ABSORPTION MACHINE, IT’s AUXILIARIES REPLACEMENT · PDF fileVAPOUR ABSORPTION MACHINE,...

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TENDER NO: NFVP/PROJ/VAM/11‐12

09.01.2012

Procurement of

VAPOUR ABSORPTION MACHINE, IT’s AUXILIARIES

& REPLACEMENT OF FILTER HOUSE

(Chiller for Process Air Compressor in Ammonia plant of Vijaipur-I)

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TENDER NO: NFVP/PROJ/VAM/11‐12

Index Sr. No.

Documents Item details Page No

1 Introduction Introduction 3

2 Enquiry Enquiry 3‐4

3 Vendor’s Scope Of Supply TECHNICAL DETAILS 5‐7

3 Mechanical Requirements MOC 7‐10

4 Electrical Requirements Motor, cable 11‐20

5 Instrumentation Requirements, Inspection, Battery limit

Instrument items, VAM BL 20

6 Erection & Commissioning ARC Job content, Procedure 20‐21

4 NFL’s Scope Assistance from NFL 21‐22

5 Guarantees Performance guarantees 22‐23

6 Time Period, Mode of Quotation Project schedule, Bid procedure 23‐24

7 Technical Data PAC data, Utility data 24‐25

8 Technical data/Documents To be furnished by the bidder

Data & document supply by the Vendor

25‐28

9 Scope of supply for Instrument items Details of Instrument supply 28‐34

10 Guarantee test run Outline 34

11 Prequalification criteria Details 34‐36

12 Annexure‐I Inlet Air Conditions

13 Annexure‐II Drawings of Existing Filter house

14 Annexure‐III Civil Design Data

15 Annexure‐IV Detailed Specifications of Pipes and Valves

LAST DATE FOR SUBMISSION: AT 2:30 PM ON ‐ 08‐02‐2012 TENDER OPENING TIME & DATE: AT 3:00 PM ON— 08‐02.2012

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NATIONAL FERTILIZERS LIMITED (A Government of India Undertaking) Vijaipur‐473111, Distt. Guna, Madhya Pradesh, INDIA

Phone: +91‐7544‐273047/ 273591 Fax: +91‐7544‐273089/273109 1. Introduction: National Fertilizers Limited (NFL) Vijaipur owns & operates two nos.

Ammonia plants of 1520 MTPD each reassessed capacity & four streams of Urea plant each having reassessed capacity of 1310 MTPD at NFL, Vijaipur, Distt Guna in the state of Madhya Pradesh. NFL, Vijaipur is already implementing Energy Saving & Capacity Enhancement projects so as to enhance capacity of existing Ammonia‐I & II plants from 1520 MTPD to 1750 MTPD & 1864 MTPD respectively & that of Urea‐I & II plants to 2 X 1515 MTPD & 2 X 1615.5 MTPD respectively.

Now, NFL intends to install a Vapour Absorption Machine (VAM) unit with associated auxiliaries for suction cooling of Process Air Compressor (PAC) of Ammonia‐I along with replacement of suction filter house. PAC is multi stage centrifugal compressor, horizontal split type having a total of 12 impellers & is supplied by M/S KOBELCO, Japan.

2. Enquiry:

You are requested to send your offer in Triplicate for the item as mentioned below subject to the terms and conditions given in the ANNEXURES enclosed herewith. Please indicate Prices, delivery periods with detailed specifications, relevant technical details, drawings, pamphlet and literature wherever applicable. ‐Your Quotation should reach to us before 2:30 PM on Last Submission date.

‐You may depute your representative for familiarization with site conditions, selection of location of VAM unit, actual witness of existing filter house & modifications required etc.

‐You may also depute your representative (with authorization letter) to witness tender opening process.

No Of Item – One Description ‐Design, procurement of raw material, manufacturing, inspection, testing, painting, insulation, supply, erection (including civil, mechanical, electrical & instrumentation), pre‐commissioning, commissioning & GTR of complete unit of Vapour Absorption Machine (VAM) with air cooling coil & ancillary items as per requirements where the air cooling coil shall be installed at inlet side of the suction filter house of Process Air Compressor, at Ammonia‐I plant of NFL Vijaipur, Guna (Distt), Madhya Pradesh, India for cooling of air from 45 °C and 40% RH to 15 °C and 100% humidity as per the technical

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specifications provided in Annexure‐I. Process Air compressor operating data is provided at Annexure‐I. Replacement of the existing filter house shall be in vendor’s scope. The filter house is to be designed with 15% margin.

Quantity required: 1 Set Preferred Completion Time: 07 months from the date of LOI/PO. Completion: Fully commissioned VAM Unit along with filter house replacement. Notes: 1. Kindly send your offer as per Annexures attached. EMD in the form of DD of Rs 500000/= (Rs Five lakh only) must be submitted along with the Unpriced Commercial Bid as per general terms & conditions of the ITB. 2. Annexures attached form part of the enquiry. ENVELOPE SHALL BE MARKED WITH ENQ.NO.

NFVP/PROJ/VAM/11‐12 LAST SUBMISSION DATE: 08‐02‐2012 & addressed to: Jodha Singh Dy. General Manager (Proj.) NFL, Vijaipur, Distt. Guna M.P., 473111 Email: [email protected] Contact No.: 9425132637

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3. Vendor’s General Scope of Supply: 3.1. Design, procurement of raw material, manufacturing, inspection, testing, painting,

insulation, supply, erection (including civil & structural, mechanical, electrical & instrumentation), pre‐commissioning, commissioning & GTR of complete unit of Vapour Absorption Machine (VAM) with air cooling coil & ancillary items as per requirements where the air cooling coil shall be installed at inlet side of the suction filter house of Process Air Compressor in Ammonia‐I plant of NFL Vijaipur, India for cooling air from 45°C/40% RH to 15°C and 100% RH. Vendor shall design the VAM and mention the consumption of all utilities including chilled water, power, cooling water make up and steam in the technical bid. Estimated refrigeration load of VAM is 500TR. However, Vendor shall mention actual TR required on the basis of furnished data in the NIT as specified in Annexure‐I & provide figures in respect of chilled water, power, cooling water & steam for actual TR so as to achieve specified cooled air temperature at post filter outlet & chilled water temperature at VAM outlet. Turn Down ratio to be given. Chilled water temperature at the outlet of VAM unit shall be 6‐70C considering cost & future application. Same shall be demonstrated.

3.2. Air cooling coil of the VAM will be located within the filter house of Ammonia‐I PAC, at an

elevation of 15‐20 metre. Complete replacement of the filter house unit shall be carried out by the vendor so as to ensure mist free air, while ensuring best particulate removal efficiency at least possible pressure drop across filter housing. Not more than 7 days shall be allowed for carrying out complete job of installation of cooling coil, replacement of filter house & hook up with PAC suction piping. This point shall be considered while designing the layout. The suitability of layout shall be finalized during technical discussions after placement of order. Drawings of existing filter house are enclosed as Annexure‐II.

3.3. Chillers shall be designed in such a way so that at rated conditions, operation at varying

load conditions is possible without any incidence of crystallization. 3.4. Vendor shall provide pre‐filter, louvers and bird screen at the inlet of the cooling coil. This

pre‐filter shall have arrangement for removal and cleaning on line. The pre filter shall be panel type construction, media‐washable, 100% synthetic, non woven, Grade G3 as per EN 779 standard. The filter media is to be fitted in SS 304 flange type frame. Thickness of the mounting frame shall be 3.0mm. Louvers shall be of SS304 with 1.0mm thickness. Bird Screen shall be of SS304, Mesh Size 5.5mm square opening with Φ1.0mm.

Vendor shall provide permanent instrumentation to measure pressure drop across the pre filter and provide digital indication for periodic observation and recording.

3.5. The fixing arrangement of bird screen, louvers and pre‐filter elements should be convenient

for easy removal for washing, in running condition. 3.6. The cooling coil shall be erected on MS structure, suitably painted for avoiding corrosion,

having separate supports grouted for taking entire load of the coil and the ducting. Civil design data is given in Annexure‐III.

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3.7. Vendor shall design and erect mist eliminator cum filter and final filter in the filter house at

the place of existing II & III stage filters. Any kind of entrainment of moisture in the droplet form is detrimental to the blades. Only inertial type moisture separation is not adequate. It is, therefore, necessary that the Vendor shall design and provide the mist eliminator and final filter so as to ensure mist free supply of air to the compressor.

The mist eliminator cum filter shall be of pocket type construction, media – water resistant, able to operate at 100% RH air, 100% synthetic, non woven, progressive density media with F6 grade as per EN 779 standard. Desired MOC of mounting frames for holding mist eliminator cum filter media elements in the filter house is SS304, 3.0mm thick. The final filter shall be of F8 grade as per EN779 standard. These elements shall ensure full utilization of the filtering area, uniform dust deposition as well as homogenous air flow coupled with a low average pressure drop.

Vendor shall provide methodology as well as instrumentation to demonstrate that the mist eliminator is functioning satisfactorily as per given specification. This methodology shall be discussed and approved by NFL during technical discussions. Vendor shall provide permanent instrumentation to measure pressure drop across the mist eliminator and final filter and provide digital indication for periodic observation and recording. The total pressure drop across pre filter, cooling coil and post filter taken together, in clean condition and rated flow, shall be less than 30 mm WC.

3.8. Vendor shall provide permanent temperature measurement system for air at the

Downstream of post filter which will be used for guarantee test as well as regular monitoring.

3.9. Complete job of removal of existing filter house including any cutting, welding of existing

metal frame for fixing of the new filter house including any civil work is in Vendor’s scope. 3.10. Vendor shall make necessary arrangement for removal of the water formed during cooling

of the air and for taking the water away from filter house and draining it at suitable location. The piping for such arrangement is in vendor’s scope.

3.11. The location for the erection of the VAM is 15‐20 meters away from the existing filter house.

Vendor shall erect and successfully commission the complete Vapour Absorption Machine with all its accessories and auxiliaries including the associated electrical, instruments & controls equipments.

3.12. The parameters of Utilities available in plant have been mentioned at Page 24. In case, the

parameters required by the Vendor are not suitable i.e. different than that mentioned in the enquiry, then same shall be mentioned clearly in the technical bid.

3.13. The Vapour Absorption Machine, single effect type, shall be factory assembled and leak

tested, packaged, water‐cooled Vapour Absorption Machine, consisting of absorber/

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evaporator assembly, condenser/steam‐fired generator, solution heat exchangers, solution and refrigerant pumps and motor, purge system, control panel with machine status, diagnostic display and safeties, interconnecting piping, absorbent, inhibitor and refrigerant, auxiliary components and accessories.

3.14. Unit shall be capable of continuous operation from 10‐100% capacity. The temperature of

air at the inlet of compressor is to be maintained automatically constant at any set point (at 150C. or any point above that) by controlling chilled water flow. The required control instrumentation shall be provided by the vendor.

3.15. Initial charge of Chemicals (Li Br etc) required for commissioning and running the system

are in Vendor’s scope as part of VAM supply itself. Vendor shall also indicate annual quantity of refrigerant chemicals, required as make‐up, for regular operation of VAM in the technical bid.

3.16. The technical data and documentation to be submitted by the Vendor has been mentioned

at page 25‐28. 3.17. Indian Vendor shall give 1 week advance intimation for shop inspection and testing where

ever required. Issue of inspection, testing & expediting shall be governed vide clause no. 10, attachment‐II of commercial ITB.

3.18. Steam Condensate disposal‐ Steam condensate formed shall be collected in a SS tank and

shall be pumped to the condensate polishing unit in ammonia‐I plant through nearby steam condensate line operates at 4.5kgf/cm² which is within 30 meters from the proposed VAM location and at 10m height. Steam Condensate pump shall be designed accordingly. Before discharging to the condensate line, the Steam condensate shall be cooled to 60°C in a SS plate type exchanger with cooling water. Bypass line at steam condensate side along with isolation valves shall be provided for plate type exchanger. Any pump/ Valves and piping inside the battery limit of the VAM unit are to be supplied, erected and commissioned by the vendor.

3.19. Vendors may send their technical representative to site, for carrying out preliminary

study and technical discussions with the plant authorities before submission of bid. 3.20. Vendors shall provide and install flow meters for flow measurement on permanent basis

for measuring the flow of steam, cooling water and chilled water. These flow measurements will be used during GTR as well as during normal operation. The flow meters shall be of reputed make and reliable in operation. Vendor shall provide temperature measurement with RTD sensor and digital readout with proper resolution for permanent measurement of air temperature at the outlet of post filter which is the guarantee point for the air temperature.

4. Mechanical requirements 4.1. Air Cooling coil and ducting – Air cooling coil shall be straight finned tubes coil. The MOC

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for tube shall be SA 213 Grade SS 304L and that for fins shall be stainless steel. The tubes used for the coil shall be seamless tubes. The tubes should be purchased from reputed SS tube manufacturers or their authorized dealers only and approved from NFL.

4.2. The cooling coil can be in modular construction and assembled at site, for ease of rigging

during installation. Flange joints shall be provided between coil header and the chilled water lines. These joints shall be outside the coil enclosure. Chilled water make up lines shall be of SS.

4.3. The outer casing of the cooling coil and the duct connecting with existing filter house inlet

shall be of IS 2002 – Steel. The duct shall be designed and fabricated such that it will be connected to filter house inlet, without much modification and with minimum pressure drop.

4.4. Any metal structural cutting and welding jobs required for connecting the new duct to the

existing filter house shall be in Vendor’s scope. 4.5. The total pressure drop on air side for pre‐filter, air Cooling Coil & moisture eliminator

cum post filter taken together at clean condition and rated flow shall not exceed 30 mmWC. Vendor shall provide instrumentation for regular on line measurement of such pressure drop.

4.6. The provision for removal of pre‐filter elements in running condition for cleaning and

cleaning of the finned tubes from outside in running condition shall be considered in design.

4.7. The pre‐filter elements shall be mounted on 3.0 mm thick SS304 frames. They are to be fixed

by bolting on CS structure. The bolts shall be of SS 304 material. The arrangement shall be such that removal and fixing will take minimum time.

4.8. Vendor shall provide arrangement for removal of the water formed during cooling of the

air and for taking the water at suitable drain location after using it for cooling the steam condensate. The piping for such arrangement is in vendor’s scope.

4.9. Pumps‐The Solution and refrigerant pumps shall be centrifugal, canned motor type. Pumps

shall be hermetically sealed. . Both solution and refrigerant pump shall be 1W + 1 STBY. Vendors list shall be got approved by NFL before ordering.

4.10. There shall be provision of Non return valve in vacuum pump line. 4.11. Vendor shall provide bearing wear monitor with entire monitoring system on the canned

pumps. 4.12. The chilled water pumps shall be of centrifugal back pull out type construction having

mechanical seal and oil lubricated. There shall be 1W + 1STBY pump. Preferred Pump makes are KSB/ Sulzer / Flowserve / Kirloskar. Vendor list shall be got approved by NFL

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before ordering. 4.13. Valves‐Isolation valves shall be installed at inlet and outlet to enable easy maintenance of

the all pumps. The isolation valves of cooling water and chilled water pump, condensate pump shall be flanged type, rising steam, gate valves of reputed make. MOC of valve for chilled water shall be CF8, MOC for steam valves shall be CS. The Isolation valves provided for vacuum pump should be of welded type.

4.14. Gaskets‐For cooling water and chilled water, acid proof non asbestos type. For steam lines

readymade spiral wound graphite gaskets to be used. Vendor is free to use better material. 4.15. MOC of pipes, pipe fittings and valves‐The MOC for chilled water line shall be SS 304L.

Cooling water pipe, steam pipes shall be A 106 Gr B. 4.16. Evaporator, Absorber and Condenser‐MOC of tubes shall be SS‐316L Seamless tubes. Shell

is IS 2062. MOC for steam condensate expansion tank shall be SS. Vendor shall specify the design and test pressure in the technical bid. The balance material of construction shall be as per vendor’s standard.

4.17. Generator – MOC of tubes shall be SS‐304L seamless tubes. Shell is IS 2062. Vendor shall

specify the design and test pressure in the technical bid. The balance material of construction shall be as per vendor’s standard. Tube sheet‐IS2062 Gr. B/ Equivalent boiler grade plate. The vendor can supply alternate suitable material; however the same shall be mentioned in the deviation list with explanation for approval of NFL.

4.18. All holding down bolts, anchor bolts (MOC‐high tensile steel) are in Vendor’s scope of

supply. 4.19. The hot insulation of steam lines and vessel including material and application, as per IS

14164 latest revision is in Vendor’s scope. 4.20. The cold insulation (PUF insulation preferably moulded) of VAM unit, chilled water lines,

Cooling coil ducting , filter house outside area up to Process Air Compressor inlet flange as per IS 7240 latest revision is in Vendor’s scope.

4.21. Painting‐ All MS parts of the VAM unit shall be painted with 2 coats of high built

chlorinated rubber based red oxide zinc phosphate primer followed by 2 coats of high built CR dark grey finished paint. Total DFT should be 140 microns. The interior CS surfaces which are in contact with cold air shall be applied with two coats of epoxy paint (Neo‐gose #200).

4.22. SS Seamless tubes shall be as per ASME‐SA213 4.23. Pipe numbers at tapping points:

For LP Steam : 18”SL101.06 B22S For DM Water : 2ʺ DW‐113.01 B50

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For Instt. Air : 3ʺ IA 101.08.B50 For Steam Condensate : 3ʺ SC 511.02 B22 For Cooling Water : 36”‐CW‐201.08‐B20

4.24. Required Piping Standards

For LP Steam : B‐22S (IBR) For DM Water : B‐50 For Steam Condensate : B‐22 For Instrument Air : B‐50 For Cooling Water : B‐20 Detailed specification of Pipes and Valves (Ball Valves, Butterfly Valves, Check Valves, Gate Valves & Globe Valves) are given in Annexure‐IV

4.25. Piping erection shall be as per ASME‐B31.3 latest revision 4.26. List of Spares for 2 years operation

Minimum Spares to be supplied with the VAM Unit are listed below. However, for the pumps, any other spares as per pump vendor recommendations shall be quoted separately as additional spares:

A) CENTRIFUGAL PUMPS 1. Impeller : 1 No. 2. Impeller locknut with washer : 1 set 3. Wear rings : 1 set 4. Bearings (thrust and radial, DE & NDE): 1 Set 5. Coupling Complete : 1 No. 6. Complete Mechanical seal (if installed) 1 No. 7. Shaft sleeve : 1 No. 8. Gaskets and O‐rings : 1 set

(For pump and seal) 9. Shaft with key : 1 No.

B) FILTERS:

1. Pre‐Filter : 2 sets 2. Mist Eliminator Filter : 2 sets 3. Post Filter : 2 sets

Any other spares as per vendorʹs recommendations shall be quoted separately. Clause may be incorporated in the NIT that the above mentioned spares are minimum and shall be considered in bid evaluation. Any other recommended spares shall be quoted separately as optional which shall not be a part of bid evaluation. The same shall be decided for procurement at the discretion of NFL.

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5. Electrical requirements:

Erection and commissioning and Testing of the entire electrical system shall be in Vendor’s scope.

5.1. Power supply:

- To feed the power & control supply to the motors, lighting etc. new MCC panel shall be installed in the Existing Amm‐1 Substation. Two sources of power shall be provided by NFL at existing Amm‐1 MCC.

- Supply of power cable to feed the new MCC of VAM from existing MCC of Amm‐1 sub‐station shall be of 3.5 X 400 mm2 size shall be under the scope of vendor, all termination at both ends, laying of cables and cable glanding along‐with supply of these items shall also be under the scope of vendor .

- Preparation & submission of test reports and co‐ordinating for inspection and clearances from Central Electricity Authorities / State Electricity Authorities as required shall be under the scope of the vendor.

Technical requirement of the New MCC panel are as follows: 5.1.1. MCC shall be single front, metal clad, sheet steel fabricated, compartmentalized, draw‐out

and free‐standing floor mounting type. 5.1.2. MCC Bus‐bars shall be horizontal type & the dropper shall be vertical type only and Bus‐

Bar shall be rated for 3‐phase, 415V, 31 MVA. 5.1.3. MCC sheet steel thickness shall not be less than 2 mm. 5.1.4. The Bus‐bars shall be made of electrolytic grade tinned copper having heat shrinkable PVC

insulated sleeves suitable for rated voltage & coloured with Red, Yellow, Blue & Black. 5.1.5. All the bus‐bars joints shall be properly shrouded. No live part shall be exposed. 5.1.6. The MCC shall be extendable type. 5.1.7. Automatic shatters shall be provided to cover the energized parts when the starter module

is withdrawn from the MCC. 5.1.8. MCC shall be with minimum IP52 degree of protection. 5.1.9. Fault level for the MCC shall be 50 KA for 1 second. 5.1.10. MCC shall have 20 % spare outgoing feeder with at least one spare of each rating.

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5.1.11. MCC shall have two Incomers & one Bus‐coupler. 5.1.12. MCC Incomer capacity shall be designed in such a way that one incomer can feed all

MCC load at a time. 5.1.13. MCC shall have Manual/ Auto changeover scheme to transfer the electrical load from one

bus to another bus and vice‐versa manually/ Automatically without interruption. 5.1.14. Each Incomer feeder shall consist of :

i) Switch & fuse unit of 400 A rating ii) Ammeter iii) Ammeter selector switch iv) Voltmeter v) Voltmeter selector switch vi) Energy meter vii) Vacuum contactor viii) Current Transformer ix) Sensitive earth fault relay with core balance CT x) LVGP type LED Indication lamps [R,Y,B] xi) Any other required to complete the system

5.1.15. Bus‐coupler shall consist of:

i) Switch & fuse unit of 400 A rating ii) Vacuum contactor iii) Sensitive earth fault relay with core balance CT iv) LVGP type LED Indication lamps v) Any other item required to complete the system

5.1.16. Each outgoing feeder shall consist of:

i) Switch & fuse unit ii) Ammeter iii) Power Contactor iv) Overload relay ( with single phase protection & reset button) v) Current Transformer vi) On (Red Colour) , OFF (Green Colour), Trip (Amber Colour) LVGP type LED

Indication lamp vii) Auxiliary contactors for multiplication of contacts /control as per process /Instrument

requirement

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viii) Any other item required to complete the system

5.1.17. MCC each bus shall consist of one no. control transformers of 415V/230 V i.e. total two no.’s control transformer for control supply.

5.1.18. Sleeved 230V AC Control Bus in the MCC shall be horizontally mounted on both Bus for

tapping of control supply to the feeders. 5.1.19. MCC each bus shall have anti‐condensation heaters with fuse protection. 5.1.20. Cable alleys shall be hinged type & fixed with SS threaded screws. 5.1.21. All the motor starters are of D.O.L. starters only. 5.1.22. MCC shall have one earth bus running throughout the MCC for which or to which all the

earthing connectors are terminated. All the modules shall have their door separately earthed through a flexible cable link.

5.1.23. All the switchgears used in the MCC shall be either Siemens make or L&T make only. No

Mixture of two makes is allowed. 5.1.24. The MCC shall be painted with anti‐corrosive moisture free light grey shade 631 of IS:5 or

RAL‐7035 only. 5.2. 415 V Motors:

All motors shall be Ex‐‘e’ type, energy efficient type of ‘eff‐1’ as per IS:12615 & high power factor type.

5.2.1. 5.2.1 All motors shall be suitable for following ambient condition:

i) Temp. Max / Min. / design Ref. ‐ 50˚C / ‐2.2˚C /50˚C ii) Relative Humidity ‐ 100% max iii) Alt. Above sea : < 1000 M iv) Atmospheric Pollution

Dust: Urea Vapour: Ammonia

5.2.2. All motors shall be suitable for Hazardous Area Zone‐2, Enclosure Gas group II C, Temp. Class T3 & outdoor installation.

5.2.3. System Voltage: 415V±10 %, Frequency: 50Hz ± 5 % & Combined V & F variation ±10 %. 5.2.4. One spare motor of each type / rating is required.

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5.2.5. Following Two years operational & maintenance spares required for the each type / rating of motor:

i) Bearing ( DE & NDE) ‐ 01 set ii) Cooling fan – 01 no. iii) Terminal block – 01 no. iv) Grease nipple & plug – 01 no. v) Fan cover – 01 no. vi) Terminal stud with bushing & star link ‐01 no. vii) Inner & outer cover for DE & NDE bearing – 01 set

5.2.6. All motors shall be provided with on line grease lubrication arrangement on both DE & NDE bearing for motors of frame size 160 & above. The arrangement shall be complete with grease nipple & drain plug located at convenient locations.

5.2.7. The rating of motor shall be as per the sizes in the ISS. The margin between installed power

and absorbed power shall not be less than the following: Motor Rating Margin above Driven M/C absorbed power Less than 22 KW 25% 22 W to 55 KW 15 % 75 W and above 10 %

5.2.8. The duty cycle of the motor shall meet the process and driven machine requirement. 5.2.9. Vendor shall submit complete technical details of the motor with the offer for review /

approval of NFL including Heating, Cooling Time Constant, starting time etc. 5.2.10. The locked rotor withstand time (tE), under hot condition at 110 %of rated voltage shall

be more than the starting time of the motor coupled to the load even at the lowest stipulated starting voltage by 2 secs, for motors, having staring time up to 10 secs. And by 5 secs. For motors, having starting time more than 10secs. For increased safety (Ex‐e) motors tE under hot condition shall not be less than 10 secs.

5.2.11. Insulation class shall be class ‘F’ but temp. rise of the motor under full load condition shall

be 10˚C less of class ‘B’. 5.2.12. All motors shall be routine tested as per relevant standards. 5.2.13. Following documents required for each type / rating of the motors;

i) Dimensional drawing ii) Characteristics curves

a) Thermal withstand curve

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b) Load v/s FL current c) Load v/s Efficiency d) Load v/s Power factor e) Load v/s speed f) Voltage v/s Thermal withstand time g) Starting current v/s Time

iii) Terminal box drawings iv) Illustrative and descriptive catalogues v) Catalogues of brought out accessories vi) Spare part list vii) Installation, operation and maintenance manual viii) Test certificates ix) Guarantee certificates

5.3. Local Control Station (LCS): 5.3.1. The material of construction for enclosure shall be of die‐cast aluminum alloy (LM‐6)

material with flameproof enclosure as per IS: 2148. Rain protecting hood fabricated out of 14 SWG aluminum sheet shall be provided as an additional 4 no’s holes suitable for 12 mm bolts shall be provided outside the enclosure for fixing / mounting the control station on wall / steel structure.

5.3.2. Local Control Station (LCS) shall have following as per rating of the motor:‐

i) Off –Auto‐On control switch with Ammeter & 1 no. indication lamp for ‘Space Heater ON’ for LT motor rated 30 KW and above.

ii) Off –Auto‐On control switch with Ammeter for LT motor rated more than 5.5 KW & Less than 30 KW.

iii) Off –Auto‐On control switch without Ammeter for LT motor rated below5.5 KW.

5.3.3. OFF‐AUTO‐ON control switch shall be three position control switch with spring return

from ON to Auto position and lockable in off position. 5.3.4. The ammeter shall be flush mounting, moving iron spring controlled type, of accuracy class

1.5 as per IS: 1248, with square face of minimum size 72 mm X 72 mm having scale range 0 ‐90˚. The ammeter for motor shall be provided with uniform scale up to CT primary current and compressed end scale up to the 6 times the CT primary current. Adjustable red pointer shall be provided to indicate the full load current of the motors. Zero adjusters shall be provided for operation from the front end of the meter. All ammeters shall be operated through 1 Amp. CTs only.

5.3.5. Indication lamp shall be LVGP type having good illumination in all direction with lumen

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output of minimum 200milli Candela ± 10 %. 5.3.6. All the components shall be mounted on a base plate inside the enclosure. Necessary

actuating system for control switches, non‐yellowing acrylic / glass cover for ammeter and indication lamps shall be provided on the front cover. No wiring shall be carried out on the front cover.

5.3.7. Each control station shall be provided with minimum 2 mm thick stainless steel name

plates indicating the code number and description and rating (KW) of the equipment controlled by it.

5.3.8. Similar labels shall be provided for all indicating lamps, push buttons, control switches.

The nameplate and label shall be fixed with screws only. 5.3.9. The enclosure shall be provided with two external earthing terminals with studs of 8 mm

dia. And shall be marked with earthing symbol. Due to flameproof LCS, one no. additional earthing terminal inside the terminal chamber shall be provided.

5.4. Cables: 5.4.1. All required power, control cables for vendor’s equipment from New MCC panel shall be

supplied & laid by the vendor. Control cables required for DCS/ESD/PLC at CCR or Compressor House control room shall also be under the scope of the vendor.

5.4.2. Laying and Terminations of cables (Power ,control cables up to LCS & DCS/ESD/PLC or at

compressor house control room), at NFL MCC, NEW MCC and LCS , DCS/ESD/PLC or at compressor house control room shall be in vendor’s scope.

5.4.3. Cable for motors shall be 3 core of stranded Al /Cu conductor, PVC insulated, PVC inner

sheathed (extruded type), GI wire/strip wounded armoured, FRLS PVC (ST1 type) outer sheathed,1100 V grade heavy duty type as per IS: 1554 (Part‐1). All cables up to 6 mm2 shall be copper conductor & those above 6 mm2 shall be of Al Conductor.

5.4.4. Size of power cables shall be selected in accordance with the permissible voltage drop as Mentioned below and considering various de‐rating factors as per IS: Motor feeding cables referred to the running current ‐‐‐‐‐‐‐ 5% Motor feeding cables referred to the starting current ‐‐‐‐‐‐‐ 10%

5.4.5. Number of cores for control cables shall be as per operational requirement of the equipment.

5.4.6. Each core of the Multi‐core cable shall be marked with number for identification of the

core. All control cables shall have 10% spare cores subject to minimum one spare one. 5.4.7. All the cables shall be terminated at the equipment by means of double compression type

rolled AL or of double compression type Ni plated Brass cable glands and crimping lugs.

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All cable Entries shall be from bottom only. 5.4.8. All cables used shall be without intermediate joint.

5.5. Cable Racks/Tray & laying of cables: 5.5.1. Existing cable tray shall be used for laying/clamping of the cables from New MCC up to

the vendor requirement but if sufficient space is not available on the existing cable tray then vendor should provide the new cable tray laid on the existing cable racks support by laying/clamping from New MCC up to vendor requirement.

5.5.2. The cable trays & risers shall generally be of G.I. pre fabricated ladder type. G.I. pre‐

fabricated cable trays & its accessories such as coupler plate, risers, bends etc. shall be fabricated from 3.0 mm thick M.S. sheets.

5.5.3. Provision of dedicated GI/Al plate earthing pits for the purpose of earthing of the

equipments shall be in the scope of the bidder. Two earthing pits to be provided an double earthing to be provided to all equipments, control panels, motors etc. Vendor shall ensure double earthing to all equipments & Control Panels of the chiller system from these earthing pits.

5.6. Spare: 5.6.1. Spare for Two years (Operational & Maintenance): Item‐wise unit prices of the spare parts with recommended quality shall be quoted along‐with the equipment as listed below:

1. Ammeter : one no. of each type & rating 2. Ammeter selector Switch : 01 no. 3. Voltmeter : one no. of each type & rating 4. Voltmeter selector Switch : 01 no. 5. Energy Meter : 01 No. 6. Push button Assembly : 01 No. 7. Vacuum Contactor : 01 no. 8. Power contactor : one no. of each type & rating 9. Thermal O/L Relay : one no. of each type & rating 10. Auxiliary Contactor : 05 nos. 11. LVGP Type Indication Lamp : 05 No. 12. Sensitive Earth fault relay (CTUM‐15) : 01 No. 13. Core Balance CT for Incomer : 01 No. 14. Current Transformer : one no. of each type & rating) 15. Potential transformer : 01 No.

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16. Power Switch : one no. of each type & rating 17. Control Switch : one no. of each type & rating 18. LV Motor : one no. of each type & rating 19. LCS : one no. of each type & rating 20. Fuse : 20% or minimum one no. each type & rating 21. Control Fuse fitting [Base & Carrier] :20% or minimum one no. each type & rating 22. Thermostat : 01 No. 23. Bearing ( DE & NDE) : 01 set 24. Cooling fan : 01 no. 25. Terminal block : 01 no. 26. Grease nipple & plug : 01 no. 27. Fan cover : 01 no. 28. Terminal stud with bushing & star link: 01 no. 29. Inner & outer cover for DE & NDE bearing : 01 set

5.6.2. Commissioning Spares:

Commissioning spares, as required, shall be supplied with the main equipment. Item wise list of recommended commissioning spares shall be furnished with the bid.

5.6.3. Any other spare parts not specified, but required, shall also be quoted along‐with the offer. 5.6.4. All spare parts shall be identical to the parts used in the equipments. 5.7. TESTS AND INSPECTION: 5.7.1. All the supplied items shall be subjected to routine test and their component as per relevant

IS. 5.7.2. Additional tests, whenever specified, shall be carried out. 5.7.3. All the above test shall be carried out in presence of owner’s representative 5.7.4. These inspections shall however, not absolve the vendor from its responsibility for making

good any defect which shall be noticed subsequently.

5.8. Drawing & Documents : 5.8.1. Drawings and documents as per following shall be supplied, unless otherwise specified.

Sl.No. Description Documents required (Y/N)

With Bid For approval Final1. Technical Details Y Y Y

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2. Feeders Details (if applicable)

Y Y Y

3. General arrangement Drawing and Foundation Drawing

Y Y Y

4. Schematic / Wiring Drawing

N Y Y

5. Calculation of Bus‐Bar Sizing (if applicable)

Y Y N

6. Terminal arrangement drawing

N Y Y

7. Illustrative and Descriptive literature

Y N Y

8. Catalogue for brought out accessories

Y N Y

9. Installation, operation and Maintenance manual

N N Y

10. Test Certificates 1) Type Test 2) Routine Test

Y N

N N

Y Y

11. Guarantee Certificates Y Y Y12. Spare Parts List Y Y Y

Note: 1. 04 No. hard copies & 1 No. Soft copies shall be supplied with bid.

2. 04 No. hard copies & 1 No. Soft copies shall be supplied for approval after order within

4 weeks from the date of LOI. 3. 06 No. hard copies & 2 copies in CD shall be supplied as final documents prior to

dispatch of the equipment. These shall be made in sets and supplied on fine plastic coated folder.

Y – YES, N ‐ No 5.8.2. All drawings & documents shall have the following description written boldly.

‐Name of Client ‐ Enquiry / Order number with plant / project name ‐ Code no. and Description

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Note: 1. Vendor shall submit all documents / drawing to NFL for approval. 2. Any other electrical equipment required for the completeness of the system shall also

be incorporated in this scope. The vendor shall not be absolved from his responsibility of providing the same if the requirement comes up at the later stage.

6. Instrumentation requirements

The details of Scope of supply for Instrumentation related items have been mentioned at page 28‐34.

7. Battery Limits

Following are the battery limits of Vendor fixed for the VAM

7.1. Inlet flange of steam line. The steam control valve is in Vendor’s scope. 7.2. The outlet flange of the cold steam condensate. 7.3. The entire piping for chilled water from VAM to the cooling coil and back to VAM along

with the structural supports and cold insulation is in Vendor’s scope. 7.4. Make up water inlet flange. 7.5. Entire cooling water piping along with valves is in Vendor’s scope. 8. Inspection and Testing 8.1. All the equipment shall be subjected to shop inspection at various manufacturing stages. 8.2. VAM shall be performance tested for offered capacity at specified chilled water, cooling

water & steam pressure, which shall be witnessed by NFL representative. Vendor shall submit QAP for approval within 03 weeks after getting LOI or PO. However acceptance of shop tests or shop inspection by Purchaser’s inspector shall not absolve the vendor of not taking responsibility to fulfil the guarantee specified.

8.3. Final acceptance test shall be carried out at the site after erection. 9. Erection and Commissioning:

Erection and commissioning job including supervision and labour for the VAM is in Vendor’s scope which includes but is not limited to

9.1. Transportation of machine to site. 9.2. Unloading of the machine. Vendor shall arrange all required manpower and tools and

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tackles for this job. 9.3. Taking the machine on the foundation and its erection including labour as required for it. 9.4. The entire hot as well as cold insulation job for the VAM is in Vendor’s scope. 9.5. Vendor shall start erection job within 1 week from receipt of the VAM unit at site. 9.6. Completeness of all the erection and pre commissioning activities will be considered as

mechanical completion. The mechanical completion will be certified by NFL. 9.7. Vendor shall take up and complete the commissioning as per schedule approved by NFL.

Vendor shall also provide supervision services for commissioning as well as GUARANTEE TEST. The entire commissioning shall be completed within 4 days.

9.8. All the consumables and spares required for commissioning are in Vendor’s scope. 10. Annual rate contract (ARC) 10.1. Vendor shall sign Annual Rate Contract for a period of 3 years for maintenance of the

VAM, after completion of Guarantee period. 10.2. This ARC contract shall include periodic check, preventive and corrective maintenance jobs

related to mechanical, electrical, and instrumentation including supply of consumables, spares and also supply and make up of chemicals. The periodicity of checking shall be adequate for detecting and rectifying equipment problems well in advance.

10.3. Cost of required spares & consumables will be separately indicated along with their unit

rates. NFL will be at liberty to decide about usage of a particular spare/consumable & order the same appropriately.

10.4. The value of such ARC as lump sum amount, excluding cost of spares & consumables, shall

be separately indicated in price bid. The cost of 3 years ARC will be considered during evaluation of the price bid.

11. NFL’s Scope 11.1. Crane required for unloading and erection jobs shall be arranged by NFL on hire charges to

pay basis. There are 120 T, 75 T, 35 T, 18 T & 08 T cranes available with NFL The crane accessibility for the existing location shall be discussed during technical discussion and Vendor shall confirm that the job can be done with existing cranes available with NFL, after considering weights of all components.

11.2. Necessary tie‐in points from existing NFL plant for Instrument Air, Steam, Chilled water

make up piping & cooling water piping for the VAM unit shall be confirmed by NFL. Tie‐in

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points will be discussed & finalized at site in presence of vendor representative. Vendor has to lay the utilities lines from tie in points up to & within VAM battery limit.

11.3. Single source incoming power cable shall be arranged by NFL up to the electrical panel

installed by the vendor. 11.4. For erection & construction jobs, power & water connection will be provided by NFL at any

one point within VAM battery limit. Construction water & power shall be metered but will not be charged. Vendor shall indicate tentative max requirement of construction power & water at any given point of time.

11.5. Instrument air header tapping near the machine. 11.6. All valves, pipings, fittings etc for the VAM unit shall be in the scope of Bidder. 12. Training:

Vendor shall impart on the job training for the operating staff and maintenance staff for proper operation and maintenance of the equipment, without any additional cost.

13. Guarantee

The guarantee test procedure is mentioned at page 34.

13.1. The supplier shall guarantee the equipment and their components against faulty Design and manufacturing with regard to mechanical / electrical / instrumentation adequacies like reliable performance and workmanship.

13.2. The supplier shall give guarantee for sustained trouble free operation of VAM unit for

cooling the process air of compressor suction side to achieve air temperature of 150 C, measured with RTD at the outlet of post filter, for conditions specified in the NIT i.e. 45 °C & 40% RH and also for any other favourable conditions considering the %RH and temperature together. Parameters for guarantee are as follows:

A) For Actual TR (Calculated by the party as per the conditions specified in Annexure‐

I): Actual TR shall be demonstrated at shop/site. Guarantee parameters shall be TR, Steam consumption, CW flow, & VAM power including those of auxiliaries.

B) For Turn‐Down ratio: As per clause 3.15 the turndown ratio for continuous running

of plant is 10‐100% of capacity. Hence party should guarantee steam consumption, CW flow, chilled air temperature, pressure drop across filter house & VAM power including those of auxiliaries at 50% and 70% load.

13.3. Above guarantees shall be for trouble free operation for period of 12 months from date of

successful commissioning or 24 months from date of mechanical completion, whichever is

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earlier. 13.4. During GTR, vendor shall demonstrate that the utility consumption, i.e power, steam and

cooling water make up, shall be as specified in the specifications submitted by the vendor during the technical bid.

13.5. The power consumption is the sum total of power drawn by all the continuous operating

pumps in VAM battery limit. 13.6. In case of any deviation in any of the above performance, vendor shall carry out all the

necessary modifications to meet the performance criteria, at his own risk and cost, within reasonable time. Even after modification, if the performance does not meet the above criteria, then equipment will not be accepted. In such case Vendor shall be given mutually agreed time frame to make any rectifications required to meet the required performance, at his own risk and cost.

13.7. The performance of the equipment shall be checked under different ambient conditions

including summer, with in the Guarantee period, i.e. within 12 months from date of commissioning, and if performance criterion is not met subject to the design conditions i.e. 45 °C & 40% RH or equivalent, then entire amount of PBG shall be deducted.

13.8. Mutually agreed damages due to delays in contractor’s performance & in case of failure to

meet performance guarantees shall be leviable as per commercial ITB clauses. 14. Time Period – 14.1. The whole system is to be designed, manufactured, supplied, erected & commissioned

within 07 months from the date of placement of clear work order/LOI. 14.2. Party shall start Erection with in 1 week of receipt of material at site and complete the

erection and pre commissioning activities in 4 weeks. 14.3. Hook up and commissioning shall be done in 4 days which shall include in the time period

for filter house replacement mentioned in clause 3.2. 15. Mode of Quotation‐ In two bids 15.1. EMD + Technical Offer + Un‐priced commercial bid with prices blanked out. 15.2. Price bid in separate envelopes‐

The price bid shall have 2 components

a) Lump sum Charges for supply of the complete VAM & it’s auxiliaries & replacement of filter house including all civil, structural, mechanical, electrical and instrumentation items

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including labour charges for erection & commissioning including supervision, & first charge of refrigerant along with annual refrigerant consumption.

b) Charges towards 3 years ARC for maintenance of the unit including cost of spares, consumables and chemicals.

15.3. Availability of Existing Utilities:

The following utilities shall be made available by NFL at the Tie‐in points of the vapour absorption machine unit.

Utility name Normal Pr. (Kg/Cm2g)

Mech. design Pr. (Kg/Cm2g)

Normal temp (°C)

Mech. design (°C)

Fouling factor ( m2h0C/Kcal)

LP Steam 3.0 6.0 225 350 0.0002 Cooling Water(S/R)

3.5/2.5 6.0 34/44 75 0.0004

DM Water* 4.0 5.0 40 70 ‐‐‐‐‐‐‐‐‐ Instt. Air 7.0 10.0 Ambient 70 Free from dust,

water & oil

Service Air 4.0 10 ambient 70 Free from dust & oil

* For chilled water, DM water shall be provided for makeup. Electricity: 50 Hz, 11 KV/3.3 KV/415 V, 3 phase 15.4. Mechanical data:

1) Dimensions of existing filter house W X H X L = 2.75m X 3.54 X5.4m` 2) Details of existing filters Details of Filters 1st stage:

Dust louver air cleaner Size: 65‐22 X 6 pockets Dp 11mmWC

2nd stage:

Wire mesh air filter Size: 600X600X25t Dp: 05 mmWC

3rd stage:

Dri‐pak air filter

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Type: 2530X20 P.C.S Dp: 18 mmWC

Specifications:

Air flow rate: 71740 M3/Hr (Rated 80000 M3/Hr)

Temperature: ‐2.2 to 46.1°C Total Efficiency: 85% AFI dust Synthetic dust weight arrestance

15.5. Vendor shall submit following data along with technical bid (For both 500 TR & for turn

down ratio TR (for guarantee purpose as well as for bid evaluation purpose). 1) Chilled water circuit:

1.1 Capacity in TR 1.2 Chilled water flow M3/hr 1.3 Chilled water temperature °C (Inlet/Outlet) 1.4 Fouling factor m2hr oC /Kcal

2) Cooling water circuit :

2.1 Cooling water flow rate M3/hr & pressure in/out. 2.2 Cooling water temperature °C (Inlet/Outlet) 2.3 Fouling factor m2hr oC /Kcal :

3) Steam circuit :

3.1 Steam consumption : Kg/hr 3.2 Steam inlet pressure Kg/cm2(g) & temperature 3.3 Condensate temperature °C 3.4 Pressure of condensate at battery limit bar g 3.5 Condensate flow m3/hr

4) Electrical Circuit :

4.1 Power supply details 4.2 Absorbent pump motor rating KW 4.3 Refrigerant pump motor rating KW 4.4 Vacuum pump motor rating KW 4.5 Chilled water pump motor rating KW 4.6 Cooling water pump motor rating KW

5) Physical Data (Indicative):

5.1 Length X Width X Height of VAM in meters 5.2 Length X Width X Height of cooling coil and duct in meters

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5.3 Weight of cooling coil, and weight of VAM in tons 5.4 Space for tube cleaning (any one side‐Lengthwise) M 5.5 Minimum clearances required around the VAM installation

6) Drawings:

6.1. Plot plan with dimensions of the entire scheme indicating location of cooling coil, duct, existing filter house, location of VAM, various pumps.

6.2. Process Flow diagram. 6.3. List of equipments in VAM system.

7) List of spares required for 2 years operation: Prices to be given separately in price bid. 8) List of Vendors/ Sub vendors ‐Item wise list of Vendors/ sub vendors for Mechanical items i.e

pumps, valves, coil, tubes for cooling coil, pre filter, mist Eliminator, tubes for various heat exchangers. Item wise list of Vendors for Electrical motors, panels, and for Instrumentation items like PLC, control valves, all field instruments, which will be approved by NFL during Technical evaluation. In case any the vendor is not known to NFL/not in the vendor list of NFL, the party shall have to submit credential of the vendor for approval from NFL.

9) Specifications of cooling coil‐including schematic drawing, other details like MOC, and

thickness of tube. 10) Specification of pre filter including Class and MOC of frame, Media and dimensions. 11) Specification of mist eliminator & post filter‐media, arrangement, dimensions. 12) List and Specification of all mechanical equipments including pumps, cooling tower, valves,

tanks, vessels, exchangers which are in Party’s scope of supply. 13) Structural and civil foundation drawings for structural and civil work for review and approval

by NFL civil department during technical discussions. B) Within 03 weeks after placement of LOI/PO

Following documents shall be supplied by the vendor: (6 copies of each along with soft copy on CD)

1. Process flow diagrams with Energy balance, P & I Diagram. 2. Structural design calculations and civil foundation drawings for approval by NFL civil

department. 3. GA drawing for all mechanical and electrical equipments

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4. GA drawing of VAM. 5. Quality Assurance Plan for NFL’s approval. 6. Time schedule for completion of manufacturing activities as well as erection and

commissioning activities‐BAR CHART. 7. List of instruments and accessories with brief specification including sizing 8. Calculation of control valves and safety valves. 9. Purchase Specification, literature & Catalogue for all instrument item for major items. 10. Loop Diagram or safety interlock diagram 11. Power Distribution diagram 12. Control panel diagram. 13. Instrument installation diagrams 14. Instrument hook‐up drawings 15. Any item not indicated above but is essential for safe and smooth operation of the system shall

also be within the scope of the vendor. C) Along with supply 1. Specification of all equipments and data sheets. 2. As built drawing of VAM. 3. Complete spare part list with part numbers and cross sectional drawings for all mechanical

equipments. 4. Equipment operation and maintenance manuals for mechanical and electrical. 5. Calculation of control valves and safety valves 6. Bill of material & essential spares list for mechanical, electrical and instrumentation for two

years trouble free operation 7. Material Safety Data Sheets (MSDS) for all the chemicals prescribed by the vendor to be used in

chillier unit. 8. Any item not indicated above but is essential for safe and smooth operation of the system shall

also be within the scope of the vendor.

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9. Material test certificates 10. Results of non‐destructive inspection (If applicable). 11. Records of dimensions. 12. Results of hydraulic tests and pneumatic tests whichever applicable as per relevant code. 13. Performance test report and 14. Guarantee certificate. 15. Test report/guarantee certificates for all bought out items. 16. Test reports for Electrical & Instrumentation equipments

15.6. Salient Design Philosophy For Instrument Items 1. All field instruments shall be suitable for working in NH3 Plant area. 2. Complete erection of all the field instruments, laying of cable trays and Commissioning are

in party’s scope. 3. The PLC for VAM Unit shall be installed in the existing Compressor control room of

Ammonia‐I plant located at the distance of 150‐200 metre from VAM machine site. 4. All the field I/O shall be connected in the VAM PLC panel through field junction boxes and

multicore signal/power cables. Cable trays and cable laying up to Compressor control room VAM PLC panel, ferruling & termination shall be in the scope of vendor.

5. The dimensional drawing of the instrument panel shall be approved by the NFL before

fabrication. 6. Control system shall be implemented in a PLC for close loop control, open loop

Monitoring, Interlocking & Trip system. The Operator Interface shall have minimum 17” colour Operator panel with touch screen and built‐in Alphanumeric keypad for data feeding and printer for alarm/event printing. The 22” LCD colour monitor (HMI) can also be provided on table top where all other existing DCS/ESD Operating Stations are available for change of set point etc. The offered system shall be supported by the PLC vendor for min. 15 years for all type of hardware and software spares and service supports.

7. All the digital inputs, digital outputs, analog inputs and analog outputs which are coming

from the field or going to the field are to be made connected in VAM unit PLC cabinet in Compressor control room for control & monitoring through local HMI. MODBUS/Ethernet connectivity shall also be provided for monitoring facility in the existing DCS.

8. Vendor shall supply license software, application programme and the programming

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terminal 17” Laptop of M/s DELL/HP make with communication cable. The original software of PLC is to be loaded in it and also the application software. The programming terminal should be the latest one of M/s DELL/HP. Party has to furnish the detail technical specifications of programming terminal.

9. Data from VAM PLC shall be also monitored from existing Yokogawa make CS‐3000 R‐3

DCS through MODBUS/Ethernet. The hardware/software required for the connectivity from PLC to DCS network shall be in vendor’s scope.

10. The VAM Unit PLC shall be redundant configuration in respect to Power Supply, CPU,

Communication modules including communication bus etc. 11. Before procurement, the technical specification of all the instruments, drawing and its

vendors are to be approved by the party from NFL. 12. During erection, if some modification is required then party has to carry it out as per NFL

engineer instruction. 13. The local interfacing panel for electrical and instrument shall be separate. 14. The local control panel, if any, shall be epoxy coated suitable for NH3 atmosphere. 15. The make of the PLC panel (cabinet) shall be Rittal. 16. The control supply provided by NFL will be UPS 115VAC 50Hz. 17. The SMPS used in the panel i.e. 115VAC to 24VDC shall be of reputed make like COSEL,

OMRON, Phonix Contact, Digitronics etc. 18. SMPS shall be redundant with diode circuit. 19. Internal cable used in the control panel shall be multi strand 1.5 mm2 copper cable. 20. Laying of 115 VAC control cable and it’s termination in the control panel will be in

vendor’s scope. 21. The cables used in the panel shall follow colour code for the phase, neutral and earth also

for + and – DC voltages. 22. Each and every cable in the panel shall have ferruling. The ferruling should be yellow with

black lettering. 23. In the control panel there shall be 20% extra phoenix terminal strips, MCB’s, holes on gland

plate etc. 24. The earthling bus bar strip shall be separate.

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25. The Air distribution pot of 10 points with ¼” needle valves for all points is in vendor’s scope. The MOC of air distribution pot and needle valve shall be SS 304. This air distribution pot shall have 1” SS 304 main isolation needle valve with ½” SS 304 needle drain valve.

26. All field transmitters shall be intrinsically safe EExib IIC T4, 2‐wire, 24 V DC, SMART with

HART protocol and with local LCD type display. 27. Level Gauges shall be reflex or transparent type with body & cover material of forged

carbon steel or SS316/304 as a min. And shall have a mechanical an thermal shock resistant type toughened borosilicate glass with suitable gaskets. High quality mica shall be used in case of steam service.

28. All temperature elements shall be RTD as per DIN 43760. All RTD shall be Duplex. 29. All temperature gauges and RTD shall have SS304 thermo well. The process connection of

thermo well shall be ¾” NPT (M) and that of the temperature gauges or RTD connection shall be ½” NPT (F).

30. Each instrument shall be suitable for ½” NPT(F) SS304 double compression cable gland. 31. Supply of SS304 double compression cable gland for each instruments side and Junction

box side is in party’s scope. 32. All control valves shall have isolation valves on the upstream and downstream side with

the bypass valves. 33. Control valve Positioner shall be pneumatic with built‐in Position feedback & limit

switches. 34. All the jobs related with control system installation, mounting etc at site in the place &

location provided by NFL is in the scope of Vendor. Cabling from VAM machine to all field instruments, from field instruments to field junction boxes and from field junction boxes to PLC panel (location at Ammonia‐I Compressor Control Room) shall be in the scope of Vendor. All the hardware including cables required to complete the job is in the scope of Vendor.

35. All the power/control and signal cables in a single or multi pair cables between field

instruments to field junction boxes and between field junction boxes/ panels to the PLC cabinet room shall be thru’ overhead cable trays/cable duct on the pipe racks. No underground cabling allowed.

36. All transmitter bodies shall be with integral SS manifold, mounting brackets wherever

necessary and double compression type cable gland with IP‐65 protection class. 37. Copper and copper alloys shall not be used for any part of the instruments and accessories

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either in contact with the process fluid or external atmosphere. 38. Power supply to instruments, alarm and interlock shall be 115V AC 50 HZ. 39. Make of instruments shall be as per vendor list indicated. For any other make prior

approval must be taken from the NFL. 40. 20% built is spare terminals, lamps, annunciation etc. must also be provided for future

addition or as a standby spares. 41. All the measurement shall be done using Transmitters. Inputs for alarm and tripping shall

be generated in the PLC by providing soft set points. Passive devices like pressure/ level switches shall not be used except special cases as required by OEM with justification.

42. Local Instruments like Pressure Gauges / Temperature Gauges / Level Gauges shall also be

provided at all the measuring point tapping in addition to Transmitters. 43. Supply of cooling water control valve, steam flow meter, steam control valve etc are in

Vendor’s scope. 44. All the events as well as critical inputs and outputs shall be provided with Audio/ Visual

Alarm Annunciator windows on PLC HMI. List of Instruments provided in the system shall be enclosed in the offer giving all the functionality of that measuring point.

45. Vendor should offer spare parts @10% or minimum 1 no. of each type (whichever is higher)

for all control valves (trim set e.g. Plug, Stem, Seat, Cage, Seal Ring etc; diaphragm/actuator seals, Positioner, packing etc.), On‐Off valves (trim set, diaphragm/actuator seals), PLC control system & communication network (spare cards e.g. Power Supply, CPU, Input & Output, Communication etc.), RTD Elements, SOV (coils, plunger, ‘O’ ring set) required for two years trouble free operation.

Technical requirement 46. Alarm system: ‐First trip alarm sequence shall be as per ISA‐S 18.1 Sequence F3A and for

normal alarm it shall be as per ISA‐S18.1 sequence ‘A’. Fault contact shall open on alarm condition.

47. Interlock System: This shall be implemented in the state of the art Programmable Logic

Controller with graphic interface for operation. Programming Software shall also be provided with the supply of the system. Man Machine interface shall be minimum 17” size colour LCD Operator Panel with provision for Alphanumeric keypad for easy data entry & printer for alarm/event printing. This interlock system shall have standard direct connectivity to the plant DCS through standard communication protocol using Ethernet/modbus connectivity.

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In Ammonia‐I plant, the DCS is M/s Yokogawa make Centum CS3000 R3. Vendor has to supply the compatible communication hardware for DCS system also with communication cable between DCS and PLC panel. The total distance is 50 meters approx. The complete communication cables shall be laid with conduit.

48. Control valve: Shall be pneumatically operated. Valve will be sized for minimum pressure

drop and at the design maximum flow rate. Shut down valve shall be of the same size as the line size.

49. Body material shall be as per piping material. But trim material shall be of 316SS Trim

with stellited facing shall be employed when the pressure drop across the valves more than 10 Kg/Cm2. Valve positioner shall be used with all control valves.

50. Pressure Gauge: Shall be sized provided with Bourdon sensing element 150 mm dial, die

cast aluminium case with epoxy paint, wetted part and bourdon material AISI‐316 SS. 51. Solenoid valve: Ex proof, Body and trim material shall be 316 SS. 52. Dial thermometer: 150 mm dial Hg filled type. Thermo well made of bar stock to suit

length and material shall be AISI‐316 SS. 53. Flow Measurement: Orifice plate shall be the standard flow measurement device. Other

type of flow meter shall be used by vendor where high accuracy is required. The material of orifice plate shall be SS316, as min.

54. Vendor shall supply 3‐sets of documentation (in hard copy) of PLC, field instruments,

final drawings, O and M manual of VAM etc. Erection Material 55. Control/Signal Cable: 1.1 KV grade 1.5 mm2 copper conductors in twisted pairs

aluminium shielding with drain wire armoured and PVC sheathed. Manufacturing and testing as per IS‐1554. Overall sheath shall have F.R.L.S. properties. Test certificate shall be furnished.

56. Power Cable: 1.1 KV grade 1.5 mm2 copper conductors PVC sheathed. Overall sheath shall

have FRLS properties, manufacture and testing as per IS‐1554. Test certificate shall be furnished.

57. Cable Tray: Aluminium (99% pure) perforated with cover. 58. Cable Gland: SS 304 Double Compression type 59. Tubing: All tubing should be SS316. The size of the tubes should be 6mm or 12mm 60. Fittings: All tube/pipe fitting should be SS316. The sizes are ½” NPT or ¼” NPT WITH

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12mm O.D or 6mm O.D. S.W. ANSI‐3000 lbs class. 61. FIELD JUNCTION BOX: The following basic design criteria is to be followed for all type of

junction boxes, throughout the specifications, including those being supplied by package unit vendors. i) Irrespective of plant’s hazardous classification, all the supplied junction boxes shall be of

Flame proof type approved for EEx‐d IIC/T4 as per CENELEC.

ii) All the field junction box shall be made of die‐cast aluminium.

iii) There shall be diff. junction box for diff. type of I/O signals as well as diff. destination like PLC system. As a minimum the following segregation shall be maintained‐

‐Analog Input and Analog output

‐24 V DC Digital Input

‐110 V DC Power cables for SOLENOID valves (if any)

‐RTD signals iv) The naming philosophy for junction box shall be adopted in such a way that from the

tag number of the particular junction box, it shall be evident to decide type of signal and destination.

v) All junction box MOC shall be die‐cast aluminium and it shall be epoxy painted. Based on requirement, there shall be diff. insulated shield and earth bus bars are to be provided in the junction box. The individual branch cable shall be brought to central cabinet room panel instrument shield bus bar via insulated shield bus bars and multi pair shields from junction boxes.

vi) All junction boxes shall have branch and multi pair cable entries from bottom only.

vii) All Branch entries of junction box shall be weather proof to IP67 as a minimum. Generally 12 branch entries of 1/2” NPT as the cable entry for instruments shall be ½” NPT and 1 no. of main multi pair cable entry type junction boxes shall be used in the total project.

viii) Each Junction box shall have 0.5 to 4.0 sqmm, screwed WAGO make terminals inside them. These shall be DIN rail mounted. The colour code shall be based on type of signals. The qty. shall be as required.

ix) Each junction box shall have engraved/embossed SS tag plate with tag number. This tag plate shall be screwed on the junction box.

NOTE:

i) All carbon steel fittings, valves, pipes coming on steam services must be supplied with IBR certificate in form IIIC.

ii) Party shall submit the vendor list at the time of technical clarifications for approval by NFL.

iii) List of spares required for 2 years operation: Prices to be given separately in priced bid for each item.

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iv) Make of instruments shall be as per vendor list.

GUARANTEE TEST RUN 1. The Vendor shall carry out GUARANTEE TEST of the VAM SYSTEM by providing supervision

services of competent personnel. 2. Vendor shall prepare detailed procedures for conducting guarantee test requirements

beforehand in consultation with NFL so as to correctly evaluate the agreed guarantees. 3. After VAM system has operated steadily (At specified chilled air & water temperature) for

about a week, NFL and VENDOR shall decide the date of commencement of GUARANTEE TEST RUN.

4. GUARANTEE TEST RUN shall be conducted under normal operating conditions without the

help of any installed stand‐by equipment and/or machinery. Sufficient and necessary measurements shall be taken to ascertain the test results

5. GUARANTEE TEST RUN shall be carried out by sustained operation of VAM system for 72

(Seventy Two) consecutive hours according to VENDOR’s instruction and recommendation. 6. During the GUARANTEE TEST RUN, average results obtained during the period shall form the

basis of comparison between actual performance and VENDOR’s performance guarantees. The VAM system shall be deemed to have completed a successful GUARANTEE TEST RUN if these average results are equal to or better than the guarantees stated.

7. If interruption of more than one hours occurs before 72 (seventy‐two) hours, VENDOR shall

repeat the GUARANTEE TEST RUN for a maximum of 3 (Three) times and the results of these test run shall be considered for determining guarantees.

8. Successful completion of Guarantee Test shall not relieve VENDOR from obligation and

responsibility in any manner with regard to modification/ rectification/replacement to meet material and workmanship guarantee.

9. If VENDOR fails to prove the guaranteed performance figures then liabilities and liquidated

damages as per NFL’s standard terms shall apply. PREQUALIFICATION CRITERIA FOR VENDORS INFORMATION/LIST OF DOCUMENS REQUIRD FOR PREQUALIFICATION A. Corporate Record:‐ v) Name, Address, telephone, fax nos. email address.

vi) History & structure of the Organisation

vii) Name of the Directors and Chief Executive/Partners along with addresses and contact numbers.

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viii) Registration certificate of the company B. Financial Status: ‐ i) Audited Annual Reports of the company for last 3 years

ii) Excise/Sales tax/VAT registration Numbers (TIN number) and PAN number along with copies of certificates/PAN card. (for Indian Vendors only)

iii) PF/ESIC Number if applicable (for Indian Vendors only)

iv) Latest Bankers solvency certificate (not older than 6 months) for at least Rs. 2.7 CR in format at Annexure F5 solvency

v) Copy of service tax registration

C. Technical Capability/Capacity i) Complete technical details of VAM units Manufactured along with its catalogue.

ii) Details of manufacturing facilities Available

iii) Accreditation from Third party Inspection agencies. Lloyds Register, TUV, BVIS

iv) Availability of After Sales service and spares in India

v) Availability of ASME certification along with its validity.

D. Past Performance / Experience i) The Bidder during the last 07 years must have designed, manufactured, supplied, installed

and commissioned at least one VAM unit of at least 60% capacity of the unit offered by them under this tender for similar duties and operating conditions and the same shall be operating satisfactorily for at least 2 years. As a documentary proof, the bidder hall submit self attested photocopies of purchase orders with full technical details of the equipment, certificate from the user regarding satisfactory performance.

ii) Similar duty shall mean Li-Br based LP steam fired VAM unit & Process air filtration

system suitable for chilling of process air in large scale process industry for use in high capacity turbo machines.

iii) The bidder/its sub vendor shall have inspection, testing, servicing facilities for VAM, in India. The bidder shall attach details of inspection & testing facilities.

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iv) Average annual financial turnover of the bidder during last three years, ending 31st March, 2011 should be at least Rs 1.8 Cr (0.38 M USD) & net worth of the bidder shall be positive.

The vendors will be prequalified based on above criteria and offer of only those bidders who satisfy these criteria shall be considered.

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