general as per tender query reply -...

5th September 2009

GENERAL As per tender Query Reply

TIME SCHEDULE

1. TIME SCHEDULE Mechanical completion within 13 (Thirteen) months from the date of LOI Trial run and Commissioning within 1 (one) month from the date of advice

The proposed cogen power plant commissioning shall be 16 months from the date of LOI/PO along with requisite advance

Delivery schedule to remain same.

PROJECT INFORMATION

2. Construction power and water is in the scope of EPC vendor.

Kindly furnish the tariffs for Construction water & power.

No tariff is applicable. Contractor to make its necessary arrangements.

3. Appendix - II Proximate & Ultimate analysis of Biomass fuels

a) Please note that, fuel analysis provided in the tender specification for biomass fuels (Julia flora, Rice husk & Cane trash) is in a range and the sum of the constituents does not match with 100%. Also sulphur percentage is not indicated. Hence we request you to furnish the complete proximate and ultimate analysis along with ash fusion characteristics (if available) (matching to 100%) along with GCV for all the fuels. b) Also furnish the complete proximate and ultimate analysis along with ash fusion characteristics (if available) for stored bagasse (to be used during off season).

This will be provided to select bidder for detail engineering. The boiler will be designed for bagasse as principle fuel and mentioned biomass will be used as supplementary fuels.

4. Appendix – XVI

RAW WATER ANALYSIS Kindly mention the reactive silica and colloidal silica value

The same may be assumed as 50:50, for design purposes.

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CHAPTER 1: DESIGN BASIS, SCOPE OF WORK, TERMINAL POINTS, PERFORMANCE GUARANTEE

1.1 DESIGN BASIS

5. 1.1.1 / 2 of 554

Feed water temperature °C: 210

Kindly specify the feed water temperature to the economiser to be considered as 210 or 220 °C

220°C

6. 2.1.4 / 176 of 554

Feed water temperature to economiser 220°C

220°C

7. 1.1.3 / 3 of 554

Ambient Conditions (d) Plant Design Wet Bulb Temperature : 27 Deg. C

Kindly clarify wet bulb temperature to be considered as 27°C or 28°C.

27°C

8. 1.1.6.4 / 13 of 554

The specified design wet bulb temperature of 27.5 C includes the necessary recirculation allowance.

27°C

9. 2.7.1 / 315 of 554

while operating under the atmospheric wet bulb temperature of about 28 Deg. C.

27°C

10. 1.1.1 / 2 of 554

Boiler capacity, TPH – 1 x 100

As per the HMBD enclosed along with tender specification the turbine inlet steam is mentioned as 100 TPH. Considering 5% VWO and 3% aging margin over and above the actual steam requirement, the required boiler capacity would be 108 TPH, However as per clause no. 2.1.4, page no: 176 of Technical basis we have considered the boiler capacity as 110 TPH. Kindly confirm.

110 TPH

11. 2.1.4 / 176 of 554

Maximum Continuous rating kg/hr: 110,000

110 TPH

12. 1.1.4 / 4 of 554

Bio-gas available from distillery as fuel (equivalent bagasse) - 2.08 TPH

Kindly clarify whether we have to consider Bio-gas firing system in our boiler design. Also furnish available biogas quantity and its analysis. Kindly clarify the term “equivalent Bagasse”

Biogas firing system to be considered. Equivalent baggase means @ 2250kcal/kg

13. 1.1.4 b / 5 of 554

The Cogeneration plant will also be designed to operate with other fuels like sugarcane trash, rice husk and maize cobs in

Since there is no specific requirement of bunker in the specification, we presume that rice husk fuel is fed along with biomass fuels in

Yes

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combination with bagasse. silo provided for the same. Kindly confirm.

14. 1.1.3 / 4 of 554

Soil Bearing Capacity* : 12 ton/m² at 2 m from NGL

Kindly clarify us whether the site Requires Pile Foundation or not. If the site requires the Pile Foundation, Kindly provide us the soil investigation report with bore hole (soil layer) details for the proposed site for us to estimate the Pile Foundation works.

Pile foundations may be required for some critical foundations. However as mentioned in the tender document, the EPC Contractor will have to carry out the necessary investigations for the same.

15. 1.1.6.2 / 10 of 554

Extraction parameters, No of Extractions, Steam Flow 3 extractions at 25 kg/cm², 8 kg/cm² and at 2.5 kg/cm². Bleed at about 25 kg/cm² is only for HP heater no. 2. Bleed at 8 kg/cm² is for HP heater no.1 and to supply 20 TPH to ethanol in season. Extraction at 2.5 kg/cm² is for deaerator and supply of 32 TPH steam to sugar process in season. Appendix XVII provides the HBD

As desired by you, we shall design the TG with normal process steam during season as per the HBD furnished below. Bleed –I : 7 TPH @ 25 ata for HP heater -2, Bleed –II : 27.5 TPH @ 8 Ata for HP heater 1 & process steam to ethanol of 20 TPH Bleed –III : 36 TPH @ 2.5 Ata for deaerator & process steam to sugar process of 32TPH . However, we request you to provide the maximum process steam requirement during season for both 8 Ata and 3 Ata extraction pressure. Kindly provide the process steam temperature and pressure at battery limit (at process point). Also we request you to provide the process condensate return quantity, quality and its temperature (for all conditions).

As per para 2.2.6.5 7& 2 ata Please refer HMBD

16. 2.2.6.5 / Extraction steam requirements

Season

Off-season As per tender

4


229 of 554 Bleed at 25 Kg/cm² for HP heater no.2

7000 5300

Extraction at 8kg/cm2 Season

Off-season

Maximum Kg/Hr Normal Kg/Hr Minimum Kg/Hr

Upto 3500

0 2750

0 Nil

Upto 20000 16000

Nil

Controlled Extraction at 3 kg/cm2

Season

Off-season

Maximum Kg/Hr Normal Kg/Hr Minimum Kg/Hr

Upto 4500

0 3600

0 5000

Upto 10000 5600 Nil

Flow through condenser kg/hr

Min. cooling

steam

flow to

generate

alternator capacity

Normal as

required to

generate 20

MW

As required To generate, alternator

capacity

17. 1.1.6.4 / 13 of 554

The motor rating of the cooling tower fans shall be at least 125% of the fan power requirement at the motor output shaft to take care of any changes in tower loading

We have considered 10% margin over and above the required shaft power to deliver the rated capacity at rated pressure for motor selection. Kindly clarify.

Agreed

5


or fan performance at a later date, Tenderer shall furnish calculations for arriving at the motor rating.

18. 1.1.6.5 / 12 of 552

Tenderer will also provide borewells at locations provided by the Owner / Consultant and connect the same to the day reservoir before the water treatment plant. The total capacity of the borewells should be 3000 m3/day

We have not considered borewell of capacity 3000 m3/day, transfer pump and its piping upto ground water reservoir in our scope. Our scope starts from the outlet header of Ground water reservoir.

Required as per tender

19. 1.1.6.5 / 12 of 552

Raw water will be drawn by the Tenderer from the delivery header of the raw water transfer pumps at the ground water reservoir.

Required as per tender

20. 1.1.6.9 / 23 of 552

Insulation High grade insulation materials suitable for out door Steam generators shall be supplied, ceramic blanket with mineral wool of multilayer with aluminium cladding, water proof lagging and protected from rain water, wind and Dust etc. for the exposed portion of the steam and mud drums, steam generator furnaces, integral pipe work from the feed pumps to the steam generators, steam & exhaust piping, hot air & gas dusting, condensates pipes, valves having high temperature fluids & hot water / condensates feed water tank, de-aerated water tanks, and other steam generator accessories to be provided.

We have considered plain aluminium cladding of thickness 22 SWG only for steam piping. Other than steam piping we have considered 24 SWG thickness plain aluminium cladding.

Agreed

21. 1.1.6.15 / 35 of 554

ii Excavation :- Excavation will include earth, weathered rock and hard rock.

Kindly provide us the soil investigation report with bore hole (soil layer) details for the proposed site, for us to estimate the extent of rock

As mentioned in the tender document and clarified earlier, all soil investigations will have to be carried out by the EPC Contractor.

6


blasting works.

22. 1.1.6.15 / 39 of 554

Site Clearance The site of the works shall be cleared of all trees, bushes and vegetation. Trees and bushes shall be uprooted and raked into windrows and burnt.

As we are unable to calculate the quantum of works to be removed during the proposal stage we are excluding the same from our scope.

It is expected that the EPC Contractor visit the site and estimate the quantum of the works. The same cannot be excluded from the scope of the tender.

23. 1.1.6.15 / 99 of 554

Concrete Block Walls Concrete block walls shall be built with new hollow concrete blocks laid and bonded with mortar

Considering the shorter delivery period for the project, we are unable to manufacture concrete block in the site. Hence we will use Brick for Masonry work.

Agreed

1.2 SCOPE OF WORK

24. 1.2 / 172 of 554

All required civil works for soil investigation, dismantling of any balance RCC structures or columns

Kindly furnish us the quantum of Structures / Buildings to be dismantled for us to estimate the demolition works.

Over all information available in the layout.

25. 1.2 / 173 of 554

p. Obtaining all required statutory approvals for construction of cogeneration plant including local body approval for construction of cogeneration plant electrical inspectorate approval for power evacuation scheme, IBR approvals, labours commissioner, excise, factory inspector as applicable, electrical inspector for electrical works, required approvals for synchronizing with grid, providing stability certificate as per local norms, registration & payment of all taxes & duties for tenderers’ staff & labour, as per all applicable laws, etc. Statutory fees, if any, will be paid by the Owner and applications required, if any will be paid by the Owner.

We have considered IBR approval & electrical inspectorate clearance in our scope of work. However, we shall render technical assistance for getting other statutory approvals.

Additionally all approvals required for carrying out the EPC job will necessarily be in your scope. Owner will provide required documents to the contractor.

1.3 TERMINAL POINT

26. 1.3 / Bagasse – at inlet of BC-1 Kindly furnish the Bagasse There is no existing sugar mill

7


173 of 554 handling tapping point height and also furnish the existing tapping point details with drawings.

and new sugar mill will be constructed.

27. 1.3 / 173 of 554

Outside Biomass - At 0 m level in bagasse yard

For biomass at yard, our scope starts from the inlet of hopper and ends with top of biomass silo. Feeding of biomass to hoppers by pay loaders or dozers is in customer scope (including pay loaders).

Agreed

28. 1.3 / 174 of 554

TERMINAL POINTS Steam supply Upto and including MP & LP headers located towards sugar side of the power house at 1.5 m level from FFL with tappings and valves. Required tapping on MP header for ethanol is for 25 TPH and required tapping on LP header for sugar is for 40 TPH.

We request you to provide the length of process steam pipe from proposed power plant boundary to Process centre (sugar mill header and Ethanol plant header) & also provide pressure & temperature of process steam (MP & LP) required at process centre.

Pls refer layout

29. 1.3 / 174 of 554

TERMINAL POINTS Condensate At outlet header of condensate transfer pumps in evaporation and juice heater area of sugar mill (35 m³/hr, 40 m head)

We request you to provide the process condensate return quantity, quality and its temperature (for all conditions).

Pls refer HMBD

2. TECHNICAL SPECIFICATIONS FOR MECHANICAL & ELECTRICAL EQUIPMENTS, INSTRUMENTATION & CONTROL AND ERECTION AND COMMISSIONING

2.1 STEAM GENERATOR & AUXILIARIES

30. Appendix - II Proximate & Ultimate analysis of Biomass fuels

a) Please note that, fuel analysis provided in the tender specification for biomass fuels (Julia flora, Rice husk, Maize cobs & Cane trash) is in a range and the sum of the constituents does not match with 100%.

This will be provided to select bidder for detail engineering. The boiler will be designed for baggase as principle fuel and mentioned biomass will be used as supplementary fuels.

8


Also sulphur percentage is not indicated. Hence we request you to furnish the complete proximate and ultimate analysis along with ash fusion characteristics (if available) (matching to 100%) along with GCV for all the fuels including corn cobs. b) Also furnish the complete proximate and ultimate analysis along with ash fusion characteristics (if available) for stored bagasse (to be used during off season).

31. 2.1.4/181 2.1.23/202

Feed water temperature to economiser:220°C Deaerator outlet temperature : 110°C – 130°C Tenderer to supply suitably designed (as per ASME / equivalent code) heat exchanger to preheat the de-aerated water from 115°C / 125°C to 220°C at MCR conditions.

Kindly confirm the feed water temperature at the outlet of Deaerator.

115o C

32. Tech. Spec. Page No:8, Clause No: 1.1.4

Bio-gas available from distillery as fuel (equivalent bagasse) - 2.08 TPH

Kindly clarify whether we have to consider Bio-gas firing system in our boiler design. Also furnish available biogas quantity / Kindly clarify the term “equivalent Bagasse”

Biogas firing system to be considered. Equivalent baggase means @ 2250kcal/kg

33. 2.1.3 / 180

ID, FD & SA fans with vibration isolators and VFD for ID, FD and SA

We have considered vibration isolators for fans from the suction & discharge ducting. However we have not considered vibration isolators for fans from the ground, which is not required for this small size fans.

Agreed

34. 2.1.1/180

The principal fuel will be bagasse or biomass. Biomass in general would include

Since we anticipate corrosion in superheater due to Chlorine content present

Agreed

9


1.1.4.b./9

sugarcane trash, rice husk and maize cobs. However during off season bio-mass fuel sugarcane trash, rice husk and maize cobs are envisaged to be used depending upon the availability.

in biomass fuels, we request you to restrict the maximum %MCR firing of biomass (Rice husk, Julia flora, Corncobs & Maize cobs) will be 10-20% MCR along with stored bagasse.

35. 2.1.4/181 2.1.4 /182 2.1.13/194

Temperature of flue gas at the outlet of air pre-heater: 150°C at MCR The Air pre-heater and economiser shall be designed so as to give final flue gas temperature within 140°C. The air pre-heater and the economiser shall be designed so as to give flue gas temperature within 150°C at the outlet of the air pre-heater.

We have considered the flue gas temperature at the outlet of airheater as 150°C, while 100% Bagasse firing.

Pls consider 140o C

36. 2.1.6.1/184 The front and rear wall tubes will be stub welded to respective bottom headers and expanded into the drum.

Since the proposed boiler is of single drum design, we have considered header to connect front and rear wall tubes instead of expanding into the drum.

Agreed

37. 2.1.6.2/185 STEAM GENERATOR BANK TUBES The tubes will be of HFS construction.

We have considered evaporator tube material as SA 210 Gr.A1 cold drawn Seamless (CDS) instead of HFS. .

Agreed

38. 2.1.11.1/189

The distributor or feeders could be mechanical or pneumatic and with AC variable frequency drive.

Since the fuels for proposed boiler are Biomass only, mechanical spreaders are not required. However pneumatic distributor will be provided which does not require any drive

Agreed

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arrangement.

39. 2.1.11.1 /189

The bagasse silo must have SS lining for smooth flow.

Since convergent- divergent chute is envisaged, we have not considered SS lining inside the silo.

Agreed

40. 2.1.12/192 Cinder re-injection system prior to economiser to be provided.

We have considered the cinder re-injection system below economiser in order to optimize the boiler layout.

Agreed

41. 2.1.18/198 The Secondary Air or cinder re-injection fan & Primary Air Fan shall be two (1SA+ 1 PA) in number shall be of constant speed, horizontal, radial, backward curved or aerofoil bladed and electric motor (squirrel Cage TEFC) driven.

Since primary air fan is not applicable, we have not considered PA fan. However we have considered 1 x 100% MCR SA fan with VFD. Also we have considered 1X100% Cinder re injection fan with constant speed drive in our scope.

Agreed

42. 2.1.21/201 2.1.26.3/224

Main FW control valve shall be pneumatically operated, by pass valve could be either pneumatic or motorized and pneumatic valve for lower sizing (around 30%) The feed regulating valves shall be capable of being operated in auto manual regimes from the control room. It is preferred to have the operating valve as pneumatic, standby as pneumatic and manual valve at 30% capacity.

We have considered following valves at feed control station and spray control station. 1x100%: Pneumatic control valve with upstream and down stream manual isolation valves. 1x30% : Pneumatic control valve with upstream and down stream manual isolation valves. 1x100%: Motorised bypass valve. For spray control station (For each desuperheater) 1x100%: Pneumatic control valve with upstream and down stream manual isolation valve. 1x100% Motorised bypass valve.

Agreed Agreed Agreed

43. 2.1.26.3.(o)/

Silencer for super heater safety valves and start-up

We have considered silencer for SH safety valve and

Agreed

11


224 vent.

S/V exhaust to be taken out from the roof of building with silencer.

startup vent only. We have not considered silencer for drum safety valves since the operation of the same is remote.

44. Chapter – 4/491

APPROVED LIST OF VENDORS

May please note that, we have considered our own make for the products which falls in our product range such as ESP, fans, deaerator cum storage tank, metallic expansion bellows, air & flue gas dampers, dosing tank, silencer, orifice plates, junction boxes, traveling grate etc. Kindly note that, we have indicated additional subvendors alongwith subvendors list furnished by you in the tender document. The same is enclosed vide Annexure-II

Agreed List of sub-vendors as per tender document

45. 1.1.4.b./9 The Cogeneration plant will also be designed to operate with other fuels like sugarcane trash, rice husk and maize cobs in combination with bagasse.

Since there is no specific requirement of bunker in the specification, we presume that rice husk fuel is fed along with biomass fuels in silo provided for the same. Kindly confirm.

Confirmed

46. Appendix XV

Electrical system requirements for motor selection SITE ALTITUDE: 350 Meters for Lauriya and Sugauli Projects.

As per the tender specification Clause No: 1.1.3, Page no: 7, the site elevation (71 M for Lauriya project & 61 M for Sugauli project) for mechanical equipments design varies considerably with electrical equipments design. Kindly confirm the same in order to design our boiler draught system correctly and to avoid over sizing.

71 M for Lauriya project & 61 M for Sugauli project

ELECTRICAL & INSTRUMENTATION DEVIATIONS

47. The noise level shall not We have not considered Agreed

12


2.2.6.13/236 exceed 85 dbA silencers except for super heater & start up vent valve. Hence the required noise level of 85 dBA cannot be maintained for other relief valves. The noise level of boiler feed pumps without motors shall be 95-100 dBA as per the approved vendor.

2.2 STEAM TURBINE GENERATOR & AUXILIARIES

48. 1.1.6.2 / 9 of 554

Basic Design Parameters for the design: Water Cooled Condenser Operating Pressure (ata) 0.1 (in off-season)

Kindly furnish the type of condenser (Air cooled or water cooled condenser) for the proposed power plant and exhaust pressure to be considered during Season and Off Season conditions.

Water Cooled condenser. To be designed for 0.1 ata exhaust pressure in off season conditions

49. 2.2.2 / 222 of 554

(viii) Air cooled condensate system complete with required vacuum breaker, rupture disc, tube bundles, fans with VFD, drains, vents, structures, air ejectors, condensate collection tank, CEP, condensate controlled station, etc.

Please read as water cooled condenser

50. 2.2.2 / 222 of 554

ix. Interconnection between the turbine and the inlet of air cooled condenser.

Please read as water cooled condenser.

51. 2.2.6.4 / 229 of 554

Exhaust pressure with air cooled condenser: Performance guarantee – 0.1 ata


52. 2.2.6.5 / 230 of 554

Condensing pressure as achieved by Tenderers design, with given cooling water temperature. For evaluation purpose, the same to be 0.1 ata

Agreed

53. 2.2.12 / 242 of 554

Condenser


54. 2.2.2 / 222 of 554

x. Gland sealing steam system consisting of gland steam condenser, valves, steam jet ejectors etc.

Gland Condenser is not offered as it is not required since quantity of leak steam is very minor.

Gland steam condenser is required.

55. 2.2.2 / xviii. Automatic exhaust hood The same shall be as per The same is required and

13


223 of 554 spray system. supplier standard. provided by all approved suppliers. The same is required during sudden grid tripping and shift to only home load.

56. 2.2.2 / 224 of 554

xxxiii. EOT crane of adequate capacity to lift the heaviest component during maintenance, along with all electrical, rails, girders, etc suitable for erection.

We have considered one no. EOT crane considering lifting of single heaviest component for maintenance purpose in our scope and separate crane will be engaged for erection.

Agreed

57. 2.2.5 / 228 of 554

as per normal steam flow rates from the double extraction cum condensing set.

The steam turbine shall be a triple extraction cum condensing type

Agreed

58. 2.2.6.13 / 231 of 554

The maximum noise pressure level at 3.0 m distance for any equipment from the equipment surface shall be equal to or less than: 85 db (A)

The predicted noise level of listed equipments measured at 1 meter distance is furnished as below: Start up and SH Vent Silencer outlet : 110 dBA at 5 M distance Boiler Feed pump : 90 dBA

Agreed

59. 2.2.9 / 232 of 554

The turbo generator Tenderer, with the unit responsibility, shall analyse the complete couple train for both lateral and torsion vibrations,

Lateral vibration will be analysed for each equipment (turbine, R.gear, Generator) as non-coupled train. Because Each equipment shall be coupled by coupling.

Agreed

60. 2.2.9.1 (b) / 235 of 554

ix. Flow and temperature indication for oil from every bearing.

One no. Duplex RTD shall be provided at each bearing for temperature measurement.

Agreed

61. 2.2.9.1 (c) / 235 of 554

The coolers shall be of shell and tube type with removable tube bundle.

Oil coolers Shell and tube fixed tube sheet type oil cooler will be provided

Agreed

62. 2.2.9.1 (c) / 235 of 554

The provided surface area shall be adequate to cool the oil with 32 Deg. C inlet cooling water temperature even with 20 % of the tubes plugged.

The Plugging margin shall be 5% only.

Agreed

63. 2.2.9.1 (g) / 236 of 554

The capacity of the purifier shall be at least one (1) percent of the rate of normal flow through the reservoir.

Capacity of oil purifier shall be as per TG supplier standard.

Agreed, subject to meeting tender requirements

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64. 2.2.22 / 252 of 554

The service factor of gearbox to be 1.4

The service factor of gearbox shall be 1.3

1.4, as per tender.

2.3 EOT CRANE AND HOIST

65. 2.3.10 / 282 of 554

Gearboxes shall have oil bath type for lubrication

Oil bath lubrication shall be provided for all high-speed gears and pinions. Low speed gears shall be lubricated by means of soft grease.

Agreed

66. 2.3.18.13 / 290 of 554

Chain Pulley Block to be provided for Boiler Feed Pump, boiler fans, CW pumps, CT fans, ESP transformers, air Compressor, etc.

Main EOT crane can be used for lifting Boiler feed pumps. We have envisaged Chain pulley block for the boiler fans, CW pumps, CT fans, ESP transformers, air Compressor.

Agreed

2.4 WATER TREATMENT PLANT

67. 1.1.6.5 / 13 & 14 of 554

SCHEME CLARIFIER – MGF-ACF-UF-SAC-DG-SBA-MB

There is no RO system in the suggested scheme in the tender, but instrumentation is given for the RO system, kindly provide the scheme to be followed.

Please read RO as mixed bed

68. 2.4.7 / 296 of 554

INSTRUMENTATION LIST Vortex flow meters – RO outlet Online PH meter – RO outlet – 2 each Conductivity meter - RO outlet – 2 each

69. 2.4.1 & 2.4.2 / 291 & 292 of 554


As the source of the raw water is River water,where the colloidal silica will vary from 0.5 ppm to 12 ppm due to seasonal variation. The colloidal silica in the surface water may not removed 100% in the resin based technology (i.e. DM system). For your power plant application, we hope the boiler steam pressure of high pressure(i.e. >60 bar),wherein the boiler make-up requirement will be of Total silica of < 0.02 ppm (Total Silica = Reactive Silica + Colloidal Silica). In addition to above, if the raw

Please follow scheme as per tender.

70. 1.1.6.5 / 13 & 14 of 554



15


water TDS value > 500 ppm in the raw water it is suggested to install RO plant instead of DM plant, where the chemical consumption cost, Handling of effluents & Handling of chemical will be reduced. Over a period of time the TDS value will detoriate and in turn the OBR of the DM will be reduced. In this situation, During high value of colloidal silica, the max load will take care by UF and accordingly, load acting on the RO membrane will reduce. Based on the above technical points we are suggesting the following scheme to achieve the required water quality for boiler feed. Clarifier + MGF + UF + RO + DG + MB. Kindly clarify the scheme to be followed.

71. 2.4.1 & 2.4.2 / 291 & 292 of 554

SCHEME CLARIFIER – MGF – ACF – UF- SAC- DG-SBA-MB, Alum dosing system

Based on the above point. If the following scheme is followed to meet the required quality. Clarifier + MGF + UF + RO + DG + MB. The Carbon in the Activated Carbon Filter will act as a breeding ground for the bacteria and it may lead to the bio fouling on the surface of RO membranes. Hence it is not advisable to use ACF prior to RO. Kindly clarify It is not advisable to dose Alum in the pretreatment prior to RO considering the fact that Al3+ ions will foul the RO membranes. Hence


72. 1.1.6.5 / 13 & 14 of 554

WATER TREATMENT SYSTEM CLARIFIER – MGF – ACF – UF- SAC- DG-SBA-MB Alum dosing system

16


Ferric chloride can be dosed prior to RO for coagulation purpose. Kindly confirm.

73. 2.4.5 / 294 of 554

BASIS OF DESIGN pretreatment plant including dosing system,MGF & ACF – 30 m3/hr or 600 m3 OBR

The DM plant capacity works out to be 30 m3/hr considering process steam of 20 TPH for Ethanol plant and 32.08 TPH for Sugar plant with condensate return quantity of 30.5 TPH. kindly furnish the DM Plant capacity and OBR, enable us design the system. Also as the hardness and alkalinity present in the raw water analysis seems to be high, we have considered Dealkaliser for cooling tower makeup stream. Kindly clarify.

30 m3/hr or 600 m3 OBR

74. 2.4.5 / 294 of 554

BASIS OF DESIGN DM plant – 600 M3 OBR


75. 2.4.5 / 294 of 554

BASIS OF DESIGN NORMAL FLOW DM PLANT – 30 M3/HR


76. 1.1.6.5 / 14 of 554

BASIS FOR DESIGN Total outflow of water – DM Plant capacity – 1000 m3/day ,OBR


77. 1.1.6.5 / 14 of 554

BASIS FOR DESIGN Total outflow of water – pretreatment Plant capacity – 1250 m3/day ,OBR

Agreed

2.5 AIR COMPRESSOR & DRIER

78. 2.5.1 / 300 of 554

It is proposed to interconnect the service air system with the instrument air system before the instrument air dryers.

We have considered common air compressor for instrument cum service air requirement. The service air will be tapped off before air drier unit.

Agreed

2.6 FUEL & ASH HANDLING SYSTEM

79. 2.6.1 / 302 of 554

This conveyor (UN BC-5) shall be partially under ground so that it should be possible to feed the bagasse to this conveyor by pay loaders at the rate of 40 MT/Hr & partially inclined to receive the bagasse from two nos. bale breakers.

We will provide 6 nos of bale breakers (each 7 TPH as per supplier standard) with one common belt conveyor which will feed bagasse at the pent house of UN BC-5.

Bale breakers of 20 TPH capacity are available & are to be provided. 7 TPH capacity bale breakers are not acceptable since during operation, we will have to arrange man power to feed all 7 bale breakers,

80. 2.6.1 / 302 of 554

2 numbers bale breakers of 20 TPH capacity along with 20 Mtr long feeding belt conveyor of 800 mm width.

81. 2.6.1 / 303 of 554

Walkway Both side walkways of 750 mm & 600 mm to be provided

Kindly furnish walkway size to be considered for belt conveyor for the fuel

Walk ways of width 750 mm to be provided on both side of the conveyor for the entire length

17


82. 2.6.8 / 313 of 554

A minimum walking /maintenance space of 750 mm on both sides shall be provided for the entire length of the conveyors.

handling system.

83. 2.6.6 / 306 of 554

The angle of inclination of conveyor belts shall not exceed 18 deg to the horizontal for standard belt. For inclination up to 300cleated type belt shall be provided.

We have considered normal belt conveyors upto 18º inclination. For above 18º inclination only, we shall provide cleated belt conveyors.

Acceptable

84. 2.6.6 / 308 of 554

The hood shall be fabricated from minimum 1.6 mm thick M S sheets with suitable stiffeners & clamping arrangement.

Kindly furnish thickness of MS sheet to be considered conveyor hood for fuel handling system.

The hood shall be fabricated from minimum 1.6 mm thick M S sheets

85. 2.6.8 / 313 of 554

The hoods shall be fabricated from minimum 2 mm thick by MS sheets/ Metapoly sheets with suitable stiffeners and clamping arrangement.

86. 2.6.2 / 304 of 552

Ash is then dumped in open space of through trucks / dumpers. This open space should preferably be near to the cogen plant to minimize the transportation cost.

As per the layout the ash dumping area is located at a distance of 800 mtrs from proposed power plant and as per clause No.: 2.6.2 you have mentioned the ash dumping area to be located near cogen power plant area. Kindly mark / indicate the area for ash dumping near proposed power plant.

EPC bidder has to suggest best location in the proposed cogen plant area. Normally ash will be disposed of by using trucks & in case of any emergencies ash will be dumped in area allocated.

87. SDP/HPCL/S/A/01/R1

Proposed Master Plan

2.7 COOLING TOWER & AUXILIARIES

88. 2.7.1 / 314 of 554

Three cells, cooling tower, 4800 m3/hr capacity with RCC basin

With the past experience had with you, we have considered cooling tower capacity of 3 x1600 m3/hr = 4800 m3/hr for the proposed power plant. Kindly confirm.

Agreed

89. MIT / HPCL-SUGAULI/21

SCHEMATIC COOLING WATER SYSTEM

2.8 FIRE FIGHTING SYSTEM

90. 2.8.7 / 326 of 554

The fire water pumps, jockey pumps, diesel engine drives, etc. will be located in the water pump house adjacent to the raw water cum fire water

Please note that we have considered common pump house for Fire water and raw water pumps.

Agreed

18


tank.

2.9 PIPING AND FITTINGS

91. 2.9.1 / 326 of 554

All cogeneration plant piping will be as per applicable IBR / ASME standards.

We have considered pressure parts piping as per IBR requirement & Non – Pressure parts piping as per IS with standard engineering practice

Agreed

92. 2.9.1 / 326 of 554

The cogeneration plant piping will inter-alia include raw water intake from the plant water reservoir,

Please confirm the terminal point for Raw water

At the bore wells in the cogen area including piping upto raw water reservoir and outlet of raw water reservoir.

93. 2.9.8 / 333 of 554

b. Cooling water piping will be routed in trenches below ground.

Cooling water piping and Fire hydrant piping shall be burried below ground.

Agreed

94. 2.9.8 / 333 of 554

f. Fire fighting piping will be located in trenches as per TAC recommendations.

Agreed

3. CIVIL WORK

3.9 ARCHITECTURAL CONCEPTS AND DESIGN

95. 3.9.9 / 478 of 556

All Architectural, Structural and RCC drawings and design calculations, shall be supplied in triplicate to the Client and their Consultants, minimum 15 days prior to construction of works at site, for approval purposes and only after approval, the works shall be taken up at site.

We shall submit the model calculations for approval and the drawings will be submitted for information only.

Model calculations for critical foundations is acceptable, however, all the detail drawings for execution at site will have to be submitted and approved from the Consultants.

96. Pile foundation Kindly clarify us whether the site Requires Pile Foundation or not. if the site requires the Pile Foundation. Kindly provide us the soil investigation report with bore hole (soil layer) details for the proposed site, for us to estimate the Pile Foundation works.

As clarified earlier for point no.14.

4. APPROVED LIST OF VENDORS, LIST OF SPARES AND LIST OF DRAWINGS / DOCUMENTS

19


97. 4.1 / 489 of 554

APPROVED LIST OF VENDORS

May please note that, we have considered our own make for the products which falls in our product range such as ESP, fans, deaerator cum storage tank, metallic expansion bellows, air & flue gas dampers, dosing tank, silencer, orifice plates, junction boxes etc. Kindly note that, we have indicated additional subvendors alongwith subvendors list furnished by you in the tender document. The same is enclosed vide Annexure-I

Own make of qualifying bidders is acceptable. Please follow as per tender

ELECTRICAL & CONTROL INSTRUMENTATION PRE-BID CLARIFICATION

Tender Query Reply

1 1.1.6.12-

B / 25 of 554

11kV Power Supply will be given to Sugar Plant Switchboard. Further downstream power distribution will be done in Sugar Plant.

As per tender specification chapter-1 / cl.No:1.3 page no:174, we presume that our scope limit up to the output terminal of 11KV HT panel in the proposed plant TG house.

Agreed. For Ethanol Plant the scope is up to PMCC of Ethanol plant as mentioned.

2 1.1.6.12-

C / 25 of 554

Motor rating above 200KW shall be operated with Soft Starter suitable for operating from starter, DCS and PB Station near Motors. Starter Shall have bypass contactor with AC3 rating.

The same will be considered for all LT motors more than 200KW (Except VFD driven motors.)

Agreed.

3 1.1.6.12-

C / 25 of 554

VFD shall be provided as per the functional requirement.

As per the tender specification chapter-2, / cl.no.2.11.7 / page no.375, we have envisaged VFD for ID, FD, BFP, fuel feeders and CWP motors only.

Agreed

4 1.1.6.13 -

E / 33 of 554

Plant communication shall be provided with Telephone system, Public Address System and Walkie-talkies

As we are not authorized to purchase and sell walkie talkie equipments, we have not considered walkie talkie

Please provide as per tender. Required certification or documents will be given by owner.

20

Tender Query Reply

1.1.6.14 / 33of 554

The Tenderer will provide a wireless handheld walkie talkie system of Motorola / Philips make for intercommunication of all plant personnel with minimum of 15 instruments. The required battery, battery charger, centralized transmission system, etc. To be included. The system will have a frequency which will not disturb any other public or radio system. The tenderer will be responsible for obtaining the in-principle and operating license and the frequency allocation. Statutory fees, if any, will be paid by the Owner

system and its related instruments in our scope.

Please provide as per tender. Required certification or documents will be given by owner.

5 1.1.6.14 / 33of 554

The EPBAX will have expandability and junction box to be interconnected to the EPBAX systems of the sugar, ethanol and non-plant buildings.

Provision for expandability is made available in our proposed plant EPABX system. However related interconnecting cables, junction box and its accessories between proposed plant EPABX system and sugar / ethanol / non plant buildings EPABX system is not in our scope.

Agreed

6 2.2.23.1 /

251 of 554

The equipment shall include one (1) No. Horizontal Shaft Three Phase Alternating Current, synchronous generator of nominal capacity 22,500 KVA or higher as per Tenderers recommendation based on normal steam flows,

Please note that the synchronous generator nominal capacity as 25000KVA at 0.8 p.f.

Agreed

7

2.2.23.-A / 269 of

554

The generator shall be completely assembled at works and type tests as specified below shall be conducted on the assembled unit and auxiliaries as per the latest edition of IS:4722.

Generally all the vendors do not recommend actual test (type test / special test) of Electrical/C&I equipment as it may lead to under performance of the equipments. However we will provide a type test certificate for the similar rating equipment for your review.

Agreed

2.12.2 / 390 of

554

The following tests shall be carried out on XLPE cables as per IS : 7098 Part-II. iv) Type Tests

Agreed

21

Tender Query Reply

8 2.2.23.-B / 271 of

554

Site test for each generator shall include

The same will be considered as per approved TG vendor standard.

Agreed

9 2.11.2 -C / 337 of 554

c. Statutory approvals : - Obtaining approvals on drawing and designs from BSEB, local Electrical Inspector and Chief Electrical Inspector authorities. - Liaison with BSEB authorities for testing, tie up and commissioning of switchyard equipments. - Arranging inspections and approvals for commissioning of total cogeneration plant electrical from Local and Chief Electrical Inspector PWD - Liaison with TQ & A as well as O & M division of BSEB authorities for obtaining approvals on drawings, arranging inspections for metering CTs, PTs and other equipments, interlocks etc.

We have considered IBR approval & electrical inspectorate clearance in our scope of work. However, we shall render technical assistance for getting other statutory approvals.

You will need to provide the clearances for all equipment in your scope. Owner will provide required assistance

10

2.11.4 / 338 to 347 of

554

Bill of Materials The quantities indicated above are as estimated and for bidding purposes. Tenderer will also provide unit rates for all above equipments for any variations in actual as build quantities

The bill of material furnished in the tender specification may vary based on the actual requirement during detail design stage. However the same shall be provided during detail design stage.

The price of equipments as per quantities given shall be included in bid price. Successful tenderer shall complete the detail engineering before ordering. The payments will be made as per actual supply for which unit rates will be refered.

11 2.11.9 / 365 of

554

Load Managers Load managers shall be provided to indicate all operating electrical parameters in single unit. These Load Managers shall have a communication port with Modbus / Universal protocol for communication with PLC/ SCADA system. Necessary hardware and

Please note that all energy meter will be load manager with RS 485 mode bus provision for hooked-up with DCS for monitoring purpose. However, the requirement of PLC/SCADA system is not applicable for us.

PLC / SCADA system is not part of Electrical Evacuation System. Required inputs such as mapping shall be provided during detail engineering.

22

Tender Query Reply

protocol shall be included in the cost of this panel.

12 2.11.10 /

365 of 554

11KV Switchboard and L. T. Panels : The panel shall be self supporting, free standing, floor mounted, modular type with construction having degree of protection of IP 54 as per IS 2147.

Please note that the enclosure protection of 11KV HT panel as IP4X only.

Agreed.

13 2.12.7 / 396 of

554

Voltage drop as follows, (i) Steady state voltage drop shall be limited to 3% and (ii) voltage drop during starting of motors shall be limited to 10%

As per tender chapter-1 / cl.No:1.1.6.12-k page no:31, the starting voltage drop at motor terminal as 15% and running voltage drop at motor terminal as 5%

Voltage drop as follows, (i) Steady state voltage drop shall be limited to 3% and (ii) voltage drop during starting of motors shall be limited to 10%

14 2.13.2 / 398 of

554

The following functions of the turbine shall be realized by dedicated independent micro processor based systems and shall be interfaced with the DCS through serial communication for monitoring / interlocking purpose : i. Turbine vibration monitoring ii. Turbine governing

The same will be hooked up with DCS for monitoring purpose through RS485 mode bus.

Agreed

15 2.13.2 / 403 of

554

All the field instruments / equipment that are used shall be of the same make for ensuring the smooth and optimal maintenance including efficient spare parts management.

We shall follow the make as per enclosed Approved vendor list.

Agreed

16 2.13.2 / 403 of

554

All field instruments used for sensing transmission and measuring shall be of electronic smart type with signal transmission in current mode of 4-20 mA.

The same shall be applicable only for Transmitters

Agreed

17 APPENDIX-XV / C /

2

METHOD OF STARTING : ID, FD, SA & PA fan, BFW Pumps & cooling tower (MCW) pumps motors shall have AC variable frequency drives & star delta bypass. Fuel feeder motors shall have AC variable frequency drives. All other motors <40 KW shall have DOL starting 40 KW &

As per tender chapter-1 / cl.No:1.1.6.12 page no:25, we have envisaged all motor stater, motor rating up to 15KW DOL, motor rating above 15KW and below 200KW star-Delta and motor rating above 200KW soft starter (exctpt VFD application motors), please

Agreed. VFD will have star delta starter as bypass.

23

Tender Query Reply

above shall have star delta starting.

clarify

18 APPENDIX-XV / C /

2

DIRECTION OF ROTATION: Bi-directional

The same is applicable for all motors except 2 pole HT motors (as applicable)

Agree

SUGAR

4.4.1 Vapour lime juice heater ( RJ1 & RJ 2 ) may not be required as draft outlet temp is 65 deg C.

Dynamic, Vapour line and direct contact juice heaters as specified in the EPC Bid are indicative. Bidders may design suitable extensive vapour bleeding system to achieve guaranteed total steam consumption of 22% on cane for the entire sugar plant.

Vapor requirement of scalding juice heater of diffuser

EPC bidder may design vapour requirement of scalding juice suitable for design parameters of cane diffuser. The final guaranteed steam consumption will be 22% on cane.

Capacity of air compressor 3 x 300 ( 2 working + 1 stand by ) may be required.

Capacities of rotary air blower fans as specified in the Bid are sufficient for crushing rate of 75 TCH, as only 50-55% juice on cane will be processed in the sugar boiling house and remaining juice will be transferred to the ethanol plant.

PI of 90 difficult to get RME 97.5

Guaranteed performance parameters of 90% PI and RME 97.5% were accepted as per the request from EPC bidders. The bid document specifies 92% PI and RME of 98.5%.

Quarters in whose scope HPCL to separately arrange for

this

Earlier Tender EMD This shall be considered a new

tender

3.2.2.1 BQC Clause The previous order value shall be changed

No Change in BQC

24

Tender Query Reply

AC VF Drive or DC DC drive

Payment on supply of Material

The milestone payment is mentioned. Same percentage will be maintained against all supply of material. Further break up of each system shall be submitted which will be approved by HPCL.

Digital Signature This is provided by various ISP

providers like BSNL etc.

Declaration of not being blacklisted Format

It is provided.

general as per tender query reply -...

Documents