-mail /

letter, after satisfactory reply only he shall proceed further. 3.2 Monitoring

a. The IBR Authority / Purchaser will monitor the progress of work during the course of

fabrication.

b. After receipt of the order, the fabricator should prepare a detailed PERT chart showing

all mile stone activities of fabrication, testing, chemical cleaning etc., and submit to the

IBR Authority for approval. The approved PERT shall not be modified without the

concurrence of the Purchaser.

3.3 The bidder shall engage IBR Authority, only as per Government of Maharashtra

authorized person. IBR approved private agency will not be accepted.

The inspection Charges for IBR Authority Inspection shall be paid “On Actuals” against

submission of documentary proof. However, the approximate IBR Authority inspection

charges shall be quoted separately.

3.4 Delivery:

a. Transportation, Erection and commissioning shall be carried out by the bidder at Propellant Complex Rasayani, Tal.: Panvel, Dist.: Raigad, PIN-410207, Maharastra.

b. All necessary Equipments like welding machine, Gas cutting set, Grinding M/C, etc, and

Consumables like Welding Electrodes, Gases, Grinding Wheels, paints, brushes, etc.,

including material handling support, skilled and semi-skilled labour required for carrying

out the above work shall be in the scope of the bidder.


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c. During activities at Propellant Complex Rasayani, Electrical supply for welding,

Drilling/Grinding etc., shall be provided at a

single point at free of cost by the purchaser. However further

distributions shall be made by the contractor thorough proper

distribution boards which meets the safety standards.

d. The equipment shall be fabricated, tested and delivered within 4 months from the date

of PO release. All open ends of nozzles shall be dummied with end caps / blinds at the

time of delivery.

3.5 Production Master File

The successful bidder along with the consignment shall supply three copies of

production master files. Production master file should contain the following.

- Purchaser Order

- Fabrication Drawings (As – built) 3 COPIES approved by IBR Authority.

- Bill of Materials

- Materials Test Certificates

- WPS, WPQ, PQR and Welding Layouts

- Radiographic reports with sketch

- Pneumatic and Hydrostatic test certificates

- Certificates of clearance

- Name plate details.

All the above reports / test results shall be bound neatly.

3.6 One set of soft copy of as-built drawings approved by IBR Authority shall be supplied to

the purchaser

3.7 All the testing charges like UT of plates/pipes, IGC, NDT, mechanical & chemical testing,

etc., should be included in the quotation.

3.8 All radiography films pertaining to the equipment shall be submitted to the Purchaser.

3.9 General Conditions :

3.9.1 Bidder shall carefully study all the points mentioned in the general notes of the enclosed

drawing and incorporate the same as and where applicable.

3.9.2 Any deviations, whatsoever from these specifications mentioned above shall be clearly

mentioned in the technical bid.

3.9.3 Bidder shall clearly mention exceptions / deviations, if any as per Annexure – V

3.9.4 Bidder shall mandatorily fill Annexure – VI and upload

3.9.5 The bidder shall submit the details as per Annexure – III & IV indicating the bidder’s

understanding of the technical requirements and company profile compliance status.


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4.0 TWO PART BID: Bidders shall quote the tender in two-part bid basis. Technical bid shall be

evaluated first, only technically suitable bidders quotes are eligible for opening of price bid.

4.1 Technical BID QUALIFICATION CRITERIA

Bidders who are qualifying / meeting following Technical and financial criteria are eligible to be

considered for further evaluation. Bidder shall furnish all the information mentioned in the

criteria with documentary proof and submit along with quotation. Bids of the parties which are

not meeting the following criteria will not be considered for evaluation and will be rejected

without seeking any further clarifications.

4.1.1. Technical Qualification Requirements:

a. The bidder shall meet the technical specification and other requirements and shall submit

relevant certificates to establish his credentials.

b. The Bidder shall be a party who has already executed similar / identical works with

minimum 3 years of experience in executing similar fabrication works of boilers, heat exchangers, etc. under the IBR authority inspection and having IBR approved fabrication shop

4.1.2. Financial Qualification Requirements:

a. Documentary proof shall be submitted with the offer indicating execution of at least one

order of value of Rs. 30 lakhs or two orders of value of Rs 20 Lakhs each or three orders

of Rs. 15 Lakhs each during preceding three Audited financial years.

b. IT/ TDS certificate shall be submitted with Loss & Profit statement for previous three

years.

c. Bidder shall submit audited statement of financial status for previous three years.

d. Bidder shall submit audited statement of financial status for preceding three years.

4.1.3 The following documents shall be submitted along with the bid for prequalification of

Bidder:

a. Firm establishment certificate and nature of work or the documents as listed under 2.29

of this document.

b. Details of work of similar type completed by providing copies of purchase orders.

c. Satisfactory work Completion certificates from the clients, with the work order copies

d. Copy of the purchase orders related to similar type of works under Execution, if any,

with purchase order name and address.

4.1.4 Bid Selection Procedure and Process of Pre-Qualification

a. Short listing based on documents submitted, satisfying all the eligibility criteria given

above by the firm or individual along with their Bid / application. (Non-submission of

any document as given in above list within stipulated time leads to rejection of Bid).

b. Subsequently Bidder's competency, their technical achievements and financial status

will be evaluated suitable for this work. Feedbacks from Bidder's clients will be

verified, if required.

Party evaluation:


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c. Visit to vendor’s premises by our technical team for accessing the technical capabilities

of bidder, if required.

d. The documents listed in Sl. No. 4.1.1 to 4.1.3 of this section will be reviewed by the

purchaser during factory visit, if required.

e. It is proposed to evaluate the bidder based on the previous experience in execution of

the similar nature of works. The supplier has to furnish/confirm the details as enclosed

in the vendor evaluation format as per Annexure – IV.


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4.2 Price Bid

To be Filled On-line only

S. No

Description Unit

Unit Cost

GST, % Landed

Cost

(in Rs.)

1

Cost of Design, Fabrication, Inspection,

Testing, Supply, Erection &

Commissioning of new WHRB and

Removal of old WHRB at Propellant

Complex, Rasayani

1 lot

To be filled On-line Only

2

Approximate IBR Authority Inspection

charges for both at Manufacture’s site as

well as purchaser’s erection site

(Charges will be paid against

documentary evidence “on actuals” or

quoted cost, whichever is lower )

1 lot

To be filled On-line Only


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ANNEXURE-I

SCOPE OF INSPECTION: AS PER QAP The equipment shall be fabricated under the inspection of IBR Authority/Purchaser

Representative as per the following QAP

PROPOSED INDICATIVE QUALITY ASSURANCE PLAN (QAP)

Sl. No.

Characteristics / type of check

Ref. Document

Method of check

Quantum of check

Manufac-turer

QC

IBR

Authority

Purc

haser

1.a Identification of plate material

with Mill T/C & ultrasonic T/C. As per PO Visual 100% H 100% R R

1.b Identification of material for

plates, pipes, fittings, etc. As per PO Visual 100% H 100% R R

2 Review of fabrication drawings

and Design Calculation

As per PO/

drawing

Material as

per design 100% H 100% R R

3 Review of welding procedure &

Qualification AWS Review 100% H 100% R R

4 Checking of root run & final

weld by dye Penetrant test As per PO Visual 100% W 100% R R

5 Marking of nozzle orientation As per

drawing

Location of

nozzle 100% W 100% W R

6 Dye Penetrant test on all fillet

welds. As per PO Visual 100% W 100% R R

7 Visual & Dimensional

inspection

As per

approved

drawing

Dimension 100% W 100% W R

8 Fit up of nozzles and welding As per std Visual 100% W 100% W R

9 Evaluation of radiography films

of weld joints As per PO

Film

evaluation 100% W 100% R R

10 Stress relieving As per PO Graph 100% W 100% W R

11 Mechanical cleaning at

accessible places. As per PO Visual 100% W 100% R R

12

Hydraulic test of Shell and Tube

shall be done separately for

WHRB as per design code

As per PO

Pressure

hold

method

100% W 100% W W


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Sl. No.

Characteristics / type of check

Ref. Document

Method of check

Quantum of check

Manufac-turer

QC

IBR

Authority

Purc

haser

13 Pneumatic leak test

(separate for tubes & shell) As per PO

Pressure

hold

method

100% W 100% W W

14 Painting As per PO Visual 100% W 100%

R R

15 Filling with dry nitrogen at 0.5

bar (g) As per PO

Gauge

reading 100% W 100% W R

16 Stamping of the vessel and issue

of certificates As per PO Visual 100% R 100% W R

17 Verification of Material test

certificates As per PO Review 100% R 100% R R

18 Insulation As per PO Review 100% R 100% R R

19 Removal of existing WHRB As per PO Review 100% R -- R

20

Mounting of WHRB at site at

identified location &

commissioning including IBR

certification on mounting of

new unit at PCR

As per PO Review 100% W 100% W W

21 Production master file As per PO Document 100% R -- R

Legend: R – Review, W – Witness, H – Hold. Note:

The purchaser reserve right to participate in the Inspection at any stage of fabrication & the supplier has to intimate the work progress periodically.


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ANNEXURE-II PROCEDURE FOR CLEANING & PAINTING

i) Mechanical Cleaning: All metallic surfaces inside and outside having scales and foreign materials and all welded

surfaces shall be cleaned. This can be done by scrubbing with metallic brush (Stainless

Steel) followed by buffing to get a polished surface. The loose scales and powders

obtained from the above process shall be cleaned by blowing, sucking or washing with

water. Mechanical cleaning and buffing shall be carried out after stress relieving, but before hydro test.

ii) Method for: a) Degreasing :

Degreasing has to be done by soaking in acetone at 60 Deg. to 70 Deg. C for at least 2 hours

or till satisfaction.

b) Passivation: The composition of passivation solution shall be as follows;

Sodium nitrite : 1 to 2%

Di-sodium hydrogen phosphate : 0.5 to 1%

Water : Balance %

Temperature : 70 deg. C

Duration :2 to 3 hours

c) Pickling:

The composition of pickling solution shall be as follows;

Hydrochloric acid : 5 to 15%

Inhibitor : 0.5 to 1%

Non-ionic wetting agent : 0.005%

Water : Balance %

Duration : 2 to 6 hours

Temperature : Ambient

The bath solution shall be changed if the level of iron in the batch reaches 8 g/liter

d) Drying The drying is done to remove water and this is done as given below:

Passing dry Nitrogen /Air having dew point less than –40 Deg. C and free from oil and grease

(less than 10 PPM) at 60 Deg. C till the moisture level at the exit comes to the inlet concentration

value.

e) Painting Carbon steel surfaces to be sand blasted & TWO coats of Red Oxide Primer to be applied

120 to 130 microns DFT followed by 30-40 microns of finish coat on outer surface of the

vessel.


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Annexure-III

FORMAT TO BE FILLED BY THE BIDDER

Sl No Description Confirmation

1 Design code

2 Design pressure

3 Stress value considered at Design temperature for design of

equipment

3.1 100% UT of plates/pipes as per applicable standard (If done at plate

mfg. Plant, with TPIA witness)

4 Allowance considered:

i) Corrosion allowance

5 Thickness selected: shell (including CA)

6 Material of Construction as per Table-I or equivalent, as approved

by purchaser

7 Welding Process as per drawing

8 Body Flange thickness and No. of joints (if any) and process

considered as per indent specifications

9 Radiography: (As per drawing)

10 Stress relieving before Hydro test at 593 deg.C

11 Mechanical cleaning

11.1 Degreasing

11.2 Surface preparation & painting of epoxy primer

12.1 Hydraulic testing of WHRB (both tube & shell side) as per design

code

12.2 Pneumatic testing both side of the equipment

13.1 Name of IBR authority that will be engaged during the course of

entire work

13.2 IBR authority inspection charges quoted separately in the price bid

(Don’t mention charges here)

14 Acceptance of proposed QAP, Approved QAP as approved by IBR &

Purchaser to be followed by successful bidder

15 Removal of existing Waste Heat Recovery Boiler from the plant and mounting of new unit after fabrication and testing.


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Annexure - IV

VENDOR EVALUATION FORMAT

The Bidder must submit the following table with documentary proof to confirm his acceptance

to meet the requirements detailed above, without which the offer will not be considered.

SR.

NO.

DESCRIPTION To be filled / confirmed by

the bidder

1. Name of Company

2. Address of Company

3. Type of Company (Proprietary/Pvt. Ltd /Public

Ltd/Joint Venture/Consortium)

4. Registration number

5. Year of inception of the company

6. Registered address

7. Name & address of the office of the Chief Executive

of the company

8. Name & Designation of the officer of the Bidder to

whom all correspondence shall be made for

expeditious technical/ commercial co-ordination.

Telephone number

Fax number

E-mail address

9. Bidder’s previous track record: The Manufacturer

should be a Company/Society/Firm registered

since last 3 (three) years or more.

10. Locations of the Branches of Company (if any)

11. Annual turn-over of the company for the last three

years

12. IT returns for the last 3 years

13. Enclose copies of the similar Purchase Orders

executed


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SR.

NO.


the bidder

14. Quality certification of the company

15. PAN Card Copy

16. The Profit & Loss Account details for the last 3

years which is duly audited and Submitted as part

of the Annual Report

17. Name of the IBR approved agency

18. IBR Approved agency inspection charges quoted

separately

19. Acceptance for Scope of work as detailed above

20. Acceptance of QAP & Inspection Clauses

mentioned in the respective annexure

21. Acceptance for Sequence of Design, Fabrication,

Erection, Testing & qualification, Commissioning,

Mechanical cleaning, pickling & passivation as per

tender specification including Removal of the

existing Equipment

22. Acceptance for the General conditions & terms as

per tender specification under 3.0

23. Details of purchase orders executed under IBR inspection to be submitted, if any

24. The bidder should not have been blacklisted by

Central Government or any State Government

organization / department in India at the time of

submission of the Bid (Self-declaration has to be attached)

25. Confirm acceptance of the Delivery schedule as per

the contract

26. Visit by Purchaser: During the Technical

evaluation of the Tender, if required the purchaser

has right to visit the bidder’s facilities to Clarify /

confirm the documents /claims submitted by him.

It is the responsibility of the bidder to submit

necessary supporting documents / to show his

facilities.

27. Supplier shall agree to all the terms and conditions

of the indent specifications

28. TWO PART BID: Bidders shall quote the tender in

two-part bid basis. Technical bid shall be evaluated


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SR.

NO.


the bidder

first, only technically suitable bidders shall be

allowed for price bid.

SIGNATURE :

NAME :

DESIGNATION:

DATE :


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Annexure V

EXCEPTIONS 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

Purchaser Spécification

Offered Spécification

DEVIATION

PAGE

NO CLAUSE

NO

NOTE : Only deviations are to be written in this Annexure.

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 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 Bidder 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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Annexure - VI

TENDER ACCEPTANCE LETTER

(To be given on Company Letter Head & Uploaded on website)

Date:

To,

SPSO, SDSC SHAR

Sub: Acceptance of Terms & Conditions of Tender.

Tender Reference No: ________________________

Name of Tender / Work: - .

Dear Sir,

1. I/ We have downloaded / obtained the tender document(s) for the above mentioned

‘Tender/Work’ from the web site(s) / Through Post.

2. I / We hereby certify that I / we have read the entire terms and conditions of the tender

documents of all pages (including all documents like annexure(s), schedule(s), etc.,), which

form part of the contract agreement and I / we shall abide hereby by the terms / conditions

/ clauses contained therein.

3. The corrigendum(s) issued from time to time by department/ organization too has also

been taken into consideration, while submitting this acceptance letter.

4. I / We hereby unconditionally accept the tender conditions of above mentioned tender

document(s) / corrigendum(s) in its totality / entirety.

5. I / We do hereby declare that our Firm has not been blacklisted/ debarred by any Govt.

Department/Public sector undertaking/Private organization.

6. I / We certify that all information furnished by the our Firm is true & correct and in the

event that the information is found to be incorrect/untrue or found violated, then

department/ organization shall without giving any notice or reason therefore or summarily

reject the bid or terminate the contract , without prejudice to any other rights or remedy

including the forfeiture of the full said earnest money deposit /Security deposit or both

absolutely.

Date:

Place: Signature of authorized person

Full Name & Designation:

Company’s Seal


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Annexure – VII

Check-list to be filled by the bidder and to be uploaded under vendor solicited documents

Sl. No.

Description / Specification Bidder Response / Compliance information

1 The scope of work involves Design, Fabrication, Inspection, Testing, Supply,

Erection & Commissioning of Waste Heat Recovery Boiler (WHRB).

2 The intended WHRB is proposed to be a one – to – one replacement of existing

unit in the operational CNA / N2O4 plant. Hence the new unit has to be

dimensionally correct and performance shall match the requirements of the

existing unit.

3 In the technical bid, bidder shall enclose the copies of design reports of similar

work carried out earlier to ascertain the bidder’s design capabilities.

4 If any advanced features based on the modern improvements in Design are to

be implemented mainly to address the operating conditions (as mentioned

under 2.4 of this document), the same shall also be proposed in the technical

bid.

5 Mechanical Design shall be approved by IBR

6 Overall dimensions and nozzle details shall be as per attached drawing. This

drawing is only meant to indicate the dimensions of the existing unit

7 The detailed fabrication drawing as per approved design of new unit and

having outer dimensions equal to existing unit shall be proposed by the

successful bidder

8 The detailed specifications are as per tender specification document for

Design, Fabrication, Inspection, Testing, Supply, Erection & Commissioning of

Waste Heat Recovery Boiler to Propellant complex, Rasayani, ISRO (PCRI), Govt. of India, Dist.; Raigad, Maharashtra PIN-410207

9 The scope of work also includes the removal of existing Waste Heat Recovery Boiler from the plant. The bidder shall arrange necessary

equipments & resources to execute the removal of existing Waste Heat Recovery Boiler. The schedule of these works for execution shall be

discussed with the purchaser and to be finalized before dispatch of the new unit to PCRI

10 Quantity Required – 01 Unit

11 2. Design Inputs:

Technical Data

2.1

Type Waste heat Recovery Boiler is of Horizontal Cylindrical type with Welded Dished ends with

adequate number of tubes (shell and tube heat

exchanger)

2.2 Design &

Construction

a. Code for WHB design shall be ASME SECTION VIII DIV 1; TEMA - B and as per IBR with latest editions of all these standards / codes


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Sl. No.


2.3 b. Allowable Stress: Based on the material with a minimum Factor

Of Safety of 4.

c. Design data for WHRB

Shell side Tube side

Operating fluid Water / Steam Nitric Oxide gas

Flow rate 2540 + 5 kg/hrs 8337 + 5

kg/hrs

Operating temperature (o C),

In/Out

218/218 + 5 Deg.

C

840 /240 + 5

Deg. C

Design Pressure kg/cm sq.(g),

In/Out

22 / 22 - 0.015 / -0.031

Design Pressure kg/cm sq.(g) 25 -0.05

Design temperature (o C)

• Generally decided based

on IBR rules

As per IBR rules

350 Deg. C preferred

Hydraulic test pressure (Kg/

cm2 (g))

At 37.5 ksc – Shell side

At -0.075 ksc – Tube side

Joint efficiency 0.9

Radiography 100%

Corrosion allowance (mm) 1.5 1.0

Heat treatment (PWHT)

Stress Relieving as per UCS 56

of ASME sec VIII div. 1 code

Yes NIL

Number of passes 1 1

Wind Load 150 kg/sq. metre

Insulation 80 mm thick, Rockwool (Density:

100kg/mm2)

Earthquake factor 0.04

2.4 Operating Conditions: • During Burner Light Up

(happens every 3rd / 4th

day) the temperature of the

process gas in burner

section raises steeply from

570C to 8400C within 20

minutes.

• WHRB is at ambient

temperature before startup.

Hence, before the burner

light up preheating of


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Sl. No.


WHRB is being done by

injecting steam to WHRB

and burner basket to raise

the temperature from

ambient to about 1000C.

2.5 Engineering Data of existing

WHRB • Surface Area: 197m2

• Heat exchanged: 1245000

kcal/hr

• Mean temperature

difference corrected: 1610C

• Overall Heat transfer

coefficient: 42 kcal/m2 hr 0C

• Empty Weight:6950 kgs

• Weight with full of

water:9950 kgs

2.6 Material selection • Proposed materials are as

per Table-1. However,

designer may propose

superior alternative

materials, if any, in the

technical bid itself for the

consideration of the

purchaser along with

separate proposal in the

commercial offer.

12 Additional Requirements of Material selection, Design, Fabrication & Testing

2.23 The raw materials for tubes and tubesheets shall be produced by

electric arc melting process.

2.24 Autogenous welding process: Only automatic TIG is acceptable by

orbital welding machine

2.25 WHRB consists of LHS & RHS tubesheets in which tube holes are to be

drilled in a circular pitch. Each hole shall be provided with two inside

grooves at a distance of 10mm & 20mm from the inner face of

tubesheets for additional longitudinal load resistance of tubes.

2.26 The tubes shall be rolled & seal welded to tubesheets at both the ends.

2.27 The strength rolling (7-10% thinning) of tubes is carried out during

which expanded tubes grips inside the grooves. This arrangement also

acts as a mechanical seal for arresting the entry of water into the gap

between the tube OD & tubesheet hole. Thus, deep crevices are

eliminated in the design by strength rolling of tubes in the tubesheets.

2.28 Face grooves are machined with tight tolerances on face of each hole

on the tubesheet which provides a thinner section for seal/lip welding

to get the desired weld profile. This also helps in minimizing the heat

input required for seal welding and makes a perfect fusion of the base

materials (tube & tubesheet).


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Sl. No.


2.29 Even though conventional heat exchanger tube to tubesheet joints are

executed first by welding and then rolling, WHRB tube to tubesheet

joints are proposed first by rolling by using mechanical tube expanders

and then single pass seal welding by automatic pulsed TIG welding

process without addition of filler wire.

2.30 This is to avoid probable stresses induced in the welds during tube

expansion step which may result in subsequent failure of the weld

joints during transient WHRB operating conditions.

2.31 The automatic welding process ensures repeatability & consistency in

quality of tube to tubesheet weld joints.

2.32 The process parameters of welding like pre - purge time, up slope,

speed of welding, down slope, post purge time. The weld quality with

respect to shape and soundness shall be controlled by process

parameters.

2.33 Tube to tubesheet seal welding shall be carried out by autogenous

pulsed TIG process after rolling. The seal weld is subjected for visual

examination and fluorescent LPE as per ASTM E-165 type-1, method C

for examination of lack of fusion at the edge of hole in the tubesheet,

surface pores, cavities, cracks etc.

2.34 Tubes to be expanded before and after tube to tube-sheet welding.

2.35 Tube Pitch is to be considered as triangular pitch.

2.36 Baffle are to be considered for tube support, care should be taken for

water circulation.

2.37 Construction and workmanship to be followed as per IBR / ASME

requirements. 13 Welding shall be carried out by autogenous pulsed TIG process after rolling

only. Orbital welding machine shall be used.

14 a) Radiography : Spot – 10% + all T joints. All welds shall be DP tested.

The dye used for Dye-penetrant test shall not have chlorides more than

50 PPM (Preferable brands: Magnaflux / Checkmate).

b) Radiographs have to be carried out using x-ray Source with a sensitivity

of 2-2T as per ASME sec V.

15 Heat treatment (PWHT): Stress Relieving as per UCS 56 of ASME sec VIII div.

1 code at 5930C with a hold time of 1 hr. shall be carried out for shell only.

16 a) All materials used shall be tested as per Code in the Reputed Govt.

approved testing labs before fabrication.

b) The plates/pipes/tubes used for construction of Equipment shall

also be ensured free from any lamination and manufacturing defects by 100% ultrasonic testing as per Practice ASTM A-435.

c) Material Test certificates shall be furnished to purchaser for approval

before start of fabrication.

17 Hydraulic Pressure Test

18 Pneumatic Leak Test

19 The recommended cleaning procedure to be followed for the fabricated

equipment shall be as per Annexure – II

20 The bidder shall fill the proforma as per Annexure- III and submit along with

technical offer.


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Sl. No.


21 The waste heat Recovery Boiler shall be fabricated under the inspection of IBR

Authority.

22 At the time of submitting technical bid, party shall quote the names of IBR

authority that will be engaged during the course of entire work.

23 At the time of submitting technical bid, party shall attach documentary

evidence indicating IBR approval of the fabrication shop

24 If the bidder is not a manufacturer, then bidder shall attach Authorized dealer

certificate or a valid partnership agreement or technical collaboration

agreement or authorized designer – business relationship agreement between

designer & fabrication agency along with technical bid

25 Bidder shall enclose his/her credentials demonstrating Design Capabilities of

Waste Heat Recovery Boiler or similar IBR inspected heat exchanger or

equivalent equipment in the form of earlier works executed with the

documentary evidence.

26 IBR Authority Inspection charges for both at Manufacture’s site as well as

purchaser’s erection site shall be quoted in the price bid. (Charges will be paid

against submission of documentary evidence. The charges will be paid “on

actuals” or quoted price, whichever is lower)

27 Delivery: e. Transportation, Erection and commissioning shall be carried out

by the bidder at Propellant Complex Rasayani, Tal.: Panvel, Dist.:

Raigad, PIN-410207, Maharastra. f. All necessary Equipments like welding machine, Gas cutting set,

Grinding M/C, etc, and Consumables like Welding Electrodes, Gases,

Grinding Wheels, paints, brushes, etc., including material handling

support, skilled and semi-skilled labour required for carrying out the

above work shall be in the scope of the bidder.

g. During activities at Propellant Complex Rasayani, Electrical supply for

welding, Drilling/Grinding etc., shall be provided at a

single point at free of cost by the purchaser. However further

distributions shall be made by the contractor thorough proper

distribution boards which meets the safety standards.

h. The equipment shall be fabricated, tested and delivered within 4

months from the date of PO release. All open ends of nozzles shall be

dummied with end caps / blinds at the time of delivery.

28 Technical Qualification Requirements:

c. The bidder shall meet the technical specification and other

requirements and shall submit relevant certificates to establish his

credentials.

d. The Bidder shall be a party who has already executed similar /

identical works with minimum 3 years of experience in executing similar fabrication works of boilers, heat exchangers, etc. under the IBR authority inspection and having IBR approved fabrication

shop

29 Financial Qualification Requirements:


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e. Documentary proof shall be submitted with the offer indicating

execution of at least one order of value of Rs. 30 lakhs or two orders of

value of Rs 20 Lakhs each or three orders of Rs. 15 Lakhs each during

preceding three Audited financial years.

f. IT/ TDS certificate shall be submitted with Loss & Profit statement for

previous three years.

g. Bidder shall submit audited statement of financial status for previous

three years. h. Bidder shall submit audited statement of financial status for preceding

three years 30 The following documents shall be submitted along with the bid for

prequalification of Bidder:

e. Firm establishment certificate and nature of work or the documents as

listed under 2.29 of this document.

f. Details of work of similar type completed by providing copies of

purchase orders.

g. Satisfactory work Completion certificates from the clients, with the

work order copies

h. Copy of the purchase orders related to similar type of works under

Execution, if any, with purchase order name and address.

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