BID DOCUMENT FOR SUPPLY OF EQUIPMENT & COMPONENTS ... Bid document, Rev.2 04.12.20… · reach the...

BID DOCUMENT

FOR

SUPPLY OF EQUIPMENT & COMPONENTS, DISMANTLING, SITE FABRICATION, ERECTION OF VARIOUS EQUIPMENT & COMPONENTS AND

PROVIDING COMMISSIONING SUPPORT SERVICES FOR REVAMPING OF 115 TPH BOILER

AT

M/S. FIJI SUGAR CORPORATION LTD RARAWAI, FIJI ISLANDS

DECEMBER 2018

Document No. 4-18138-300-0351 Rev.2 dt. 04.12.2018

AVANT-GARDE ENGINEERS AND CONSULTANTS (FZC) EXECUTIVE SUITE, P.O. BOX 122632

SHARJAH, UAE.

TEL: +97 1566924002 E-MAIL: [email protected] Web site: http://www.avantgarde-uae.com

M.Pandikumar C.Damodaran S.Sivakumar Prepared by Checked by Approved by

mailto:[email protected]

http://www.avantgarde-uae.com/

FIJI SUGAR CORPORATION LTD RARAWAI, FIJI ISLANDS

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------------------------------------------------------------------------------ BID DOCUMENT FOR REVAMPING OF 115 TPH BOILER

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CONTENTS 1.0 INTRODUCTION AND INVITATION FOR BID ..................................................................................... 3 2.0 PROJECT INFORMATION AND SITE DATA .......................................................................................... 6 3.0 BOILER NO.4 - EQUIPMENT DATA ........................................................................................................... 8 4.0 SCOPE OF SUPPLY AND SERVICES ......................................................................................................... 13 5.0 ESTIMATED QUANTUM OF SUPPLY AND SERVICES ....................................................................... 20 6.0 EXCLUSIONS ................................................................................................................................................. 21 7.0 TECHNICAL SPECIFICATION FOR CONTINUOUS BAGASSE FEEDING SYSTEM .................. 22 8.0 TECHNICAL SPECIFICATION FOR DUMPING GRATE ASSEMBLY ............................................... 28 9.0 TECHNICAL SPECIFICATION FOR BAGASSE SPREADER AIR FAN ............................................ 32 10.0 TECHNICAL SPECIFICATION FOR AIR PRE-HEATER ASSEMBLY ................................................ 35 11.0 TECHNICAL SPECIFICATION FOR FLY ASH ARRESTOR ................................................................ 36 12.0 TECHNICAL SPECIFICATION FOR SECONDARY STEAM SEPARATORS .................................... 37 13.0 TECHNICAL SPECIFICATION FOR WATER TREATMENT PLANT ................................................. 38 14.0 SPECIFIC REQUIREMENTS / SERVICES .............................................................................................. 39 15.0 DOCUMENTS TO BE SUBMITTED ........................................................................................................... 42 16.0 GENERAL TERMS AND CONDITIONS .................................................................................................... 43 17.0 RESPONSIBILITIES OF M/S.FIJI SUGAR CORPORATION LTD .................................................. 45 18.0 PERFORMANCE GUARANTEE PARAMETERS ......................................................................................... 46 19.0 PRICE SCHEDULE .......................................................................................................................................... 47 20.0 REFERENCE DRAWINGS AND DOCUMENTS ........................................................................................ 48


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1.0 INTRODUCTION AND INVITATION FOR BID 1.1.0 Introduction 1.1.1 M/s. The Fiji Sugar Corporation Ltd (FSCL) is operating three (3) sugar

plants in Fiji Islands. The following sugar plants are located in Viti Levu, the largest island of Fiji:

a) M/s. The Fiji Sugar Corporation Ltd, Rarawai unit, 300 TCH capacity. b) M/s. The Fiji Sugar Corporation Ltd, Lautoka unit, 300 TCH capacity. The following sugar plant is located in Vanua Levu, the second large island of

Fiji: a) M/s. The Fiji Sugar Corporation Ltd, Labasa unit, 300 TCH capacity. 1.1.2 The steam requirement of the FSCL Rarawai unit is presently met by the

following boilers, using bagasse as fuel:

Sl no

Boiler No.

Capacity TPH

Steam pressure

kg/sq.cm(g)

Steam temperature

Deg.C

Make of boiler & year

Remarks

1 #1 40 17.57 205

Saturated steam

JTA 1965

2 #4 115 17.57 280

Superheated steam

Yoshimine Japan, 1979

Capacity indicated is

at 46% bagasse moisture

1.1.3 Presently, the boiler No.4 is connected to 4 MW and 5 MW back pressure

TG sets. The boiler No.1 is connected to three mill turbines, which works with saturated steam. Manual provision is available in the plant to tap the superheated steam to saturated steam piping as and when required, during low steam pressure conditions. However, the saturated steam from boiler No.1 is not allowed to enter superheated steam piping, to prevent possible damage to power turbines.


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1.1.4 The boiler No.4 has been generating about 85 TPH of steam last year. But the capacity of boiler has reduced to about 55 to 65 TPH during the current year. Besides, reduced steam output of boiler, the steam pressure and temperature are not stable and fluctuating widely, even at lower output of 60 TPH.

1.1.5 Reportedly, the boiler No.1 is currently generating about 7 to 10 TPH of steam only.

1.1.6 The ID fan of boiler No.4 is equipped with steam turbine drive. Pony motor

is not provided for ID fan, to facilitate initial start-up of the same, at lower speed. Currently, boiler No.4 cannot be started on its own, due to absence of pony motor for ID fan. Hence, start-up of boiler No.4 is dependent on working of boiler No.1. The mill is planning to provide a pony motor for the ID fan of boiler No.4, to facilitate its start-up, without the need for steam from boiler No.1.

1.1.7 Though the installed capacity of both the boilers put together is 155 TPH of steam, currently the boilers are able to generate only about 75 TPH of steam, restraining the cane crushing capacity of the plant.

1.1.8 To ensure reliable and smooth operation of the plant, FSCL had decided to restore the condition of boiler No.4, by carrying out repairs / replacement, as required, during the next off-crop. The proposed repairs / replacement in boiler should improve the overall performance of the boiler and ensure maximum continuous rating of 100 TPH and above, at rated steam parameters.

1.1.9 To ensure accountability for the revamping of 115 TPH boiler, the complete

scope of supply and services via applicable design and detailed engineering, dismantling, fabrication, erection and commissioning support services will be awarded as a turnkey job to a prospective bidder. The supply of equipment / components and providing services are to be carried out as per the scope of supply and services furnished in chapter No.4 of this document.

1.1.10 At FSCL Rarawai unit, the current cane crushing season is expected to end

approximately by mid December 2018. The trials for crushing season 2019 will commence from 01.06.2019. The contract for revamping of 115 TPH boiler will be finalized with successful bidder, before 20th December 2018. The revamping program shall commence soon after the crushing season is


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completed by mid December 2018 and shall be completed before 31.05.2019. Hence, time is the essence of this bid. The time schedule for manufacturing of material is two (2) months. The time schedule for transit is two (2) months. The time schedule for erection is one (1) month. All materials shall reach the site by end of April 2019. Dismantling, site fabrication, erection and insulation work shall be overlapped suitably, to suit the target completion date.

1.2.0 INVITATION TO BID: 1.2.1 M/s.FSCL now invites bids from eligible bidders for supply of equipment /

components, dismantling, site fabrication, erection of site fabricated and bought-out items, in-situ repairs in boiler and commissioning support services, for revamping of the existing 115 TPH boiler for performance improvement. Only those bidders having experience on supply, dismantling, fabrication, erection and commissioning of boilers of 100 TPH and above for modifications / performance improvement / capacity up-gradation work with a minimum reference of two units will be considered for award of this job.

1.2.2 The drawings of existing boiler equipments and components are attached

with this bid document. Since the subject boiler is very old, bidders may consider in their offer, providing latest and efficient equipment and systems, where advantage is more with same expenses as that of the existing equipment and systems. However, it should be noted that the boiler is expected to serve for about 10 years only.

1.2.3 The bidders may send their technical queries, if any, to FSCL / Avant-Garde, to the contact persons and e-mail IDs provided in chapter No.2 for Project Information.

1.2.4 The bidders are requested to submit their competitive offer on or before 14.12.2018.


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2.0 PROJECT INFORMATION AND SITE DATA

2.1 Project Title : Revamping of 115 TPH Yoshimine boiler 2.2 Purchaser : M/s. Fiji Sugar Corporation Limited

2.3 Purchaser’s Address : Drasa Ave, Balawa, for communication Private Mail Bag, Lautoka, Fiji Islands. Contact Person : Mr. Jakir Hussain, Manager-Capital Projects E-mail: [email protected] Ph: +679 999 1519 +679 666 2655 2.4 Consultants : Avant-Garde Engineers & Consultants (FZC) 2.5 Consultant's Address: Executive Suite, for communication P.O. Box 122632, Sharjah, U.A.E. Contact Person : Mr.C. Damodaran, DGM - Services E-mail: [email protected] Ph: +91 9840043322 +91 44 4598 1200 2.6 Plant Location : Ba, Rarawai, The Republic of Fiji Islands 2.7 Nearest Airport : Nadi, Fiji Islands 2.8 Port of disembarkation: Lautoka, Fiji Islands (for sea transport) 2.9 Ambient Temperature (°C)

a. Absolute maximum : 33 b. Absolute minimum : 20 c. Performance design : 30 d. Design wet bulb temp : 28 e. Electrical design : 50


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2.10 Relative Humidity (%)

a. Maximum : 81.6 b. Minimum : 64.8 c. Design : 70

2.11 Altitude : 5 M above MSL 2.12 Barometric Pressure : 760 mmHg 2.13 Soil Bearing Capacity : 25 T/SQ.M at 1.5 M Depth from NGL 2.14 UTILITIES DATA

2,14,1 Plant Air

a. Pressure (Bar(G)) : 7.0 b. Temperature (Deg.C) : 40 c. Dew Point (Deg.C) : No free moisture d. Oil Content : Traces

2.14.2 Instrument Air

a. Pressure (Bar(G)) : 7.0 b. Temperature (Deg.C) : 40 c. Dew Point (Deg.C) : -40

2.14.3 Cooling Water

a. Water Temperature (Deg.C) : 32.0 b. Water Pressure (Bar(G)) : 3.0

2,14.4 Auxiliary Steam

a. Pressure (Bar(A)) : 2.5 b. Temperature (Deg.C) : 130


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3.0 BOILER NO.4 - EQUIPMENT DATA

SL NO TITLE DESCRIPTION

1. Make of boiler / Country

Yoshimine Boiler Industries Ltd, Japan

2. Year of manufacture

1977

3. Year of boiler commissioning

1979

4. Number of boiler

One

5. Boiler capacity

115 TPH

6. Superheated steam pressure

17.57 kg/sq.cm(g)

7. Superheated steam temperature 280 deg C

8. Heating surface area of boiler Radiation heating surface : 730 sq.m Convection heating surface : 2640 sq.m Total heating surface : 3370 sq.m

9. Type of boiler

Bi-drum, water tube, natural circulation, bottom supported, bagasse fired

10. Type of furnace Dumping grate -Pneumatic cylinder operated Number of Grate sections: 6 Number of pneumatic spreaders: 6 Number of dumping sections: 12

11. Type of Bagasse feeders Drag chain type : 6 Nos. Each feeder is driven by two (2) motors Motor power -Drag chain: 1.5 kw Motor power -Fluffer wheel: 1.9 kw

12. Main bagasse conveyor type Belt conveyor with plough arrangement is provided for diverting the bagasse to feeders. The bagasse chutes are provided with level sensors for auto operation of plough.


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SL NO

TITLE DESCRIPTION

13. Oil burner and its accessories Provided. But not being used for more than 10 years. Not in operable condition.

14. Type of furnace walls

Spaced tubes with back up walls made of refractory & Insulation bricks, calcium silicate board and weather proof steel sheet casing, seal welded on Front, LHS and RHS. Refractory baffle wall between furnace rear wall tubes and bank tubes, on furnace rear.

15. Type of bank side and rear walls Spaced tubes with back up walls made of refractory & Insulation bricks, calcium silicate board and weather proof steel sheet casing, seal welded on LHS and RHS. Refractory baffle wall between rear most two rows of bank tubes, with plain refractory tiles on outside and external steel casing, seal welded, on boiler rear.

16. Economiser Not provided

17. Air preheater Provided at boiler bank outlet Type: Tubular (gas through tubes) Number of blocks : 4 Number of pass : 2 Heating surface area : 2980 Sq.m Air inlet temperature : 27 Deg.C Air outlet temperature : 227 Deg.C

18. Type of dust collecting equipment provided

Multi-cyclone type Mechanical Dust Collector, provided below the APH. No. of cyclones: Width 16 x Depth 7 = 112 Clean gas outlet pipe: OD 216.3 x 5.8 thk Cyclone outside pipe: OD 406.4 x 6 thk Gas inlet : Vertical, top entry Gas outlet: Horizontal, rear exit


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19. Ash handling system Grate ash hoppers 12 Nos.: Periodically dumped to wagon through rack & pinion gates Mud drum ash hoppers 2 Nos.: Continuously discharged to wagon through rotary air lock valves Fly ash arrestor ash hoppers 3 Nos.: Continuously discharged to a screw conveyor through rotary air lock valves and transferred to a belt conveyor and in turn to an ash silo, for further disposal to trucks.

20. Water treatment plant for generation of feed water for boiler start-up and make-up requirement

Not provided. Boiler is started with raw water and subsequently vapour condensate from evaporator station is used as make-up water.

21. Deaerator cum storage tank Provided. But not used separately. Deaerator cum storage tank is connected to a horizontal cylindrical storage tank, kept at a lower elevation. Deaerator is charged with steam.

22. Feed water temperature at deaerator outlet

No instrument is available to measure the water temperature

23. Induced draft (ID) fan Number of fan : One (1) Volume flow : 133.33 m3/sec Static pressure : -200 mmwc Gas temperature : 370* Deg.C Drive type : Steam turbine Installed Power : 475 KW Impeller speed : 900 RPM *- Gas temperature mentioned in ID fan drawing is very high


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24. Primary Forced Draft (PFD) Fan Number of fan : One (1) Volume flow : 45 m3/sec Static pressure : 200 mmwc Gas temperature : 27 Deg.C Drive type : Motor, directly coupled Installed Power : 150 KW Impeller speed : 980 RPM

25. Secondary Forced Draft (SFD) fan

Number of fan : One (1) Volume flow : 10.5 m3/sec Static pressure : 300 mmwc Gas temperature : 250 Deg.C Drive type : Motor, directly coupled Installed Power : 55 KW Impeller speed : 1460 RPM

26. Bagasse Spreader air fan Number of fan : One (1) Volume flow : 10.5 m3/sec Static pressure : 200 mmwc Gas temperature : 250 Deg.C Drive type : Motor, directly coupled Installed Power : 37 KW Impeller speed : 1460 RPM

27. Electrical motor driven Feed pump

Number of pump : One (1) Pump capacity : 150 cu.m/hr Differential head : 24.75 kg/sq.cm(g) Pumping temperature: 102 Deg.C Motor power / speed: 150 KW/ 2970 rpm

28. Steam turbine driven Feed pump

Number of pump : One (1) Pump capacity : 150 cu.m/hr Differential head : 24.75 kg/sq.cm(g) Pumping temperature: 102 Deg.C Turbine power / speed: 150 KW/ 2970 rpm


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29. Soot Blowers Type Manually operated Rotary soot blowers -6 Nos., for boiler bank and 2 Nos., for superheater zones, were provided originally. However, almost all the soot blowers are missing now.

30. Chimney A parallel steel chimney is provided for 32 m height. Diameter of the chimney: 2480 mm

31. Controls & Instrumentation Yokogawa make CS-3000 DCS is provided for boiler, with only about 15 inputs and 14 outputs, which includes a few parameters of boiler No.1 and Pressure reducing stations (RS1 & RS2).


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4.0 SCOPE OF SUPPLY AND SERVICES 4.1.0 SCOPE OF SUPPLY:

4.1.1 Water Treatment Plant (DM plant) of 20 cu.m/hr capacity for generation of

treated water for boiler start-up and make-up duty.

4.1.2 Straight furnace tubes OD 76.1 mm x 4 mm thick x 3000 mm long - 8 Nos., as SA 210 Gr.A1, to replace the bend tubes of oil burner opening in RHS wall of furnace.

4.1.3 Pipe 350 NB x 3000 mm long - 1 No., as per SA 106 Gr.B, to replace the steam separator inside the boiler house, in existing main steam piping.

4.1.4 Three drum bagasse feeders with drives, power cables, control cables and Variable Frequency Drives.

4.1.5 Structural members required for modification of existing feeder floor, to suit the installation of new three drum feeders.

4.1.6 Inclined portions of Bagasse chutes above the new feeder, up to the existing discharge hood of belt plough.

4.1.7 Bagasse chute between the three drum feeder and the new pneumatic distributor.

4.1.8 Pneumatic distributors and its mounting frame, Rotary air dampers and its drives, base frames, inlet / outlet ducts & supports, Stainless steel flexible hoses for air connection to distributors.

4.1.9 Bagasse spreader air fan of adequacy capacity and static head, with motor, power and control cables, switch gear, suction damper, applicable expansion bellows.

4.1.10 Components / consumables required for restoration of ID fan impeller, via wear plates, blades, hard facing and in-situ dynamic balancing of ID fan.

4.1.11 Pony motor, switch gear, cables, base frames, foundation bolts, clutch system with pneumatic cylinder, 'V' grooved pulleys and belts, control


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instruments, which are required for incorporating pony motor drive for the existing turbine driven ID fan, for initial start-up.

4.1.12 Refractory bricks, insulation bricks, castable refractory, high temperature mortar, ceramic wool for expansion gaps / insulation purpose, reinforcement anchors, retaining flat irons, steel plates for closing the gap, as applicable, incidental to the following works: a. Replacement of existing bagasse spreader with new pneumatic

distributors. b. Replacement of existing dumping grates assembly with new dump grate

assembly. c. Repairs to the brick lining of existing dumping grate ash hoppers. d. Repairs to the brick lining of mud drum ash hoppers. e. Repair / closing of explosion door openings on LHS and RHS walls of

furnace. f. Refractory lining of new ash hoppers of fly ash arrestor. g. Repairs at miscellaneous locations in the boiler, where refractory and

insulation works are disturbed.

4.1.13 Dump grate assembly with supporting frame above the firing floor, grate operating levers, pneumatic cylinders and its air lines, cylinder operating valves, air filter cum regulator and speed controllers, as applicable.

4.1.14 Manually operated Rack & pinion gates for dumping grate ash hoppers.

4.1.15 Secondary steam separators with stainless steel elements and its supporting components, for steam drum.

4.1.16 Air preheater, with tube plates, tubes, casing, integral supports, stiffeners, expansion bellows, supports structure and frames. Preference will be given to the bid, envisaging separate air heater blocks for first pass and second pass, with associated modifications in inlet and outlet air ducting, for ease of maintenance and tube replacement in first block, which will be working at low temperature.

4.1.17 Assorted plates and structural members to be used as flanges, stiffeners & supports for ducts, columns, bracings and supports, for repair / replacement of damaged portions in boiler, at the following locations: These materials


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may be partially raw materials and partially semi finished to reduce the work content at site.

a. Cold air ducting between FD fan and APH Inlet, including internal guide

vanes. b. Flue gas ducting between fly ash arrestor and ID fan. c. Flue gas ducting between ID fan and chimney. d. Casing and suction cone of primary forced draft fan. e. Casing, suction cones and suction boxes of ID fan. f. Damaged chairs of boiler columns. g. Damaged bracing members in boiler structure. h. Damaged stairway supports and floor members

4.1.18 Angle irons and GI corrugated roofing sheets, for covering the top of flue

gas ducting between fly ash arrestor and ID fan, to prevent rain water entrainment into insulation and damage to insulation during movement of personnel.

4.1.19 Floor gratings and chequered plates for boiler floors, where damaged.

4.1.20 Suction box cum silencer for primary forced draft fan, including bird screen, rain hood and supports.

4.1.21 Control damper for primary forced draft fan, without power cylinder.

4.1.22 Fly ash Arrestor components, with lower fitting plate, lower casing, upper casing, inside pipes, outside pipes, guide vanes, upper fitting duct, hoppers, rotary air lock valves & its drives, cables and switch gears, man-hole doors for hoppers.

4.1.23 Metallic expansion bellow with welded ends, for fly ash arrestor outlet, with stainless steel sheet Gr.304 convolutes and carbon steel skirt sheet.

4.1.24 Metallic expansion bellow with welded ends, for both the suction boxes of ID fan, with stainless steel sheet Gr.304 convolutes and carbon steel skirt sheet.

4.1.25 Dampers for both the suction boxes of ID fan, with coupler shaft & universal coupling for joining both the dampers, for common cylinder operation.


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4.1.26 Materials for thermal Insulation of boiler components, for 1300 sq.m area

(actual area to be covered, irrelevant of measurement area as per standard), including mattress of assorted thickness, fixing materials for mattress and cladding sheet, plain aluminium sheet, bitumen felt / sealing compound.

4.1.27 Assorted steam traps - 10 Nos., with size ranging from 15 NB to 25 NB, for installation in drain lines of steam piping at various locations (15 NB-2 Nos., 20 NB-6 Nos., and 25 NB-2 Nos.).

4.1.28 Assorted valves - 10 Nos., with size ranging from 15 NB to 40 NB, for installation in drain lines of steam piping at various locations (15 NB-3 Nos., 20 NB-3 Nos., and 25 NB-2 Nos., 40 NB-2 Nos.).

4.1.29 Sheet 4 mm thick and stiffener flat iron 75 x 6, for covering 40 sq.m area of boiler casing, for use wherever, casing is missing / damaged.

4.1.30 Instruments required for providing pressure and temperature compensation for the existing steam flow meter and feed water flow meter.

4.2.0 SCOPE OF PERMANENT DISMANTLING OF UNWANTED ITEMS IN

BOILER STATION: 4.2.1 Oil burner assembly

4.2.2 Skid mounted Pumping & Heating unit and associated piping

4.2.3 Oil day tank and its support structure, including piping

4.2.4 Combustion air fan and its discharge ducting of oil burner

4.2.5 Burner cooling air fan and its discharge piping

4.2.6 Explosion doors on LHS and RHS walls and its duct vents

4.2.7 Steam separator assembly and its drain arrangements in main steam piping

at boiler end.

4.2.8 Unused, multi compartment chemical dosing tank and its supports, near the feed water pump turbine.


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4.2.9 Unused panel and its cables, for dump grate ash handling system

4.2.10 Unwanted supports / structures left in boiler, over the years

4.3.0 SCOPE OF DISMANTLING TO FACILITATE REPAIRS / REPLACEMENT IN BOILER:

4.3.1 Bagasse chutes above the drag chain type feeders.

4.3.2 Drag chain type feeders and its drives.

4.3.3 Floor gratings and members in feeder floor.

4.3.4 Bagasse chutes below the drag chain type feeders.

4.3.5 Existing bagasse spreaders and its duct connections.

4.3.6 Common drive shaft arrangement for pulsating movement of trajectory

plate.

4.3.7 Front brick wall of furnace to facilitate replacement of spreaders and dumping grate assembly.

4.3.8 Dumping grate assembly and its operating lever arrangement.

4.3.9 Supporting frame for dumping grate assembly, above the firing floor.

4.3.10 Refractory bricks and castable refractory lining below the dumping grate.

4.3.11 Existing spreader air fan, its motor and its base frame.

4.3.12 Portions of suction and delivery ducting of spreader air fan.

4.3.13 Rack & pinion gates below the grate ash hoppers.

4.3.14 Existing secondary steam separator assembly and its supports in the steam drum.

4.3.15 Tubular air preheater assembly and its casing.


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4.3.16 Supports for air preheater.

4.3.17 Cold air ducting between primary forced draft fan and APH.

4.3.18 Primary forced draft fan casing, suction silencer with supports, rain hood

and bird screen.

4.3.19 Portions of hot air ducting from APH to common bus duct at bottom.

4.3.20 Fly ash arrestor assembly, with internal elements, ash hoppers & its refractory lining, bypass chutes for the hoppers, portions of supporting structure, rotary air lock valves and its drives, ash screw conveyor and its drives.

4.3.21 Air lock ash discharge valves and its drives below the mud drum ash hoppers, damaged bottom mouth portions of ash hoppers.

4.3.22 Flue gas duct between fly ash arrestor and ID fan and its supports.

4.3.23 Expansion bellows and dampers at the inlet of ID fan.

4.3.24 Suction boxes, inlet cones, impeller casing of ID fan.

4.3.25 Flue gas duct between ID fan and chimney, including a fabric bellow at fan discharge.

4.4.0 SCOPE OF FABRICATION IN BOILER: 4.4.1 Components for restoration of damaged chairs of columns in boiler station.

4.4.2 Replacement of fan casing, inlet cone, suction box cum silencer for primary

forced draft fan.

4.4.3 Replacement of fan casing, inlet cones and suction boxes for ID fan.

4.4.4 Flue gas ducting from APH to chimney through fly ash arrestor and ID fan.

4.4.5 Cold air duct from primary forced draft fan to APH.


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4.4.6 Hot air duct from modified APH outlet to existing common bus duct near the grate ash hoppers.

4.4.7 Supporting structure for the air preheater and fly ash arrestor.

4.4.8 Replacement floor members, bracing between columns, stairway supports, chequered plates and gratings for boiler floors.

Note: It is left to the discretion of bidder, considering fabrication of items

at site or send shop fabricated items to site, depending on their convenience.

4.5.0 SCOPE OF ERECTION WORK IN BOILER: 4.5.1 All items supplied by the contractor as part of the revamping program of

boiler, shall be installed.

4.5.2 All items to be fabricated at site or all items fabricated at shop and supplied in fully finished or semi finished condition, are to be installed.

4.5.3 Fixing of thermal insulation with weather proof cladding sheet, after ensuring complete welding and air tightness of the system.


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5.0 ESTIMATED QUANTUM OF SUPPLY AND SERVICES

SL NO

SCOPE UNIT ESTIMATED QUANTITY /

REMARKS

1 Supply of equipment and components, as per chapter No.4 for revamping of boiler. MT 405

2 Dismantling of unwanted items from boiler area permanently. MT 25

3 Dismantling of equipment / components to facilitate repairs / replacement in boiler. MT 355

4 Fabrication of equipment / components at site for repairs / replacement in boiler. MT 80

5

Erection of equipment / components for revamping of boiler, including application of thermal insulation, brick/ refractory works and De-mineralization plant

MT 405

6 Fixing of thermal insulation for areas to be repaired / replaced and wherever missing / damaged.

SQ. M 1300

7 Providing commissioning support services after the revamping of boiler. LOT 1

8 Critical spares for two (2) years operation LOT 1**

**-Bidder to attach a list of critical spares considered for two (2) years operation of the boiler.


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6.0 EXCLUSIONS

6.1 Civil works, incidental to the revamping program of boiler. 6.2 New bagasse spreader air fan's foundation, if required. 6.3 Repairs to the existing civil foundation of bagasse spreader air fan, if

required. 6.4 Routine maintenance of boiler like, cleaning of boiler free of ash, repairs to

brick lining, castable refractory lining at various locations, where modifications are not planned as part of boiler revamping.

6.5 Servicing of various valves, including drum and superheater safety valves. 6.6 Arresting of leakages in flange joints / gland arrangement / bonnet flange

joints of valves at different locations. 6.7 Hydraulic testing of various valves and carrying out repairs to the valves. 6.8 Restoration of existing draft gauges, temperature measuring instruments

and multi-point temperature indicator. 6.9 In-situ dynamic balancing of primary forced draft fan, secondary forced

draft fan and bagasse spreader air fan. 6.10 Power and control cables disconnection for existing motors and switch

gears at the time of dismantling and providing connections to new motors and switch gears.

6.11 Permanent lighting for the boiler. 6.12 Cleaning of steam coil air prehater free of ash deposit in finned tubes. 6.13 Level sensors and cables for new bagasse chutes, above the proposed three

drum feeders. FSC to dismantle the existing sensors and associated cables, preserve them for reuse and re-install after the erection of new chutes.


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7.0 TECHNICAL SPECIFICATION FOR CONTINUOUS BAGASSE FEEDING SYSTEM

7.1 This specification is intended to cover the design, engineering, manufacture,

fabrication, assembly at manufacturers works, packing and shipment of critical components for bagasse feeding system, as specified, to M/s. Fiji Sugar corporation, Rarawai Unit.

7.2 Bagasse Feeding system shall be continued from the existing discharge hood

of belt plough, through new bagasse storage chute, three drum feeder, discharge chute, and Pneumatic distributor with rotary air dampers. According to the new fuel feeding system equipments, feeder floor modification shall be considered.

7.3 The equipment and services furnished shall meet all the requirement of this specification, data sheets etc. In case of any conflict / contradiction among various parts of the specification and data sheets, the same shall be referred to the consultants for clarification whose decision shall be final and binding.

7.4 The equipment covered by this specification shall comply with the requirements of all applicable and latest Codes.

7.5 DESIGN PARAMETERS: a. Total Bagasse quantity at MCR (Kg/hr) : 50,000 Kg/hr (Approx.)

b. Bagasse analysis

• Hydrogen - 3.25% • Carbon - 23.5% • Oxygen - 21.75% • Moisture - 50.0% • Ash - 1.5% • GCV - 2272 Kcal/Kg


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The main fuel for the boiler is Bagasse. No other biomass fuel with high ash content will be used, in view of dumping grate furnace in the boiler. c. Density of Bagasse

• For equipment Design : 120-150 kg/m3 • For Power Loading : 350 kg/ m3 • For bagasse storage chute load

calculations : 250 kg/ m3

d. Required air pressure for spreader : About 500 mmWC e. Spreading Air temperature : 227 ° C f. No. of feeding streams per boiler : 6 g. Three drum feeder capacity : 12000 kg/hr

h. Bagasse distributor capacity : 13000 kg/hr

7.6 The fuel feeders shall be sized with (n-1) feeders, to meet MCR fuel requirements while firing the mill bagasse with a density of 120 to 150 kg/m3 and with the moisture content of 50 ±2%. Under this condition if one feeder is out of service, the remaining feeders shall be able to meet the 100 % MCR capacity of the boiler. However, with all the feeders running the boiler shall be capable of generating the MCR capacity even with the bagasse density of 120 kg/m3

7.7 The bagasse feeding system, in addition to the storage chute, shall consist

of feeders, discharge chutes and the distributor.

7.8 The discharge chutes shall be designed to prevent choking of bagasse and necessary poking facilities shall be given. For sizing the feeding system the density of bagasse shall be taken as 120 to 150 Kg/m3 with a moisture content of 50 ± 2%.


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7.9 The three drum feeder shall be of proven design and shall be capable of handling occasional lumps. As the three drum feeder is used for the regulation of bagasse flow, suitable variable frequency drive shall be provided.

7.10 The three drum feeder motor rating shall be 5.5 kW. However, the motor

rating shall be as per design requirement along with the gear unit, to provide increased margin in the drive, to meet wide fluctuation in the bagasse moisture.

7.11 The feeders shall be driven by motors running at 1500 rpm, capable of VFD operation. The gear box used for speed reduction shall be planetary gear box. The body of the extraction feeder shall be min 8 mm carbon steel.

7.12 The feeder shall be provided with internal lining, using 3 mm thick sheet, made of stainless steel Grade 304, to prevent corrosion of parts.

7.13 The fuel distributor shall be a proven equipment to distribute bagasse uniformly across the furnace. The distributor shall have provision for on load adjustment of throw of the fuel. The distributor parts facing the radiation from the furnace shall be of proven heat resistant material Grade 304 stainless steel. The number of feeders shall be 6 nos.

7.14 Adequate secondary air shall be given to the distributor for its cooling and preventing warping from direct radiation from the furnace, especially when there is no or less fuel flow.

7.15 The distribution air supplied to the pneumatic distributor shall be supplied through a rotating damper which will close and open the air supply alternatively imparting weaving motion to the bagasse being distributed over the grate. This will ensure uniform distribution of fuel across the width and depth of the furnace. The damper flap area will be such as to ensure a minimum air flow always to the distributor, even in its closed position. The rotating dampers of three distributors shall be driven by a geared motor, through a common drive shaft and sprockets and chains. The bearings of


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the rotary air dampers shall be of steel-on-steel teflon coated bush type, with provision for grease lubrication, as hot air is handled by the dampers.

7.16 The counter part of coupling being supplied in the scope of Bidder should

have the bore of connecting driving equipment. 7.17 Surface Preparation and Painting

• Surface quality - St 2 ½ • No. Of coats - 2 P+1F (P=Primer & F=Finish) • DFT/Coat (P/F) - 35 microns + 35 microns • Paint system- P – High Build chloro rubber based

zinc phosphate primer. F – Chloro rubber paint

• Color - Smoke grey

7.18 The list of items to be supplied shall be as below:

Sl. No Item Description Qty.

7.18.1 Three drum feeder 6

7.18.2 Coupling between gear box and three drum feeder 6

7.18.3 Coupling between motor and gear box for three drum feeder 6

7.18.4 Base frame for three drum feeder drives 6

7.18.5 Coupling Guards for three drum feeder 1 Lot

7.18.6 Motor for three drum feeder (Suitable for VFD) 6

7.18.7 Planetary Gear box for three drum feeder 6

7.18.8 Pneumatic distributor 6

7.18.9 Mounting Frame for pneumatic Distributor 1 Lot


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Sl. No Item Description Qty.

7.18.10 Cooling air pipe for pneumatic distributor 1 Lot

7.18.11 SS flexible hoses for pneumatic distributor 20 nos.

7.18.12 Rotary air damper assembly with motor 2set

7.18.13 Coupling between geared motor & rotary air damper 2

7.18.14 Coupling Guards for rotary air damper drive 1 Lot

7.18.15 Chain Guard for rotary air damper 1 Lot

7.18.16 Support for rotary air damper assembly 1 Lot

7.18.17 Inter connecting ducts at inlet and outlet of rotary air damper 1 Lot

7.18.18 Geared Motor for rotary air damper 2+1

7.18.19 Feeder discharge chutes 6

7.18.20 Bagasse storage chutes 6

7.18.21 Fasteners 1 Lot

7.18.22 Platform for supporting feeding system 1 Lot

7.18.23 Feeder floor 1 Lot

7.18.24 Critical spares for two (2) year operation of boiler 1 Lot

7.19 DOCUMENTS TO BE SUBMITTED AFTER AWARD OF ORDER: 7.19.1 Technical specification for bagasse feeding system

7.19.2 GA drawing for the continuous bagasse feeding with the levels of belt

conveyor.

7.19.3 Load data on feeder floor, for feeder locations.


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7.19.4 GA drawings for the items supplied by BIDDER

7.19.5 Selection calculations of Drive, Gear box and coupling.

7.19.6 Brief specification of Bought-out items, to be procured by customer, if any.

7.19.7 Specification of Variable frequency drives and control panel.

7.19.8 Control schematics, as applicable.

Note: The documents listed in clause 7.19 shall be furnished within four (4) weeks from the data of our order. The schedule of document submission shall be furnished to consultant for their approval.


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8.0 TECHNICAL SPECIFICATION FOR DUMPING GRATE ASSEMBLY

8.1 The dumping grate is divided into small sections which can be dumped by

sequence one after another without causing high pressure drop in the boiler during dumping process.

8.2 The dumping grate arrangement shall ensure that the air distributed

across the grate section is uniform and does not bypass across the grate assembly, through unintended large gaps between grate bars and between rows of grate bars.

8.3 The vendor shall furnish adequate information for fully understanding the

construction and supporting details of the grate along with their offer. 8.4 The material of the grate bar and expansion gaps shall be suitably selected

considering the hot air temperature entering to the dumping grate at about 227°C and combustion temperature above the Grate at about 1200°C for bagasse firing.

8.5 Well established and proven sealing system has to be provided between

the pressure parts / brick wall and the grate. 8.6 For other data of equipment, refer the table given below:

TITLE: Dumping grate assembly with supporting frame

Project:115 TPH, 17.57 kg/sq.cm(g), 280°C

SL. NO.

DESCRIPTION UNIT PURCHASER’S

REQUIREMENTS/ BIDDER’S DATA

8.6.0 EQUIPMENT DATA

8.6.1 Dumping grate type **

8.6.2 Grate area m2 45.70 (approx)


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SL. NO.



8.6.3 Grate bar overall size mm x mm **

8.6.4 Grate section size, width and depth mm x mm **

8.6.5 Air plenum pressure below the grate bars mmWC **

8.6.6 Actual grate area loading MMkcal/ m²/ hr **

MATERIAL OF CONSTRUCTION

8.6.7 Grate bars **

8.6.8 Square shaft **

8.6.9 Bearing holder **

8.6.10 Bearing housing **

8.6.11 Bearings **

8.6.12 Connecting lever **

8.6.13 End bars **

8.6.14 Supporting structures **

8.6.15 Bolts, Nuts, Washers **

8.6.16 Pins **

8.6.17 Split pins

Erection & Commissioning Spars List

8.6.18 Grate bars each type

Nos 25

8.6.19 Square shaft Nos 5


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SL. NO.



8.6.20 Connecting lever Nos 5

8.6.21 Bearing Holder Nos 2

8.6.22 Bearing Nos 5

8.6.23 Bearing Housing Nos 5

8.6.24 Pins and split pins Nos 10 sets

Furnace Details

8.6.25 Furnace width (CC distance between LHS & RHS water walls tubes) mm 9025

8.6.26 Furnace depth (CC distance between front & rear water walls tubes) mm 4815

8.6.27 Operating floor elevation mm 3700

8.6.28 Bagasse quantity at MCR, considering low boiler efficiency

kg/hr 50000 (approx)*

8.6.29 Bagasse quantity at Design kg/hr 55000 (approx)*

8.6.30 Ash in bagasse % 1.5% (approx)

Note:

1. ** - Bidder to furnish the details, in their offer.

2. * - Bidder to furnish the Bagasse consumption of boiler at MCR, after implementing the revamping of boiler

8.7 DOCUMENTS TO BE SUBMITTED ALONG WITH OFFER 8.7.1 General Arrangement drawing for Dump grate assembly.

8.7.2 List of critical spares considered for supply, for two years operation.


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8.8 DOCUMENTS TO BE SUBMITTED AFTER AWARD OF THE CONTRACT

8.8.1 GA of Dumping grate assembly with bill of materials.

8.8.2 GA of Dumping grate operating levers and details.

8.8.3 GA of Dumping grate supports and details.

8.8.4 O & M manual for the dumping grate assembly.


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9.0 TECHNICAL SPECIFICATION FOR BAGASSE SPREADER AIR FAN

9.1 BAGASSE SPREADER AIR FAN - DATA SHEET:

SL NO PARAMETERS UNIT DATA

1. Application - Bagasse spreader air fan for boiler

2. Duty - Continuous

3. Medium to be handled - Hot air at 227˚C

4. Mechanical design temperature ˚C 250

5. Fan mounting arrangement - **

6. Volume flow at Design M3/sec 10.5

7. Available suction air pressure MMWC 25

8. Static pressure (MCR) MMWC 550

9. Static pressure (Design) MMWC 650

10. Static efficiency of fan at MCR % **

11. Quantity No. One (1)

12. Type of drive - Electrical motor with 1500 rpm, Directly coupled

13. Method of fan control - IGV damper

14. Coupling - **

15. MOC Casing / suction box / scroll plate -

IS 2062 / IS 2062 / IS 2062

16. MOC of impeller BP/blade / shroud **


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SL NO

PARAMETERS UNIT DATA

17. Shaft - EN 8D / 080A42 cleared by UT

18. Inlet Guide Vane (IGV) control damper -

Required with arrangement for locking the damper at different

% of opening

19. IGV damper operation - Manual

20. DE & NDE bearing - **

21. DE & NDE bearing housing - **

22. Expansion joint at the inlet and outlet of the fan -

Metallic bellows required at the inlet and outlet of fan with

stainless steel Gr.304 convolutes

23. Shaft seal at penetration points in the casing -

Required for both drive and non-drive ends

24. Dynamic balancing standard for the fan - As per IS 1940 Gr.2.5

25. Noise level dB(A) Less than 85 at 1.0 meter

distance from the fan

26. Surface preparation and painting -

Grit blasting, two coats of primer and one coat of Heat Resistant Aluminium paint

Note: The foundation details of the existing bagasse spreader air fan is attached as annexure-I. The bidder to check the possibility of using the existing foundation of bagasse spreader air fan for the proposed new bagasse spreader fan.


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9.2 SCOPE OF SUPPLY - BAGASSE SPREADER AIR FAN:

SL NO Particulars Quantity

1. Casing with drain plug & inspection door 1 No.

2. Inlet Box with drain plug & inspection door 1 No.

3. Inlet Guide Vane damper with provision for locking the damper at different percentage of opening. 1 No.

4. Impeller 1 No.

5. Hub 1 No.

6. Shaft 1 No.

7. Bearings, adapter sleeves, locating rings 2 Nos.

8. Bearing housings with grease nipples and provision for RTD sensors 2 Nos.

9. Short steel Bearing pedestal for DE & NDE Bearing housings 2 Nos.

10. Base frame for Drive motor 1 No.

11. Shaft seals for drive and non-drive ends 2 Nos.

12. Resilient coupling 1 No.

13. Coupling cover 1 No.

14. Cooling Disc 2 Nos.

15. Cooling Disc Guard 2 Nos.

16. Metallic expansion joint at fan inlet 1 No.

17. Metallic expansion joint at fan outlet 1 No.

18. Foundation bolts, Hexagonal bolts and nuts for flanges, sealing rope for flanges. 1 Set

19. Any other item that may be required to make the bagasse spreader air fan assembly complete 1 Lot

20. Grit Blasting & Painting As per the data sheet

9.3 DOCUMENTS TO BE SUBMITTED ALONG WITH OFFER 9.3.1 Filled in data sheet and a list of spares considered for supply for 2 years

operation


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10.0 TECHNICAL SPECIFICATION FOR AIR PRE-HEATER ASSEMBLY SL. NO

PARAMETER DATA

1. No. of Tubes and length(mm) 1986 Nos., & 6000 mm long each

2 Tube Dimensions OD 76.2 mm & 3.5 mm Thk

3 Tube plates size (mm)

22 mm thk plate: 2990 x 2205 & 2990 x 2580 12 mm thk plate: 2990x 1758 and 2990 x2210 6 mm thk plate: 3060 x 2615 & 3060 x 2205

4 Number of Tube plates (thickness in mm) 02 Nos. (22mm), 02Nos. (12mm), 02Nos. (6mm)

5 Material of construction for tube **

6 Materials of construction for tube plates and casing Carbon steel

7 Material of construction for supporting structural’s A36 / IS 2062 E250 BR

8 Total Tonnage of casing, Structural and tube sheet As per attached drawing

Note: 1. ** - Bidder to furnish the details in their offer.


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11.0 TECHNICAL SPECIFICATION FOR FLY ASH ARRESTOR

SL NO

PARAMETERS UNIT DATA

Refer drawing DC-112 BA TYPE Fly ash arrestor assembly drawing attached

1 Application - Fly ash arrestor for bagasse fired boiler

2 Flue gas temperature ˚C 250

3 Capacity m3/min 6950

4 Pressure loss Pa 785

5 Quantity No. One (1)

6 Lower and upper Casing MOC A36 / IS 2062 E250 BR

Lower fitting plate and upper fitting ducts MOC A36 / IS 2062 E250 BR

7 Inside pipe MOC A36 / IS 2062 E250 BR

Outside pipe MOC A36 / IS 2062 E250 BR & Stainless steel Gr.304

8 Guide vane MOC FC 20 / equivalent

9 Hopper with bypass MOC A36 / IS 2062 E250 BR

10 Ash discharge rotary valve MOC A36 / IS 2062 E250 BR

11 RAV motor details 0.75 KW, 50Hz, 415 V

12 Supporting structure MOC A36 / IS 2062 E250 BR

13 Inspection Door MOC A36 / IS 2062 E250 BR


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12.0 TECHNICAL SPECIFICATION FOR SECONDARY STEAM

SEPARATORS

SL. NO

DESCRIPTION REQUIRED

1. Application For Boiler steam drum internals

2. No. of Drier Boxes ** ( To meet 100% MCR)

3. Medium handled Saturated steam

4. Size of the Drier Boxes **

5. Material of construction for drier boxes A36 / equivalent

6. Materials of construction for steam separator elements A 478 Gr.304

7. Material of construction for supporting structural A 515 Gr.70 / equivalent

8. Type of elements in Drier Boxes Woven wire mesh

9. Steam Quality 98 %

10. Width and depth of feed 600 MM x 5400 MM (approx)

11. Materials of construction for fasteners. IS 1353 & IS 1364

12. Drain system for separator assembly Required

13. Type of construction Bolted


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13.0 TECHNICAL SPECIFICATION FOR WATER TREATMENT PLANT

13.1 SCOPE OF WORK: The scope is intended to cover the design, engineering, procurement,

manufacture, shop fabrication, assembly, pre-assembly, tests and inspection at manufacturer’s works, packing, shipment, supply, unloading, leading to storage area, reloading, leading to erection site, erection & commissioning, trial run and performance testing of water treatment plant, including critical spares for two years operation at M/s.Fiji Sugar Corporation, Rarawai mills, Fiji Islands.

13.2 THE SCHEME AND CAPACITY OF WATER TREATMENT PLANT:

Raw water →Multi Grade Filter → Strong Acid Cation (SAC) Exchanger → Degasser System → Strong Base Anion (SBA) Exchanger → Mixed Bed Polishing System (MB) → DM water storage tank. The Multi grade Filter shall be sized for the flow rate of 20 cu.m/hr. The Strong Acid Cation (SAC) Exchanger shall be designed for the flow rate of 20 cu.m/hr with an OBR of 320 cu.m with 16-8 cycle of operation. Degasser system shall be sized for the flow rate of 20 cu.m/hr. Strong Base Anion Exchanger shall be designed for the flow rate of 20 cu.m/hr with an OBR of 320 cu.m with 16-8 cycle of operation. The Mixed Bed (MB) polishing system shall be designed for a flow rate of 20 cu.m/hr. with an OBR of 2240 cu.m.


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14.0 SPECIFIC REQUIREMENTS / SERVICES

14.1.0 General

14.1.1 The contractor shall select and adopt methods and procedures for equipment dismantling and erection, to suit nature of the equipment and site condition, according to the best practices and experience. However, the contractor shall not make any alteration to the equipment or to the facility to facilitate assembly or erection work, without approval of the owner / consultant.

14.1.2 All assembly in erection procedures adopted by the contractor shall be

open for inspection and approval by the owner / consultant. It is obligatory on the part of the contractor to give / identify daily feedback on work progress and on technical aspects.

14.1.3 Minor rectification work to equipment and structural steel work for

proper assembly and fitting work like grinding, chipping, tack welding, cutting, drilling etc. are considered part of the dismantling and erection work. Temporary erection / alignment / edge preparation / straightening / temporary supports etc, which are incidental to erection work and necessary to complete the work satisfactorily, shall be carried out by the contractor as part of the work.

14.1.4 During the course of the work, the contractor shall keep the equipment /

structures adequately braced by guys, struts or other approved means which shall be arranged by the contractor. All work shall be executed considering adequate precautions towards safety of equipment / building and the work force.

14.1.5 The power supply for dismantling / erection work will be supplied at one

point by the owner. The contractor will arrange all power distribution required for the execution of the scope of work. Similarly, the contractor shall arrange for temporary area lighting requirements for the dismantling, erection and fabrication work.

14.1.6 The contractor shall schedule his work to meet the targets set by the owner. The contractor shall reschedule the work / employ more work force / work overtime at his own cost, as may be necessary to meet the requirements of schedule.


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14.1.7 Provide all tools and tackles, hand tools, grinding machines, welding

generators / rectifiers, welding cables, welding helmets, hand ovens for electrodes, gas cutting sets, chain pulley blocks and other equipment as required for the proposed dismantling, fabrication and erection work.

14.1.8 Provide qualified HP welders, skilled, semi skilled, unskilled work force,

supervisory staff, site engineers, technicians as required, for the dismantling, fabrication and erection work.

14.1.9 Carry out kerosene chalk leak test of the fabrication works like duct

welding, field welds joints.

14.1.10 Supply the required consumables like welding electrodes / wires, argon cylinder, oxygen cylinder, acetylene cylinder, grinding wheels, cotton waste, emery sheets etc, as applicable.

14.1.11 Provide the painting materials and brush, as required.

14.1.12 Provide the required safety gears to the workers, supervisory staff, site

engineers and technicians, as per the safety standards.

14.1.13 Meet all statutory requirements like insurance, safety requirements, first aid, welfare for the workforce etc as required, for the boiler contractor’s work force and staff.

14.1.14 Organize security / stores person as required, during the dismantling,

fabrication, storage and erection activity, for the contractor's tools and tackles.

14.1.15 Provide isolation switches, switch boxes, electrical cables for welding

machine, grinding machine, hand lamps, and power strip for single phase power etc.

14.1.16 Provide the required scaffolding materials for the dismantling and

erection work.


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14.2.0 Welding:

14.2.1 The contractor shall provide all tools, plant and instruments for carrying out the welding at site. Welding shall be carried out as per relevant codes / good engineering practice.


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15.0 DOCUMENTS TO BE SUBMITTED

15.1 List of tools and tackles to be employed. 15.2 Quality Assurance Plan (QAP) for dismantling, fabrication and erection of

equipment / components for revamping of boiler. 15.3 Site organization chart clearly indicating the man-power to be employed at

various stages and experience of key personnel. 15.4 Write-up on safety precautions to be followed during the contract stage. 15.5 Documentary evidence to show that the firm has executed similar boiler

modifications in the past.

15.6 List of critical spares considered for supply along with major equipment being supplied.


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16.0 GENERAL TERMS AND CONDITIONS

16.1.0 Inspection and testing 16.1.1 Stage inspection by owner / consultant 16.2.0 Guarantee 16.2.1 The bidder shall guarantee for satisfactory performance of the materials

supplied and workmanship in the dismantling, fabrication and erection work for a period of twelve (12) months duration from the date of satisfactory commissioning.

16.2.2 In case of defects in the materials supplied, the bidder shall replace the

defective materials at his cost to the satisfaction of the owner / consultant.

16.2.3 The workmanship shall be in accordance with the good engineering

practice. 16.2.4 In case of poor workmanship in the fabrication / erection work noticed by

the owner / consultant, the contractor shall carry out modification at his cost in the fabrication / erection work, to satisfy the owner / consultant.

16.3.0 General 16.3.1 If the bidder could not meet the delivery schedule provided by the

owner/ consultant for reasons other than Force Majeure condition, the owner at their discretion can engage some other contractor to complete the fabrication and erection work and the payment made to this contractor will be deducted from the original contractor’s payment

16.4.0 Payment terms for Supply: 16.4.1 Twenty Five (25%) percent of the order value shall be paid towards order

acceptance. 16.4.2 Sixty (60%) percent of the order value shall be paid towards proforma

invoice as per billing schedule, inspection clearance and prior to dispatch.


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16.4.3 Ten (10%) percent of the order value shall be paid on erection completion

in all respect and commissioning of the boiler.

16.4.4 Five (5%) percent of the order value shall be retained and paid after defect liability period of one crushing season (8 months) from the date of commissioning of the boiler.

16.5.0 Payment terms for Dismantling and Erection: 16.5.1 Twenty five (25%) percent of the order value shall be paid as down

payment on order acceptance, for mobilization at site. 16.5.2 Sixty (60%) percent of the order value shall be on prorata basis against

the progress of work against weekly running bills. 16.5.3 Ten (10%) percent of the order value shall be paid on completion of all

erection jobs and commissioning of the boiler.

16.5.4 Five (5%) percent of the order value shall be retained and paid after defect liability period of one crushing season (8 months) from the date of commissioning of the boiler.

16.6.0 Delivery (Assuming that the order will be finalized by 20.12.2018): 16.6.1 The complete scope of supply, dismantling, site fabrication, erection of

boiler shall be completed by 31.05.2019.

16.6.2 Pre-commissioning of boiler / steam trials of plant shall be commenced by 01.06.2018 and completed by 09.06.2019.

16.6.3 The boiler shall be ready for crushing operation from 10.06.2019.


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17.0 RESPONSIBILITIES OF M/S.FIJI SUGAR CORPORATION LTD

17. 1 Provide the required copies of original GA drawings and manufacturing drawings with bill of materials / specifications and quantities, for the portions proposed for revamping in boiler No.4, for reference.

17. 2 Provide the required copies of O & M manual of boiler and its auxiliaries

for reference during the revamping program of boiler.

17. 3 Provide the drawing for GA of ID fan and details of impeller with shaft assembly along with material of construction for various components.

17. 4 Clearing the materials from Lautoka seaport / Nadi airport and transporting the materials to Rarawai plant site, after paying the applicable import duty / taxes / fees.

17. 5 To provide power, water and compressed air at one point in the work area, for dismantling, fabrication and erection work.

17. 6 To provide clear work front and work permit for dismantling and erection

work. 17. 7 Initiation of correspondence with local inspector of boilers / factories,

other applicable statutory authorities and further co-ordination, to complete the statutory formalities applicable for revamping of boiler.

17. 8 Providing invitation letters to the staff of contractor for entry to Fiji

Islands and co-ordination with visa authorities for extension of visa and work permit for the staff of contractor, including applicable fees.

17. 9 Providing accommodation for the Engineers and staff of contractor, near to

the plant, for ease of operation. 17. 10 Providing the available first-aid facilities to the Engineers and staff of

contractor, deputed at FSC, Rarawai mills site.


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18.0 PERFORMANCE GUARANTEE PARAMETERS

18. 1 The bidder to provide performance guarantee for operation of boiler No.4 at Maximum Continuous Rating (MCR) of 100 TPH and above, at rated superheated steam parameters of 17.57 kg/sq.cm(g) and 280 Deg.C, after implementation of the revamping program. The existing instruments in the boiler will be used while carrying out performance testing of boiler, after implementing the revamping program. The existing instruments will be tested, calibrated and made to work, by FSC, Rarawai mills.

18. 2 The performance test code for boiler will be as per ASME - PTC 4.

18. 3 The bidder to perform thermal calculations of boiler No.4, considering the modifications to be implemented during revamping of boiler and furnish the predicted operating parameters of the boiler. The predicted operating parameters of the boiler to be provided, will be used as only guide line values for efficient operation and maintenance of boiler and will not form part of guaranteed parameters.


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19.0 PRICE SCHEDULE

Sl. No. Description

Basic price in million

USD

Packing & forwarding in million

USD

Freight & Transit

Insurance in million USD

Total price in million USD on 'CIF Lautoka'

basis

1 Supply of equipment and components, as per chapter No.4 for revamping of boiler.

2 Dismantling of unwanted items from boiler area permanently.

3 Dismantling of equipment / components to facilitate repairs / replacement in boiler.

4 Fabrication of equipment / components at site for repairs / replacement in boiler.

5

Erection of equipment / components for revamping of boiler, including application of thermal insulation, brick/ refractory works and De-mineralization plant

6 Fixing of thermal insulation for areas to be repaired / replaced and wherever missing / damaged.

7 Providing commissioning support services after the revamping of boiler.

8 Supply of critical spares for two years operation.

Note: Price basis shall be 'CIF' Lautoka, Fiji Islands.


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20.0 REFERENCE DRAWINGS AND DOCUMENTS

SL NO Description Drawing Number Remarks

1. Boiler Assembly H-25627 Refer note below

2. Water tube assembly H-34796 Refer note below

3. Superheater tube assembly H-13550

4. Superheater headers H-13549

5. Air Pre Heater Assembly H-14653

6. Frame Assembly for Air Pre Heater H-14654

7. Casing Assembly for Air Pre Heater H-14671

8. Top casing for Air Pre Heater H-14606

9. Tube plate for Air Pre Heater H-14588

10. Fly Ash Arrestor Assembly Yz-17047

11. Inside pipe for fly ash arrestor Y-17904

12. Outer pipe for fly ash arrestor Y-17905

13. Guide Vane for fly ash arrestor Y-17906

14. Lower casing for fly ash arrestor Y-17930

15. Lower fitting plate for fly ash arrestor Yz-17042

16. Upper fitting duct for fly ash arrestor Yz-17043

17. General arrangement for ID Fan -

18. Non-Drive end view for ID fan -


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SL NO Description Drawing Number Remarks

19. Elevation view for Bagasse Spreader Fan -

20. Foundation view for Bagasse Spreader Fan -

21. Dumping Grate Details -

22. Pneumatic air power system for Dumping Grate -

Note: Since the drawings for Boiler assembly and water tube assembly of 115 TPH Yoshimine boiler at Rarawai mills are not available, corresponding drawings for Penang mills are attached, for reference. Boiler make and capacity are reportedly identical for both Rarawai and Penang plants, as Yoshimine Boiler and 115 TPH. However, at Penang mills boiler had no superheater. Whereas, the boiler at Rarawai mills is provided with superheater.

PROJECT : 115 TPH YOSHIMINE BOILER REFERENCE DRAWING : GENERAL ARRANGEMENT FOR ID FAN CUSTOMER : M/S FIJI SUGAR CORPORATION LIMITED-RARAWAI

PROJECT : 115 TPH YOSHIMINE BOILER REFERENCE DRAWING : NON DRIVE END VIEW FOR ID FAN CUSTOMER : M/S FIJI SUGAR CORPORATION LIMITED-RARAWAI

PROJECT : 115 TPH YOSHIMINE BOILER REFERENCE DRAWING : ELEVATION VIEW FOR BAGASSE SPREADER FAN CUSTOMER : M/S FIJI SUGAR CORPORATION LIMITED-RARAWAI

PROJECT : 115 TPH YOSHIMINE BOILER REFERENCE DRAWING : FOUNDATION VIEW FOR BAGASSE SPREADER FAN CUSTOMER : M/S FIJI SUGAR CORPORATION LIMITED-RARAWAI

PROJECT : 115 TPH YOSHIMINE BOILER REFERENCE DRAWING : DUMPING GRATE DETAILS CUSTOMER : M/S FIJI SUGAR CORPORATION LIMITED-RARAWAI

PROJECT : 115 TPH YOSHIMINE BOILER REFERENCE DRAWING : PNEUMATIC AIR POWER SYSTEM FOR DUMPING GRATE CUSTOMER : M/S FIJI SUGAR CORPORATION LIMITED-RARAWAI

BID DOCUMENT FOR SUPPLY OF EQUIPMENT & COMPONENTS ... Bid document, Rev.2 04.12.20… · reach the...

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