E- TENDER FORMsarasmilkfed.rajasthan.gov.in/Tender/MalpuraTENDER-ID...406-414 415-417 418-420...

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(Signed & sealed by the tenderer (RCDF)

in token of acceptance of above) Jaipur

TENDER ID 2017_RCDF_75828_1

FOR

“SUPPLY, ERECTION, TESTING AND COMMISSIONING OF PLANT AND

MACHINERY FOR SETTING UP INDIGENOUS PRODUCT PLANT ON TURN

KEY BASIS” AT MALPURA (TONK) RAJ.

RAJASTHAN CO-OPERATIVE DAIRY FEDERATION LIMITED SARAS SANKUL, JAWAHARWAL NEHRU MARG, JAIPUR

Phone No: 0141-2702501-508, Telefax: 0141-2710209, 0141-2702135 Website: www.sarasmilkfed.co-op, E-mail: [email protected],

[email protected]

E- TENDER FORM

http://www.sarasmilkfed.coop/

mailto:[email protected]


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Important Information

Subject: e-Procurement/tendering system at RCDF

Government of Rajasthan has decided to implement e-procurement system for their departments and PSU to enhance efficiency & transparency in public procurement from April 2012, in which all purchases/ works/ services etc. of value ` 50.00 Lacs or above will be processed electronically through State e-procurement portal i.e. www.eproc.rajasthan.gov.in. Accordingly at RCDF, the existing process of manually submitting bids will be discontinued. Information regarding tenders will be posted on the above mentioned website & bids will also be accepted via the website. A registered user with a valid Digital Signature Certificate (DSC) will be able to access the website, view & download tender details, fill in tender bids & upload (send) to the website. At the scheduled time of tender opening, details of all bids can be viewed by the bidders. Requirement for participating: Internet access (details available on the home page of website www.eproc.rajasthan.gov.in), DSC & registration on the website.

Bidders will need to get a class III digital certificate with encryption – decryption facility through controller of certifying authorities (CCA) approved certifying agencies. Information regarding DSC is available at the home page under ‘Information regarding DSC’. A bidder should enroll on the e-procurement

website & register the DSC. Please arrange to fulfill the necessary requirements of e-procurement, since only the authorized bidders can participate in the tender. A additional fee ( ` 1000/- per tender/bidder for tender value > 50.00 lacs) is payable to RajCOMP info services ltd.(RISL) for participating in e-procurement. Help manual for bidder is available on the home page of the website under ‘Help for contractors’. You can also call on 0141-4022688 & 1800-233-7315 for any

assistance regarding e-procurement during office hours. Bidders training will be provided free of cost by RISL. You may contact concerning department for further clarification(s).

General Manager (DPM & Proj.)

http://www.eproc.rajasthan.gov.in/

http://www.eproc.rajasthan.gov.in/

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RAJASTHAN CO-OPERATIVE DAIRY FEDERATION LTD., “SARAS SANKUL”,J.L.N. MARG, JAIPUR–302017

Phone No. 0141-2702501-508 : Telefax 0141-2702135 : Website : sarasmilkfed.rajasthan.gov.in E-mail : [email protected], [email protected]

INDEX

S.N. PARTICULARS PAGE NO.

1. NIT 01-03

2. INDEX 04-05

3. CHECK LIST OF DOCUMENTS TO BE SUBMITTED 06

4. ELIGIBILITY & QUALIFICATIONS CRITERION 07-09

5. SYNOPSIS OF TENDER 10-20

6. GENERAL TERMS AND CONDITIONS 21-46

7. ADDITIONAL GENERAL TERMS AND CONDITIONS 47-51

8. GENERAL TERMS AND CONDITIONS FOR ERECTION CONTRACT WHEREEVER APPLICABLE

52-98

9. ANNEXURE – I Tender Acceptance Letter (to be given on Company letter head)

99

10. ANNEXURE – II Section –I Manufacturers authorization form format

100

11. ANNEXURE – III Section –II- Schedule-I format of Major works completed during past five years.

101

12. ANNEXURE –IV Section –II- Schedule-II format of Works in hand during current year

102

13. ANNEXURE – V Section –III- Technical Deviation statement format

103

14. ANNEXURE – VI Rate quotation form for supply / supply, installation & commissioning of equipment. Rates to be filled in prescribed file .XLS only.

104-114

15. ANNEXURE – VII Form of agreement required to be submitted by the supplier

115-117

16. ANNEXURE –VIII Form of Bank Guarantee for 30% advance payment

118-119

17. ANNEXURE – IX Performa of Bank Guarantee for releasing 10% balance payment.

120-121

18. ANNEXURE- IX(A) Performa bank guarantee for EMD & SD 122-123



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18. ANNEXURE – X

Detailed technical specification Sub Section-1- Technical Specification Sub Section-2 Project Information Sub section-3 Design Basis Sub section-4 Responsibilities Sub section -5 Battery Limit Sub section-6 Drawing, Data & Documents Sub section-7 Bidders Meeting

124-405 406-414 415-417 418-420 421-422 423-424 425-426

19. List of Recommended Makes 427-430

20. BUILDING LAYOUT 431

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A check list of documents required to be submitted (Each Tenderer is required to upload the required documents failing which the

tender will become liable for no further consideration/evaluation)

Sr. no.

Particulars Cover Yes/No Page

No.

1. Copies of documents defining the constitution of tendering firm along with duly attested

power of attorney for participating in tender on behalf of the firm.

Cover-A

2. Whether manufacturer if yes please attach scanned copy of manufacturing licence. Cover-A

If no, manufacturer’s authorization form be uploaded as per Section I. Cover-A

3. Submit experience of past performance in works of similar nature within the past five

years as per Schedule I of Section II. (Attach copies of Purchase Orders & performance

certificates).

Cover-A

4. Submit details of current works in hand and other contractual commitments, if any, as per

Schedule II of Section II. (Attach copies of Purchase Orders).

Cover-A

5. Submit Technical Deviation statement form as per Section III. (Where there is no deviation,

the statement should be uploaded duly signed with an endorsement indicating “No

Deviations”.

Cover-A

6. Enclose P&L statement and balance sheet for last three years. (Summary only) Cover-A

7. Enclose information regarding current litigation if any. Cover-A

8. Furnish copies of documents showing that the bidder has completed three dairy projects having indigenous product section for production of Ice Cream, Flavoured Milk, Curd, Chhach, Lassi, Paneer, Shrikhand of similar or above capacity.

Cover-A

9. Submit copy of IT returns submitted for the previous three years. Cover-A

10. Submit copy of PAN Card Cover-A

11. Submit copies of Sales Tax Returns submitted for the previous three year. Cover-A

12. Submit copy of Registration certificate of VAT Cover-A

13. Submit acceptance of tender document and specifications in the enclosed format. Do not up-

load tender document.

Cover-A

14. Scanned copy of Demand Draft of Rs. 1,000/-, for each item separately, in favour of MD,

RCDF payable at Jaipur, towards the tender fee.

Cover-A

15. Scanned copy of Demand Draft towards the prescribed EMD in favour of MD, RCDF, payable

at Jaipur.

Cover-A

16. Scanned copy of Demand Draft of Rs. 1000/- towards the Tender Processing Fee in favour of

MD, RISL Payable at Jaipur

Cover-A

17. Please furnish your complete Correspondence address along with all details viz. Telephone

Numbers, Fax Numbers, E-mail ID and the name & designation of the contact person(s) &

his/their mobile numbers. The information may be submitted on the firm’s letter head.

Cover-A

18. Submit a list of recommended spare parts along with their individual prices valid for one

year, as per clause 5.3, in PDF format in part two of the bid.

Cover-B

19. Rates quotation in prescribed .XLS file only. Cover-B

Note : Please submit the documents as per check list S. No. and also mention the S. No. on respective documents.

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Eligibility & Qualifications Criterion

1. The bidder shall furnish, as Part-I of its bid, documents establishing the bidder’s

eligibility to bid and its qualifications to perform the contract if its bid is accepted. The bidder should also give information in the format attached to the bid document.

2. The documentary evidence of the bidder’s qualification to perform the

contract if its bid is accepted shall establish to the purchaser’s satisfaction :

(a) that in the case of a bidder offering to supply goods under the

contract which the bidder did not manufacture or otherwise produce the bidder has been duly authorised by the goods manufacturer or producer to supply the goods. The bid shall include Manufacturers Authorisation Form given under Section-I. Annexure-II. Offers from other agents, brokers & middlemen shall not be accepted.

(b) that the bidder has the financial, technical and production capability

necessary to perform the contract. To this end, all bids submitted shall include the following information under Section – II :

(i) Copies of original documents defining the constitution or legal

status, place of registration and principal place of business of the company or firm or partnership etc.

(ii) Power of Attorney or a true copy thereof duly attested by a

Gazetted Officer in case an authorised representative has signed the bid.

(iii) Details of experience and past performance of the bidder (or each party to a joint venture) on works of similar nature within the past five years, and details of current works in hand and other contractual commitments shall be submitted as per Schedule-I Annexure-III and Schedule-II Annexure-IV given in Section-II respectively of this bidding document.

(iv) Reports on financial standing of the bidder such as profit and

loss statements, balance sheets and Auditors report of the past three years, bankers certificates etc.

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(v) Information regarding any current litigation, past debarment / blacklisting in which the bidder is involved is required to be furnished.

3. For the purpose of establishing the bidders ability to execute this

particular contract, bidders shall submit the following documents :

(a) The bidder should be in business of the jobs tendered for a minimum period of three years at the time of bid opening in the same name and style.

(b) The bidder’s annual financial turnover in the same name and style

during any one of the last three years shall not be less than the estimated value of the contract quoted value.

(c) The bidder in the same name and style shall have completed the three projects of similar nature or above.

(d) The bidder shall furnish a copy of the Income Tax Returns and the Income Tax Clearance Certificates for the previous three years in original certified true copies.

(e) Solvency certificate equal to 3 months requirements of cash flow at the peak execution period for the project.

4. Bid submitted by a joint venture of two or more firms as partners shall comply with the following requirements :

(a) the bid and in case of a successful bid, the form of agreement shall be

signed so as to be legally binding on all the partners; This parternership or association or alliance or JV should have completed in the same form 3 or more successful projects.

(b) one of the partners shall be nominated as being incharge and this authorisation shall be evidenced by submitted a power of attorney signed by legally authorised signatories of all the partners;

(c) the partner incharge shall be authorised to incur liabilities and received instructions for an on behalf of any and all the partners of the joint venture and the entire execution of the contract including payment shall be done exclusively with the partner incharge;

(d) all the partners of the joint venture shall be liable jointly and severally for the execution of the contract in accordance with the contract terms and a relevant statement to this effect shall be included in the authorisation mentioned (b) above as well as in the form of bid and the form of agreement (in case of the successful bid) and

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(e) a copy of the agreement entered into by the joint venture partners shall be submitted with the bid;

(f) experience, resources, men and machinery of each party to the joint venture will be taken into account only to the extent of their participation for performing tasks under the joint venture agreement.

(g) A newly formed JV or partenership or alliance of any sort will not be eligible for this project unless they have executed successfully, at least three similar installations.

5. Documents Establishing Goods – Eligibility and Conformity to Bidding

Documents

5.1 The bidder shall furnish as part of its bid, documents establishing the eligibility and conformity to the bidding documents of all goods and services which the bidder proposes to supply under the contract.

5.2 The documentary evidence of the goods and services eligibility shall consist of a statement in the price schedule on the country of origin of the goods and services offered which shall be confirmed by a certificate of origin issued at the time of shipment.

5.3 The bidder should clearly confirm that all the facilities exist for inspection

and shall be made available to the inspecting authority.

5.4 The bidder shall note that standards for workmanship, material and equipment, and references to brand names of catalogue numbers designated by the purchaser in its technical specifications are intended to be descriptive only and not restrictive. The bidder may substitute alternative standards, brand names and/or catalogue numbers in its bid, provided that it demonstrates to the purchaser’s satisfaction that the substitutions are substantially equivalent or superior to those designated in the technical specifications.

5.5 The bidder shall furnish Photocopy of PAN card.

5.6 The bidder shall furnish Photocopy of VAT registration.

6. The Taxation on the supply, installation and commissioning of Plant & machinery and Civil construction of ETP shall be governed as per latest Taxation norms i.e. IGST.

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SYNOPSIS OF THE TENDER

1.0 Purchaser : The Rajasthan Co-operative Dairy Federation Ltd., Jaipur Saras Sankul, Jawaharlal Nehru Marg, Jaipur 2.0 Contact : Phone No.2702501 : Fax 2702135 : Website :

www.sarasmilkfed.coop : E-mail: [email protected], [email protected]

3.0 Job : Supply, Erection, Testing and Commissioning of Plant &

Machinery for Setting up Indigenous Product Plant on Turn Key Basis” at Malpura (Tonk) Raj

4.0 Functional requirement : The Plant & Machinery for setting up indigenous product

plant for production of Ice Cream, Flavoured Milk, Curd, Chhach, Lassi, Paneer, Shrikhand at Malpura (Tonk) Raj.

The supplier shall require to ensure that no damage occur to any of the structure/building of plant. If any existing structure/line is required to be removed from the job the contractor has to make it good and restore to its existing state at his cost. The tenderer is advised to visit the site so as to apprise himself of actual site conditions & quantum of work involved.

5.0 Exclusions : All Workshop Tools & Machines, Sanitary Installation, Water

Disposal, Water Hydrants, Environmental Works, Laboratory Glassware, Chemicals & Equipment, Workshop tools, furniture, Fire fighting / safety equipment, Telephone & Intercom Systems and civil works.

6.0 Scope of Work : The scope of work includes supply, installation, testing &

commissioning of plant and machinery for setting up Indigenous product plant as per list detailed below: -


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Plant & Machinery for Setting up Indigenous Product Plant on Turn Key

Basis at Malpura (Tonk) Raj

(Ice Cream, Flavoured Milk, Curd, Chhach, Lassi, Paneer, Shrikhand)

INDIGENOUS PRODUCT AT MALPURA (TONK)

1.0 MILK RECEPTION SECTION

S.No. Particulars Capacity Quantity Unit

1.01 Tanker unloading hose ( Food grade) as per site condition

suitable 1 lot.

1.02 Tanker unloading pump 10 KLPH 1 No.

1.03 Electric Weighing Scale with bowl and dock automation

500 Kg 1 lot.

1.04 Dump Tank 1,000 Kg 1 No.

1.05 Milk Transfer pump 10 KLPH 1 No.

1.06 Duplex Filter Suitable 1 No.

1.07 Milk Chiller 10 KLPH 1 No.

1.08 Raw Milk Storage Tanks (HMST) 15 KL 2 Nos.

1.09 Chain Can Conveyor with can tipping bar (powered )

Suitable 1 No.

1.10 S.S. can Scrubber Suitable 2 No.

1.11 Can drip saver Suitable 1 No.

1.12 Platform balance 100 Kg. 1 No.

2.0 MILK PROCESSING SECTION



2.02 Milk Pasteurizer 5,000 LPH 1 No.

2.03 Milk Separator 5,000 LPH 1 No.

2.04 Balance Tank 200 L 1 No.

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2.05 Pasteurised Milk Storage Tanks (HMST) 15 KL 2 Nos.


2.07 Cream Tanks 1 KL 2 Nos.

2.08 Cream Transfer pump 500 LPH 1 No.

2.09 Sour Milk Separator 500 LPH 2 Nos.

3.0 ICE CREAM MIX PREPARATION SECTION


3.01 Mix preparation tank (Insulated & Cladded) 500 ltrs 2 Nos.

3.02 Mix transfer Pump 1 KLPH 1 No.

3.03 Duplex filter 500 LPH 1 No.

3.04 Powder / Sugar blender with venture, 3.5 HP

Suitable 1 No.

3.05 Mix pre heater (4 to 45 degree with indirect hot water heating system)

Suitable 1 No.

3.06 Mix pasteurizer 500 LPH 1 No.

3.07 Mix homogenizer 500 ltrs 1 No.


3.09 Aging Vat / Tank with condensing unit 500 ltrs 2 No.

3.10 Mix transfer Pump 500 LPH 1 No.

4.0 MIX FREEZING SECTION



4.02 Flavour mixing tank with three compartments insulated

100 ltrs 1 No.

4.03 Continuous Ice Cream Freezer with all accessories

100-400 ltrs 1 No.

4.04 Fruits and nut feeder 100-400 ltrs 1 No.

4.05 Ripple machine with pumps 3 x 20 ltrs. 1 No.

4.06 Ice Cream cup and Cone filling machine with PLC

700-3000 cup per hr

1 No.

4.07 Chocolate dozer 700-3000 cup per hr

1 No.

4.08 Conveyor with cartooning table Suitable 1 No.

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4.09 SS working table Suitable 1 Lot.

4.10 CHOCOBAR & ICE CANDY SECTION


4.11 Candy tank suitable for 10 Nos. standard moulds (with refrigeration plant)

10 Moulds size

1 Lot.

4.12 Candy hardener (with refrigeration plant) Suitable for 20 Moulds

1 No.

4.13 Candy pouch raping / packing machine 30 Pcs/Min 1 No.

4.14 Candy moulds with stick holder Standard 3 Sets.

4.15 Chocolate melting vat 100 Ltrs 1 No.

4.16 Chocolate transfer Pump 100 Ltrs 1 No.

4.17 Kulfi mix preparation vat 100 Ltrs 1 No.

4.18 Chocolate coating tank with electric heater 20 Ltrs 1 No.

4.19 Thawing Tank With Electric Heater Capacity 20 Ltrs 1 No.

4.20 SS tables Suitable 1 Lot.

5.0 MISCELLANEOUS


5.01 Suitable Evaporating/ atmospheric and cooling system with ducting, cooling tower etc.

Suitable 1 Lot

5.02 Ozonisation system. Suitable 1 Lot

5.03 Batch Coding machine with Conveyor Suitable 1 Lot 5.04 Cooling towers (wherever required) Suitable 1 Lot

5.05 Metal Detector Suitable 1 Lot

5.06 Crate Washing Trough (S.S) 1000 L 1 Nos.

5.07 Over head S.S balance tank with float, Spray balls, Support arrangement for chhach packing machines

500 L 2 Nos.

5.08 Pre Fab Cold Storage

5.09 Pre Fab Ice Cream (ballast) Hardening room -30 degree C

3.10 m x 4.4 m x 3.5 m

1 Lot

5.10 Pre Fab Ice Cream Cold Storage -25degree C

3.10 m x 4.4 m x 3.5 m

1 Lot

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5.11 Pre Fab cold Store for Milk and Milk Product-4 degree C

5.2 m x 6.7 m x 3.5 m

1 Lot

5.12 Pre Fab Incubation Room with Blast Chilling 4 m x 3m x

3.5 m 1 Lot

5.13

Dispatch Air Lock 10mx3mx3.5m with air curtains

6.7 m x 2.10 m + 6.23 x

3.10 m

1 Lot

6.0 FLAVOURED MILK SECTION

6.1 Mix Preparation Section


6.02 Milk storage tank (Triple jacketed ) 1000 ltrs 1 No.

6.03 Milk transfer Pump 500 LPH 1 No.

6.04 Milk heating/Preparation tank 500 ltrs 1 No.


6.06 Tubular heat exchanger 1000 LPH 1 No.

6.07 Sugar syrup tank 100 ltrs 1 No.

6.08 Milk/Mix homogenizer 500 LPH 1 No.

6.09 Milk/Mix storage tank 500 ltrs 1 No.


6.11 Milk chiller (80-35-4) cooling tower 500 ltrs 1 No.

6.12

Bottling & Sterilization Section

6.13 Bottle Rinsing and filling machine (Rotary type)

500 bottles per hr

1 No.

6.14 Bottle Cap induction sealing machine 500 bottles

per hr 1 No.

6.15 Bottle sterilizer counter presser retort (PLC based) with steam control valve.

500 bottles per hr

1 No.

6.16 SS working table Suitable 1 No.

6.17

Bottling labelling, printing & Packing Section

6.18 Bottle drying machine 500 bottles

per hr 1 No.

6.19 Shrink wrapping machine for individual bottle

500 bottles per hr

1 No.

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6.20 Shrink wrapping machine for 12 bottles in one tray (Optional)

25-50 tray per hr.

1 No.

6.21 Bottle batching printing machine 500-1000

bottle per hr. 1 No.

7.0 FERMENTED PRODUCT SECTION

7.01 Curd, Chhach & Lassi

7.02 Milk Tank (Vertical) 2 KL 01 set

7.03 Multi-Purpose pasteurizer for Curd & Paneer Milk

1 KLPH 01

set

7.04 Homogenizer for Curd milk 1 KLPH per

hr. 01

set

7.05 Inoculation tank insulated with pump 500 ltrs 02 set

7.06 Chhach storage tank (vertical) insulated triple jacketed

1000 ltrs. 02

set

7.07 Curd Cup filling machine 1200 cups

per hr. 01

set

7.08 Packing machine for Chhach & Lassi 5000 pouch

per hr. 02

set

7.09 Chiller for Chhach 2KLPH 01 set

7.10 Pumps (various capacity) Suitable 1 Lot

7.11 Salt water/Sugar syrup dosing system with tank and dosing pump

200 ltrs. 01

set

8.0 PANEER

8.01 Milk storage tank for paneer milk 1 KL 02 set.

8.02 Paneer Vat 1000 ltrs. 01 set

8.03 Paneer press with hoops 120 Kg. 01 set

8.04 Paneer washing cum cooling tank 200 ltrs. 01 set

8.05

Paneer Vacuum Packing machine (double head)

packing size 200gms., 1000gms., 5 Kg.

01

set

8.06 SS table for paneer packing Suitable 01 set

8.07 Paneer Cutting /slicing knives Suitable 01 set

8.08 Paneer weighing machine (Platform type) Suitable 01 set


9.0 Shrikhand Section

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9.01 Curd storage tank (vertical) insulated triple jacketed

1000 ltrs 01 set

9.02 Shrikhand mixing machine Suitable 01 set

9.03 Balance tank for curd / sugar 100 ltrs. 02 set

9.04 Chacka stand Suitable 01 set

10.00 SERVICES


10.01 Complete Refrigeration Plant. 30 KPLPD 1 Set.

10.02 Steam Boiler with Accessories

10.03 FO fired Steam Boiler with Accessories Suitable for 1000 Kg/hr

1 Set.

(a) Chimney for 1 Ton boiler

(b) Boiler feed water tank Cap.2000 ltr

(c) Suitable R.O system for boiler capacity 2000 LPH

(d) F.O. Service Tank cap. 825 Ltrs. with structure

(e) F.O. tanks of 35 KL with, F.O. Loading & Unloading system with oil pumps, oil service line, with heating arrangement etc.

10.04 Water softening plant with accessories

1,00,000 Kg/hr

1 Set.

10.05 Air Compressor (Screw) Suitable 1 Set.

11. ELECTRICAL


11.01

Complete electrical work consisting of HT & LT panels.

1 Set.

12. GENERAL


12.01 D.G. Set 160 KVA 1 lot.

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12.02 Supply, Erection & commissioning of equipments along with allied pipe lines i.e. (SS pipe line, GI pipe line with required valves, MS Pipe line HP / LP with insulation and steam valves, Steam control valves etc.)

1 lot.

12.03 Effluent treatment plant 1 lot.

12.04 CIP system (Single circuit) 1 lot.

12.05 Work shop tools 1 lot.

12.06 Lab equipments 1 lot.

12.07 Fire fighting / safety equipment 1 lot.

Note:-

(1) The plant & machinery, shall be supplied as per respective specification detailed at Annexure - X

(2) The supplied Plant & Machinery shall be efficiently installed at site, same should be connected electrically and mechanically. The associated (SS,GI,MS) pipes and pipe fittings (valves, flange, nipple, bend etc), insulation wherever required, electrical wire and cables, cables trays, mimic control panels etc. We have mentioned the tentative quantity of same in respective technical specification, the quantity may vary as per actual site condition.Tenderer has to supply the aforesaid item as per site condition and no additional charges shall be paid.

(3) Tenderer has to include steam control valve and its allied circuit with provision of bypass arrangement control valves, steam trap assembly etc. wherever control of steam supply is needed . Example :- Milk Pasteurizer, Multi Purpose pasteurizer for curd and paneer, retort for flavored milk sterilization etc.

(4) S.S service tables of suitable size where ever needed to be included in the scope of supply .

(5) Wherever mimic control panel is required for the ease of plant operation need to be considered and scope of supply .

(6) The platform and overhead sheds need to be provided for outdoor refrigerator units. The suitable capacity of Cooling tower should be considered in case of water cooled compressors used in refrigeration units for Candy Tank, Candy Hardener etc.

(7) Suitable capacity of Milk Pump / Water Pump etc. need to be installed in Milk / CIP / Water circuit etc. accordingly same should be considered in the scope of supply.

(8) Tenderer has to carry out Supply, Erection, Testing and Commissioning of supplied Plant & Machinery as per site condition.The plant layout is hereby enclosed with tender document for the analysis of quantam of work involved .

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(9) Following approvals are required from RCDF before fabrication of equipment and for the execution of awarded work:- General arrangement drawing for the plant and machinery layout , defining inter-connection of equipment and flow of milk and milk products, water, steam etc.

(10) Complete electrical work: The scope of electrical covers complete electrical

connection, earthing and controls to supplied plant and machinery, electrical panel with required switch gears i.e MCCB, MCB, ampere meter, volt meter, relay, single phase preventer, earth fault relay, contractors, push buttons etc., mimic control panels where ever required along with control wiring, related cables, cable trays, suitable structure for support of cable tray etc. need to be provided. The drawing of electrical panel and controls and cable layout etc. shall be get approved before execution of electrical work.

(11) In addition to the standers mentioned, all works shall also conform to the

requirements of the following for which necessary certifications of the concerned departments are to be obtained and submitted to the concerned Milk Union/RCDF :-

a. Indian Electricity Act and rules framed there under. b. Fire, Insurance and Regulations Act. c. Regulations laid down by the Chief Electrical Inspector of the State/State

Electricity Board. d. Regulations laid down by the Chief Inspector of the Factories & Boilers of

the State. e. Regulations laid down under the Explosive Act. f. Regulations as per Weight and Measure Act. g. Pollution Control Board of Rajasthan (i.e. consent to established , consent

to operate. h. Bureau of Indian Standards i Any other regulations laid down by the local authorities.

Applications under various Acts should be moved through MD, Union well in advance so that operation of the plant could be started as per rules and regulations from the day one after handing over the plant. However, actual fee and other charges deposited with the government authorities will be reimbursed to the Contractor after production of receipt. 7.0 Eligibility

(a) The bidder should be in business of the jobs tendered for a minimum period of

three years at the time of bid opening in the same name and style.

(b) The bidder’s annual financial turnover in the same name and style during any

one of the last three years shall not be less than the estimated value of the

contract quoted value.

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(c) The bidder in the same name and style shall have completed the three dairy

projects having indigenous product section for production of Curd, Chhach,

Lassi, Paneer, Shrikhand of similar or above capacity.

(d) The bidder shall furnish a copy of the Income Tax Returns and the Income

Tax Clearance Certificates for the previous three years in original certified

true copies.

(e) Solvency certificate equal to 3 months requirements of cash flow at the peak

execution period for the project.

8.0 Completion: “Supply, Erection, Testing and Commissioning of Plant & Machinery for Setting up Indigenous Product Plant on Turn Key Basis” at Malpura (Tonk) Raj “within 8 Months from the date of issue of purchase order.

9.0 Payment : For Supply of equipment

30% advance against Bank guarantee 60% after third party inspection and quality verification at works, and on safe receipt of the equipment ordered at site The third party for inspection and quality verification shall be appointed by the RCDF.

10% after completion of job & against performance BG For Erection & Commissioning 10% advance against Bank guarantee 80 % after erection, commissioning & completion of trial runs 10% after completion of job & against performance BG

10.0 Compensation of delay :-The Compensation for delay shall be as per terms and

condition on. 11.1 , Clause 1.

11.0 Bid validity : 120 days from the date of opening of bids

12.0 Quality Control A : The equipment under the purview of your supply should

be inspected by your own technical experts at your works and such inspection report should be forwarded to us in triplicate alongwith dispatch documents. However, the RCDF, reserves its right of inspection at any stage of fabrication manufacture of the equipment/material. The final inspection in any case will be carried out at RCDF project site. You should forward to us the test certificate, wherever applicable, obtained from the concerned authorities/principal manufacturers either regarding quality or any other details

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of the items utilised in the process of manufacture/fabrication. B : Bidder should submitte the quality assurance plan for

equipment under scope of supply for approval, accordingly the inspection may be carried out by Third Party / RCDF to ensure the quality of respective item.

13. PRE-BID MEETINGS

13.1 Bidders are requested to attend pre-bid meeting on scheduled date and time for technical/commercial discussion related to project.

13.2 Bidders may have technical discussions with the Dairy / clients, project team

before the tender closing date. Subjects for discussion at the pre-bid / technical meeting may include:

Project management Technical clarifications Scope of supply Concept of the design Processes Equipment designs Equipment suppliers Automation Plant management Quality control Existing equipment to be utilized in the job Battery limits Acceptable alternatives

This will be the only opportunity for bidders to discuss the project in detail with Dairy

before the commercial bid opening, and all technical matters / clarification related to

tender should be resolved in this meetings.

21



GENERAL TERMS AND CONDITIONS

1.0. PREFACE

Note:- This tender is an e-tender. Consequently offline submission of tender

documents other than Demand Drafts is not allowed. All the terms & conditions may be read and interpreted in this light. Only offline submission of DD’s towards tender fee, tender processing fee & EMD is required. These are required to be sent by post so as to reach the office of General Manager (Purchase) , Rajasthan Co-operative Dairy Federation Ltd. “SARAS SANKUL” Jawahar Lal Nehru Marg, Jaipur-302017 before the tender opening date & time.

1.1 The Rajasthan Co-Operative Dairy Federation Limited, Jaipur hence

forth termed as R.C.D.F. LTD., invites the competitive bids from the technically

& financially sound individual / HUF / firm / Company for “Supply, Erection, Testing and Commissioning of Plant & Machinery for Setting up Indigenous Product Plant on Turn Key Basis” at Malpura (Tonk) Raj “.

1.2 The Managing Director, Rajasthan Co-operative Dairy Federation reserves the right to reject any or all the tenders in full or part thereof, which in his opinion justifies such action without further explanation to the tenderers.

2.0 TENDERING PROCEDURE

IMPORTANT NOTES 1. ALONG WITH THE SAME ALL IN THE DESIRED FORMAT DOCUMENTS THAT

ARE REQUIRED TO BE SUBMITTED AS PER ELIGIBILITY & QUALIFICATION CRITERION SHOULD ALSO BE SELF ATTESTED ALONG WITH SEAL OF TENDERER & SHOULD BE SCANNED AND UPLOADED / SUBMITTED IN THE FIRST COVER OF THE TENDER.

2. ON THE BASIS OF THE ABOVE DOCUMENTS THE TENDER SHALL BE TECHNICALLY EXAMINED & ONLY IF FOUND TO BE QUALIFIED TECHNICALLY THEN THE FINANCIAL BIDS OF THE TECHNICALLY QUALIFIED TENDERS WOULD BE OPENED.

3. THE FINANCIAL BIDS ARE REQUIRED TO BE SUBMITTED ONLY IN THE PREESCRIBED PERFORMA IN THE XLS SHEET PROVIED FOR THE SAME.

2.1 The tender form is not required to be submitted at the time of e-bidding. In lieu of the same a acceptance letter accepting the tender in its entirety in the prescribed format enclosed at Annexure-I is required to be submitted on the Company letter head. In addition self attested photocopies of all the documents required for fulfilling the eligibility & qualifications criterion are also required to be scanned and submitted with the e-bid

22



2.2 No telegraphic/telephonic/telex/Fax tenders shall be considered. Further the tenderer may please note that the successful tenderer would be required to submit a duly sealed & signed hard copy of the tender form along with the security deposit, agreement etc. upon award of rate contract

2.3 LEGAL COMPETENCY OF SIGNING THE TENDER

Individual signing the tender or other documents connected with this tender must specify whether he signs as : a) “Sole Proprietor” of the firm or constituted attorney of such proprietor. b) The partner of the firm, if it is a partnership firm in which case, he must

have authority to refer to arbitration disputes pertaining to business of the partnership either by virtue of the partnership deed or by holding the power of attorney.

c) Constituted attorney of the firm, if it is a Company. NOTE:

1) In case of (b) above, a copy of the partnership deed or general power of attorney duly attested by a notary public should be furnished or any affidavit on stamp paper of all the partners admitting execution of the partnership deed or the general power of attorney should be furnished.

2) In case of partnership firms, where no authority to refer disputes concerning to the business of the partnership has been conferred on any partner, the tender and all other related documents must be signed by every partner of the firm.

3) A person, signing the tender form or any documents constituting an integral part of the contract, on behalf of another shall be deemed to warranty that he has authority to bind such other and if, on enquiry it appears that the person so signing has no authority to do so, the buyer may without prejudice to other civil remedies, terminate the contract and hold the signatory liable for all costs and damages.

2.4 EARNEST MONEY DEPOSIT

2.4.1 (a) Earnest money as mentioned in the NIT, must accompany the tender. The earnest money shall be required to be paid by a crossed demand draft in favour of Managing Director, Rajasthan Co-operative Dairy Federation Ltd., drawn on any scheduled or nationalized bank in India, payable at Jaipur. The tenders accompanied by cheques instead of demand draft towards earnest money will not be considered. Earnest money shall have to be paid according to the items offered by tenderer covering the total quantity required for all the projects.

2.4.1 (b) In addition tender processing fees of Rs. 1000/- payable by demand draft in

favour of Managing Director, RISL (payable at Jaipur and non- refundable) and tender fees Rs.1,000/- for each item separately, payable by demand draft in favour of RCDF Ltd., Jaipur (payable at Jaipur and non-refundable) are also

23



required to be submitted along with the tender failing which the tender will be summarily rejected.

2.4.2 Any tender whose tender fee, tender processing fee & EMD as stated above

does not reach this office before the tender opening date & time is liable to be summarily rejected. Earnest money of unsuccessful tenderer will be returned within 120 clear / working days from the date of opening of the tender.

2.4.3 No interest shall be paid for the earnest money deposit for the period during which it (the earnest money) lies in deposit with the Rajasthan Co-operative Dairy Federation Ltd.

2.5. The tenderers should state herein the complete address to which the orders,

notices and further correspondence pertaining to the tender and agreements are to be sent. Any correspondence made by the RCDF/milk union at the address given herein shall be deemed to have been delivered to the party notwithstanding that such correspondence may not in fact have been delivered. Any change in the address thereafter must be notified to the Managing Director, Rajasthan Co-operative Dairy Federation Ltd., Jaipur and the concerned milk unions and a copy in confirmation of RCDF/milk union having recorded change in address be obtained in writing from RCDF/milk union. In absence of such confirmation the correspondence made on the address given herein shall be valid once the confirmation is issued by RCDF/milk union subsequent correspondence shall be sent to the new notified address.

Address_______________________ Telegraphic

Address_______________________________________________

Phone No./ ________________________ Mobile no.______________

Fax No.________________ E-mail _________________

Name of contact Person: _______________________.

2.6 The tenders received shall be opened on the date and time given in the N.I.T. at the Office of the Managing Director, Rajasthan Co-operative Dairy Federation Ltd., Jaipur. The tenderers or their accredited agents will be allowed to be present at the time of opening of the tender.

2.7 Negligence on the part of tenderer in preparing the tender confers no right to withdraw the tender after it has been opened.

2.8 The specifications, conditions, schedules drawing of the tender constitute an integral part of the tender.

2.9 All tenders in which any of the prescribed conditions are not fulfilled or which have been vitiated by errors in calculations totaling, or other discrepancies or which contain overwriting in figures or words or corrections not initialed and dated will be rejected.

2.10 In the place of substantial non conformity with the specifications or if it contains any inadmissible reservations seen or otherwise, in contravention to the sprit and latter of the tender documents, such tenders shall be summarily rejected.

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2.11 The tenderer whose tender is accepted (hereinafter called the supplier/contractor) will be required to furnish security for the due fulfillment of his contract in the form of a bank Demand Draft or Bank Guarantee of 5% of the contracted value (F.O.R. site). This bank Demand Draft / Bank Guarantee of Nationalized / Scheduled Bank drawn in favour of Managing Director, RCDF, Jaipur is to be submitted within a period of 10 to 15 days from the date of placement of Purchase Order. The EMD amount shall be adjusted in the aforesaid security. The security will be refunded if otherwise found to be qualifying for refund within six months from the date of expiry of contract. No interest will be paid by the RCDF on such security amount. In case of breach of any terms and conditions of the contract or on unsatisfactory performance of the contract the RCDF shall have an absolute right of being compensated through liquidated damages or penalties and the amount of security deposit shall also, in such an event, be liable to forfeiture in full or part for being appropriate towards aforesaid liquidated damages and the decision of MD RCDF shall be final in this regard. If the tenderer fails to deposit the security or to execute the agreement within the period specified, such a failure will be treated as a breach of the terms and conditions of the tender and shall result in the forfeiture of the Earnest Money besides any other action for the default. The expenses of completing & stamping the agreement shall be paid by the tenderer who shall furnish to the RCDF one executed stamped counter part of the agreement free of charge.

In case the contractor/supplier completes it contractual obligations, except for performance of equipment for which 10% amount is deducted/retained while processing payments against supply and / or erection, the security deposit can be refunded at such point of time as may be decided by the Purchase Section at its sole discretion.

All compensation or other sums of money payable by the contractor to

Rajasthan Co-operative Dairy Federation Ltd. under the terms of this contract may be deducted from, or paid by the sale of a sufficient part of his security deposit or from any sums which may be due or may become due to the contractor by the Rajasthan Co-operative Dairy Federation Ltd. on any account whatsoever, and in the event of his security deposit being reduced by reason of any such deduction or sale as aforesaid, the contractor shall within ten days thereafter make good in cash endorsed as aforesaid any sum or sums which may have been deducted from or raised by sale of his security deposit or any part thereof.

2.12 No refund of tender fee is claimable for tenders not accepted or Forms returned

or tenders not submitted.

2.13 SPECIAL NOTES TO TENDERER

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2.14 PRE BID CONFERENCE : Pre bid conference dates for the equipments are given in the NIT. The tenderers can seek any clarifications in the Pre-bid conference on the tenders they intend to participate in, and so the tenderers are advised to depute their authorised representative to attend the same, without fail.

3.0 SCOPE OF WORK.

The scope of work includes supply, installation, testing & commissioning of plant and machinery, utilities as per list detailed below:-





suitable 1 lot.



500 Kg 1 lot.







Suitable 1 No.










26














Suitable 1 No.


Suitable 1 No.










100 ltrs 1 No.


100-400 ltrs

1 No.

4.04 Fruits and nut feeder 100-400 ltrs

1 No.



700-3000 cup per hr

1 No.


1 No.


27







10 Moulds size

1 Lot.


1 No.









5.0 MISCELLANEOUS



Suitable 1 Lot






500 L 2 Nos.



3.10 m x 4.4 m x 3.5

m

1 Lot

5.10 Pre Fab Ice Cream Cold Storage -25degree C 3.10 m x

4.4 m x 3.5 1 Lot

28



m


5.2 m x 6.7 m x 3.5 m

1 Lot


3.5 m 1 Lot

5.13


6.7 m x 2.10 m +

6.23 x 3.10 m

1 Lot














6.12



500 bottles per hr

1 No.


per hr 1 No.


500 bottles per hr

1 No.


6.17


6.18 Bottle drying machine 500 bottles 1 No.

29



per hr


500 bottles per hr

1 No.


25-50 tray per hr.

1 No.







1 KLPH 01

set


hr. 01

set



1000 ltrs. 02

set


per hr. 01

set


per hr. 02

set




200 ltrs. 01

set

8.0 PANEER





8.05



01

set




30






1000 ltrs 01 set




10.00 SERVICES





1 Set.







1,00,000 Kg/hr

1 Set.


11. ELECTRICAL


11.01


1 Set.

12. GENERAL


31



12.01 D.G. Set 160 KVA 1 lot.


1 lot.






Note:-

(1) The plant & machinery, shall be supplied as per respective specification detailed at Annexure - X

(2) The supplied Plant & Machinery shall be efficiently installed at site, same should be connected electrically and mechanically. The associated (SS,GI,MS) pipes and pipe fittings (valves, flange, nipple, bend etc), insulation wherever required, electrical wire and cables, cables trays, mimic control panels etc. We have mentioned the tentative quantity of same in respective technical specification, the quantity may vary as per actual site condition.Tenderer has to supply the aforesaid item as per site condition and no additional charges shall be paid.

(3) Tenderer has to include steam control valve and its allied circuit with provision of bypass arrangement control valves, steam trap assembly etc. wherever control of steam supply is needed . Example :- Milk Pasteurizer, Multi Purpose pasteurizer for curd and paneer, retort for flavored milk sterilization etc.

(4) S.S service tables of suitable size where ever needed to be included in the scope of supply .

(5) Wherever mimic control panel is required for the ease of plant operation need to be considered and scope of supply .

(6) The platform and overhead sheds need to be provided for outdoor refrigerator units. The suitable capacity of Cooling tower should be considered in case of water cooled compressors used in refrigeration units for Candy Tank, Candy Hardener etc.

(7) Suitable capacity of Milk Pump / Water Pump etc. need to be installed in Milk / CIP / Water circuit etc. accordingly same should be considered in the scope of supply.

(8) Tenderer has to carry out Supply, Erection, Testing and Commissioning of supplied Plant & Machinery as per site condition.The plant layout is hereby enclosed with tender document for the analysis of quantam of work involved .

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(9) Following approvals are required from RCDF before fabrication of equipment and for the execution of awarded work:- General arrangement drawing for the plant and machinery layout , defining inter-connection of equipment and flow of milk and milk products, water, steam etc.

(10) Complete electrical work: The scope of electrical covers complete electrical

connection, earthing and controls to supplied plant and machinery, electrical panel with required switch gears i.e MCCB, MCB, ampere meter, volt meter, relay, single phase preventer, earth fault relay, contractors, push buttons etc., mimic control panels where ever required along with control wiring, related cables, cable trays, suitable structure for support of cable tray etc. need to be provided. The drawing of electrical panel and controls and cable layout etc. shall be get approved before execution of electrical work.

(11) In addition to the standers mentioned, all works shall also conform to the

requirements of the following for which necessary certifications of the concerned departments are to be obtained and submitted to the concerned Milk Union/RCDF :-

i. Indian Electricity Act and rules framed there under. j. Fire, Insurance and Regulations Act. k. Regulations laid down by the Chief Electrical Inspector of the State/State

Electricity Board. l. Regulations laid down by the Chief Inspector of the Factories & Boilers of

the State. m. Regulations laid down under the Explosive Act. n. Regulations as per Weight and Measure Act. o. Pollution Control Board of Rajasthan (i.e. consent to established , consent

to operate. p. Bureau of Indian Standards i Any other regulations laid down by the local authorities.

Applications under various Acts should be moved through MD, Union well in advance so that operation of the plant could be started as per rules and regulations from the day one after handing over the plant. However, actual fee and other charges deposited with the government authorities will be reimbursed to the Contractor after production of receipt.

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3.1 Supply : The suppliers shall supply the material/articles in accordance with specifications

stipulated for the article in the tender at ANNEXURE –X.

3.1.1 Erection, Testing & Commissioning: The tenders shall erect/install the equipment in accordance with the terms and conditions/specifications stipulated in Schedules of the tender.

4.0 TURN – KEY CONTRACT This is a turn - key project. All necessary material which may be required for the successful completion of the project falls in the scope of the work. Cost of installation for any addition or deletion in quantities will be calculated based on the unit prices indicated. If any extra quantities of quoted items are needed then the tenderer shall supply those at the quoted unit price. If any extra item (s), not included in the tender but required for successful completion of the work, the same will be either supplied by the RCDF/Milk Union and erected by the tenderer or supplied and erected both by the tenderer at mutually agreed rates considering purchase price, taxes and handling charges etc. Necessary ESI/PF deductions, wherever applicable shall be borne by the tenderer. The requisite approval from Chief Electrical Inspectorate, Government of Rajasthan must be obtained by the tenderer and the actual payment shall be reimbursed by RCDF/Milk Union against production of original documents.

The tenderers are required to give the price bid for all items section-wise in the same faction as of Part – A showing the F.O.R. unit rate for supply as well F.O.R. unit rate installation, testing & commissioning as well the total cost.

In addition to the standards mentioned, all works shall also conform to the requirements of the following for which necessary certifications of the concerned departments are to be obtained and submitted to the concerned Milk Union/RCDF:-

a. Indian Electricity Act and rules framed there under. b. Fire, Insurance and Regulations Act. c. Regulations laid down by the Chief Electrical Inspector of the

State/State Electricity Board. d. Regulations laid down by the Chief Inspector of the Factories & Boilers

of the State. e. Regulations laid down under the Explosive Act. f. Regulations as per Weight and Measure Act. g. Pollution Control Board of Rajasthan. h. Bureau of Indian Standards i. Any other regulations laid down by the local authorities.

Applications under various Acts should be moved through MD, Union well in advance so that operation of the plant could be started as per rules and regulations from the

34



day one after handing over the plant. However, actual fee and other charges deposited with the government authorities will be reimbursed to the Contractor after production of receipt.

5.0 BID PRICES

5.1 The price should be quoted on the basis of F.O.R. site inclusive of all taxes. All taxes are to be built up in the financial bid part as on 12.10.2017 (Technical bid opening) and are to be shown separately. Any addition/deletion/variation in taxation or future taxes leveled by the State or Central Govt. beyond this date shall be born by RCDF/Concerned Unions. It should be absolutely clear that any tax applicable as on 12.10.2017, but not considered by the tenderer while submitting financial bid shall be deemed to have included in the rate offered by the tenderer.

The bidder shall quote for the total package of Design, Fabrication, Supply, Erection, Testing & Commissioning on the Turn key basis. The prices quoted under different heads should be grouped as under.

Supply - Including packing, forwarding, taxes & duties, freight, loading & unloading at site and insurance etc. Detailed price break and list of equipment as given under Annexure – X.

Erection & commissioning – Labour charges including service tax should be

given for all the equipment and the steel structure as per the list given under Annexure – X. Discount - If any should also be indicated separately. The bidders‟ separation of

price components as above will be solely for the purpose of facilitating the comparison of bids by the purchaser and will not in any way limit the purchasers right to contract on any of the terms offered.

5.2 FIXED PRICE:

Prices quoted by the bidder shall be fixed during the bidder’s performance of the contract and not subject to variation on any account.

5.3 PRICE OF SPARE PARTS:

All the bidders are required to submit the list of spares with rates. In case of bought out items a list giving full particulars, including available sources and current prices, of all spare parts, special tools, etc. which are necessary for the proper and continuing functioning of the plant for a period of two years should be furnished. These prices should be valid, for acceptance by the purchaser and placement of orders, for one year from the date of bid opening.

5.4 The prices thus quoted by firm, free from all escalations and valid for a period of

120 clear days from the closing date of the tender.

35



5.5 All the tenderers should quote for supply of equipment in fully fabricated and

assembled condition. 5.6 BREAK – UP PRICES

All the bidders shall furnish the cost separately for the supply and installation/commissioning along with detailed cost break-up (item-wise), which will be applicable for progressive payments. Items and works for which no break-up price is furnished by the bidder will not be paid for by the purchaser when supplied/executed and shall be deemed covered by other break-up prices. Such break up cost should be based on ex-works cost and percentage of ex-works cost should be indicated separately for packing and forwarding, transportation, insurance and other incidental charges, erection and commissioning on percentage basis for each item.

5.7 Spare Parts : The tenders shall submit a recommended list of spare parts alongwith the price valid for one year for each items of the equipment which would be reasonable to anticipate as necessary, to enable the equipment to be operated and maintained in a satisfactory manner for a period of 24 calendar month from the date of commissioning.

5.7.1 The cost of spare parts will not be considered in evaluating the tenders. 5.7.2 The prices thus quoted for the spares should be valid for 12 calendar months

from the date of opening of the tender.

5.8 Sales Tax/ Entry Tax:

The Sales Tax, Entry Tax , Surcharge and any other type of taxes prevailing up to date of submission of the rates must be included in the net rate. This however should be shown separately, so that in the event of any subsequent change in these charges by the Government (State or Central), the same will be considered for increase/decrease over the net rates. Wherever possible C/D forms shall be issued to avail concessional rates of the Central/State Tax. The Entry Tax, if applicable, should be included where the supplier belongs to outside Rajasthan and Purchase Order/RAL placed on outside Rajasthan. The tenderer must also indicate the details of Sales Tax Registration and the number allotted to them by Sales Tax authorities.

5.9 Octroi :

Octroi duty, if applicable at the destination shall be paid extra on all dispatches made from the suppliers works/warehouses to the point of destination.

36



5.10 Excise Duty:

Excise duty or surcharge prevailing upto the date of submission of the rates must be included in the net rate. This however, should be shown separately, so that in the event of any subsequent change in these charges by the Government (State or Central), the same will be considered for increase/decrease over the net rates. However, the increased excise duty due to change in slab on higher turnover shall be payable by the tenderer.

5.11 Service Tax:

The Service Tax and Surcharge prevailing upto date of submission of the rates must be included in the net rate. This however should be shown separately, so that in the event of any subsequent change in these charges by the Government (State or Central), the same will be considered for increase/decrease over the net rates.

5.12 Unloading charges at site – For supply order the price should exclude

unloading charges. However for installation contract the price must include these charges.

5.13 If the price for reasons of change in statutory taxes and duties by Government

taking place during the period of bid finalisation or during the normal delivery period envisaged in the Purchase Order/Contract.

(a) The material/equipment/machinery offered must be securely packed at

the cost of the suppliers to withstand tough handling enroute by road/rail/air. Packing should be provided with protective lining to avoid damage to the surface of the packing and the items packed inside.

(b) Marking :

Each package delivered under this tender shall be marked by the suppliers at their own expenses. Such markings shall be distinct and should bear the following: (i) Name of the supplier. (ii) Details of the items in the package. (iii) Weight gross, net and tare. (iv) Name and address of the consignees as mentioned in the Purchase

Order. Marking shall be carried out with such a material as may be considered necessary as regards quickness of drying, fastness and indelibility.

6.0 Insurance:- The supplier shall arrange insurance coverage, according to the dispatch

instructions issued by Rajasthan Co-operative Dairy Federation Ltd., Jaipur and the supplier should cover all dispatches. However, to avoid any complications

37



that may arise at the time of settlement of claims by the underwriters for the transit losses it is proposed that the insurance coverage shall be arranged by the supplier as under: (a) The insurance coverage shall have to be arranged commencing from their

warehouse/works to the warehouse of the buyer (All Transit risks). (b) Suppliers are requested to take insurance with any Nationalised

Insurance Company. (c) The cover provided by the insurance shall be in such amount so as to

allow complete replacement for any item lost or damaged.

7.0 Guarantee :- The supply of equipment as well as installation, if entrusted shall have to be carried out by the supplier to the entire satisfaction of the buyer. The supplier shall also guarantee to repair/replace without any extra cost, the items or parts there of if found defective due to defective design, workmanship or substandard material brought to the attention within 12 calendar months from the date of satisfactory commissioning or within 24 months from the date of receipt of material at site, whichever is earlier. If it is necessary to send the defective equipment or parts thereof for repair/replacement the cost of loading, unloading, repacking and transportation from the site to works and back to site shall have to be borne by the supplier. The guarantee however does not cover any damage resulting from normal wear and tear or improper attendance or mishandling of the equipment by the buyer/his authorised representatives. The contractor shall have to guarantee the complete installation for satisfactory performance for a minimum period of one year from the date of commissioning of the plant. Any defect arising out of faulty erection/installation or use of substandard material or workmanship shall have to be rectified by the contractor at his own cFost.

7.1 Warranty: All the suppliers shall provide a warranty for a minimum period of 12 calendar months from the date of commissioning of the equipment for the satisfactory performance of the equipment supplied to the designed/rated/installed capacity or any other norms fixed by the buyer. Also, they should provide a warranty for the period as stated above to the effect that supplier shall alone be responsible for all the litigations/disputes/claims and other legal complications that may arise in connection with the patent rights design rights and the rights of ownership of the materials.

7.2 Right to operate & use unsatisfactory material or equipment :- If after delivery, acceptance and installations and within the guarantee period, the operation of use of materials or equipment proves to be unsatisfactory to the buyer, he shall have the right to continue to operate or use such materials

38



or equipment until rectifications of defect, errors or omissions by repair or by partial replacement can be made without interfering with the buyer’s operation.

8.0 Technical information required with tenders :- 8.1 The tenderers have to mention clearly that the specification of the materials

tendered are strictly in adherence to the technical specifications stipulated in Schedule. In case of any deviation, the tenderers shall have to mention the same in details.

8.2 Maximum outputs of machines are to be specified for information only. 8.3 Schematic drawings and technical literature of equipment tendered shall have to

be furnished. 8.4 Overall dimensions of the various equipment shall have to be mentioned in

detail. 8.5 The total weights (in dry and working) of the various equipment/item shall have

to be stated clearly. 8.6 The safety interlocks/devices in the equipment shall have to be highlighted. 8.7 The consumptions and services requirements of various equipment shall have to

be detailed.

9.0 Commercial information required with tender :- 9.1 Brand Names: If the supplier is quoting for spare parts, which is not manufactured by him, but

he has obtained the same from another manufacturer then he should state the name of the manufacturer with address, brand name and catalogue number etc. and the spare parts offered should conform to the same performance capability as that of the main item for which it is meant.

9.2 Terms of Payment : Following terms of payment would be applicable to this order subject to supplier/ contractor having furnished security deposit for 5% of the F.O.R. order value for the due fulfilment of this contract in form of cash/DD in accordance with the Clause No.2.11 of the tender document. In case the contractor/supplier completes its contractual obligations before 12 months the cash/DD deposit can be refunded before 12 months at the sole discretion of RCDF before aforesaid period of 12 months.

9.2.1 For supply of equipment :- 30% of the ex-works order value (basic cost) shall be paid on acceptance of the order subject to the supplier furnishing a Bank Guarantee valid for 12 calendar months from the date of guarantee for an equivalent amount from a scheduled

39



or Nationalised Bank in the enclosed proforma given at Annexure-VIII. The Bank Guarantee can be released by RCDF once the advance is fully recovered / adjusted. The execution of agreement in the format at Annexure-VII is also a precondition for clearing advance. 60% (90% in case of the supplier/contractor who has not taken advance) after third party inspection and quality verification at works, and on safe receipt of the equipment ordered at site but not later than 45 days from the date of receipt of the equipment at site. The third party for inspection and quality verification shall be appointed by the RCDF. The 10% of the FOR site value shall be paid within 12 calendar months from the date of commissioning or 24 months from the date of receipt of the same at site, whichever is earlier. However the balance 10% will also be released, if so desired by the supplier, provided the supplier furnishes a Bank Guarantee from a Scheduled or Nationalised Bank for the 10% value valid for a period of 12 calendar months from the date of issue of Bank Guarantee in the proforma enclosed given at ANNEXURE – IX.

9.2.2 For Erection :- 90% on submission of progressive bills duly certified by the authorised representatives/Site Engineer of RCDF and balance 10% within 12 months from satisfactory commissioning of the equipment. However, the balance 10% will also be released, if so desired by the supplier, provided the supplier furnishes a Bank Guarantee from a Scheduled or Nationalised Bank for the 10% value valid for a period of 12 calendar months from the date of issue of Bank Guarantee in the Performa enclosed.

10.0 Delivery Schedule of Items:- (a) Bidders should submit a detailed item wise delivery schedule keeping in

view the completion period of the contract. Such items shall be grouped under monthly delivery schedule with total value of such items. This will facilitate for ensuring the cash flow requirement for the project.

(b) The delivery time given in the contract is to be adhered to strictly. For this purpose the supplier has to inform RCDF the progress made towards fabrication of the items ordered from time to time during the delivery period. The supplier has to maintain good progress of work during the delivery period so as to deliver the items ordered in time. It is essential that RCDF is informed of the quantified progress made by the supplier by Registered Post once after 1/3rd of delivery time elapses and again after 2/3rd of delivery time elapses. In case RCDF does not receive such progress reports it will presume that the work has not been taken up by the supplier in the right earnest and that RCDF in such a situation will be at liberty to withdraw the work order and forfeit the earnest money as well as security deposit simultaneously. The supplier is therefore advised strictly to follow this essential condition of the contract.

40



(c) It may be noted that delay/time taken in release of advance payment whether for reasons of supplier not furnishing the Bank Guarantee exactly in the Performa given in this tender document or any other reasons whatsoever, will not affect the delivery period. Similarly delay in execution of the agreement will also not affect the delivery period. The tenderer is therefore advised to take note of this important condition. The successful tenderer should therefore take immediate action for execution of agreement and submission of bank guarantee of advance, if desired, within 10 to 15 days of placement of purchase order. It normally takes 30 days to release the advance, subject to submission of B.G. as per our format.

(d) In case of failure by supplier in making deliveries within the time specified, the Rajasthan Co-operative Dairy Federation Ltd. may procure the materials supplies and services from any other sources and hold the suppliers responsible for any losses occurred thereby. Further the Rajasthan Co-operative Dairy Federation Ltd. reserves the right to terminate the services of such suppliers in such case without assigning any reasons thereof.

(e) In case supplier fails to supply machinery/equipment in delivery period, interest at the rate of 19% per annum will be charged on the advance amount from the date by which delivery fails due to the actual date of supply unless an extension in delivery period is mutually agreed to by the supplier and RCDF.

11.0 Completion of work :

The entire job of “Supply, Erection, Testing and Commissioning of Plant & Machinery for Setting up Indigenous Product Plant on Turn Key Basis at Malpura (Tonk) Raj “ is to be completed within 08 months from the date of issuing the work order. It may be noted that delay/time taken in release of advance payment whether for reasons of supplier not furnishing the Bank Guarantee exactly in the proforma given in this tender document or any other reasons whatsoever, will not affect the completion period. Similarly delay in execution of the agreement will also not affect the completion period. The tenderer is therefore advised to take note of this important condition. The successful tenderer should therefore take immediate action for execution of agreement and submission of bank guarantee of advance, if desired, within 10 to 15 days of placement of purchase order. In case of failure by contractor in completing the job within the time specified, the Rajasthan Co-operative Dairy Federation Ltd. Will have liberty to get the job completed from any other sources and hold the contractor responsible for any losses occurred thereby. Further the Rajasthan Co-operative Dairy

41



Federation Ltd. reserves the right to terminate the services of such contractor in such case without assigning any reasons thereof.

11.1 Compensation for delay : Clause 1 :

The time allowed for carrying out the work as entered in the tender shall be

strictly observed by the contractor and shall be reckoned from the 15th day

after the date of written order to commence the work as given to

the contractor. The work shall throughout the stipulated period of the

contract be proceeded with all due diligence, time being deemed to be the

essence of the contract on the part of the contractor and the contractor shall

pay as compensation an amount equal to two and half percent or such

smaller amount as the Managing Director, RCDF Ltd. (whose decision shall

be final) may decide on the tendered amount for every 1/4th of the

prescribed delivery period that the work remains unfinished after the proper

date subject to a maximum of 10% of the net value of each item of the

accepted order which remains undelivered or partially delivered e.g

Delay of 1 day to 1/4th of delivery period 2.5%

Delay >1/4th delivery period but <1/2 of delivery period

5%

Delay >1/2 of delivery period but <3/4th of delivery period

7.5%

Delay > 3/4th of delivery period and upto = delivery period

10%

Maximum deduction on account of delay 10%

If the delivery has not been made the order can be cancelled even after

expiry of the delivery period after giving a 15 days notice in writing by

RCDF, if it so deems fit without prejudice to any of its rights/ remedies for

the breach of contract by the party.

And further to ensure good progress during the execution of work, the

contractor shall be bound in all cases in which the time allowed for any work

exceeds one month (save door special jobs) to complete 1/8th of the whole of

the work before ¼ th of the whole time allowed under the contract has

elapsed. The contractor shall further be bound to carry out the work in

accordance with the dates and quantities as may be given by RCDF from

time to time.

In case the party is not able to execute the work in time because of any justified reason/ reason beyond his control then the party should give a request in writing before the expiry of stipulated delivery period stating the same along with the justifications and RCDF/Milk Union may grant an extension in the delivery period with/ without penalty, if it so deems fit.

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Further in case the delay in the execution of the work is due to non completion of some related work by milk union/ another contractor or due to non supply of road permits in time etc. then that period of delay shall not be counted on account of the party and party shall not be penalized for the same.

Clause 2 :-

The Managing Director, RCDF Ltd. may without prejudice to his right against the contractor in respect of any delay or inferior workmanship or otherwise or any claims for damage in respect of any breaches of the contract and without prejudice to any rights or remedies under any provisions of this contract or otherwise and whether the date for completion has or has not elapsed by notice in writing absolutely

determine the contract in any of the following cases :-

(i) If the contractor having been given by the Officer-in-charge or authorised representative, a notice in writing to rectify, reconstruct or replace any defective work or that the work is being performed in an inefficient or otherwise improper or unworkman like manner shall omit to comply with the requirements of such notice for a period of seven days thereafter or if the contractor shall delay or suspend the execution of the work so that either in the judgment of the Officer-in-charge or authorised Engineer (which shall be final and binding) he will be unable to secure completion or he has already failed to complete the work by that date.

(ii) If the contractor being a company shall pass a resolution or the

court shall make an order that the company shall be wound up or if a receiver or a manager on behalf of a creditor shall be appointed or if circumstance shall arise which entitle the court or creditor to appoint a receiver or a manager or which entitle the court to make a winding up order.

(iii) If the contractor commits breach of any of the terms and conditions of the contract.

(iv) If the contractor commits any acts mentioned in clause 19 hereof.

When the contractor has made himself liable for action under any of the cases aforesaid, the Managing Director, Rajasthan Co-operative Dairy Federation Ltd. shall have powers:- a. to determine or rescind the contract as aforesaid (of which

termination or rescission notice in writing to the contractor under

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the hand of the Managing Director, RCDF Ltd. shall be conclusive evidence). Upon such determination or rescission the full security deposit of the contractor calculated on the tendered amount shall be liable to be forfeited and shall absolutely be at the disposal of Rajasthan Co-operative Dairy Federation Ltd.

b. to employ labour paid by the Federation and to supply materials to carry out the work or any part of the work debiting the contractor with the cost of the labour and the price of the materials (of the amount of which cost and price certified by the Officer-in-charge shall be final and conclusive) and crediting him with the value of the work done in all respects in the same manner and at the same rates as if it has been carried out by the contractor under the terms of his

contract. The certificate of the Officer-in-charge as to the value of work done shall be final and conclusive against the contractor provided always that action under the sub-clause shall only be taken after giving notice in writing to the contractor. Provided also that if the expenses incurred by the Federation are less than the amount payable to the contractor at his agreement rates, the difference shall not be payable to the contractor.

c. after giving notice to the contractors on measure up the work of the contractor and to take such part there of as shall be unexecuted out of his hands and to give it to another contractor to complete in which case any expenses which may be incurred in excess of the sum which would have been paid to the original contractor if the whole work had been executed by him (of the amount of which excess, the certificate in writing of the Officer-in-charge shall be final and conclusive) shall be borne and paid by the original contractor and may be deducted from any money due to him by Rajasthan Co-operative Dairy Federation Ltd. under this contract or on any other account whatsoever or from his security deposit or the proceeds of sales thereof or a sufficient part thereof as the case may be.

In the event of any one or more of the above courses as may

be deemed best suited to the interest of the Federation being adopted by the Managing Director, Rajasthan Co-operative Dairy Federation Ltd., the contractor shall have no claim to compensation for any loss sustained by him by reason of his having purchased or procured by him by reason of his having purchased or procured any materials or entered into any engagements, or made any advances on account of or with a view to execution of the work or the performance of the contract. And in case action is taken under any

44



of the provisions aforesaid, the contractor shall not be entitled to recover or be paid any sum for any work there for actually performed under this contract unless and until the Officer-in-charge has certified in writing the performance of such work and the value payable in respect thereof and he shall only be entitled to be paid the value as certified.

Contractor remains liable to pay compensation if action not taken under Clause 3.

Clause 3 :-

In any case in which any of the powers conferred by Clause 3 hereof shall have become exercisable and the same shall have not been exercised, the non-exercise thereof shall not constitute waiver of any of the conditions hereof, and such power shall notwithstanding be exercisable in the event of any future case of default the contractor for which by any clause or clauses hereof he is declared the contractor for which by any clause or clauses hereof he is declared liable to pay compensation amounting to the whole of his security deposit and the liability of the contractor for past and future compensation shall remain unaffected.

11.2 Force Majeure Clause :-

The terms and conditions mutually agreed shall be subject to the Force Majeure Clause. Neither the supplier nor the buyer shall be considered in default in performance of its obligations hereunder, if such performance is prevented or delayed because of war, hostilities, revolutions, civil commotion, strike, epidemic, accident, fire, wind, flood, earthquake or because of any law, order, proclamation, regulation, or ordinance of any Government or any act of God or any other cause whether of similar or dissimilar nature, beyond the reasonable control of the party affected should one or both of the parties be prevented from fulfilling his/their contractual obligations by a state of Force Majeure lasting continuously for a period of six months, the two parties should consult with each other regarding the future implementation of the agreement/purchase order.

12 Settlement of disputes :

In the event of any dispute in the interpretation of the terms of this agreement/ Purchase Order or difference of opinion between the parties on any point in the Purchase Order arising out of, or in connection with the

45



agreement/accepted purchase order or with regard to performance of any obligations hereunder by the either party, the parties hereto shall use their best efforts to settle such disputes or difference of opinion amicable by mutual negotiations. In case, no agreement is reached between the two parties in respect of or concerning any of the provisions herein contained or arising out of this supply order/ tender/ agreement as to the rights, liabilities or duties of the said parties hereunder or as to the recovery of any amount, the same shall be referred to the Sole Arbitrator M.D., RCDF who in turn may refer the dispute to any officer of RCDF for adjudication. The arbitration shall be in accordance to the law of Arbitration & Conciliation Act, 1996. The decision

of the Sole Arbitrator shall be final and binding on both the parties. All the disputes pertaining to the said contract / supply order / tender / agreement shall vest to the jurisdiction of Courts at Jaipur.

13 Right of Acceptance :

The Rajasthan Co-operative Dairy Federation Ltd. does not pledge itself to accept the lowest or any tender and reserves to itself the right to accept the whole or any part of the tender or portion of the quantity offered. The tenderer is at liberty to tender for whole or any portion or to state in the tender that the rates quoted shall apply only if the entire quantity is taken from them.

14 Form of Tender Rate Quotation : The form of tender rate quotation is given at Annexure-VI enclosed with Schedule–I.

15.0 IMPORTANT NOTES :

15.1 TIMELY DELIVERY, OF SPECIFIED QUALITY OF MATERIAL, PLANT & MACHINERY SATISFYING ALL DESIGN AND FUNCTIONAL REQUIREMENTS ORDERED, IS THE ESSENCE OF THE CONTRACT. THEREFORE, FAILURE TO DELIVER IN TIME OR NOT CONFORMING TO PRESCRIBED CIFICATIONS & QUALITY WILL MAKE THE SUPPLIER LIABLE FOR BLACKLISTING THE FIRM AND THEREBY DEBARRING THE SUPPLIER FROM PARTICIPATION IN FUTURE TENDERS BY RCDF, MILK UNIONS & OTHER AFFILIATED UNITS. AS FOR THE PRESENT CONTRACT PENALTIES, COMPENSATION AND OTHER PROVISIONS AS GIVEN IN THE TENDER DOCUMENT SHALL BE INVOKED ON FAILURE OF THE PARTY.

15.2 RCDF and milk unions shall have the fullest liberty to notify the defaulting firm to Business/Trade Associations/Public Sector undertakings/autonomous bodies and the like about the default and breach of contract committed by a firm giving

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out names of the partners of the firm. A register is intended to be maintained for such defaulting firms and their partners.

15.3 RCDF will not consider the tender of such firms who has earlier been debarred/censured/black listed or even those firms who have on their role key employees/ key executives/ proprietors/ partners of another already debarred/censured/ black listed firms in one or the other capacity.

15.4 All the tenderers without fail, should furnish full technical details about tendered project.

16.0 The quantities mentioned in the tender are tentative and the actual quantities to be procured may vary upward or downward suiting to the actual requirements.

17.0 Supplier will execute agreement on non-judicial stamp paper of Prescribed

value before 30% advance can be released to him. Format of the agreement is given at Annexure-VII.

18.0 If the Managing Director shall at any time, and for any reasons whatever, think any portion of the work should not be executed or should be withdrawn from the contractor he may, by notice in writing to that effect, require the contractor not to execute the portion of the work specified in the notice or may withdraw from the contractor the portion of the work so specified and the contractor shall not be entitled to any compensation by reason of such portion of the work having been executed by him, and the value (i.e. cost at tendered rates) of the portion of work so omitted or withdrawn shall in cases where the contractor has for any reason already received payment for it or in the cases of lump-sum contracts be deducted from any sum them due or thereafter to become due under the contract or otherwise against or from the security deposit or the proceeds of sale thereof.

19.0 The taxation on the “Supply, Erection, Testing and Commissioning of

Plant & Machinery for Setting up Indigenous Product Plant on Turn Key Basis” at Malpura (Tonk) Raj “ shall be governed as per latest

taxation norms i.e IGST.

20.0 No term or condition in addition to those mentioned above will be agreed to.

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Additional General Terms and Conditions which shall form an integral part of Purchase Order

1. INSPECTION :

The equipment under the purview of your supply should be inspected by your own technical experts at your works and such inspection report should be forwarded to us in triplicate alongwith dispatch documents. However, the RCDF, reserves its right of inspection at any stage of fabrication manufacture of the equipment/material. The final inspection if any case will be carried out at RCDF project site. You should forward to us the test certificate, wherever applicable,

obtained from the concerned authorities/principal manufacturers either regarding quality or any other details of the items utilised in the process of manufacture/fabrication.

2. DESPATCH INSTRUCTIONS : The material are to be despatched to the project site by the mode of transport specified in the order under intimation to us. Depending on the type of material, you shall have to carryout proper packing/creating to avoid breakage in transit. Other details of despatch such as marking, consignee a particulars etc. are given under clause No.4 of this purchase order. For using any mode of transport other than the specified one prior concurrence from us in writing should be obtained. All consignments should be despatched on freight paid basis irrespective of price basis. In the event of freight paid basis irrespective of price basis. In the event of freight payable by us, you shall have to obtain our prior approval and produce necessary documentary evidence in support of your claims. Unless otherwise stated, the original RR/LR should be sent by registered post directly to the consignee alongwith a copy of invoice and two copies of delivery challan/packing list.

3. INSURANCE : You shall have to arrange all transit risk insurance on warehouse basis for the items to be supplied by you. In the cases, where orders are placed on ex-works basis, the premium shall be paid by us at actuals to you against production of documentary evidence. In the event of any damage to /loss of consignment in transit, it will be your responsibility to lodge necessary claims with the cariers/underwriters and pursue them till settlement. Since insurance policy will be taken in our name, if required, we shall give you necessary authorisation letter, authorising you to lodge and pursue claims on your behalf with the carriers/underwriters. Also you shall have to make

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good the losses/damages occurred in transit by making replacement/payment to us in the first instance and if claims are settled by the underwriters and any amounts are released by us, the amount thus realised in settlement of claims shall be reimbursed to you. In other words, the prime facie responsibility rests on you for getting compensation of the damages/losses incurred if any, due to all transit hazards. In the case, when order is placed on ‘free delivery at site’ basis, no insurance premium will be paid by us. However, in such case also, all transit risk insurance policy must be taken to safeguard your own interest and to protect the material against transit hazards.

4. DELIVERY CLAUSE :

The stipulated delivery time given in the order is the essence of this contract. You must, therefore, strictly adhere to the delivery schedule mentioned in the order.

5. DEMURRAGE : You shall bear and reimburse to useful demurrage charges, if any paid by reason of delay on your part in forwarding the original despatch documents to destination given in the purchase order.

6. REJECTION : We reserve the right to reject the goods either in part or full if at the time of delivery, it is noticed that the goods supplied do not conform to the specifications/description given in the order. The rejection, if any, will intimated to you in writing within a reasonable time. You will be liable to repair/replace the rejected goods within the stipulated time. Till the repair/replacement is done, the rejected goods shall be lying at your risk, cost and responsibility. If you do not arrange to repair/replace the rejected goods within a period stipulated by us, we may dispose of such goods at your risk and in the manner which we think fit. We shall be entitled to retain the incurred on storage, handling and disposal of the rejected goods. We shall also be entitled to recover the expenses made by us on storage land handling of such rejected goods till the goods are removed from our premises/stores.

7. COMPENSATION FOR DELAY : The accepted delivery schedule of supply and/or installation shall be governed by the compensation for delay clause as given in the tender. Under the clause, if the delivery or installation of the equipment is not

49



made by the stipulated date, you shall have to pay a penalty @ half percent the value of each item per week subject to a maximum of five percent of the net value of the unexecuted part of the accepted order. Alternatively in the event of non delivery of the materials or non completion of installation within the stipulated time, we reserve the right to cancel the order and procure the material/get installed from any other the order land the party.

8.0 GUARANTEE : The supply of equipment as well as installation, if entrusted, shall have to be carried out by you to the entire satisfaction of RCDF. You shall also guarantee to repair/replace without any extra cost, the

items or parts thereof, if found defective due to bad designing, workmanship or substandard material, within 12 months from the date of commissioning or 24 months from the date of receipt of material at site whichever is earlier. If it is necessary to send the defective equipment or parts thereof to your works for repair/replacement, without forming any precedence the cost of repacking, loading, unloading, transportation from the site to your works and back to site shall have to be borne by you. The guarantee however, does not cover any damage resulting from normal wear and tear or improper attendance or mishandling of the equipment during repair by personnel other than the supplier or their authorised agents.

9. WARRANTY : You must provide a warranty for a minimum period of one year from the

date of commissioning of the equipment for satisfactory performance of the supplied equipment according to the designed/rated/installed capacity or any other norms fixed by RCDF.

10. DRAWINGS, SPECIFICATIONS & MANUALS : 10.1 Prior to commencement of fabrication, you shall have to submit for our

approval, two sets of drawings of all the items ordered for supply showing overall dimensions with typical sections, details of service connection and their requirement, details of drive units etc. The drawing should also show a complete bill of material, wherever applicable.

10.2 Three copies of each operation and maintenance manuals and service instructions alongwith the drawings showing details of part list, against each item of your supply should be sent to us. You should also furnish us service requirements like water (hot water, chilled water and main’s water), electricity, lubricant air etc. for each equipment, wherever applicable.

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10.3 You shall provide a list of spare parts, which will be required for the plants and equipments supplied by you for at least two years of normal operation with the names and the addresses of the manufacturers from whom they can be procured. The list should contain the code numbers of the parts, which are required to be procured in addition to the machine number and model etc.

10.4 In case, any documents, drawings are supplied to you by RCDF the same must be treated as confidential, must not be copies, reproduced, transmitted or disclosed otherwise in whole or part, not duplicated, modified, divulged or discussed to any third party nor misused in any other way without the consent of the RCDF in writing. All such documents, and drawings shall be the property of RCDF and they must be returned to

RCDF after done with. 11. SUBMISSION OF BILLS : Bills in triplicate under registered post, stating therein our purchase order

reference alongwith necessary inspection certificates from your inspector in respect of the material supplied and copies of despatch documents should be sent to our Head Office at Jaipur. Unless otherwise state, the payment shall be made to you by Crossed Account Payee Cheque by post according to the terms of payment mentioned in the Purchase Order.

12. CANCELLATION OF CONTRACT AND REFUND OF ADVANCES : We shall be free to cancel our order in part or full, in the case of non-

delivery of material/non-completion of installation within the stipulated delivery period or breach of any one of the clauses mentioned herein. Consequential losses, if any, on account of our getting installation done or obtaining supplies from alternative sources besides payment of higher price shall be recovered from you. In the event of cancellation of the order, you will be liable to refund the advance amount, if any, to the RCDF in full. Suppliers will have no right to forfeit the advance amount received by them.

13. SUB-CONTRACT :

In the event of awarding sub-contract to any of the parties by you for the manufacture/supply/erection of any parts/spares/components that will be used in the ordered equipment, you must furnish us details about your sub-contractors, their experience, specification etc. The sub-contract can be awarded by you only after obtaining written approval from us. In the event of sub-contract also the prime facie responsibility rests on you regarding quality, quantity, guarantee/warranty of the materials supplied by the sub-contractors.

14. FORCE MAJEURE CLAUSE :

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The terms and conditions mutually agreed upon shall be subject to For Majeure Clause. Neither the supplier nor the purchaser shall be considered in default in performance of its obligations hereunder, if such performance is prevented or delayed because of war hostilities, revolution, civil commotion, strike, epidemic, order, proclamation, regulation, or ordinance of any Government or of any act of God or of any other cause whether of similar or dissimilar nature, beyond the reasonable control of the party affected. Should one or both the parties be prevented from fulfilling his/their contractual obligations by a state of Force Majeure lasting continuously for a period of six months, the two parties should consult each other regarding the future implementation of the contract.

15. ARBITRATION CLAUSE : For settlement of any dispute arising out of this order, Jaipur shall be the jurisdiction irrespective of any jurisdiction clause mentioned in your correspondence. The arbitration proceedings shall be governed by the provisions of the Indian Arbitration & Conciliation Act, 1996 and the rules made there under or any enactment or statutory modifications thereof for the time being in force subject to condition No.13 of General Terms & Conditions Schedule – I of the tender document.

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TERMS & CONDITIONS

FOR

ERECTION/TESTING/

COMMISSIONING

53



SCHEDULE-III

GENERAL TERMS AND CONDITIONS FOR ERECTION CONTRACT

1.0 Material drawings etc.

1.1 All goods or materials shall be erected/supplied under the scope of erection with the specifications stated herein, and those covered under scope of work.

1.2 All goods or materials supplied or used shall be unused, new and of first quality.

Where foreign or partly foreign goods or material are to be used, this must be specifically stated and brought to the notice of RCDF.

1.3 Wherever necessary or required by RCDF, the erector shall furnish the necessary

test and/or inspection certificate etc. from the appropriate authorities as per IBR, IER and other statutory regulations at no extra cost.

1.4 All remarks, suggestions and modifications as suggested by the authorities

mentioned in 1.3 above, shall be carried out by the erector to the entire satisfaction of the referred authorities and no extra cost shall be payable in this regard to the erector by the RCDF.

1.5 The supplier shall furnish the necessary foundation drawings with all pertinent

details for each of the equipment under the purview of the supply alongwith the sets of drawings for approval.

2.0 Assigning & Subletting :

Assigning or subletting the contract shall not be done by the party unless written permission is obtained from RCDF. Written permission if given shall not relieve erector from his obligations under the contract and he shall take full responsibility for all the works carried out by the Sub-vendor.

3.0 Purchaser’s comments :

Erector shall not be relieved of his obligations under the order including but not limited to his warranty obligations stated herein merely by incorporating the purchaser’s design and fabrication comments on the goods hereunder.

4.0 Secrecy Clause :

4.1 The technical information, drawings, specifications and other related documents forming part of purchase order are the property of Purchaser and shall not be used for any other purpose, except for the execution of the order. All rights, including rights in the event of grant of a patent and registration of designs are reserved. The technical information, drawings, specifications, records and other documents shall not be copied, transcribed, traced or reproduced in any other form or otherwise, in whole or part and/or duplicated, modified, divulged and/or disclosed to a third party nor misused in any other form whatsoever without

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Owner’s or his collaborators previous consent in writing, except to the extent required for the execution of this order. This technical information, drawings, specifications and other related documents shall be returned to owner with all approved copies and duplicate, if any, immediately after they have been used for the agreed purpose.

4.2 In the event of any breach of this provision, erector shall indemnify the owner

from any loss, cost or damage or any other claim whatsoever from his collaborator and or any other parties claiming from or through them or from any other party in respect of such a breach.

5.0 Scope of Contract for Erection :

The erection would comprise of positioning and installing all MILK DAIRY PROJECT, miscellaneous and service equipments under the purview of his supply and those mentioned herein as per the approved machinery layout drawings. The scope of mechanical erection involves access preparation for moving of the plant and equipment including their fittings, from the work site godown(s) or from the place within the site where they have been unloaded, to the place of erection, decorating, placing on foundation wherever specified or required; erection of pipes and connections of necessary services to the main or ancillary branch of the service lines, but all within the battery limits, specified starting up and successful commissioning to get the specified rated output for each equipment. The installation should be carried out as per the drawing(s) submitted by the erector and approved by RCDF. Necessary Pipes fittings and valves etc. for interconnecting the equipment would be installed by the erector and it would generally be done according to the piping layout to be prepared by the erector and approved by RCDF. All the serviced pipes, fittings and valves etc. shall be supplied and installed by the erector and this should be carried out as per service piping drawings prepared by the erector and approved by RCDF. All necessary foundation bolts and their grouting on floor, walls, etc. as per the requirement, are included in the scope of erection & installation. All the supply covered in this part shall be governed by the same general terms and conditions given in the tender document against which the offer was made. Further the specifications of the contract are intended to describe and provide for a finished piece of work. They are intended to be complementary and what is equired by either shall be as if required by all. It is to be understood and agreed by erector that the work described shall be complete in every details even though every item necessarily involved is not particularly mentioned herein. Erector shall be required to provide all Labour materials and equipments necessary for the entire completion of the work describe and shall not avail himself of any manifesting or unintentional error, omission or inconsistency that may exist. Erector shall carry out and complete the work in every respect in accordance with the contract and accordance with the directions and to the entire satisfaction of RCDF and the manufacture’s representatives.

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6.0 Engineer’s Instructions :

RCDF may in his absolute discretion, from time to time issue further drawings and/or written instructions, details directions and explanations which are collectively referred to as ‘Engineer’s instructions’ in regard to :

6.1 Any additional drawings and explanations to exhibit or illustrate details. 6.2 The variation or modifications of the design, quality or quantity of work or the

additional or omissions or substitutions of any works.] 6.3 Any discrepancy in the drawings or between the schedule of quantities and/or

specifications. 6.4 The removal from the site of any material brought thereon by erector and the

substitution of any other material thereof. 6.5 The removal and/or re-execution of any work executed by the erector. 6.6 The dismissal from the work of any persons employed thereupon. 6.7 The opening up for inspection of any work covered up. 6.8 The amending and making good of any defects.

7.0 Right of RCDF :

7.1 The various parts of the contract are intended to be complementary to each other but should any discrepancy appear or any misunderstandings arises as to the interpretations of anything contained therein, the explanation of RCDF shall be final and binding.

7.2 Right to direct work :

7.2.1 RCDF shall have the right to direct the manner in which all work under this contract shall be conducted in so far as it may be necessary to secure the safe and proper progress and specified quality of the work, all work shall be done and all materials shall be furnished to the satisfaction and approval of RCDF.

7.2.2 Whenever, in the opinion of the RCDF, erector has made marked departures

from the schedule of the completion laid down in the agreement or when untoward circumstances force a such departure from the said schedule, RCDF in order to assure the compliance with the schedule and the provisions of the agreement, shall direct the order, pace and method of conducting the work, which shall be adhered to by the erector.

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7.2.3 If, in the judgment of RCDF, it become necessary at any time to accelerate the over all pace of the plant erection work erector when, ordered and directed by RCDF shall cease work at any particular point and transfer his men to such other point or points and execute such portion of his work, as may be required, to enable RCDF to hasten and properly engage and carry on their work, all directed by the RCDF.

7.2.4 Night work will be permitted only with prior approval of RCDF, RCDF may also

direct erector to operate extra shifts over and above normal day shift to ensure completion of contract as scheduled or due to exigent circumstances, if in his opinion, such work is required.

7.3 Right to order Modifications of Methods & Equipment:

If at any time the erectors methods, materials or equipment appear to RCDF to be unsafe, inefficient or inadequate for securing the safety of workmen or the public, the quality of work or the rate of progress required, he may order erector to ensure their safety, and increase their efficiency and adequacy and the erector shall promptly comply with such orders. If at any time erectors working force and equipment are in the opinion of RCDF is inadequate for securing the necessary progress as herein stipulated erector shall if so directed increase the working force and equipment to such an extent as to give reasonable assurance of compliance with the schedule of completion. The absence of such demands from RCDF shall not relieve erector of his obligations to secure the quality, the safe conducting of the work and the rate of progress required by the contract the erector alone shall be and remain liable and responsible for the safety, efficiency and adequacy of his methods, materials, working force and equipment, irrespective of whether or not he makes any changes as a result or any order or orders received from RCDF.

8 Changes/ Variation in the work :

8.1 If it becomes necessary or desirable to modify the contract and the specifications therein contained and the drawings, in a manner not materially affecting the substance thereof, or to make changes by altering, adding to or deducting from the work, or to add correlated work not now covered by the contract to the work to be done under his contract RCDF may, without invalidating the contract, direct such changes increase the cost of work and payment therefore is not covered by the prices bid for the various items, erector shall be reimbursed for such changes under a supplementary contract. In case such changes shall diminish the cost of the work, appropriate deductions towards such reduction in cost shall be made from the contract price.

8.2 Erector when requested in writing by RCDF shall perform extra work and furnish

extra material not covered by the specifications but forming an inseparable part

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of the work contracted for and shall be paid extra for all such work at rates and terms mutually agreed upon.

8.3 Extra items, if any, shall be paid on the basis of vouchers of cost of materials

and labour procured by erector. Erector shall be paid 15% of the cost of material and labour towards his profit, supervision and overhead charges.

8.4 Items not covered by the schedule of quantities but similar in nature to the

items already covered shall be paid for, the rates being worked out on the basis of rates quoted for similar items.

8.5 The purchaser shall make any variation of the form, quality or quantity of the works or any part there of that may. In his opinion, be necessary and for that purpose, or if for any other reason it shall, in his opinion be desirable, he shall have power to order the supplier to do and the supplier shall do any of the following:

a. Increase or decrease the quantity of any work included in the contract, b. Omit any such work, c. Change the character or quality or kind of any such work, d. Change the levels, lines, position and dimension of any part of the works,

and

e. Execute additional work of any kind necessary for the works and no such variation shall in any way vitiate or invalidate the contract, but the value, if any, of all such variations shall be taken into account in ascertaining the

amount of the contract price. 8.6 The supplier shall make no such variations without an order in writing of the

purchaser.

8.7 Provided that no order in writing shall be required for increase or decrease in the quantity of any work where such increase or decrease is not the result of an order given under this clause, butis the result of an order given under this clause, but is the result of the quantities exceeding or being less than those stated in the contract/bill of quantities. Provided also that if for any such order verbally, the supplier shall comply with such verbal order given by the purchaser, whether before or after the carrying out of the order, shall be deemed to be an order in writing within the meaning of this clause. Provided further that if the supplier shall within seven days confirm in writing to the purchaser and in writing within 14 days, it shall be deemed to be an order in writing by the purchaser.

8.8 All extra or additional work done or work omitted by order of the purchaser shall be valued at the rates and prices set out in the contract if in the opinion of the purchaser, the same shall be applicable. If the contract does not contain any rates or prices applicable to the extra or additional work, then suitable rates or prices shall be agreed upon between the purchaser and the supplier.

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In the event of disagreement the purchaser shall fix such rates or prices as shall, in his opinion, be reasonable and proper.

8.9 Provided that if the nature or amount of any omission or addition relative to the nature or amount of the whole of the works or to any part thereof shall be such that, in the opinion of the contract for any item of the works, is by reason of such omission or addition, rendered unreasonable or inapplicable, then a suitable rate or price shall be agreed upon between the purchaser and the supplier. In the event of disagreement the purchaser shall fix such other rate or price as shall, in his opinion, be reasonable and proper having regard to the circumstances.

8.10 Provided also that no increase or decrease mentioned above or variation of rate or price shall be made unless, as soon after the date of the order as is practicable and, in the case of extra or additional work before the commencement of the work or as soon thereafter as is practicable, notice shall have been given in writing:

a. By the supplier to the purchaser of his intension to claim extra payment or

a varied rate or price, or b. By the purchaser to the supplier of is intension to vary a rate or price.

8.11 If, on certified completion of the whole of the works, it shall be found that a reduction or increase greater than 15 percent of the sum named in the letter of acceptance results from the aggregate effect of all variation orders but not from any other cause, the amount of the contract price shall be adjusted by such sum as may be greed between the supplier and the purchaser or, failing agreement, fixed by the purchaser having regard to all material and relevant factors, including the suppliers site and general overhead costs of the contract.

8.12 The supplier shall send to the purchasers representative once in every month an account giving particulars, as full and detailed as possible, of all claims for any additional payment to which ordered by the supplier may consider himself entitled and of all extra or additional work ordered by the purchaser which he has executed during the preceding month.

8.13 No final or interim claim for payment for any such work or expense will be considered which has not been included in such particulars. Provided always that the purchaser shall be entitled to authorize payment to be made for any such work or expense, notwithstanding the suppliers failure to comply with this condition, if the supplier has, at the earliest practicable opportunity, notified the purchaser in writing that he intends to make a claim for such work.

8.14 The work shall be carried out as approved by the purchaser or his authorized

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representative/s from time to time, keeping in view the overall schedule of completion of the project. The suppliers job schedule must not disturb or interfere with purchasers or the other suppliers schedules of day-to-day work. The purchaser will provide all reasonable assistance for carrying out the jobs.

8.15 Night work will be permitted only with prior approval of the purchaser. The purchaser may also direct the supplier to operate extra shifts over and above per schedule. Adequate lighting wherever required should be provided by the supplier at no extra cost. The supplier should employ qualified electricians and wiremen for these facilities.

8.16 In-case of suppliers failure to provide these facilities. in case of suppliers failure to provide these facilities and personnel, the purchaser has the right to arrange such facilities and personnel and to change the cost thereof to the supplier.

8.17 In order to enable the purchaser to arrange for insurance of all items received at the site including the items of supply covered under this contract, the supplier shall furnish necessary details of all the equipment immediately on its receipt at site, to the purchaser. Any default on the part of the supplier due to which any item does not get covered under the insurance of the purchaser; the consequential losses shall be charged to the supplier.

8.18 The purchaser shall not be liable for or in respect of any damages or compensation payable at law in respect or in consequence of any accident or injury to any workman or other person in the employment of the supplier or any sub-supplier, save and except an accident or injury resulting from any act or default of the purchaser, his agents, servants. The supplier shall indemnify and keep indemnified the purchaser against all such damages and compensation, save and except as aforesaid and against all claims, proceedings, costs, charges and expenses whatsoever in respect thereof or in relation thereto.

8.19 The supplier shall ensure against such liability with as insurer during the whole of the time that any persons are employed by him on the works shall,

when required, produced to the purchaser or purchasers representative such policy of insurance and the receipt for payment of the current premium. Provided always that, in respect of any persons employed by any sub-supplier, the suppliers obligations to ensure as aforesaid under this sub-clause shall be satisfied if the sub-supplier shall have insured against the liability in respect of such persons in such manner that the purchaser is indemnified under the policy, but the supplier shall require such sub-supplier to produce to the

purchaser or purchasers representatives, when required such policy of insurance and the receipt for the payment of the current premium

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8.20 Whenever proper execution of the work under the contract depends on the jobs carried out by some other supplier, the supplier should inspect all such erection and installation jobs and report to the purchaser regarding any defects or discrepancies. The suppliers failure to do so shall constitute as acceptance of the other suppliers installation/jobs as fit and proper for reception of suppliers works except those defects which may develop after execution. Supplier should also report any discrepancy between the executed work and the drawings. The supplier shall extend all necessary help/cooperation to other suppliers working at the site in the interest of the work.

8.21 Supplier shall carryout final adjustments of foundations, leveling and dressing of foundation surfaces, bedding and grouting of anchor bolts, bedplates etc. required for seating of equipment in proper position. The supplier shall be responsible for the reference lines and proper alignment of the equipment. However, all civil works like making cutouts in walls, floors and ceilings for pipelines shall be done by the purchaser. Adjustment & leveling are to be carried out by the supplier at no extra cost. The purchaser shall arrange the necessary refilling/repairs of these cutouts and pockets. The supplier should arrange for laying the supports, cutouts, grouting of bolts, etc. when the civil works are in progress, so as to avoid refilling/repair works. The purchaser at suppliers costs shall make the damages occurring to civil and other works good. For fixing of piping/equipment supports on wall/beams/roof floor etc. preferably anchor bolts shall be used by the supplier. Drilling of holes for fixing anchor bolts is in the scope of supplier without any extra cost.

8.22 The supplier shall keep a check on deliveries of the equipment covered in the scope of erection work and shall advise the purchaser well in advance regarding possible hold-up in suppliers work due to the likely delay in delivery of such equipment/components to enable him to take remedial actions.

DUTIES OF THE SUPPLIER VIS-À-VIS THE PURCHASER.

The equipment and the items, if any, to be supplied by the purchaser for

erection, testing and commissioning shall be as listed in the contract.

Besides the utilities/services as specified in battery limits the following assistance/facilities shall also be provided to the supplier by the purchaser for carrying out the installation work.

Plant building ready for installation of equipment/items.

Necessary temporary water for carrying out the installation shall be supplied at only one point within the project site by the purchaser free of charge. All necessary distribution tapings from this point onwards shall be the suppliers responsibility.

Necessary temporary power is provided by the purchaser, the recovery @1%

mailto:@1%25

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of total installation charges will be recovered. However, the supplier shall supply all the items such as energy meter, switchgear etc. required for getting temporary power.

The details of temporary water and power requirements shall be furnished seven days in advance by the supplier to enable the purchaser to make timely arrangement.

If the supplier suffers delay and/or incurs costs from failure on the part of the purchaser to give possession of the civil works in accordance with mutually agreed schedule, the purchaser shall determine:

Any extension of time to which the supplier is entitled under the contract

The amount of such costs, which shall be added to the contract price, and shall notify the supplier accordingly.

9 Erector’s functions :

9.1 Erector shall provide everything necessary for the proper execution of the

works, according to the patent and meaning of the drawings, schedule of quantities and specifications taken together whether the same may or may not be particularly shown or described therein provided that the same can reasonably be inferred there from and if the erector finds any discrepancy therein, he shall immediately and in writing refer the same to RCDF where decision shall be final and binding on all the parties.

9.2 It is not expected that the work under contract will be subcontracted. However,

in case erector desires to subcontract a part of the work in the interest of the project, he shall request in writing to RCDF for approval for the same giving full and complete details regarding the proposed subcontractor, his experience and the terms of subcontract. Approval from RCDF for subcontracting part of the work shall not relieve the erector from any of his obligations and responsibilities under this contract.

9.3 Erector shall proceed with the work to be performed under this contract and each and every part and details thereof, in the best and most workman like manner by engaging qualified, careful and efficient workers, and do the several parts thereof at such time and in such order as RCDF may direct and finish such work in strict conformance with the plans, drawing and/or specifications, and any changes, modifications thereof made by RCDF.

9.4 The supplier shall provide everything necessary for proper execution of the works, according to the drawings, schedule of quantities and specifications taken together whether the same may or may not be particularly shown or described therein, provided that the same can reasonably be inferred there from and if the supplier finds any discrepancy therein, supplier shall immediately refer the same to the purchaser whose decision shall be final and binding on the supplier.

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9.5 The supplier shall proceed with the work to be performed under this contract in the best and workman like manner by engaging qualified and efficient workers and finish the work in strict conformance with the drawings and specifications and any changes/modifications thereof made by the purchaser.

9.6 Any work is to be done at place other than the site of the works erector shall obtain the written permission of RCDF for doing so.

10 Unloading, Inspection & Storing : 10.1 Erector shall promptly unload from the carriers all the materials/equipment

covered under this contract. It is the erectors sole responsibility to keep in touch with the RCDF and others to inform himself on the expected date and time or arrival of carriers at site and ensure that his men aids are available in time to unload the material/equipment and promptly release the carriers. Any demurrage charges incurred due to the delay in unloading the materials/equipment and releasing the carriers shall be changed to the erector’s account. Erector shall plan in advance his requirements of jacks, cranes, sleepers etc. including those not specified here in but required to unload the material/equipment promptly and efficiently.

10.2 Unless excluded in the specifications, erector shall safety transport the

material/equipment to the storage area and store the same in systematic manner with tags for easy identification and retrieval. He shall also maintain all required stores records and furnish all required reports. If in the opinion of RCDF the erector is not taking any action to unload and transport the material to site. RCDF reserves the right to arrange for the same through alternative agencies, entirely at the cost of the erector. It is further clarified that even in the event RCDF arranges for the unloading, transportation storage space etc. under the circumstances described above, the liability and responsibility will rest with the erector.

10.3 All materials and equipment received at site, before erector arrives at site, shall

be unloaded and stored by RCDF at the risk responsibility and cost of the erector. These materials shall be handed over to the erector and there upon the erector shall inspect the same and furnish the receipt to the RCDF. The protection safety and security of the material so taken over shall be the responsibility of the erector until it is handed over to the RCDF after erection and/or commissioning. Any and all the material/equipment covered under the scope of this contract, received at site after erector arrives at a site shall be unpacked, inspected and checked and against invoices by the erector. He shall furnish shortage and damages reports to RCDF within a week of the receipt of material and assist the RCDF in lodging claims with the Insurance Companies. In case RCDF incurs a loss due to the delay in lodging insurance claims, which are attributable to erector all such losses shall be deducted from erector’s bills.

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Erector shall repack materials/equipments as required and store the same in an orderly manner.

10.4 Erector shall also inform RCDF in right time regarding the repairs/replacement

required towards the items damages/lost in order to enable the RCDF to arrange for repairs/replacement well in time and avoid delays due to non availability of equipment and part at the time of their actual need.

10.5 Erector shall arrange for periodical inspection of material equipment in his

custody until taken over by the RCDF and shall carry out all protective and preservative measures thereupon.

10.6 Erector shall also keep a check on the deliveries of the equipment/material

covered in his scope of erection and shall advise RCDF well in advance regarding possible hod ups in his work due to expected delays in delivery of equipment, to enable RCDF to expedite the deliveries and take other remedial action.

11 Other Contractors/Erector’s Work :

If any part of Erector’s work depends, for proper execution, upon the work of any other erector, the erector shall inspect and promptly report to RCDF any defect in such work of other contractors that render it unsuitable for use. Failure to do so shall be deemed as an acceptance of the other erector’s work as fit and proper for the erection of his work except as to defects which may develop in the work of other contractors after the proper execution of the work. To ensure proper execution of his subsequent work, erector shall measure work already in place and shall at once report to RCDF and discrepancy between the executed work and the drawings.

12 Supply of Tools, Tackles & Materials : 12.1 For full completion of the work, erector shall at his own expense furnish all

necessary erection tools, machine tools, power tools, tackles, hoists, cranes, derricks, cables, slings, skids scaffolding work benches, tools for rigging, cribbing and blocking, welding machines and all other associated protective equipment, instruments, appliances, materials and supplies required for unloading, transporting, storing, erecting, testing and commissioning all the equipment of the plant that may be required to accomplish the work under the contract unless otherwise provided for. Adequacy of such tools will be subject to final determination by RCDF.

12.2 Erector shall also furnish all necessary expandable device like anchors, grinding

and abrasive wheels, raw plugs hacksaw blades, tape, dyes, drills, reamers, chisels, files carborundum stones, oil stones, wire brushes, necessary bamboo scaffolding, ladders wooden planks timers, sleeper and consumable material like oxygen, acetylene, argon, lubricating, oils, greases, cleaning fluids, welding rods cylinder oils, graphite powder and flakes fasteners, gaskets temporary supports stainless steel shims of various thickness as required, cotton waste, cheese cloth

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and all other miscellaneous supplies of every kind not necessarily listed above but required for carrying out the work under contract.

12.3 Erector shall provide all reasonable facilities including tools personnel etc. and

ensure coordination with RCDF and erection supervisors of other equipment suppliers to enable them to carry out all supervision measurements checks etc. in a satisfactory manner.

12.4 Erector shall not dispose of transport or withdraw any tools, tackles, equipment

and material provided by him for the execution of the work without taking prior written approval from RCDF at all times shall have right to refuse permission for disposal, transport or withdraw all of tools, tackles, equipment and material which in the opinion of RCDF will adversely affect the efficient and expeditious completion of the project.

12.5 Machinery Foundation :

All the civil foundations as per the drawings furnished by the manufactures/suppliers shall be arranged by RCDF. The erector shall place the equipment on the foundations and carry out final adjustment of the foundations alignment dressing of foundation surface, providing and grouting of anchor bolts pockets etc. and set the equipment properly as per approved layout drawing and manufacture instructions.

12.6 Structural Platform : Supply of all necessary materials and installation of structural platforms,

structural supports and access arrangement required for the various equipment is included within the scope of mechanical installation and should be so carried out that all operation can be easily manoeuvred.

The details and drawings in regard of the platforms shall be worked

out/prepared by the erector and submitted to the RCDF for approval. The items should be executed as per the approval details drawing. The payment will be made on the basis of cost per unit weight as offered by erector and accepted by RCDF.

13 For Erection & Commissioning :

The erector will be required to take a ‘storage-cum-erection’ insurance for the items to be erected and commissioned by him. For this insurance premium shall however be reimbursed to him by the buyer. In case, the erector is not able to arrange insurance at reasonable rates acceptable to the buyer, the buyer shall arrange the same on behalf of the erector. However, in the event of any loss/damage to the equipment during storage or erection and commissioning, the erector alone shall have to lodge the claims with underwriters and pursue the same till settlement irrespective of the fact whether the insurance policy is

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taken by the erector or arranged by the buyer on his behalf. Further, it shall be sole responsibility of the erector to make good the losses/damages expeditiously without any extra cost to the buyer.

14. All the equipment/machineries including motors, pumps, starters, junction

boxes, isolators, and boxes, tanks supporting structures, pipe supports and brackets of MS, GI, Pipes which are not insulated and all exposed and visible cost Iron parts shall be given a double coat of anticorrosive primers. MS and GI parts (within the building) should be given a final coat of paint of approved shade. However, if so instructed by RCDF in respect of certain particular items/equipments, the erect should touch up breaches in the paintings. All surfaces must be properly cleaned and all scale, dirt and grease should be removed prior to painting. Spray painting must preferably be used on all the equipment, machineries and wherever else practicable. Suitable and necessary cleaning/wiping of slight/dial glasses, other non-metallic parts, flooring, walls and other surfaces which have been spoiled by paint during painting must also be carried out by the erector. Lettering and other markings, including capacity and flow direction markings, shall also be carried out by the tenderer on the tanks, pipe lines, starters, motors, isolators and wherever else necessary as directed and as per the standard practice of installation. The scope of paining includes a double steel primer under coat and a top coat of paint of approved shade and quality, wherever possible ISI colour codes and colour charts must be adhered to. However, the final colour code shall have to be got approved from RCDF and any changes suggested thereby should be carried out.

15.0 Cleaning Chemicals & Lubricants :

The necessary quantities of cleaning chemicals, make-up lubricants, etc. required for the installation, commissioning, testing and start-up all the equipments are to be supplied by the erector free of cost.

16.0 Access preparation :

In case access preparation is required to be made for shifting the equipment the erector shall bring to the notice of RCDF, the quantity of work involved for making such a preparation. Consequently RCDF would review the matter in consultation with the erector and decide the course of action.

17.0 Setting put works, lines & Grades : 17.1 Building, foundation and other civil works shall be provided by RCDF unless

indicated otherwise. Erector shall carry out all adjustments of foundations, levels, dressing of foundation surfaces, bedding and grouting of anchor bolts and bed plate etc. as may be required for seating of the equipment in proper position. Erector shall be responsible for obtaining correct reference lines for purposes of fixing the alignment of various equipments from master bench marks furnished by RCDF. Any minor alternation required in rectifying the

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anchor bolts pockets, anchor bolts, etc. shall be carried out by erector at no extra cost. The erector shall supply all the necessary foundation and anchor bolts, bed plates etc. without any extra cost.

17.2 Erector shall supply, fix and maintain at his cost during the execution of any

work, all the necessary centring, scaffolding, staging, planking, timbering, strutting, shorting pumping, fencing boarding guarding and lighting by night as well as by day, required not only for the proper execution and protection of the said work, but also for the protection of the pumping station and of the safety of any adjacent roads, streets, cellars, vaults ovens, walls, houses, buildings and all other erections, matters or things. Erector shall take out and remove any or all such centring, scaffolding, staging, planking timbering, strutting, shorting etc. as occasion shall require or when ordered to do so and shall fully reinstalled and make good all matters and things disturbed during execution of the work, to the satisfaction of RCDF. Erector shall be paid no additional amount for the above.

18.0 Erection & Inspection :

18.1 Erector shall prepare a detailed and comprehensive erection schedule for review and approval of RCDF’s site Engineer and supplier’s erection supervisors. This ‘Approved’ erection schedule shall form the basis for evaluating the pace of all the erection works to be performed by erector.

18.2 The schedule shall show approximately the date on which each part of divisions

of the work is expected to begin based on his knowledge of the works of the other contractors and the date when the work is schedules to be finished. Upon the request of RCDF erector should be prepared to discuss his schedule in relation to the master schedule and shall co-ordinate his work with that of the other erectors/contractors as determined by RCDF.

18.3 The work so far as it is carried out on RCDF’s promised shall be carried out at

such time as RCDF may approve consistent with the construction schedule and so as not to interfere unnecessarily with the conduct of RCDF’s business and RCDF will give erector all reasonable assistance for carrying out the work.

18.4 Erector shall revise and up date his erection schedule periodically (at least once

every calendar month) to indicate actual progress of works, in relation to scheduled progress. Erector shall also submit monthly progress reports indicating progress work giving scheduled and actual percentage completions, causes for delay etc. as well as such other reasonable reports RCDF may request from time to time.

18.5 Adherence to the instructions of supervisory engineers of manufacturers, where

provided by RCDF is compulsory. Erector shall work as per the procedure suggested by manufacturer and shall complete erection of equipment in such a way so as not to interfere with or prevent equipment from functioning as intended, as well as to the entire satisfaction of the manufacturer’s

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supervisor/RCDF. Erector shall also permit and provide all facilities for manufacturer’s erection super visors to carry out all checks that they may wish to and approve any erection procedure and/or final setting and alignment of components, in order to satisfy themselves that erection has been carried out as intended by them. This shall, however, in no way relieve erector of his responsibility for providing adequate and competent supervision and quality workmanship. In case of any dispute, the decision of the RCDF/Manufacturer’s erection supervisor shall be final and binding on the erector.

18.6 Erector shall haul materials and equipment furnished at RCDF’s storage or

unloading areas to the points where they are to be used, in the construction work, install the materials and equipment in their final location and classify and store all surplus and auxiliary parts in a systematic manner in the warehouse, where they can be readily identified and located when needed at a later date.

18.7 In the execution of the work no person other than erector or his duly appointed

representatives, his subcontractors and their workman shall be allowed to do work at the site except by the special permission, in writing of RCDF or their representatives, but access to everywhere in the site at all times shall be accorded to RCDF and their representatives and other authorized officials and statutory public authorities. Nevertheless, erector shall not object to the execution of the work by other erector/contractor or tradesman whose names shall have been previously communicated in every facility for the execution of their several functions simultaneously with his own.

18.8 Erector shall carry out the required ‘minor modification work’ at site as required

to efficiently complete the work covered in this contract at no extra cost over his contracted sum. However ‘minor modifications’ shall not involve more than 24 man hours per each item of such work. However, in case of ‘major modifications’ which are required to be done on the equipment, for no fault of erector he shall be compensated on the basis of man day rates. It is the responsibility of the erector to get the prior approval for such ‘major modifications work’ from RCDF before such works are taken up. Erector shall also get the estimates and the actual time sheets certified by RCDF and these certified time sheets will be the basis for processing his bills for the ‘Major modifications’.

18.9 If the work or any portion thereof shall be damaged in any way excepting by the

acts of RCDF, or if defects not readily detected on prior inspection and which shall develop before the final completion and acceptance of the whole work, erector shall forthwith make good, without compensation, such damage or defects in a manner satisfactory to RCDF. In no case shall defective or imperfect work will be retained.

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18.10 Erector at all times shall work in co-ordination with RCDF’s engineering staff and after them all reasonable facilities to become familiar with the erection, operation and maintenance of the equipments.

18.11 In respect of observation of local rules, administrative orders, working staff and

the like, erector and his personnel shall co-operate with the RCDF. 18.12 Erector shall not sell, assign, mortgage, hypothecate or remove equipment or

materials which have been installed or which may be necessary for the completion of the contract without the consent of RCDF in writing.

18.13 Inspection of work :

RCDF of any person appointed by them shall have access and right to inspect the work, or any part thereof at all times and places during the progress of the work. The inspection and supervision is for the purpose of assuring RCDF that the plans and specifications are being properly executed and while RCDF and their representatives will extend to the erector all desired assistance in interpreting the plan and specifications, such assistance shall not relieve erector of any responsibility for the work. Any work which proves faulty shall be corrected by erector without delay. The fact that RCDF or their representatives have not pointed out faulty work or work which is not in accordance with plans and specifications shall not relieve the erector from correcting such work as directed by RCDF without additional compensation. RCDF their representatives and the employees shall at all reasonable times have free access to the works and/or to the workshop factories or other places where materials are being prepared or constructed or fabricated for the contract and also to any place where the materials are lying or from where they are being obtained and erector shall give every facility to RCDF and his representative for inspection examination and test of the materials and workmanship even to the extent of discontinuing portion of the work temporarily or of uncovering or taking down portion of finished work.

19.0 Protection to Plant :

19.1 Except in case where RCDF’s express permission, is applied for and received in

writing no use of RCDF’s plant facilities such as cranes, passenger elevator, toilets showers or machine shop etc. shall be made by erector or his employees.

19.2 RCDF shall not be responsible or held liable for any damage to person or

properly consequent upon the use, misuse or failure of any construction tools and equipment used by erector of any of his subcontractors, even though such constructions tools and equipment may be furnished rented or loaned to erector or any of this contractors. The acceptance and/or use of any such constructions tools and equipment by erector or his subcontractor shall be constructed to mean that erector accepts all responsibility for and agrees to indemnify and save

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harmless RCDF from any and all claims for said damages resulting from said use, misuse or failure of such construction tools and equipments.

19.3 Erector and his subcontractors shall be responsible during work for protection of

the work which has been completed by other contractors/suppliers. Necessary care shall be taken to see that no damage to the same is caused by his own men during the course of execution of their work.

19.4 All other work completed or in progress as well as machinery and equipment

that are liable to be damaged by erector’s work shall be protected by erector and such protection shall remain and be maintained until its removal is directed by RCDF.

19.5 Erector shall effectively protect all the works from action of weather and from

damages or defacement and shall cover finished parts wherever required for their through protection. Face work shall be perfectly clean and free from defects.

19.6 The work shall be carried out to completion without damage to any work and

properly adjacent to the area of his work to whom so ever it may belong, without interference with the operation of their existing machines or equipment.

19.7 Adequate lighting at and near all the shortage, handling, fabrication, preassembly and erection sites for properly carrying out the work and for safety and security shall be provided by erector. Erector should adequately light the work area during night time also. Erector should also engage adequate electricians/wireman, helpers etc. to carry out and maintain these lighting facilities. RCDF may provide such facilities as he may deem necessary and charge the cost thereof to the erector. In any case, erector shall be liable for all damages and consequences arising out of his neglect in this regard.

20.0 Clean up of work site

20.1 All soils, filth or other matter of an offensive nature taken out of any trench,

sewer, drain, cesspool or other place shall not be deposited on the surface, but shall at once be carted away by the erector from the site of work for suitable and proper disposal.

20.2 Erector shall not store or place the equipment, materials or erection tools on the

drive ways and streets and shall take care that his work in no way restricts or impedes traffic or passage of men and material. During erection, erector shall, without any additional payment, at all times, keep the working and storage area used by him free from accumulation of dust or combustile material, waste materials or rubbish, to avoid fire hazards and hindrance to other works, of RCDF.

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20.3 If erector fails to comply with these requirements inspite of written instructions from RCDF, RCDF will proceed to clear these areas and the expenses incurred by the RCDF in this regard shall be payable by erector. Erector shall remove or dispose off in a satisfactory manner all scaffoldings, temporary structures, waste and debris and leave the premised in a conditions satisfactory to RCDF. Any packing materials received with the equipment shall remain as the property of RCDF and may be used by erector on payment of standard charges to RCDF and with prior approval of RCDF. At the completion of his work and before final payment, erector shall remove and shall restore the site to a neat workman like conditions, at his cost.

21.0 Erector’s Personnel : Erector shall function as on erection organisation and furnish adequate courteous and competent labour (unskilled, semiskilled and skilled, watchman, supervisors, and engineers of all classes for the duration of the work to maintain the rate of erection in accordance with the requirement of the schedule of completion, and shall be in the work included in the contract at such times as will ensure its completion as specified and shall complete the same force of all lines and charged, at or before the time specified for completion. Erector shall make available qualified engineers for placing the equipment in operation and carrying out the necessary tests and trials. Conducts required of erector’s men are specified below :

21.1 It is important that erector shall employ men known to be reliable and competent for the work in general and it shall be requirement of the contract that men used on special works shall be competent, well trained and trusted employees.

21.2 Erector shall furnish details of the qualifications and experience of his senior supervisors and engineers assigned to the work including their experience in supervising erection and commissioning of plant and equipment of comparable capacity.

21.3 Erector shall be personally present or employ at least one competent

representative (whose name shall have previously been communicated in writing to RCDF to supervise the erection of the equipment and carrying out the work under the contract. This representative shall have full technical capability and complete administrative and financial powers to expeditiously and efficiently execute the work under the contract. Erector or his representative or if more than one be employed, one of the representative shall be present at the site at all times when work is in progress, and any written orders or instructions which RCDF may give to the said representative of erector shall deemed to have been given to the erector. He shall maintain an office near/or adjacent to the site of the work, and shall at all times keep in office a complete set of specifications and drawings. RCDF shall normally communicate directly with the said representative at site.

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21.4 Erector’s representative at the site shall be posted and be available at site within a reasonable time after RCDF shall inform erector in writing to the effect. The service of erector’s representatives shall be made available during the progress of the work for such periods during the working days as RCDF may require.

21.5 When erector or his representative is not present on any part of the work where

it may be desired to give directions in the event of emergencies, orders may be given by RCDF and shall be received and obeyed by the supervisors or foreman who may have charge of the particular part of the work in reference to which order given. If requested to do so, RCDF shall confirm such orders in writing. Any such instruction, direction or notices given by RCDF shall be held to have been given to the erector.

21.6 Erector shall furnish RCDF a fortnightly labour force report showing by

classifications the number of employees engaged in the work. Erector’s employment records shall include any reasonable information as may be required by RCDF. The erector should also display necessary information as may be required by statutory regulations.

21.7 None of the erector’s superintendents, supervisors, engineers, or labour may be

withdrawn from the work without the notice given to RCDF and further no such withdrawals shall be made if in the opinion of RCDF, it will jeopardize the required pace of progress and/or the successful completion of the work.

21.8 RCDF shall be at liberty to object to any representatives or person or skilled,

semiskilled or unskilled worker employed by the erector in the execution, or otherwise, of the worker who shall misconduct himself, or be incompetent, or negligent or unsuitable and erector shall remove the person so objected to upon receipt of notice in writing from RCDF requiring him to do so and shall provide in his place a competent representative at his own expense within reasonable time.

22.0 Construction, Electric Power & Water :

Electric power and water will be made available for use by RCDF free of cost. These supplies will be made, where available at one central point in the site convenient to RCDF and all piping for service water to work area shall be furnished, installed and maintained by erector at his own expense. He shall also furnish, install and maintain at his cost the power lines, junction boxes and any other electrical receptacles, apparatus or equipment from the central point of his work area.

23.0 Drawings :

23.1 Within three weeks from the date of receipt of the order, erector shall submit list of necessary drawings as mentioned in 1.5, that he proposes to submit for approval, identifying each by a serial number and descriptive, title and giving

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the expected date of submission. This list shall be revised and extended, as necessary during the progress of work.

23.2 Erector shall also submit copies of design calculations, material specification and

detailed drawings as called for in the equipment specifications for RCDF review. Erector must satisfy RCDF as to the validity of his design with reference to the requirement of statutory Code Authorities.

23.3 Drawings submitted for approval shall be signed by responsible representatives

of erector and shall be to any one of the following sizes in accordance with

Indian Standards : A0, A1, A2, A3, or A4

23.4 All drawings shall show the following particulars in the lower right hand corner in

addition to Vendor’s name :-

a) Name of RCDF b) Project Title c) Title of Drawing d) Scale e) Date of drawing f) Drawing number g) Space for RCDF drawing number.

23.5 In addition to the information provided on drawings, each drawing shall carry a

revision number, date of revision and brief of revision carried out. Whenever any revision is carried out, correspondingly revision must be up dated.

23.6 All dimensions on drawings shall be in metric units, unless otherwise, specified. 23.7 Drawings submitted by erector for approval will be checked reviewed by RCDF

and comments, if any, on the same will be conveyed to erector. It is the responsibility of the rector to incorporate correctly all the comments conveyed by RCDF on erector’s drawings. The drawings which are approved with comments are to be resubmitted to RCDF for purpose of records. Such drawings will not be checked/reviewed by RCDF to verify whether all the comments have been incorporated by the erector. If erector is unable to incorporate certain comments in his drawings, he shall clearly state in his forwarding letter such non-compliance along with the valid reasons.

23.8 Upon completion of the installation, erector shall make in a neat and accurate

manner, a complete record of all changes and revision to the original design, as installed in the complete work. Six copies of these drawings shall be submitted to RCDF for records and these becomes the property of RCDF.

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23.9 Drawings prepared by erector and approved by RCDF shall be considered as a part of the specifications. However, the examination and approval of the drawings by RCDF shall not relieve erector of his responsibility for engineering, design, workmanship and material under the contract.

23.10 If, at any time before the completion of the work, changes are made

necessitating revision of approved drawings, erector shall make such revision and proceed in the same routine as for the original approval.

24.0 Inspection Right & Privileges :

24.1 RCDF reserves the right to inspect any machinery or material or equipment furnished or used by erector under the contract, and to project any, which is found defective in workmanship or otherwise unsuitable for the use and purpose intended, or which is not in accordance with the intent of the contract.

24.2 Should RCDF waive the right to inspect any equipment, such waiver shall not

relieve erector in anyway of his obligation under the contract. 24.3 RCDF representatives shall be permitted free access to erector’s or his

subcontractor’s shop at all working hours for the purpose of inspecting work at all stages of progress.

24.4 RCDF representatives shall be given full assistance in the form of necessary

tools, instruments, equipment and qualified operations to facilitate inspection. 24.5 RCDF reserves the right to call for certificate of origin and test certificates for all

raw material and equipment at any stage of manufacture. 24.6 In the event of RCDF inspection reveals poor quality of goods RCDF shall be at

liberty to specify additional inspection procedures, if required, to ascertain Vendor’s compliance with the equipment specifications.

24.7 Even though inspection is carried out by RCDF or his representatives, such

inspection shall not however, relieve Vendor of all responsibility for furnishing equipment conforming to the requirements of the contract, nor prejudice any claim right or privilege which RCDF may have because of the use of defective or unsatisfactory equipment.

24.8 A set of latest prints of the approved drawings shall be kept available by the

controller, in the shop floor for reference of RCDF representative during inspection.

25.0 Storage of equipment :

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25.1 In general, erector is responsible for the proper storage and maintenance of all materials/equipments entrusted to him. He shall take all required steps to carry out frequent inspection of equipment/materials/stores as well as erected equipments until the same is taken over by the RCDF. The following procedure shall apply for the same.

25.2 Erector’s inspector shall check stored and installed equipments/materials to

observe signs of corrosion, damage to protective coating, to parts, open ends in pipes, vessels and equipment, insulation resistance of electrical equipment etc. In case open ends are noticed, he shall immediately get them capped. In case signs of wear damage to protective coating are noticed, he shall immediately arrange a coat of protective painting. A clean record of all observations made on equipments, defects noticed shall be promptly communicated to RCDF and his advise taken regarding the repairs/rectification erector shall thereupon carryout such repairs rectifications at his own cost. In case erector is not competent to carry out such repairs/rectification, RCDF reserves the right to get this done by other competent agencies at the erectors responsibility and risk and the entire cost for the same shall be recovered from erectors bill.

25.3 Erector’s inspectors shall also inspect and provide lubrication to the assembled

pumps etc. The shafts of such equipment shall be periodically rotated to prevent rusting in certain zones as well as to check freeness of the same.

25.4 Inspectors shall check for any sign of ingress or moisture of rusting in any

equipment. 25.5 If the commissioning of the equipment is delayed after installation of the

equipment, erector shall carry out all protective measures suggested by the Manufacturer RCDF during such period.

25.6 Adequate security measures shall be taken by erector to prevent theft and loss

of material entrusted to him by RCDF shall carry out periodical inventory of the material received stored and installed by him and any loss noticed shall be immediately reported to RCDF. A proper record of these inventories shall be maintained by the erector.

25.7 A suitable grease recommended for protection of surface against rusting (refined

from petroleum oil with lanclin mincu, 70 C and water in traces) shall be applied over all equipment every six months.

25.8 These equipments shall be stored inside a closed shed or in the open depending

upon whether they are of indoor or outdoors design. However, in case of equipment stored in the open, suitable protective measures including covering with tarpaulin must be carried out by the erector. The space heaters, where provided in the electrical equipment shall be kept connected with power supply irrespective of their type of storage. Where space heaters are not provided

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adequate heating with bulb is recommended. In LT. motors a low voltage current flow through the windings is recommended. Frequent checks on insulation resistance is essential for all electrical equipments. A records of the inspection reports and megger readings shall be maintained equipment wise. Such records shall be presented to RCDF whenever demanded.

25.9 All the necessary items/goods required for the protection as described above

shall be arranged by the erector and no extra cost is payable in this regard by RCDF.

26.0 Deployment of erection team to site and Co-ordination meetings :

The erector shall depute a qualified and experienced engineers together with a adequate skilled and unskilled labourers for carrying out the installation and commissioning. All necessary staff shall be at the site till the completion of all works, commissioning/start-up, trial runs and handling over of the plant. No member of the staff deputed to site shall be withdrawn unless agreed to by RCDF. The erector shall depute a senior personnel to attend the site co-ordination meeting that would generally be held at the site every month. The erector shall take necessary action to implement the decision arrived at such meetings and shall also update the schedule. In case of lag in the progress the erector shall act suitably to make up for the lag. RCDF shall be at liberty to object to any representative or person or skilled, semiskilled or unskilled worker employed by the erector in the execution or otherwise of the work, who shall misconduct himself or be incompetent, or negligent or unsuitable and the erector shall remove the persons so objected to, upon receipt of notice in writing from RCDF requiring him to do so and shall provide in his place a competent representative at his own expense within reasonable time.

27.0 Programme of Installation & Commissioning :

The successful erector should submit a scheduled programme for carrying out the work. The erection schedule should describe the estimated time of installation of each of each item against each section of the project and should also clarify when each of the item to be supplied by RCDF should be made available to the erector in order to adhere to the schedule. The schedule should be so prepared that the erection, commissioning, testing and start-up is completed in all respect, within _________________________ from the date of placement of order. RCDF shall have the right to direct the manner in which all work covered under the scope of this contract shall be conducted by the erector in so far as it may be necessary to secure the safe and proper progress and the specified quality of the work and all work shall be carried out and all material shall be furnished to the satisfaction and approval of RCDF whenever, in the opinion of RCDF, the

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erector has made departures from the schedule of completion of work submitted by him and approved by RCDF or when untoward circumstances force a departure from the said schedule or if in the judgment of RCDF, if becomes necessary at any time to accelerate pace of erection work, then RCDF shall direct the order pace and method of conducting the work and erector shall fully comply with all such directions. If erector doesn’t comply with the direction as described above or complete the erection and commissioning by the end of 4th week after programmed completion, RCDF will operate the penalty clause and shall also have the option to deploy their own staff/other agencies to complete the job at the erectors risk, responsibility and cost. It is however, clarified that the above or any such directions from RCDF or abstinence of RCDF in deploying their own staff/other agencies as described above shall not relieve the erector of his obligations to secure the quality, the safe conduction of work, rate of progress required and adherence to scheduled programme. IF THE ERECTOR FAILES TO COMPLETE ERECTION IN ALL ASPECTS WITHIN THE STIPULATED PERIOD & TIME. THE ERECTOR SHALL HAVE TO PAY RUPES @ ½% PER WEEK AS PENALTY FOR THE PERIOD FOR WHICH THE WORK REMAINS INCOMPLETE.

28.0 Approvals :

The erector shall obtain the necessary approval of the factory Inspector, Boiler Inspector, Electrical Inspector weights & Measures Inspector, Explosives Inspector, and any other state and local authorities as may be required. All the necessary details, drawings, submission of application and proformas will be furnished by the Erector to RCDF for rectification/signature. The necessary application duly filled in, together with the prescribed fees shall be submitted to the authorities by the erector on behalf of the RCDF. However all the actual prescribed fees paid by the erector shall be reimbursed by RCDF upon production of the receipt/vouchers of the above said authorities. RCDF shall, however, extend all possible assistance to the erector for obtaining the necessary approvals. Nevertheless the ultimate responsibility for obtaining the necessary approvals lies with the erector.

29.0 Final Drawings & Manuals : The erector shall, upon completion of the job, submit six complete sets of final drawings towards the equipment layout different pipe lines, cables, conduits, layout drawings and other necessary drawings. All the drawings must conform to actual executing carried out.

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30.0 Progress of Work :

If the erector does not commence/complete the entire job or sections of the job within four weeks from programme schedule of commencement/completion, the RCDF shall be free to deploy their own staff/agencies to commence/complete the job entirely at the risk, responsibility and cost of the erector.

30.1 Start-up of manufacturer’s representatives during commissioning/trial runs.

30.2 In the following cases the RCDF reserves the right to invite the representative(s) of the original manufacturer and/or supplier at the cost of the erector for start by help, assistance and guidance during commissioning and start-up.

a) The erector has no previous experience of commissioning and starting-up of

the similar equipment. b) The RCDF is of the opinion that the erector is incompetent to commission

and start-up of certain specific equipment. 31.0 Commissioning :

The erector shall operate, maintain and give satisfactory trial run of the plant satisfactory for a period of continuous one month at the rated output. All rectifications of damages/defects and routine troubles shooting should be carried out by the erector to achieve aforesaid satisfactory running of the plant. The erector shall incorporate/execute necessary minor modification during the trial period for maximising operational efficiency. The erector should also execute miner modification as may be suggested by RCDF. The erector shall suggest recommended log sheet proformas for recording necessary operating data and pass it on to RCDF in proof of satisfactory rated output and performance of the equipment/plant. The commissioning shall also include the following for each equipment : a) Field disassembly and assembly. b) Cleaning of lubrication system including chemicals cleaning and passivation

wherever required. c) Circulation of lubricant to check flow. d) Cleaning and checking of all the service lines. e) Checking and commissioning of instruments, equipment and plants, filtering

of transformer, and other oils so that if deteriorated, they shall attain the required properties/standard, specified tests in this regard must be carried out by approved authorities and their satisfactory reports submitted to RCDF before start-up.

f) Recharging or make-up filling of lubricant oil up to the desired level in the lubrication system of individual machine.

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g) Operation in empty condition to check general operation details wherever required, and wherever possible.

h) Closed loop dynamic testing with water wherever required. i) Operation under load and gradual load increase to attain maximum rated

output. j) Trouble shooting during the trial period. k) Guarantee of installation.

32.0 Guarantee :

The supply of equipment as well as installation shall have to be carried out by the erector to the entire satisfaction of the RCDF. The erector shall also guarantee to repair/replace, without any extra cost, the items or parts thereof, if found defective due to bad design, workmanship or substandard material within 12 months from the date of commissioning or 36 months from the date of receipt of material at site whichever is earlier. If it is necessary to send the defective equipment or parts thereof for repair/replacement, cost of transportation including package, insurance etc. from the site to works and back to site shall have to be borne by the erector. The guarantee does not cover any damage resulting from normal wear and tear or improper attendance or mishandling of the equipment by the RCDF.

33.0 Training of personnel : Necessary staff as may be deputed by RCDF shall be trained by the erector for operating the plant. The personnel will be associated for the training during the installation, testing, commissioning and start-up period and training tenure shall be minimum for a period of one month from the date of commissioning and start-up.

34.0 Outline of the scope of duties of the Contractor Viz-a-viz RCDF :

34.1 The equipment and items as specified in purchase order shall be supplied by RCDF for erection, installation, commissioning by the erector.

34.2 Besides the utilities/services as specified in battery limits the following shall also

be provided to the erector by RCDF for carrying out the installation/erection.

a) Suitable lockable space for storage of tools, tackles and erection materials (No accommodation for erectors personnel will be provided under any circumstances) the security of these materials will be the responsibility of the erector.

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b) Plant building ready for installation/erection of all the equipment/items (flooring will generally be carried out after positioning of main equipment and laying of necessary conduits).

c) Necessary temporary power for carrying out the installation (the power shall

be supplied at only one point within the dairy site). All necessary tapping from this point onwards shall be erector’s responsibility.

d) Temporary water at one point within the site for the water required for

testing etc. The erector shall arrange on his own to tap and transfer the water to the points required.

34.3 Prior Information :

a) The details of temporary water and power requirements shall be furnished one month in advance by the erector to enable RCDF to make timely arrangement.

b) Detailed drawings of the required main cut-outs must be supplied by the

erector in advance to RCDF to provide the same at the time of civil construction. The cutting in the walls, floors etc. which are not informed earlier and required for erection work will be done by the erector and to repair the same will also be the responsibility of the erector.

c) Detailed drawings and other specifications of foundation and any other

special structure must be submitted by the erector within one month after award of contract to RCDF.

35.0 Damage :

If the work or any portion thereof shall be damaged in any way excepting by the acts of RCDF or if defects not readily detected by prior inspection shall develop before the final completion and acceptance of the whole work. Erector shall forthwith make good, without compensation, such damage or defects in a manner satisfactory to the RCDF. In no case shall defective or imperfect work be retained.

36.0 Observation of local rules etc.

In respect of observation of local rules, administrative orders, working hours, labour compensation act, applicable labour laws and the like erector and his personnel shall strictly abide by the same.

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37.0 Stand by manufacturer’s representative :

In the following cases the RCDF reserves the right to invite the representative(s) of the original manufacturer and/or supplier at the cost of erector for stand by them, assistance and guidance during the commissioning and start-up. a) The erector has no previous experience of commissioning and start-up of the

similar equipments.

b) The RCDF is of the opinion that the erector is not competent to commission and start-up of certain specific equipment, the opinion of RCDF shall be final and binding.

38.0 Inspection & test reports :

The equipment and items supplied under the purview of erector shall be inspected by the inspector at works and copies of inspection test reports shall be forwarded to RCDF.

39.0 Terms of payment for erection work :

1) 10% of the order value of acceptance of the order subject to the supplier

furnishing Bank Guarantee from a National Bank or Scheduled Bank in India for an equivalent amount valid for a period of 12 calendar months.

2) 80% against monthly progress bills duly certified by RCDF’s Site Engineer/In-

charge.

3) 10% balance within 12 calendar months from the date of satisfactory commissioning of the plant.

40.0 Battery Limits :

The services/utilities will be made available at battery limits specified in the job description and it will be the erectors responsibility to transmit them to the various points required in the project. All the necessary fittings tappings, that would be required to tap the utility at battery limits for onward transmission shall be supplied and installed by the erector.

41.0 GENERAL GUIDELINES FOR ELECTRICAL INSTALLATION :

41.1 a) The specifications detail the broad guide lines for erection, testing and commissioning of electrical equipment. The work shall however, at all times be carried out strictly as per the instructions of RCDF and in accordance with latest IER.

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b) The installation would also comprise for the supply laying and inter

connecting, cables form the battery limits of the power supply to the various switchboards controls and electrical equipments.

c) The cable of electric power should be of PVC armoured type approved from

ISI unless otherwise specified and with sufficient cross section depending on the feeder.

d) The cable for control and flexible connection should be unarmoured type

with copper conductors. Wherever required, multicore copper cable should be used.

e) Wherever necessary drip proof junction boxes and isolators, cable carrying

trays, necessary clamps etc. shall be provided.

f) Necessary isolators of appropriate sizes are to be provided near the motors as per IER. All the involved supply included within the scope of electrical installation and erection should be approved type and make and conform to ISI standard.

g) Detailed electrical diagrams and cable layout should be prepared by the

erector according to the specifications and the same should be approved by RCDF before the execution.

41.2 Electrical installation work shall comply with all currently applicable statues,

regulations and safety codes in the locality where the equipment will be installed. Nothing in this specifications shall be construed to relieve erector of his responsibility.

41.3 Unless otherwise specified installation work shall comply with the requirements

of latest additions of applicable Indian standards. 41.4 In accordance with the specific installation instructions, as shown on

manufacturer’s drawings or as directed by Site Engineer of RCDF, the erector shall unload, erect, install wire test and put into commercial use all the electrical equipment included in the contract. Equipment shall be installed in neat workman like manner so that if is in level and plumb, properly aligned and oriented. Tolerance shall be established in manufacturer’s drawings or as stipulated by an Engineer. No equipment shall be permanently bolted down to foundation or structure until the alignment has been checked.

41.5 Erector shall furnish all supervision, labour, tools, equipment, ribbing, materials

and incidental materials such as holts, wedges, anchors, concrete, inserts etc. required to completely install test and adjust the equipment.

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41.6 Where assemblies are supplied is more than one section erector shall make all necessary mechanical and electrical connections between sections including the connection between buses. Erector shall also do necessary adjustment/alignments necessary for proper operations of circuit breakers isolators, and their operating mechanism. All insulators and bushings chipped, cracked or damaged due to negligence or carelessness of erector shall be replaced by him at his own expense.

41.7 Switchgear and control panels/desks shall be installed in accordance with Indian

Standard Code of Practice IS:3072 and manufacturer’s instructions. The switch gears panels shall be installed on finished surfaces or concrete or steel sills. Erector shall be required to install align any channel sills which from part of the foundations. In joining shipping suctions of the switch gears/panels/control centres together, adjacent housing or panel section or flanged throat sections provided shall be bolted together after alignment has been completed. Power bus, enclosures, ground and control splices of conventional nature shall be cleaned and bolted together, being drawn up with torque wrench of proper size or by other approved means. Tapes or compounds shall be applied where called for as per manufacturer’s drawings. Base of outdoor type units shall be sealed in an approved manner to prevent ingress of moisture.

41.8 All switch gear, control panels, desks etc. shall be made absolutely vermin proof. 41.9 Induction motors shall be installed and commissioned as per IS Code of Practice

ISS 900 and manufacturer’s instructions. 41.10 After installation of all power and control wiring, erector shall perform operating

test on all switch gear and panels to verify proper operation of switch gear/panels and correctness of the interconnections between the various items or equipment. This shall be done by applying normal AC or DC voltage to the circuit and operating the equipment. Megger tests for insulations, polarity checks on the instruments transformers, operation tests shall be carried out by erector, who shall also make all necessary adjustments as specified by the manufacturer for the proper functioning of equipment.

41.11 Installation and testing of battery and battery charges shall be in strict

compliance with the manufacturer’s instructions. Each cell shall be inspected for breakage and conditions of the cover seals as soon as received at site. Each cell shall be filled with electrolyte in accordance with the manufacturer’s instructions. Battery shall be set up on racks as soon as possible after receipt, utilizing lifting devices supplied by manufacturer. The cells shall not be lifted by terminals. Contact surfaces of battery terminals and intercell connections shall be cleaned, coated with protective grease and assembled. Each connection shall be properly tightened. Each cell shall be tested with by hydrometer and thermometer and result logged. Freshening charge, if required, shall be provided. When turned

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over to RCDF the battery shall be fully charged and electrolyte shall be at full level and of specified specific gravity.

42.0 Cable Installation : 42.1 Erector shall install, test and commission the suitable cables. Cables shall be

laid directly buried in earth on cable racks, in built up trenches, on cable trays and supports, in conduits, and ducts or bare on walls, ceiling etc. as follows :

a) Outside the building premises :

The scope of installation of underground cables includes digging necessary trenches, laying of the cables in the trench, covering them with sand and bricks and then refilling the trenches. Necessary cable markers at appropriate points to indicate the path of under ground cable should also be supplied and installed by the erector.

b) With in the building :

Under ground cables will be laid in GI light duty class pipes of not less than 37 mm. dia.

c) Cables above ground :

Cables above the ground shall be fixed either on wall or in cable trays of slotted angle with necessary clamps, bolts etc. as directed by RCDF.

d) The main cables inside the building should be laid in hume pipes wherever provided by RCDF. At the places where hume pipes have not provided the main cables shall be laid as per 40.1 (c).

42.2 Installation and testing of proper insulated cables shall be in accordance with

Indian Standard Code of Practice IS:1255. 42.3 Inspection on receipt unloading, storage and handling of cables shall be in

accordance with IS:1255 and other Indian Standards Code of Practice. 42.4 Sharp bending and kinking of cables shall be avoided. The bending radius for

various types of cables shall not be less than those specified below unless specifically approved by the Site Engineer of RCDF.

Type of Cable Minimum bending radius Voltage grade Single Multi Core

Core Unarmoured Armoured Paper insulated upto 11 kv 25 D* 20 D 15 D

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Paper insulated upto 22 kv 32 D 25 D 20 D Paper insulated upto 33 kv 38 D 32 D 25 D

PVC insulated 650/1100 V 10 D 10 D 10 D Rubber insulated 600 V - 8 D 15 D Mineral insulated 300 V - - 8 D * ( D – OVER ALL DIAMETER OF THE CABLE)

If shorter radius appears necessary, no bend shall be made until clearance and instructions have been received from Engineer.

42.5 Where cables cross roads and water, oil, gas or sewage pipes, the cables shall be laid in reinforced upon concrete or steel pipes to be supplied and laid by the erector. For road crossing, the pipes for the cables shall be buried at not less than one meter depth. Cables laid below railway tracks should be at a depth not less than 180 mm. unless otherwise approved by the Engineer.

42.6 In each cables run some extra length shall be kept at a suitable point to enable

one or two straight through joints to be made should be the cable develop fault at a later date.

42.7 Control cable terminations shall be made in accordance with wiring diagrams,

using colour codes established by Engineer for the various control circuits, by code marked wiring diagrams furnished to the erector for this purpose or other approved means of identification. It is the intent that erector shall terminate the cables which he installs. Additional work of testing and reconnecting and connected, but where on further testing reversal or other rearrangement of load turns out to be necessary. Additional work of testing and reconnecting shall be performed by erector at no extra cost of RCDF.

42.8 Special tools, clips and saddles, glands, seals, PVC sealing compound, locknut etc. required for the connection and termination of insulated cables shall be supplied by erector. During installation, connection and termination of insulated cables, care shall be exercised to ensure that aluminium sheet is not damaged. Groups of mineral insulated cables shall be bent neatly around the corners by using inner most cables as a form around, which to bend the next cable. Cables shall not be fastened or clamped close to the point of entry of the equipment which may vibrate severely. Special instructions furnished by the manufacturer shall be strictly followed.

42.9 After installation and alignment of motors, erector shall complete the conduit

installation, including a section of flexible conduit between the motor terminal

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box and cable trench/tray. Erector shall install and connect the power, control and heater supply cables. Erector shall be responsible for correct phasing of the motor power connections and shall interchange connections at the motor terminals box if necessary, after each motor is test run.

42.10 Connections shall be made to small electrically operated device on equipment

installed as accessories to or assembled with other equipment and requiring two wire or three wire connection. Connections to recording instruments, float switches, limit switches, pressure switches, thermocouples, thermostats and other miscellaneous equipment shall be done as per Manufacturer’s drawing and instructions.

42.11 Metal sheets and armoured of the cable shall be bonded to the earthing system. 42.12 All new cables shall be megger tested before jointing. After jointing is completed

all LT. cables shall be megger tested and HT. Cables (3.3 KV to 11 KV) pressure tested before commissioning. The test voltage for pressure testing shall be as per Appendix-F of IS:1255. 1100/650 Volt grade cable shall be tested by 1000 Volt Megger.

Cables cores shall be tested for : a) Continuity b) Absence of cross phasing c) Insulation resistance to earth d) Insulating resistance between conductors.

Erector shall furnish all testing kit and instruments required for field testing.

43.0 Cable Trays, Accessories and Tray Supports :

43.1 Cable trays shall either be run in concrete trenches or run overhead supported from building steel, floor slab etc.

43.2 Cables shall be clamped to the cable trays in the horizontal runs and vertical runs.

43.3 All cable trays including perforated sheet trays and vertical raceways shall be hot

dip galvanized or primed with red lead and oil primer followed by a finish coat of grey lacquer paint or aluminium paint as specified.

44.0 Conduits, Pipes & Ducts :

44.1 Erector shall supply and install G.I. light duty conduits, pipes and ducts. All

accessories/fittings required for making installation complete, including but not limited to ordinary and inspection tees and elbows, check nuts, male and female reducers and enlargers, wooden plugs, caps square headed male plugs, nipples,

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gland sealing fittings, pull boxes, conduits, outlet boxes, splice boxes terminal boxes, glands gaskets and box covers, saddles and all steel supporting work shall be supplied by Erector. Conduit fittings shall be of same material as conduits.

44.2 Conduits or pipes shall run along walls, floors and ceilings, on steel supports,

embedded in soil, floor, wall or foundation, in accordance with relevant layout drawings, under ground portions of conduit installation to be embedded in the foundation or structural concrete shall be installed in close co-ordination with collateral work. Exposed conduit shall be neatly run and evenly spaced, with conduits parallel when in racks or in banks. Conduits embedded in foundation or structural concrete shall be run as directly as possible among with generally indicated route between two points with a minimum length and with a minimum of crossing bending and cutting but without creating interferences with other installations.

44.3 When two lengths of conduits are joined together through a coupling, running

threads equal to twice the length of coupling shall be provided on any one length to facilitate easy dismantling of the two conduits whenever required.

44.4 When one or more cables are drawing through a conduit, cross sectional area of

the cables shall be 40% of the internal cross sectional area of the conduit. 44.5 Conduits and accessories shall be adequately protected against mechanical

damage as well as corrosion. 45.0 Earthing :

45.1 The scope of supply and installation should also include absolutely independent double earthing of individual electric motors, control gears and switchboards, complete with necessary copper/GI wire, copper strip, earthing plate, top funnel, salt, cola etc. The earthing process include digging of earthing pit, filling the same with alternative layers of coal and salt, refilling the pit and providing perforated GI pipe making housing pit and cover as per IER & ISI code of practice No. ISI:3034-1966.

45.2 Erector shall install bare/insulated aluminium/GI Cables and strips, etc. required

for system and individual equipment earthing. All work such as cutting, bending, supporting soldering, coating drilling, brazing, clamping, bolting and connecting into structures, pipes, equipment frames, terminals, rails or other devices shall be in Erector’s scope of work. Unless otherwise specified, the excavation and trenching shall be done by Erector. Erector shall also backfill and reinstate the trenches after installation of earthing conductors.

45.3 Earthing shall conform to the Indian Standard Code of practice IS:3043 and

Indian Electricity Rules, 1956. All materials and fittings used in the earthing

87



installation shall conform to the relevant Indian Standards or approved by RCDF’s Engineer. Any change in routing, size of conductors etc. shall be subject to the prior approval of RCDF Engineers.

45.4 Metallic frame of all electrical equipment shall be earthed by two separate and

district connections with earthing system. 45.5 All underground connections for the earthing system shall be brazed/welded.

Connections to equipment and devices shall be normally of the bolted type. 45.6 On completion of the installation, continuity of all conductors and efficiency of all

bends and joints shall be tested. The earth resistance shall be tested in the presence of RCDF Engineer’s/representative. All equipment necessary for the test shall be furnished by Erector.

45.7 EARTHING NETWORK The entire ear thing installation shall be done in accordance with the ear thing drawings, specifications and instructions of the Engineer-in-charge. The entire ear thing system shall fully comply with the Indian electricity act and rules framed there under. The supplier shall carry out any changes desired by the electrical inspector or the owner in order to make the installation conform to the Indian electricity rules, at no extra cost. The exact location of the earth pits, earth electrode and conductors and ear thing points of the equipments shall be determined at site, in consultation with the engineer-in-charge. Any change in the methods, routing, size of conductor etc. shall be subject to

approval of the owner/engineer-in-charge before execution.

45.8 Earth Pit with Electrode 1. Plate or pipe type earth electrode with earth pit shall be provided for this

work unless otherwise advised and pit shall be as per IS:3043 – 1966 (code of practices for ear thing). All earth electrodes shall preferably be

driven to a sufficient depth to reach permanent. 2. Earth pit centre shall be at a minimum distance of 2m distance shall be

maintained between centres of 2 earth pits. 45.9 Earth Bus. Ear thing Lead & Earth wire /strip

All electrical equipment is to be doubly earthed by connecting two earth strips / wire conductor from the frame of the equipment to a ear thing pit / main ear thing ring. The ear thing ring will be connected via. Links to several earth electrodes. The cable armored will be earthed through the cable glands. Conductor size for connection to various equipment shall be as specified in the drawing or as instructed by the engineer-in charge. However the length of the branch leads from equipment to ear thing grid/ring shall not be more than 10

88



to 15 meters. All hardware for ear thing installation shall be hot dip galvanized. Spring washers shall be used for all ear thing connections of equipment having vibrations. Size of earthing lead/wire shall be as specified in schedule of quantities/drawings. Following may be considered as general guidelines:

Sr.No Ite

m Size

Control switches G.I. wire 14 SWG

Motor upto 10 HP G.I. wire 8 SWG

Motor above 10 HP upto 125 HP G.I. strip 25 x 3mm

Motor above 125 HP G.I. strip 25 x 6mm

Switch Board G.I. strip 25 x 6mm

Power control centre / LT panel of sub-station

G.I. strip 40 x 6mm

When ear thing wire is to be drawn under floor / in underground, aluminium wire 10mm dia. With PVC insulation shall be used. Instead of GI wire, PVC insulated copper conductor wires can also be used. However, while deciding type & size of earth lead the resistance between the ear thing system and the general mass of the earth shall be as per IS code of practice. The earth loop impedance to any point in the electrical system shall not be in excess of 1.0 ohm in order to ensure satisfactory operation of protective devices. G.I. wire/aluminium wire shall be connected to the equipment by providing crimping type socket/lug. Wherever ear thing strip to be provided in cable tray, it shall be suitably bolted on cable tray and electrically bonded to the cable tray at regular interval. Excavating & refilling of earth, necessary for laying underground earth bus loops shall be the responsibility of the supplier. Wherever earth leads/strips/wire are laid in cable trenches, these shall be firmly and suitably cleaned to the walls/supporting steel structure on which cable is clamped. The neutral of the transformer shall be connected to earth pit independently and earth pit shall have copper earth plate. Long runs of GI strip shall be connected at each end with lap type welding to ensure continuity.

89



Bureau of Indian Standards to be Followed for Electrical Erection

1. PVC insulated cables (light duty) for working voltage upto 1100 volts

694-1990 Part I & II

2. PVC insulated cables (heavy duty) for voltage upto 1100 volts 1554-1988 Part I

3. PVC insulated cables (heavy duty) for voltage 3.3 KV to 11 KV 1554-1988 Part II

4. Specification for polyethylene insulated PVC sheathed heavy duty electric cables for voltage not exceeding 1100 V

5959-1970 Part I

5. Specification for polyethylene insulated PVC sheathed heavy duty electric cables for voltage 3.3 KV to 11 KV

5959-1970 Part II

6. Guide for marking of insulated conductors 5578-1970 or 5575

7. Code of practice for installation and maintenance of power cables upto 33 kV

1255-1983

8. Code of practice for earthing 3043-1987

9. Guide for safety procedures and practices in electrical work 5216-1982

10. Code of practice for installation and maintenance of AC induction motor starters

5214-1969

11. Code of practice for installation and maintenance of induction motors

900-1992

12. Code of practice for installation and maintenance of switchgears 10118 - 1982 Part I, II, III, IV

13. Code of practice for installation and maintenance of transformers 10028 – 1981 Part I

14. Code of practice for electrical wiring installation, voltage not exceeding 650 V

732-1989

15. Code of practice for electrical wiring installation (system voltage exceeding 650 V)

2274-1963

16. Guide for testing three-phase induction motor 4029-1967

17. Guide for safety Procedures & Practices in electrical works 5316

18. XLPE Cables for working voltage upto and including 1100 Volts 7098 – 1988 Part I

19. XLPE Cables for working voltage upto 33 kV 7098 – 1988 Part II

20. Boxes for enclosures of electrical accessories 5133

21. Electric Power connectors 5561

22. HRC Cartridge Fuse Link up to 650 V 2208

23. Code of Practice for Selection, Installation & Maintenance of Fuse up to 650 V

3108

24. Cables methods of testing 10810

25. Danger / Lattice Boards 3551

26. National Electric Code SP :30

Recommended Cable Size for Industrial Wiring

The following selection table shall be followed for cables of motors unless otherwise specified:

3 Phase 415 Direct-on-line Star-Delta Starter

90



V Motor H.P.

Supply side Motor side Supply side Motor side

Copper conductor Cable Size : Sq mm

Up to 7.5 2.5 2.5 2.5 2 X 2.5

10 4 4 4 2 X 2.5

15 6 6 6 2 X 2.5

20 10 10 10 2 X 4

25 16 16 16 2 X 6

30 16 16 16 2 X 6

40 25 25 25 2 X 10

50 35 35 35 2 X 16

Aluminium conductor Cable Size: Sq mm

60 70 70 70 2 X 35

75 95 95 95 2 X 50

100 120 120 120 2 X 70

125 185 185 185 2 X 95

150 240 240 240 2 X 120

180 - - 300 2 X 150

200 - - 2 X 150 2 X150

250 - - 2 X 185 2 X 185

275 - - 2 X 240 2 X 240

300 - - 2 X 240 2 X 240

Note: Cables indicated above in the table shall be only armoured copper conductor cable for DOL starter upto 50 HP motor. For motors rating 60 HP and above, armoured aluminium cable should be used.

91



Pro forma for PCC, DB, Motor Control Centres Test

SN Test Report

1 Circuit (Breaker/Bidder/Supplier Module Designation/Bus Number)

2 Insulation resistance (Contacts open, breaker Racked in position)

a. Between each Phase & Bus (Mega Ohm)

b. Between each phase and earth (Mega Ohm)

c. DC and AC control & auxiliary circuits (Mega Ohm)

d. Between each phase of CT/PT and between CT & PT circuit if any

(Mega Ohm)

3 CT Checks

a. CT ratio

b. CT secondary resistance

c. CT polarity check

4 Check for contact alignment and wipe

5 Check/test all releases/ relays

6 Check mechanical interlocks

7 Check electrical interlocks

8 Check switchgear/control panel wiring

9 Checking breaker/Bidder/Supplier circuits for

a. Closing- local and remote (wherever applicable)

b. Tripping-local and remote (wherever applicable)

10 Opening time of breaker/ contactor

11 Closing time of breaker/ contactor

Signature and seal of Engineer-in-charge of RCDF,

Jaipur

Signature of Consultant(Perfect Solutions)

Signature and seal of Engineer-in-charge

of Bidder/Supplier

92



Pro forma for motor testing SN Test Report

1 Name plate details

A Voltage

B HP / KW

C Mounting

D Current

E RPM

F Frame size

G Make

H Sr No

I Others

2 Insulation test (before cable connection)

A Between Phase and Earth (Mega Ohms)

B Between each Phase (Mega Ohms)

3 Insulation test (after cable connection)

A Between Phase and Earth (Mega Ohms)

B Between each Phase (Mega Ohms)

4 No load current

A R Phase Amps

B Y Phase Amps

C B Phase Amps

5 Full load current

A R Phase Amps

B Y Phase Amps

C B Phase Amps

6 Temperature rise after 4 hours run

A On no load degree C

B On full load degree C

C Ambient temperature during test degree C

7 Operation of thermal overload relay

A At normal Full Load current of motor

B At twice Full Load current of motor trips in seconds

Signature and seal of Engineer-in-charge of RCDF, Jaipur

Signature of Consultant(Perfect Solutions)

Signature and seal of Engineer-in-charge of Bidder/Supplier

93



Pro forma for Testing Cables

Sr No Test Report

1 Date of Test

2 Drum Number (from which cable is

taken)

3 Cable From -> To

4 Length of run of this cable (meter)

5 Insulation resistance test (In Mega Ohm)

A Voltage of Megger Volts

B Between core-1 to earth

C Between core-2 to earth

D Between core-3 to earth

E Between core-1 to core-2

F Between Core-2 to Core-3

G Between Core-3 to Core-1

6 High Voltage Test (Voltage Duration)

A Between Cores and Earth

B Between Individual Cores

Signature and seal of Engineer-in-charge of

RCDF, Jaipur

Signature of Consultant (Perfect Solutions)

Signature and seal of Engineer-in-charge of

Bidder/Supplier

46.0 Supply, Fabrication, Erection and Testing of Piping : 46.1 Codes and standards :

All piping system including sub-contracted materials shall comply with the latest editions of the following wherever applicable :

a) Indian Boiler Regulation b) Regulation of Inspector of Explosives c) All applicable Indian Standards d) All applicable State Laws.

94



46.2 Scope of Supply :

Erector shall supply all piping materials like pipes, fittings, flanges and other items as shown in his scope in the flow diagrams/specifications.

46.3 Scope of erection to be performed by Erector is outlined below : a) The scope of erection for piping includes all system covered under his scope

of work in the flow diagram/specification. b) Erector shall also install small accessory, piping an any specialities furnished

with or for equipment such as relief valves, built is bypass, and other items of this type.

c) Erector’s work terminates at the final tube or pipe connection at pumps, including the final connection.

d) Erector shall install primary elements for flow measurement, control valves, and on line metering equipment.

e) Erector shall perform necessary internal machining of pipe for installing crevices, flow nozzles, straightening vances, control valves.

f) Erector shall install all valves and specialities being procured from others. g) Erector shall hydrostatically test all piping systems including valves and

specialities & instrument impulse line at suitable pressures. h) All piping shall be internally cleaned and flushed by Erector before and after

erection in a manner suited to the service as directed by RCDF. i) For hydrostatic testing and water flushing, erector shall furnish necessary

pumps, equipment and instruments, piping etc. Purchase will provide water at available points of supply to which Erector’s temporary piping will be connected.

46.4 Colour code shall be used to identify pipe material. Erector shall be able to identify on request all random piping prior to any field fabrication.

46.5 All steam piping shall be fabricated in complete accordance with Indian Boiler

Code and all approval required shall be obtained by Erector from the inspecting authority.

46.6 Erector shall be responsible for the quality of welding done by his organisation

and shall conduct tests to determine the suitability of the welding procedure used by him.

46.7 Erector shall employ welded construction for all black steel piping. All black steel

pipes 50 mm. and below shall have socket welded joints unless otherwise specified.

95



46.8 All piping supports, guides, anchors, rod hangers, spring hangers, rollers with incidental structural sub framing shall be furnished and erected by Erector.

46.9 All piping shall be suspended, guided and anchored with due regard to general

requirements and to avoid interference with other pipes, hangers, electrical conduits and their supports, structural members and equipment and to accommodate insulation to conform to purchaser’s loading limitation. It is the responsibility of the piping Erector to avoid all interferences while locating hangers and supports.

46.10 Anchors and/or guides for pipe lines or for other purpose shall be furnished

when specified for holding the pipe line in position or alignment. Hangers shall be designed fabricated and assembled in such a manner that they cannot become disengaged by any movement of the support pipe.

46.11 All piping shall be wire brushed and purged with air blast to remove all dust, mill

scale from inner surface. The method of cleaning shall be such that no material is left on the inner or outer surfaces which will affect the serviceability of the pipe.

46.12 Effective precaution such as capping and sealing shall be taken to protect all

pipes ends against ingress of dirt and damage during transit or storage. The outside of the carbon steel pipe (black) shall receive two coats of red lead paint.

47.0 Testing for :

1. HP Steam 4. Soft and Raw Water 2. LP Steam 5. Air 3. Glycol 6. SS Piping 7. Insulation 8. Electricals 9. Motors 10. Equipments.

Should conform to the latest ISI standards.

48.0 Service piping Installation guide lines : 48.1 Chilled water & Glycol piping (if mentioned in purchase order) The scope of erection and installation if mentioned, comprises a set of GI ‘B’

class pipes and fittings for chilled water and glycol including supports, isolation and non-return valves etc. for providing chilled water or glycol to all the equipment which would require chilled water or glycol. All the necessary headers for interconnecting all the chilled water and glycol pumps and auxiliary materials like adapters, reducers, flanges, union, valves/cocks/ (of gun-metal/brass for valves upto 100 mm. dia), strainers, gaskets, packing etc.

96



required for the pipe should also be supplied and installed by the erector. The pipeline should be insulated as per the specification detailed.

48.2 Steam & Hot Water and molasses Piping (if mentioned in purchase

order)

The scope of supply and installation of mentioned, comprises the following set of steam pipes and fittings for providing steam connections from the indicated battery point to all the equipments requiring steam in accordance with IBR, MS Class ‘C’ pipes, fittings and auxiliary items. The scope of supply and installation includes the necessary pipes supports, isolation supports, isolation valves, nonreturn valves, safety valves, check valves, pressure reducing valves steam traps, strainers, expanders, bends, gaskets, packing, sight glasses, pressure gauges etc. The manufacturer’s certificates that the material conforms to IBR duly attested by concerned authority should be furnished for all items as per requirements. The necessary check valves(s) and other fittings required at the sources of tapping at the battery point should also be supplied and installed by the erector. Set of condensate pipes and fittings of MS Class ‘C’ to interconnect the condensate return line. The supply is inclusive of necessary pipe supports isolation valves, check valves, bends, gaskets, packing etc.

48.3 Soft well water piping (if mentioned in purchase order)

The scope of installation comprises (if mentioned) a set of well water pipes and fittings including supports, isolation and non-return valves etc. Pipes of GI Class ‘B’ for providing well water to sterlizer would be required. All the necessary headers for inter-connecting the water pumps and auxiliary material like adopters reducers, flanges, union valves/checks (of gun metal/brass for valve upto 100 mm dia), bends, strainers, gaskets, packing etc. required for the pipe should also be supplied and installed by the erector.

48.4 Water distribution (if mentioned in purchase order)

The scope of supply and installation if mentioned comprises of the following: Set of water pipes and fittings of GI Class ‘B’ for providing water connection to the various equipment/items and points requiring water (raw and soft water) from battery limits. The scope is also inclusive of the necessary pipes and fittings, GI Class ‘B’ for the soft water from the softening plant to soft water overhead tank if specifically mentioned and further to all the equipments requiring soft water and interconnections with suitable valves etc. from all the compartments of the overhead tank. The supply and installation is inclusive of necessary pipe supports, isolated valves, strainers, bends gaskets, packing, polythene/copper tubes and all other necessary auxiliary items.

97



48.5 Air requirement (if mentioned in purchase order)

The scope of supply and installation if mentioned comprise of the following: Set of air pipes and fittings in accordance with MS ‘C’ Class for providing air to the various equipments/items and controls and points requiring the same. The scope of supply and installation is inclusive of necessary pipe supports, valves, filters, bends, gaskets, packing, polythene, copper tubes and all other necessary auxiliary items.

48.6 All the above referred piping should generally be of welded execution and must be removed of mill scales and properly cleaned before installation.

49.0 Important Note : 49.1 All the necessary materials, of a quality and make approved by RCDF required

for carrying out the installation mentioned in 46.2 shall be supplied by the Erector.

49.2 Piping (SS) (if mentioned in Purchase Order)

The scope includes the installation and inter connection of a set of SS Pipes and fittings, including cocks, valves, Tees, flanges, unions, bends, reducers, liners and other necessary fittings SMS/IDF standards, for inter connecting all the equipment listed. Necessary pipe supports shall be also installed by the Erector.

49.3 Pipe fittings at connection points

All the required fittings that would be needed in the piping at all the tapping, termination, connection and intermediate points must be installed by the Erector.

49.4 The erector shall prepare and submit the piping layout drawing, details of supports, details of tapping, termination interconnection etc. for approval. All the piping work shall be carried out strictly in accordance with the approved drawings/details. The respective milk flow diagram to which the piping layout correspondence must also be furnished by the erector.

50.0 Insulation (if mentioned in Purchase Order) 50.2 Insulation of Steam condensate & Hot water pipe lines :

All the steam and hot water pipes shall be insulated with 50 mm. thick mineral wool or equivalent. The insulation shall be carried out in the following manner:

98



1) Cleaning of surface to be insulated. Applying a coat of red oxide primer and fixing glass wool/mineral wool of suitable thickness tightly to the pipe, butting all joints to be tied with lacking wire.

2) The insulation should be covered with GI wire netting. 3) The steam and hot water lines, after insulation must be covered with 22

gauge aluminium sheet with proper grooves and overlaps and secured in position with 12 mm. self tapping Parker screws.

4) In case the insulation does not have the desired insulation properties, the

entire insulation will have to be redone at the erector’s cost to give the desired results.

5) In case of condensate return piping, all the steps mentioned above shall be

executed except that the thickness of insulation shall be 30 mm.

All the necessary materials of quality and make approved by RCDF required for carrying out the insulation mentioned in 50.2 shall be supplied by the erector.

99



ANNEXURE-I TENDER ACCEPTANCE LETTER

(To be given on Company Letter Head) To, Managing Director, Rajasthan Co-operative Dairy Federation Ltd., Saras Sankul, JLN Marg, Jaipur -302017

Sub: Acceptance of Terms & Conditions of Tender. Tender Reference No.__________________________ Tender ID No. ________________________________ Name of Tender/ Work / Item ________________________________________________ _________________________________________________________________________ Dear Sir,

1. I / We have downloaded / obtained the tender documents(s) for the above mentioned “Tender / Work / Item” from the web site(s) namely: ____________________________________________________________________________________________________________________________ as per your advertisement, given in the above mentioned website(s).

2. I / We hereby certify that I/We have read and understood the entire

terms and conditions of the tender documents (including all documents like Special Notes, annexure(s), Schedules(s), Specifications of the item(s), etc.) which form part of the contract agreement and I / We shall abide hereby the terms / conditions / clauses contained therein.

3. The corrigendum(s) issued from time to time by your department/

organization too has also been taken into consideration, while submitting this acceptance letter.

4. I / We hereby unconditionally agree & accept the tender conditions of above mentioned tender document(s) corrigendum(s) in its totality / entirety.

5. In case any provisions of this tender are found violated or breached then

your department / organization shall without prejudice to any other legal right or remedy be at liberty to reject this tender / bid including the forfeiture of the full said earnest money deposit absolutely.

Yours Faithfully,

(Signature of the Bidder, With Official Seal)

100



ANNEXURE-II

SECTION-I

MANUFACTURERS’ AUTHORISATION FORM

(Please see Clause 2(a) of Eligibility Criterion)

No.__________________________________Dated___________________________

To,

RAJASTHAN CO-OPERATIVE DAIRY FEDERATION

“SARAS SANKUL”, J.L.N. MARG,

JAIPUR – 302 017.

Sub : - Tender reference No._______________________________________.

Dear Sir,

We________________________________________ an established and reputable

manufacturers of ______________________________________________ having factories at

________________ and _______________________ do hereby authorise

M/s._____________________________________________ (Name and address of Agents) to

bid, negotiate and conclude the contract with you against tender reference

No.__________________________________ for the above said goods manufactured by us.

No company or firm or individual other than

M/s._________________________ ________________________________ are

authorise to bid, negotiate and conclude the contract in regard to this business against

this specific tender.

We hereby extend our full guarantee and warranty for the goods offered for

supply against your tender.

Yours faithfully,

(NAME)

for and on behalf of M/s.

(Name of Manufacturers)

Note : This letter of authority should be on the Letter Head of the manufacturing concern and

should be signed by a person competent and having the power of attorney to bind the

manufacturer.

101



ANNEXURE-III

SECTION-II – SCHEDULE-I

(Refer clause No.2(b) of Eligibility Criterion)

Major works successfully completed during the past five years

Sr. No.

Name

of Work

Place Contract

Reference

Name

of client

Value

of Work

Time of Completion

Date of Completion

Note : Indicate plant capacity and major parameters handled. Completion Certificate from Clients should be enclosed with the bid.

102



ANNEXURE-IV

SECTION-II – SCHEDULE-II

(Refer clause No.2(b) (iii) of Eligibility Criterion)

WORKS IN HAND DURING THE CURRENT FINANCIAL YEAR

Sr.

No.

Name of

Work

Work order

reference

Name of

client

Place of work

order

Value of Work

order

Completion period

Date

Note : Indicate plant capacity and major parameters handled.

103



ANNEXURE-V SECTION – III

TECHNICAL DEVIATION STATEMENT FORM

(Refer Clause 5 of Eligibility Criterion)

The following are the particulars of deviations from the requirements of the tender specifications : CLAUSE DEVIATION REMARKS (Including justification)

Dated Signature and seal of the Manufacturer/Bidder NOTE : (1) Where there is no deviation, the statement should be returned duly signed

with an endorsement indicating “No Deviations”. (2) The technical specifications furnished in the bidding document shall

prevail over those of any other document forming a part of our bid, except only to the extent of deviation furnished in the statement.

104



ANNEXURE-VI

DETAILS

PART I : “Supply, Erection, Testing and Commissioning of Plant & Machinery for Setting up Indigenous Product Plant on Turn Key Basis” at Malpura (Tonk) Raj.

All Rates To Be Filled In Prescribed .Xls File Only List Of Equipments As Follows

Item Wise BoQ

Tender Inviting Authority: MD, RAJASTHAN CO-OPERATIVE DAIRY FEDERATION LIMITED, JAIPUR (RAJASTHAN)

Name of Work: Supply, Erection, Testing and Commissioning of Plant & Machinery for Setting up Indigenous Product Plant on Turn Key Basis at Malpura (Tonk) Raj.

Contract No: RCDF/DPM& Proj./(C-4008)/2016-17/831-32 dated:14.09.2017

Bidder Name :

PRICE SCHEDULE (PART -I)

(This BOQ template must not be modified/replaced by the bidder and the same should be uploaded after filling the relevent columns, else the bidder is liable to be rejected for this tender. Bidders are

allowed to enter the Bidder Name and Values only )

NUMBER

#

TEXT # NUMBER #

TEXT #

NUMBER #

NUMBER NUMBER #

NUMBER #

NUMBER

#

TEXT #

Sl. No.

Item Description Quantity

Capacity

Unit Rate

of Suppl

y

Unit rate of

erection &

Commisioning

Total rate of supply

Total rate of erection &

Commisionin

g

TOTAL

AMOUNT

TOTAL AMOUNT In Words

1 2 3 4 5 6 7 8 9 10

1.00 MILK RECEPTION

SECTION


1.00 capacit

y

0.00 0.00 0.00 INR Zero Only

105



1.02 Tanker unloading pump

1.00 10

KLPH

0.00 0.00 0.00 INR Zero Only


1.00 500 Kg

0.00 0.00 0.00 INR Zero Only

1.04

Dump Tank 1.00 1,000

Kg

0.00 0.00 0.00 INR Zero Only

1.05

Milk Transfer pump 1.00 10

KLPH

0.00 0.00 0.00 INR Zero Only

1.06

Duplex Filter 1.00 Suitabl

e

0.00 0.00 0.00 INR Zero Only

1.07

Milk Chiller 1.00 10

KLPH

0.00 0.00 0.00 INR Zero Only

1.08 Raw Milk Storage Tanks (HMST)

2.00 15 KL 0.00 0.00 0.00 INR

Zero Only


1.00 Suitabl

e

0.00 0.00 0.00 INR Zero Only

1.10

S.S. can Scrubber 2.00 Suitabl

e

0.00 0.00 0.00 INR Zero Only

1.11

Can drip saver 1.00 Suitabl

e

0.00 0.00 0.00 INR Zero Only

1.12

Platform balance 1.00 100 Kg.

0.00 0.00 0.00 INR Zero Only

2.00 MILK PROCESSING

SECTION

2.01

Milk Transfer pump 1.00 5 KLPH 0.00 0.00 0.00 INR

Zero Only

2.02

Milk Pasteurizer 1.00 5,000 LPH

0.00 0.00 0.00 INR Zero Only

2.03

Milk Separator 1.00 5,000 LPH

0.00 0.00 0.00 INR Zero Only

2.04

Balance Tank 1.00 200 L 0.00 0.00 0.00 INR

Zero Only

106



2.05 Pasteurised Milk Storage Tanks (HMST)

2.00 15 KL 0.00 0.00 0.00 INR

Zero Only

2.06

Milk Transfer pump 1.00 5 KLPH 0.00 0.00 0.00 INR

Zero Only

2.07

Cream Tanks 2.00 1 KL 0.00 0.00 0.00 INR

Zero Only

2.08

Cream Transfer pump 1.00 500 LPH

0.00 0.00 0.00 INR Zero Only

2.09

Sour Milk Separator 2.00 500 LPH

0.00 0.00 0.00 INR Zero Only

3.00 ICE CREAM MIX

PREPARATION

SECTION

3.01 Mix preparation tank (Insulated & Cladded)

2.00 500 ltrs 0.00 0.00 0.00 INR

Zero Only

3.02

Mix transfer Pump 1.00 1 KLPH 0.00 0.00 0.00 INR

Zero Only

3.03

Duplex filter 1.00 500 LPH

0.00 0.00 0.00 INR Zero Only


1.00 Suitabl

e

0.00 0.00 0.00 INR Zero Only


1.00 Suitabl

e

0.00 0.00 0.00 INR Zero Only

3.06

Mix pasteurizer 1.00 500 LPH

0.00 0.00 0.00 INR Zero Only

3.07

Mix homogenizer 1.00 500 ltrs 0.00 0.00 0.00 INR

Zero Only

3.08

Mix transfer Pump 1.00 1 KLPH 0.00 0.00 0.00 INR

Zero Only

3.09 Aging Vat / Tank with condensing unit

2.00 500 ltrs 0.00 0.00 0.00 INR

Zero Only

107



3.10

Mix transfer Pump 1.00 500 LPH

0.00 0.00 0.00 INR Zero Only

4.0 MIX FREEZING

SECTION

4.01

Mix transfer Pump 1.00 500 LPH

0.00 0.00 0.00 INR Zero Only


1.00 100 ltrs

0.00 0.00 0.00 INR Zero Only


1.00 100-400 ltrs

0.00 0.00 0.00 INR Zero Only

4.04

Fruits and nut feeder 1.00 100-400 ltrs

0.00 0.00 0.00 INR Zero Only

4.05 Ripple machine with pumps

1.00 3 x 20 ltrs.

0.00 0.00 0.00 INR Zero Only


1.00

700-3000

cup per hr

0.00 0.00 0.00 INR Zero Only

4.07

Chocolate dozer 1.00

700-3000

cup per hr

0.00 0.00 0.00 INR Zero Only

4.08 Conveyor with cartooning table

1.00 Suitabl

e

0.00 0.00 0.00 INR Zero Only

4.09

SS working table 1.00 Suitabl

e

0.00 0.00 0.00 INR Zero Only

4.10 CHOCOBAR & ICE

CANDY SECTION


1.00 10

Moulds size

0.00 0.00 0.00 INR Zero Only

4.12

Candy hardener (with refrigeration plant)

1.00

Suitable for 20

Moulds

0.00 0.00 0.00 INR Zero Only

108



4.13 Candy pouch raping / packing machine

1.00 30

Pcs/Min

0.00 0.00 0.00 INR Zero Only

4.14 Candy moulds with stick holder

3.00 Standa

rd

0.00 0.00 0.00 INR Zero Only

4.15

Chocolate melting vat 1.00 100 Ltrs

0.00 0.00 0.00 INR Zero Only

4.16 Chocolate transfer Pump

1.00 100 Ltrs

0.00 0.00 0.00 INR Zero Only

4.17 Kulfi mix preparation vat

1.00 100 Ltrs

0.00 0.00 0.00 INR Zero Only

4.18 Chocolate coating tank with electric heater

1.00 20 Ltrs 0.00 0.00 0.00 INR

Zero Only

4.19 Thawing Tank With Electric Heater Capacity

1.00 20 Ltrs

0.00 0.00 0.00 INR Zero Only

4.20

SS tables 1.00 Suitabl

e

0.00 0.00 0.00 INR Zero Only

5.0 MISCELLANEOUS

5.01

Suitable Evaporating/ atmospheric and cooling system with ducting, cooling tower etc.

1.00 Suitabl

e

0.00 0.00 0.00 INR Zero Only

5.02 Ozonisation system. 1.00 Suitabl

e

0.00 0.00 0.00 INR Zero Only

5.03 Batch Coding machine with Conveyor

1.00 Suitabl

e

0.00 0.00 0.00 INR Zero Only

5.04 Cooling towers (wherever required)

1.00 Suitabl

e

0.00 0.00 0.00 INR Zero Only

5.05 Metal Detector 1.00 Suitabl

e

0.00 0.00 0.00 INR Zero Only

5.06 Crate Washing Trough (S.S)

1.00 1000 L 0.00 0.00 0.00 INR

Zero Only

109



5.07

Over head S.S balance tank with float, Spray balls, Support arrangement for chhach packing machines

2.00 500 L

0.00 0.00 0.00 INR Zero Only



1.00 3.10 m x 4.4 m x 3.5 m

0.00 0.00 0.00 INR Zero Only

5.10

Pre Fab Ice Cream Cold Storage -25degree C

1.00 3.10 m x 4.4 m x 3.5 m

0.00 0.00 0.00 INR Zero Only


1.00 5.2 m x 6.7 m x 3.5 m

0.00 0.00 0.00 INR Zero Only

5.12

Pre Fab Incubation Room with Blast Chilling

1.00 4 m x 3m x 3.5 m

0.00 0.00 0.00 INR Zero Only

5.13 Dispatch Air Lock 10mx3mx3.5m with air curtains

1.00

6.7 m x 2.10 m + 6.23 x 3.10

m

0.00 0.00 0.00 INR Zero Only

6.0 FLAVOURED MILK

SECTION

6.01 Mix Preparation

Section

6.02 Milk storage tank (Triple jacketed )

1.00 1000 ltrs

0.00 0.00 0.00 INR Zero Only

6.03 Milk transfer Pump 1.00 500 LPH

0.00 0.00 0.00 INR Zero Only

6.04 Milk heating/Preparation tank

1.00 500 ltrs

0.00 0.00 0.00 INR Zero Only

6.05 Milk transfer Pump 1.00 500 LPH

0.00 0.00 0.00 INR Zero Only

6.06 Tubular heat exchanger

1.00 1000 LPH

0.00 0.00 0.00 INR Zero

110



Only

6.07 Sugar syrup tank 1.00 100 ltrs 0.00 0.00 0.00 INR

Zero Only

6.08 Milk/Mix homogenizer 1.00 500 LPH

0.00 0.00 0.00 INR Zero Only

6.09 Milk/Mix storage tank 1.00 500 ltrs 0.00 0.00 0.00 INR

Zero Only

6.10 Mix transfer Pump 1.00 500 LPH

0.00 0.00 0.00 INR Zero Only

6.11 Milk chiller (80-35-4) cooling tower

1.00 500 ltrs 0.00 0.00 0.00 INR

Zero Only

6.12 Bottling & Sterilization

Section

6.13

Bottle Rinsing and filling machine (Rotary type)

1.00 500

bottles per hr

0.00 0.00 0.00 INR Zero Only

6.14 Bottle Cap induction sealing machine

1.00 500

bottles per hr

0.00 0.00 0.00 INR Zero Only

6.15

Bottle sterilizer counter presser retort (PLC based) with steam control valve.

1.00 500

bottles per hr

0.00 0.00 0.00 INR Zero Only

6.16 SS working table 1.00 Suitabl

e

0.00 0.00 0.00 INR Zero Only

6.17

Bottling labelling,

printing & Packing

Section

6.18 Bottle drying machine

1.00 500 bottles per hr

0.00 0.00 0.00 INR Zero Only

6.19

Shrink wrapping machine for individual bottle

1.00 500 bottles per hr

0.00 0.00 0.00 INR Zero Only


1.00 25-50 tray

per hr.

0.00 0.00 0.00 INR Zero Only

111



6.21 Bottle batching printing machine

1.00 500-1000 bottle per hr.

0.00 0.00 0.00 INR Zero Only

7.00 FERMENTED

PRODUCT SECTION


7.02 Milk Tank (Vertical) 1.00 2 KL 0.00 0.00 0.00 INR

Zero Only


1.00 1 KLPH

0.00 0.00 0.00 INR Zero Only

7.04 Homogenizer for Curd milk

1.00 1 KLPH per hr.

0.00 0.00 0.00 INR Zero Only

7.05 Inoculation tank insulated with pump

2.00 500 ltrs 0.00 0.00 0.00 INR

Zero Only


2.00 1000 ltrs.

0.00 0.00 0.00 INR Zero Only

7.07 Curd Cup filling machine.

1.00 1200 cups

per hr.

0.00 0.00 0.00 INR Zero Only

7.08 Packing machine for Chhach & Lassi

2.00 5000 pouch per hr.

0.00 0.00 0.00 INR Zero Only

7.09 Chiller for Chhach 1.00 2KLPH 0.00 0.00 0.00 INR

Zero Only

7.10 Pumps (various capacity)

1.00 Suitabl

e

0.00 0.00 0.00 INR Zero Only


1.00 200 ltrs.

0.00 0.00 0.00 INR Zero Only

8.00 PANEER

8.01 Milk storage tank for paneer milk

2.00 1 KL 0.00 0.00 0.00 INR

Zero Only

8.02 Paneer Vat 1.00 1000 ltrs.

0.00 0.00 0.00 INR Zero Only

8.03 Paneer press with hoops

1.00 120 Kg.

0.00 0.00 0.00 INR Zero

112



Only

8.04 Paneer washing cum cooling tank

1.00 200 ltrs.

0.00 0.00 0.00 INR Zero Only

8.05


1.00

packing size

200gms.,

1000gms., 5

Kg.

0.00 0.00 0.00 INR Zero Only

8.06 SS table for paneer packing

1.00 Suitabl

e

0.00 0.00 0.00 INR Zero Only

8.07 Paneer Cutting /slicing knives

1.00 Suitabl

e

0.00 0.00 0.00 INR Zero Only

8.08

Paneer weighing machine (Platform type)

1.00 Suitabl

e

0.00 0.00 0.00 INR Zero Only

8.09 Pumps (various capacity)

1.00 Suitabl

e

0.00 0.00 0.00 INR Zero Only


9.01

Curd storage tank (vertical) insulated triple jacketed

1.00 1000 ltrs

0.00 0.00 0.00 INR Zero Only

9.02 Shrikhand mixing machine

1.00 Suitabl

e

0.00 0.00 0.00 INR Zero Only

9.03 Balance tank for curd / sugar

2.00 100 ltrs.

0.00 0.00 0.00 INR Zero Only

9.04 Chacka stand

1.00 Suitabl

e

0.00 0.00 0.00 INR Zero Only

10.00 SERVICES

10.01

Complete Refrigeration

Plant.

1.00 30

KLPD 0.00 0.00 0.00 INR

Zero Only

10.02 Steam Boiler with

Accessories

113



10.03

FO fired Steam Boiler

Accessories

(a) Chimney for 1 Ton

boiler

(b) Boiler feed water

tank Cap.2000 ltr

(c) Suitable R.O system

for boiler capacity 2000

LPH

(d) F.O. Service Tank

cap. 825 Ltrs. with

structure

(e) F.O. tanks of 35 KL

with, F.O. Loading &

Unloading system with

oil pumps, oil service

line, with heating

arrangement etc.

1.00

1000 Kg/hr

0.00 0.00 0.00 INR Zero Only

10.04

Water softening plant

with accessories

1.00 1,00,000 Kg/hr

0.00 0.00 0.00 INR Zero Only

10.05

Air Compressor (Screw)

1.00 As per

TS

0.00 0.00 0.00 INR Zero Only

11.00 ELECTRICAL

11.01 Complete electrical work

consisting of HT & LT

panels.

1.00 As per

TS 0.00 0.00 0.00 INR

Zero Only

12 GENERAL

12.01 D.G. Set

1.00 160 KVA

0.00 0.00 0.00 INR Zero Only

12.02 , Steam control valves

etc.)

1.00 As per

TS 0.00 0.00 0.00 INR

Zero Only

12.03 Effluent treatment plant

1.00 As per

TS 0.00 0.00 0.00 INR

Zero Only

12.04 CIP system (Single

circuit)

1.00 As per

TS 0.00 0.00 0.00 INR

Zero Only

Total in Figures

0.00 0.00 0.00 0.00 0.00 INR Zero Only

Quoted Rate in Words

114



“Supply, Erection, Testing and Commissioning of Plant & Machinery for Setting up Indigenous Product Plant on Turn Key Basis” at Malpura (Tonk) Raj.

PART II : ALL RATES TO BE FILLED IN PRESCRIBED .XLS FILE ONLY (TO BE UPLOADED IN FINANCIAL BID COVER-2)

Bidder Name

:

NUMBER # TEXT # NUMBER # NUMBER NUMBER NUMBER NUMBER NUMBER NUMBER NUMBER NUMBER NUMBER # TEXT #

Sl.

No.

Item Description Basic Price of

supply (in. Rs.)

(Part I)

Packing &

forwarding

charge

Transporta

tion &

insurance

Total

Amount of

supply

GST Total

amount of

supply with

GST

Installation

and

Commssioni

ng

Charges(par

t I)

GST Total

Amount

Installation

and

commissioni

ng with

GST

Total Amount In

Rs. (8 +11)

TOTAL AMOUNT

In Words

1 2 3 4 5 6 7 8 9 10 11 12 13

1 PRICE SCHEDULE

1.01 Total Net FOR Unit Price for supply, installation &

commissioning

0.00 0.0000 0.0000 0.0000 0.0000 0.0000 INR Zero Only

Total in Figures 0.0000 INR Zero Only

Quoted Rate in Words

PRICE SCHEDULE (The total rate of supply and Installation & Commissioning quoted in Part-I will automaticaly shift to column no. 3 and 9 respectively of PART-II).Only fill column no.4,5, 7 and

10 in Part-II.

Part-II(This BOQ template must not be modified/replaced by the bidder and the same should be uploaded after filling the relevent columns, else the bidder is liable to be rejected for this tender. Bidders are allowed to enter the Bidder Name and Values only

)

Item Wise BoQ

Tender Inviting Authority: MD, RAJASTHAN CO-OPERATIVE DAIRY FEDERATION LIMITED, JAIPUR (RAJASTHAN)

Name of Work: Supply, Erection, Testing & Commissioning of Plant and Machinery for setting up Indigenous Product Plant on Turn Key Basis” At Jhalawar (Raj).

Contract No: No. RCDF/DPM& Proj./(C-4008)/2016-17/803-5 dated:08.09.2017

Validate Print Help

115



ANNEXURE – VII

AGREEMENT

(On non judicial stamped paper of value Rs.500/-, 1000/- & 5000/-)

1. An agreement made this ___________ day of ____________ between M/s.____________________ hereinafter called “approved supplier” which expression shall where the context so admits, be deemed to include his heirs, successors, executors and administrators of the one part and the Rajasthan Co-operative Dairy Federation Ltd. (hereinafter called “the Federation” which expression shall, where the context so admits, be deemed to include his successors in office and assigns) of the other part.

2. Whereas the approved supplier has agreed with the Federation for supply,

installation, testing and commissioning of & all those articles set forth in the supply order/work order issued vide No._________ and in the manner set forth in the aforesaid order.

3(a) And whereas the approved supplier has deposited a sum of Rs._______ in

form of Demand Draft as security for the due performance of the agreement.

3(b) And whereas the approved tenderer/supplier has agreed :

(i) to keep the security deposit with the Federation in form of demand draft for an initial period of 12 months or such extended period so as to cover the period of performance of contract i.e. supply/erection/commissioning as per purchase order. In case the contractor/supplier completes its contractual obligations before 12 months the deposit can be refunded before 12 months at the sole discretion of RCDF before aforesaid period of 12 months.

(ii) that no interest shall be paid by the Federation on the security deposit.

(iii) that in case of breach of any terms & conditions of the aforesaid supply order of this agreement by the contractor/supplier the amount of security deposit shall be liable to forfeiture in full or part by the Federation.

NOW THESE PRESENT WITNESS

1. In consideration of the payment to be made by the Federation at the rates setforth in the aforesaid supply order/work order, the approved supplier will duly supply the articles setforth/execute the work in the aforesaid supply order/work order and in the manner setforth and within the period stipulated in the conditions of the tender and order.

116



2. The conditions of the tender as given in the tender document for the

work, conditions of the aforesaid supply order/work order and also any subsequent amendment as may be issued by the Federation will be deemed to be taken as part of this agreement and are binding on the parties executing this agreement.

3(a) The Federation do hereby agree that if the approved supplier shall duly

supply the said articles/execute the work in the time and manner aforesaid, observe and keep the said terms & conditions, the Federation shall pay or cause to be paid to the approved supplier, at the time and in manner set forth in the said conditions, the amount payable for each and

every consignment/work executed on supplier’s raising bills. 3(b) The mode of payment will be as specified in the supply order/work order.

4. Delivery shall be effected and completed in the manner and time specified in the supply order.

5. In case the approved supplier fails to deliver the goods/execute the work within the time specified in the aforesaid supply order/work order, the conditions of liquidated damages clause and penalty those for late deliveries as stipulated in the aforesaid tender/supply order/contract shall be enforced.

6. In case of any doubt or question arising on the interpretation pertaining to the supply order/tender the terms of the contract shall be binding, override and final over the supply order/tender.

7. If any dispute or difference shall at any time arise between the two parties in respect of or concerning any of this herein contained or arising out of this supply order/tender/agreement as to the rights, liabilities or duties of the said parties hereunder or as to the recovery of any amount, the same shall be referred to the sole arbitrator M.D., RCDF who in turn may refer the dispute to any officer of RCDF for adjudication. The arbitration shall be in accordance to the law of Arbitration and Conciliation Act, 1996. The decision of the Sole Arbitrator shall be final and binding on

both the parties.

8. All the disputes pertaining to the said contract shall vest to the jurisdiction of Courts at Jaipur.

In witness whereof the parties hereto have set their hands on the _____________ day ______________________.

SIGNATURE OF THE SIGNATURE FOR AND ON APPROVED SUPPLIER: BEHALF OF the Federation:

117



Witness No.1 Witness No.1 Signature :______________________ Signature :_________________ Name :______________________ Name :_________________ Address :______________________ Address :_________________

______________________ _________________ ______________________ _________________

Witness No.2 Witness No.2

Signature :______________________ Signature :_________________ Name :______________________ Name :_________________ Address :______________________ Address :_________________ ______________________ _________________ ______________________ _________________

118



ANNEXURE-VIII

(Form of Bank Guarantee against 30% advance sought from the Dugdh Sanghs

for supply/erection contracts) 1. In consideration of the ______________ ZILA DUGDH UTPADAK SAHAKARI SANGH

LTD.,_______________ (hereinafter called “The SANGH”) having agreed to grant an advance of Rs.___________(Rupees____________________________ only) to M/s.________________________ (hereinafter called the said supplier(s) under the terms and conditions of an agreement /Purchase Order No._________________ dated _____________ made between the Rajasthan Co-operative Dairy Federation Ltd., Jaipur and / or SANGH and M/s.______________________ for supply/erection and commissioning (hereinafter called the said agreement/purchase order) on production of a Bank Guarantee for Rs.________________ (Rupees ___________________________ only), We _______________________(hereinafter called “The Bank”) do hereby undertake to pay the SANGH an amount not exceeding Rs.______________(Rupees________________________ only) against any loss/damage caused to or suffered or would be caused to or suffered by the SANGH by reasons of any breach by the said supplier(s) or any of the terms and conditions mentioned in the said agreement/Purchase Order.

2. We ________________________ (Name of the Bank) do hereby undertake to pay the

amount due and payable under this guarantee without any demur, merely on a demand from the SANGH stating that the amount claimed is due by way of loss or damage caused to or would be caused to or suffered by the SANGH by reasons of any breach by the said supplier(s) or any of the terms and conditions contained in the said agreement/Purchase Order, or by reason of the supplier(s) failure to perform the said agreement/purchase order. Any such demand made on the Bank shall be conclusive as regards the amount due and payable by the Bank under this guarantee. However our liability under this guarantee shall be restricted to an amount not exceeding Rs.___________ (Rupees ____________ only).

3. We _______________ (Name of the Bank) further agree that the guarantee herein

contained shall remain in full force and effect during the period that would be taken for the performance of the said agreement/purchase order and that it shall continue to be enforceable till all the dues of the SANGH, under or by virtue of the said agreement/purchase order have been fully paid and its claims satisfied or discharged or till the SANGH certifies that the terms and conditions of the said agreement/purchase order have been fully and properly carried out by the said supplier(s) and accordingly discharge the guarantee unless a demand of claim under this guarantee made on us in writing on or before _______________. We shall be discharged from all liabilities under this guarantee thereafter.

4. We _______________ (Name of the Bank) further agree with the SANGH that the

SANGH shall have the fullest liberty without our consent and without affecting in any

119



manner our obligations hereunder to vary any of the terms and conditions of the said agreement/purchase order to extend the time of performance by the said supplier(s) from time to time or to postpone for any time or from the time to time any of the power exercisable by the SANGH against the said supplier(s) and to forbear or endorse any of the terms and conditions relating to the said agreement/purchase order and we shall not be relieved from our liability by reason of any such variation of extension or for any forbearance, act or omission on the part of the SANGH or any indulgence by the SANGH to the said supplier(s) or by any such matter or thing whatsoever which under the law relating to sureties would but for this provision have effect of so relieving us.

5. We _________________ (Name of the Bank) lastly undertake not to revoke this

guarantee during its currency except with the previous consent of the SANGH in writing.

6. Notwithstanding anything stated above our liability under this guarantee is restricted

to Rs.________________(Rupees __________________________ only). Our guarantee shall remain in force until unless a suit or an action to enforce a claim under this guarantee is filed against us before that date, i.e. on or before ____________ all your rights under the said guarantee shall be forfeited and we shall be released and discharged from all liability thereunder.

The Bank agrees that the amount hereby guaranteed shall be due and payable to the

SANGH on SANGH’s serving a notice requiring the payment of the amount and such notice shall be served on the Bank either by actual delivery thereof to the Bank or by despatch thereof to the Bank by registered post at the address of the said Bank. Any notice sent to the Bank at its address by Registered Post shall be deemed to have been duly served on the Bank notwithstanding that the notice may not in fact have been delivered.

NOTWITHSTANDING – anything contained herein :

1) Our liability under this Bank Guarantee shall not exceed Rs.____________(Rupees______________________________________only).

2) This Bank Guarantee shall be valid upto _________________ and, 3) We are liable to pay the guaranteed amount under this Bank Guarantee only and

only if you serve upon us a written claim or demand in the manner specified above on or before ______________.

7. Notwithstanding anything stated above the Bank Guarantee shall be discharged by the

SANGH once the advance amount released against the Bank Guarantee along with interest or penalty if any payable on such advance has been fully recovered/adjusted.

Place : Date :

Signature & Seal

120



ANEXURE-IX

(Performa of Bank Guarantee for releasing 10% balance payment) (On Non-judicial stamp paper)

This deed of Guarantee made on this __________ day of ____________ 20 (Two thousand___________________) by _____________ (Name and address of the Bank) (hereinafter referred to as “The Bank”) which expression shall where the context or meaning so requires, includes the successors and assignees of the Bank and furnished to the ____________ ZILA DUGDH UTPADAK SAHKARI SANGH LTD., _____________________ (hereinafter referred to as “The SANGH” which expression shall unless repugnant to the context or the meaning there of include its legal representatives, successors and assignees. WHEREAS the Rajasthan Co-operative Dairy Federation Ltd., Jaipur and / or SANGH has placed its purchase order bearing No._________ dated ________ (Name and address of the party) (Hereinafter called “The supplier”) for supply /and erection of ________________ and WHEREAS the SANGH has agreed to pay to the supplier final 10% of the value of the equipment on submission of a Bank Guarantee of equal amount, which will be kept valid up to ________ from the date of supply or 12 months from date of commissioning of material at site. In consideration of the SANGH having agreed to pay to the supplier Rs.___________(Rupees_______________only) being the last 10% of the value of the equipment, we__________(Name of the Bank) hereby undertake and guarantee to make repayment to the SANGH of the said 10% amount or any part thereof which does not become payable to the supplier by the SANGH in accordance with the terms and conditions of the said purchase order. The Bank further undertakes not to revoke this guarantee during its currency except with the previous consent of The SANGH in writing and this guarantee shall be a continuous and irrevocable guarantee upto a sum of Rs.______ (Rupees___________only). The Bank shall not be discharged or released from this guarantee by any arrangement between the supplier and the SANGH with or without the consent of the Bank or any alterations in the obligations of the parties or by any indulgence, forbearance shown by the SANGH to the supplier and that the same shall not prejudice or restrict remedies against the Bank nor shall the same in any event be a ground of defence by the Bank against the SANGH. We_________ (Name of the Bank) do hereby undertake to pay an amount due and payable under this guarantee without any demur, merely or demand from the SANGH stating that the amount claimed is due to the SANGH. In case the SANGH puts forth a demand in writing on the Bank for the payment of the amount in full or in part against this guarantee, the Bank shall consider that such demand by itself is a conclusive evidence and proof that the supplier has failed in complying with the terms and conditions stipulated by the Rajasthan Co-operative Dairy Federation Ltd., Jaipur and / or SANGH without raising any dispute regarding the reasons for any such lapse/failure on the part or the supplier.

121



This guarantee shall be in addition to and without prejudice to any other securities or remedies which the SANGH may have or hereafter possess against the supplier/tenderer and the SANGH shall be under no obligation to marshal in favour of the Bank any such securities or fund or assets that the SANGH may be entitled to receiving or have a claim upon and the SANGH at its absolute discretion may vary, exchange, renew, modify or refuse to complete or enforce or assign any security or instrument. The Bank agrees that the amount hereby guaranteed shall be due and payable to the SANGH on SANGH’s serving a notice requiring the payment of the amount and such notice shall be served on the Bank either by actual delivery thereof to the Bank or by despatch thereof to the Bank by registered post at the address of the said Bank. Any notice sent to the Bank at its address by Registered Post shall be deemed to have been duly served on the Bank notwithstanding that the notice may not in fact have been delivered to the Bank. In order to give full effect to the provisions of this guarantee the Bank hereby waives all rights inconsistent with the above provisions and which the Bank might otherwise as a guarantor be entitled to claim and enforce. Notwithstanding anything contained here in before, our liability under this guarantee is restricted to Rs.____________(Rupees_______________________only) and it shall remain in force until __________, unless a suit or action is filed against us to enforce such claims, within three months from the aforesaid date, all the SANGH’s rights under this guarantee shall be forfeited and we shall be relieved and discharged from all liabilities thereunder. Place : Date :

(SIGNATURE) Seal

122



ANNEXURE – IX(A)

123



124



TECHNICAL

SPECIFICATION OF

ITEMS UNDER HEAD

MILK RECEPTION

125



TECHNICAL SPECIFICATION OF MILK PUMPS & TANKER UNLOADING HOSES

1.0 FUNCTIONAL REQUIREMENTS The pump will be used to transfer Milk. 2.0 DESIGN REQUIREMENT 2.1 Capacity : 10000 LPH at30 MWC Head. 2.2 Type : The pump should be centrifugal type. 2.3 Design : It should be of sanitary design. 2.4 Prime Mover : TEFC electrical motor of suitable HP. 2.5 Finish : All the surfaces coming in contact with ghee & butter oil should

be finished to 150 grit.

3.0 SCOPE OF SUPPLY 3.1 Motor : The stainless steel (AISI 316) pump should be supplied with

flanged type electrical motor of standard make having hygienic sealing arrangement. - 1 No.

3.2 Legs : The stainless steel (AISI 316) pump with motor should have legs having ball feet arrangement to adjust the height of the pump. - 1 Set.

3.3 Shroud : The motor portion of the pump should be SS shrouded. The shroud should have provision for circulation of air and entry of electrical cable along with junction box (terminal box) - 1 No.

3.4 Union : Stainless steel (AISI 316) unions should be provided on the inlet and outlet of the pump. - 2 Nos.

3.5 Drain Hole : A drain hole should be provided in seal housing between SS pump and electric motor.

Tanker Unloading Hoses.

Function: The flexible hose is used to connect the Milk Tanker outlet to the fixed position-unloading Pump . Construction: Food grade rubber hose, with adapter & SMS Unions at both ends. Hoses will be heavy duty, CIP compatible. The unions should be pre-fixed to the ends through vulcanizing process.

126



ELECTRONIC WEIGH SCALE WITH WEIGH BOWL (SINGLE COMPARMENT) & DOCK AUTOMATION

CAPACITY : 500 L.

1.0 FUNCTIONAL REQUIREMENTS

This would be mounted in a weighing machine for weighing milk (milk would be tipped manually in to it from 40L cans

2.0 DESIGN REQUIREMENTS 2.1 Capacity 500 L with 75 mm allowance in depth.

2.2 Dimensions of the bowl :should be suitable for the electronic weigh scale. 2.3 Slope ; 1.8 towards the outlet (from three sides ) 2.4 Finish : All the welding joints are to be ground smoothly . All stainless steel

surface are to be polished to 150 grits. 2.5 Joint Curvatures : All inside Corners should have minimum radii of 25 mm . 3.0 SCOPE OF SUPPLY 3.1 The bowl : the bowl should be fabricated from 2 mm thick stainless steel

sheet conforming to (ASI 304.) the top edges should be bent outward . It should be suitable to be suspended from the weigh scale .

3.2 Out let Valve : The outlet Valve would be mechanically operated from the

reading position . The outlet valve disc and stainless steel chain for hanging valve from the operating lever is within the scope of supply

3.3 Strainer –cum Anti-splash unit : This should be made from 2 mm thick

stainless steel sheet conforming to ASI 304 . This would have an antis plash bowl , slanting strainer made from perforated stainless steel sheet and mild steel pipe legs with stainless steel pipe cladding . The legs would be grouted in the floor and the entire unit can be withdrawn from the legs. The design and dimensions of the unit should conform to RCDF sketch.

4.0 TESTS The following tests should be conducted by the manufacturer at its works .

4.1 Dye penetration test for welding joints. 4.2 Water fill –up test for water tightness.

Note:- 1. Bidder should supply electronic weighing machine suspended type were with

digital display suitable for weigh bowl. The weigh bowl should be fabrication as per aforesaid specification.

2. Dock Automation : The Dock Automation consist of S/I & Commissioning of

Three Computers i.e. for testing, weighing and server mode, Printer, Data cable / network cable, suitable earthing etc.

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TECHICAL SPECIFICATION OF

DUMP TANK CAPACITY: 1000L


It will work as a balance tank for milk in between the weigh bowl and milk chiller ,

2.0 DESIGN REQUIREMENTS 2.1 CAPACITY: 1000L 2.2 Dimensions of the tank: The dimensions of the tank in general will be as under ;

Inner length - 1500 mm Inner width - 1100 mm Overall height - 980 mm

(including the legs) However, looking to site conditions RCDF may vary dimensions. 2.3 Slope: 1:15 towards the outlet (from all the three sides). 2.4 Finish: All the welding joints are to be ground smoothly. All stainless steel surfaces are to be polished to 180 grits. 2.5 Joint Curvatures: All inside corners should have minimum radii of 25 mm 3.0 SCOPE OF SUPPLY 3.1 Tank: The tank should be fabricated from 2mm thick stainless steel, sheet

conforming to AISI 304. The top edges of the tank should be bent outward smoothly. – 1 no.

3.2 Accessories 3.3 Cover: The loose fitting tri-sectional top cover with lifting handles should be

fabricated from 2mm thick stainless steel sheet conforming to AISI 304. – 3 nos. 3.4 Legs: Mild Steel legs with stainless steel pipe (AISI 430) cladding with stainless

steel ball feet provided at the bottom of the tank. The stainless less steel ball feet should have provision for height adjustment of 50 mm. – 4 nos.

3.5 Outlet: The single bottom – outlet of 63.5 mm diameter located in the middle of a long side. It should be fitted with a 63.5 mm dia stainless steel plug type flanged valve with complete stainless steel union on the other end. The outlet should be cup type and should be at a height of 230 mm from the finished floor level. – 1 no.

4.0 TESTS The following tests should be conducted by the manufacturer at its works

Dye penetration test for welding joints

Water fill-up test for water tightness of the tank.

NOTE :-

1. General arrangement of this equipment should be as per the attached reference drawing. However there may be some changes in dimensions to suit site conditions, maintaining the same volume.

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TECHNICAL SPECIFCATIONS FOR MILK CHILLER

1. Functional requirement :

The plate heat exchanger would be used for chilling milk with chilled water.

2. Capacity : 10KLPH

3. Design parameter

1. Milk : feed temperature : 35 deg. C

2. MILK outlet temperature : 4 deg. C

3. Chill water feed temperature : 1.5 deg. c4.

flow rate to milk ,

4. Ratio of chilled water flow rate to milk : 3 Times

5. Maximum pressure drop on Milk side : 6 MWC

6. Maximum pressure drop on Water side : 11 MWC

4. Finish

All welding joints to be ground smoothly. All SS surface are to be polished to

150 grit.

5. Plate Material : AISI 316 Quantity.

6. plate gasket : Food grade quality , Nitrite rubber Gasket which should

withstand water sterilisation temperature of 100 deg C and CIP with caustic

solution at 80 deg. C (Alkanity 0.7 % ) and Nitric Acid Solution at 70 deg C

(Acidity 0.5 % )

7. Supporting frame ;The supporting frame for the plate pack should be of self

supporting design made of stainless steel (AISI 304) clad mild steel with

manually operated tightening device. The tightening device should be able to

exert uniform pressure on all the part of heat transfer plate, The frame and

tightening device should prevent the plates from deflecting under pressure

differential of minimum 4 kg / sq , cm The frame should be capable of

accommodating the additional plates for the expanded capacity.

8. Accessories :

8.1 Inlet /Outlet : The inlet and outlet for chilled water and product should be

provided with complete SMS stainless steel (AISI 304 ) union.

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8.2 Thermowells : Stainless steel (AISI 304) pockets for thermometer on all the

inlet and outlet (Total 4 Nos.) Each pocket should be complete with suitable

stainless steel (AISI 304 ) inclined pocket suitable for mounting stem/ probe of

digital thermometer of size 4" x 4". One pocket should be provided for digital

electronic thermometer for chilled milk outlet temperature (The thermometers

are in the scope of the supply).

8.3 Ball feet : The frame should be provided with adjustable stainless steel ball

feet with provision for height adjustment of 50 mm – 4 Nos.

9 Tools ; A set of essential special tools.

10 The supplier would supply the Chiller in the frame size to be intimated separately

by the Milk Union as per their requirement.

11 No of plates would be as mentioned in the tender document and technical

discussions.

IMPORTANT NOTES :

1. Plate Thickness shall be minimum 0.6mm.

2. Gaskets (food grade) shall be non-glude type.

3. Chilled water flow rate shall be three times the flow rate of milk for 5, 10, 20 & 40 KLPH.

4. The plates shall be of AISI 316 grade.

5. Four Nos. Digital Temperature Indicator (PT 100 sensor of reputed make like Honeywell) size 2" x 4" house-in SS Box, front open, floor / wall mountable with minimum three meter cable length shall be provided.

Drawings :

The supplier is required to submit detailed fabrication drawings to RCDF on receipt of RAL/PO for examination. The drawings should generally be as per standard drawings for the item of similar capacities.

Details : The supplier should furnish the following details of plates in the format given below :

Chilling Section No of Plates H.T.A./Plate

(H.T.A. = Effective Heat Transfer Area)

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TECHNICAL SPECIFICATIONS OF INSULATED HORIZONTAL MILK STORAGE TANKS, CAPACITY : 15000L 1.0 FUNCTIONAL REQUIREMENTS

The milk storage tank would be used to store chilled milk at 4 degree centigrade temperature.

2.0 DESIGN REQUIREMENTS

2.1 Capacity : 15000 L The volume of the tank should be such that after filling it up to the rated capacity , the level of milk would be at least 50mm below the bottom end of sight / light glass. 2.2 Constructional Features : Double walled, insulated and welded

construction of sanitary design. 2.3 Slope : 1.50 towards the outlet at the bottom of the tank.

2.4 Metal contact : The only metal to metal contact between the inner and

the outer shells shall be at the places where fittings for the tank are provided. At the places where mild steel stiffeners are provided insulated padding should be fixed between the inner stainless steel shell and stiffeners.

2.5 Finish : All welding joints are to be ground smoothly. All stainless steel

surfaces are to be polished to 150 grits. 2.6 Joint Curvatures : The radii of welded and permanent attachment joints

should be at least 6 mm. Where the conical ends join the cylindrical shell the radii should not be less than 25 mm.

3.0 SCOPE OF SUPPLY

3.1 Inner Cylindrical Body : The inner shell and conical ends should be fabricated from 2.5 mm thick stainless steel sheet confirming to AISI 304 .

3.2 Outer Cylindrical Body : It should be fabricated from 2mm thick stainless

steel sheet conforming to AISI 304. 3.3 Insulation : The inner stainless steel shell , conical top and flat bottom

should be insulated in three layers as follows : First layer - 25 mm thick resin bonded crown 150 fibre glass compressed to 10mm.

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Second layer - 50 mm thick expanded polystyrene.

Third layer - 50 mm thick expanded polystyrene. The efficacy of the insulation should be such that temperature rise of the milk at 4 degree C in the tank should not be more than 1 degree C in 24 hours during summer season. 3.4 Accessories 3.4.1 Inlet -cum- out let : 51 mm dia cup type inlet cum outlet with two way

plug type stainless steel (AISI 304) flanged valve ending in complete stainless steel union . It should be provided at a height of 450 mm from the finished floor level. - 1 No. 3.4.2 Air Vent : Stainless steel (AISI 304 ) 150 mm dia air vent to prevent

formation of partial vacuum during CIP and pressure during filling . - 1 No. 3.4.3 Man Way : Oval shaped stainless steel (AISI 304) man way of

dimensions approximately 540 x 380 mm at the front end and provided with leak proof hinged insulated stainless steel (AISI 304 ) door with tightening and locking device. The man way door should open inward but at the same time it can be taken out also when necessary. The gasket should be of neoprene or nitrile rubber food quality. - 1 No. 3.4.4 Sight Glass : Stainless steel (AISI 304) sight glass assembly should be provided with toughened glass. It should be provided in such a way that one can easily read from the lowest level up to the maximum level mark - 1 No. 3.4.5 Sand blasted level marks : It should be calibrated at 500 L intervals

and provided on the inner rear end of the tank opposite to the sight glass. 3.4.6 Light glass : Stainless steel (AISI 304) light glass assembly should be

provided with toughened glass and stainless steel lampshade for mounting 24 Volt and 100 watt bulb. The lamp holder should be of brass - 1 No. 3.4.7 Platform : A small platform of stainless steel (AISI 304) with two steps

on the front end of the tank and two nos. of stainless steel handle 300 mm below sight glass to enable view through the sight glass. The platform should be located at around 1400 mm below the sight glass for the convenience of operator. 3.4.8 Agitator : It should be in stainless steel (AISI 304 ) construction

complete with geared motor of adequate capacity and should be able to uniformly agitate and mix milk in the tank within 10 minutes. The agitator shaft should be a rod.

- 1 Set 3.4.9 Spray Balls : Removable stainless steel (AISI 304 ) cleaning device

located on top to provide flooding of Liquid over the complete interior surface during CIP. The spray balls should have stainless steel unions at the outer end connections. - 2 Nos.

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3.4.10 Sampling cock : This should be provided on the inlet cum outlet

and should be in stainless steel (AISI 304 ) construction with sanitary design. - 1 No. 3.4.11 Thermowell : 300 mm long stainless steel (AISI 304) inclined pocket

suitable for mounting stem /probe of digital thermometer of size 4'' x 4'' . It should have suitable male threads (The thermometer is in the scope of supply ) - 1 No. 3.4.12 Legs : Conical mild steel legs with stainless steel (AISI 304 ) sheet cladding and stainless steel ball feet provided at the bottom of the tank. The stainless steel ball feet should have provision for height adjustment of 50 mm. - 6 Nos. 3.4.13 Drain hole : The outer shell should be provided with one or more drain holes at the lowest point. Any aperture in the shell should be designed so as to prevent ingress of moisture. 3.4.14 Ladder : Stainless steel (AISI 304) ladder for access to the geared motor assembly of agitator. - 1 No. 3.4.15 Lifting Lugs : Stainless steel (AISI 304) lifting lugs should be

provided at top. - 2 Nos. 3.5 Painting : All the mild steel stiffeners used in the construction of the

milk storage tank should be painted with two coats of epoxy primer after thorough de - rusting. 4.0 TESTS :- The following tests should be conducted by the manufacturer at its works. 4.1 Dye penetration test for welding joints. 4.2 Water fill - up test of inner vessel for water - tightness. 4.3 When man way is closed and cover tightened without gasket then the gap between the man way neck and cover should not exceed 0.5 mm .

Notes :-

1. General arrangement The equipment should be as per the attached reference drawing of RCDF.

2. Makes of gear box ELECON / RADICON or Equivalent (Equivalent make subjected to purchaser approval.

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TECHNICAL SPECIFICATION OF CHAIN CAN LOADING CONVEYING SYSTEM WITH CAN TRIPPING BAR.


The can conveyor shall be used to carry 40 L capacity milk filled cans for reception dock up to the tipping point for milk dumping.


2.1 Can tipping height - 1000mm (approx.) 2.2 POWERED DOUBLE CHAIN CONVEYOR : The powered double chain conveyor

is to carry all filled cans from the edge of the reception dock to the tripping in a stable manner. This conveyor should have an effective length of 4 Mtrs. (subject to actual site conditions) and rise from in floor position to the can tipping height. The complete conveyor assembly should be made from mild steel and heavily galvanized after fabrication, should be sand blasted and galvanized. The powered conveyor shall have to be as per site conditions and for which the party should visit the site at Dairy Plant for collecting the data for exact placement of the conveyor and subsequently submit the detailed drawing for its approval to RCDF. Only after the drawing has been duly approved by RCDF, the party should commence the fabrication.

The powered double chain conveyor shall have the gear box with a 3 HP drive motor. The gear box should be of a reputed make and the motor should be of Kirloskar/NGEF/ Crompton/ Bharat Bijlee/ Jyoti make.

2.3 LEGS : All the conveyor assemblies shall have sufficient number of galvanized

mild steel legs with stainless steel ball feet having 50mm vertical adjustment - 1 Lot

2.4 LUBRICATION : Adequate and accessible lubricating points for all the moving

parts and power transmission assemblies. 2.5 PAINTING : All the galvanized mild steel surfaces are to be painted with a

coat of epoxy primer followed by two coats epoxy paint of grey colour. 2.6 TOOLS : Essential special tools should be supplied with the conveyor without

charging any extra cost. NOTES :

1. General arrangement of this equipment should be designed to ensure the placement of conveyor above ground level (trench system will not be preferred). The tenderer is required to provide detailed drawing to be got approved from RCDF.

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TECHNICAL SPECIFICATION OF SS CAN SCRUBBER

(Manually operated)


1.1 General Description - The machine is required to mechanically scrub the inside (including bottom) and outside surfaces of standard 40 liters milk cans (max dia 352mm, height 595mm and neck dia 200mm). The cans are to be manually loaded/unloaded.

2.0 DESIGN REQUIREMENT

The generally accepted design should have a horizontal immersion bath in SS 316

construction with the two electrically driven brushes mounted in the horizontal

axis. However, other designs would also be considered.

2.1 The brush drive motor and transmission assembly should be securely mounted at one end of the bath. The brush drive, which should rotate in the same direction, should extend through the end wall and be fitted with a proper sealing arrangement to prevent leakage from the bath. Bearings must be adequately protected from the ingress of water and have adequate greasing points. The whole driving assembly should be enclosed in a waterproof cover.

2.2 The bath should be of a robust construction (3mm thick plate) with a rigidly

formed top edge, can overflow connection and a valve discharge drain. 2.3 The high quality nylon brushes which are within the scope of the supply should

be suitable for securing rigidly to the extended drive shafts.

2.4 Frame : - Except for specialized components the machine should be

constructed in SS 316 and mounted on a rigid frame. 2.5 Finish :- The complete SS sheet parts should be polishe. 2.6 Electrical requirement – Electrical motor should be wound for 400-440 V/ 3

phase/ 50 HZ AC supply. The motors would be of NGEF/Bharat Bijli Make.

Electrical switchgear is not included in the scope of this supply.

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TECHNICAL SPECIFICATION OF SS CAN DRIP SAVER


The milk can after unloading of milk in milk weigh bowel will be placed manually on can drip Saver & can drip Saver will facilitate collection of milk left on the inner surface of milk can. The milk will flow to drip Saver tray and from tray same will be diverted to dump tank with the help of pipe, placed at the outlet of can drip Saver.


2.1 General arrangement of can drip Saver should be should be as per the attached reference drawing.

2.2 Slope: 1:15 towards the outlet for perfect flow of milk.

2.3 Finish: All the welding joints are to be ground smoothly. All stainless steel

surfaces are to be polished to 180 grits. 2.4 Joint Curvatures: All inside corners should have minimum radii of 25 mm 3.0 SCOPE OF SUPPLY 3.1 The Can drip Saver SS tray of size 2000mm x 200mm x 100mm should be

fabricated from 2mm thick stainless steel sheet conforming to AISI 304. The top edges of the tray should be bent outward smoothly and it should be placed on SS pipe frame at the height of 750mm.

3.2 The SS can drip Saver frame should be fabricated as per drawing from SS pipe dia 50mm thickness 2mm conforming to AISI 304.

3.3 The stainless steel ball feet conforming to AISI 304 should be provided at the

bottom of legs. The stainless steel ball feet should have provision for height adjustment of 50 mm.

3.4 SS ball valve should be provided at the outlet of can drip Saver to facilitate

flow of milk up to dump tank. TESTS : The following tests should be conducted by the manufacturer at works. 1. Dry penetration test for welding joints. 2. Water fill-up test of SS tray vessel for water tightness.

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PLATFORM BALANCE

The Electronic weight balance capacity 100 kg of standard make is required .

137



TECHNICAL

SPECIFICATION OF MILK

PROCESSING SECTION

138



TECHNICAL SPECIFICATION FOR MILK PUMPS

CAP. : 5000 LPH

1.0 FUNCTIONAL REQUIREMENTS The pump will be used to transfer Milk. 2.0 DESIGN REQUIREMENT

2.1 Capacity : 5000 LPH at30 MWC Head. 2.2 Type : The pump should be centrifugal type.

2.3 Design : It should be of sanitary design.

2.4 Prime Mover : TEFC electrical motor of suitable HP.

2.5 Finish : All the surfaces coming in contact with ghee & butter oil should be finished to 150 grit.

3.0 SCOPE OF SUPPLY

3.1 Motor : The stainless steel (AISI 316) pump should be supplied with flanged type electrical motor of standard make having hygienic sealing arrangement. - 1 No.

3.2 Legs : The stainless steel (AISI 316) pump with motor should have legs

having ball feet arrangement to adjust the height of the pump. -1 Set.

3.3 Shroud : The motor portion of the pump should be SS shrouded. The

shroud should have provision for circulation of air and entry of electrical cable along with junction box (terminal box) -1 No.

3.4 Union : Stainless steel (AISI 316) unions should be provided on the inlet

and outlet of the pump. - 2 Nos.

3.5 Drain Hole : A drain hole should be provided in seal housing between

SS pump and electric motor.

Note :- Pump should be able to handle milk & milk products

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TECHANICAL SPECIFICATIONS FOR MILK PASTEURIZER CAPACITY – 5000 LPH

Technical specifications of the skid mounted milk pasteuriser, capacity 5,000 LPH along with accessories suitable for heating the milk by steam heated hot water as heating media: FUNCTIONAL REQUIREMENT :

The milk pasteuriser is required to pasteurise the milk having maximum 7% fat & 9.5 % SNF the pasteuriser should be able to heat the milk upto pasteurisation temperature 80 degree c & finally chil it to 4 degree c. 1. Design requairement of plate pack of milk pasteuriser. capacity - 5,000 LPH temperature program : - 4-45-60-80 c raw milk inlet temperature - 4 c provision to take milk out to filteration or separation at - 45 c / 50 c provision to take milk for homogeisation at - 60 c / 65 c milk pasteurisation temperature - 80 c pasteurised milk outlet at - 4 c heat regeneration efficiency - 92% holding time for hot milk at 80 c - 20 seconds type of holding section - plate type maximum pressure drop on milk side - 1.5 kgs. /sq.cm.

Chilled water flow rate - 3 times of milk flow rate

2. Finish

All weld joints should be ground smooth. All stainless steel surfaces are to be polished to 150 grits.

3.0 scope of supply: 3.1 Heat exchanger:

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3.2 Plate pack:

The PHE plates offered should be of 0.6 mm thickness having MOC of ss-316 with adhesive free NBR gaskets & should be of sanitary design. All contact surfaces of the plates should be easily accessible or readily removable for cleaning & inspection.

3.3 Plate gaskets:

The sealing gaskets of the plates should be designed in such a way to ensure the complete sealing & prevent any cross leakage in between the plates the gasket offered should be adhesive free. The MOC of gaskets should be of NBR & suitable for maximum working temperature of 112 degree c. The gaskets offered should also be suitable to withstand 2% caustic soda & 2% nitric acid solution at 60 to 80 c during cip cleaning.

3.4 Holding section:

The holding section offered should be of plate type. The plate pack of milk pasteuriser should be designed in such a way that it also accommodates the plates of holding section in the milk pasteuriser.

3.5 supporting frame:

The supporting frame for the PHE should be of self supporting design. The frame & pressure plate & fixed plate should be made of mild steel clad in stainless steel-304. PHE should be provided with multi bolt tightening design to exert uniform pressure on all the parts of heat transfer plates to prevent any leakages from PHE and damage to plates. The design of frame and tightening device should be such so as to prevent any deflection under pressure difference of minimum 4 kg. / sq.cm.

4. Accessories of the milk pasteuriser 4.1 inlet / outlet:

The inlets & outlets in each section of the heat exchanger for products as well as service liquids should be provided with SMS union.

4.2 Thermowells for glass thermometers:

SS thermowell alongwith guard should be provided at following sections (glass thermometers are not covered in the scope of supply)

Milk inlet Outlet of holding section Chilled water in

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Chilled pasteurised milk outlet To separation outlet point Chilled water outlet Hot water inlet Hot water outlet

4.3 Thermowell for RTD:

SS thermowell of suitable sizes for resistance temperature detector should be provided for sensing the temperature of final chilled past. Milk, pasteurized hot milk after & before holding section. These sensors should also provide signals to the panel to audio visual alarm for under heated milk, and temperature recorder for controlling the milk pasteurization temperature.

4.4 Skid:

The constructional design of skid should be such so as to accommodate phe, milk pumps, hot water pumps, milk balance tank, line and duplex filter and control penal the MOC of skid should be made of ISMC sections duly claded in ss-304.

4.5 Pressure gauges:

The necessary pressure gauges should be provided to observe the pressure drop in product & service liquid at various points wherever required.

4.6 Float balance tank:

The 100 litres capacity float balance tank should be fabricated from 2 mm thick SS 304 sheet. The tank should be cylindrical in shape having tubular legs with necessary inlet, outlet & flow diversion connections. The design of float control should such that it can hold the pump pressure in case the tank is full.

4.7 Milk pump :

The SS centrifugal pump should be used for feeding the milk to the PHE. The pump offered shall be of sanitary design as per dairy standards. It should be of suitable capacity & head as required complete with TEFC drive motor. The motor of the pump should be provided with SS shroud & ball feet. With air louvers and suitable terminal box for cable connections the impellor of the pump should be of SS investment casting duly balanced. The milk pump should be provided with mechanical shaft seal. The inlet & outlet connection should be with SMS union.

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4.8 Heating devicie : final stage of heating should be done with steam heated water. The hot water generation system should be a all stainless steel construction (AISI 430), efficient, silent and rugged unit with all the necessary accessories including hot water pump required to make the system complete. The hot water pump should be stainless steel shrouded with louvers for air cooling and suitable arrangement for cable connection. The heating device should be suitable for expanded capacity. The hot water generating set should be provided with a thermowell of atleast 200 mm long inclined down wards for fixing probe of temp. Controller. However the temperature controller is within the scope of supply.

4.9 Duplex filter

The unit should be supplied with two filter containers fabricated from 2 mm thk ss 304 sheet the filter containers should be coupled with each other with three way valves so as to ensure that any filter can be cleaned when the other is under operation i.e. cleaning of one filter shall not disrupt the operation. The cylindrical filter drum should be made from the perforated ss-304 sheet having 1.5 mm square pitch. The perforated drum should contain the nylon filter bag of 280 micron mesh size. The filter drum shall be provided with the necessary inlet / outlet & air purge valves.

5. Instruments & control panel :

The instrumentation panel should be dust & vermin proof prewired mounted on the skid. The panel should be fabricated from 1.6 mm thick ss 304 sheet.

the indicative details of the panel are given below:

S. No. Push buttons with indicators Selection switch

1. Milk separator - 1 L 1 Man on

2. Milk separator - 2 L 2 Auto

3. Hot water pump L 3 Manual

4. Milk cream feed pump L 4 Diversion flow

5. Milk cream transfer pump L 5 Forward flow

6. Honogeniser L 6 Hooter

7. Chilled water pump Ss 1 Forward / diversion s/s

8. Spare – 1 Ss 2 Auto / manual s/s

9. Hot water inlet temp. Indicator

Pb22 Acknowledge pb 1 s 1 Power on / off sw

The tenderer should furnish the information as per following format which is indicative only:-

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Item Descripition Qty. Remark / perferable make

Control panel Ss sheet metal panel suitable for free floor standing

1 no. Fabricated from ss 304 sheet

Air filter cum regulator

0-10 kgs./sq. Cm. Shavo norgen

Solenoid valve 220 v

Nc connections 2 nos

Shreader / flowcon

Hooter For deviation in parameters

Mimic

Temperature recorder

Two pen recorder for recording the temperature of hot & chilled milk

1 no. G-tek

Acknowledge push button & other push buttons

For acknowledging the deviation

L & t

Main on / off rotary switch with indication

L & t

The control panel should be prewired with a provision to ensure that under

heated milk is diverted back to the float balance tank and audio visual alarm

blows in case of under heated milk. The pasteurization temperature of the

milk should be maintained automatically by controlling the temperature and

flow rate of hot water generated through hot water generator.

6. FLOW DIVERSION VALVE :

Standard IDMC/equivalent make pneumatically operated SS 304 three way

valve should be provided for diversion of the under heated milk.

7. S.S. INTERCONNECTING PIPES & FITTINGS :

One set of prefabricated SS interconnecting pipes shall be supplied for

interconnecting all the above mentioned accessories with the PHE based on

the closed coupled layout on the skid.

All terminal connection battery limits for Raw milk inlet, pasteurized milk

outlet, milk to and from separator and homogenizer should terminate with

51mm SMS union. However the swing on bend connections at the battery

limit for separtor and homogenizer should be provided so that the milk

pasteurizer can be operated without milk separator and homogenizer.

Following GM Valves should be provided in the utility lines of the skid.

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At he outlet of the hot water pump for regulating the flow of hot water.

One No of Globe Valve at the inlet of the chilled water to the PHE and one No

of NRV at the outlet of chilled water from the PHE.

One no of NRV in the steam line.

Hot water vessel capacity shall be minimum 12 litres and shall be provided

with POP type of safety valve for removal of the steam condensate.

8. TOOLS

Necessary tools like Hook Spanner, C-Spanner etc. should be provided with

the plant.

9. OPERATING SPARE PARTS:

Necessary operating spare parts like SMS gaskets, Plate gaskets, Gasket for

the float valve, Filter Bags, Mech. Seal of the milk feed pump etc. should be

supplied with the milk pasteurizer.

10. UTLITIES REQUIRED: The tenderer is required to furnished the details of

the following:-

1. Electric Power :

2. Soft Water :

3. Compressed Air :

4. Chilled Water :

5. Hot Water : @ …………. LPH at …. degree C

11. SUPERVISION IN ERECTION & COMMISSIONING:

As the milk pasteurizer should be supplied on the basis of prefabricated on the

skid so that installation shall be required by the tenderer at site however we

shall ensure the skid mounted milk pasteurizer supplied by you is

interconnected with our existing milk plant at the battery limits provided in the

skid. However if required the tenderer should depute their Engineer to the site

and guide our staff to carry out this interconnection.

The tenderer shall be required to depute their Engineer for commissioning of

the milk pasteurizer after our confirmation that your milk pasteurizer have

been hooked with our milk plant. However performance and satisfactory

commissioning of the milk pasteurizer is under your scope of work.

12. DESIGN DATA FOR MILK PASTEURISATION PLANT AS A WHOLE: The

tenderer is required to furnish the information in the following format

wherever blanks are left:-

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S. No. PARTICULARS UNIT PARAMETERS

1. PDT SPECIFICATIONS WHOLE MILK MAX.

6% FAT & 9% SNF

2. FLOW RATE - PRODUCT / CIP LPH 5000/7000

3 FEED TEMPERATURE C 4/6

4 FINAL PRODUCT TEMPERATURE C 4

5 REGEGERATION EFFICIENCY AS A

WHOLE

% 90

6 TOTAL PRESSURE DROP ON MILK

SIDE

Kg./sq.cm.

7 PASTEURISATION TEMPERATURE C 80 C

8 MAX. DESIGN PRESSURE Kg./sq.cm.

9 MAX. WORKING TEMPERATURE C

10 GASKET TYPE & MATERIAL CLIP ON ADHESIVE

FREE GASKET

11 CONSTRUCTION OF PLATES

12 MAXS. Nos. OF PLATES THAT CAN

BE ACCOMODATED ON THE FRAME

13 PLATE CORRUGATION TYPE HIGH & LOW THETA

DEPENDING UPON

DESIGN

14 PLATE THICKNESS MM 0.6

15 PLATE DIMENSIONS ( L X W ) mm

16 AREA PER PLATE Sq. Mtrs.

17 GAP GETWEEN PLATES Mm

18 TOTAL FRAME LENGTH Mm

19 PHE MODEL NO. Mm

THE TENDERER IS REQUIRED TO FURNISH SECTION WISE DETAILS OF

THE STANDARD MILK PASTEURISER CAP 5KLPH.

SIZE OF FRAME NOS. OF PLATES IN EACH SECTION

HTA PER PLATE

TOTAL HTA

REGENERATION SECTION – 1 ……… NOS. …….. sq.m. …….. sq.m.



HEATING SECTION ……… NOS. …….. sq.m. …….. sq.m.

CHILLED SECTION ……… NOS. …….. sq.m. …….. sq.m.

HOLDING SECTION ……… NOS. …….. sq.m. …….. sq.m.

G. TOTAL ……… NOS. …….. sq.m. …….. sq.m.

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Note :

1. The scope of supply includes all required pumps, filters, pressure gauges, temperature indicator, complete steam control system with by-pass arrangement, steam water mixing battery, pneumatic control system equipped with Air filter cum regulator at inlet of control panel etc.

2. Control panel should equipped with all required accessories to ensure

automatic / manual operation of milk pasteurization.

3. Heat transfer area per plate should not be less than 0.22 Mtr. Sq.

4. The total Heat transfer area of all plates of milk pasteurizer capacity 5000 LPH should not be less than 44.00 Mtr. Sq.

5. Tenderer should strictly furnished the details of plates of each section i.e. Regeneration I, Heating, Cooling and Chilling sections and the heat transfer area of each section considered in the designed fabrication of Milk Pasteurizer capacity 5000 LPH.

147



TECHNICAL SPECIFICATIONS OF TRI PURPOSE CENTRIFUGE

Capacity : 5000 LPH

1.0 FUNCTIONAL REQUIREMENTS :

It would be used as hermetic separator, clarifier and standardize for milk at the incoming temperature of 40 – 50 degree centigrade.

2.0 DESIGN REQUIREMENTS :

2.1 Separation, standardization and clarification – 5000 LPH.

2.2 Only clarifier – 1.2 times the capacity mentioned against point no 2.1.

2.3 Finish : All welding joints are to be ground smoothly . All stainless steel

surface are to be polished to 150 grits.

3.0 SCOPE OF SUPPLY :

3.1 The centrifuge : The centrifuge should be made from stainless steel

confirming (AISI 304). The whole body including the drive should be stainless steel (AISI 304) shrouded-1 no.

3.2 Drive : The drive for the centrifuge should be just under the centrifuge and

integrated together - 1 set.

3.3 Accessories:

3.3.1 Lubricating system : Self-contained system for effective lubrication .

3.3.2 Controls : Fittings and controls to maintain required degree of standardization -1 set.

3.3.3 Flow gauge : For continuous measurement of milk and cream .

3.3.4. Pressure gauge : For continuous measurement of discharge pressure of skim/ standardization milk. -1 no.

3.3.5 Gasket : The gasket should be of food grade rubber. It should be nontoxic,

fat resistant and non-absorbent. It should have smooth surface. 3.4 Tools: Essential special tools should be supplied with the machine without

charging any extra cost .

Note :- Scope of supply also include supervision of installation & commissioning of supplied equipment at site.

148



TECHNICAL SPECIFICATION OF BALANCE TANK WITH STRAINERS

CAPACITY : 200 LTRS.


The balance tank with strainers is required to collect the cream from cream separator.


2.1 CAPACITY: 200 Ltrs.. 2.2 Dimensions of the tank: The tank should be Cylindrical of capacity 200 ltrs. of

suitable height to collect in form Cream Separator. Slope: 1:15 towards the outlet.

2.2 Finish: All the welding joints are to be ground smoothly. All stainless steel surfaces are to be polished to 180 grits.

2.3 Joint Curvatures: All inside corners should have minimum radii of 25 mm 3.0 SCOPE OF SUPPLY 3.1 The Tank: The tank should be fabricated from 2mm thick stainless steel sheet

conforming to AISI 304. The top edges of the tank should be bent outward smoothly. It should be suitable to support the strainer – 1 no.

3.2. Accessories 3.2.1 SS Strainer : It should be fabricated from 2mm thick stainless steel sheet

conforming to AISI 304. It should be perforated, hole dia 2 mm the strainer should have S.S. flat stiffener strips 25 mm x 6 mm thick to carry leakage pouch load.

3.2.2 Legs: Mild Steel legs with stainless steel pipe (AISI 304) cladding, with stainless steel ball feet provided at the bottom of the tank. The stainless steel ball feet should have provision for height adjustment of 50 mm. – 4 nos.

3.2.3 Outlet: The single bottom – outlet of 38 mm diameter. It should be fitted with

a 38 mm dia stainless steel plug type flanged valve with complete stainless steel union on the other end. The outlet should be cup type and should be at a height of 230 mm from the finished floor level. – 1 no.


4.1 Dye penetration test for welding joints

4.2 Water fill-up test for water tightness of the tank.

NOTE :-

1. General arrangement of this equipment should be as per the attached reference drawing. The tenderer is required to provide detailed drawing to be got approved from RCDF.

149



TECHNICAL SPECIFICATIONS OF INSULATED HORIZONTAL MILK STORAGE TANKS, CAPACITY : 15000L 1.0 FUNCTIONAL REQUIREMENTS


2.0 DESIGN REQUIREMENTS 2.1 Capacity : 15000 L The volume of the tank should be such that after filling it up to the

rated capacity , the level of milk would be at least 50mm below the bottom end of sight / light glass.

2.2 Constructional Features : Double walled, insulated and welded

construction of sanitary design.

2.3 Slope : 1.50 towards the outlet at the bottom of the tank.

2.4 Metal contact : The only metal to metal contact between the inner

and the outer shells shall be at the places where fittings for the tank are provided. At the places where mild steel stiffeners are provided insulated padding should be fixed between the inner stainless steel shell and stiffeners.

2.5 Finish : All welding joints are to be ground smoothly. All stainless

steel surfaces are to be polished to 150 grits.

2.6 Joint Curvatures : The radii of welded and permanent attachment joints should be at least 6 mm. Where the conical ends join the cylindrical shell the radii should not be less than 25 mm.

3.0 SCOPE OF SUPPLY

3.1 Inner Cylindrical Body : The inner shell and conical ends should be fabricated from 2.5 mm thick stainless steel sheet confirming to AISI 304 .

3.2 Outer Cylindrical Body : It should be fabricated from 2mm thick stainless

steel sheet conforming to AISI 304. 3.3 Insulation : The inner stainless steel shell , conical top and flat bottom

should be insulated in three layers as follows : First layer - 25 mm thick resin bonded crown 150 fibre glass compressed

to 10mm.

150



Second layer - 50 mm thick expanded polystyrene.

Third layer - 50 mm thick expanded polystyrene. The efficacy of the insulation should be such that temperature rise of the milk at 4 degree C in the tank should not be more than 1 degree C in 24 hours during summer season. 3.4 Accessories 3.4.1 Inlet -cum- out let : 51 mm dia cup type inlet cum outlet with two way

plug type stainless steel (AISI 304) flanged valve ending in complete stainless steel union . It should be provided at a height of 450 mm from the finished floor level. - 1 No. 3.4.2 Air Vent : Stainless steel (AISI 304 ) 150 mm dia air vent to prevent formation of partial vacuum during CIP and pressure during filling . - 1 No. 3.4.3 Man Way : Oval shaped stainless steel (AISI 304) man way of

dimensions approximately 540 x 380 mm at the front end and provided with leak proof hinged insulated stainless steel (AISI 304 ) door with tightening and locking device. The man way door should open inward but at the same time it can be taken out also when necessary. The gasket should be of neoprene or nitrile rubber food quality. - 1 No. 3.4.4 Sight Glass : Stainless steel (AISI 304) sight glass assembly should be

provided with toughened glass. It should be provided in such a way that one can easily read from the lowest level up to the maximum level mark - 1 No. 3.4.5 Sand blasted level marks : It should be calibrated at 500 L intervals

and provided on the inner rear end of the tank opposite to the sight glass. 3.4.6 Light glass : Stainless steel (AISI 304) light glass assembly should be

provided with toughened glass and stainless steel lampshade for mounting 24 Volt and 100 watt bulb. The lamp holder should be of brass - 1 No. 3.4.7 Platform : A small platform of stainless steel (AISI 304) with two steps

on the front end of the tank and two nos. of stainless steel handle 300 mm below sight glass to enable view through the sight glass. The platform should be located at around 1400 mm below the sight glass for the convenience of operator. 3.4.8 Agitator : It should be in stainless steel (AISI 304 ) construction

complete with geared motor of adequate capacity and should be able to

151



uniformly agitate and mix milk in the tank within 10 minutes. The agitator shaft should be a rod.

- 1 Set 3.4.9 Spray Balls : Removable stainless steel (AISI 304 ) cleaning device

located on top to provide flooding of Liquid over the complete interior surface during CIP. The spray balls should have stainless steel unions at the outer end connections. - 2 Nos. 3.4.10 Sampling cock : This should be provided on the inlet cum outlet

and should be in stainless steel (AISI 304 ) construction with sanitary design. - 1 No. 3.4.11 Thermowell : 300 mm long stainless steel (AISI 304) inclined pocket

suitable for mounting stem /probe of digital thermometer of size 4'' x 4'' . It should have suitable male threads (The thermometer is in the scope of supply ) - 1 No. 3.4.12 Legs : Conical mild steel legs with stainless steel (AISI 304 ) sheet cladding and stainless steel ball feet provided at the bottom of the tank. The stainless steel ball feet should have provision for height adjustment of 50 mm. - 6 Nos. 3.4.13 Drain hole : The outer shell should be provided with one or more drain

holes at the lowest point. Any aperture in the shell should be designed so as to prevent ingress of moisture. 3.4.14 Ladder : Stainless steel (AISI 304) ladder for access to the geared

motor assembly of agitator. - 1 No. 3.4.15 Lifting Lugs : Stainless steel (AISI 304) lifting lugs should be provided at top. - 2 Nos. 3.5 Painting : All the mild steel stiffeners used in the construction of the

milk storage tank should be painted with two coats of epoxy primer after thorough de - rusting. 4.0 TESTS :- The following tests should be conducted by the

manufacturer at its works. 4.1 Dye penetration test for welding joints. 4.2 Water fill - up test of inner vessel for water - tightness. 4.3 When man way is closed and cover tightened without gasket then the gap between the man way neck and cover should not exceed 0.5 mm . Notes :-


2. Makes of gear box ELECON / RADICON or Equivalent (Equivalent make subjected to purchaser approval.

152



TECHNICAL SPECIFICATION FOR CREAM STORAGE TANK

CAPACITY : 1000 L 1.0 FUNCITIONAL REQUIREMENTS :

Pasteurizer cream having a fat content of 40 – 45 % / Cream would be ripened and stored in this tank at a temperature of 6 degree centigrade.

2.0 DESIGN REQUIREMENTS 2.1 Capacity : 1000 L

The volume of the tank should be such that after filling it up to the rated capacity, the level would be 100 mm below the line where cylindrical shell joints the conical top.

2.2 Constructional feature :

Triple walled insulated and welded construction of sanitary design.

2.3 Slope : Sufficient slope should be provided towards the inlet – cum out let

along the periphery of the reverse conical bottom. 2.4 Metal contact : The only metal to metal contact between the inner and

outer shells should be at the places where fittings for the tank are provided. 2.5 Finish : All welding joints are to the ground smoothly. All stainless steel

surfaces are to be polished to 150 grits. 2.6 Joint – Curvatures: The radii of all welded and permanent attachment

joints should be at least 6 mm. Where the conical top and reverse conical bottom join the cylindrical shell the radii should not be less than 25 mm.


3.1 Inner cylindrical Body : The inner shell, conical top and reverse conical

bottom should be fabricated from 2 mm thick stainless steel sheet for 1000 L capacity conforming to AISI 304.

3.2 Intermediate cylindrical Body : The intermediate shell and flat bottom

should be fabricated from 2 mm thick stainless steel sheet conforming to AISI 304.

3.3 Outer cylindrical Body : The outer shell, conical top and flat bottom should

be fabricated from 2 mm thick stainless steel sheet conforming to AISI 304. 3.4 Insulation : The entire intermediate shell, flat bottom and inner conical top

shall be insulated in three layers as follows:

153



First layer: 25mm thick resin bonded crown 150 fiber glass compressed to

10mm. Second layer: 50mm thick expanded polystyrene. Third layer: 50mm thick expanded polystyrene.

3.5 Accessories : 3.5.1 Inlet-cum-outlet: 38mm dia cup type inlet cum outlet with two way plug

type stainless steel (AISI 304) flanged valve ending in complete stainless steel union. It should be provided at a height of 450 mm from the finished floor level – 1 No.

3.5.2 Air vent: Stainless steel (AISI 304) 150mm air vent to prevent formation of

partial vacuum during CIP and pressure during filling – 1 No. 3.5.3 Man way : Stainless steel (AISI 304) man way of 450mm diameter and

located at the conical top – of the tank and provided with air tight hinged insulated stainless steel (AISI 304) door with tightening and locking device. The cover should be provided with stainless steel (AISI 304) anti-splash guard stainless steel (AISI 304) cleats should be provided near the man way for fixing and hanging rope ladder :- 1 No.

3.5.4 Sand Blasted level marks: It should be calibrated at 200 L intervals and provided on the inner shell at opposite side of the sight glass. The level mark should be dark enough so it may be clearly visible.

3.5.5 Sight Glass: Stainless steel (AISI 304) sight glass assembly should be

provided with toughened glass. It should be provided in such a way that one can easily read from the lowest level up to the maximum level mark. Stainless steel lamp shade for mounting 24 V and 100 watt bulb. The lamp holder should be made from brass – 1 No.

3.5.6 Agitator : Vertical heavy duty sweeping type Stainless steel (AISI 304)

agitator complete with mountings with geared motor of adequate capacity and should be able to uniformly mix cream in the tank within 10 minutes. The agitator shaft should be a rod – 1 No.

3.5.7 Sprinkler Pipe: A 25mm dia pipe ring of Stainless steel (AISI 304) should be

provided at the top of the jacket for sprinkling hot / chilled water on the outer surface of the inner shell. The complete sprinkler pipe ring should be removable when necessary. The complete pipe ring should end outside in a header with two separate connections for hot and chilled water. In addition to this a Stainless steel (AISI 304) steam sparger pipe / water steam ejector should also be provided in the bottom jacket and it should end outside in a flange and counter flange.

3.5.8 Spray Ball: Removable Stainless steel (AISI 304) cleaning device located on

conical top at either sides of the agitator drive to provided flooding of liquid over the complete interior surface and agitator during CIP. These should have stainless unions at the outer end connections – 2 No.

154



3.5.9 Drain: Made from Stainless steel (AISI 304) pipe of 38mm dia at the bottom

of the jacket with gun metal valve – 1 No. 3.5.10 U-seal: Made from Stainless steel (AISI 304) pipe 38mm dia at the bottom of

the jacket – 1 No. 3.5.11 Over flow: Made from Stainless steel (AISI 304) pipe 38mm dia at the top of

the jacket – 2 Nos. 3.5.12 Sampling Cock: It should provided on the inlet – cum – outlet and should be

in Stainless steel (AISI 304) construction with sanitary design – 1 No. 3.5.13 Thermowell : 200 mm long Stainless steel (AISI 304) inclined pocket suitable

for mounting probe of digital thermometer. The portion of the thermowell which is in the jacket should be insulated with rock wool or equivalent and totally shrouded so that hot water or chilled water does not come in contact with the insulating material. It should have 10mm BSP male threads and the digital thermometer is also to be provided by the tenderer.

3.5.14 Legs: Conical mild steel legs with Stainless steel (AISI 304) sheet cladding

and stainless steel ball feet provided at the bottom of the tank. The stainless steel ball feet should have provision for height adjustment of 50mm – 4 Nos.

3.5.15 Ladder: Stainless steel (AISI 304) ladder for access to the sight glass and

geared motor assembly of agitator – 1 No. 3.5.16 Lifting lugs: Stainless steel (AISI 304) lifting lugs should be provided at top –

2 Nos. 3.6 Painting: All the M.S. stiffeners used in the construction of the tank should

be painted with two coats of epoxy primer after thorough de-rusting. 4.0 TESTS: The following tests should be conducted by the manufacturer at

works. 4.1 Dye penetration test for welding joints. 4.2 Water fill-up test of inner vessel for water tightness.

Note : General arrangement of the equipment should be provided the attached

reference drawing. Makes of bought out items are as bellow : Geared motor Elecon. / Radicon (1) Scope of supply also include supervision of Installation & commissioning, water trial of supplied equipment to ensure perfect working of systems at site. (2) Name plate should be provided on equipment define the connection.

155



TECHNICAL SPECIFICATION FOR S.S. CREAM PUMPS

CAP. : 500 LPH

1.0 FUNCTIONAL REQUIREMENTS The pumps will be used to transfer Cream from Cream balance Tank to

Cream Tank. 2.0 DESIGN REQUIREMENT 2.1 Capacity : 500 LPH at 15 MWC Head. 2.2 Type : The pump should be centrifugal type. 2.3 Design : It should be of sanitary design. 2.4 Prime Mover : TEFC electrical motor of suitable HP. 2.5 Finish : All the surfaces coming in contact with ghee & butter oil should

be finished to 150 grit. 3.0 SCOPE OF SUPPLY 3.1 Motor : The stainless steel (AISI 316) pump should be supplied with






156



TECHNICAL SPECIFICATIONS OF SOUR MILK SEPARATOR

Capacity : 1000 LPH

1.0 FUNCTIONAL REQUIREMENTS:

1.1 General Description : It would be used as separator for milk at the in-coming temperature of varying from 26º C to 40º C at Atmospheric temperature.

1.2 Capacity:

Separator capacity 1000 LPH.

2.0 DESIGN REQUIREMENTS :

2.1 All parts coming in contact with milk should be faoricated from SS conforming to AISI 304 or equivalent at Atmospheric Temperature.

3.0. The prime mover should be complete with suitable motor of Siemens / Cormption / GEC / NGEF make for operation on 400/440 Volts, 3-phase, 50Hz, AC supply.

3.1 The centrifuge should be completely SS shrouded with .S.S plate open type.

3.2 Necessary tools for the operation of the machine should be provided.

3.3 Price list of spare parts for two years normal operation should be provided.

3.4 All SS surface should have a finish of 150 grits.

3.5 All SS pipes and fittings should conform to SMS standards.

3.6 All MS surfaces should have i coat of anti-corrosive epoxy primer followed by coats of paint of approved shade.

4.0 Rubber Gaskets which come in contact with Milk is resistant and non-absorbant.

5.0 Fat percentage in skimmed milk after separation should not be more than 01.%.

157



ICE CREAM MIX

PROCESSING PLANT

158



ICE CREAM MIX PREPARATION SECTION

1. Design features: This section will have 2 numbers of 500l ice cream mix preparation tanks with all accessories. Liquid milk will be provided to the mix preparation tank. The powder ingredients will be added by the venture system with a PHE type pre-heater (up to 40-45deg C) for the efficient and fast mixing.

2. Technical Specification and scope of supply:

NO DESCRIPTION CAPACITY QTY

ICE CREAM MIX PREPARATION SECTION

1. ICE CREAM MIX PREPARATION TANK 500L 2NO

This will be a cylindro-conical stainless steel tank made out of SS 304, 2mm thick inner shell. Inner shell duly insulated with mineral wool, and cladded with SS304, 2mm thick sheet. The tank will be provided with a stirrer .The product circulation inlet will be provided with no foam type inlet, and out let connection with flush bottom valve. The tank will be provided man hole, light glass, geared motor RPM-80, and spray ball etc. The tank will be mounted on SS legs with ball feet. All the surfaces will be finished to 180 grit finishing.

2. DUPLEX TUBULAR STRAINER STD 1NO

This will be a duplex tubular strainer with changeover valves and SS perforated pipe as filter element this can be removed for cleaning without dismantling the filter housing online

3. MIX TRANSFER PUMP Suitable 1NO

Type: Centrifugal

MOC: SS 304

Head-15MWC

Type of seal-Single mechanical seal

159



S.M.P. and Sugar Loading Section

1.

Technical specification of the skid mounted s.m.p and sugar adding system Mix pre heater

Design parameters :- Milk feed temperature :- 4 deg c Milk outlet temperature :- 45 deg c

Hot water feed temperature – 85 deg c

Hot water flow rate :- 1:8 times

Finish All weld joints should be ground smooth. All stainless steel surfaces are to be polished to 150 grits. heat exchanger: plate pack: The phe plates offered should be of 0.6 mm thickness having moc of ss-316 with adhesive free nbr gaskets & should be of sanitary design. All contact surfaces of the plates should be easily accessible or readily removable for cleaning & inspection.

PLATE GASKETS: The sealing gaskets of the plates should be designed in such a way to ensure the complete sealing & prevent any cross leakage inbetween the plates the gasket offered should be adhesive free. The moc of gaskets should be of nbr & suitable for maximum working temperature of 112 degree c. The gaskets offered should also be suitable to withstand 2% caustic soda & 2% nitric acid solution at 60 to 80 c during cip cleaning. SUPPORTING FRAME:

The supporting frame for the phe should be of self supporting design. The frame & pressure plate & fixed plate should be made of mild steel clad in stainless steel-304. Phe should be provided with multibolt tightening design to exert uniform pressure on all the parts of heat transfer plates to prevent any leakages from phe and damage to plates. The design of frame and tightening device should be such so as to prevent any deflection under

5000LPH

1NO

160



pressure difference of minimum 4 kg. / sq.cm. INLET / OUTLET:

The inlets & outlets in each section of the heat exchanger for products as well as service liquids should be provided with sms union. thermo wells :- Aisi 304 pockets for temperature indicators on all the inlet and outlet. ACCESSORIES :- Inlet / Outlet: Connections for chilled water and product are provided with complete SMS union.

2 RE-CIRCULATION PUMP

Type: Centrifugal MOC: SS 304 Head-35MWC Type of seal-Single mechanical seal

The pump offered shall be of sanitary design as per dairy standards. It should be of suitable capacity & head as required complete with tefc drive motor. The motor of the pump should be provided with ss shroud & ball feet. With air louvers and suitable terminal box for cable connections the impellor of the pump should be of ss investment casting duly balanced. The milk pump should be provided with mechanical shaft seal. The inlet & outlet connection should be with sms union.

8000LPH 1NO

3 S.S.HOPPER WITH VENTURY STD 1NO

S.S. Hopper will be made out of S.S.304 2mm thick sheet with

rectangular shape and conical ventury with ball valve to suck

the

powder. The hopper will be provided with a top mesh screen

and

a loose top cover with handle to lift.

161



4 SS 304 INTERCONNECTING PIPES AND FITTINGS STD 1LOT

S S pipes and fittings to interconnect the equipments from

circulation pump to ventury and ventury to milk pre heater

along

with by pass arrangement . All Pipes and Fittings will be of SS

304

SMS standard.

5 SKID: THE CONSTRUCTIONAL DESIGN OF SKID SHOULD BE SUCH SO AS TO ACCOMMODATE PHE, MILK/ MIX PUMPS, HOT WATER PUMPS, MILK BALANCE TANK, LINE AND DUPLEX FILTER AND CONTROL PENAL THE MOC OF SKID SHOULD BE MADE OF ISMC SECTIONS DULY CLADED IN SS-304.

STD 1 LOT

162



6 IN-DIRECT STEAM HEATED HOT WATER PREPARATION MODULE 8000L Heating will be done with steam-heated water. The hot water preparation module will be shell and tube heat exchanger. Shell and tube heat exchanger: The inside tubes for water flow will be of SS 316 corrugated seamless tubes and outer shell for steam will be fabricated of SS 304 pipe. Steam inlet and condensate outlet connections are with SMS unions. HOT WATER PUMP SS mono block with union, 8000lph – 20MWC. The hot water pump will be stainless steel shrouded with louvers for air cooling and suitable arrangements for cable connection.

STEAM PIPES AND FITTINGS:

A. Steam Modulating valve with flanges Make: Pneucon/Samson/Forbesmarshall

B. 3 Nos. 3 piece weld able steam valve with flange C. 1 No. Steam Trap Float type valve Make: Forbes

Marshall D. 2 Nos pressure gauges 0-7 bar with siphon cock E. Make up line for water with condensate pipe Air

Vent size 15NB with ball valve F. SS Hydro pneumatic expansion tank to take

care of expansion of hot water in closed circuit. Inter connecting pipes and fittings for steam set up to Shell and Tube Heat Exchanger.

1NO

163



TECHNICAL SPECIFICATION FOR ICE CREAM MIX PASTEURIZER

1. Design features:

This section is designed for an ice cream mix pasteurization of 500lph capacity

Basis of design of the pasteurizer:

Mix inlet temperature: 45 deg C

Mix outlet to homogenizer: 65 deg C

Mix outlet temperature: 6 deg C

Hot water inlet temperature: 85 deg C

Hot water flow rate: 1:3 times

Cooling tower water inlet temperature: 32 deg C

Cooling tower water outlet temperature: 36 deg C

Chilled water inlet temperature: 2 deg C

Regenerative heating section: 45-65deg C

Final heating with hot water: 65-85deg C

Regenerative cooling section: 80-65deg C

Cooling section I: 65-35deg C

Cooling Section II: 35-6 deg C

Chilled Water Flow rate 3 Times of Mix Flow rate

164



2. Technical specification and scope of supply:


1.

FLOAT BALANCE TANK: The 100 litres capacity float balance tank should be fabricated from 2 mm thick ss 304 sheet. The tank should be cylinderical in shape having tubular legs with necessary inlet, outlet & flow diversion connections. Design- sanitary type mechanical float valve which will withstand a pressure of 3.0 bar, with ice cream mix inlet, outlet, and, loose top cover with lifting handle.

100L 1NO

2. MIX FEED PUMP 500LPH 1NO

Type: Centrifugal

MOC: SS 304

Head- 25MWC

Type of seal- Single mechanical seal The pump offered shall be of sanitary design as per dairy standards. It should be of suitable capacity & head as required complete with tefc drive motor. The motor of the pump should be provided with ss shroud & ball feet. With air louvers and suitable terminal box for cable connections the impellor of the pump should be of ss investment casting duly balanced. The milk pump should be provided with mechanical shaft seal. The inlet & outlet connection should be with sms union.

3. TUBULAR STRAINER STD 1NO

This will be a simplex tubular strainer with SS perforated pipe as filter element this can be removed for cleaning without dismantling the filter housing online

4. FLOW CONTROLLER 500LPH 1NO

Stainless steel flow controller device is required to control manually the required flow rate under varying pressure conditions The flow controller will be of sanitary design. It shall maintain the desired flow rate manually during the continuous run against the increased resistance due to milk scale formation.

5. PLATE HEAT EXCHANGER 500LPH 1NO

165



(PASTEURIZER)

PLATE PACK:

The pasteurizer is designed to accept ice-cream mix at temperature of 45 deg. C.the phe plates offered should be of 0.6 mm thickness having moc of ss-316 with adhesive free nbr gaskets & should be of sanitary design. All contact surfaces of the plates should be easily accessible or readily removable for cleaning & inspection.

PLATE GASKETS:

The sealing gaskets of the plates should be designed in such a way to ensure the complete sealing & prevent any cross leakage inbetween the plates the gasket offered should be adhesive free. The moc of gaskets should be of nbr & suitable for maximum working temperature of 112 degree c. The gaskets offered should also be suitable to withstand 2% caustic soda & 2% nitric acid solution at 60 to 80 c during cip cleaning. SUPPORTING FRAME: The supporting frame for the phe should be of self supporting design. The frame & pressure plate & fixed plate should be made of mild steel clad in stainless steel-304. Phe should be provided with multibolt tightening design to exert uniform pressure on all the parts of heat transfer plates to prevent any leakages from phe and damage to plates. The design of frame and tightening device should be such so as to prevent any deflection under pressure difference of minimum 4 kg. / sq.cm. INLET / OUTLET: The inlets & outlets in each section of the heat exchanger for products as well as service liquids should be provided with sms union. THERMO WELLS :- AISI 304 pockets for temperature indicators on all the inlet and outlet.

ACCESSORIES :-

Inlet / Outlet: Connections for chilled water and product are provided with complete SMS union.

BALL FEET: The frame will be provided with adjustable stainless

166



steel ball feet with provision for height adjustment of 50.0mm - 4 Nos.

6. HOLDING TUBE 20SEC 1NO

Holding tube is designed for continuous holding of the product

for20 Sec, at the pasteurization temp. Holding Tube is of tubular

design made of SS 304 pipes and suitable number of bends

7. FLOW DIVERSION VALVE STD 1NO

Flow diversion device is of sanitary design made of SS 304. Flow diversion valve is supposed to divert the flow automatically if pasteurization temperature is not attained. The pneumatically operated SS 304 three way valve should be provided for diversion.

8. S.S.INSTRUMENT/CONTROL PANEL STD 1NO

The control panel should be equipped with all required accessories to ensure automatic/ Manual operation of Ice-Cream Pasteurizer. Automatic controls will be provided to ensure that the pasteurization temperature of product is maintained. If the required temperature is not reached, the flow of product will be automatically diverted to the float balance tank with an audible electric horn. Temperature accuracy will be plus minus 0.5 deg C. ON and OFF push buttons with indicating lamps and suitable inscriptions will be provided for the following Pumps:

Ice cream Mix feed pump ----------- ----------------- 1No Hot Water Pump ___________ ____________ 1 No. Spares-------------------------------------------------------

4 Nos The controls, electric push buttons, alarm, starter,data logger for ice cream pasteurizer pumps, will be enclosed in a self supporting dust, weather and vermin proof S.S. Enclosure (conforming to AISI 304). The control panel will be pre-wired and will be of 3 wire circuit.

167



9. SS PIPES & FITTINGS

Inter connecting pipes with necessary fittings for products as well as services will be supplied. The sizes of all pipes and fittings will be decided as per the capacity. Product piping:

The supply will include all the necessary stainless steel pipes and fittings from float balance tank to the finished pasteurized mix outlet. Hot Water piping: The supply will also include necessary S.S. pipes and fittings for shell and tube heat exchanger to ice-cream mix pasteurizer along with hot water pump. Tools:

Essential special tools will be supplied with the plant. Finish: All welded joints will be ground smoothly. All stainless steel surfaces are to be polished to 180 grits.\

The total pasteurizer module will be skid mounted SKID:

The constructional design of skid should be such so as to accommodate phe, milk/ mix pumps, hot water pumps, milk balance tank, line and duplex filter and control penal the moc of skid should be made of ismc sections duly claded in ss-304.

SMS STD SS 304

1LOT

10. IN-DIRECT STEAM HEATED HOT WATER PREPARATION MODULE

Heating will be done with steam-heated water. The hot water preparation module will be shell and tube heat exchanger. Shell and tube heat exchanger: The inside tubes for water flow will be of SS 316 corrugated seamless tubes and outer shell for steam will be fabricated of SS 304 pipe. Steam inlet and condensate outlet connections are with SMS unions. HOT WATER PUMP

SS mono block with union, 3000lph – 20MWC. The hot water pump will be stainless steel shrouded with louvers for air cooling and suitable arrangements for cable connection.

3000LPH 1NO.

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STEAM PIPES AND FITTINGS:

G. Steam Modulating valve with flanges Make:

Pneucon/Samson/forbes marshall H. 3 Nos. 3 piece weld able steam valve with flange I. 1 No. Steam Trap Float type valve

Make: Forbes Marshall J. 2 Nos pressure gauges 0-7 bar with siphon cock K. Make up line for water with condensate pipe Air

Vent size 15NB with ball valve L. SS Hydro pneumatic expansion tank to take care

of expansion of hot water in closed circuit. Inter connecting pipes and fittings for steam set up to Shell and Tube Heat Exchanger.

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TECHNICAL SPECIFICATION FOR SUPPLY, INSTALLATION & COMMISSIONING OF HIGH PRESSURE HOMOGENIZE 500 LPH

This shall be used for Homogenization of Ice cream mix , etc. 1. Functional Requirement : 1. CAPACITY: 500 LITRE PER HOUR 2. PRESSURE: 200 Kg. per cm Sq. 3. MOTOR : 10 HP/7.5 KW 4. The Homogenizer will be of rugged design suitable mounted on solid Mild Steel frame

covered with SS cabinet enclosure made of imported AISI 304. 5. Homogenize will be of sanitary design. 6. Crankcase is made out of solid spheroidal Gray cast iron suitable to withstand the load 7. Homogenize Chamber is made out of single piece forged AISI 316 Block and tested

with ultra sound and grounded to get the required finish. 8. The chamber block is housed with removal and replaceable type suction and delivery

valve and valve sheets. All concerned parts shall be made out of SS 316. The Gasket coming in contact with the product will be of Food Grade, Non-toxic, Fat resistant and Non-absorbent with smooth surface.

9. Crank shaft, connecting rode and bearings would be made out of single piece forged Alloy steel, checked by ultra sound and grounded to get the required tolerance.

10. Suction and discharge valves will be of Ball Type and are made of special material to withstand the impact load due to continuous opening and closing of valves.

11. Homogenizing valves are made of special Material (tungsten carbide) to withstand the abrasion and turbulence created because of high velocity of the product (satellite or tungsten carbide valves).

12. The high pressure Homogenizer will be two-stage design suitable for operating pressure of 200 Kg. per cm Sq..

13. Pressure adjustment system will be manual with the help of adjustment screw. 14. The Homogenizer will be coupled through belt & pulley with the suitable HP/RPMTEFC

Electric motor of Reputed make (Three phase) TEFC Electric motor of Crompton / NGEF make.

15. The Homogenizer equipped with speed reduction system. 16. Homogenizer will be provided with :- (i) Diaphragm type pressure gauge on chamber. (ii) Commissioning spares – 1 Set. (iii) Instruction Manual – 3 Sets. (iv) Tool Kit – 1 Set. 17. A control panel equipped with all automation and control, moter starter etc. 18. The Homogenizer should be supplied with adjustable ball feet. 19. Inlet/Outlet connection of suitable size. 20. Tenderer should fill the details mentioned at Annexure – I. Note: .The supervision of erection and commissioning of the Homogenizer is also included in the scope of supplier, for which no extra charges would be payable.

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DETAIL OF HOMOGENIZER, 500 LITRE PER HOUR TO BE FILLED BY

TENDERER. Name of Tenderer : ____________________________________________

S. No. Item Specification

1. Model

2. Capacity 500 LPH

3. Pressure

4. Electrical Motor

5. No. of Plungers / material

6. Homogenizing heads 2 Stage

7. Homogenizing Valve Material Tungsten Carbide

8. Inlet / Outlet connection

9. Mounting frame MS frame with SS enclosure

10. Contact parts SS 316

11. Pressure

12. Set of essential Spare

13. Set of Essential Tools

14. Dimensions

15. High Pressure Pump Block (Chamber) material

Single piece forge SS 316 tested with ultra sound.

16. Gasket Food grade Non toxic. Fat resistant and non absorbtant

17. Crank case material Spheorodal Cast Iron

18. Crank shaft, connecting rod and bearings

Forged steel

19. Plunger Packing should be suitable for Hot CIP.

20. Control Panel (Define detail of items to be supplied in control panel)

21. Diaphram type SS 316 pressure gauge.

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TECHNICAL SPECIFICATION FOR ICE CREAM MIX PUMPS

CAP. : 500 LPH

1.0 FUNCTIONAL REQUIREMENTS The pump will be used to transfer Ice Cream Mix. 2.0 DESIGN REQUIREMENT

2.1 Capacity : 500 LPH at 15 MWC Head. 2.2 Type : The pump should be centrifugal type.

2.3 Design : It should be of sanitary design.

2.4 Prime Mover : TEFC electrical motor of suitable HP.

2.5 Finish : All the surfaces coming in contact with ghee & butter oil should be finished to 150 grit.

3.0 SCOPE OF SUPPLY

3.1 Motor : The stainless steel (AISI 316) pump should be supplied with flanged type electrical motor of standard make having hygienic sealing arrangement. - 1 No.

3.2 Legs : The stainless steel (AISI 316) pump with motor should have legs having

ball feet arrangement to adjust the height of the pump. -1 Set. 3.3 Shroud : The motor portion of the pump should be SS shrouded. The shroud

should have provision for circulation of air and entry of electrical cable along with junction box (terminal box) -1 No.

3.4 Union : Stainless steel (AISI 316) unions should be provided on the inlet and

outlet of the pump. - 2 Nos. 3.5 Drain Hole : A drain hole should be provided in seal housing between SS pump

and electric motor.

Note :- Pump should be able to handle Ice Cream Mix (milk & milk products).

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TECHNICAL SPECIFICATION OF ICE CREAM AGEING VAT

1. Design features: The ageing section is designed for storing the ice cream mix of one production shift.

Technical specification and scope of supply:


1. AGING VAT WITH CONDENSING UNIT

This will be a cylindrical stainless steel vat made out of SS 304 inner shell and jacketed shell 2mm thick with dimple jacketed evaporator and 100mm thick insulation cladded by 2mm thick SS 304 sheet. All SS surface to be polished to 180 grits. Mounted on SS legs with ball feet. The tank will be provided with following accessories : 1:-Gear box with Sweep type agitator-32 RPM 2:-C I P Connections. 3:-Inlet connection with No foam inlet and Outlet connection with valve. 4:-Condensing unit for above aging vat

Temperature difference is from 8 0C to 40C.

(Refrigerated unit should be designed with required safety)

500L 2NO

MIX TRANSFER PUMP Type: Centrifugal

MOC: SS 304

Capacity: 1000lph

Head: 25MWC Electrical connection: standard TEFC 3 phase motor operated on 400/440V AC supply. The pump offered shall be of sanitary design as per dairy standards. It should be of suitable capacity & head as required complete with tefc drive motor. The motor of the pump should be provided with ss shroud & ball feet. With air louvers and suitable terminal box for cable connections the impellor of the pump should be of ss investment casting duly balanced. The milk pump should be provided with mechanical shaft seal. The inlet & outlet connection should be with sms union.

1000 LPKH

1NO

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MIX FREEZING SECTION

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FREEZING SECTION

1 FLAVOUR MIXING TANK

The Flavour mixing tank will be used for mixing different flavours in the Ice-cream mix before it goes to ice cream freezer . The tank has three independent compartment with separate outlet. The specification as follows:

The tank will be made of 2mm thick SS of 304. The tank will be insulated at sides & bottom.

Three separate compartment will be provided outlet complete with 38 mm Dia SS valve.

The top of the tank will be open and will be provided with removable top cover. The tank will be supported on four SS legs with adjustable Ball Feet.

2. CONTINUOUS ICE CREAM FREEZER CAPACITY 100 to 400 LPH

The self contained continuous Ice Cream Freezer will be of 400 Ltrs/Hr capacity at – 5 Deg. C, with Ice Cream mix of 4 Deg. C at inlet. The Freezer should be suitable for 130% over rum. The Freezer should be complete with all necessary parts like Cooling Tower, Freezing tunnel with dashers Refrigeration System, Mix Pump, hardness controller, power meter, Anti freeze protection device, Speed variable device for mix pump, S.S sanitary design pressure gauge, Suction and discharge pressure gauges for refrigerant circuit, Defrosting arrangement for freezing cylinder, All electrical and mechanical interlocking and safety controls along with refrigerant control with respective to load etc. All these components should be mounted on a structure with SS Sheet covering on all the sides. The Freezer should be mounted on adjustable SS Legs.

3 FRUIT AND NUT FEEDER CAPACITY 100 TO 400 LTS. PER HR.

The Ingredient Fruit and nut feeder should be designed for connection to freezer having capacity 400 Lt./Hr. Ice-Cream. It should efficiently and gently inject dry nuts or fresh fruits into the Ice-cream floor. The Fruit and nut feeder will be used to feed cut fruits & nuts in the Ice Cream after the Ice Cream comes out of continuous Ice Cream Freezer. Dry nut/fresh fruit feeding done through product hopper. Control of adjustment of quality is by variable AC frequency drive. The design for suitable C.I.P. of system . Agitator & dosing screw should be easily dismantled for manual cleaning.

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To make butter scotch ice cream, chikee should be button shape without dust. Ingredients are feed from top of the pump and pump rotor will take it down & transferred to the ice cream flow with the help of three blades, then final mixing of ingredients in the ice cream will be done in a vertical mixer. Ingredients are feed from top of the rotor are taken down by rotor & transferred to the ice cream flow with the help of blades, then mixing of ice cream & ingredients is done in a vertical mixer. Dry Nut Hopper capacity 15-liter suitable for 400 liter freezer Drive details: Rotor with AC variable frequency Drive

Mixing Auger with AC variable frequency Drive Screw Feeder with AC variable frequency drive

4 RIPPLING MACHINE (TRIPPLE FLAVOUR) CAPACITY 3X20 LTRS/HR

The Rippling Machine is required for adding different flavored/colour of ripple/syrup/thick resin/ honey/ Strawberry crush upto specific gravity 100 gm/20 minimum into the flow of Ice Cream coming out of Continuous Ice Cream Freezer capacity 400 LPH. The machine should be complete with following

Material - All contact part should be of SS304/ food grade material. Flavour container with three compartment each of 20 Ltrs capacity of SS 304.

The containers will be complete with SS cover.

The containers should be provided with Pumps, valves, Drain Valve.

Container to be supported on adjustable SS Legs.

The machine should be suitable for Pneumatic operation. 5 ICE CREAM CUP / CONE FILLING MACHINE WITH PLC CAPACITY

700 - 3000 CPH

The Ice Cream Cup / Cone filling Machine will be automatic PLC based suitable for filling varieties of Ice Cream such as pain or with ingredients or with ripple using required attachment. All the parts coming of Ice Cream will be made of SS-304 or Food Grade material. The machine will be complete with following features

Filling quantity may be changed between 40 to 120 ML.

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The output may vary from 700 to 3000 Cups/cons/Hr

Dispensing of Cone manually

Cone expansion

Chocolate Spray into Cones.

Filling Ice Cream into Cones

Top Filling with Chocolate or fruit spray

Dry nut sprinkling

Card Board Lid Dispenser

Closing of Cone

Injection of Finished Cone

Control Panel showing various parameters.

The Ice Cream Cup / Cone Filling Machine will be self contained based on pneumatic operation.

The control panel should be equipped with PLC ensuring perfect automation of machine operation and associated safety along with facility to prevent damage of cups if lids are not placed, display of total packed cups and cone, working hour of machine, speed of machine, provision of speed control etc.

6 CHOCOLATE DOZER CAPACITY 700 to 3000 CPH

The Chocolate Dozer will work with the Cup / Cone Filling Machine and to be hooked up to the PLC System of the Filling Machine . The Machine will be complete with following.

Chocolate Tank capacity 20 Ltrs.

In direct Chocolate heating arrangement.

There is jacket on Chocolate Tank filled with oil. The heating system of oil is PID auto –tune temperature controlled.

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Chocolate toping Tank

Chocolate Dozing Unit with variable quantity of Dozing.

The Chocolate Dozer will be mounted with the Ice Cream Filling Machine.

7 CONVEYOR WITH CARTONING TABLE

The Conveyor will be used to take Ice Cream Cups/ Cones from Filling Machine to the packing / cartooning tables. The Conveyor will be provided with single tracking facility and will have following facilities.

Side collecting trays for cartooning length 900 mm.

Conveyor Length – 1800 mm.

The conveyor can be bolted with packing machine.

Collection Table 900 mm x 600 mm made of SS – 304 .

The conveyor will be mounted on SS Pipe Frame with Ss Adjustable ball feet.

The conveyor belt will be food grade with width 220 mm.

Driving arrangement.. 8 SS WORKING TABLE (2MX1M)/ Suitable

The packing table top will be made of 2 mm thick SS 304 and will be of size 2M x 1 M. The supporting frame & legs will be made out of SS Square pipe of 50 mm x 50 mm.

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CHOCOBAR AND ICE-CREAM CANDY SECTION

01 CANDY TANK ( WITH REFRIGERATION PLANT ) 10 MOULDS

The Candy Tank will be used for freezing Ice Candy and Chocobars in the Glycol solution . The Candy Tank will be self contained with following

SS Puff Insulated Brine Tank suitable to accommodate 10 Moulds of

Chocobars

SS Spray Pipe for Brine

Brine circulation pump with filter and piping

Water cooled brine chilling unit complete with semi hermetic sealed compressors.

Water Cooled Condenser

Brine Chiller

Refrigeration Piping and Insulation

Controls

Prewired Electric Panel

Moulds should accommodated 24 pieces . 02 CANDY HARDNER ( WITH REFRIGERATION PLANT )

The Candy Hardner will be required to Harden the Candy and dry moisture from surface of Candy before its goes for Chocolate Coating . The self contained hardner will be complete with following

Insulated Chamber with high velocity air circulation fans. Refrigeration plant water cooled system Track for manual shifting of candy moulds. Inlet / outlet windows to insert and take out the moulds from the chamber.

The candy hardener should be suitable to accommodate the output of 20 moulds.

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03 CANDY POUCH PACKING MACHINE CAPACITY 30 PCS/MIN

The Candy Pouch Packing Machine will be required to pack individual candy in the plastic pouch. The machine will be complete with the following

Loading Conveyor of food grade material .

Driving arrangement with Electric Motor and switch gear.

Plastic film loading points with pouch making & sealing system.

Control Panel with control or adjustments of different parameters and speed of the machine.

The individual piece of candy will be placed manually of the conveyor belt with pouch film. The pouch film will be automatically made & sealed in the machine.

04 CANDY MOULDS

The Candy Moulds will be made of SS- 304 with various size of Candy moulds i.e. 40 ML, 50 ML. Each moulds will be provided with 24 cups. The candy stick will be hold with stick holder with spring loaded clamping mechanism for quick release of the Candy after freezing. The moulds will be filled with the Candy material the stick will be hold by stick holder and the mould will be placed in the candy tank.

05 CHOCOLATE MELTING VAT CAPACITY 100 LTRS

The Chocolate Melting Vat will be steam jacketed SS Vat with Agitator . The solid pieces of Chocolate will be placed in the Vat. The chocolate will melt and will be agitated with the help of slow speed agitator. The vat will be provided with the following

SS Vat of 100 Ltrs Capacity made of 5mm thick SS- 304 Slow speed agitator with Geared Motor. MS Jacket around the Vat for steam supply complete with steam valve,

steam trap assembly. Insulation of Glass wool on the vat and finally cladding of 2mm SS-304. 4 Nos. of SS legs with adjustable ball feet.

Out let for melted chocolate with butter fly valve of 38 mm Dia. Top SS cover Thermometer Electronic Type with thermowell.

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06 KULFI MIX PREPARATION VAT CAPACITY 100 LTRS

Specification same as given under Item No. 5 07 CHOCOLATE COATING TANK WITH ELECTRIC HEATER

CAPACITY 20 LTRS

The Chocolate Coating Tank will be made of SS, insulated and cladded with SS Sheet. The tank will be provided with electric heater & thermostat. The tank will be supported of SS Legs.

08 THAWING TANK WITH ELECTRIC HEATER CAPACITY 20 LTRS

The Thawing Tank will be made of SS, insulated and cladded with SS Sheet. The tank will be provided with electric heater & thermostat. The tank will be supported of SS Legs.

09. SS WORKING TABLE (2MX1M)/Suitable


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MISCELLANEOUS EQUIPMENT

SECTION

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01 EVAPORATOR COOLING SYSTEM

The Suitable Evaporative Cooling System will be required for cooling the Ice Cream manufacturing & packing section by indirect cooling of filtered air with the help of evaporative cooling and distribution the cool filtered air in the ice cream manufacturing & packing section with the help of air ducting . The System will be complete with following

Evaporative Water Cooling Section including Fan, Water Pump & Spraying arrangement, plastic fins , water sump etc.

Air supply fan, Air Filters, Fins Type Radiator, Cooling Water supply Pump.

GI Air ducting with Air supply ports at different locations.

The unit will be located at the terrace of the production block. The ducting will supply cool filtered air in side the Ice Cream production & Packing Room. The ducting will be properly fixed in the ceiling of the room.

02 OZONISATION SYSTEM

The Ozonisation System will be complete with following

Feed gas preparation system ( Oxygen Plant ) – 1No.

Ozone Generator – 2 Nos.

Ozone Monitor and Controller

Supply Pipe & Fittings

Diffusers

The ozone diffusers will be placed at the out lets of the cooled air duct from evaporated air cooling unit. The ozone monitor will be installed at different locations in the plant room

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03 BATCH COADING MACHINE WITH CONVEYOR

The Coading machine will be based on Ink Jet Printing .The line of printing will be 3 Nos. with a speed of 300 ft/min . The machine should be suitable for linear bar coading. The machine should be complete with conveyor stand control panel with LCD display. The final specification will be decided with the approval of Project Authority.

04 COOLING TOWER WITH WATER PUMP CAPACITY 100 TR

The Cooling Tower should be made of FRP and should be complete with

Body and bottom basin made of FRP

Fills of plastic

Exhaust Fan of required size

Water supply centrifugal pump 5 HP – 2 Nos.

GI Pipe & Fittings from cooling tower to the Header & Water Pumps

Note : - (Colling tower of suitable capacity wherever required should be consider in the scope of supply)

5. METAL DETECTOR

The Metal Detector will be required to detect any metal particles going with the packed Ice Cream. The Cups/Cones/Bulk Pack will be put on the conveyor of the machines and its will detect if any pack is containing metal piece in its. The machine should be complete with

SS Stand Conveyor with Food grade belt & Driving arrangement The metal detecting mechanism with display board. (The Metal deducting system should be in scope of supply)

6. CRATE WASHING TROUGH CAPACITY 1000 LTRS The crate washing trough will be made of 3mm thick Mild Steel Sheet. The washing trough will be supported on four MS legs made of 65 mm dia MS Pipe. The trough should be provided with drain of 25 mm with valve. (Crate washing through should be considered in scope of supply)

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7. Over head s.s balance tank with float, spray balls to ensure proper cip of tank , support arrangement etc. To ensure proper flow of liquid by gravity for chhach packing machine

8. ELECTRICAL

The supply of electrical panels and Cables shall be as detailed under the head complete electrical work . The complete HT / LT, Electrical panel i.e power control panel, motor control panel, mimic panel etc. where ever required for to control of motors within the section need to be provided as per site requirement.

There shall the one power control panel to control the electrical supplier of entire plant. Accordingly motor control panel i.e Refrigeration panel, Process panel, Boiler Panel, CIP Panel, External lighting, internal lighting and mimic panel/ motor control panel for ice cream section , flavored milk section, curd section, paneer section, shrikhand making section need to be considered in the scope of the supply

The electrical supply of the plant will be controlled as detailed below. All the cabling to connect 11 KVA HT to metering to HT switch to transformer to PCC power control panel to motor control panel to individual motors, earthings end connection , cable trays are with in the supply under electrical.

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Technical Specifications of pre-fabricated hardening room for ice cream

The Ice cream hardening chamber is to be Supplied, installed and commissioned for 5000 ltr capacity. Ice cream hardening chamber : The size of the Ice cream hardening chamber should be suitable to store 5000 ltr of packed ice creams and same packs are to be kept in plastic crates for difference of - 5 degree C to -30 degree C load. The size of the Ice cream hardening chamber would be as under:-

Ice cream hardening chamber Capacity

Size (In side)

5000 Ltrs 3.10 m x 4.4 m x 3.5 m

Functional requirement:- Ice cream hardening chamber at – 30 degree C :- It is desired to construct Ice cream hardening chamber fabricated out of pre-fabricated PUF panels to store packed ice cream and same packs are to be kept in plastic crates. The cooling shall be required from - 5 degree C to - 30 degree C in 12 hours. Design Parameter:- This Ice cream hardening chamber is to be designed to store packed

ice cream and same packs are to be kept in plastic crates at - 30 degree C. The cooling shall be required from -5 degree C to - 30 degree C in 12 hours to freeze batch of 2000 ltrs. The daily loading of the Ice cream shall be 4000 ltrs at -5 degree C in Ice cream hardening chamber in two batches. The Ice cream hardening chamber insulated floor is to be designed with Kota stone flooring to stock the product up to maximum possible height. The loading time will be maximum 1 hours. Scope of work:- This is a turnkey job. It includes design, supply erection and

commissioning of complete Ice cream hardening chamber. The scope of work is:-

1. Supply & installation of pre-fabricated PUF Panels for construction of Ice cream hardening chamber. The panel should be fabricated from 0.5mm thick pre-coated GI sheet outer & SS-304 inner, puff thickness 150mm.

2. Supply of Kota stone and fixing on PUF slabs for flooring. The floor should be designed to withstand heavy duty work of routine dairy plant including movement of loaded trolleys etc. Minimum size of this Kota stone slab i.e. 2100Sq.cm. to 5000Sq.cm. and thickness 25mm to 30mm.

3. Supply and installation of 1 No. door of PUF panel size 0.965 Mtr. widths, 1.93 Mtr. high in Ice cream hardening chamber.

4. Supply and installation of suitable numbers of Freon – R-404a refrigeration machines with this Ice cream hardening chamber completely independent. The unit should be split type having condenser to be located outside. The refrigerant used should be Freon – R-404a.

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5. The refrigeration plant should have complete auto operation. No attendant should be required for the same.

6. All safety requirements are to be incorporated. 7. Ambient temperature for design is +45 degree C. 8. Product temperatures are as mentioned above. 9. The salient features of PUF Panel required are :-

(i) Foamed in P.V.C. bubble, Gasket in all panels for air tight joints.

(ii) Cam locking system.

(iii) Wall & ceiling insulation 150mm with 0.5mm internal SS-304a and external

PPGI of 0.5mm sheet with 40Kg.+-2 density Kg. per cum.

(iv) Cam lift imported hinges.

(v) Door closers.

(vi) Long life door lock and hinges.

(vii) Vapour proof light fittings.

(viii) Radiused walls and floor to impede bacterial growth.

(ix) View Ports.

(x) Kick plates – Both side

10. Suitable lighting for Ice cream hardening chamber. 11. Accessories required for this room:-

(i) Electronic temperature indicator.

(ii) Switch light.

(iii) Door closer

(iv) Vapour proof light.

(v) Glass view port 12” x 12”

(vi) Kick Plate both side (internal SS-304a and external GI)

12. One No. strip curtain with 50% overlap to be provided at the door of Ice cream

hardening chamber.

13. Alarm for Ice cream hardening chamber as per legal requirement is to be supplied

and installed.

14. Complete installation and commissioning of the Ice cream hardening chamber is

included.

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15. The other technical details with regard to Ice cream hardening chamber and

cooling unit to be supplied are given in the attached sheet.

Following technical details in respect of Pre-fabricated Ice cream hardening chamber Cap. 5000 ltr are to be confirmed by this tenderer:-

S. No.

Description of Items Yes / No

1. Prefabricated PUF Panels to prepare a room of external size of 3.10 m x 4.4 m x 3.5 m.

2. Ice cream hardening chamber temperature -30 Deg. Celcius

3. Wall & Ceiling insulation 150mm with 0.5mm internal SS-304a and external PPGI of 0.5mm sheet with 40Kg.+-2 density Kg. per cum.

4 Pre-fabricated PUF slab of 150mm with tar felt & bitumen for floor with top layer of Kota stone.

5 Supply of 1 No. flush type Door with strip heater of 150mm PUF panel size 0.965 Mtr. widths, 1.93 Mtr. high in Ice cream hardening chamber with 0.5mm sheet thickness. Internal SS-304a and external GI finish.

6 Heat Load: Please indicate the Heat Load in kW, minimum Refrigeration Capacity of 9 kW x 2 = 18 KW @ -35 deg. C evaporating and +54 deg. C Condensing temperature required. Double stage Air cooled condensing unit with semi hermetic Compressor. Condensing unit make Blue Star / Carrier / Voltas/Ice maker. Quantity 2 Nos. Refrigerant R-404a, for total 18kW capacity.

7 Evaporator unit matching with condensing unit complete with coil section and suitable Air defrosting arrangement make Blue Star / Star Coolers / Carrier/ Ice maker/voltas. No. of Fans 2; Min. fan Dia.: 600 mm; Min. Air Flow: 26000 CMH Quantity 2 Nos. Refrigerant R-404a, of total 18kW capacity.

8 (Catalogue of machines to be provided as supporting document otherwise bidder will be disqualified)

9 Split Type Units

10 Refrigeration units are automatic without any operator

11 Safety equipment’s are incorporated HP/LP cut out & Thermostat controlled unit. Safety release lever to open the Ice cream

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hardening chamber from inside in case some person is locked inside the Ice cream hardening chamber.

12 Design at ambient temperature of 45 Deg. C

13 Cam Lift imported hinges for automatic closure of door without any manual push.

14 Door closure with positive sealing

15 Long life door lock and handle

16 Digital Thermometer

17 Radiused wall to impede bacterial growth

18 Kick Plates both side.

19 Vapor proof Light 2 nos.

20 PVC Strip curtains 1 no. with 50% over lapping

21 Safety alarm

22 Refrigerant piping with copper pipes, Drain piping and Suction Line Insulation. Maximum of 10 m for Suction line. Maximum of 10 m for Liquid line with first ref. Charge. Quantity as per no. of machines

23 Refrigerant controls that includes a) Thermostatic expansion valve. b) Liquid line and filter drier c) HP/LP switches d) Protection by thermostats Make Danfoss / Equivalent (Purchaser to approve) Quantity as per no. of machines

24 Safety alarm for the room.

25 Three phase voltage stabilizer, voltage range 352 to 480 Volts.

Note :- The tenderer is required to submit following information essentially with the tender :-

1. Heat load calculation. 2. The make and models offered along with design for compressor unit, condensing unit,

evaporator unit and other items included in offer. 3. The detailed technical specifications and make of insulated PUF Panels to be used. 4. All the technical documents should be provided in form of catalogue. 5. Equivalent make subjected to approval of purchaser (i.e. RCDF).

Name of the Firm &

Signature of the representative in confirmation of the above.

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Technical Specifications of pre-fabricated cold storage for Storage ice cream

The Ice cream cold store is to be Supply, installed and commissioned for 5000 ltr capacity. Ice cream cold store: The size of the Ice cream cold store should be suitable to store

5000 ltr of packed ice creams and same packs are to be kept in plastic crates for difference of - 30 degree C to -25 degree C load. The size of the Ice cream cold store would be as under:-

Ice cream cold store Capacity

Size (In side)

5000 Ltrs 3.10 m x 4.4 m x 3.5 m

Functional requirement:- Ice cream cold store at – 25 degree C :- It is desired to

construct Ice cream cold store fabricated out of pre-fabricated PUF panels to store packed ice cream and same packs are to be kept in plastic crates. The ice cream from hardening chamber at – -30 deg. C shall be shifted to ice cream cold store to maintain the stored ice-cream temperature at -25 degree C. The ice cream cold store shall be used to store the ice cream at – -25 degree continuously. The room shall be complete with PUF doors and locking arrangements. Design Parameter:- This Ice cream cold store is to be designed to store packed ice cream

shifted from ice-cream hardening chamber at -30 degree C and the ice cream cold store shall be used to store the ice cream at – 25 degree continuously. The cooling shall be required to maintain the temperature of ice cream at -25 degree C and quantity of ice cream to freeze batch of i.e 5000 to 7000 Ltrs. The daily loading of the Ice cream shall be 4000 ltrs at -30 degree C in Ice cream cold store. The Ice cream cold store floor is to be designed with Kota stone flooring to stock the product upto maximum possible height. The loading time will be maximum 1 hours. Scope of work:- This is a turn key job. It includes design, supply erection and

commissioning of complete Ice cream cold store. The scope of work is :-

1. Supply & installation of pre-fabricated PUF Panels for construction of Ice cream cold store. The panel should be fabricated from 0.5mm thick pre-coated GI sheet outer & SS-304 inner, puff thickness 60mm.


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3. Supply and installation of 1 No. door of PUF panel size 0.965 Mtr. widths, 1.93 Mtr. high in Ice cream cold store.

4. Supply and installation of suitable numbers of Freon – R-404a refrigeration machines with this Ice cream cold store completely independent and 100% stand by unit suitable to maintain the required temperature. The unit

should be split type having condenser to be located outside. The refrigerant used should be Freon – R-404a.


6. All safety requirements are to be incorporated. 7. Ambient temperature for design is 45 degree C. 8. Product temperatures are as mentioned above. 9. The salient features of PUF Panel required are :-

(i) Foamed in P.V.C. bubble, Gasket in all panels for air tight joints. (ii) Cam locking system. (iii) Wall & ceiling insulation 60mm with 0.5mm internal SS-304a and external

PPGI of 0.5mm sheet with 40Kg.+-2 density Kg. per cum. (iv) Cam lift imported hinges. (v) Door closers. (vi) Long life door lock and hinges. (vii) Vapour proof light fittings. (viii) Radiused walls and floor to impede bacterial growth. (ix) View Ports. (x) Kick plates – Both side

10. Suitable lighting for cold store room. 11. Accessories required for this room:-

(i) Electronic temperature indicator. (ii) Switch light. (iii) Door closer (iv) Vapour proof light. (v) Glass view port 12” x 12” (vi) Kick Plate both side (internal SS-304a and external GI)

12. One No. strip curtain with 50% overlap to be provided at the door of Ice cold

store.

13. Alarm for Ice cream hardening chamber as per legal requirement is to be supplied

and installed.

14. Complete installation and commissioning of the Ice cream cold store is included.

15. The other technical details with regard to Ice cream cold store and cooling unit to

be supplied are given in the attached sheet.

Following technical details in respect of Pre-fabricated Ice cream cold store Cap. 5000 ltr are to be confirmed by this tenderer:-

191



S. No.


1. Prefabricated PUF Panels to prepare a room of external size of 3.10 m x 4.4 m x 3.5 m.

2. Ice cream cold store temperature - 25 Deg. Celcius

3. Wall & ceiling insulation 120mm with 0.5mm internal SS-304a and external PPGI of 0.5mm sheet with 40Kg.+-2 density Kg. per cum.


5 Supply of 1 No. flush type Door with strip heater of PUF panel size 0.965 Mtr. widths, 1.93 Mtr. high in Ice cream hardening chamber with 0.5mm sheet thickness. Internal SS-304a and external GI finish.

6 Heat Load: Please indicate the Heat Load in kW, minimum Refrigeration Capacity of 2.09 kW @ -30 deg. C evaporating and +54 deg. C Condensing temperature required. Single Air cooled condensing unit with Hermetic Compressor. Condensing unit make Blue Star / Carrier / Voltas/Ice maker. Quantity 2 Nos. (1 W + 1 S). Refrigerant R-404a.

7 Evaporator unit matching with condensing unit complete with coil section and suitable Air defrosting arrangement make Blue Star / Star Coolers / Carrier/ Ice maker/voltas. No. of Fans 4; Min. fan Dia.: 300 mm; Min. Air Flow: 5233 CMH at 25 pascal static pressure. Quantity 2 Nos. (1 W + 1 S). Refrigerant R-404a.


9 Split Type Units with 100% stand by


11 Safety equipment’s are incorporated HP/LP cut out & Thermostat controlled unit. Safety release lever to open the Ice cream cold

store from inside in case some person is locked inside the Ice cream hardening chamber.


13 Cam Lift imported hinges for automatic closure of door with out any manual push.




192







21 Safety alarm


23 Refrigerant controls that includes e) Thermostatic expansion valve. f) Liquid line and filter drier g) HP/LP switches h) Protection by thermostats Make Danfoss / Equivalent (Purchaser to approve) Quantity as per no. of machines




1. Heat load calculation.

2. The make and models offered along with design for compressor unit, condensing unit, evaporator unit and other items included in offer.

3. The detailed technical specifications and make of insulated PUF Panels to be used.

4. All the technical documents should be provided in form of catalogue.

5. Equivalent make subjected to approval of purchaser (i.e. RCDF).

Name of the Firm & Signature of the representative

in confirmation of the above.

193



Technical Specifications of pre-fabricated Cold room for milk Storage

The Cold Store is to be delivered, installed and commissioned for 25000 ltr capacity. Cold Store : The size of the Cold Store should be suitable to store 25000 ltr milk in

pouches kept in plastic crates for difference of 10 degree C to 4 degree C load. The size of the Cold Store would be as under:-

Cold Room Capacity Size (In side)

25000 Ltrs 5.2 x 6.7 x 3.5 Meter

Functional requirement:- Cold Store at + 4 degree C :- It is desired to construct Cold Store fabricated out of pre-fabricated PUF panels to 25000 ltr milk in pouches kept in plastic crates. The cooling shall be required from 10 degree C to 4 degree C in 6 hours. The room shall be complete with PUF doors and locking arrangements. Design Parameter:- This Cold Store is to be designed to store milk in pouches in plastic

crates at 4 degree C. The cooling shall be required from 10 degree C to 4 degree C in 6 hours. The daily loading of the Cold Store shall be 25000 ltr milk of 10 C. in this Cold Store. The Cold Store floor is to be designed with Kota stone flooring to stock the product upto maximum possible height. The loading time will be maximum 1 hours. Scope of work:- This is a turn key job. It includes design, supply erection and commissioning of complete cold store room. The scope of work is :-

1. Supply & installation of pre-fabricated PUF Panels for construction of cold store. The panel should be fabricated from 0.5mm thick pre-coated GI sheet outer & SS-304 inner, puff thickness 60mm.


3. Supply and installation of 1 No. door of PUF panel size 0.965 Mtr. widths, 1.93 Mtr. high in cold store room.

4. Supply and installation of suitable numbers of Freon – R-404a refrigeration machines with this cold store completely independent and 100% stand by unit suitable to maintain the required temperature. The unit should be split type

having condenser to be located outside. The refrigerant used should be Freon – R-404a.


194









(v) Door closers.




(ix) View Ports.




(ii) Switch light.

(iii) Door closer




12. One No. strip curtain with 50% overlap to be provided at the door of cold store.

13. Alarm for cold store room as per legal requirement is to be supplied and installed.

14. Complete installation and commissioning of the cold store room is included.

15. The other technical details with regard to Cold Store Room and cooling unit to be

supplied are given in the attached sheet.

195



Following technical details in respect of Pre-fabricated Cold Store Cap. 25000 ltr milk are to be confirmed by this tenderer:-

S. No.


1. Prefabricated PUF Panels to prepare a room of external size of 5.2 x 6.7 x 3.5 Meters.

2. Cold Room temperature + 2 Deg. Celcius



5 Supply of 1 No. flush type Door without strip heater of PUF panel size 0.965 Mtr. widths, 1.93 Mtr. high in cold store room with 0.5mm sheet thickness. Internal SS-304a and external GI finish.

6 Heat Load: Please indicate the Heat Load in kW, minimum Refrigeration Capacity of 30 kW @ -3 deg. C evaporating and +54 deg. C Condensing temperature required. Single Air cooled condensing unit with Scroll Compressor. Condensing unit make Blue Star / Carrier / Voltas/ Ice maker. Quantity 3 Nos. (2 W + 1 S). Refrigerant R-404a.

7 Evaporator unit matching with condensing unit complete with coil section and suitable Air defrosting arrangement make Blue Star / Star Coolers / Carrier/ Ice maker/voltas. No. of Fans 3; Min. fan Dia.: 450 mm; Min. Air Flow: 15500 CMH Quantity 3 Nos. (2 W + 1 S). Refrigerant R-404a.




11 Safety equipment’s are incorporated HP/LP cut out & Thermostat controlled unit. Safety release lever to open the cold room from

inside in case some person is locked inside the cold room.





196








21 Safety alarm


23 Refrigerant controls that includes i) Thermostatic expansion valve. j) Liquid line and filter drier k) HP/LP switches l) Protection by thermostats Make Danfoss / Equivalent (Purchaser to approve) Quantity as per no. of machines




(1) Heat load calculation.

(2) The make and models offered along with design for compressor unit, condensing unit, evaporator unit and other items included in offer.

(3) The detailed technical specifications and make of insulated PUF Panels to be used.

(4) All the technical documents should be provided in form of catalogue.

(5) Equivalent make subjected to approval of purchaser (i.e. RCDF).



197



Technical Specifications of pre-fabricated Cold room for Curd Incubation & Curd Blast and Storage

The Cold Store is to be delivered, installed and commissioned for 1500 Kg capacity. Cold Store : The size of the Cold Store should be suitable to store 1500 Kg Curd in Cups &

Pouches kept in plastic crates for difference of 42 degree C to 10 degree C load. The size of the Cold Store would be as under:-

Cold Room Capacity Size (In side)

1500 Kg 4.0 X 3.0 X 3.5 Meter

Functional requirement:- Cold Store at + 2 degree C :- It is desired to construct Cold

Store fabricated out of pre-fabricated PUF panels to 1500 Kg Curd in Cups & Pouches kept in plastic crates. The cooling shall be required from 42 degree C to 10 degree C in 4 hours and then to 2 Deg. C. The room shall be complete with PUF doors and locking arrangements. Design Parameter:- This Cold Store is to be designed to store Curd in Cups & Pouches in plastic crates at 2 degree C. The cooling shall be required from 42 degree C to 10 degree C in 4 hours and then to 2 Deg. C. The daily loading of the Cold Store shall be 1500 Kg Curd of 42 C. in this Cold Store. The Cold Store floor is to be designed with Kota stone flooring to stock the product upto maximum possible height. The loading time will be maximum 1 hours. Scope of work:- This is a turn key job. It includes design, supply erection and

commissioning of complete cold store room. The scope of work is :-




19. Supply and installation of suitable numbers of Freon – R-404a refrigeration machines with this cold store completely independent and 100% stand by unit suitable to maintain the required temperature. The unit should be split type

having condenser to be located outside. The refrigerant used should be Freon – R-404a.


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(v) Door closers.




(ix) View Ports.




(ii) Switch light.

(iii) Door closer









Following technical details in respect of Pre-fabricated Cold Store Cap. 1500 Kg curd are to be confirmed by this tenderer:-

199



S. No.


1. Prefabricated PUF Panels to prepare a room of external size of 4.0 x 3.0 x 3.5 Meters.

2. Cold Room temperature + 2 Deg. Celcius




6 Heater of 8kW for curd incubation of milk to increase the temp. to 42 Deg. C

7 Heat Load: Please indicate the Heat Load in kW, minimum Refrigeration Capacity of 13 kW @ -5 deg. C evaporating and +55 deg. C Condensing temperature required. Single Air cooled condensing unit with Scroll Compressor. Condensing unit make Blue Star / Carrier / Voltas. Quantity 2 Nos. (1 W + 1 S). Refrigerant R-404a.

8 Evaporator unit matching with condensing unit complete with coil section and suitable Air defrosting arrangement make Blue Star / Star Coolers / Carrier. No. of Fans 3; Min. fan Dia.: 450 mm; Min. Air Flow: 15500 CMH Quantity 2 Nos. (1 W + 1 S). Refrigerant R-404a.



11 Safety equipment’s are incorporated HP/LP cut out & Thermostat controlled unit. Safety release lever to open the cold room from inside

in case some person is locked inside the cold room.










21 Safety alarm

22 Refrigerant piping with copper pipes, Drain piping and Suction Line Insulation. Maximum of 10 m for Suction line.

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Maximum of 10 m for Liquid line with first ref. Charge. Quantity 2 Lot. (1 W + 1 S)

23 Refrigerant controls that includes m) Thermostatic expansion valve. n) Liquid line and filter drier o) HP/LP switches p) Protection by thermostats Make Danfoss / Equivalent (Purchaser to approve) Quantity 2 Lot (1 W + 1 S).





2. The make and models offered along with design for compressor unit, condensing unit, evaporator unit and other items included in offer.





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TECHNICAL SPECIFICATION OF AIR LOCK ROOM.

The Dispatch air lock room size shall be 6.7 m x 2.10 m + 6.23 x 2.10 m. The total Integrated Pre fabricated system i.e Pre Fab Ice Cream (ballast) Hardening room -30 degree C Size 3.10 m x 4.4 m x 3.5 m , Pre Fab Ice Cream Cold Storage -25degree C , Size 3.10 m x 4.4 m x 3.5 m and Pre Fab cold Store for Milk and Milk Product-4 degree C Size 5.2 m x 6.7 m x 3.5 m shall be integrated and interlink through air lock room. The Air Lock room shall be equipped air conditioning unit along with Two doors sliding/hinged of 120 MM Thick puf Panel and suitable air curtain for doors . The total integrated pre fab system should be equipped with temperature indicator cum controller and defrosting system/ arrangement for indoor units should be considered.

Cold Room Layout Size (In side)

Refer the attached layout (L Shape)

6.7 m x 2.10 m x 3.5m + 6.23 x 2.10 m. x 3.5m

Functional requirement:- Air lock room at + 15-20 degree C. The room shall be

complete with PUF doors and locking arrangements. Scope of work:- This is a turn key job. It includes design, supply erection and

commissioning of complete cold store room. The scope of work is :-




4. Supply and installation of suitable numbers of Freon – R-404a refrigeration machines with this cold store completely independent. The unit should be split type having condenser to be located outside. The refrigerant used should be Freon – R-404a.


6. All safety requirements are to be incorporated. 7. Ambient temperature for design is 45 degree C. 8. The salient features of PUF Panel required are :-



202






(v) Door closers.




(ix) View Ports.




(ii) Switch light.

(iii) Door closer









203



Following technical details in respect of Pre-fabricated air locked room are to be confirmed by this tenderer:-

S. No.


1. Prefabricated PUF Panels to prepare a room of external size of 6.7 m x 2.10 m x 3.5m + 6.23 x 2.10 m. x 3.5m (Refer the layout)

2. Cold Room temperature + 15- 20 Deg. Celcius




6 Heat Load: Please indicate the Heat Load in kW, minimum Refrigeration Capacity of 5.7 kW @ +10 deg. C evaporating and +54 deg. C Condensing temperature required. Single Air cooled condensing unit with Scroll Compressor. Condensing unit make Blue Star / Carrier / Voltas/ Ice maker. Quantity 2 Nos. (2 W). Refrigerant R-404a.

7 Evaporator unit matching with condensing unit complete with coil section and suitable Air defrosting arrangement make Blue Star / Star Coolers / Carrier/ Ice Maker/voltas. No. of Fans 2; Min. fan Dia.: 350 mm; Min. Air Flow: 4500 CMH Quantity 2 Nos. (2 W). Refrigerant R-404a.


9 Split Type Units


11 Safety equipment’s are incorporated HP/LP cut out & Thermostat controlled unit. Safety release lever to open the cold room from

inside in case some person is locked inside the cold room.




204









21 Safety alarm

22 Refrigerant piping with copper pipes, Drain piping and Suction Line Insulation. Maximum of 10 m for Suction line. Maximum of 10 m for Liquid line with first ref. Charge. Quantity 2 Lot.

23 Refrigerant controls that includes q) Thermostatic expansion valve. r) Liquid line and filter drier s) HP/LP switches t) Protection by thermostats Make Danfoss / Equivalent (Purchaser to approve) Quantity 2 Lot





2. The make and models offered along with design for compressor unit, condensing unit,

evaporator unit and other items included in offer.


4. All the technical documents should be provided in form of catalogue.




205



TECHNICAL SPECIFICATION FOR STERILISED FLAVOURED MILK

A MILK PREPARATION SECTION 1. MIX/ MILK STORAGE TANK CAPACITY -1000L

1.0 FUNCITIONAL REQUIREMENTS :


2.0 DESIGN REQUIREMENTS 2.1 Capacity : 1000 L

The volume of the tank should be such that after filling it up to the rated capacity, the level would be 100 mm below the line where cylindrical shell joints the conical top.



2.8 Slope : Sufficient slope should be provided towards the inlet – cum out let along the

periphery of the reverse conical bottom. 2.9 Metal contact : The only metal to metal contact between the inner and outer shells

should be at the places where fittings for the tank are provided. 2.10 Finish : All welding joints are to the ground smoothly. All stainless steel surfaces are

to be polished to 150 grits. 2.11 Joint – Curvatures: The radii of all welded and permanent attachment joints should

be at least 6 mm. Where the conical top and reverse conical bottom join the cylindrical shell the radii should not be less than 25 mm.

5.0 SCOPE OF SUPPLY : 3.1 Inner cylindrical Body : The inner shell, conical top and reverse conical bottom

should be fabricated from 2 mm thick stainless steel sheet for 1000 L capacity conforming to AISI 304.

3.6 Intermediate cylindrical Body : The intermediate shell and flat bottom should be

fabricated from 2 mm thick stainless steel sheet conforming to AISI 304. 3.7 Outer cylindrical Body : The outer shell, conical top and flat bottom should be

fabricated from 2 mm thick stainless steel sheet conforming to AISI 304. 3.8 Insulation : The entire intermediate shell, flat bottom and inner conical top shall be

insulated in three layers as follows:

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3.9 First layer: 25mm thick resin bonded crown 150 fiber glass compressed to 10mm.

Second layer: 50mm thick expanded polystyrene. Third layer: 50mm thick expanded polystyrene.

3.10 Accessories : 3.6.1 Inlet-cum-outlet: 38mm dia cup type inlet cum outlet with two way plug type

stainless steel (AISI 304) flanged valve ending in complete stainless steel union. It should be provided at a height of 450 mm from the finished floor level – 1 No.

3.6.2 Air vent: Stainless steel (AISI 304) 150mm air vent to prevent formation of partial

vacuum during CIP and pressure during filling – 1 No. 3.6.3 Man way : Stainless steel (AISI 304) man way of 450mm diameter and located at

the conical top – of the tank and provided with air tight hinged insulated stainless steel (AISI 304) door with tightening and locking device. The cover should be provided with stainless steel (AISI 304) anti-splash guard stainless steel (AISI 304) cleats should be provided near the man way for fixing and hanging rope ladder :- 1 No.

3.6.4 Sand Blasted level marks: It should be calibrated at 200 L intervals and provided

on the inner shell at opposite side of the sight glass. The level mark should be dark enough so it may be clearly visible.

3.6.5 Sight Glass: Stainless steel (AISI 304) sight glass assembly should be provided with

toughened glass. It should be provided in such a way that one can easily read from the lowest level up to the maximum level mark. Stainless steel lamp shade for mounting 24 V and 100 watt bulb. The lamp holder should be made from brass – 1 No.

3.6.6 Agitator : Vertical heavy duty sweeping type Stainless steel (AISI 304) agitator complete with mountings with geared motor of adequate capacity and should be able to uniformly mix, flavored milk mix/ milk in the tank within 10 minutes. The agitator shaft should be a rod – 1 No.



3.6.8 Spray Ball: Removable Stainless steel (AISI 304) cleaning device located on conical

top at either sides of the agitator drive to provided flooding of liquid over the complete interior surface and agitator during CIP. These should have stainless unions at the outer end connections – 2 No.

207



3.6.9 Drain: Made from Stainless steel (AISI 304) pipe of 38mm dia at the bottom of the

jacket with gun metal valve – 1 No. 3.6.10 U-seal: Made from Stainless steel (AISI 304) pipe 38mm dia at the bottom of the

jacket – 1 No. 3.6.11 Over flow: Made from Stainless steel (AISI 304) pipe 38mm dia at the top of the

jacket – 2 Nos. 3.6.12 Sampling Cock: It should provided on the inlet – cum – outlet and should be in

Stainless steel (AISI 304) construction with sanitary design – 1 No. 3.6.13 Thermowell : 200 mm long Stainless steel (AISI 304) inclined pocket suitable for

mounting probe of digital thermometer. The portion of the thermowell which is in the jacket should be insulated with rock wool or equivalent and totally shrouded so that hot water or chilled water does not come in contact with the insulating material. It should have 10mm BSP male threads and the digital thermometer is also to be provided by the tenderer.

3.6.14 Legs: Conical mild steel legs with Stainless steel (AISI 304) sheet cladding and

stainless steel ball feet provided at the bottom of the tank. The stainless steel ball feet should have provision for height adjustment of 50mm – 4 Nos.

3.6.15 Ladder: Stainless steel (AISI 304) ladder for access to the sight glass and geared

motor assembly of agitator – 1 No. 3.6.16 Lifting lugs: Stainless steel (AISI 304) lifting lugs should be provided at top – 2 Nos. 3.7 Painting: All the M.S. stiffeners used in the construction of the tank should be

painted with two coats of epoxy primer after thorough de-rusting. 6.0 TESTS: The following tests should be conducted by the manufacturer at works.

6.1 Dye penetration test for welding joints. 6.2 Water fill-up test of inner vessel for water tightness.

Note : General arrangement of the equipment should be provided the attached

reference drawing. Makes of bought out items are as bellow : Geared motor Elecon. / Radicon (1) Scope of supply also include supervision of Installation & commissioning, water trial of supplied equipment to ensure perfect working of systems at site. (2) Name plate should be provided on equipment define the connection.

208



2. MILK PUMP CAPACITY 1 KLPH

The SS centrifugal milk pump will be directly coupled to a 1 HP/2900 RPM TEFC motor suitable for the operation on 3 phase, 400/440 volts, 50 Hz, AC supply. All the components coming into direct contact with the milk will be fabricated out of stainless steel of AISI 304 quality. The SS parts will be finished to the dairy standards. The motor portion of the pump will be SS shrouded. The shroud will have air circulation holes and cable entry. The pump will be fitted over 3 legs and SS ball feet for vertical adjustment.

3. MILK HEATING TANK CAPACITY 500 LTRS

Design Requirement :

The Heating Tank will be vertical insulated open top tank.

Capacity – The volume of the tank should be such that after filling upto the rated capacity, the level would be 100 mm below the top of shell portion..

Constructional feature : Vertical double walled, insulated and welded construction of

sanitary design. Finish – All welding joints are to be ground smooth. All stainless steel surfaces are to

be polished to 150 grits.

Inner Cylindrical Body – The inner shell and Flat bottom should be fabricatedfrom 2 mm thick stainless steel confirming to AISI 304 respectively.

Outer Cylindrical Body – The outer shell and Flat bottom should be fabricated from 2

mm thk. SS 304 grade.The top lids in two half will be fabricated from 2mm thick SS - 304

Insulation- The intire shell with Flat bottom should be insulated with 100 mm

glasswool insulation.

ACCESSORIES

Outlet – 38 mm dia. Outlet with two way plug type stainless steel flanged valve - 1 No.

No Foam Type inlet at the SS gurder on top of the Tank.

Sand blasted level marks

209



Agitator – It should be in stainless steel ( AISI 304 ) sweeping type construction complete with geared motor of adequate capacity – 1 No.

Spray Ball – 1 No.

Thermowell complete with digital type thermometer will SS stand.

Legs- Conical mild steel legs with stainless steel sheet cladding and stainless steel ball feet should have provision for height adjustment of 50 mm.



5. TUBULAR HEAT EXCHANGER CAPACITY 1 KLPH

The tubular heat exchanger will be vertical shell & Tube in construction made of SS tubes of 19 mm dia, SS team jacket of 5 mm thick , fiber glass insulation and finally 2mmthick SS plate cladding . The THE , should be complete with steam pipe inlet with valve condensate outlet, with steam trape assembly & by pass, milk inlet and outlet. The THE should be mounted on SS Square Pipe Frame.

6. SUGAR SYRUP TANK CAPACITY 100 LTRS Design Requirement :



Constructional feature : Vertical double walled, insulated and welded construction of sanitary design. Finish – All welding joints are to be ground smooth. All stainless steel surfaces are to be polished to 150 grits.

210



Inner Cylindrical Body :-

Inner Cylindrical Body – The inner shell and Flat bottom should be fabricated from 2 mm thick stainless steel confirming to AISI 304 respectively. Outer Cylindrical Body – The outer shell and Flat bottom should be fabricated from 2 mm thk. SS 304 grade.

The top lids in two half will be fabricated from 2mm thick SS - 304

Insulation- The intire shell with Flat bottom should be insulated with 100 mm glasswool insulation.

ACCESSORIES










211



8. INLINE FILTER

The inline filter will be installed the milk pipe line of 38 mm size to screen out foreign matters from milk. It should be in tubular design with a concentric cylindrical filter made of SS screen. The inline strainer should be complete with following :

SS outer cylindrical body made of 2mm thick SS 304 . The dia meter of the cylindrical body should be 100 mm.

The filtering element should be cylindrical element made of SS 304 , 18 screen of 1.5mm pitch. The dia of filtering element should be 71.5 mm.

The inlet & outlet should be at right angle to facilitate cleaning of filter element without disturbing the SS Pipe line , SS Union to be provided on inlet & Outlet.

The inline strainer should be quick opening type and should be made of sanitary design as per dairy standards.



10 MILK HOMOGENIZER CAPACITY 500 LPH

The milk homogenizer should be made of SS 304 and designed to homogenize milk at 210 Kg/cm2 pressure at 1st stage and 50 Kg / cm2 at second stage. Homogenizer should be complete with following accessories/ design features.

The body frame will be completely cladded with SS Sheet.

The Homogenization valve at both the stages will be made of sterilite

material.

Powder Transmission system including Electric Motor of suitable capacity v belt & pullies , gear box, lubrication system, 3 No . plunger & Homogenizer head.

Cooling System for Gear Box Oil , and water spray on plungers.

212



Pressure gauge sanitary type for both the Homogenization stages. The manual pressure adjustment system for homogenization pressure at both the stages.

11. MILK STORAGE TANK CAPACITY 500 Ltr.

Design Requirement : The Heating Tank will be vertical insulated open top tank.


Constructional feature : Vertical double walled, insulated and welded construction of sanitary design. Finish – All welding joints are to be ground smooth. All stainless steel surfaces are to be polished to 150 grits.

Inner Cylindrical Body :-


Outer Cylindrical Body – The outer shell and Flat bottom should be fabricated from 2 mm thk. SS 304 grade.

The top lids in two half will be fabricated from 2mm thick SS - 304

Insulation- The intire shell with Flat bottom should be insulated with 100 mm glasswool insulation.

ACCESSORIES

Outlet – 38 mm dia. Outlet with two way plug type stainless steel flanged

valve - 1 No.




213






12. Milk Chiller 80-35-4 with Cooling Tower: The Milk chiller is required to chill the flovered milk mix coming out of homonizer at 80 Deg. to 35 Deg. by normal water and 35 to 4 Deg. by chilled water. The suitable cooling tower should be consider in the scope. Further the design, plate thickness, gasket etc. should be as per the specification of milk chiller defined earlier capacity 1 KLPH .

B Bottling & Sterilization Section

01. Bottle Rinsing & Filling Machine , Capacity 500 BPH.

The automatic bottling plant will be made out of SS- 304 frame & other parts. The bottling plant will perform the following functions.

PET Bottle loading with the help of in feed SS chain conveyor.

PET Bottle rinsing with the help of water jet.

PET Bottle filling with Flavoured Milk .

PET Bottle capping

Unloading PET Bottle with the help of out feed SS Chain conveyor.

All the above mentioned function will be controlled with the help of PLC variable speed drives.

The Machine should be equipped over head balance tank having arrangement of float to ensure gravity filling of flavored milk to packing machine.

02. Bottle Cap Induction Sealing Machine , Capacity 500 BPH.

The filled & capped bottle will be placed on the conveyor of the machine, the induction sealable wad will be sealed on the top of the bottle with the induction heating .

214



03. Bottle Sterilizer Counter Pressure Retort ( Hot Water ) with steam control valve, capacity 500 to 1000 BPB.

The Counter Pressure Retort will be used for Sterilization of Flavoured Milk in HDPE Bottles of 200 ML capacity and will take care of the deshaping of the container due to pressure difference between the chamber pressure and the container to avoid permanent deformation and damage to the container and the closure. The Report will use the top spray sterilization through uniform, unified roof openings. The Report should be complete with following features Salient Features

Steam and atomizing water make thermal mixing in sterilizer directly, which increases speed of temperature rise and drop.

Few quantity of process water makes quick cycle, and reaches presetting

sterilizing temperature quickly.

Water jets from different angles, steam, air and water mix, make convection and form perfect temperature distribution.

The Retort equips 3 movable temperature sensing probes, which can monitor F

value of HDPF/PET bottle and thermal distribution situation in sterilizer, and know thermal penetration at any time.

Prefect pressure control throughout the production process pressure is constantly adjusted to accommodate the pressure changes inside the product packaging.

Each carriage should be provided with Floor Trolley .

The Floor Trolley is fabricated from Stainless Steel square, tubular sections and is provided with adjustable railing for the Loading Carriage. The trolley is fitted with two fixed and two swiveling type polyurethane castor wheels with brakes. PROCESS MANAGEMENT SYSTEM The Retort should be designed to perform production programs to meet the latest regulatory requirements PROGRAMMABLE LOGIC CONTROLLER

The control system should be provided with a PLC and user-friendly HMI as a front end user interface. The key salient features are as follows: -

215



3 level password protection for process security.

RS 232 port for data communication.

In-built Real Time Clock with date and time function.

Battery back-up for automatic restart in case of power failure.

EEPROM for secure software storage.

F0 calculator for automatic computation of process lethality. SAFETY AND ALARMS

The process management system should be provided with a series of safety and alarm features:

High temperature and pressure.

Sterilization timer stop in case of temperature drop. Sterilization timer reset in case of further temperature drop. Water level low Circulation pump trips If accidental vacuum is created

WATER RECIRCULATION SYSTEM

The re-circulation system is used for heating, cooling and showering the process water on the load to be Sterilized. The circulating loop comprises of the Heat Exchanger, Circulating Pump and Water Shower Manifold. HEAT EXCHANGER

The Retort should be provided with shell and tube type heat exchanger for heating and cooling the process water. The sealing gaskets are of food grade materials. All contact parts of heat exchanger are S.S 304. The secondary side of the heat exchanger has a piping manifold for the heating steam and cooling water. There is also a safety valve for over pressure safety.

SHELL TUBE

WORKING PRESSURE 3.0 KG/CM2 6 KG/CM2

HYDROTEST PRESSURE

4.5 KG/CM2 9 KG/CM2

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CIRCULATING PUMP

For the circulation of the process water a high flow centrifugal pump is provided. The pump is driven by a 3 phase electric motor. WATER SPRINKLING MANIFOLD

At the top of the chamber and along the depth a SS 304 spray manifold is provided. The system ensures a dense and uniform shower over the entire load. Loading carriage is made from Stainless Steel welded to form a supporting structure to hold trays on which the containers are loaded. Shelves are provided for loading which are fabricated from Stainless Steel with adequate holes drilled for circulation of the process water. DETAILED TECHNICAL SPECIFICATIONS

DOOR

The unit is provided with single Tongue& Groove rotary door. The door has swing type opening arrangement. The door is fabricated from SS 304 with mild steel re-enforcement. The door is insulated with mineral wool / resin bonded glass wool insulation. The door sealing is affected with the help of a silicone door gasket. The gasket is pressurized by compressed air and retracted by vacuum. The door is rotated via a pneumatic cylinder. A compound gauge with door status indication is provided. The following door safety feature is provided for maximum operator safety:

Process-lock to prevent opening of the door during the process.

Process will not start unless the door is locked and sealed. INSULATION The Retort chamber is insulated with 50 mm thick mineral wool, which is, held in place by an outer cover of stainless steel. The surface temperature of the machine will be NMT ambient + 25C

217



PROCESS RECORDING – PRINTER

80-column dot matrix data printer for recording – date, time, process parameters, process status, alarms F0 value etc. TEMPERATURE SENSORS

Three RTD Pt100 sensors are provided; one in the heat exchanger, one in the sump and one in the chamber. PRESSURE SENSORS A pressure transmitter is connected to the chamber. This generates a 4-20mA output in a range of –1.0 to 3.0 Bar. The system has a pressure lease count of 0.002 bar. ELECTRICAL SWITCH GEAR

The control cabinet is provided with a main isolator for the three-phase supply and a separate switch for the control supply. All cabling is flexible, PVC cabling routed via PVC channels mounted in the panel. All cabling for temperature and pressure signals is shielded for minimum electro-magnetic interference. Necessary relays, contactors, MCB’s, etc. are also mounted in the control panel. The facia of the control panel is provided with indication LED’s and switches for operation. The service and maintenance area is provided with a lighting fixture and plug and socket. The bidder should give all technical parameter the dimension of the machine, Steam, Electric Consumption. Designed temperature etc.

04. SS WORKING TABLE (2MX1M)


C BOTTLE LEVELLING , PRINTING & PACKANG SECTION

01. BOTTLE DRYING MACHINE

CAPACITY 500 BPH

The SFM Bottles of HDPE/PP will be received from the sterilizer (Report ) in wet condition. The HDPE/PP Bottles will be dried before it is sent for the shrink wrapping of plastic wrapper. The machine will be provided with motorized conveyor. Hop Air spraying mechanism on bottle and other necessary accessories..

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02 SHRINK WRAPPING MACHINE CAPACITY 500 BPH

The Shrink Wrapping Machine will be used for wrapping plastic level on the individual bottles. The plastic level will be put on the bottles and the bottles will be placed manually on the conveyor. The bottles will pass through the heating chamber where the level will shrink wrapped on the bottles. The machine will be provided with the following accessories.

Bottle Conveyor of SS – 304.

The Electric Drive of the Conveyor.

Stand for the Conveyor.

Heating Chamber with Electric heater. 03. SHRINK WRAPPING MACHINE FOR TRAY –25- 50 TRAY/HR

The shrink wrapping machine will be used to shrink wrap the 12 Nos. of SFM bottles placed in one paper tray. The tray with 12 bottles will be put on the conveyor of the machine . The plastic shrinkable film will be loaded in the machine. The tray after shrink wrapping will come out of the machine. The machine should be complete with SS Conveyor , Shrink film loading arrangement , shrinking chamber with heaters. SS stand to mount the machine.

04. BOTTLE BATCH PRINTING MACHINE CAPACITY 500 BPH

The batch printing machine will be continuous on line inkjet printer. The leveled bottles will be put on the conveyor . The ink jet printer will print batch no, date and other details on the bottles. The Ink Jet Printer will be complete with variable drive bottle conveyor, Ink Jet printer should be of heavy duty type.

D SERVICE SECTION

01. SS PIPE AND FITTINGS

The SS Pipe and fitting made of SS- 304 grade and suitable for 38mm Dia SS Pipe for interconnection the following items in a compact layout.

Milk Storage Tank Pumps

Heating Tanks Tubular Heat Exchanger.

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Sugar Syrup Tank

Inline Filter Homogenizer Bottle Filling Machine

The fitting should be SMS standards . The OD SS Pipe should be 1.6mm thick .

02. MS/GI PIPE AND FITTINGS

The MS/GI Pipe and fittings will be required to tape different services like steam, raw water , compressed air etc from a distance of about 50 meters from the SFM production section. The design details can be worked out on a compact layout basis.

03. ELECTRIC PANEL, CABLES ETC

The electric panel will be provide with all the electric motor starter as per the individual HP of the electric motors. The panel should be as per the applicable regulation in the state. This should also include the cable , cable tray earthings required for the compact layout of the different machines in the SFM section.

04. PLANT ERECTION AND COMMISSIONING

This will includes the positioning of individual machines as per the approved layout , connecting the machines with SS Piping , MS/GI piping electric connection ,earthings etc. The machining after erection will be commissioning first on water and then on the actual product. The bidder should include the on job training of the plant personnel’s, operators for 15 day on actual production.

220



FERMENTED PRODUCT SECTION

221



CURD

CHHACH AND

LASSI

SECTION

222



TECHNICAL SPECIFICATIONS OF INSULATED VERTICAL MILK STORAGE TANK,

CAPACITY :2000 L




2.1 Capacity : 2000 L

The volume of the tank should be such that after filling it up to the rated capacity, the level

would be 100 mm below the line where cylindrical shell joints the conical top.

2.2 Constructional features : Double walled insulated and welded construction of sanitary

design .

2.3 Slope : 1:15 towards the out let at the bottom of the tank .

2.4 Metal contact : The only metal-to-metal contact between the inner and the outer shells should

be at the places where fittings for the tank are provided . At the places where mild steel

stiffeners are provided, insulated padding should be fixed between the inner stainless steel shell

and stiffeners.

2.5 Finish : All welding joints are to be ground smoothly. All stainless steel surfaces are to be

polished to 150 grits.

2.6 Joint – Curvatures: The radii of all welded and permanent attachment joints should be at

least 6 mm. Where the conical top and flat bottom joint the cylindrical shell, the radii should

not be less than 25 mm.

3.0 SCOPE OF SUPPLY

3.1 Inner cylindrical Body : The inner shell, conical top and flat bottom should be fabricated

from 2.5 mm thick stainless steel sheet conforming to AISI 304.

3.2 Outer cylindrical body : It should be fabricated from 2 mm thick stainless steel sheet

conforming to AISI 304.

3.3 Insulation : The inner stainless steel shell, conical top and flat bottom should be insulated in

three layers as follow:

First layer - 25 mm thick resin bonded crown 150 fiber glass compressed to 10 mm.

Second layer -50 mm thick expanded polystyrene

Third layer -50 mm thick expanded polystyrene

The efficacy of the insulation should be such that temperature rise of the milk at 4 degree C in

the tank should not be more than 1 degree C in 24 hours during summer season.

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3.4 Accessories :

3.4.1 Inlet –cum outlet : 51 mm dia cup type inlet cum outlet with two way plug type stainless steel

(AISI 304 ) flanged valve ending in complete stainless steel union . It should be provided at a

height of 450 mm from the finished floor level.

3.4.2 Air Vent : Stainless steel (AISI 304 ) 450mm dia air vent to prevent formation of partial

vacuum during CIP and pressure during filling.

3.4.3 Man way : Stainless steel (AISI 304 ) man way of size 550 mm x 405 mm diameter and

located near the outlet valve (centre to centre distance from outlet valve to main hole to be 700

mm.) provided with leak proof hinged insulated stainless steel (AISI 304) door with tightening

and locking device. The cover should be provided with stainless steel (AISI 304 ) anti splash

guard. Stainless steel (AISI 304) cleats should be provided near the man way for fixing and

hanging rope ladder. - 1 no.

3.4.4 Sight glass : Stainless steel (AISI 304 ) sight glass assembly should be provided with

toughened glass. It should be provided in such a way that one can easily read from the lowest

level up to the highest level mark. – 1 no.

3.4.5 Sand Blasted level marks : It should be calibrated at 500 L intervals and provided on the

inner shell at opposite side of the sight glass.

3.4.6 Light Glass ; Stainless steel (AISI 304 ) light glass assembly should be provided with

toughened glass and stainless steel lamp shade for mounting 24 Volt and 100 watt bulb. The

lamp holder should be made of brass. – 1 no.

3.4.7 Agitator : It should be in stainless steel (AISI 304 ) construction complete with geared motor

of adequate capacity and should be able to uniformly agitate and mix milk in the tank within 10

minutes. The agitator shaft should be a rod. – 1 set.

3.4.8 Spray Ball : Removable stainless steel (AISI 304 ) cleaning device located at the apex of the

conical top to provide flooding of liquid over the complete interior surface during CIP. It

should have stainless steel union at the outer end connection. – 1 no.

3.4.9 Sampling cock : This should be provided on the inlet cum outlet and should be in stainless

steel (AISI 304 ) construction with sanitary design. – 1 no.

3.4.10 Thermowell : 300 mm long stainless steel (AISI 304 ) inkling pocket suitable for mounting

stem type dial thermometer. It should be suitably located in the alcove. It should have 21 mm.

BSP male threads (but the thermometer is not with in the scope of supply). – 1 no.

3.4.11 Legs : Conical mild steel legs with stainless steel (AISI 304 ) sheet cladding and stainless

steel ball feet provided at the bottom of the tank . The stainless steel ball feet should be

provided for height adjustment of 50 mm. – 4 nos.

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3.4.12 Ladder : Stainless steel (AISI 304 ) ladder for access to the geared motor assembly of agitator.

– 1 no.

3.4.13 Drain Hole : The outer shell should be provided with one or more drain holes at the lowest

point. Any aperture in the shell should be designed so as to prevent ingress of moisture.

3.4.14 Lifting lugs : Stainless steel (AISI 304 ) lifting lugs should be provided at top. – 3 nos.

3.5 Painting : All the mild steel stiffeners used in the construction of the milk storage tank should

be painted with two coats of epoxy primer after thorough de- rusting .

4.0 TESTS:

The following rests should be conducted by the manufacturer at its works.

4.1 Dye penetration test for welding joints.

4.2 Water fill –up test for inner vessel for water tightness,

Note : Makes of bought out items are as below:

Geared motor ELECON / RADICON

225



TECHANICAL SPECIFICATION FOR MULTI PRODUCT MILK PASTEURIZER – CAP. 1000 LPH

Technical specifications of the skid mounted multi product milk pasteurizer for curd milk, Paneer milk capacity 1,000 LPH alongwith accessories suitable for heating the milk by using steam as heating media: FUNCTIONAL REQUIREMENT :

The Multi product milk pasteurizer is required to pasteurize the curd milk, paneer milk the pasteuriser should be able to heat the product as per following Multi product pasteurisation module Multy Product Pasteurization Module 1. Curd Milk

Temperature Programme : 4 – 52 – 65 – 90 – 42/4 Capacity : 1000 LPH, with 6 minutes holding 2. Paneer Milk

Temperature Programme : 4 – 52 – 90 Capacity : 1000 LPH, with no holding Type : Plate Heat Exchanger MOC of plates : SS 316 Gasket : Glue free (Nitrile) Utilities: Hot water @ 2000 LPH (93 deg C) Generated by steam

at 2 bar. Raw milk temperature : 4 C Chilled Water flow rate : 3 times of milk flow rate 2. FINISH

All weld joints should be ground smooth. All stainless steel surfaces are to be polished to 150 grits.

3.0 SCOPE OF SUPPLY:

3.5 HEAT EXCHANGER: 3.6 PLATE PACK:

The PHE plates offered should be of 0.6 mm thickness having MOC of SS-316 with adhesive free NBR gaskets & should be of sanitary design. All contact surfaces of the plates should be easily accessible or readily removable for cleaning & inspection.

226



3.7 PLATE GASKETS:

The sealing gaskets of the plates should be designed in such a way to ensure the complete sealing & prevent any cross leakage in-between the plates the gasket offered should be adhesive free. The MOC of gaskets should be of NBR & suitable for maximum working temperature of 112 degree c. The gaskets offered should also be suitable to withstand 2% caustic soda & 2% nitric acid solution at 60 to 80 c during CIP cleaning. It shall be snap in or lock in type and does not require any glue i.e. glue free. Gasket MOC shall be of good quality Nitrile.

3.8 HOLDING SECTION:

It shall be designed for continuous holding of the product i.e. curd milk for at least the minimum specified holding time of 6 minutes at the pasteurisation temperature of 90 degc. The holding shall be spiral type housed in SS 304 tank (tank shall be dumped with insulated material). In case of Paneer milk, milk should be automatically bye pass the holding section and re-generate section to ensure Paneer milk outlet at 90 degree c after heating.

3.5 SUPPORTING FRAME:

The supporting frame for the PHE should be of self supporting design. The frame & pressure plate & fixed plate should be made of mild steel clad in stainless steel-304. PHE should be provided with multibolt tightening design to exert uniform pressure on all the parts of heat transfer plates to prevent any leakages from PHE and damage to plates. The design of frame and tightening device should be such so as to prevent any deflection under pressure difference of minimum 4 kg. / Sq.cm.

4. ACCESSORIES OF THE MILK PASTEURISER 4.1 INLET / OUTLET:

The inlets & outlets in each section of the heat exchanger for products as well as service liquids should be provided with complete stainless steel (AISI 304 unions).

227



4.10 THERMOWELLS FOR GLASS THERMOMETERS:

SS Thermo-well alongwith guard should be provided at following sections (glass thermometers are not covered in the scope of supply)

Milk inlet Outlet of holding section Chilled water in Chilled pasteurised milk outlet To separation outlet point Chilled water outlet Hot water inlet Hot water outlet Heating section inlet

4.11 THERMOWELL FOR RTD:

SS Thermo-well of suitable sizes for resistance temperature detector should be provided for sensing the temperature of final chilled past. Milk, pasteurized hot milk after & before holding section. These sensors should also provide signals to the panel to audio visual alarm for under heated milk, and temperature recorder for controlling the milk pasteurization temperature.

4.12 SKID:

The constructional design of skid should be such so as to accommodate PHE, milk pumps, hot water pumps, milk balance tank, line and duplex filter and control penal the MOC of skid should be made of ISMC sections duly claded in SS-304.

4.13 PRESSURE GAUGES:

The necessary pressure gauges should be provided to observe the pressure drop in product & service liquid at various points wherever required.

4.14 FLOAT BALANCE TANK:

The 200 litres capacity float balance tank should be fabricated from 2 mm thick SS 304 sheet conforming to AISI 304 that shall be suitable for operation and cleaning of the pasteurization plant. The inlets and outlets shall be provided with complete stainless steel (AISI 304) forged unions and should have flow diversion connection. The tank shall be provided with cover, sanitary type SS (AISI-304) float valve with the milk inlet, cup type outlet, return milk inlet, inlet for water, over flow and adjustable SS ball feet. The float valve shall be designed to give the rated flow rate and withstand an inlet pressure of 3.0 kg/Sq.cm.

228



4.15 MILK FEED PUMP AND BUSTER PUMP:

The stainless steel (AISI 316) feed pump shall be standards. Its capacity shall be adequate to facilitate efficient CIP. The pump shall generate a head of 30 MWC at the rated capacity and shall be provided with flanged motor with hygienic mechanical seal arrangement. The motor shall be 3 phase, 415 V (+/-10%), 50Hz (+/-5%), TEFC, squirrel cage with class “F” insulation with IP 55 protection. The pump and drive should be integrated together. The drive motor shall be fitted with stainless steel SS 304 arrangement for cable connection. The shroud shall also have louvers for air-cooling and suitable arrangement for cable connection. The pump and drive shall be of supported on legs with SS (AISI 304) ball feet with provision for height adjustment of 50 mm.

4.16 Flow Controller (mechanical Type): Flow Controller for Product: Stainless steel flow control device is required to maintain the required flow rate. The flow controller shall be of a sanitary design.

4.17 Heating Device:

Hot water system (Two sets) shall be PHE based and shall have an expansion chamber and other safety devices to take care of the volume of expansion and increased pressure ensuring the complete operational safety. It will be designed as per duty parameters required for pasteurization. The hot water shall be generated in a stand alone PHE (with SS 316 plates and MS painted frame with SS 304 cladding) and provided with SNAP-IN type EPDM gasket to withstand 150 Deg. C. The supporting frame for the plate pack shall be of a self supporting design made of stainless steel (AISI 304) clad mild steel with a manually operated stainless steel (AISI 304) tightening device. The tightening device shall be able to exert uniform pressure on all the parts of heat transfer plates to prevent any leakages from Pasteurizer. The frame and tightening device shall prevent the plates from deflecting under pressure differential of minimum 4 kg/Sq.cm. The system shall be supplied with steam control valve with bye pass assembly, expansion chamber, safety valve, water make up valve and a suitable steam trap. Safety Device: A safety device shall be provided in the hot water side of heating section to avoid damage to the heat exchanger caused by excessive pressure. It shall be of sanitary design. Hot water: Two number of Hot water pump will be supplied which will be used for hot water circulation for heating of milk up to final product temperature i.e. 90 deg C. It shall be vertical multistage type in industrial design in standard construction.

229



Two number of PID Temperature control arrangement for control of pasteurization temperature together with Steam Regulating and control valve is included.

5.0 SS DUPLEX STRAINER

SS Duplex Strainer (Suitable Size) shall be used for pre-filtration of Milk.

6.0 Instrumentation and control panel:

Automatic controls shall be provided to ensure pasteurization temperature of product and outlet temperature of pasteurizer. If the required temperature of product is not reached, the flow of product shall be automatically diverted to the float balance tank with an audible alarm. The instrumentation and control panel shall be made in standard execution built to dust and vermin proof design. It should be fabricated from 1.6mm thick SS-304 sheet. The control panel shall be leg supported and house the following components all pre-wired to terminal strip: (a) PID Controller for temperature of pasteurized Product with display of set temperature

and actual Product temperature. The controller has a facility to automatically tune to the requirement of set temperature.

(b) Temperature Recorder : The temperature recorder shall have six channel

and with digital temperature indicator. It shall be microprocessor based and strip type. The recorder shall have the facility to download the data to the computer. All the RTD supplied shall be of duplex type.

(c) Audio alarm with hooter and acknowledge and reset push button. (d) Auto manual selection switches and forced forward flow provision (e) I/P Converter for steam control valve operation and electrically operated solenoid valve

for air supply to flow diversion valve. (f) Air pressure regulator cum moisture separator with isolating valve to ensure proper air

supply to the I/P Converter and solenoid valves. (g) Incoming on/off switch for control supply.

One set of `ON’ and `OFF’ push buttons with indicating lamps and suitable inscriptions shall be provided for operation of motors of various module. (Three numbers spare push buttons are included)

230



(h) Indication lamp for showing the position of flow diversion valve (forward/diverted mode)

(i) PLC with monochrome HMI shall be provided, which shall be Siemens / Allen Bradley

make. It shall control the heating/ pasteurization temperature and also the final heating temperature of 42 deg. C for curd milk. Their should also be an option to chill the curd milk up to 4 degree C and required arrangement should be incorporated accordingly.

The indicative details of the panel are given below it should also accommodate all aforesaid components as defined from a to h :

S. No. PUSH BUTTONS WITH INDICATORS

SELECTION SWITCH

9. MILK SEPARATOR - 1 L 1 MAN ON

10. MILK SEPARATOR - 2 L 2 AUTO

11. HOT WATER PUMP L 3 MANUAL

12. MILK CREAM FEED PUMP L 4 DIVERSION FLOW

13. MILK CREAM TRANSFER PUMP L 5 FORWARD FLOW

14. HONOGENISER L 6 HOOTER

15. CHILLED WATER PUMP SS 1 FORWARD / DIVERSION S/S

16. SPARE – 1 SS 2 AUTO / MANUAL S/S

9. HOT WATER INLET TEMP. INDICATOR

PB22 ACKNOWLEDGE PB 1 S 1 POWER ON / OFF SW

The tenderer should furnish the information as per following format which is indicative only:-

ITEM DESCRIPITION QTY. REMARK / PERFERABLE MAKE

CONTROL PANEL SS SHEET METAL PANEL SUITABLE FOR FREE FLOOR STANDING

1 NO.

FABRICATED FROM SS 304 SHEET

AIR FILTER CUM REGULATOR

0-10 Kgs./Sq. Cm. SHAVO NORGEN

SOLENOID VALVE 220 V

NC CONNECTIONS 2 NOS

SHREADER / FLOWCON

HOOTER FOR DEVIATION IN PARAMETERS

MIMIC

TEMPERATURE RECORDER

TWO PEN RECORDER FOR RECORDING THE TEMPERATURE OF HOT & CHILLED MILK

1 NO.

G-TEK

ACKNOWLEDGE PUSH BUTTON &

FOR ACKNOWLEDGING THE DEVIATION

L & T

231



OTHER PUSH BUTTONS

MAIN ON / OFF ROTARY SWITCH WITH INDICATION

L & T

7. FLOW DIVERSION VALVE :

Standard IDMC/equivalent make pneumatically operated SS 304 three way valve should be provided for diversion of the under heated milk.

8. S.S. INTERCONNECTING PIPES & FITTINGS :

One set of prefabricated SS interconnecting pipes shall be supplied for interconnecting all the above mentioned accessories with the PHE based on the closed coupled layout on the skid. All terminal connection battery limits for Raw milk inlet, pasteurized milk outlet, milk to and from separator and homogenizer should terminate with 51mm SMS union. However the swing on bend connections at the battery limit for separator and homogenizer should be provided so that the milk pasteurizer can be operated without milk separator and homogenizer. Following GM Valves should be provided in the utility lines of the skid.

At he outlet of the hot water pump for regulating the flow of hot water. One No of Globe Valve at the inlet of the chilled water to the PHE and one No of NRV

at the outlet of chilled water from the PHE. One no of NRV in the steam line.

9.0 Product: The supply shall include all the necessary SS 304 pipes, fittings and valve

connecting float balance tank, Duplex filter, Milk feed pump, Flow Regulating Valve, Piping within Heat Exchanger & up to the finished pasteurized product outlet.

10.0 Steam / Hot Water / Condensate: A suitable steam pressure reducing valve shall be

supplied with the pasteurization plant so as to limit the steam pressure within 1.5 kg/cm2. The supply shall also include necessary SS 304 pipes and fittings connecting Hot Water from Hot Water generating PHE to the heating section of the pasteurizer and return to the Hot Water Pump. The piping shall also includes the SS 304 pipes, fittings and valves required from make-up soft water expansion tank to the inlet of the hot water pump. The overflow line from the expansion tank shall be extended down with a ball valve. The condensate assembly from pasteurizer shall end with a CS strainer; float type steam trap and by-pass CS ball valves.

232



11.0 A dial type pressure gauge for chilled water & steam shall be provided.

12.0 The module shall be mounted on SS SKID based on our compact. 13.0. TOOLS

Necessary tools like Hook Spanner, C-Spanner etc. should be provided with the plant.

14. OPERATING SPARE PARTS:

Necessary operating spare parts like SMS gaskets, Plate gaskets, Gasket for the float valve, Filter Bags, Mech. Seal of the milk feed pump etc. should be supplied with the milk pasteurizer.

15. UTLITIES REQUIRED: The tenderer is required to furnished the details of the

following:- 1. Electric Power : 2. Soft Water : 3. Compressed Air : 4. Chilled Water : 5. Hot Water : @ …………LPH at …. degree C 16. SUPERVISION IN ERECTION & COMMISSIONING:

As the milk pasteurizer should be supplied on the basis of prefabricated on the skid so that installation shall be required by the tenderer at site however we shall ensure the skid mounted milk pasteurizer supplied by you is interconnected with our existing milk plant at the battery limits provided in the skid. However if required the tenderer should depute their Engineer to the site and guide our staff to carry out this interconnection.

The tenderer shall be required to depute their Engineer for commissioning of the milk pasteurizer after our confirmation that your milk pasteurizer has been hooked with our milk plant. However performance and satisfactory commissioning of the milk pasteurizer is under your scope of work.

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17. DESIGN DATA FOR MILK PASTEURISATION PLANT AS A WHOLE: The

tenderer is required to furnish the information in the following format wherever blanks are left:-

S. No.

PARTICULARS UNIT PARAMETERS

1. PDT SPECIFICATIONS WHOLE MILK MAX. 6% FAT & 9% SNF

2. FLOW RATE - PRODUCT / CIP LPH 10000

3 FEED TEMPERATURE C 4/6

4 FINAL PRODUCT TEMPERATURE C 4

5 REGEGERATION EFFICIENCY AS A WHOLE

% 90

6 TOTAL PRESSURE DROP ON MILK SIDE Kg./sq.cm.

7 PASTEURISATION TEMPERATURE C 80 C

8 MAX. DESIGN PRESSURE Kg./sq.cm.

9 MAX. WORKING TEMPERATURE C

10 GASKET TYPE & MATERIAL CLIP ON ADHESIVE FREE GASKET

11 CONSTRUCTION OF PLATES

12 MAXS. Nos. OF PLATES THAT CAN BE ACCOMODATED ON THE FRAME

13 PLATE CORRUGATION TYPE HIGH & LOW THETA DEPENDING UPON DESIGN

14 PLATE THICKNESS MM 0.6

15 PLATE DIMENSIONS ( L X W ) mm

16 AREA PER PLATE Sq. Mtrs.

17 GAP GETWEEN PLATES Mm

18 TOTAL FRAME LENGTH Mm

19 PHE MODEL NO. Mm

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THE TENDERER IS REQUIRED TO FURNISH SECTION WISE DETAILS OF THE STANDARD MULTY PRODUCT MILK PASTEURISER CAP 1 KLPH. SIZE OF FRAME NOS. OF PLATES IN EACH

SECTION HTA PER PLATE

TOTAL HTA

REGENERATION SECTION – 1

……… NOS. …….. sq.m. …….. sq.m.

HEATING SECTION 1 ……… NOS. …….. sq.m. …….. sq.m.



REGENERATION SECTION – 3

……… NOS. …….. sq.m. …….. sq.m.

CHILLED SECTION 1 ……… NOS. …….. sq.m. …….. sq.m.

HOLDING SECTION ……… NOS. …….. sq.m. …….. sq.m.

G. TOTAL ……… NOS. …….. sq.m. …….. sq.m.

235



TECHNICAL SPECIFICATION FOR SUPPLY, INSTALLATION & COMMISSIONING OF HIGH PRESSURE HOMOGENIZE 1000 LPH

This shall be used for Homogenization of Milk, etc. 1. Functional Requirement : 2. CAPACITY: 1000 LITRE PER HOUR 3. PRESSURE: 200 Kg. per cm Sq. 4. MOTOR : 10 HP/7.5 KW 5. The Homogenizer will be of rugged design suitable mounted on solid Mild Steel frame

covered with SS cabinet enclosure made of imported AISI 304. 6. Homogenize will be of sanitary design. 7. Crankcase is made out of solid spheroidal Gray cast iron suitable to withstand the load 8. Homogenize Chamber is made out of single piece forged AISI 316 Block and tested

with ultra sound and grounded to get the required finish. 9. The chamber block is housed with removal and replaceable type suction and delivery

valve and valve sheets. All concerned parts shall be made out of SS 316. The Gasket coming in contact with the product will be of Food Grade, Non-toxic, Fat resistant and Non-absorbent with smooth surface.

10. Crank shaft, connecting rode and bearings would be made out of single piece forged Alloy steel, checked by ultra sound and grounded to get the required tolerance.

11. Suction and discharge valves will be of Ball Type and are made of special material to withstand the impact load due to continuous opening and closing of valves.

12. Homogenizing valves are made of special Material (tungsten carbide) to withstand the abrasion and turbulence created because of high velocity of the product (satellite or tungsten carbide valves).

13. The high pressure Homogenizer will be two-stage design suitable for operating pressure of 200 Kg. per cm Sq..

14. Pressure adjustment system will be manual with the help of adjustment screw. 15. The Homogenizer will be coupled through belt & pulley with the suitable HP/RPMTEFC

Electric motor of Reputed make (Three phase) TEFC Electric motor of Crompton / NGEF make.

16. The Homogenizer equipped with speed reduction system. 17. Homogenizer will be provided with :- (i) Diaphragm type pressure gauge on chamber. (ii) Commissioning spares – 1 Set. (iii) Instruction Manual – 3 Sets. (iv) Tool Kit – 1 Set. 18. A control panel equipped with all automation and control, moter starter etc. 19. The Homogenizer should be supplied with adjustable ball feet. 20. Inlet/Outlet connection of suitable size. 21. Tenderer should fill the details mentioned at Annexure – I. Note: .The supervision of erection and commissioning of the Homogenizer is also included in the scope of supplier, for which no extra charges would be payable.

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DETAIL OF HOMOGENIZER, 1000 LITRE PER HOUR TO BE FILLED BY

TENDERER. Name of Tenderer : ____________________________________________

S. No. Item Specification

22. Model

23. Capacity 1000 LPH

24. Pressure

25. Electrical Motor

26. No. of Plungers / material

27. Homogenizing heads 2 Stage

28. Homogenizing Valve Material Tungsten Carbide

29. Inlet / Outlet connection

30. Mounting frame MS frame with SS enclosure

31. Contact parts SS 316

32. Pressure

33. Set of essential Spare

34. Set of Essential Tools

35. Dimensions

36. High Pressure Pump Block (Chamber) material

Single piece forge SS 316 tested with ultra sound.

37. Gasket Food grade Non toxic. Fat resistant and non absorbtant

38. Crank case material Spheorodal Cast Iron

39. Crank shaft, connecting rod and bearings

Forged steel

40. Plunger Packing should be suitable for Hot CIP.

41. Control Panel (Define detail of items to be supplied in control panel)

42. Diaphram type SS 316 pressure gauge.

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TECHNICAL SPECIFICATION FOR INOCULATION TANK WITH STRAINERS CAPACITY : 500 LTRS.


The Inoculation tank with strainer is required to collect the milk from for inoculation. The tank should be insulated, vertical opened type tank equipped with strainer and with removable top lid.

Design Requirement : The Inoculation Heating Tank will be vertical insulated open top tank.










ACCESSORIES


No Foam Type inlet at the SS gurder on top of the Tank. Sand blasted level marks Agitator – It should be in stainless steel ( AISI 304 ) sweeping type

construction complete with geared motor of adequate capacity – 1 No. Spray Ball – 1 No. Thermowell complete with digital type thermometer will SS stand.


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CURD/CHHACH STORAGE TANK CAPACITY : 1000 L


The storage tank shall be used for storage curd , chhach etc. or Pasteurizer cream having a fat content of 40 – 45 % / Cream would be ripened and stored in this tank at a temperature of 6 degree centigrade.

2.0 DESIGN REQUIREMENTS 2.1 Capacity : 1000 L. The volume of the tank should be such that after filling it up to

the rated capacity, the level would be 100 mm below the line where cylindrical shell joints the conical top.









should be fabricated from 2mm thick stainless steel for capacity 1000 L conforming to AISI 304.


fabricated from 2mm thick stainless steel sheet conforming to AISI 304. 3.3 Outer cylindrical Body : The outer shell, conical top and flat bottom should be

fabricated from 2mm thick stainless steel sheet conforming to AISI 304. 3.4 Insulation : The entire intermediate shell, flat bottom and inner conical top shall be

insulated in three layers as follows: 3.5 First layer: 25mm thick resin bonded crown 150 fiber glass compressed to 10mm.


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4. Accessories : 4.1 Inlet-cum-outlet: 38mm dia cup type inlet cum outlet with two way plug type


4.2 Air vent: Stainless steel (AISI 304) 150mm air vent to prevent formation of partial

vacuum during CIP and pressure during filling – 1 No. 4.3 Man way : Stainless steel (AISI 304) man way of 450mm diameter and located at


4.4 Sand Blasted level marks: It should be calibrated at 500 L intervals and provided on the inner shell at opposite side of the sight glass. The level mark should be dark enough so it may be clearly visible.

4.5 Sight Glass: Stainless steel (AISI 304) sight glass assembly should be provided with toughened glass. It should be provided in such a way that one can easily read from the lowest level up to the maximum level mark. Stainless steel lamp shade for mounting 24 V and 100 watt bulb. The lamp holder should be made from brass – 1 No.

4.6 Agitator : Vertical heavy duty sweeping type Stainless steel (AISI 304) agitator

complete with mountings with geared motor of adequate capacity and should be able to uniformly mix cream in the tank within 10 minutes. The agitator shaft should be a rod – 1 No.

4.7 Sprinkler Pipe: A 25mm dia pipe ring of Stainless steel (AISI 304) should be


4.8 Spray Ball: Removable Stainless steel (AISI 304) cleaning device located on conical

top at either sides of the agitator drive to provided flooding of liquid over the complete interior surface and agitator during CIP. These should have stainless unions at the outer end connections – 2 No.

4.9 Drain: Made from Stainless steel (AISI 304) pipe of 38mm dia at the bottom of the

jacket with gun metal valve – 1 No. 4.10 U-seal: Made from Stainless steel (AISI 304) pipe 38mm dia at the bottom of the

jacket – 1 No. 4.11 Over flow: Made from Stainless steel (AISI 304) pipe 38mm dia at the top of the

jacket – 2 Nos. 4.12 Sampling Cock: It should provided on the inlet – cum – outlet and should be in

Stainless steel (AISI 304) construction with sanitary design – 1 No.

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4.13 Thermowell : 200 mm long Stainless steel (AISI 304) inclined pocket suitable for


4.14 Legs: Conical mild steel legs with Stainless steel (AISI 304) sheet cladding and stainless steel ball feet provided at the bottom of the tank. The stainless steel ball feet should have provision for height adjustment of 50mm – 4 Nos.

4.15 Ladder: Stainless steel (AISI 304) ladder for access to the sight glass and geared

motor assembly of agitator – 1 No. 4.16 Lifting lugs: Stainless steel (AISI 304) lifting lugs should be provided at top – 2 Nos. 4.17 Painting: All the M.S. stiffeners used in the construction of the tank should be

painted with two coats of epoxy primer after thorough de-rusting.

5. TESTS: The following tests should be conducted by the manufacturer at works.

5.1 Dye penetration test for welding joints. 5.2 Water fill-up test of inner vessel for water tightness.

Note : General arrangement of the equipment should be provided the attached reference

drawing. Makes of bought out items are as bellow : Geared motor Elecon. / Radicon Note :- (1) Scope of supply also include supervision of Installation & commissioning,

water trial of supplied equipment to ensure perfect working of systems at site.

(2) Name plate should be provided on equipment define the water, steam, inlet, out let, overflow, airvent connection etc.

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AUTOMATIC CURD CUP FILLING & SEALING MACHINE

CAPACITY : 1200 CUPS PER HOUR

1. FUNCTIONAL REQUIREMENT

The machine is required to fill the Curd in to 100, 200 & 400 gms. cups and subsequently heat /seal the top with heat salable film. Filled cups will then be ejected on a motorized conveyor cum working table for onwards packing in to carton.

2. DESIGN REQUIRMENT :

2.1 Capacity 1200 cups / hour ( for 100, 200 & 400 gms)

2.2 The filling machine should be completely automatic without PLC based control and suitable for volumetric filling into the polystyrene cups.

2.3 Dimension of Cups : Diameter 80-110 and height 120 maximum. However exact

size of 100ml, 200ml cup shall be conform separately.

2.4 Accuracy : As per weights & measures department but not exceeding plus minus 2

%.

2.5 The machine shall be pneumatically operated.

2.6 Material : All product contact surface are to be of SS AISI 304, food grade material.

2.7 Finish : All welding joints are to be ground smooth. All SS surface are to be finished

to 150 grit finish.

2.8 Joints Curvatures : There should not be any sharp corners of edges on the product

contact surface. All SS surface should have radii of 25 mm.

2.9 CIP cleaning : Machine should have suitable arrangement for cleaning in Place . The

machine top should have proper sealing to prevent leakage down in the chamber.

2.10 Machine should be equipped with following work stations .

2.10.1 Cup release station : Empty cup shall be stacked in the magazine on the top of the

table and release one by one in the respective cavities on the rotary table. The magazine shall be suitable to hold min . 100 Nos. of cups of each size and adjustable type to accommodate minor variations in cup size.

2.10.2 Product fill station : Pre – set quantity of the product shall discharge in the cup

smoothly without splashing on be table top. The filling nozzle should be leakage free and should not form bubbles at the beginning or at the end of filling. The station shall be equipped with No cup – No fill control. In case of failure of control, suitable product collection arrangement should be there below the filling station cup holder.

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2.10.3 Lid placing station : Empty lid shall be stacked in the magazine on the top of the

table and release one by one on the respective filled cups on the rotary table . The magazine shall be suitable to hold min. 400 lids of each size and adjusted type to accommodate minor variation in lid size. The station shall be equipped with No cup- No lid control.

2.10.4 Heat sealing station : Heat sealing station with suitable Teflon coated heating

arrangement for sealing of the heat sealable lid cover . It shall have provision of increasing or decreasing the sealing temperature. It should be suitable for 100, 200 & 400 gms cups . The station shall be equipped with no cup – no seal control. The sealing pad should be easily accessible.

2.10.5 Discharge station : Suitable cup ejector to eject filled cup on a motorized flat belt

conveyor supplied along with the machine .

2.10.6 Counting station: A suitable mechanical / electronic counter should be provided to

count filled cups .

2.11 Discharge conveyor cum working table : The suitable motorized food grade flat belt discharge conveyor with suitable working table on both side of the conveyor should be provided.

2.12 Control panel : A control panel made out of SS AISI 304 grade, 2 mm thick sheet

material with IP 55 protection construction, prewired having contactors, relays, indicators, start and push buttons etc with controls such as.

2.12.1 No cup- No fill control

2.12.2 No cup – No lid control

2.12.3 No cup- No seal control .

2.12.4 Emergency OFF switch.

2.12.5 Digital counter for filled cups.

2.12.6 Low air pressure control & indicator.

2.12.7 Heat sealing temperature control .

2.12.8 Mechanical overload protection.

3. SCOPE OF SUPPLY :

3.1 The complete filling machine should be of floor mounted free standing type , shrouded with SS AISI 304 grade sheet and with aluminum alloy rotary table and as per the design requirements specified above for filling different volume in cups.

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3.2 Cultured milk will either be pumped or flow by gravity from cultured milk tank (not in the present scope of supply ) to the filling machine balance tank from where the milk should flow to the filling heads.

3.3 Change parts for 100, 200 & 400 ml cup, filling shall be provided along with the machine.

3.4 The filling shall be on volumetric basis. The filling piston valve should have step less setting to achieve the filling accuracy of less than 2 % as per the requirement of weighs & measures. Minor adjustment of volume should be possible without stopping the machine,

3.5 The machine should be provided with suitable drive with fixed speed motor.

3.6 Suitable air filter, regulator and moisture separator for compressed air should be provided with machine in case pneumatically operated one. Lubrication should be separately provided for lubrication of pneumatic cylinders.

3.7 Control panel: The control with all controls shall either be machine mounted or self

supported pedestal mounted.

3.8 Free spare parts supplied along with the machine shall be as per annexure- II and all essential spares for two years trouble free operations should be supplied as per annexure-III .

3.9 A set of tools required for operation and maintenance of the machine should be supplied along with the machine.

3.10 Three sets of operation maintenance and installation manual should be supplied along with the machine.

3.11 All interconnecting pipes and fitting shall be of SS AISI 304 grade confirming to SMS standard.

3.12 Discharge conveyor: The suitable motorized food grade flat belt discharge conveyor of 1800 mm long and 200 mm width should be provided. On both side of the conveyor 900 mm long and 300 mm wide SS AISI 304 grade minimum 1.6 mm thick top working table shall be attached. The filled cup from the machine with lid will be released on to the conveyor from where it will be picked up manually for packing in cartons on working table.

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3.13 In order to run the machine and to meet the capacity specified above party shall consider following features of the machine: 3.13.1 Filling station – 1 no sealing station – 2 Nos., rows on the rotary table – 1 No . 3.13.2 Capacity of the balance tank – 20 L .

3.13.3 Flow rate of the pressurized air – 80 CFM at 6.0 Kg/ sq .cm .

3.13.4 There phase electricity supply .

3.13.5 Space requirement 6’ x 6’.

4. INSPECTION & TESTING : The cup filling machine shall be manufactured following

good engineering manufacturing practices , However RCDF reserve the right to inspect the equipment during various stages of fabrication and check the overall workmanship. The following tests should be conducted at the manufacturer ‘s work.

4.1 Dye penetration and water leakage test for stainless steel balance tank 4.2 Running trial & capacity test.

5. DRAWINGS: Manufacturer shall submit drawing of cup filling machine & working table for necessary approval.

6 Batch No. printing station to be provided.

7. Change over dies for 2nd cups size to be provided i.e. provision for filling of product in cups of two different diameters.

8. DETAILS OF MATERIAL and makes USED IN THE CUP filling MACHINE

ITEM DESCRIPTION Qty REMARK/ MAKE

CONTROL PANEL

SS SHEET METAL SUITABLE FOR FREE FLOOR STANDING

1 No

FABRICATED FROM S.S SHEET WITH BACK OPENABLE COVER

TIMERS 0-30 SECONDS 2 NO

FINDER/ SELECTRON MAKE

RELAYS 1 SET

FINDER/ SIEMENS/ SELECTRON MAKE

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WITH MECHNICAL INDCATOR & MANUAL OPERATION LEVER

TEMPERATIRE CONTROLLER

0- 400 C 1 No

HANYOUNG/ SELECTRON

AIR FILTER CUM REGULATOR

0-10 kgs/sq cm SHAVO NORGEN MAKE

SOLENOID VALVE _ 220v

NO CONECTIONS

1 S ET

PNUMAX & GENETICS/ FIESTO MAKE ,

MCB & CONTRACTORS

1 SET

SIEMENS / L& T

MAIN ON/ OF ROTARY SWICH WITH INDICATION ,

1 NO

SIEMENS / L& T

GEARED DRIVE HOLLOW SHAFTY GEAR BOX

1 No

BONFIGILIOLI

INFRA RED PHOTO SENSORS

3 NOS

P& F VISOLUX MAKE GERMANY / PROXIMOM

PROXIMITY SWICH

3 NOS

P& P GERMANY / PROXIMOM

PRESSURE SWICH

1 NO

INDFOSS/ FIESTO MAKE

PNEUMATIC GYLINDERS

1 SET

FESTO MAKE

VACCUM VALVE

1 NO

FESTO MAKE

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ANNEXURE - II

ESSENTIAL SPARES TO BE SUPPLIED WITH CURD MACHINE

S. No.

Item Specification Qty. (in Nos)

1) Cartridge heater for sealing

16mm dia, 400 W, 230 VAC

01

2) Proximity switch 01

3) Relay 24 VDC 01

4) Air Cylinder seal kit for cup lifting

01

5) ‘O’ ring 7mm ID X 12MM OD

01

6) ‘O’ ring 46mm ID X 50mm OD

02

7) Cup placement station cup

01

8) Lid placement section cup

02

9) Tube connector 6mm x ¼”

02

10) Flow regulator 01

11) Filter element 01

12) 6mm PBC tube 06

13) 38mm SMS gas kit 02

14) PVC tube 8mm 03

15) PVC tube 12mm 03

16) Printing Ink 0.5 ltrs

17) Diluter 2 ltrs.

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ANNEXURE - III

RECOMMENDED SPARES FOR TWO YEARS SMOOTH OPERATION FOR CURD MACHINE

S. No.

Item Specification Qty. (in Nos)

1. Pt. 100 temp. sensor 01

2. Timer 0 to 10 second Selection 01

3. Photo sensor 01

4. Bearing 6206ZZ 01

5. Bearing 4906 02

6. Cylinder for stamping station

DNC 32160 01

7. Cylinder for cup loading station

01

8. Solenoid valve 5/2 way 01

Note :- The curd cup filling machine capacity 1200 Cups Per hour should be equipped with provision for filling shrikhand on 100, 200 & 400 gms. cups .

248



TECHNICAL SPECIFICATION FOR DOUBLE HEAD MECHANICAL POUCH PACKING MACHINE FOR MILK /CHHACH / LASSI WITH ACCESSORIES.

CAPACITY : 5000 Packs/Hr.

1.0 FUNCTIONAL REQUIREMENTS Milk/Chhach/Lassi would be fed to the float balance tank of the pouch filling machine by

gravity flow. The pouches should be formed of film, filled with Milk/Chhach/Lassi and sealed by the machine.

2.0 DESIGN REQUIREMENT 2.1 Machine Model : ___________________ 2.2 Capacity : 5000 Packs/hr. of sizes 200 ml. or 500 ml. or 1000 ml.

2.3 Functional : Machine operations should mechanically controlled except for feeding system which can be either air or electrically operated.

2.4 Finish : All stainless steel surfaces are to be polished to 150 grits.

2.5 Feeding System : Gravity filler.

2.6 Type of Seal : Overlap/Impulse seal.

2.7 Injection System : A constant level with mechanical float should be fixed on the roof of the machine. The product from tank should be passed through injection tube in to the film tube. The filled quantity of product in each pouch should be controlled by adjustment of opening distance of the gate valve at the lower end of the injection tube. The flow of the product through injection tube in the

pouches should be continuous and the sealing takes place through the product.

2.8 Electrical Control Panel : The electrical switches, control relays solid state device and various pouch counters are mounted in this panel. The electric control panel can be fixed on left or right side of the machine, as per requirement.

3.0 SCOPE OF SUPPLY

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3.1 Description of the Machine Body : The machine should have Stainless Steel Body built on a treated aluminium chassis. All the sub-assemblies are mounted on these machined plates.

All parts in contact with the product are AISI-304 Stainless Steel with smooth finish.

3.2 Float Balance Tank: Stainless Steel float balance tank of suitable capacity

should be provided at the top of the pouch filling machine. - 1 no. 3.3 The machine should have following arrangements in it.

3.3.1 Film guard device to stop the machine when the film gets exhausted.

3.3.2 Liquid level controller.

3.3.3 Sterilizing mechanism for pouch film.

3.3.4 Pouch counter.

3.3.5 Date printing device.

3.3.6 Apportioning device for 200 ml., 500 ml. and 1000 ml.

3.3.7 Facility to insert a closed circuit in place cleaning system for the machine.

3.3.8 Variable frequency drive - 02 nos are included in the scope of supply.

3.3.9 PLC controlled to pack milk in pouches. Tools : Essential special tools should be supplied with the machine without changing any extra coat. Note : The machine should be designed to pack Milk/Chhach (Zeera in

granule form) /Lassi in 200ml / 500ml / 1000 ml. packing size.

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TECHNICAL SPECIFCATIONS FOR MILK CHILLER CAP. 2 KLPH

1. Capacity : Milk Chiller capacity 2 KLPH 1. Functional requirement :

The plate heat exchanger would be used for chilling milk, chhach, lassi with chilled water .

2. Design parameter i) Milk : feed temperature : 35 deg. C

ii) MILK outlet temperature : 4 deg. C

iii) Chill water feed temperature : 1.5 deg. C.

flow rate to milk ,

iv) Maximum pressure drop on water : 1.00 Kg. / cm²

v) Maximum pressure drop on Water side : 11 MWC

5. Finish All welding joints to be ground smoothly. All SS surface are to be polished to 150 grit.

6. Plate Material : AISI 316 Quantity.

7. Plate gasket : Food grade quality , Nitrite rubber Gasket which should withstand water terilization temperature of 100 deg C and CIP with caustic solution at 80 deg. C (Alkanity 0.7 % ) and Nitric Acid Solution at 70 deg C (Acidity 0.5 % )

8. Supporting frame ;The supporting frame for the plate pack should be of self supporting design made of stainless steel (AISI 304) clad mild steel with manually operated tightening device. The tightening device should be able to exert uniform pressure on all the part of heat transfer plate, the frame and

tightening device should prevent the plates from deflecting under pressure differential of minimum 4 kg / sq , cm the frame should be capable of accommodating the additional places for the expanded capacity.

9. Accessories :

9.1 Inlet /Outlet : The inlet and outlet for chilled water and product should be provided with complete SMS stainless steel (AISI 304 ) union.

11.2 Thermowells : Stainless steel (AISI 304) pockets for thermometer on all the inlet and outlet (Total 4 Nos.) Each pocket should be complete with suitable stainless

251



steel (AISI 304 ) inclined pocket suitable for mounting stem/ probe of digital thermometer of size 4" x 4". One pocket should be provided for digital electronic thermometer for chilled milk outlet temperature (The thermometers are in the scope of the supply).

11.3 Ball feet : the frame should be provided with adjustable steel ball feet with provision for height adjustment of 50 mm – 4 Nos.

12 Tools ; A set of essential special tools. 13 The supplier would supply the Chiller in the frame size to be intimated separately

by the Milk Union as per their requirement. 14 No of plates would be as mentioned in the tender document and technical

discussions.

IMPORTANT NOTES :

1. Plate Thickness shall be minimum 0.6mm.

2. Gaskets (food grade) shall be non-glude type.

3. Chilled water flow rate shall be three times the flow rate of milk.

4. The plates shall be of AISI 316 grade.

5. Four Nos. Digital Temperature Indicator (PT 100 sensor of reputed make like Honeywell) size 2" x 4" house-in SS Box, front open, floor / wall mountable with minimum three meter cable length shall be provided.

Drawings :

The supplier required to submit detailed fabrication drawings to RCDF .

No of Plates in chilling section, heat transfer area per plate (H.T.A./Plate)

(H.T.A. = Effective Heat Transfer Area)

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TECHNICAL SPECIFICATION FOR PUMPS S.S. MILK PUMP CAP. : 500/1000 LPH

1.0 FUNCTIONAL REQUIREMENTS The pumps will be used to transfer Milk and Milk Products i.e. Chhach,

Lassi, Curd etc. 2.0 DESIGN REQUIREMENT 2.1 Capacity : 500/1000 LPH at 15 MWC Head. 2.2 Type : The pump should be centrifugal type. 2.3 Design : It should be of sanitary design. 2.4 Prime Mover : TEFC electrical motor of suitable HP. 2.5 Finish : All the surfaces coming in contact with ghee & butter oil should

be finished to 150 grit. 3.0 SCOPE OF SUPPLY 3.1 Motor : The stainless steel (AISI 316) pump should be supplied with






Note : The pumps for the Indigenous product section are defined in lot accordingly pump

should be placed as per site requirement and milk circuit. The type of pump (impeller) should be selected with respect to transfer of products. The two nos. of pump should be consider in spare to total number of pumps required as per site condition.

253



TECHNICAL SPECIFICATION FOR SALT WATER/ SUGAR SYRUP TANK WITH STRAINERS

CAPACITY : 200 LTRS.


The salt water/ sugar syrup tank with strainer is required to mix salt/sugar in water for chhach and lassi . The tank should be equipped with strainer with removable top lid.











glasswool insulation. ACCESSORIES


No Foam Type inlet at the SS gurder on top of the Tank. Sand blasted level marks Agitator – It should be in stainless steel ( AISI 304 ) sweeping type

construction complete with geared motor of adequate capacity – 1 No. Spray Ball – 1 No. Thermowell complete with digital type thermometer will SS stand.


254



PANEER

SECTION

255



MILK/ CREAM /CURD STORAGE TANK CAPACITY : 1000 L

1. FUNCITIONAL REQUIREMENTS :

The aforesaid storage tank would be used to store chilled milk at 4 degree centigrade temperature / Pasteurizer cream having a fat content of 40 – 45 % / Cream would be ripened and stored in this tank at a temperature of 6 degree centigrade or can be used for storage of Milk,Curd,Chhach,Cream etc.

2. DESIGN REQUIREMENTS

2.1 Capacity : 1000 L. The volume of the tank should be such that after filling it up to

the rated capacity, the level would be 100 mm below the line where cylindrical shell joints the conical top.




periphery of the reverse conical bottom.

2.4 Metal contact : The only metal to metal contact between the inner and outer shells should be at the places where fittings for the tank are provided.

2.5 Finish : All welding joints are to the ground smoothly. All stainless steel surfaces are

to be polished to 150 grits.

2.6 Joint – Curvatures: The radii of all welded and permanent attachment joints should be at least 6 mm. Where the conical top and reverse conical bottom join the cylindrical shell the radii should not be less than 25 mm.

3. SCOPE OF SUPPLY :

3.1 Inner cylindrical Body : The inner shell, conical top and reverse conical

bottom should be fabricated from 2mm thick stainless steel for capacity 1000 L conforming to AISI 304.

3.2 Intermediate cylindrical Body : The intermediate shell and flat bottom

should be fabricated from 2mm thick stainless steel sheet conforming to AISI 304.

3.3 Outer cylindrical Body : The outer shell, conical top and flat bottom should

be fabricated from 2mm thick stainless steel sheet conforming to AISI 304.

3.4 Insulation : The entire intermediate shell, flat bottom and inner conical top

shall be insulated in three layers as follows:

256



First layer: 25mm thick resin bonded crown 150 fiber glass compressed to 10mm. Second layer: 50mm thick expanded polystyrene. Third layer: 50mm thick expanded polystyrene.

3.5 Accessories :

3.7.1 Inlet-cum-outlet: 38mm dia cup type inlet cum outlet with two way plug type


3.7.2 Air vent: Stainless steel (AISI 304) 150mm air vent to prevent formation of partial

vacuum during CIP and pressure during filling – 1 No. 3.7.3 Man way : Stainless steel (AISI 304) man way of 450mm diameter and located at


3.7.4 Sand Blasted level marks: It should be calibrated at 500 L intervals and provided

on the inner shell at opposite side of the sight glass. The level mark should be dark enough so it may be clearly visible.

3.7.5 Sight Glass: Stainless steel (AISI 304) sight glass assembly should be provided with

toughened glass. It should be provided in such a way that one can easily read from the lowest level up to the maximum level mark. Stainless steel lamp shade for mounting 24 V and 100 watt bulb. The lamp holder should be made from brass – 1 No.

3.7.6 Agitator : Vertical heavy duty sweeping type Stainless steel (AISI 304) agitator

complete with mountings with geared motor of adequate capacity and should be able to uniformly mix cream in the tank within 10 minutes. The agitator shaft should be a rod – 1 No.



3.7.8 Spray Ball: Removable Stainless steel (AISI 304) cleaning device located on conical

top at either sides of the agitator drive to provided flooding of liquid over the

257



complete interior surface and agitator during CIP. These should have stainless unions at the outer end connections – 2 No.

3.7.9 Drain: Made from Stainless steel (AISI 304) pipe of 38mm dia at the bottom of the

jacket with gun metal valve – 1 No. 3.7.10 U-seal: Made from Stainless steel (AISI 304) pipe 38mm dia at the bottom of the

jacket – 1 No. 3.7.11 Over flow: Made from Stainless steel (AISI 304) pipe 38mm dia at the top of the

jacket – 2 Nos. 3.7.12 Sampling Cock: It should provided on the inlet – cum – outlet and should be in

Stainless steel (AISI 304) construction with sanitary design – 1 No. 3.7.13 Thermowell : 200 mm long Stainless steel (AISI 304) inclined pocket suitable for


3.7.14 Legs: Conical mild steel legs with Stainless steel (AISI 304) sheet cladding and stainless steel ball feet provided at the bottom of the tank. The stainless steel ball feet should have provision for height adjustment of 50mm – 4 Nos.

3.7.15 Ladder: Stainless steel (AISI 304) ladder for access to the sight glass and geared

motor assembly of agitator – 1 No. 3.7.16 Lifting lugs: Stainless steel (AISI 304) lifting lugs should be provided at top – 2 Nos.

3.8 Painting: All the M.S. stiffeners used in the construction of the tank should be

painted with two coats of epoxy primer after thorough de-rusting.

4. TESTS: The following tests should be conducted by the manufacturer at works.

a. Dye penetration test for welding joints. b. Water fill-up test of inner vessel for water tightness.

Notes :-


2. Makes of gear box ELECON / RADICON or Equivalent (Equivalent make subjected to purchaser approval. 3. Scope of supply also include supervision of Installation & commissioning,


4. Name plate should be provided on equipment define the water, steam, inlet, out let, overflow, airvent connection etc.

258



TECHNICAL SPECIFICATIONS FOR PANEER VAT (Double Jacketed) CAPACITY 1000L

1.0 FUNCTIONAL REQUIREMENTS:

Paneer vat would be used for coagulating milk solids for production of Paneer. 2.0 DESIGN REQUIREMENTS:

2.1 Capacity : 1000L 2.2 Constructional Features : The vat should be welded and jacketed in construction

having rectangular cross section with semi circular ends. 2.3 Dimensions of Paneer Vat for 1000 ltrs:

Inner length - 2400 mm Inner width - 1000 mm Depth (shallow side)- 500 mm (Deep side) - 550 mm 2.4 Slope : Both the inner and outer shells should slope towards the whey outlet as per

the dimensions given above for free and complete drainage of liquid. 2.5 Finish : All welding joints are to be ground smoothly. All stainless steel surface are

to be polished to 120 grits. 2.6 Joint Curvatures : All inside corners should have minimum radii of 25mm.

3.0 SCOPE OF SUPPLY : 3.1 Inner Vat : The inner vat should be made from minimum 2mm thick stainless steel

sheet – 304, - 1 No. 3.2 Outer Vat : The outer vat should be made from minimum 2 mm thick stainless steel

sheet – 304. 1 No. 3.3 Frame : The frame should be made from 75mm dia mild steel ‘C’ class pipes. The

complete frame should be spray galvanized after fabrication. 3.4 Double Jacketed : The inner steam jacket of minimum 80 mm width at all the four

sides and the bottom should be provided. The outer of the Jacket should be insulated in 3 layers as under:-

First layer: 25mm thick resin bonded crown 150 fiber glass compressed to 10mm. Second layer: 50mm thick expanded polystyrene. Third layer: 50mm thick expanded polystyrene. Outer Body : The outer shell including the bottom of this after above insulation

should be fabricated from 2 mm thick stainless steel sheet conforming to AISI 304. 3.5 Accessories : 3.5.1 Agitator : Two pairs of agitator blades located suitably. The agitator blades should

be of rectangular shape of size approx. 400mm x 300mm each. The blades should have circular perforations of diameter approximately 40mm each all over the blades. The blades should be thick enough to retain their shape and form under operation.

- 1 Set. Suitable drive mechanism (electrical) for the agitator and other accessories required

for the agitator assembly should also be provided. - 1 Set

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3.5.2 Steam Distribution : Steam distribution system should comprises of two nos. of

perforated steam distribution pipes provided in the bottom jacket, one no. of steam header and one no. of steam inlet pipe ending outside in a flange and counter flange. Complete steam entry and distribution system should be made of stainless steel pipe.

3.5.3 Overflow : Overflow pipe of 51m diameter for the jacket ending near the floor level. 3.5.4 Whey Outlet : Stainless steel cup type outlet of diameter 63.5mm with stainless

steel plug type flanged valve for the vat. Outlet should be at a height of 230mm from the finished floor level. - 1 No.

3.5.5 Drain : Suitable stainless steel drain with blank for the jacket. - 1 No. 3.5.6 Strainer : Silding type strainer for the whey outlet (item 3.4.5). The strainer should

be made from perforated stainless steel sheet. 3.5.7 Water Inlet : Stainless steel water inlet of size 38mm dia with flange and counter

flange. - 1 No. 3.5.8 Legs : Mild steel legs with stainless steel pipe cladding with stainless steel ball feet

provided at the bottom of the tank. The ball feet should have provision for height adjustment of 50mm. - 6 Nos.

3.5.9 Painting: All mild steam pipes and shell stiffeners provided within the jacket should

be painted with two coats of epoxy primer. Mild steel parts which are outside the jacket should be painted with a coat of epoxy primer followed by two coats of epoxy paint of cream colour after thorough derusitng.

4.0 Tests : The following tests should be conducted by the manufactures at it’s works.

4.1 Dyepenetration test for all stainless steel welding joints. 4.2 Water fill-up test of inner vessel and jacket for water tightness. 4.3 The jacket should be tested for a pressure of 3 Kg. / Sq. Cm. guage.

NOTE :

1. General arrangement of this equipment should be as per the attached reference drawing for capacity up to 1000 L Equivalent make subjected to approval of the purchaser.

2. Scope of supply also include supervision of Installation & commissioning, water trial of supplied equipment to ensure perfect working of systems at site.

Name plate should be provided on equipment define the connection. 3. Tender should considered all required measures to ensure perfect working and safety of

supplied equipment.

260



PANEER PRESS WITH SQUARE HOOPS

CAP_120 Kg/Batch

1.0 FUNCTIONAL REQUIREMENTS :

The paneer press shall be used to expel the whey from coagulated mass poured in along with whey in the perforated hoops. The mass in the hoop shall be put under applied through pneumatic cylinder.

2.0 DESIGN REUIREMENT:

2.1 Capacity: 120 kgs/batch (30 kg/cylinder in one batch)

2.2 Constructional features: The paneer press shall have four pressing equipped with pneumatic cylinders. The station shall have table top on which the filled hoops are to be placed just below the pneumatic cylinder. Each cylinder shall have independent air control valve. Below the table a tray with an out let shall be provided to collect the whey expelled out from the paneer block.

2.3 Paneer Hoop: The hoops shall be made out of perforated sheet. The size of the

hoop is 325L x 325 W x 85 H.

2.4 Finish: All weld joints are to be ground finish. Product contact surface shall be

polished to 150 grit finish.

3.0 SCOPE OF SUPPLY:

3.1 Paneer Press: The paneer press shall be mounted on MS table of size 2425 L x 690 W x 1410 H. Four pneumatic cylinder with press pad are to be fitted equi-destance across the length of the table. The pneumatic cylinder shall be 3” dia. x 6” stroke with 1” shaft hard crome and ground of EN8 material. The pressing pad shall be MS plate cladded with SS 304. Each cylinder shall hae a manually operated air control valve to control the forward & reverse motion of the piston. The operating pressure of the pneumatic cylinder shall be 5.0 kg/cm2. Suitable guide shall be provided on the raised table for positioning of the filled hoops below the pressing cylinders. A SS 304 tray shall be provided to collect the whey expelled out from the paneer hoops.

3.2 Air Supply Header: ½ “ MS “C” class pipe air header of full length of the table shall be provided complete with air regulator ½ “, 0-10 kg/sq. cm, pneumatic tubing & ON-OFF control valve at each station.

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3.3 Table: The table shall be fabricated from suitable size MS angles & channels. The table top shall be 4 mm thick MS plate duly supported at each station.

3.4 Why Collection Tray: The tray shall be of SS 304, 1.2 mm thick and of table size. The tray shall have 6 nos., 20 mm dia. drain holes, two at the centre and one each of the for end of the both side gutter. The drain holes shall protrude through the MS tabletop, which act as stray locator also. The tray shall be welded with paneer hops guide of SS 304 angle 25x25x3 mm at each station.

3.5 Paneer Hoops: Paneer hoops shall be suitable for approximate holding capacity of 1 Kgs. The size of the hoop shall be 325 L x 325 W x 85 H, made out of SS 304, 2mm thick perforated sheet complete with guide ring, covers, bar handles and spacing bars.

4.0 MANUFACTURING CODE: The paneer press shall be manufactured following good engineering manufacturing practices.

5.0 INSPECTION & TESTING: RCDF reserve the right to inspect the equipment during various stages of fabrication. The manufacturer at their works should conduct the following tests.

5.1 Dye penetration test for all stainless steel welding joints.

5.2 Water leakage test.

6.0 DRAWING: Bidder shall submit a GA drawing of the equipment along with offer giving details of the material of construction, details of the bought out items. However successful bidder has to submit detailed manufacturing drawing of approval from RCDF, prior to start fabrication.

7.0 MAKES OF BOUGHTOUT ITEMS: Bidder shall furnish makes of all both items considered for manufacturing/ assembly of the paneer press along with technical leaflet.

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TECHNICAL SPECIFICATION FOR PANEER WASHING CUM COOLING TANK

CAPACITY -200 L Design Requirement : The Tank will be rectangular insulated open top tank.





Inner Body – The inner shell and Flat bottom should be fabricatedfrom 2 mm thick stainless steel confirming to AISI 304 respectively.

Outer Body – The outer shell and Flat bottom should be fabricated from 2 mm thk. SS

304 grade.The top lids in two half will be fabricated from 2mm thick SS - 304



ACCESSORIES




Thermowell complete with digital type thermometer will SS stand. Legs- Conical mild steel legs with stainless steel sheet cladding and

stainless steel ball feet should have provision for height adjustment of 50 mm.

Note :- The suitable height of the tank should be designed for ease of Paneer washing.

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TECHNICAL SPECIFICATIONS OF VACUUM PACKAGING MACHINE CAPACITY : UP TO 5 KG PACK SIZE.

2 Cycles/Min.

1.0 FUNCTIONAL REQUIREMENT :

The vacuum packaging machine shall be used for packing of various dairy products viz paneer, cheese, khoa, chhena, peda etc. in the retail packing of 200 grams to 1000 grams or bulk packing of 5 Kg. in pre-formmed pouches of multi – layer oxygen barrier film.

2.0 DESIGN REQUIREMENT :

2.1 The trolley type model shall have high density acrylic see through lid with body

fabricated out of stainless steel material confirming to AISI 304 All product contact parts shall be fabricated from food grade stainless steel material conforming to AISI 304. The size of the vacuum chamber shall be 500 x 550 x 125 mm, which shall be sufficient to hold at least four filled pouches of 1000 gms on two seal bars located one on each side of the machine or one pack of 5 kg. at a time.

2.2 The machine shall have facility for inert gas flushing. It shall also have additional

seal pressure arrangement. The machine shall have facility to cut the excess material on sealed edge during sealing operation itself. Approximate bag size may be taken as 8” W x 10” L for 1 kg. product.


3.1 Type : Double chamber, double seal bar and trolley mounted type machine. 3.2 Capacity : Suitable to seal retail packs of 200 gms to 1000 gms, 4 packs at a time or

single bulk pack of 5 kg. The cycle time for sealing shall be 2 – cycles / min. with full vacuum, loading and unloading time shall be at actual.

3.3 Model : The machine shall be costom made to suit the requirement of technical specifications.

3.4 Material of construction : Chamber and housing shall be fabricated out of stainless steel material conforming to AISI 304. See through openable lid should be of high – density acrylic material of 25 mm thickness.

3.5 Chamber : The chamber shall be suitable to hold minimum four packs of retail size at

a time or one pack of bulk size. The chamber should be 500 x 550 x 125 mm.

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3.6 Seal Bar : The vacuum machine shall be provided with two seal bar, one of each side. The bioactive seal bar shall be suitable for sealing multilayer oxygen barrier material of thickness up to 200 MICRONS. The length of the seal bar is min. 475 mm.

3.7 Gas flushing : The machine shall have in built gas flushing facility to remove effectively air from the pouch and the chamber and flush inert gas in the chamber. The flushing arrangement shall have necessary controls for calculated quantity of inert gas flushing per cycle.

3.8 Seal pressure : Machine shall be equipped with an inbuilt facility for applying

additional seal pressure particularly when higher film thickness is used. 3.9 Excess material cutting : The machine shall have inbuilt facility to cut the excess at

the seal edge during sealing cycle itself. At the same time cut off film material should not be stuck with the seal bar.

3.10 Bag Size : Machine shall be suitable to pack any size of the bag up to 8” x 10” (4 bags

at a time) per cycle or single bigger bulk pack per cycle. 3.11 Overall size : The overall size of the machine shall be 600 x 750 x 900 mm. 3.12 Vacuum level : The maximum vacuum level can be achieved on this machine shall be

99.9% (725 Hg) in any of the cycle and the vacuum level shall remain constant during the operation to achieve better packing results. To achieve the desired vacuum level, a Hindvac, 21m3/h vacuum pump with 1 HP single phase motor should be provided.

3.13 Electric load : Total electrical load to run the machine should be mentioned. 3.14 The supply available shall be 1/3 phase, 230/240V, 50Hz. 3.15 Other features : Digital microprocessor control with 15 memories and accuracy up to

1/10th of a second. 4.0 TESTING & COMMISSIONING :

The manufacture shall be responsible for satisfactory commissioning of the machine at site. Supplier shall demonstrate the performance of the machine by packing different sizes of product’s packs at various vacuum levels. The necessary services if any shall be arranged by the Milk Union up to the machine.

5.0 DRAWING APPROVAL & INSPECTION :

Before starting of manufacturing of machine the supplier shall get their drawing approved by RCDF by submitting two sets of drawings. Inspection shall be carried out during manufacturing based on the approved drawing and specifications.

6.0 TOOLS & MANUAL :

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Supplier shall provided one set of tools and three sets of O & M manual along with machine required for day to day operation and maintenance.

7.0 SPARES : Manufacturer should also enclose a list of essential spares required for two years normal operations of the machine and their offer.

Note:-

S.S table for handling paneer for packing etc. and carrying out

miscellaneous work related to products of indigenous product . The size of

the table should be 6 ft. X 3 ft. of suitable height equipped with to S.S stool,

S.S paneer cutting / slicing knice four set.

Suitable paneer weighing machine platform type weighing capacity 10 kg.

Pumps of suitable capacity as specified earlier in the techanical

specification of pumps capacity 500 / 1000 should be supplied in paneer

section.

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SHRIKHAND

SECTION

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PANEER MILK STORAGE TANK CAPACITY : 1000 L


The storage tank shall be used for storage paneer milk, curd , chhach etc. or Pasteurizer cream having a fat content of 40 – 45 % / Cream would be ripened and stored in this tank at a temperature of 6 degree centigrade.

2.0 DESIGN REQUIREMENTS 2.1 Capacity : 1000 L. The volume of the tank should be such that after filling it up to the

rated capacity, the level would be 100 mm below the line where cylindrical shell joints the conical top.


Triple walled insulated and welded construction of sanitary design. 2.3 Slope : Sufficient slope should be provided towards the inlet – cum out let along the






should be fabricated from 2mm thick stainless steel for capacity 1000 L conforming to AISI 304.


fabricated from 2mm thick stainless steel sheet conforming to AISI 304. 3.3 Outer cylindrical Body : The outer shell, conical top and flat bottom should be

fabricated from 2mm thick stainless steel sheet conforming to AISI 304. 3.4 Insulation : The entire intermediate shell, flat bottom and inner conical top shall be

insulated in three layers as follows: 3.5 First layer: 25mm thick resin bonded crown 150 fiber glass compressed to 10mm.


4. Accessories :

a. Inlet-cum-outlet: 38mm dia cup type inlet cum outlet with two way plug

type stainless steel (AISI 304) flanged valve ending in complete stainless steel union. It should be provided at a height of 450 mm from the finished floor level – 1 No.

4.1 Air vent: Stainless steel (AISI 304) 150mm air vent to prevent formation of

partial vacuum during CIP and pressure during filling – 1 No.

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4.2 Man way : Stainless steel (AISI 304) man way of 450mm diameter and

located at the conical top – of the tank and provided with air tight hinged insulated stainless steel (AISI 304) door with tightening and locking device. The cover should be provided with stainless steel (AISI 304) anti-splash guard stainless steel (AISI 304) cleats should be provided near the man way for fixing and hanging rope ladder :- 1 No.

4.2.1 Sand Blasted level marks: It should be calibrated at 500 L intervals

and provided on the inner shell at opposite side of the sight glass. The level mark should be dark enough so it may be clearly visible.

4.2.2 Sight Glass: Stainless steel (AISI 304) sight glass assembly should be provided with toughened glass. It should be provided in such a way that one can easily read from the lowest level up to the maximum level mark. Stainless steel lamp shade for mounting 24 V and 100 watt bulb. The lamp holder should be made from brass – 1 No.

4.2.3 Agitator : Vertical heavy duty sweeping type Stainless steel (AISI 304)

agitator complete with mountings with geared motor of adequate capacity and should be able to uniformly mix cream in the tank within 10 minutes. The agitator shaft should be a rod – 1 No.

4.2.4 Sprinkler Pipe: A 25mm dia pipe ring of Stainless steel (AISI 304)

should be provided at the top of the jacket for sprinkling hot / chilled water on the outer surface of the inner shell. The complete sprinkler pipe ring should be removable when necessary. The complete pipe ring should end outside in a header with two separate connections for hot and chilled water. In addition to this a Stainless steel (AISI 304) steam sparger pipe / water steam ejector should also be provided in the bottom jacket and it should end outside in a flange and counter flange.

4.2.5 Spray Ball: Removable Stainless steel (AISI 304) cleaning device

located on conical top at either sides of the agitator drive to provided flooding of liquid over the complete interior surface and agitator during CIP. These should have stainless unions at the outer end connections – 2 No.

4.2.6 Drain: Made from Stainless steel (AISI 304) pipe of 38mm dia at the

bottom of the jacket with gun metal valve – 1 No. 4.2.7 U-seal: Made from Stainless steel (AISI 304) pipe 38mm dia at the

bottom of the jacket – 1 No. 4.2.8 Over flow: Made from Stainless steel (AISI 304) pipe 38mm dia at the

top of the jacket – 2 Nos. 4.2.9 Sampling Cock: It should provided on the inlet – cum – outlet and

should be in Stainless steel (AISI 304) construction with sanitary design – 1 No.

4.2.10 Thermowell : 200 mm long Stainless steel (AISI 304) inclined pocket

suitable for mounting probe of digital thermometer. The portion of the thermowell which is in the jacket should be insulated with rock wool or equivalent and totally shrouded so that hot water or chilled water does

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not come in contact with the insulating material. It should have 10mm BSP male threads and the digital thermometer is also to be provided by the tenderer.

4.2.11 Legs: Conical mild steel legs with Stainless steel (AISI 304) sheet cladding and stainless steel ball feet provided at the bottom of the tank. The stainless steel ball feet should have provision for height adjustment of 50mm – 4 Nos.

4.2.12 Ladder: Stainless steel (AISI 304) ladder for access to the sight glass

and geared motor assembly of agitator – 1 No. 4.2.13 Lifting lugs: Stainless steel (AISI 304) lifting lugs should be provided at

top – 2 Nos. 5.0 Painting: All the M.S. stiffeners used in the construction of the tank should be

painted with two coats of epoxy primer after thorough de-rusting. 6.0 TESTS: The following tests should be conducted by the manufacturer at works.

6.1 Dye penetration test for welding joints. 6.2 Water fill-up test of inner vessel for water tightness. Note : General arrangement of the equipment should be provided the attached reference

drawing. Makes of bought out items are as bellow : Geared motor Elecon. / Radicon Note :- (1) Scope of supply also include supervision of Installation & commissioning,


(2) Name plate should be provided on equipment define the water, steam, inlet, out let, overflow, airvent connection etc.

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SHRIKHAND MIXING MACHINE

Shrikhand mixing machine having capacity to mix shrikhand gradients of 10 kg at a time. All the parts of machine in contact with the product should be of S.S 304. The system should be of reputed make and ensuring the performance, guarantee of the product as per tender terms and condition . the system should be equipped with all required safety. i.e electrical and mechanical.

SHRIKHAND PACKING/ SEALING MACHINE

The shrikhand packing and sealing shall be carried out by curd cup filling machine.

SHRIKHAND CHACKA STAND

Suitable chacka stand need to be provided for shrikhand making.

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TECHNICAL SPECIFICATION OF BALANCE TANK WITH STRAINERS CAPACITY : 200 LTRS.


The balance tank with strainers is required for handling curd/ sugar for shrikhand making .

2.0 DESIGN REQUIREMENTS 2.1 CAPACITY: 200 Ltrs..

2.2 Dimensions of the tank: The tank should be Cylindrical of capacity 200 ltrs. of suitable height for handling curd/ sugar for shrikhand making . Slope: 1:15 towards the outlet.

2.3 Finish: All the welding joints are to be ground smoothly. All stainless steel surfaces are to be polished to 180 grits.

2.4 Joint Curvatures: All inside corners should have minimum radii of 25 mm 3.0 SCOPE OF SUPPLY 3.1 The Tank: The tank should be fabricated from 2mm thick stainless steel sheet

conforming to AISI 304. The top edges of the tank should be bent outward smoothly. It should be suitable to support the strainer – 1 no.

3.2. Accessories 3.2.1 SS Strainer : It should be fabricated from 2mm thick stainless steel sheet conforming

to AISI 304. It should be perforated, hole dia 2 mm the strainer should have S.S. flat stiffener strips 25 mm x 6 mm thick to carry leakage pouch load.

3.2.2 Legs: Mild Steel legs with stainless steel pipe (AISI 304) cladding, with stainless steel

ball feet provided at the bottom of the tank. The stainless steel ball feet should have provision for height adjustment of 50 mm. – 4 nos.

3.2.3 Outlet: The single bottom – outlet of 38 mm diameter. It should be fitted with a 38

mm dia stainless steel plug type flanged valve with complete stainless steel union on the other end. The outlet should be cup type and should be at a height of 230 mm from the finished floor level. – 1 no.


4.1 Dye penetration test for welding joints

4.2 Water fill-up test for water tightness of the tank.

NOTE :-

1. General arrangement of this equipment should be as per the attached reference drawing. The tenderer is required to provide detailed drawing to be got approved from RCDF.

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TECHNICAL

SPECIFICATIONS

OF

SERVICES

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TECHNICAL SPECIFICATIONS FOR THE TURNKEY JOB OF REFREGERATION PLANT FOR HANDLING 30KLPD MILK FOR INDIGENOUS PRODUCT PLANT AT MALPURA, RAJASTHAN. The job involves the turnkey project to be executed towards the supply, erection, testing & commissioning of various equipment for establishing refrigeration plant for milk processing capacity 30,000 litre per day at Malpura in Rajasthan. The equipment mainly shall comprise of ammonia compressors, ice bank tanks, ice accumulating coils, accumulator, air-purser, atmospheric condensers, condenser pumps, ammonia receiver, chilled water pumps, temperature indicator for IBT suction and discharge lines vapors.

A. Scope of work:-

The turnkey project shall cater to a load of milk chilling, milk pasteurization and keeping the packed milk at predefined temperature in cold store for 30,000 litre of milk per day. To cater to the refrigeration load of Malpura Dairy 2 numbers Ammonia compressors (1 operating + 1 standby) with IBTs, Ice Accumulating coils, Ammonia Receiver, Chilled water pumps, forward and return chilled water pipe lines with due insulations, necessary valves and fittings & related accessories, condenser pipes, condenser pumps, related valves and fittings, related ammonia valves and fittings, related accessories like electronic float, gauges, RTD alongwith temperature indicator of suitable range to indicate the temperature of suction and discharge line vapours, airpurser system etc. need to be supplied and installed.

The job involves supply, installation and commissioning of 2 Nos. 6”x6” size Frick/equivalent size Kilsokar make ammonia compressors, (equivalent make subjected to purchaser approval) Ice Bank Tanks, Ice Accumulating Coils, 2 Nos.

Accumulator, IBT Agitators with motors for the IBTs and wooden covers of Assam Teak / seasoned wood, forward & return chilled water pipe lines, Chilled water header, chilled water pumps, overflow and drain piping, atmospheric condensers, condenser pumps, related pipes, valves, NRVs, filters, various ammonia valves and water line valves, insulation and aluminium cladding of various pipe lines, electricals alongwith accessories viz electronic float, solenoid valve, ice limit switch, oil purging line, LCD temp. indicators, pressure gauges etc., related valves, fittings & gauges etc. at Malpura Dairy.

The supplier shall be required to ensure that no damage occurs to any of the structure / building of the Plant. If any existing structure / line is required to be removed for the job, the contractor has to make it good and restore to its existing state at his cost.

Important Note :- 1. The tenderer is advised to visit the site so as to apprise himself of actual

site conditions & quantum of work involved. 2. The Refrigeration Plant should be designed for operation of 2

compressor of capacity 6” x 6” at a time. The factor of safety for designing the plant should be considered accordingly.

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1.0 TECHINCAL SPECIFICATIONS:

1.1 Ammonia Compressors - 2 Nos. Two Nos. heavy duty industrial type double cylinder reciprocating Frick make ammonia compressor 6” x 6” size Frick / equivalent Kilsokar make (equivalent make subjected to purchaser approval) to operate at minus 10 degree C suction & plus 40 degree C

condensing temperature while running at 440 RPM. Supplier should specify the make, model and operating RPM of compressor. Maximum allowable RPM should also be specified. Each ammonia compressor should be complete with the following:-

- Automatic un-loader and capacity controller. - Suction and discharge manifolds with isolating valves. - Safety relief valve. - High, low oil pressure gauge. - High, low & differential pressure cutouts of Indfoss make - Gauge board (to be installed separately) - Oil gauge glass with valves, high pressure gauge and cutouts - All interconnecting lines and valves - Thermowell to be provided in suction and discharge lines - Provision for reverse cycle - Fly wheel - Belt guard, V. Belts. - Anchor bolts. - Tools and wrenches - Motor pulley.

1.2 For the Ammonia compressors – Ammonia oil separator of suitable capacity complete

with counter flanges with float valve and oil filter for automatic return of oil to the crank case shall have to be provided.

1.3 For each ammonia compressor Kirloskar / Siemens make 40 HP/ 30 KW TEFC squirrel

cage induction motor complete with Key shall have to be provided. The motor should be 3 phase, 440 V, 50 Hz. and for continuous rating for driving the above compressor. It should be provided with slide rails, foundation bolts etc.

1.4 SIEMENS/L&T make star-delta starter for each of above motor for the ammonia

compressor. Cable with tray for connecting motor and starter are included in the tender. Cable should be of reputed make of suitable size.

1.5 The likely length of each Gas Header of 100mm & 80mm will be 8 to 10 meters

approx. the suction vapour pipe is to be insulated. The actual suction vapour and hot discharge gas pipe length may vary. Hence supplier must quote their unit rate for supply and erection and insulation of gas pipes.

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All pipes to be used are to be of Tata Make ‘C’ class ERW only.

1.6 Supplier should note that scope of work includes complete supply, installation, testing and commissioning of compressors, motors, starters etc and therefore all allied work and requisite material falls in the scope of supplier except civil works of foundation. The suction and discharge lines are to be supplied and erected along with requisite valves & NR valves etc.

2.0 IBTs - 2 Nos.

Two Nos. of Ice Bank Tanks each of inner dimensions as 6.5 M x 2.25 M x 2.00 M high to accommodate a total of approximate 900 RMT Accumulating coil (say 450 RMT of coil in each IBT) & 2 nos. agitators (1 in each tank) are to be supplied and installed. The tanks shall be fabricated out of 6 mm thick M.S. sheet for walls including compartment/partition walls and 8 mm thick M.S. sheet for bottom. The tanks shall be complete with M.S. Framed structure and sufficient stiffeners to keep all the sides of tanks straight (without deflection) when full with water as well as during operations. 50 mm thick wooden covers of Assam Teak / Seasoned wood for tanka, overflow, outlet and valved drain connections shall have to be provided. The tanks shall be supplied in knock down conditions and fabricated at site.

However all civil jobs pertaining to construction of foundation for IBTs and wall all around IBTs (after insulation) etc. shall be carried out by concerned Milk Union, and is not in the scope of tenderer.

On the top of the IBTs necessary M.S. angle structure shall be required to be provided in order to make the wooden covers rest on it and to bear additional load of operators moving on roof of IBTs for operation / maintenance. The wooden covers for the tank should be fabricated in two equal layers each of 25 mm thick Assam Teak / seasoned wood. The two layers should be separated by a water proof paper. The covers should be made in sections for easy removal and inspection of tanks. The covers should be suitably varnished and provided with sufficient no. of sturdy lifting handles. The IBTs is to be compartmented in two suitable parts with suitable no. of coils on each side. Necessary horizontal and vertical stiffeners/supports to be clamped with coils to keep them in position. At the bottom, the coils shall have to be supported on M.S. channel of at least 75 x 40 mm size. All these shall have to be galvanized. General arrangement drawing of the coils, accumulator etc. shall have to be got approved by the supplier before fabrication.

NOTE: The dimensions of IB Tank can be altered to suit to site condition.

2.1 The Ice Accumulating coils are required to be supplied and installed. These coils shall be accommodated in the IBTs. The Ice Accumulating coils are required to be fabricated out of 32 mm N.B. M.S. ‘C’ class ERW pipe TATA make, sand blasted and spray galvanized after fabrication with the upper and lower headers, oil purging

276



arrangements etc. complete with accumulator, requisite ammonia valves etc. The Ice accumulating coils should be designed to ensure accumulation of minimum of 50 mm thick ice.

For each IBT 2 Nos. upper headers one each for one set of columns of coils shall be provided and each upper header shall be of 4” in dia and of M.S. ‘C’ class TATA make pipe. Similarly for each IBT the 2 Nos. lower headers, one each for one set of columns of corresponding coils shall have to be provided and each lower header shall be of 3” dia and M.S. ‘C’ class TATA make pipe. All the headers should be duly sand blasted and spray galvanised with risers.

2.2 The total length of Ice Accumulating coils shall be approximately 900 RMT. 2.3 The coil is to be so arranged in each tank so that there is a 6” clear air gap between

the adjacent coil in horizontal plane and 5” clear air gap between adjacent coils in vertical plane. However the first coil and the last coil shall have an air gap of at least 4” from the wall (including the partition/compartment wall). General arrangement drawing of the coils, accumulator and valves arrangement shall have to be got approved by the contractor before fabrication.

2.4 Each coil is to be placed in the IBT in such a fashion that top pipe of the coil is nearly

11” below the top of IBT. 2.5 Oil purging connections and valves shall have to be provided and installed. 2.6 Suitable accumulator shall have to be provided and placed on each IBT, with due

connections and fittings and accessories properly / placed. The accumulator shall have to be suitably insulated with 2” thick insulation and cladded by 26 gauge aluminimum sheet. The drawing showing the details of accumulator and arrangement of fittings and accessories upon it shall have to be got approved from RCDF.

The requirement of ammonia suction line approx. 5 Mtr. for the accumulator should be of MS ‘C’ class TATA make. This shall have to be supplied and installed with ammonia flanged valve of Super / Super Maini make in between the suction line and the accumulators. This piping shall have to be suitably insulated with 2” thick insulation and cladded with the aluminium sheet after making due connections to the accumulators. This pipe line shall be suitably supported on wall supports as per existing arrangement. Ammonia liquid line approx. 12 Mtr. OF MS ‘C’ class TATA make shall have to be provided from the receiver to the IBTs alongwith two Nos. Super / Super Maini make flanged valves.

2.7 Ammonia liquid receiver of suitable size and of adequate capacity (approx. 2000 Kg.) to receive the refrigerant of the system complete with the following:-

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Liquid inlet valve of suitable size for Double the capacity mentioned above. Liquid outlet valve of suitable size -do- -do- Oil and air purging valves of suitable sizes. Gauge glass with double valves, the gauge glass should be enclosed in a metal casing. Pressure gauge with valve. Safety valve with arrangement to connect its outlet to a place of safety and equalizing connection. Necessary water sprinkler system needs to be provided to safeguard against high head pressure and in the event of any leakage of ammonia.

2.8 Suitable electronic float of Manik/Manor/Cstle make alongwith solenoid valve interconnecting ammonia line and valves (bye pass line, expansion valve, strainer etc.) as required shall have to be provided for proper flow of refrigerant in ice accumulating coils. All ammonia valves should be of flange type.

(Schematic drawing to be got approved before installation).

2.9 3 Nos. (2 operating + 1 standby) 5 H.P. Suitable chilled water centrifugal type for 31 Mt. head gun metal Beacon make monoblock pumps having 3 phase 440 Volt TEFC motor.

2.10 One No. Ice Accumulating limit switch (for each of the IBT coil)o of

Danfoss/Indofoss/Manik make to be provided for automatic stoppage of ammonia compressors when desired thickness of ice is achieved on coils, for each set.

TESTING:- 2.11 The coil set shall have to be pressure tested at 18 Kg./Sq.Cm. pressure for leakage of

joints etc. and vacuum test before charging of Ammonia finally flushed with Nitrogen followed by vacuum testing before charging of Ammonia. Ammonia compressor will not be used of pressure and vacuum testing.

2.12 One M.S. ladder shall have to be supplied and installed for making access to the top

of the tanks. 2.13 The IBTs are to be painted suitably from inside with two coats of anti-rust paint. 2.14 The IBTs shall have 2 Nos. of chilled water agitators each with 5 HP TEFC motor

(Cromption/Jyoti/NGEF/Siemens make) and 18” dia impeller with proper guiding chute to be provided at IBT for ensuring proper circulation / agitation of water through coil spacing and all around IBT.

Suitable isolator, cable (upto 20 mtr.) double earthing with wire of 8 gauge for each IBT agitator motor to be supplied and installed.

2.15 Suitable overflow and drain pipe line shall have to be provided to cater to the new IBT and it should be of MS ‘C’ class of TATA make suitably supported maintaining

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aesthetic symmetry. The overflow pipe of 2” dia MS ‘C’ class TATA make with funnel arrangement shall have to be provided for the IBT. The drain pipe of 2½” dia MS ‘C’ class TATA make with butterfly valve of 2½” (65 mm ) size of Audco / Crowley & Ray / Castle make shall have to be provided for the set.

2.16 The chilled water outlet pipe of 100 mm dia MS ‘C’ class TATA make shall have to be

provided alongwith 100 mm strainer with 100 mm butterfly valve of Audco/ Crowley & Ray / Castle make. It shall be led to suction of the chilled water pumps. Necessary non-return valve of 100 mm dia and of Leader make shall have also provided for each IBT.

3.0 Sufficient quantity of insulation material (expanded polysterene) for chilled water tank

is to be supplied and fitted.

(a) 100 mm heavy density expanded polystyrene having average density of 18 Kg./cu.m. for floor of the tank in two layers of 50 mm each.

(b) 100 mm normal density expended polystyrene having average density of 16 Kg./cu.m. for sides of the tank in two layers of 50 mm each.

(c) Sufficient quantity of vapour barrier like tar felt and polythene sheet, bitumen, chicken wire-mesh etc. as required are included.

3.1 All ammonia valves are to be of Frick/Super/Super Maini / Crown make and water line butterfly valves of Audco / Crowley & Ray / Castle make.

3.2 The necessary compressor oil and ammonia gas required shall be provided by Milk

Union and shall have to be charged into the system by the contractor while commissioning the plant.

3.3 All pipe lines, cable installation should be properly supported. 3.4 The power supply shall be provided by Malpura Dairy free of cost. The supply shall

be made at one point at site. The contractor shall make his own arrangement to carry and distribute the power wherever it is required within the site as per Indian Electricity Rules. Water shall also be provided free of cost by Malpura Dairy.

The temporary supply lines shall be removed and the site shall be cleared by the contractor after the completion of the work at his own cost. Forward & Return Chilled Water Pipe Lines

Supply, installation, testing & commissioning of necessary forward & return chilled water pipes, duly insulated and aluminium claded for connecting to 10,000 LPH milk chiller & 5,000 LPH milk pasteurizer.

The forward chilled water line shall be required to commence from refrigeration room and to lead to process hall and terminating at the end of the process hall working out

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to be approx 42 mtrs. in length. This pipe line should be of 4” dia M.S. ‘C’ class TATA make. Piping of 2½” dia M.S. ‘C’ class TATA make from this main pipe in the process hall shall lead to the milk chiller of 10000 LPH capacity & the length of this pipe shall be approx 9 mtrs. Similarly piping of 2½” / NB 65 dia M.S. ‘C’ class TATA make from this main pipe in the process hall shall lead to the milk pasteurizer of 5,000 LPH capacity & the length of this pipe shall be approx 9 mtr. Thus there shall be requirement of approximately following piping for forward chilled water pipes :-

1. M.S. ‘C’ class TATA make – 4” dia. – approx 42 mtr. 2. M.S. ‘C’ class TATA make – 2½” / NB 65 dia. – approx 18 mtr.

In the similar fashion there shall be requirement of approximately following piping for return chilled water pipes :-

1. M.S. ‘C’ class TATA make – 4” dia. – approx 42 mtr. 2. M.S. ‘C’ class TATA make – 2½” / NB 65 dia. – approx 18 mtr.

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These pipes shall be suitably insulated by thermocole pipe halves and than bound by suitable wire meshing and finally cladded with at least 26 gauge aluminimum sheet suitably. For the 2½” dia pipe lines leading to the chiller as well as pasteurizer necessary 2” size non-return valve (vertical) of Leader make shall have to be provided in each line. All these pipe lines shall be required to be fixed properly on suitable supports drawing of which should be got approved from Project cell of RCDF. All pipes shall be terminated with flange and counter flange / dead counter flange as per the requirement. The quantities of above pipe lengths shall depend on actual site conditions and may vary and hence the tenderer is required to quote the unit rate for the above pipe sizes separately for bare pipes and pipes with due insulation and cladding. However for the purpose of drawing financial comparative statement, above quantities of pipes shall be taken into consideration. Necessary inter locking arrangement for safe operation of Ammonia compressors, condenser water pumps, LP HP cut-outs etc. need be provided. Two numbers independent earthings for ammonia compressors & one number independent earthing for chilled water pumps, IBT agitator motors need be provided.

Atmospheric Condensers – Supply, installation, testing & commissioning of atmospheric condensers :-

To cater to the refrigeration requirement, 10 stacks of atmospheric condensers with 12 pipe high in each stack & with each pipe length of 20 ft. (and with a provision to add 3 stacks further in future) need be supplied, installed & commissioned

1.1 There shall be 10 stacks of atmospheric condensers with 12 pipes high in each

stack & with each pipe length of 20 ft. long. The condenser coils should be fabricated from 2” dia heavy duty M.S. ‘C’ Class TATA make ERW pipes duly hydraulically tested. The pipes need to be 20 ft. long x 12 high x 1 RD supported on channels of 3” x 1.5” (with the provision to add 3 stacks further in future). These should be duly sand blasted and properly spray galvanised and complete with the following :-

- Gas header of 100 mm dia and liquid header of 80 mm dia. These should be of

M.S. ‘C’ class heavy duty TATA make ERW pipes duly sand blasted and spray galvanised.

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- Gas and liquid valves of suitable size flanged type and of Super / Super Maini / Crown Make.

- Each stack should have suitable size flanged valves in-between every stack & header - both for gas as well as liquid.

Water sprinkler pipe to be fabricated from 2” dia G.I. ‘C’ class heavy duty TATA make pipes with suitable flange connections. These shall have to bhe suitably supported on channels etc.

Necessary ammonia valves and related piping for suction and liquid lines shall have to be supplied and installed. All piping should be of M.S. ‘C’ class TATA make and all ammonia valves should be of Super / Super Maini / Crown Make.

Necessary non return valves of suitable size and of Leader Make shall have to be supplied and installed in the water circulation system set up.

All nuts and bolts should be of good quality and duly cleaned and properly spray galvanised.

Condenser coils should be duly supported on M.S. Channel with nuts and bolts both sides complete with inlet and outlet flanges for gas inlet and liquid outlet and duly galvanised. The drawing should be got approved from RCDF.

Sub headers of suitable size and connecting required coils to each sub header shall have to be provided. The main header should be suitable to connect suitable stacks coils of condensers equidistantly spreading over the beams of the condenser tank by means of flanges. The header should be sand blasted and spray galvanised.

One number independent earting shall have to be provided for the condenser pumps. Consensor water circulation pumps 5 HP – 2 Nos. (1 operating and 1 stand by) of suitable model to deliver maximum discharge at 12 MWC for condensers and compressor jacket cooling. The pump should be monobloc type of Kirloskar / Becon make (Gland type). The pumps should be mounted on a MS channel frame. The pumps should be supplied with suitable GI covers for rain protection.

GI ‘B’ class pipe valves and fitting comprising of butterfly valves, non-return valves, strainer etc. to interconnect pumps, condensers and compressor jacket cooling valves and fittings etc. - One lot

Ammonia pipes and fittings conforming to IS 1239 comprising of ammonia valves, non

return valves, stainers, supports etc. to interconnect all refrigeration equipments viz compressors, condensers, receiver and IBT accumulators etc.

Controls for IBT comprising of electronic level controllers, solenoid valves of Manik /

Castle make.

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2.0 Testing :

The coil shall have to be pressure tested at 18 Kg. / sq.cm. for 24 hours by air for detecting of leakage of joints. 2.1 One air purser alongwith all necessary valves to be provided. 2.2 The instruments and controls like digital thermometer, pressure gauges

etc. are of standard make as specified in tender document. Photocopy of calibration / test certificate as available from manufacturer covering the batch no. or lot size shall be provided by supplier.

Note : A. Scope of electrical work & other items :

1. Complete control wiring of refrigeration system with suitable control cable. 2. Connection of condenser pump with main refrigeration panel with suitable

coper armored cable. Four core 2.5 Sq.mm. 3. Connection of compressor motor & starter from main panel with suitable

aluniminium armored cable. 4. All required Inter lockings LP, HP cutouts, Solenoid valves, condenser pump

etc. 5. Supply, installation & commissioning of digital temperature indicator, RTD’s

with suitable cable, same placed to indicate the suction and discharge vapour temperature.

6. Placement of isolator on both IBT agitator 7. The cables of Gloster / CCI / ICL / Ralison / Hawell make needed to supplied.

All necessary lugs of Dowell make for the various cables with due crimping shall have to be supplied and installed.

8. Arrangement of reverse cycle operation. 9. RTD & Temperature indicator for indication of temperature of section and

discharge vapour line. 10. Two valves at suction of compressor. 11. Minimum two week trial run of Refrigeration plant, replacement of compressor

oil and filters etc. during trial run is in the scope of tenderer. 12. The make of all the motors would be Bharat Bijlee / Kiroloskar / ABB /

Siemens. 13. All ammonia pipes lines would be of MS ‘C’ Class and water pipe lines would be

of GI ‘B’ Class only. However chilled water pipe line would be of MS ‘C’ Class. 14. The support for condenser would be of double MS angle 50x50 size instead of

channel. 15. The preferred choice would be Frick Make compressor model 6”x6” being slow

speed. However, in case of any delivery problems the Kirloskar Make KC-2 also be considered.

16. The Ice limit switch would be of Manik / Manor make. 17. The size of chilled water supply and return line should be 4” dia. 18. Chilled water connection from main chilled water supplier line to Cream tank(s)

and cream tank to main chilled water return line is also scope of work. Approximate supply and return pipe line size 40 NB qty. 36 Mtrs.

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19. Enclosed site building plan for your ready reference and assessment of quantum of work involved.

B. Equivalency of other make ammonia compressor with Frick make 6 x 6 compressor should be made at minimum operating RPM not at maximum say operating range of any equivalent compressor is 450 to 1000 RPM then TR of compressor should be matched at 450 RPM not at 1400 RPM, equivalency at maximum RPM is not acceptable.

Special notes : This is a turn key project. The quantities of various items listed are tentative only and may vary on either side during execution. The final quantities of these would be as per site conditions. Cost of installation for any addition or delition in quantities will be calculated based on the unit prices indicated. All necessary material which may be required for the successful completion of the project falls in the scope of the work. If any extra quantities of quoted items are needed then the tenderer shall supply those at the quoted unit price. If any extra item(s), not included in the tender but required for successful completion of the work, the same will be either supplied by the RCDF or Milk Union and erected by the tenderer or supplied and erected both by the tenderer at mutually agreed rates considering purchase price, taxes and handling charges etc. In addition to the standards mentioned, all works shall also conform to the requirements of the following:- a) Indian Electricity Act and rules framed thereunder. b) Fire insurance regulations. c) Regulations laid down by the Chief Electrical Inspector of the State / State

Electricity Board. d) Regulations laid down by the Pollution Control Board. e) Regulations laid down by the Factory Inspector of the State. f) Any other regulations laid down by the local authorities. g) Installation operating manuals of original manufacturers of equipment.

Note:- It is a turnkey project, of complete refrigeration work for setting up

indigenous product plant at Malpura. The scope of the work include supply, installation and commissioning of aforesaid refrigeration system and chilled water pipe line circuit, valves and fittings etc. required as per site condition.

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TECHNICAL SPECIFICATIONS FOR SUPPLY, INSTALLATION AND

COMMISSIONING OF OIL FIRED BOILER SHELL TYPE CAPACITY 1000 KG./HR.

1.0 FUNCTIONAL REQUIREMENT

1.1 General Description :

The oil fired boiler would be required to generate a dry saturated steam for use in various processes in plant. It would cater to considerable varying steam requirements depending on various processes schedules.

2.0 DESIGN REQUIREMENTS 2.1 Capacity and Working Pressure : Capacity, working pressure and quantity for the

boiler should be as per the details given in clause 11.0. 2.2 Dryness of steam :

Dryness of steam shall be 98%. The boiler should be designed for adequate size of barrel having necessary internals, etc.

2.3 Type of Boiler :

The boiler should be IBR, horizontal shell type smoke tube fully packed 3 pass wet back automatically control tested proven under rigorous conditions and subject to the strictest quality control procedures and arrangement for obtaining higher boiler efficiency.

2.4 Fuel : The boiler should be designed to use Furnace oil of net calorific value as given below : Furnace oil - 9650 Kcal/Kg. 2.5 Thermal efficiency :

The thermal efficiency on NCV basis of oil at 100% load is 89% and 88% at 50% load. Any tolerance on efficiency to be specified, Thermal efficiency should be 89% at NCB.

2.6 STATUTORY REQUIREMENTS

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The boiler should comply with the latest Indian Boiler Regulations (IBR), International Standards Organization (ISO), PCB and other statutory regulations/requirements. The minimum requirement shall be as per the details furnished hereunder. The electrical equipments, installation should comply with the latest Indian Electricity Regulations, CEIG and the EB regulations of the state in which the boiler is installed.

The boiler should be got approved by the supplier from the statutory authorities and any modifications changes if suggested by the authorities shall be carried out by the supplier without any additional cost. IBR certificate shall have to be obtained by the supplier and handed over to the buyer.

3.0 SCOPE OF SUPPLY

3.1 The complete boiler having steam generating arrangement, casing, burners, pumps, controls, instruments, ducting, chimney and all necessary accessories should be supplied. a. Boiler should be horizontal, shell type fully packaged 3- pass smoke tube design,

automatically controlled, tested and proven under rigorous conditions and subject to the strictest quality control procedures.

b. The boiler should be of genuine three pass flue path. Flue gases should pass through the furnace (first pass) whereas second and thirds passes should be formed by nests of smoke tubes. At the end of the furnace the flue gas reverses into second pass tubes. (i) The boiler shall be complete with all mountings, accessories, controls etc. (ii) Boiler construction shall be in accordance with the latest revision of Indian Boiler

Regulations 1950, Act 1923 applicable and in conformity with AOTC requirements for unattended boilers. All materials used shall be approved and tested as per relevant existing codes. All the welded joints shall be as per code requirement.

(iii) The boiler should be of modern compact design and be genuinely packaged design. The design source should confirm to international design. The boiler and the burner design must be preferably from the same source to ensure perfect matching of burner and boiler.

(iv) The fire tubes in the tubes nest should be plain without any restriction inside. These tubes should be easily accessible both from inside as well as outside for inspection and maintenance. These tubes are to be tightly expanded in the tube plate and seal welded. The required number of stay tubes and stay bars are to be fitted the boiler. The stay tubes should be seamless & strength-welded to tube plates.

(v) All working parts of the boiler should be accessible for ease of inspection and maintenance. On the shell, one elliptical mandoor and on tube plate one mud hole must be provided. Access to the combustion chamber should be through bolted refractory lined access door whereas tube nest should be exposed through hinged mounted front door.

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(vi) Boiler front door is lined with ceramic fiber blanket with SS sheeting on the tube side of the door.

(vii) The boiler mountings shall be as per the Extent of Supply.

(viii) The boiler shall be designed and constructed to generate steam at efficiency of 89% on net calorific valve (NCV) basis. Efficiency shall be demonstrated as per standard BS – 845 Part 1 Indirect method.

(ix) The cylindrical shell of the boiler should be insulated. A movable ladder shall be provided which can be moved as per convenience. Boiler should be skid mounted. (x) Boiler and accessories shall be mounted on a single base frame. Individual

systems such as feed water pump etc. may be on separate base plates welded to the boiler base frame.

(xi) The boiler shall not require any special foundation for the boiler and its mountings/fittings. It should be able to be mounted on simple PCC foundation.

c. Fuel oil system : This shall be suitable for handling the fuel specified. Burner shall be mono-bloc type, step-less modulating sequence control, turn down ration 1:3. Oil pump and FD fan is driven by the same motor. The built in electric heater with three elements is provided for ensuring the conditioning of furnace oil for firing in the boiler. The electrical oil pre-heating system shall 100% pre-heating for the rated boiler capacity.

d. Combustion system: This system consists of a forced draft combustion air blower

with motor, mechanical atomizer burner assembly, photocell operated safety device, ignition electrodes, transformers, etc. Burner assembly shall be bolted on combustion chamber and that the burner is lit only when the entire burner assembly is fitted and is in a closed position, ready for operation. Pressure jet atomisation shall be provided. The burner should be capable of firing furnace oil of viscosity upto 3500 Red. Sec. at 100 deg. F .Spring loaded explosion door & fusible plug provided for ultimate safety. The entire assembly should be engineered in such a way that burner moves alongwith the door when the door is opened for tube cleaning. Burner must be with turn down ratio 1:3.

e. Feed water System: 2 nos. electrically driven vertical centrifugal multistage pumps

mounted on the boiler frame itself with motor capable of using feed water at temperature of 120 deg C with all SS internals, interconnected pipework between pumps and feed check valves. Feed water day tank (by customer) shall be placed at an elevation of 3.5m approx. from finished floor level.

f. Blowdown system : Automatic Blowdown Control System based on conductivity

principle with pneumatically actuated valve for efficient control of TDS level within the boiler shell. This system shall be installed in parallel to the manual blowdown valve.

g. Controls : The sequence control system shall be provided. The relay based control

panel cum MCC shall be mounted on the same boiler frame. (i) Interlocking of the feed water pumps and water level in the boiler (ii) Audio–visual alarm for danger level of water in the boiler and also for flame

failure.

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(iii) Programmer controller to ensure sequence of boiler start-up after ensuring required temperature and pressure of oil, air etc.

(iv) MCB’s and contactors shall be provided for all electrical drives for the boiler (v) Pilot lamp to indicate operating status of the various equipment. (vi) Complete internal wiring to ensure power supply at a single point on the panel. (vii) Indicating lamps/ Audio alarm shall be provided for the following parameters -

- Low water level in the boiler - Burner flame failure - Feed water pumps failure - Damper closed position

Pressure switch should be provided for burner interlock. 3.1.3 Insulation : All portions of the Boiler not covered by the Boiler casing, are to be

lagged with glass wool mattress 75mm thick & density 150 Kg./mз retained in position with wire mesh.

The boiler shell is then to be covered by GI/Alunimium cladding of 24 SWG thickness duly pre-treated before painting. The temperature of the outer shell should not be more than 15° C of the ambient temp.

3.2 Burner :

Boiler burner should have multi nozzle control with sequence controller on variable

load. Burner turndown rations 1:3. 3.3 Chimney & Ducting :

CHIMNEY : The technical specification of Chimney and flue gas ducting suitable for Oil Fired IBR Boiler Capacity – 1000 Kg./ Hr. are as per enclosed schedule - II

For the flue gas duct between boiler and chimney a length of 4 metre has been envisaged to be supplied and erected. However as per site conditions there may be requirement of some variation in this length. The tenderer is required to quote rate as per running meter basis for fabrication & erection both, for any additional length of such ducting.

4.0 Extent of Supply

The package boilers for specified duty shall be supplied complete with all accessories in all respects, but not limited, to the following, within vendor’s battery limit.

- Oil fired package boiler complete with all accessories as specified such as fuel oil system, FD fan, oil heating system, boiler mountings, motors, starters, etc. Foundation bolts for all items to be supplied.

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- Two feed water pumps of adequate capacity and rating complete with motor, starters etc.

- All necessary instrumentation complete with pre-wired control panel - Inter connecting piping, fittings etc. - Inter connected power & control wiring and instrument tubing etc. - Items required for installation, commissioning & start up of boiler

The following items, but not limited to those mentioned, shall be supplied with the boiler. Pressure Parts

a. Boiler Shell 1 no.

b. Tube Plates 2 nos.

c. Furnace Flue 1 no.

d. Combustion Chamber 1 no.

e. Boiler Tubes 2 lots

f. Stays (Tubes, Bars, Gussets) 1 lot

g. Mud door on tube plate 1 no.

h. Man door 1 no.

i. Stand Pipes for Stop, Feed check, Safety and Blowdown Valves

1 lot

j. Stand pipes for gauge glass and level controller

1 lot

General Construction Parts

a. Front casing with hinged door 1 no.

b. Rear casing with removable doors, Flue outlet flange

2 lot.

c. Insulation and sheeting for boiler shell

1 lot.

d. Refractory for front & rear access doors with support base frame. Refractory for furnace ring / burner ring

1 lot.

Accessories

a. Oil firing equipment Pressure jet, automatic, with necessary valves, fittings & mountings – 1 set

b. Oil pump with drive motor 1 no.

c. FD fan with drive motor 1 no.

d. Electric pre-heater 1 no.

e. Multistage feed pumps with motors 2 nos.

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Mounting & Fittings

a. Main steam stop valve 1 no.

b. Safety valve 2 nos. (with each capable of 50% venting capacity)

c. Feed check valve 2 nos.

d. Auxillary valve 1 no.

e. Blowdown valve with Automatic Blowdown Control System

1 no.

f. Isolating valve for water level controllers

2 nos.

g. Isolating valve for pressure switches and pressure gauge

2 nos.

h. Drain valve for water level controller

2 nos.

l. Sight glass assembly 1 set

* all the valves should be Piston valve with Asbestos free packings.

Instrumentation

a. Water level controllers 2 no. for feed pump operation and low water level alarm

b. Over-ride controller 1 no. for lockout under extra low water level alarm

c. Steam pressure gauge with cock

1 no. For display of boiler steam pressure

d. Water level gauge assembly

2 nos. For display of water level in the boiler

c. Switch gears, relays, connectors

1 set For individual controls of equipment through control panel

d. Audio / visual alarm 1 set In case of unsafe operation for lockout under extreme conditions

e. Pressure and temp gauge with thermostat

1 set for burner operation

f. Control panel 1 no. For housing above instruments and switchgears

Controls & Safeties

a. Oil temperature indicator 1 no. Local cum panel mounted to indicate oil temperature

b. Pressure switch 2/3 nos.

For firing positions of burner

c. Photo resistant cell 1 no. Flame failure and audio visual alarm

d. Temperature controller 1 no. To control oil temperatures in burner heater before nozzle with audio visual alarm and burner trip

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e. Sequence controller 1 no. To control sequence of firing, pre-purging etc.

f. Modulating mechanism 1 no. Stepped / Three stage modulation

g. Low oil pressure switch 1 no. To trip burner with audio visual alarm

h. Level controller 2 nos. To regulate feed water pump operation and trip burner in case of very low level with audio visual alarm.

Safety Interlocks

Unsafe condition Instrument Action

High water level Level controller No. 1 Feed water pump trip. Low water level Level controller No. 1 Alarm & Burner Shut down

Extra low water level Level Controller No. 2 (Overriding controller)

Alarm & lock-out

Flame failure Photocell Alarm & burner trip

Boiler high pressure Safety valves Lift & discharge

Piping

Feed water : Feed pumps outlet to boiler shell Oil : Burner integral oil piping

Drain : Interconnecting drain piping within battery limits

Electricals

The control panel must be a part and parcel of boiler/boiler package. It should contain all necessary switchgears, safety alarms/interlocks and burner management system and is to be mounted on the boiler itself eliminating any cabling requirement at site. Boiler should be complete with all necessary electrical cabling from the control panel till burner / FW pumps etc. Power cables shall be 1100 V grade, PVC insulated & PVC overall sheathed. Control cables shall be multi-strand copper conductors of minimum 2.5 sq.mm. All motors shall conform to squirrel cage induction motors, TEFC, IP-55, class ‘F’ insulation.

MCC Cum Control Panel

A MCC cum control panel, complete with main isolator switch, starters, auxiliary contactors, relays, fuses, rotary switches, indicating lamps, isolator, hooters with programmer and combustion safety relay. The panel should be completely pre wired and factory tested. It should be mounted on the boiler itself and shall not require any separate foundation.

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Insulation & Cladding

The boiler should be completely insulated in the factory itself and there should not be any site work involved for insulation and electrical cabling. The cylindrical shell of boiler must be insulated with glass wool / Rock wool mattresses of desired thickness and should be housed in a box shaped CRCA covered frame giving the boiler a provides neat appearance and also reducing heat loss due to the air gap between insulated shell and outer sheet metal cover. The top plate of the box should be designed to provide working platform for maintenance.

Refractory

Suitable refractory material is provided for all required parts as follows : Front door : Ceramic fiber blanket with SS sheeting Rear door : Hysil blocks with Kynex HG / Insulyte 7 Furnace ring / burner ring : Hysil blocks with Insulyte 7

5.0 Services

The following services shall be provided by the vendor –

Supervision of Erection & Commissioning IBR Approval of Boiler upto Provisional Firing Order.

6.0 BATTERY LIMITS :

a) Feed water The scope of work of the supplier starts from the existing header of feed water

located within the existing boiler house. b) Fuel gas The scope of work of the supplier is up to outlet of flue gas chimney. c) Steam The main steam out put connecting pipe of suitable size shall be drawn from the

outlet flange of non-return valve fitted after the outlet valve of the boiler. Same to be connected in steam header having provision of one stand by boiler of similar capacity, the high pressure line from this header has to be extended up to approximately 35 Mtrs. and to be connected with PRS (Pressure Regulating Station). The supply, installation and commissioning of PRS is also in the scope of supply. The aforesaid high pressure line and PRS should be able to accommodate steam flow rate i.e 2000Kg. per hr. at boiler pressure i.e. 10.5 Kg. per Cm2. The steam pipe from safety valve discharge shall be taken

outside the boiler house and the steam pipe for heating of fuel in the pre-heaters, burner etc., steam outlet shall be taken up to the respective units. All

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necessary pipe fittings and accessories, valves, strainers, PRV controls etc., as required shall be provided by the supplier.

d) Blow down The scope of work of supplier is to take the piping from each blow down

connection to the separate blow down pits located outside the boiler house. Existing trench to be used.

e) Drains All drains from water level controllers, gauges, press stats, steam pre-heater,

sample cock, mobrey etc. shall be taken outside the boiler house using the existing trenches.

f) Fuel oil The scope of work of the supplier starts from oil service tank outlet valve

(service tank located within the boiler house) to boiler through oil pre heater and return line from boiler to oil return header, adequately sized. Necessary steam tracing of these pipelines is to be carried out and is included in the scope of the work. Existing trenches are to be used.

g) Electricals The purchasers/client shall provide incoming electrical connection and earthing

to the supplier's boiler control panel. From control panel all power and control cable distribution shall be done by the supplier. Earthing network from boiler control panel/control panel trench to the various equipment is in the scope of the supplier. Existing trenches are to be used.

h) General

All necessary bolts/nuts, templates etc. shall be provided by the supplier. All indoor trenches have already been provided by the client/purchaser and these shall be used for the oil, water, drain and electrical as described above, but necessary steel supports/cable trays etc. for piping/ducting and cabling etc. are in bidder's scope. The supplier shall visit the dairy plant and familiarize himself with the layout of existing trenches within the boiler house, proposed location of chimney, location of feed water and oil service tanks and also the location proposed for the new boiler. The list of drawings to be prepared by supplier and submitted to purchaser for approval is listed elsewhere in the order. Any foundation/structures at the

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chosen location shall be removed by the client and new foundations as proposed by the supplier shall be provided.

7.0 Guarantees

The boiler supplier shall guarantee the following 1. The boiler shall be guaranteed for trouble free operation for a period of 12 months

form the date of handing over. 2. Performance guarantee runs shall be conducted as per BS 845 part I – 1987 indirect

test method – after one month of continuous trouble free operation. 3. Any defect shall be rectified free of cost to the entire satisfaction of the purchaser. 4. All guarantees from equipment suppliers will be vested in the client. 8.0 Makes

1. Boiler J N Marshall, Thermax or equivalent make (Purchaser to approve)

2. Feed Water Pump Salmson, Grundfoss, KSB

3. Fuel oil pump Neels – Entees, Suntec

4. Burner As per Mfg Standards

5. Blower Burner manufacturer’s standard

6. Sequence controller Burner manufacturer’s standard

7. Photocell Burner manufacturer’s standard

8. Motors Crompton, Laxmi Hydraulics

9. Main steam stop valve & Mobrey Isolation valve

Forbes Marshall, BDK, Uniklinger

10. Steam & Water Valves Forbes Marshall, Uniklinger, BDK

11. Non Return valve Spirax Marshall

12. Safety valve Fainger Lesser, Sempell

13. Blow down valve Levcon

14. Level indicator Teleflo / Tectrol

15. Level controller Malhotra

16. Pressure switches Indfoss

17. Pressure gauges Forbes Marshall, Eq

18. Steam flow meter Forbes Marshall, Eq

19. Automatic Blowdown Control System

Spirax Marshall

20. Electrical Switch Gears L&T

21. Cables Polycab

22. MCB L&T

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9.0 Control Panel : 9.1 The complete control panel shall be supplied and installed with all instruments and

components such as sequential controller, push buttons, indicating lights, window annunciator, temperature / pressure controller, digital temperature indicators etc. The control panel should be made from 14 Gauge CRCA sheet duly pretreated and painted. It should also have audio alarming system for all the fault condition, which should appear, visually on annunciator window.

Few of the fault conditions are : a) Flame failure :

Flame failure protection should be provided. However, in case of flame failure and accumulation of fuel oil inside the combustion chamber, the audio, visual alarm should be energized.

b) Fuel oil temperature low :

In case fuel oil temp is low, the audio visual alarm should be energized. The interlock should be provided such that, without proper fuel oil temp boiler can not be started.

c) Electrical heater on : The electrical heaters should maintain the temperature of fuel oil, whenever

starts there should be indication on annunciator. d) Steam pressure more than set value : If the steam pressure goes above the burner cutoff set pressure value,

boiler should be stopped and there should be audio-visual signals. e) High, low and extra low water level should energies the audio-visual

alarm.

The low and extra levels apart from audio-visual alarm should switch off the burner.

The hooter should stop once it is acknowledged, but the annunciator

should keep light 'ON' till the time fault conditions are attended. f) Following controls also should be provided :

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- The boiler can not be started till the correct fuel inlet conditions like temperature, pressure and other parameters are met.

- There should be control for start up and shut down purge sequences.

- The control also should be provided for burner ignition and modulating.

- To maintain steady steam pressure steam pressure switches to control the combustion should be provided.

- MCB and contractor should be provided with electrical device of boiler. 9.2 The control panel should have suitable incoming and outgoing feeders. All

contactors, switches, starters, HRC fuses, relays, terminals etc., should be neatly mounted and pre-wired in the panel board terminating in suitably rated terminal blocks/epoxy based insulators. All fuses should be HRC link type. The components of the control panel should also selected as follows:

The main incomer to the control panel shall be of suitably rated, TP, 35 KA,

MCCB, with shunt coil. Suitable copper terminal extensions shall be made and fixed on epoxy based insulators if required for terminating the incoming power cable to the control panel.

Ammeter and voltmeters shall be provided with selector switches. Resin cast CT

shall be provided for connecting the ammeter and the voltmeter shall have control fuses.

All contactors shall have rated coil voltage of 240 V AC. Individual isolators,

fuses, starters, controls etc., shall be provided for each of the outgoing feeders.

Minimum rating of contractor shall be 16 Amps. For star-delta starters all contractors shall have same rating.

The wiring within the panel shall be done using copper wires. Minimum section

of power wiring shall be 4 Sq.mm and that of control cable shall be 1.5 Sq.mm Indicating ferrules at both cable ends shall be provided. Lugs shall be provided for all power and control cable terminations.

Star-Delta starters shall be provided for the motor ratings above 10 HP. DOL

starters shall be provided for the motor ratings of 10 HP and below. However, for feed water pumps DOL starters may be provided irrespective of pump horse power.

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Aluminum armored power cables shall be used for the motors. Minimum size shall be 4 Sq.mm. All cables shall be sized as per the standard practice and as per approval of client

Aluminum earth bus of 25 x 6mm or equivalent area shall be provided at the

bottom of the panel for connecting the earth grid to the panel at two places. Makes shall be as per the approved makes : 9.3 All starters, fuses, isolator, heater ON/OFF push button indicating lamp etc. shall

be mounted in the panel and the same shall be dust and vermin proof. 9.4 Indicators, rotary switches etc. shall be provided on top of the panel and the

same shall be at convenient operating height. 9.5 The panel shall be completely pre-wired. The electric supply shall be 415 volts,

50Hz AC. 9.6 The panel board shall be installed in boiler house as per approved layout. 9.7 Necessary isolators near motors shall be provided as per statutory requirement. 9.8 All feeders above 10 HP to be provided with ammeter with selector switch. 9.9 All field wiring (between control panel and field instruments/controls) shall be in

flexible conduits and shall be heat resistant type. 9.10 Painting : All the exposed MS surfaces and boiler shall be thoroughly cleaned with sand

blasting followed by two coats of heat resistance anti corrosive primer followed by two coats of heat resistance paint as given below :

Item Colour

All Valves Oxford Blue

Front and rear casings Black

Platform Black

Sheeting Oxford Blue

Burner As per manufacturer's

Control panel Siemens Grey

Feed pump As per manufactur's standard

9.11 Boiler fitting and accessories :

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The boiler should have all necessary standard mounting and fittings for safe and efficient operation of the boiler and in accordance with the latest IBR regulations. The boiler shall have all the components as listed below. It will be the supplier's responsibility to indicate any components not listed in this specification but required as per the statutory regulations. Unless otherwise specified the steam valves shall be flanged (flanges as per BS 10 TAB H). All screwed connections shall be BSP.

It will be the supplier's responsibility to provide any components / items not

appearing in the list, nor additionally listed by the bidder in their offer and the same are found to be required as per the statutory regulations. Supplier shall provide such additional components / items within the scope of the work and no additional cost will be considered for the same. All valve should be piston type and Asbestos free packing.

9.12 Spring loaded full lift type safety valve having a total discharge rate exceeding

the maximum steam producing capacity of boiler with exhaust pipe to discharge outside the boiler house. - 2 Sets.

9.13 Access doors (front and rear) - 2 Nos. 9.14 Main steam stop valve with counter flanges - 1 No. 9.15 Non return valve for main steam with counter flanges - 1 No. 9.16 Blow down valve with counter flanges & necessary handles for operating the

valves and necessary pipes and fittings upto blow down pit which will be located outside the boiler house. - 1 Set

9.17 Steam stop valve with counter flanges for auxiliary steam connection

- 1 No. 9.18 Steam pressure gauge of minimum size 200mm dia. with siphon tube and cock.

- 1 Set. 9.19 Auxiliary steam connection with cock for fixing test pressure gauge and for

removal of air. - 1 Set. 9.20 Water level sight glasses with safety shields and isolating cocks. - 2 Sets. 9.21 High, low and extra low water level alarms with isolating valve and drain point

(screwed) having a drain pipe up to blow down pit. -2 Sets.

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9.22 Flame observation port/fire view glass of suitable thickness and design shall be of rotating type with blue tint colour glass/plain glass and the glasses not be exposed to fire. - 2 Nos.

9.23 Access ladder service platform and top walkway platform complete with railings.

- 1 Set. 9.24 Rigid MS base frame (for boiler & other eqpt) - 1 Lot. 9.25 Fusible plug in the furnace tube - 1 No. 9.26 Pressostats for automatic operation - 1 Set. 9.27 Flue gas temperature indicator (digital type) - 1 No. 9.28 Steam pressure switch for combustion controls by interlocking with burner. 9.29 Steam temperature indicator. - 1 No. 9.30 Water level controller (heavy duty) Mobrey type. - 2 Sets. 9.31 Water flow meter magnetic type, suitable to operate up to 100° C and the

maximum boiler pressure. The flow meter should be connected with flanged type isolating valves & accessories at the discharge side of feed water pumps for measurement of water consumption in the boiler. 1 No.

10.0 ERECTION AND COMMISSIONING :

10.1 Scope of Work The scope of work in brief includes unloading, shifting and positioning of the

boiler on foundation, connecting feed water, oil and drain lines, steam line up to main valves and connection to the existing HP steam header, safety valve vent line outside building, blow down lines up to blow down pit, electrical panel installation, power and control supply, installation and termination of all electrical machines upto electric panel, double earthing of the panel and all the equipment, fabrication of ducting as per layout, positioning of the chimney on foundation and making all necessary connections, completing all other associated works.

10.2 The following items in brief shall be supplied and installed by the supplier as per

the battery limits mentioned at 5.0.

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a) The steam pipes (HP/LP, vent lines, steam heating pipes for burner pre-heater with PRV and controls, PRS if included in the scope of the work), water pipes, and oil pipes along with pipe fittings for the above.

b) Safety valves, controls, instruments, gauges (dial type and digital type),

valves, sensors and all associated instruments/gadgets.

c) Insulation of steam line and oil pipe lines as per the battery limits and cladding with 24 Gauge aluminum sheet.

d) Asbestos rope insulation of drain lines and safety lines as per requirement. e) Heat tracing materials for fuel oil pipe line from furnace oil service tank to the

oil pre-heater of boiler. f) All foundation bolts. g) Cables, wires with all interconnections. Earthing materials and laying of the

earthing conductor (on surface, indoor and outdoor trenches including excavation and back fitting of the outdoor trenches.

h) Supply and installation of earth station, 2 Nos. for lightening arrester

complete with earth electrode and associated accessories as per relevant IS, including excavation for the earth pit, back filling, providing CI chamber and the associated concrete masonry work, of pit etc. complete. The Panel board shall be connected to a third earth pit.

i) Necessary bolts, nuts, fittings, consumables, tools and tackles and labour for

the job.

It will be the supplier's responsibility to execute any works, which are neither furnished in the specification, nor additionally listed by the bidder in their offer and the same are found to be required as per the statutory regulations. Supplier shall execute such works within the scope of the ordered price and no additional cost will be considered for the same.

10.3 The boiler should be transported by the supplier after receiving intimation regarding readiness of the foundation. Boiler should be insured, transported and unloaded on foundation by the supplier.

10.4 All mountings, fittings, accessories etc. should be installed, aligned and piping,

electrical connections etc. should be carried out as per the latest engineering practices.

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10.5 Chimney and ducting should be fabricated after getting the drawings approved

from the purchaser and concerned Statutory authorities. 10.6 For commissioning and trail run of the boiler, necessary materials for 1st charge

like lubricating oil, grease, and other chemicals, if any, required for commissioning, shall have to be supplied by the supplier. However, fuel, water, shall be supplied by the purchaser.

10.7 After commissioning the boiler the following parameters are to be established

and recorded by the supplier. * Steam generating capacity * Efficiency of the boiler * Dryness fraction of steam, if available * Fuel consumption * Electricity consumption * Water consumption The supplier shall carry out the efficiency test as per BS 845 Part 1. It will be

the supplier's responsibility, to provide all the necessary efficiency monitoring and any other additional instruments required for establishing the design parameters during testing and till the time the results are achieved and accepted by the Purchaser. Efficiency shall be established by indirect method and output by direct method.

Thereafter, the boiler should be on trial run for minimum two months, during this

period training should be imparted to the authorized operating personnel before handing over the boiler to Project Authority.

10.8 The erection and commissioning should be carried out as per general terms and

conditions of erection contract mentioned in the tender. 10.9 The rates with the quantity breakup for essential spares considering normal

operation of the plant for two years shall be provided in the tender. These rates shall be valid for at least two years from date of commissioning. The purchaser/end user may place the order for spares any time at a later date as desired within the validity.

It may please be noted that, any spares required during startup and

commissioning and trials of the boiler and all its associated equipment, the same shall be deemed to be included in the quoted price of the steam raising plant and shall have to be supplied by the supplier without any extra cost.

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10.0 This is a complete turn key job for supply, installation, testing and commissioning of steam raising plant. Any items not mentioned in the specification/scope of the work but are required for completion of the work, the same shall be supplied and installed by the boiler supplier without claiming extra payment.

IBR Certification and Boiler firing certificate :

The IBR certification and Boiler firing certificate is in the scope of the supplier.

All test certificates and necessary approvals from Boiler, PCB, Electrical Inspectorate etc., shall also be obtained by the boiler supplier and the same is within the scope of the work, Statutory fees paid shall be reimbursed to the supplier at actual by the Project Authority/Purchaser based on the production of the acknowledged receipt from the Statutory Authorities. The complete IBR documents shall be submitted in duplicate in two neat folders containing the necessary form II, Form III, form IV, As fabricated pressure part drawings, IBR test certificates of all the mountings and accessories in form IIIC for of mountings and accessories coming under IBR.

The operation and maintenance manual in 3 sets shall be submitted. 11.0 Details of the Boiler :-

8.1 The name of the project ................ DAIRY EXPANSION

(a) Capacity Continuous water evaporation at the rate of 1000 Kg./hr F&A 100°C

(b) Pressure (Maximum operating)

10.5 Kg./Sq.cm

(c) Quantity One no.

(d) Turn down ratio (minimum) 1:3

(e) Chimney Height As per statutory regulation and the minimum height of the chimney from the finished floor level should be 25 Mtrs.

(f) Chimney quantity One no. (individual chimney)

(g) Type of chimney Guyrope supported type and mounted outside the boiler house.

(h) Length of flue gas The length of the ducting would be approximately 6 Mts. and shall be provided from the boiler up to the chimney.

Special Notes :

1. The sequence controller would be of Petercem / Diligent / DDC make. 2. Party should quote rates for suitable Chimney approx. weight 4000Kg. maximum

variation plus 10%, Oil service tank, and Feed water tank separately. Insulated Feed Water Tank capacity 2000 ltrs and oil service tank capacity 900 ltrs. cylindrical / rectangular sheet thickness 5mm make TATA / Jindal / SAIL / SR with self supporting structure having elevation of minimum 3 mtrs. with ladder. MS stricture for

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placement of Feed water tank capacity 2000 ltrs and oil service tank capacity 900 ltrs. approximate weight 1000 Kg. maximum variation plus 10% (Rates for per Kg. weight of structure should be quoted). Structure drawing as per site condition should be submitted to General Manager (DPM & Proj.), RCDF for approval.

3. The IBR pipe line length 12 mtrs. of 50 NB with IBR header of 150 NB of length 1.5 mtr. alongwith valves and raps with provision of additional nozzle for future expansion.

4. One set of pressure reducing station size 50 NB x 80 NB, pressure reduction from 10.5 Kg. to 3.5 Kg.

5. Insulation of non-IBR pipe line of length 6 mtrs. and dia 80 NB is required. 6. The scope includes supply, installation, testing and commissioning of new steam

generation system & hooking up the same to the existing steam generation system. 7. The tenderer must have supplied, tested, erected & commissioned at least 5 boilers of

such capacity and photocopy of performance certificate from the clients towards the satisfactory performance of the equipment must accompany the technical part of the bid.

8. All tools and tackles required for execution of the work on turn key basis shall be in the bideer’s scope. Any item which is not included in the scope of supply but required for completion and to meet the functional requirements and norms to be complied with the statutory authority shall be without any extra cost.

9. All statutory approvals will have to be obtained by the bidder. However, statutory fee shall be reimbursed by purchaser.

Note:- It is a turnkey project,the boiler should be equipped with chimney , oil

service tank, feed water tank , R.O system of capacity 2000 LPH along with allide pipe lines i.e high pressure line, low pressure line, suitable stream traps , valves and accessories etc. required as per site condition.

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Schedule - II

//Final technical sp. for Chimney//

Technical specifications of Chimney suitable for 1000 Kg. / hr. IBR boiler & ducting for connecting to boiler.

Supply, installation, testing & commissioning of chimney suitable for 1000 Kg. / hr. IBR boiler shall be Straight up guyrope / self supported made out of MS sheet of suitable thickness with stiffeners, helical strakes for safety of chimney, complete with base plate, cleaning door, flanges, gussets, clits and holding accessories like C clamps etc. painted externally with two coats of red oxide and one coat of black heat resistance paint.

Height : 25 meters. However the height of the chimney should be in accordance with

the regulations of Air and Pollution Control Board, Rajasthan and other statutory State / National Agencies, as per the case, thus for the additional height of chimney, the bidder must quote the rates for the additional per meter height separately. The top & bottom dia should be 14” & 28” respectively.

One set of flue gas ducting made of suitable gauge MS sheet and of 12” dia shall have to be provided for connection from the Boiler outlet to the chimney. The tenderers are required to quote for 8 mtrs. of flue ducting with due insulation (as per requirement) and also the unit rate for such bare ducting as well as unit rate for insulated ducting. For the purpose of drawing comparative statement a length of 8 mtrs. of ducting shall be considered. Drawings for the chimney and ducting shall be submitted to General Manager (Projects & DPM), RCDF, Jaipur for necessary approval. Note :

1. Base plate size 1.5 mtr. x 1.5 mtr. x 25 mm thick. 2. Chimney MS sheet thickness 8 mm up to 5 Mtrs. and 6 mm up to 10 Mtrs. & 5

mm up to remaining height. 3. Stiffner to be provided on base with 25 mm thick MS plate. 4 The Chimney shall be Guyropes supported type (total height 25 Mtrs.)

Guyropes of suitable size and length to be supplied and installed by tenderer. 5 The Chimney should also be provided with hood, lightning arrestor, aviation

lamp, sampling point & platform, pulley arrangement for fixing of aviation lamps (Including necessary conditues, cable, lighting arrestor) (Copper) with GI strip of 25 x 6 mm section approx. length 30 Mtrs., ladder etc.

6 Party should also quote separately the unit rate for GI strip 25 x 6 mm section. 7 The necessary earthing pit would be provided by concerned Milk Union.

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8 Necessary foundation drawings & bolts shall be supplied by the supplier. The civil foundation work would be done by concerned Milk Union.

9 The earthing pit shall consist of plate earthing with G.I. earth plate of size 600mm X 600mm X 6.0mm by emboding 3 to 4 mtr. Below the ground level with 40 NB dia. G.I. ‘B’ class watering pipe including all accessories like nut, bolts & G.I. strips 25 x 6mm section, reducer, nipple, wire meshed funnel, and brick masonary finished chamber covered with ferro cement cover C.I. Frame of size 300mm x 300mm complete with alternate layers of salt and coke/charcoal, testing of earth resistance as required. In case of hard surface Chemical Gel Earthing of equivalent capacity may be considered.

10 Duct thickness should be 4mm and actual length as per site condition and connection of Chimney and boiler through duct is in the scope of tenderer.

11 Installation of ducting to be carried out by tenderer. 12 Length of guy rope alongwith necessary hooks as per site condition. 13 Party should supply required template alongwith foundation bolts and

installation of same to be supervised by the tenderer at the time of Chimney foundation work.

14 Party should depute their engineer alongwith required manpower for perfect installation of Chimney.

15 Unit rate for additional length of Chimney will be calculated based on rates submitted by party for additional lengthy of Chimney. The Chimney fabrication should follow all air and pollution norms and should be equipped with all required accessories such as sampling point platform, provision of ladder up to top of chimney, earthing strip, lighting arrestor etc.

16 The weight of chimney approximately 4000 Kg. maximum variation plus 10%. Party should mention the rates per Kg. weight of Chimney and submit the drawing.

17 Tenderer should ensure the safety of Chimney.

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Technical Specifications for Furnace Oil Storage Tank 35000L, fuel oil service tank, heat tracing, fittings and allied equipments

The following items related with steam generation are required to be supplied, installed, tested and commissioned:-

A) For F.O. Tank 35000L Cap.

Functional Requirements

The furnace oil storage tank will be used to store furnace oil required for steam raising plant. Capacity – 35,000 ltrs.

Quantity required – 1 No.

Design Requirement The tank shall be cylindrical in design. It shall be made out of 6 mm thick for the shell and top cover whereas 8 mm thick for the bottom made of M.S. plate. All welds of the tank will be staggered. The size of the tank will be approximately 3.2 mtr. ID x 4.6 mtr. height (Excluding conical top portion).

The tank will be complete with the following:- One manhole (at the top) 500 mm dia complete with manhole lid with locking arrangement. Suitable level indicating device preferably float type with indicator moving in a slot fabricated out with the help of channel/angles. 65 mm NB CI class B inlet connection with unit flange and counter flange. The inlet connection shall be provided at the top and inlet pipe extending right upto the bottom and taking a short U turn with a clearance of 80 mm from bottom. The inlet shall be provided with 15 mm connection with a valve (open to atmosphere) to avoid siphoning out of furnace oil after filling. Outlet of 80 mm NB flange and counter flange alongwith valves. Air vent (50 mm NB) covered with double layer of brass wire mesh 11 per sq.cm.

Heating Arrangement :

The heating arrangement shown in the drawing for heating oil by steam heating coil need be provided along with suitable electrically operated outflow heater of 12 kW approved from Petroleum Explosive and Safety Organization (PESO) suitable for heating furnace oil per hr. upto the temperature of 50 degree C shall have to be provided alongwith required thermo-state control and related safety etc.

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a. M.S. ladder with railing to go to the top of the tank. b. 50mm NB drain with Gun Metal gate valves flanged type. c. Overflow connection on the top running to bottom up to 1.5 mtr. above ground

level with flange and counter flange. d. Railing (as per tentative drawing) shall be provided with a kick plate of 100 mm

high all around on the top of the F.O. tank for safety of personnel. e. Suitable monkey ladder fabricated using flats angles and rods as rungs shall also

be provided inside & outside the tank to carry out cleaning and maintenance. f. FO Tank cap. 35000 ltrs should be designed, fabricated and tested confirming to

IS 803. g. Outer surface shall be wire brushed, cleaned and painted with two coats of red

oxide primer and finally painted with two coats of anticorrosive paints.

NOTES :

1) All flanged connections should be provided with counter flanges also. 2) Detailed drawing of the tank indicating the heating arrangement should be got

approved from RCDF prior to taking on fabrication of the tanks. However all important fabrication details as mentioned above are to be incorporated in the drawing. Orientation of various manholes ladder etc. must be clearly specified suiting to the site conditions.

3) 80 NB rubber hose pipe for unloading Furnace Oil length 3 mtrs is required. One side flange and other tanker side flange/nipple confirming to SB 1435 type S-7.

B) For fuel oil service tank

To act as an intermediate storage prior to feeding furnace oil to the boilers. Capacity - 825 Ltrs. Quantity required – 1 No.

Design Requirements Material of construction : Mild steel

Main body shall be made from 5mm thick plate. Top cover shall be made from 4mm thick plates having half cover welding at the top and half cover hinged with other half and having lifting handle.

It shall be rectangular in construction having inside dimensions 1300 x 850 x 825 mm deep complete with following accessories : Main inlet of 50 mm NB flanged end near top : 1 No. Excess oil return inlet of 20 mm NB flanged and near top : 1 No. Outlet of 40 mm NB flanged end at side : 1 No.

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The tank should be provided with flanged sockets of 2 ½ inch BSP for holding the two nos. electrical heaters in position. : 2 Nos. Overflow of 50 mm NB flanged end : 1 No. Drain of 50 mm NB flanged end with valve : 1 No. Level indicating arrangement complete : 1 Set with two nos. small pulleys, suspension rope with pointer, counter-weight, measuring scale etc. The scale should be well painted with divisions of 100 L, 50 L indicated upon it Channel based for tank, made from MS channel of size 75 mm x 40 mm x 3.7 mm thick : 2 Nos. Painting : Inside – Black bituminous paint Outside – Primer painted alongwith standard enamel paint of colour as per norms Sketch of the oil service tank is enclosed.

Notes : 1. All flanged connections should be provided with counter flanges also. 2. Insulation 25 mm thick on all sides, bottom and top (top in two halves) covered by

cladding of Aluminium sheet of 24 gauge. 3. The insulation of the oil service tank shall be carried out at site after the oil service

tank has been placed on the existing angle iron supports in the wall for this purpose, and tested for leakage. The placement of furnace oil service tank on the available angle iron supports is in the scope of bidder.

C) For Oil Transfer Pumps General Description :

The pump shall be used to transfer furnace oil from furnace oil storage tank to oil service tank located in the boiler house.

Capacity : 185 litre per minute against head of 15 mtr. Quantity required - 2 Nos. (1 operating + 1 standby)

Design Requirements :

Multipurpose rotary gear oil pump motor set with common base plate alongwith bolts and nuts for securing. The pump should be suitable for discharge of 185 litre per minute against head of 15 mtr. at 2 Kg. per Sq.cm pressure, built in relief valve. The pump should be Roto Del /Wilo/Groundfoss make with motor suitable for 3 phase 400/440 Volts A.C. supply.

Inlet and outlet connection should be flanged type complete with counter flanges.

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The pump should be equipped with the built in relief valve for byepassing the transported liquid when the said pressure is exceeded, that to the suction space of the pump by a channel inside the cover or housing of the pump.

The tenderer shall have to supply the necessary rain hood covers made out of 24 G. Galvainised plain sheet for the pump motor set for their outdoor type duty. The civil works related to foundations for the pumps is also in the scope of the work. The tenderer must enclose complete catalogue of the pump alongwith its performance chart while bidding.

D) Various pipelines, heat tracing, valves and fittings & MS structure etc.

The quantities mentioned in this section may vary as per site conditions. The tenderers are required to quote for the quantities mentioned for various items in this section based on which the financial comparative statement shall be drawn but they should also quote the unit rate price (F.O.R. site) for each item separately also in order to make concerned Milk Union release payment for bills of the firm for the actual quantities of items supplied, installed, tested and commissioned as per site conditions. Tender should quote unit rate for various pipe lines, per mtr. rate for insulation of respective pipe line. Unit rate of clubbed insulation of oil pipe line with 20 NB steam line. All pipe line should be supported over the ground. The tender should include 500 kg. MS Structure in the scope of supply for supporting purpose. Tender should quote unit rate for structure for variation in quantity as per site condition i.e. quantity of structure may increase or decrease. Civil work related to placement of support is also in the scope of tenderer. Tenderer should include supply of one outdoor type control panel to control two Nos. of Oil pumps, one Oil heater cap. 12 kW inclusive of cables with temperature indicator and RTD.

For connecting various equipments following pipelines shall be required :-

M.S.’C’ class TATA make ERW pipes (for oil lines) of following sizes :- a) 80 mm N.B. – 12 Mtr. b) 65 mm N.B. – 18 Mtr.

c) 50 mm N.B. – 36 Mtr. d) 40 mm N.B. – 12 Mtr. e) 20 mm N.B. – 36 Mtr. For connecting various equipments following valves (for oil line) shall be required :-

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Cast steel globe valves (with S.S. working parts) flanged type of Leader / Flow jet /Fluid line make of following sizes :-

a) 80 mm N.B. – 3 Nos. b) 65 mm N.B. – 3 Nos. c) 50 mm N.B. – 1 No. d) 40 mm N.B. – 1 No. e) 20 mm N.B. – 3 Nos. Non return valve horizontal (with gun metal working parts) for oil line for 65 mm N.B. size – 2 Nos.

Oil filter bucket type with S.S. 40 mesh, flanged for 80 mm N.B. oil line, inlet & outlet both 80 mm – 2 Nos.

Valves for oil line should be fire safe ball valves make of Flowjet/Fluid line or equivalent make.

Thermo dynamic Steam Trap float type assembly :- The thermo dynamic steam trap assembly of Samsung/JN Marshall make shall have to be provided – 4 Nos.

Heat Tracing – All oil piping from furnace oil storage tank to fuel oil service tank in boiler house and from fuel oil service tank to boiler pre heater should be electrically heat traced and all heat traced lines should be insulated with 40 mm thick Glass wool/mineral wool of Singla Insulation/Polybond make for thermal insulation with suitable. chicken wire mash & aluminimum cladding sheet of 24 SWG shall have to be used for thermal insulation of pipe lines of following sizes and Unit rate of heat tracing must be provided All pipe lines should be well supported over the ground, placement of pipe lines etc. on MS supports is also in the scope of tender :-

i) for 80 mm N.B. oil line ii) for 65 mm N. B. oil line iii) for 50 mm N. B. oil line iv) for 40 mm N.B. oil line v) for 20 mm N.B. oil line

The following pipe lines of M.S. ‘C’ class TATA make for steam distribution shall be required :-

a) For 40 mm N.B. steam line – 36 Mtr. b) For 20 mm N. B. steam line – 54 Mtr. c) For 15 mm N.B. steam line – 18 Mtr. d) For 25 mm N.B. steam line – 12 Mtr.

For the purpose of steam line due insulation with sizes mentioned against each piping shall be as under :-

a) For 50 mm N.B. steam line, 40 mm thick insulation of Glass wool/mineral

wool, chicken wire mesh, and cladding with aluminimum sheet of 24 SWG shall have to be provided.

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b) For 20 mm N.B. steam line, 40 mm thick insulation of Glass wool/mineral

wool, chicken wire mesh, and cladding with aluminimum sheet of 24 SWG shall have to be provided.

c) For for 15 mm N.B. steam line, 40 mm thick insulation of Glass wool/mineral wool, chicken wire mesh, and cladding with aluminimum sheet of 24 SWG shall have to be provided.

Steam valves of Leader / Audco make suitable for following utility pipings :-

a) 40 mm N.B. – 2 Nos.

b) 20 mm N.B. – 4 Nos. c) 15 mm N.B. – 4 Nos. d) 25 mm N.B. – 1 No.

Necessary heavy duty MS ‘C’ class bends, tees, elbows of sizes

a) 80 mm N.B. – 6 Nos. b) 65 mm N.B. – 6 Nos. c) 50 mm N.B. – 6 Nos. d) 40 mm N.B. – 6 Nos. e) 20 mm N.B. – 6 Nos. Special notes :

This is a turn key project. The quantities of various items listed are tentative only and may vary on either side during execution. The final quantities of these would be as per site conditions. Cost of installation for any addition or deletion in quantities will be calculated based on the unit prices indicated. All necessary material which may be required for the successful completion of the project falls in the scope of the work. If any extra quantities of quoted items are needed then the tenderer shall supply those at the quoted unit price. If any extra item(s), not included in the tender but required for successful completion of the work, the same will be either supplied by the RCDF / Concerned Milk Union and erected by the tenderer or supplied and erected both by the tenderer at mutually agreed rates considering purchase price, taxes and handling charges etc. * Party should quote rates for Furnace Oil Tank cap. 35000L separately.

In addition to the standards mentioned, all works shall also conform to the requirements of the following for which necessary certifications of the concerned departments are to be obtained and submitted to the concerned Milk Union / RCDF :- h) Indian Electricity Act and rules framed thereunder. i) Fire insurance regulations. j) Regulations laid down by the Chief Electrical Inspector of the State / State Electricity

Board. k) Regulations laid down by the Pollution Control Board.

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l) Regulations laid down by the Factory Inspector of the State. m) Any other regulations laid down by the local authorities. n) Installation operating manuals of original manufacturers of equipment.

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SUPPLY, ERRECTION & COMMISSIONING OF WATER SOFTENING PLANT 1,00,000 LPD (One Lac Ltrs. per Day) CAPACITY FOR MALPURA DAIRY PLANT

FUNCTIONAL REQUIREMENT : Suitable Water Softening Plant for treatment of hard water as per enclosed water analysis report. MALPURA - 1 No. – 1,00,000 LPD Capacity (1,00,000 LPD / per generation & flow rate on 12 Hrs. basis) DESIGN REQUIREMENT : It should be self contained complete water treatment plant which should have following major equipment.

1. Vertical Pressure vessel of welded steel construction fitted with manhole and cover, support legs and nozzles for pipe connections. The softener tank and frontal piping should be epoxy painted externally and rubber lined internally with a minimum 3mm lining.

2. Set of internal distribution / collection systems for brine and water. 3. Set of frontal and regeneration pipe work of welded steel construction. 4. Set of manually operated cast iron diaphragm type control valves. 5. Initial charge of high capacity polystyrene bead cation exchange resin. 6. Orifice board with level markers to be placed in drain sump. 7. Enclosed pattern integrating type water meter of Kaycee or equivalent make. 8. Set of inlet and outlet pressure gauges. 9. Cylindrical salt saturator tank of corrosion resistant construction for salt storage

and preparation of brine. 10. Hydraulic brine ejector. 11. Water testing set for qualitative determination of soft water. 12. Centrifugal Water Pump : All iron horizontal centrifugal pump having maximum

discharge head 30 MWC complete with motor and base plate, suction and discharge valves and piping both suction and discharge pipe terminating at 500 mm from the pump terminals.

13. Water Softening plant should have pressure and sand filter of requisite capacity. Supply of same shall be optional and for which the rates should be quoted separately.

14. The item-salt saturation tank/brince tank shall be optional and for which the rates should be quoted separately. This tank should be open form the top and of HDPE resistant to chemical and of Sintex/Rotex/Indion make. The capacity of the tank should be such that it meets all duty conditions.

15. The battery limit for scope of RCDF / Milk Union shall be up to the suction of pump set and delivery from softener outlet. The scope of work for the tender will be from pump delivery up to the softener outlet flange.

NOTES : 1. The tenderer can also quote for better, cost effective, efficient water treatment plant.

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2. Detailing is to be given in the enclosed format.

MALPURA DAIRY PLANT

S. No.

PARAMETER UNIT POTABLE WATER ANALYSIS

REMARKS

1

pH Value Number 7.5

2

Total dissolve solid mg/l 3649

3

Total Hardness as CaCo3

mg/l 500 ppm

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WATER SOFTENING PLANT FOR MALPURA DAIRY PLANT

I. Softening Plant of capacity 1,00,000 LPD to reduce hardness to 5 ppm

01. Softening Plant :

Quantity (Nos.) : Type : Down flow Design Code : Diameter (mm ) : Height (mm) (HQS) : Material of Construction : MS tested quality (IS 2062) Torispherical dish (IS 1063) Operating pressure (kgs./cm.sq. Maximum : 3.5 Minimum : 1.5 Design Pressure (kgs/cm.sq.) : Hydraulic Test Pressure (Kgs./ : cm.sq. Shell Thickness (mm ) : 6 Dished End Thickness (mm) : 8 Bed Plate (mm ) : 10 Corrosion Allowance (mm ) : + 2mm Service Flow Rate (Cu.M./Hour) Min . :

Max. : Output/regeneration (Cu.M. Hour) : Inlet Hardness as CaCO3 (ppm ) : Outlet Hardness as Ca CO3 :

315



Type of Resin : Duolite C-20 strongly Acidic Cation exchange resin or Indion or equivalent.

Make of Resin : Ion Exchange /Thermax/ Duolite.

Quantity of Resin ( litres ) : Resin Bed Height (mm ) Salt / regeneration (100% NaCI ) ( Kgs. ) : Backwash Time (Minutes ) Brine Flow Rate (Cu.M/Hr. : Injection Time (Minutes ) : Slow Rinse Flow Rate (Cu.M/Hr. : Slow Rinse Time (Minutes ) : Fast Rinse Flow Rate (Cu.M/Hr.) : Fast Rinse Time (Minutes ) Total Regeneration Time (Minutes ) : Pressure Drop (Kgs./cm.Sq. ) : Valves Inlet/Outlet : Backwash Inlet/Outlet : Rinse Outlet : Brine : Power Water Inlet :

316



Types of Valves : CIEL (cast iron ebonite lined) diaphragm

type and of Crane. Alfa Leval / BDK Make Material of Construction : CI Flanges : BST ‘D’ Ejector : CI Underbed : PVC / HDPE Top Distributor : Deflector Plate Painting External : Epoxy Internal : Epoxy Instrumentation : Accessories : 02. Salt Saturator Tank :

Quantity ( Nos. ) : Capacity (liters ) :

Diameter (mm ) : Height (mm ) : Type : Material of Construction : 03. Centrifugal Pump :

Quantity ( No. ) : Capacity (Cu.M. Hour ) : Head ( MWC ) : Material of Construction : Type : Horizontal (Centrifugal) Suction/Discharge (NB ) : Motor H.P. :

317



Motor R.P.M. : Make : Kirloskar Accessories :

0.4. Hardness Testing Kit : Quantity ( No.) : 05. Orifice Board : Quantity ( No.) : Material of Construction :

06. Water Meter : Quantity ( No.) : Type : Line size ( NB ) : Material of construction : Make : 0.7 Brine solution tank : Qty. : Material of construction : (Internal lining 3mm thick natural rubber with Gore hardness upto 78 Degree ) Size : 0.8 Strainers : 10% to be provided extra as spares.

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TECHNICAL SPECIFICATIONS FOR SCREW AIR COMPRESSOR , CAPACITY 56 CFM, TANK MOUNTED

1.0 Functional Requirements : The compressor is required to deliver compressed

air at an operating pressure of 7.0 kg. per sq.cm. The air is to be used to operate process controls of various dairy plants equipment and packing machineries, indigenous product manufacturing machines etc.

2.0 Design Requirements :

2.1 The compressor should be screw delivering 56 CFM per hour air at a working pressure of 7.0 kg. per sq.cm at the final outlet after moisture separator driven by a suitable size of motor 11 kw, Siemens/ Kirloskar/NGEF or equivalent make TEFC induction motor. The motor should be suitably mounted for minimum vibration.

2.2 It should be of air cooled design.

2.3 It should be mounted on suitable common base frame.

2.4 It should be provided with efficient oil air separator so that oil carry over level in the air is bare minimum.

2.5 It should be supplied with good quality moisture separator with automatic drain so that bulk of the moisture is removed before outlet.

2.6 It should also comprise with the following: - Heavy duty suction filter to ensure proper filtration of air at inlet. 3.0 Supplier will have to depute his engineer for supervision of erection &

commissioning of the compressor for which no extra charges should be payable.

4.0 The tenderer is required to provide information and enclose related technical catalogues giving detailed technical specifications of the model offered :-

- Model offered :

........................................................................

- FAD at outlet moisture separation at 7.5 kg./sq. cm : ........................................................................ - Oil carried over : ................................PPM................................ - Air delivery per : ........................................................................ - Unit of Kwh : ........................................................................ 5.0 Control & Instrumentation:- Air compressor should be equipped with all control and

safety

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Blow down solenoid valve

High air discharge temperature trip Motor overload trip Air discharge pressure gauge Running hours meters. Automatic pressure switch for cut off and cut in.

High efficiency refrigerator type air dryer with pre filter and post filter 6.0 One year AMC during guarantee period is also included during which spares and

consumables shall be provided by the concerned Milk Union. Note : 1. Due consideration would be given for ease of operation, easy

diagnostic facilities, facilities, efficiency of equipment like air delivery per unit of electric power. 2. One time oil charge is in the scope of supply

320



COMPLETE ELECTRICALS

321



TECHNICAL SPECIFICATION

Technical Specifications for the Complete Electrical work (Panels, Cables, Auto Power Factor correction panel, Transformer etc.) on turn key basis for Indigenous product plant at Malpura. For the electrical work on turn key basis for the establishing of Indigenous product plant at Malpura. , the following items are required to be supplied, installed, tested and commissioned, the lengths of cables & cable trays mentioned in the tender document are indicative only and may vary as per actual site conditions and the financial comparative shall be drawn based on quantities mentioned in the tender document while the payment shall be released on actual quantities consumed based on unit rate and hence the tenderer must quote the unit rate for the concerned items positively:- Part A

S. No.

Description Qty. Unit Rate (Rs.) Supply Installation

Total (Rs.)

1 Supply, Installation, Testing & Commissioning of Outdoor type HT Switch Tripal pole 200Amp. 350 MVA, Oil based 11 KV rated E – SFU (Extendable Switch Fuse Unit) with Drawout type fuse carrier immersed in oil for 3 Nos. of HT fuses. Alongwith one spare set of 3 Nos. of HT fuses of rated capacity) Make Crompton / MEI.

One set

2 Supply, Installation, testing & commissioning of 315KVA copper-wound, 3 – phase, 50 Hz oil immersed, naturally cooled, out door type Power Transformer having a vector configuration DY11 with plus/minus 5% tapping taken out in tap changing switch, HT winding connection in Delta and LT winding connection in Star and neutral brought out and connected to

322



a separate terminal with outdoor open porcelain bushing and complete with first charge of requisite transformer oil, with following being available :- - Fitting and Accessories - Oil conservator tank with

drain plug and filling cap. - silicla gel dehydration

breather charged with silica gel

- oil level gauge - oil drain valve - thermometer pocket with

thermometer - earthing terminal - lifting lugs - four bidirectional roller

wheels - air release valve - explosion vent

Parallel operation of transformers:-

- Transformers offered for the same vector group DY 11,

rating and voltage ratio should be capable of operating in

parallel satisfactorily. It shall

be installed and commissioned as per IS 10028-1981 or latest.

- Other item- Fire bucket 3 nos capacity 20 ltrs, Fire

extinguishers CCL type 5 Kg-2

no, Shock treatment chart 5 n0, Danger plate-5 Nos.

Further the tenderer is advised to submit the foundation drawings of transformer and get it approved. The detail specification of 315 KVA transformer are detailed at Schedule – II.

Supply, erection commissioning & testing One set

3 Supply, testing and commissioning HT meter box cubical panel of size approx

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4’ x 4’ x 5’ fabricated from 14 SWG sheet steel with M.S. angle iron and provision of 6mm backelite sheet in CT/PT as per required. The panel should be as per approved design of JVVN (RSEB). (optional item)

One set

4

Providing and laying underground cable IS:1554 and approved make suitable for working voltage upto and including 11 KV in aluminium conductor XLPE armoured including excavation of 30cm x 75cm size trench as per IS:1225, 25cm thick under the layer of sand, IInd class brick covering refill earth in the removing portion making necessary connection including testing etc. as required. The size of the cable should be 3 x 35 sq.mm make ICL/Gloster/Hawells.

160Mtr.

5 Supplying and making of Indoor / outdoor cable jointing for 11 KV XLPE cable of heat shrinkable type termination kit including preparation of cable ends. Make M Seal/Denson. (This item will include all requisite hardwares lugs etc.)

a) Indoor type .. .. .. .. ..

b) Outdoor type .. .. .. .. ..

4 Nos. 4 Nos.

6. Supply, Installation and Commissioning of advance maintenance free chemical gel earth single pole earthing system of 2 mtrs. Length and

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80mm dia 2mm thick electrolytic grade copper tube duly filled with conducting natural mineral with permanent sealing at both ends with lead terminals at the top along 1 set of Part – I 5Kg. mixture of calcium carbonate, tetra sodium Hexcyno Ferrate, Sdium sulphate. Part – II 5Kg. Copper sulphate. Note : Supply and laying GI strip by reveting shading using steel hardware to following size :

1. G.I. Strip 25x5 2. G.I. Strip 50x5 3. G.I. Wire 8SWG

14 Nos. 150 Mtr. 50 Mtr. 150 Mtr.

7 Supply, Installation, Testing & Commissioning of panel board as per enclosed Annexure ‘1’ and as per the recommended make and list.

A MAIN LT PANEL

1 No.

B REFRIGERATION SECTION PANEL

1 No.

C PROCESSING SECTION PANEL (Ice cream Plant, Flavored Milk Plant, Curd and Paneer

1 No.

D BOILER SECTION PANEL 1 No.

E PANEER SECTION 1 No.

F CURD SECTION 1 No.

G ICE CREAM SECTION 1 No.

H FLOVOURED MILK SECTION 1 No.

I EXTERNAL LIGHTING 1 No.

J INTERNAL LIGHTING 1 No.

8

Supply and laying of LT cable as per IER specifications of 3 ½ / 4 core of 185 Sq.mm (two run) XLPE armoured

325



GLOSTER/CCI make from transformer to LT panel with terminations on both ends. The cable should be laid in excavation of 30 cm x 75 cm. size trench as per IS 1225, 25 cm. thick under the layer of sand, IInd class brick covering, and refilling the earth. * Please refer Part – D also.

*60 Mtr.

The tenderer is required to take necessary approvals from the concerned Inspectorate of Electrical. The supplier or erector should submit ‘A’ Class contractor Certificate. Note :-

(i) All the panel boards should be properly pre wired and requisite ferrules must be provided for easy identification of wiring.

(ii) All electrical motors above 7.5 HP should have start delta starters and each start delta starter should have Amp. meter and volt meter of required rating.

(iii) The main panel should have provision for placement of one standby ACB of 630 Amp.

(iv) The main LT Panel should be equipped with over / under voltage, Earth fault, Neutral fault current setting, change in phase sequence, over-load, protections etc.

(v) The panel for paneer section, curd section, ice cream section, flovoured milk section should be designed as per respective load of section, Mimic panel wherever required shall be provided for control of system. The required control wiring and other accessories should be considered. The input power to aforesaid panels shall be from process panel.

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Part - B

TECHNICAL SPECIFICATIONS OF MOTOR CONTROL CENTRES (SHEET STEEL)

1.0 Motor Control Centre (sheet steel) 1.1 Functional requirement :

To receive, control and distribute electrical power at 440V 50Hz. AC on a sheet steel housing.

1.2 Design requirement and scope of supply : 1.2.1 Statutory requirement :

Motor Control Centre is to be manufactured / assembled as per the latest ISI specifications, Indian Electricity rules, including special requirements of Rajasthan State Electrical Inspectorates.

1.3 Housing details : 1.3.1 The switchboard shall be fabricated out of 16SWG sheet steel and shall consist of free

standing front openable panels arranged to from a continuous line up of uniform height. Cold rolled sheets shall be used for doors and front covers. Front doors shall be hinged type and bus bars, bars and cables alloys covers shall be bolted type. Suitable M.S. channel base frame should be provided.

1.3.2 Switch Board shall be extensible at both the ends by addition of vertical sections. Ends of the bus bars shall be suitably drilled for this purpose.

1.3.3 The Switch board shall be totally enclosed, dust, weather and vermin proof. Gaskets of durable material shall be provided for doors and other openings. Suitable hooks shall be provided for lifting the boards. These hooks when removed, shall not leave any opening in the board.

1.3.4 All hardware shall be corrosion resistant. All joints and connections shall be made by galvanised zinc passivated or cadmium plated high tensile strength steel bolts, units and washers secured against loosening.

1.3.5 The switch board shall be in cubical design (each feeder components are housed in individual cubical). Suitable cable and bus bar alleys shall be provided. All components of the switch board should be approachable from front. The maximum and minimum operating handle / push button height of any feeder shall not be more than 1800 mm or less than 400 mm with reference to panel bottom. Supporting arrangement for dressing of power and control cables in cable alleys shall also be provided.

327



1.3.6 Painting :

All metal surfaces shall be thoroughly cleaned and degreased to remove all scales, rust, grease and dirt. Fabricated structures shall be pickled and treated to remove any trace of acid. The under surface shall be prepared by applying a coat of phosphate paint and a coat of yellow zinc chromate primer. The under surface shall be made free from all imperfections before undertaking the final coat. After preparation of the under surface, the panel shall be spray painted with final two coats of approved paint. Supplier shall obtain details of approved paint from the purchaser before final painting. The finished panels shall be dried in stoving ovens in dust free atmosphere. Panel finish shall be free from imperfections like pin holes, orange peals, fun-off paint etc. All unpainted steel parts shall be cadmium plated or suitably treated to prevent rust, corrosion etc.

1.3.7 Name Plates :

Name plates for all incoming and out coming feeders shall be provided on doors of each compartment. Name plates shall be fixed by counter sunk screws only and not by adhesives. Special danger plates shall be provided as per requirement.

1.4 Busbar sizing, connecting and supports : 1.4.1 The busbar shall be made from high conductivity electrolytic aluminium. The busbars

and supports shall be capable of withstanding the rated and short circuit current, stated in the feeder details. Minimum size of main power busbars shall be 200 Amps. rating. Maximum current density permissible for aluminium busbars shall be 8.2 Amps/mm². An earthing busbar of minimum 150 mm² section aluminium shall be provided outside panel at bottom throughout the length of the panel.

1.4.2 The busbars shall be provided with PVC/heat shrinkable insulating sleeve. Supports for busbars shall be made of suitable size hyleum sheets/epoxy compound blocks and these should be adequate in number so as to avoid any sag in the busbars.

1.4.3 Minimum clearance between phase to phase shall be 32 mm and between phase to neutral / earth shall be 26 mm.

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1.5 Power Connections : 1.5.1 For power inter-connections within the panel board :

Copper conductor PVC insulated cables of adequate cross section shall be used. For current rating above 63 Amps. aluminium busbar strips of adequate rating shall be used. Minimum size of copper conductor to be used shall be 2.5 mm². Cables lugs/sockets of suitable size and type shall be used for all inter-connections.

1.5.2 For all aluminium to copper connections, suitable bimetallic material (“CUP-al” washers) shall be used.

1.5.3 For each outgoing motor (upto 60 HP) feeder, suitable size terminal blocks (min. 3 ways) shall be provided in its cubical and wiring upto these from contactors shall be done by panel supplier. All the terminal blocks shall be suitable for aluminium conductor cable.

1.5.4 For incoming and outgoing feeders of the MCC aluminium conductor cable will be used and hence the panel is to be designed for receiving these and wherever required cable boxes shall be provided in panel by supplier. Removable gland plates shall be provided on top/bottom of panel for cable entries.

1.5.5 To prevent accidental contacts, all interconnecting cables/busbars and all terminals also shall be shrouded.

1.5.6 Standard colour code of red, yellow and blue for phases and black for Neutral to be followed for all busbars / conductors.

1.6 Auxiliary wiring and Terminals : 1.6.1 Wiring for all controls, protection, metering, signaling etc. inside the switch board

shall be done with 650 volts PVC insulated copper conductors. Minimum size of those conductors shall be 1.5 mm². Control wiring to component fixed on doors shall be flexible type.

1.6.2 The complete panel would be sub-divided into different sections by purchaser and each section shall have its own control circuit with fuse and indication. Terminal block (Minimum 3 – ways) for control wiring shall be provided for each outgoing Motor feeder in its cubical. 10% spare terminals shall always be available in each terminal block. Control wiring upto these terminal blocks shall be done by supplier.

1.6.3 All control wiring should be provided with necessary cable / sockets / lugs at both ends.

1.6.4 Conductor shall be terminated using compress on type lugs. Each termination shall be identified at both the ends by PVC ferrules. The identification termination numbers should match with those on drawings.

1.6.5 Control wiring for motor feeders should be such that the “green” light of motor feeder is “NO” only when control as well as power circuit of feeder is “NO”.

1.7 Switchgears : 1.7.1 Air Circuit Breaker : The technical specifications given subsequently.

329



1.7.2 Moulded case circuit breakers (MCCBs) :

MCCBs shall be provided with interlocking system suitably.

1.7.3 MCB:

4 poles MCB of suitable rating for all electrical loads shall be provided.

1.7.4 The rating of the power contractors shall be as required depending upon the feeder rating indicated in the specifications and as per the table given below. Contractor coils shall be suitable for 230 / 440 Volts, 50Hz. Unless otherwise specified. All contractors shall be supplied with minimum 2 NO + 2 NC auxiliary contacts. Additional contacts if required for inter-licking etc. shall also provide.

1.7.5 Protective devices :

Electronic relays shall be provided for all motor feeders. The relays shall be adjustable and self reset type. There should be SPP (single phase prevention) built up in the relay. Any other relays, if required for motor feeders shall be specified in the feeder details.

1.7.6 Timers :

The timers shall be electronic type, suitable for 240V 50Hz. supply.

1.7.7 Push Buttons (PBs) :

push buttons shall be luminous type with 22mm hole size. Push buttons shall be with contact elements, shall be generally mounted on openable covers. Colours shall be as follows : Stop / open / emergency - Red Start / close - Green It should have minimum 1 NO + 1 NC contacts. Push buttons with built-in indication lamps shall also be accepted in with case separate indication lamps are not required.

1.7.8 Indication Lamps :

Indication lamps shall be LED type with 22 mm hole size. Colours shall be as under:-

330



Phase : Red, yellow and blue Open/Stop/Emergency : Red Close/Start : Green/Black Bulbs shall be suitable for 250 volts AC supply.

1.7.9 Current Transformers (CTs) :

CTs shall be cast resin insulated type. Primary and secondary terminals shall be marked individually. CTs shall preferably be mounted on stationary parts. CT rating and rations shall be as per feeder ratings. These shall be capable of withstanding momentary short circuit and symmetrical short circuit current for 1 second. Neutral side of CTs shall be earthed. Protection on CTs shall be low reactance, accuracy should be class I VA burden. The CTs shall be of ALPHA make.

1.7.10 Measuring Instruments :

These shall be of square pattern having approximate dimensions 96mm x 96mm, flush mounting type. Necessary auxiliary instruments like CTs PTs etc. are also included in the scope of supply. The voltmeter shall be of 0-500 V range with VSS. The ampere meter shall be 800/5 A range with ASS. The voltmeter and Ampere meter shall be of AEI / IMP make and the voltage selector switches shall be of Sulzer / Kaycee make All AC meters shall be moving iron type having class 1.0 accuracy. Ammeters for motor feeders shall have a non liner compressed scale at the end to indicate starting current. Voltmeter shall be suitable for direct line connection. Voltmeter shall be connected through fuses only Energy meters shall be suitable to measure unbalanced loads of 3 phases, 4 wire systems.

2.0 Special requirements : 3.0 D.G. set change over switch :

There is a requirement of 1 No. change over switch. There will be change over switch so that operation of DG set 250 KVA is possible when there is no power & also to isolate State Electricity Board power supply when there is necessity to operate the DG set.

4.0 Incomer :

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a) For incoming feeders upto and 800 A rating provide MCCBs with 40 KA breaking capacity with overload / short circuit and earth fault protection.

b) For all incoming feeders provide CT operated ammeter with rotary selector switch; voltmeter with selector switch and 3 Nos. indicating lamps with red lines.

4.1 Outgoing feeders :

a) Motor feeders of rating of 10 HP or above shall be provided with suitable automatic star-delta starters along with electronic protected relay, timer, triple pole switch fuse unit/MCCB and ammeter. All motor feeders upto 60 HP shall be provided with MCB and above 60 HP MCCBs with a minimum breaking capacity of 40 KA shall be provided. For feeders below 15 HP rating provide direct reading ammeter and for feeders of 15 HP and above rating provide CT operated ammeters. All the power contractors of star-delta starters shall have same current rating.

b) Feeders for star-delta starters will be provided with specified current rating in the distribution boards.

c) Motor feeders of rating less than 10 HP will be provided with suitable direct on line starters along with thermal overload relays with single phase preventing and MCBs as per requirement.

d) The motor feeders wired for remote control will be provided with only an OFF push buttons the distribution board whereas for the feeders wired for local control from the board, both ON and OFF push buttons along-with green indicating lamp for ON will be provided on the distribution board.

e) Suitable cable glands provision will be provided for each of the incoming and outgoing feeders.

f) The components to be used will be of either L&T/ Siemens / Bhartiya Cutler Hammer / C&S / GE make. Tenderer should specify the make offered.

g) The following selection table shall be followed for starters of motor feeders unless otherwise specified:

S. No.

415 V Motor H.P. Contractor Rating Amps.

MCB / MCCB Rating / Amps.

1 0 to 10.0 HP 16 25 Switch

2 15 HP 32 63 -do-

3 20 to 25 HP 63 63 -do-

4 30 HP 63 100 -do-

5 40 to 50 HP 100 100 -do-

6 60 HP 100 100 -do-

7 75 HP 150 150 / 175MCCB

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8 100 HP to 150 HP 150 225 MCCB

Starters / S.F. units of higher ratings should be preferably located at the bottom portion of MCC. IMPORTANT NOTES : 1. Interlocking sequences : Condenser water pump Jacket cooling water pump HDI Compressor Capacitor 2. The HP of various motor have not been specified above as the same would depend on

the design of respective equipment to be offered by the tender. 3. The necessary fully automatic star – delta starters (soft starter) for 120 HP motors

shall have to supplied & installed near the ammonia compressors and tested & commissioned.

333



Part – C Technical specifications of Air Circuit Breakers.

Quantity Required : - 1 No. The air circuit breaker shall be 4 pole manually operated draw out type with microprocessor based protection release for overload, short circuit. & earth fault protection. The design shall be quick make and quick break type with slow closing facility for ease in maintenance. The total break time should be less than 30m sec including arcing time of 10m sec. The release shall be R.M.S. sensing type requiring no external supply for its basic function of tripping against fault. The release should diagnose the different fault i.e. there shall be inbuilt LED’s in protection release for over current, short circuit & earth fault. The release shall have provision for function blocking. The ACB shall be provided with under voltage protection. The setting of over load in release shall be 40% to 100%. The setting of short circuit shall be minimum 2 to 10 times. The ACB shall have Ics = Icw for 1 Sec. for short circuit breaking capacity of not less than 50 KA rms at 415 Volts 50HzAC. The overload current setting may be 40% to 100% of maximum rated value. The ACB neutral pole shall make earlier & break later than main pole.

Overload (phase) current setting 0.4 to 1.0. Neutral fault current setting 0.5 to 1.0.

Earth fault current setting 0.1 to 0.6.

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Part – D Necessary Cables, Cable Trays etc.

All necessary cables for connecting HT side to the primary of the transformer and LT side of the transformer to the main panel on LT side, main panel to distribution panels, from various panel boards to various equipments falls in the scope of the work. The quantities mentioned for cables & cable trays in this tender document are indicative only and may vary as per site conditions. The tenderers are required to quote for the quantities mentioned for various items in this section based on which the financial comparative statement shall be drawn but they should also quote the unit rate price (F.O.R. site) for each item separately also in order to make Milk Union release payment for bills of the firm for the actual quantities of items supplied, installed, tested and commissioned as per site conditions. For

connecting various equipments following cables and related shall be required :- 1100 KV GRADE, 3.5 C ARMOURED ALUMINUM CONDUCTOR, PVC INSULATED LT CABLE SELECTION CHART AS PER THE FEEDER DETAILS AT 8 VOLTS DROP. Table ‘A’

S. NO.

FEEDER TYPE FEEDER RATING

CABLE SIZE LENGTH OF CABLE (in Mtrs.)

Unit Rate

TOTAL AMT. (in Rs.)

1 TRANSFORMER TO MAIN ACB

630 A 2 X 3.5 X 185 Sq.mm. XLPE

40

2 REFRIGERATION PANEL INCOMER

400 A 1 X 3.5 X 185Sq.mm. XLPE

20

3 PROCESS SECTION

300 A 1 X 3.5 X 150 Sq.mm. XLPE

80

4 BOILER SECTION

150 A 1 X 3.5 x 50 Sq.mm.

25

5 INTERNAL LIGHTING

150 A

1 X 3.5 x 50 Sq.mm.

50

6 EXTERNAL LIGHTING

150 A 1 X 3.5 x 50 Sq.mm.

50

7 E.T.P. 100 A 1 X 3.5 x 25 Sq.mm.

100

8 CIP SYSTEM 100 A 1 X 3.5 x 25 Sq. mm

25

9 PUMP HOUSE 100 A 1 X 3.5 x 6 Sq.mm.

100

10 ICE-CREAM SECTION

150 A 1 X 3.5 x 35 Sq. mm

70

11 CABLE FOR MISC. WORK

100 A 1 X 3.5 x 10 Sq.mm.

50

335



1 X 3.5 x 16 Sq.mm.

50

1 X 3.5 x 25Sq.mm.

50

1 X 3.5 x 35 Sq.mm.

50

Following size flexible 4 core copper cables for connecting miscellaneous electrical motors. Table ‘B’

S. NO.

SIZE QTY. (in mtrs.)

Unit Rate TOTAL AMT. (in Rs.)

1. 1.5 sq.mm 400

2. 2.5 sq.mm 200

3 4 sq.mm 200

4 6 sq.mm 100

5 6 ,12 core control cable 100

TOTAL

The cables of Gloster / CCI / ICL / Ralison / Hawell / Hawells standard make need be

supplied. All necessary lugs of Dowell make for the various cables with due crimping shall have to be supplied and installed. Necessary loops for cables shall have to be provided wherever necessary. The unit rates for the cables of all sizes mentioned in the tender document also need be quoted. Cable trays : - following sizes of cable trays with covers of MS painted black for the cables of various sizes to be run upon them :- Table ‘C’

S. NO.

SIZE QTY. (in mtrs.) Unit Rate TOTAL AMT. (in Rs.)

1 Cable tray with cover of 8” width 84 Mtr.

2 Cable tray with cover of 4” width. 175 Mtr.

TOTAL

The unit rates for the cable trays with covers also need be quoted for all above sizes. Total of Table A + B + C =

336



MAIN LT PANEL FOR INDIGENOUS PRODUCT PLANT AT MALPURA

S. No. Particulars Qty. UNIT Make

Transformer 315 KVA

A MAIN INCOMER

1

630 A FP, MANUAL DRAW OUT TYPE ACB WITH MICROPROCESSOR RELASE HAVING O/L, S/C & E/F PROTECTION Icu= Ics= Icw= 50 kA 1 No. L&T / Siemens

2

Digital Energy Analyser capable of measuring all the Power and Energy parameters with class 1.0 accuracy 1 No. Conzerv/ Schneider

3 Digital Volt Meter 96 x96 of 500 V rating 1 No. Conzerv/ Schneider

4 Digital Ampere Meter 96 x96 of 1250 A rating 1 No. Conzerv/ Schneider

5 2 A SP MCB 3 No. Schneider/ L&T /

Siemens

6 CAM TYPE ROTARY VOLT SELECTOR SWITCH 1 No. Salzer/ Vaishno

7 CT LINKED ROTARY AMPERE SELECTOR SWITCH 1 No. Salzer/ Vaishno

8

Current Transformer of 630/5 A ratio of class 1.0 accuracy with 5 VA burden FORAPFC 3 No. Alpha

9 LED TYPE (R, Y B) 22.5 mm Indication Lamp 220 V 3 No.

Esbee/Raas/ Telemechanique

10 LED TYPE Trip, ON, OFF 22.5 mm Indication Lamps 220 V 3 No.


11 63 A FP MCB, 'C' curve with 10 kA breaking Capacity 1 No.

Schneider/ L&T / Siemens

12 63 A TPN + E 5 pin Panel Mounting Plug & Socket 1 No. Schneider/ L&T

13 Under / Over voltage protection relay with time delay setting 1 RISHABH / MINILEC

14 3 O/C and 1E/F protection relay with necessary current transformer 1 L&T / ALSTOM

B DG SET INCOMER

1

400 A FP MCCB 35 kA with adj. O/l and S/c protection Micro Processor Release with Rotary Handle 1 No.






337




Siemens

5

Digital Energy Analyser capable of measuring all the Power and Energy parameters with class 1.0 accuracy 1 No. Conzerv/ L&T

6 CT 400/5 class 1.0 3 No. ALPHA

7 630 A FP ONLOAD CHANGEOVER SWITCH 1 No. L&T / Siemens

OUTGOINGS

1 FOR REFRIGERATION SECTION

a

400 A FP, MANUAL DRAW OUT TYPE ACB WITH MICROPROCESSOR RELASE HAVING O/L, S/C & E/F PROTECTION Icu= Ics= Icw= 50 kA 1 No.


b LED TYPE Trip, ON, OFF 22.5 mm Indication Lamps 220 V 3 No.


c 2 A SP MCB 3 No. Schneider/ L&T /

Siemens

d


e CT 400/5 class 1.0 3 No. Alpha

2 FOR PROCESSING SECTION

a






Siemens

d



3 INDIGENOUS PRODUCT SECTION

a






Siemens

d Digital Energy Analyser capable of measuring all the Power and Energy 1 No. Conzerv/ L&T

338



parameters with class 1.0 accuracy


4 FOR ETP SECTION

a






Siemens

d



5 FOR CIP SECTION

a






Siemens

d



6 FOR BOILER SECTION

a






Siemens

d


5 CT 150/5 class 1.0 3 No. Alpha

7 FOR LIGHTING LOADS (INDOOR / OUTDOOR) No.

a



339





c 2 A SP MCB 6 No. Schneider/ L&T

d



8 SPARE No.

a 100 A FP MCCB 4 No. Schneider/ L&T /

Siemens



c 2 A SP MCB 6 No. Schneider/ L&T

d CT 100/5 class 1.0 6 No. Alpha

9 APFC Panel

a 6-32 A TP MCB, 'D' curve with 10 kA 7 No. Schneider/ L&T /

Siemens

b 40-63 A TP MCB, 'D' curve with 10 kA 5 No. Schneider/ L&T /

Siemens

c Capacitor duty Contactor up to 12.5 KVAr 7 No.

Telemachanique/ Sprecher Schu

d Capacitor duty Contactor up to 20 KVAr 5 No.

Telemachanique/ Sprecher Schu

e APFC Relay 12 Stage 3 phase sensing with sensitivity upto 50 mA 1 No. NEPTUNE/ EPCOS

f

3 phase, 415 V, with Discharge Resistor, MPP type Heavy Duty Capacitor Bank 140 KVAr

NEPTUNE (LL-10)/ EPCOS(MP-HDDD)/

L&T (MDXL)

g LED TYPE (Red) 22.5 mm Indication Lamp 220 V 12 No. TE/ESBEE/ Rass

h

2 pole 2 way & 1 way off 22.5 mm dia Rotary switch for Auto/ Manual Operation with necessary Element 12 No. TE/ESBEE/ Rass

i 2 A SP MCB 3 No. Schneider/ L&T /

Siemens

j 8 " dia Ventilation Fan controlled by thermostat 1 No.

10 BUSBAR

340



a

1200 A TPN, CONTINOUS RATED E 91 GRADE ALUMINUM BUSBAR COMPLETE ON ALL RESPECT MOUNTED ON SMC/ DMC INSULATOR WITH PROPER STEEL HARDWARE AND INSULATTED WITH HEAT SHRINKABLE PVC TUBES HAVING MINIMUM CREEPAGE DISTANCE OF 30 mm IN EACH BUS LOT

HINDALCO/ NALCO/ BALCO

b

PANEL ENCLOSURE shall be fabricated out of mild steel / CRCA sheet with required bracing and support with proper siemens grey epoxy coated powder coated paint on outer/ inner side of the panel. The enclosure be made of 14/16 SWG MS sheet. The doors holding meters and relays and the whole panel will be PU/Neoprene gasketted on doors. With quality of dust and Vermin proof suitable for comprising sideways capacitor bank and wiring with PVC insulated copper wires. LOT

341



REFRIGERATION SECTION PANEL AT INDIGENOUS PRODUCT PLANT MALPURA


INCOMER

1 400 A TPN , SFU UNIT 1


3 Digital Ampere Meter 96 x96 of 400 A rating 1 No.

Conzerv/ Schneider


Siemens



7 Current Transformer of 300/5 A ratio of class 1.0 accuracy with 5 VA burden 3 No. Alpha







11 TPN + E 5 pin Panel Mounting Plug & Socket 1 No. Schneider/ L&T

OUTGOINGS

1

Ammonia Compressor 6 x 6 with suitable range of Amp. & Volt Meter

40 HP 2 Nos.

MCB

2

Spare for Ammonia Compressor 6 x 6 with suitable range of Amp. & Volt Meter

40 HP 1 No.

MCB

3 Chilled water pumps 5 HP 3 Nos.

4 Spare for Chilled water pump 5 HP 1 No.

5 IBT Agitators 5 HP 2 Nos.

6 Spare for IBT Agitators 5 HP 1 No.

7 Condenser pumps 5 HP 2 Nos.

8 Spare for Condenser pumps 5 HP 1 No.

9 SWR pump 5 HP 1 No.

10 Spare for SWR pump 5 HP 1 No.

11 Air compressor 15 HP 1 no. MCB 63 Amp.

342



13

800 A TPN, CONTINOUS RATED E 91

GRADE ALUMINUM BUSBAR COMPLETE ON ALL RESPECT MOUNTED ON SMC/ DMC

INSULATOR WITH PROPER STEEL HARDWARE AND INSULATTED WITH HEAT

SHRINKABLE PVC TUBES HAVING MINIMUM CREEPAGE DISTANCE OF 30 mm IN EACH

BUS LOT HINDALCO/

NALCO/ BALCO

14

PANEL ENCLOSURE shall be fabricated out

of mild steel / CRCA sheet with required bracing and support with proper siemens

grey epoxy coated powder coated paint on outer/ inner side of the panel. The enclosure

be made of 14/16 SWG MS sheet. The doors

holding meters and relays and the whole panel will be PU/Neoprene gasketted on

doors. With quality of dust and Vermin proof suitable for comprising sideways capacitor

bank and wiring with PVC insulated copper wires. LOT

343



PROCESSING SECTION PANEL AT INDIGENOUS PRODUCT PLANT MALPURA


INCOMER



3 Digital Ampere Meter 96 x96 of 400 A rating 1 No.

Conzerv/ Schneider

4 2 A SP MCB 3 No. Schneider/ L&T

/ Siemens











OUTGOINGS

1 Milk storage tank agitator 15 KL 1.5 HP 4 Nos.

2

Spare for Milk storage tank agitator 15 KL

1.5 HP 1 No.

3 Milk Reception Pump 10 KLPH 3.5 HP 2 Nos.

4 Raw Milk Pump 10 KLPH 3.5 HP 2 Nos.

5 Cream Separator 5 KLPH 7.5 HP 2 Nos.

6 Spare for Cream Separator 5 KLPH 7.5 HP 1 No.

7 Milk Pasteurizer Milk Pump 3 HP 1 No.

8 Spare for Milk Pasteurizer Milk Pump 3 HP 1 No.

9 Milk Pasteurizer Hot water Pump 2 HP 1 No.

10

Spare for Milk Pasteurizer Hot water Pump

2 HP 1 No.

11

Cream Pasteurizer Cream pump Hot water Pump

2 HP 1 No.

12 Cream Pasteurizer Hot water Pump 2 HP 1 No.

13 Tanker loading pump 3 HP 1 No.

14 Cream un-loading pump 3 HP 1 No.

344



15 Chilled water return pump 5 HP 1 No.

16 Cream tank agitator 1 HP 2 Nos.

17 Spare for Cream tank agitator 1 HP 1 No.

18 Can Scrabbers 2 HP 2 Nos.

19 Spare for Can Scrabbers 1 HP 1 No.

20 Welding point MCB 63 1 No.

21 Milk Packing machine MCCB

Suitable 4 Nos.

22

Paneer Section MCCB Suitable

1 No.

23 Curd Section MCCB

Suitable 1 No.

24 Ice Cream Section MCCB

Suitable 1 No.

25 Flavoured Milk Section MCCB

Suitable 1 No.

26 Ice Cream Cold Store -30

27 Ice Cream Cold Store -25 MCCB

Suitable 1 No.

28 Milk Cold Store -30 MCCB

Suitable 1 No.

29

Incuvation and Blast Chilling Cold store for Curd

MCCB Suitable

1 No.

30 Spare MCCBs MCCB

Suitable 4 Nos.

25

600 A TPN, CONTINOUS RATED E 91 GRADE ALUMINUM BUSBAR COMPLETE ON ALL

RESPECT MOUNTED ON SMC/ DMC INSULATOR

WITH PROPER STEEL HARDWARE AND INSULATTED WITH HEAT SHRINKABLE PVC

TUBES HAVING MINIMUM CREEPAGE DISTANCE OF 30 mm IN EACH BUS LOT


26

PANEL ENCLOSURE shall be fabricated out of mild steel / CRCA sheet with required bracing

and support with proper siemens grey epoxy coated powder coated paint on outer/ inner side

of the panel. The enclosure be made of 14/16 SWG MS sheet. The doors holding meters and

relays and the whole panel will be PU/Neoprene

gasketted on doors. With quality of dust and Vermin proof suitable for comprising sideways

capacitor bank and wiring with PVC insulated copper wires. LOT

345



INDIGENOUS PRODUCT SECTION PANELS AT MALPURA


SUITABLE CONTROL PANEL FOR ICE CREAM SECTION WITH THE FOLLOWING OUTGOING CONTROL

INCOMER





Siemens











OUT GOINGS

ICE CREAM MIX PREPRATION SECTION

1 Mix preparation tank (agitator) 2 HP 2 Nos.

2 Mix transfer Pump 1 HP

3 Powder / Sugar blender with venture 3 HP 2 Nos.

4

Mix pre heater (4 to 45degree with indirect hot water heating system) pumps 1 HP 2 nos.

5

Mix pasteurizer pumps 1 HP 2 Nos.

6

Spare for Mix pasteurizer pumps

346



7

Mix homogenizer 7.5 HP 2 Nos.

8

Mix transfer Pump 1.5 HP 2 nos.

9

Aging Vat / Tank with condensing unit 5 HP 2 nos.

10

Mix transfer Pump 1.5 HP 2 Nos.

MIX FREEZING SECTION

Particulars

1 Mix transfer Pump 1.5 HP 2 nos.

2

Flavour mixing tank with three compartments insulated (transfer pump) 0.5 HP 2 nos.

3

Continuous Ice Cream Freezer with all accessories 20 HP 2 Nos.

4 Fruits and nut feeder 3 HP 2 Nos.

5 Ripple machine with pumps 1 HP 2 Nos.

6

Ice Cream cup and Cone filling machine with PLC 1 HP 2 Nos.

7 Chocolate doze 0.25 HP 2 Nos.

8 Conveyor with cartooning table 1 HP 2 Nos.

CHOCOBAR & ICE CANDY SECTION

Particulars

1

Candy tank suitable for 20 Nos. standard moulds (with refrigeration plant) 5 HP 2 Nos.

2 Candy hardener (with refrigeration plant) 7.5 HP 2 Nos.

3 Candy pouch raping / packing machine 3 HP 2 Nos.

4 Chocolate melting vat 2 HP 2 Nos.

5 Chocolate transfer Pump 0.5 HP 2 Nos.

6 Kulfi mix preparation vat 0.5 HP 2 Nos.

7 Chocolate coating tank with electric heater 2 HP 2 Nos.

FLAVOURED MILK SECTION

Mix Preparation Section

Particulars

1 Mix preparation tank (Agitator ) 1 HP 2 Nos.

2 Mix transfer Pump 1 HP 2 Nos.

3 Milk heating tank (Agitator) 1 HP 2 Nos.


5 Sugar syrup tank (agitator) 0.5 HP 2 Nos.

6 Milk homogenizer 7.5 HP 2 Nos.

7 Milk storage tank (agitator) 0.5 HP 2 Nos.


347



9 Milk chiller (80-35-4) cooling tower 1 HP 2 Nos.


1

Bottle Rinsing and filling machine (Rotary type) 2 HP 2 Nos.

2 Bottle Cap induction sealing machine 1 HP 2 Nos.

3

Bottle sterilizer counter presser retort (PLC based) related load 7.5 HP 2 Nos.

Bottling labelling,printing & Packing Section

1 Bottle drying machine 1.5 HP 1 Nos.

2 Shrink ripping machine for individual bottle 1 HP 1 Nos.

3

Shrink ripping machine for 24 bottles in one tray 1 HP 1 Nos.

4 Bottle batching printing machine 1 HP 1 Nos.

FERMENTED PRODUCT SECTION

Paneer Section

Particulars

1

Multi product pasteurizer for Curd milk & Paneer milk (Feed pump, Hot water pump) 2 HP 2 Nos.

2

Spare for Multi product pasteurizer for Curd milk & Paneer milk 2 HP 2 Nos.


4 Paneer vat (Whey transfer pump) 0.5 HP 2 Nos.

5 Paneer Press Suitable 1 No.

Curd Section

1 Curd milk homogenizer 7.5 HP 2 Nos.

2 Inoculation tank insulated with pump 1 HP 2 Nos.

3 Curd Milk transfer Pump 1 HP 2 Nos.

4 Incubation chamber/ Blast Chilling 15 KW 1 No.

5 Curd cup filling machine 1.5 HP 2 Nos.

6 Pouch filling machine for chhach 2 HP 2 Nos.

7 Sugar syrup transfer Pump 1 HP 2 Nos.

Cold Storage Room

Ice Cream Cold Storage -25degree C 15 KW 2 Nos.

Ice Cream (balast) Hardening room -30degree C 20 KW

2 Nos.

Milk & Milk Product Cold Store 10 KW 2 Nos.

348



The panels for Ice Cream Section, Paneer Section, Curd Section, Flavoured Milk Section, Milk Cold Store etc. should be considered with aforesaid out goings and some of the equipment may have their own control panel, accordingly provision for supply from the said panels should be consider, Mimic panel equipped with controls wherever required shall be provided as per site condition for efficient control of equipment.


349



BOILER SECTION PANEL AT INDIGENOUS PRODUCT PLANT MALPURA


INCOMER





Siemens











12 OUTGOINGS

13 FO loading and un-loding pump 3 HP 2 Nos.

14 Spare for FO loading and un-loding pump 3 HP 1 No.

15 Boiler MCCB 63 A 63 A 1 No.

16 Spare for Boiler MCCB 63 A 63 A 1 No.

17 Pump House 7.5 HP 2 Nos.

18 Heat Tracing 12 KW 2 Nos.

19 Spare MCB 32 A 4 Nos.

20 Feed water pump 3 HP 3 Nos.

21 Spare for Feed water pump 3 HP 1 Nos.

350



22



23


351



INTERNAL LIGHTING DB AT INDIGENOUS PRODUCT PLANT MALPURA


INCOMER

1

150 A FP MCCB 25 kA with adj. O/l and S/c protection Thermal Magnetic Release with Rotary Handle 1 No.





Siemens











OUTGOINGS

1 40 A FP MCB 'C' curve with 10 kA breaking capacity 2 No.


2 16 A DP MCB 'C' curve with 10 kA breaking capacity 4 No.




BUSBAR

1



352



2


353



EXTERNAL LIGHTING DB AT INDIGENOUS PRODUCT PLANT MALPURA


INCOMER

1

100 A FP MCCB 25 kA with adj. O/l and S/c protection Thermal Magnetic Release with Rotary Handle 1 No.





Siemens











OUTGOINGS



2 16 A DP MCB 'C' curve with 10 kA breaking capacity 8 No.




BUSBAR

5



354



6

OUTDOOR TYPE PANEL ENCLOSURE shall be fabricated out of mild steel / CRCA sheet with required bracing and support with proper siemens grey epoxy coated powder coated paint on outer/ inner side of the panel. The enclosure be made of 14/16 SWG MS sheet. The doors holding meters and relays and the whole panel will be PU/Neoprene gasketted on doors. With quality of dust and Vermin proof suitable for comprising sideways capacitor bank and wiring with PVC insulated copper wires. LOT

355



SCHEDULE - II TECHNICAL SPECIFICATIONS FOR 315 KVA TRANSFORMER

Supply of 315 KVA Cooper wound 3 Phase 50 Cycles, oil immersed, naturally cooled, Core type, outdoor type with HV outdoor & cable box on LV side power transformer with stepping down provision from 11 KV to 440 V, having a vector configuration DY 11 with plus/minus 5% tapping taken out in tap changing switch (with provision of 5 steps), HT winding connection in Delta and LT winding connection in Star and neutral brought out and connected to a separate terminal with outdoor open porcelain bushing and complete

- With first charge of requisite transformer oil. - 1 Set - Fitting and accessories (as detailed on next page) - Oil conservator tank with drain plug and filling cap. - Silica gel dehydrating breather charged with silica gel. - Oil level gauge. - Oil drain valve. - Thermometer pocket with thermometer. - Earthing terminal. - Lifting lugs. - Four bidirectional roller wheels. - Air release valve. - Explosion vent. The transformer should conform to the IS specifications. The winding temperature rise – 55 deg C above ambient, oil temp. rise – 50 deg. C above ambient, impedance – 4.5% or above, permissible no load losses - 650 W (max.), permissible on load losses –4600 W (max.). The quality of oil should be good conforming to IS : 335 and the oil should be of SAVITA/APAR make or equivalent make (equivalent make subjected to purchaser approval).

The winding temperature indicator with alarm & tip contacts should be of Thermal make (mercury type). The number of earthings (independent) should be four.

356



Standard Fittings & Accessories

S. No.

Particulars Quantity

1. Rating & Diagrams Plate 1 No.

2. Earthing Terminals 4 Nos.

3. Lifting Lugs of Transformer 2 Nos.

4. Lifting Lugs of Top Cover 2 Nos.

5. Drain Valve with Plug 1 No.

6. Filter Valve with Plug 1 No.

7. Conservator Tank 1 No.

8. Oil level gauge 1 No.

9. Oil Filling hole with Plug 1 No.

10. Air Release Plug 1 No.

11. Thermometer pocket 1 No.

12. Silica gel breather with oil seal 1 No.

13. Explosion Vent 1 No.

14. Off. Ckt. Tap Changer Switch Handle & Position indicator 1 No.

15. L.V. Terminal Box with Extended Copper Flats/suitable Bus palm

1 No.

16. Neutral brought out terminal for earthing externally 1 No.

17. Bi-Directional rollers 4 Nos.

18. Oil temp indicator 6” with alarm & trip contacts 1 No.

19. Double Float Buckholz relay with alarm and trip contacts 1 No.

20. Inspection cover 1 No.

21. Marshalling Box with complete wiring 1 No.

22. Magnetic oil level gauge with low 1 No. 1 No.

23. Jacking Pads 4 Nos.

24. Winding temp. indicator with alarm trip contacts 1 No.

25. Prismatic oil level gauge. 1 No.

26. HV Cable Box, Long pin bushings, suitable for connecting on primary side 11 KV grade XLPE Cable entry.

1 Set

Note : 1. Further the tenderer is advised to submit 3 sets of the foundation drawings of transformer and get it approved. The supplier will also have to submit test certificates of transformer and oil. 2. The Transformer should be supplied as per latest electricals norms, accordingly has to provide the testing report.

357



Important Note :

The tenderer is advised to visit to site so as to apprise himself of actual site condition and quantum of work involved. Special notes :

This is a turn key project. The quantities of various items listed are tentative only and may vary on either side during execution. The final quantities of these would be as per site conditions. Cost of installation for any addition or deletion in quantities will be calculated based on the unit prices indicated. All necessary material which may be required for the successful completion of the project falls in the scope of the work. If any extra quantities of quoted items are needed then the tenderer shall supply those at the quoted unit price. If any extra item(s), not included in the tender but required for successful completion of the work, the same will be either supplied by the RCDF Milk Union and erected by the tenderer or supplied and erected both by the tenderer at mutually agreed rates considering purchase price, taxes and handling charges etc. Necessary ESI / PF deductions, wherever applicable shall be borne by the tenderer. The requisite approval form Chief Electrical Inspectorate, Government of Rajasthan must be obtained by the tenderer and the actual payment shall be reimbursed by RCDF / Milk Union against production of original documents. The tenderers are required to give the price bid for all items section-wise in the same faction as of Part – A showing the F.O.R. unit rate for supply as well F.O.R. unit rate installation, testing & commissioning as well the total cost. In addition to the standards mentioned, all works shall also conform to the requirements of the following for which necessary certifications of the concerned departments are to be obtained and submitted to the concerned Milk Union / RCDF:- o) Indian Electricity Act and rules framed thereunder. p) Fire insurance regulations. q) Regulations laid down by the Chief Electrical Inspector of the State / State Electricity

Board. r) Regulations laid down by the Pollution Control Board. s) Regulations laid down by the Factory Inspector of the State. t) Any other regulations laid down by the local authorities. u) Installation operating manuals of original manufacturers of equipment.

358



GENERAL ITEMS

359



TECHNICAL SPECIFICATION FOR 160 KVA

DIESEL GENERATING SET

Rating 128 KW continuous output, 160 KVA at 0.8 p.f. (lag) operating at 1500 rev./min. Output corresponds to standard operating conditions as per BS:649:1958. Generating Set comprise of :- 1. Kirloskar/Cummins or equivalent make (purchaser to approved) fuel efficient

diesel engine of suitable capacity, radiator water/air cooled, mechanical injection turbocharged, capable of developing around 195 BHP (Prime Power

rating) as per BS:649 when operating at 1500 r.p.m. on high speed diesel oil conforming to IS : 1460. The tenderer should give full details of Model No., number of cylinders etc. of the engine. The engine is supplied complete with accessories and services as detailed below :-

General:

Basic engine unit will be as per standard practice. The tenderer need specify complete details of its latest standard design. Following features are indicative only.

Fuel System :

Cummins PT/Mico BOCH fuel pump and injectors, fuel pump and injectors (or any other improved design), fuel filters, self contained piping. Fuel Oil service tank of suitable capacity having level indicators air-vent, filling cap., drain-plug, piping from tank to engine, over flow return, mechanical digital governing system & pumps.

Cooling System :

Base frame mounted radiator complete with fan and guard, belt-driven engine mounted water pump, thermostat, water separator, self contained piping.

Lubricating System : Engine oil sump strainer, oil pump, lub. Oil cooler, oil filter, by-pass valve, self

contained piping. Starting System :

360



Electric starting by 24 volts starter motor, engine driven alternator, voltage regulator, automotive dry batteries with self charging system of 24 Volt of 180 Ampere Hour capacity at 20 Hours rate of Cummins/ Exide / Prestolite or equivalent make (purchaser to approved).

Air Intake System : Dry type type air filter, intake manifold, turbo-charger with self contained

connections. Exhaust System :

Engine mounted exhaust manifold, exhaust silencer (industrial type), exhaust

pipe as per latest norms of Central Pollution Control Board. The exhaust pipe would be or suitable size and up to 10 Mtrs. height from the roof of the DG room.

Instruments :- Electronic type instrument panel incorporating (a) Lubricating Oil pressure

gauge, (b) Lubricating oil temperature gauge, (c) Water temperature gauge, (d) Battery charging ammeter, (e) Push button starting switch, (f) Hour Meter and R.P.M. Indicator (g) Indicator for voltage, current, KVA and frequency for one or three phase (h) Indicator for under and over battery voltage.

Controls :- The generator controller should consist of micro processor based integrated

generator set monitoring, metering, protection and control system with built in torque, matched, volts / overload control. It should have single control for all genset functions like as mentioned below :-

Digital governing. Digital voltage control Operator Inter face

Protection Advance control function

361



Engine :- Metering Protection -RPM Low lube oil pressure - Fail to crank Battery High water temp. - Fail to

start Lube oil pressure High / low DC voltage - Sensor

failure Coolant temp. Weak battery Running hours Overspeed

Alternator :-

Metering Protection 3 phase voltage Under voltage (L-L and L-N) Over voltage 3 phase current Over current Frequency Under / Over- frequency kVA Loss of sensing Others :-

Battle switch function Delay start / stop Configurable cranking cycle Sleep mode time Protection / Indicator :- Automatic tripping of engine in the event of low lubricating oil pressure and

high engine jacket water temperature. Others :- Flywheel, flywheel housing, coupling guard, vibration damper, Drip Tray. Tests : Engine should be fully tested at manufacture’s works and test certificate issued. Literature :

362



3 Nos. operating maintenance manual. Consumption Data : Consumption of fuel oil at 1500 rpm on 100%, 75% & 50% of load should be

provided alongwith the tender. 2. The Alternator :

The Generator set incorporate self-ventilated, self-exciting and self regulating

type AVKC/IEC/ Stamford/ Kirloskar make alternator in screen protected, drip-proof enclosure complying with IS : 4722. The output voltage is maintained within + 5% of the rated value from no-load to full load including cold to hot variations at a power factor between 0.8 lagging and unity. The alternator is provided with efficient damper windings to facilitate parallel operation. The alternator is to be designed for 415/440 volts, 3 phase, 4 wire, 50 Hz, continuously at a driven speed of 1500 rpm plus the tolerance in voltage of + 2% on account of the difference in speed at no load and full load. The tenderer can quote for improved design, if any, by giving details and justification of the improved version.

Technical particulars : - Alternator Output : 128 KW continuous 160 KVA (net) - Rated current : 222 Amps. - Winding connections : STAR

- Design ambient temperature: 40oC - Type of insulation : Class H. Alternator shall be complete as supplied by manufacturer in original packing

with test certificate.

363



The transient reactance of the Alternator is as low as possible consistent with

the need to limit voltage drop on sudden application of the load. The engine and alternator shall be mounted and aligned on a common skid mounting type base frame fabricated from suitable MS channel machined to ensure perfect alignment of the engine and alternator with rigid construction and necessary reinforcement to ensure minimum vibrations. The alternator conform to BSS :

2613/1970. AVM PADS : Suitable numbers of AVM pads of Polybond/Resistoflex/

Gerb/Dunlop made and of ‘B’ series shall be supplied with the D.G. Sets. 3. CONTROL PANEL OF GENERATOR SET : The Diesel Generator switch gear is housed in an indoor floor mounting type,

totally enclosed, sheet metal (of 14 SWG), including the front door and sides to be of 14 gauge, cubicle, free standing and fully extensible type and consist of :-

1- MCCB 250 Amps Micro processor Based., 4 Pole MCCB having symmetrical

breaking capacity of 32 KA (rms.) 500 V, manually operated and provided with overload protection, short circuit protection, and Under voltage trip.

1. T.P. Thermal time delay trip for over load protection rated Amps.

1. T.P. Magnetic instantaneous trip for short circuit protection adjusted between 4 to 12 times.

1. Trip free mechanism complete with mechanical ON/OFF indicator. 1. Under voltage trip front of panel operating lever drive, type KH-1. 1. 5 Pole auxiliary switch. 1. Breaker should be with HRC fuse base. 1. Shunt trip.

364



1. Phase tester. 1. A.C. voltmeter, 0 to 500 volt range, electronic type. 1. Volt meter selector switch with OFF position and suitable for reading

voltage between phases of Kaycee/Thakur make. 1. A.C. Ammeter, range 0 to 500 Amps., C.T. operated, Electronic type. 1. Ammeter selector switch with OFF position for reading current in each

phase of Kaycee / Thakur make.

1. 3 nos. Current transformers, 15 VA, Class 1, 500/5A of ALPHA make or

equivalent approved by RCDF. 1. 1 no. KWH meter, 3 phase, 4 wire unbalanced load type, electronic type. 1 no. Power factor meter, Electronic type. 1 no. Frequency meter Electronic type of range 47-50-53. Indicating lamps for Set Run Loan On indication and off indicating lamp

with over cap. Push Button for breaker off. H.R.C. fuse links – 3 nos. Extensive Aluminum bus bar of suitable capacity.

Note : Tenderer may provide single meter having display for Voltage, Current, KWH, KW and Power Factor.

EARTHING :- Four earthings as per IS for the generator set and two earthing for pannel shall have to be provided this will include civil work related to earth pits etc. The tranches shall be provided by RCDF / Milk union in DG set room only. All earthing material (the earthing should be with 600 x 600 x 6 mm. GI plate) to be supplied by the supplier and job to be done by the supplier (total six nos. earthings) CABLE :-

365



The cable connection between the alternator to control panel of DG Set and control panel to change over switch / LT Panel is to be done by 1 x 3.5 x 185 Sq.mm. aluminium armoured cable of Gloster / Polycab/ Havlles/ KEI or equivalent make. The comparative statement shall be prepared taking in to consideration of run of 20 Mtrs. length but Cost of 20 meters of length of cable is included in the price. However, the actual requirement shall be as per actual site condition and contractor shall have to supply the necessary cable without joint. Therefore, tenderer should quote the unit rate of this cable. The cost of extra length of cable, if required shall be paid as per the unit price mentioned in the order. Cable layout shall be discussed at site with the Engineer In-charge of the Milk Union.

ACOUSTIC ENCLOUSER (SOUND & ALL WEATHER PROOF)

1. Sound Proof : It should be compact, modular construction and sleek design

with low noise level confirming to CPCB guidelines of 75 db at 1 meter distance.

2. It should be type approved from the authorised agency as per guidelines of CPCB vide letter no B-31011/7/93/PCI-II/98 dated 3.1.2005 and B-31013/7/93/PCI-II/1840 dated 2.2.2005, with regard to extension of the type approval certificate to the concerned generator original equipment manufacturer (GOEM) for the assembly of genset model including acoustic enclosure.

3. Supplier should provide copy of approval certificate. 4. Weather Proof : The roof of the canopy is covered to ensure no water

accumulation on the roof. There is no chance of water entering the canopy from outside and suitable EDPN gasketings is provided. All hardware are zink coated.

5. Surface treatment : It is chemically treated for removing rust, dirt and

grease.Two coats of premier and two coats of paint/ powder coated is provided on canopy. Bottom portion is provided with black rubber paint.

6. Ventilation :- It should be properly ventilated to met the CPCB norms.. 7. Protection & tripping :-Safety devices is provided against high enclosure

temperature limited to 50 oC. 8. Exhaust silencer of residential type.

366



11. Emergency push button stop is provided outside the canopy. 12. Proper illumination is also provided inside the enclosure. SCOPE OF TESTING & COMMISSIONING OF D.G. SETS

The supplier is required to complete the supply, erection, testing & commissioning of the Diesel Generating Set on turnkey basis and the job description given hereunder for erection, testing & commissioning is to be treated as set of broad guide lines :

a) Providing of foundation drawing indicating details of concrete reinforcement steel etc.

b) Marking Gen. Set layout.

c) Guidance for making foundation. Foundation to be made by RCDF/ Milk Union.

d) Getting machines unloaded at site and getting machines shifted on to the

foundation.

e) Providing of earthing as mentioned above.

f) Alignment of machines.

g) Cable connections between alternator to control panel of D.G. Set, control panel to change over switch, change over switch to main supply.

h) Supply and installation of service fuel tank of capacity for 12 hours run and fuel

connection between daily service fuel tank to engine.

i) Fixing of exhaust piping (including minor civil works in fixing) as per State Pollution Control Board standards.

j) Conduction of trial run of Gen. Set, first charge of lub. Oil to be provided by

supplier and Diesel to be supplied by RCDF/Milk Uion.

k) 3-4 hours of full load test run of gen. set. In case of full load is not available with RCDF/Milk Union, the trial may conducted on available load.

l) Brief training of operators at site in normal maintenance and operation of gen. set.

m) RCDF/Milk Union may depute on operator each for training on engine and

alternator at respective manufacturer’s works. For training on electricals and

367



panels RCDF/Milk Unions may depute operator at tenderer’s works. No training charges as such will be payable to supplier for arranging training.

n) Supplier will have to get its installation approved from the statutory authorities if

applicable. Note :- Civil works of the nature incidental to erection like making holes & grouting for pipe

supports, panel fixing, tank fixing, etc. is included in supplier’s scope of work. LIST OF TOOLS TO BE SUPPLIED WITH D.G. SETS FREE OF CHARGE

1. Set of spanner 5 nos. – 1set

2. Screw Drier 6” – 1

3. Plier – 1

4. Hammer 1.5 kg. – 1

5. Phase Tester – 1

6. Leak stop roll – 1

7. Allen wrench set 3/63” to 3/8” – 1

8. Ring spanner (15”/16”) – 1 MAKE OF FOLLOWING ELECTRICAL ITEMS / INSTRUMENTS OF CONTROL PANEL BE SUPPLIED BY THE TENDERER 1. ACB : 250 A Microprocessor based L & T make 2. Voltmeter & Ammeter : IMP/ AE/ CADEL/ ENERCON 3. KWH meter : IMP/ AE/ CADEL/ ENERCON 4. Frequency meter : IMP/ AE/ CADEL/ ENERCON 5. Power factor meter : IMP/ AE/ CADEL/ ENERCON

368



Statement of Supply, Erection & Commissioning of Service Pipelines & Allied

Equipments at Malpura Dairy Plant.

CAPACITY : 25 KLPD

ANNEXURE – 1

S. No.

Description Qty. tentative Unit Rate of supply

Unit Rate of Erection

Total amount of Supply

Total amount of Erection

Total amount of Supply & Erection

1 Supply Erection & Commissioning of S.S. pipe line dia 25MM, 38mm, 51MM.

Erection Rate to include installation of SS valves & fittings which will be supplied by Milk Union/RCDF/ or Tenderer

Note: Every SS Union joint should be placed with leak proof Argon-Arc welding.

(a) S.S. pipe Dia 51 MM 196 Mtrs.

S.S. Pipe Fittings Dia 51 MM

Erection included in per meter rate of respective pipe

line

(A) S.S.Three way Cock With complete Union Dia 51 MM

25 Nos.

(B) S.S. Two way Cock with complete union Dia 51 MM

05 Nos.

(C) S.S. Short Band Dia 51 MM Without Union

70 Nos.

(D) S.S. Union complete Dia 51 MM

150 Nos.

(E) S.S. Tee Dia 51 MM without union

6 Nos.

(F) S.S. clamp Dia 51 MM 70 Nos.

(G) S.S. Blank Caps with wings 51 MM

2 Nos.

(H) S.S. Reducer liners 51X38 MM Dia

4 Nos.

(I) SS Vertical Non-Return Valve dia 51MM

4 Nos.

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(J) SS Line Filter (Disc Type) 2 Nos.

(b )

S.S.Pipe Dia 38 MM 450 Mtrs.

S.S. Pipe Fittings Dia 38 MM

(A)Three way Cock With complete Union Dia 38 MM

25 Nos. Erection included in per meter rate of respective pipe

line

(B) S.S. Two way Cock With complete Union Dia 38 MM

5 Nos.

© S.S. Short Band without Union Dia 38 MM

100 Nos.

(D) S.S. Union Complete Dia 38 MM

200 Nos.

(E) S.S. Tee without Union Dia 38 MM

4 Nos.

(F) S.S. clamp Dia 38 MM 100 Nos.

(G) S.S. Blank Caps with wings 38 MM

4 Nos.

(H) SS Reducer 38 x 25 mm dia

05 Nos.

(c) Supply Erection & Commissioning of SS support for placement of SS pipe lines,. Erection rates to include installation of SS clamp, SS nipple, hanging support etc.

(a) SS Square pipe 50mm thickness 2mm

48 Mtrs.

(b) S.S. Nipple Dia 15mm x 8"

65 Nos.

2 Supply Erection & Commissioning of various MS/ G.I. 'B' Class pipe line TATA / Jindal for water distribution circuit. Erection rate to include installation of required valve and fittings.

a) 150 NB 6 Mtrs.

b) 65 NB 162 Mtrs.

c) 50 NB 14 Mtrs.

d) 40 NB 420 Mtrs.

e) 25 NB 24 Mtrs.

f) 20 NB 30 Mtrs.

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(B)

Supply Erection & Commissioning of following valves on MS / G.I. Pipeline.

Erection included in per meter rate of respective pipe line.

a) Butter Fly Valves.

II. Dia 65 NB 5 Nos.

III Dia 50 NB 1 Nos.

IV Dia 40 NB 15 Nos.

b)Ball Valve Audco Make

I. Dia 25 NB 10 Nos.

I. Dia 20 NB 10 Nos.

3 Supply Erection & Commissioning of

Non Return Valve (Vertical) in water circuit

65 NB (Water) 2 Nos.

4 Supply Erection & Commissioning of Horizontal monoblock submersible pumps discharge Cap. 30000 LPH, Outlet Dia 65 NB working head 30 Mtrs, 3 Phase, 7.5 HP. Kirlosker / KSB/ Jyoti/ GRUNDFOS, or equivalent make.

2 Nos.

5 Supply Erection & Commissioning of MS 'C' Class pipe Make TATA /Jindal (JSL) for steam pipe line, insulation with 50MM thick glass wool (LRB) Pad of 100 density with 24 SWG. Aluminum cladding.

a) MS pipe 100 NB 78 Mtrs.

b) MS pipe 80 NB 24 Mtrs.

c) MS pipe 65 NB 21 Mtrs.

d) MS pipe 50 NB 30 Mtrs.

e) MS pipe 40 NB 90 Mtrs.

f) MS pipe 25 NB 12 Mtrs.

g) MS pipe 20 NB 21 Mtrs.

Required Fitting for above pipelines

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6 Supply Erection & Commissioning of Steam flange type CS globe valves with SS working part, class 150. Audco /KSB or equivalent make

a) 80 NB 1 Nos. Erection included in per meter rate of respective pipe

line

b) 65 NB 1 Nos.

c) 50 NB 1 Nos.

d) 40 NB 3 Nos.

7 Supply Erection & Commissioning of Steam ball valve (thread end) Audco make

a) 25 NB 5 Nos.

b) 20 NB 10 Nos.

8 Supply Erection & Commissioning of steam trap assembly with steam stainer, steam valve and TD type steam trap, JN Marshal make.

a) 20 NB 6 Nos.

9 Steam Pressure gauge with syphon tube, hex nipple, socket & pressure cock (IBR)

a. Pressure gauge range (0-7 kgs) per cm2

4 Set

10 Supply Erection & Commissioning of SS Steam water mixing battery with SS Hex Nipple, non-return valve, Hose Nipple, SS hanger and mounting bracket.

a) Steam battery 7 Set

b) Stem Hose (Dundlop) make or equivalent make dia

50 Mtr.

372



20 NB

11 Air pursing system on Steam line (Air vent)

1 No.

12 Supply Erection & Commissioning of MS 'C' Class pipe Make TATA /Jindal (JSL) for Air along with required moisture separator FRL.

a) 25 NB 176 Mtr.

13 Supply Erection & Commissioning of MS structure for platform, pipe support etc.

Structure to be fabricated

with required MS channel size are mentioned below:-

a)100 x 50 X 6 MM,

b)75 X 40X 6 MM 4 MT

c) MS Angle 50X50

d) Checker plate 5 MM Thick.

e) MS. Plate 5 MM thickness

F) Galvalume roofing sheets for outdoor refrigerator unit

45 Sqm.

14 Shifting, lifting, placement, orientation & installation of all supplied equipment.

1Lot

GRAND TOTAL

Note: - 1. Equivalent makes to be approved by RCDF.

2. Party has to insurance HMST 10/15 KL before shifting & lifting of same.

3. All required SS pipeline/SS union joints should be leak proof Argon Arc-welded. 4. Tender should provide the SS/MS/GI Pipe circuit diagram defining the flow of milk, steam/

water etc. the milk circuit diagram should have a provision of flow plate along with swing bends to ensure the diversion of milk as per requirement.

5. The pipe line circuits should ensure proper flow of milk, steam and water as per requirement it includes provision of wash points, tanker loading and unloading points powder mixing venture, re-chilling, provision of CIP of milk circuit etc.

6. Tenderer has to include supply of S.S flow plates for Milk and CIP System to ensure proper flow of milk and milk product and ensure proper CIP circulation through CIP system etc.

7. Tenderer has to provide required support for pipe lines and platform structure etc. if

373



required for proper operation need to be provided. The approximate MS structure quantity of 4 MT already considered.

8. Tenderer has to provide painting on all pipeline as per industrial color code, pipeline supports, MS structure etc.

9. Tenderer has to provide sheds for outdoor refrigerator units

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Technical Specification for S.S. pipes and fittings

S.S. Pipe 1.0 FUNCTIONAL REQUIREMENTS

1.1 General Description - These SS Pipes would be used to interconnect all milk

processing equipments, storage tanks, in place cleaning system etc.


2.1 All SS Pipes should conform to SMS standards.

2.2 All SS Pipes should be externally polished to dairy standards and internally pickled

to dairy sanitary conditions.

2.5 All pipes should be externally polished to dairy standards and internally pickled to

dairy sanitary conditions. All pipes should have wall thickness as 1.6mm (16 SWG) &

of SS 304 (ERW).

2.6 The following sizes of S.S. pipes shall be required :-

a) 63.5 mm

b) 51 mm

c) 38 mm

1. The raw material should be procured only from reputed manufacturer and should have following composition in case of material SS 304 :

Max. C : 0.08 % Max. Si : 0.75 % Max. Mn : 2.00 % Cr. : 18 to 20% Ni : 8 to 10.50 % Max P : 0.045 % Max S : 0.03

375



S.S. VALVES AND FITTINGS

1.0 FUNCTIONAL REQUIREMENTS 1.1 General Description - These SS valves and fittings would be used to interconnect all milk processing equipments, storage tanks, in place cleaning system etc. 2.0 DESIGN REQUIREMENTS 2.1 All valves and fittings should conform to SMS standards. 2.2 All valves and fittings should be externally polished to dairy standards and internally pickled to dairy sanitary conditions.

UNIONS

2. The union should be made in accordance with the SMS standard. As per international standard, the unions should be produced out of hot (closed die type ) forgoing only and subsequently should be duly solution treated (annealed ) to remove the internal stresses.

3. The raw material should be procured only from reputed manufacturer and

should have following composition in case of material SS 304 : Max. C : 0.08 % Max. Si : 0.75 % Max. Mn : 2.00 % Cr. : 18 to 20% Ni : 8 to 10.50 % Max P : 0.045 % Max S : 0.03 4. The union should be complete with liner, male part, nut and neoprene food

grade rubber gasket. Liner and male part should be suitable for expansion joint. 5. The thread profile should be generated on precise CNC machine so as to have

correct dimension, finish and accuracy. The union components should be interchangeable so as to have lesser inventory cost.

6. All the dimensions should be checked with calibrated measuring instruments and GO - NOGO type gauges. The thread profile should be as per DIN 405 std.

7. The union gasket should be of food grade with appropriate hardness and composition.

8. All the dimensions of the union should be in accordance with DIN 11851

including its tolerance.

9. The surface finish should be less than 1.0 Ra value. PLUG, BUTTERFLY, NON RETURN AND FLOW REGULAING VALVES

376



10. The valves should be made in accordance with the SMS standard. The valve body and plug should be made out of material SS 304 with following material composition :-

Max. C : 0.08 % Max Si : 0.75 % Max. Mn : 2.00 % Cr. : 18 to 20 % Ni : 8 to 10.50 % Max P : 0.045 % Max S : 0.03 11. Each valve should be manufactured on precise CNC machine. The inner of the

valve body and the contact surface of the plug should be ground smooth and lapped to get full metal to metal contact.

12. All the dimensions should be checked with calibrated measuring instruments

and GO - NOGO type gauges. The thread profile should be as per DIN 405 std.

13. The outer visible surface of the valve body and the plug should be mirror

polished. The male part should be an integral part of the valve body casting. 14. Each valve should be tested for a hydraulic pressure of minimum 6 bar for

minimum 3 minutes. 15. The supplier should furnish material and hydro test certificate along with the

supply of material . BEND AND TEE

16. The bends and tees should be in accordance with the SMS standard. The thickness of fittings made from tube section should be 1.6 mm for dia upto 63.5 mm and 2.0 mm for above 63.5 mm. The bend should be suitable for expandable union joint.

17. The testing certificate of parent material ( i.e. pipe ) should be submitted along

with the supply of bends and tees. 18. The material composition, in case of material SS 304, should be as per

following: Max. C : 0.08 % Max. Si : 0.75 % Max. Mn : 2.00 % Cr. : 18 to 20 % Ni : 8 to 10.50 % Max P : 0.045 %

377



Max S : 0.03 19. The outside surface should be polished to min. 150 grits and inside should be

pickled and shot blasted. 20. The bends should be free from wrinkles and the ''T'' should have uniform

flaring on the radius ( for bends ) should be within the acceptable / permissible limit specified in the DIN 11852.

LIST OF RECOMMENDED ITEMS ( SS VALVES & FITTINGS)

S.No Items Size(mm) FOR Site

Unit Rates 1 SS BEND W/O UNION 38 51 63.5 76 2. SS UNION COMPLETE 38 51 63.5 76 3. SS EXTENDED BEND WIHOUT UNION

500 MM LONG ONE SIDE 38

51 63.5 76 4. SS TEE WITHOUT UNIONS 38 51 63.5 76 5. SS 3 WAY COCK WITH COMPLETE

UNIONS 38

51 63.5 6. SS 2 WAY COCK WITH COMPLETE

UNIONS 38

51 63.5 7. SS INLINE STRAINER 38 51 63.5 76 8. SS NON RETURN VALVE 38 51 63.5 76

378



9. SS HOSE CONNECTION WITH MALE PART

38

51 63.5 76 10. SS HOSE CONNECION WITH NUT &

LINER 38

51 63.5 76 11. HOSE CLAMPS 38 51 63.5 76 12. SS INLINE SIGHT GLASS WITH

COMPLETE UNIONS 38

51 63.5 76 13. SS PIPE CLAMPS 38 51 63.5 76 14. Pneumatic SS valves 2 way 38 51 63.5 76 15. Pneumatic SS valves 3 way change

over type angular type. 38

51 63.5 76 16. SS RED LINERS 38 X 25 51 X 38 63.5X 51 17. SS NIPPLE PIPES 80 MM X ½'' 18. PLASTIC STOPPERS 38 19. FLOOR PLATES WITH 1/2 IN THREAD 38 20. SS BLANK CAPS WITH WINGS

379



DETAILED TECHINICAL SPECIFICATIONS AND SCOPE OF WORK FOR EFFLUENT TREATMENT PLANT

1. The scope of work includes complete designing, supply, installation, testing and

commissioning of effluent treatment plant, along with civil work suitable to treat

effluent load of 50 Mtr Cub per day.

This should be followed by clearance / approval and Certification by Rajasthan Pollution Control Board, Jaipur.

The total job is to be taken up on Turnkey basis. 2. Design Data:

The UASB process (Upflow anaerobic sludge blanket), aerobic process is to be

designed on the basis of the following characteristics of raw dairy effluent as indicated below in Table 1.

Table 1 - Raw Effluent Parameters (At the inlet of Inlet Channel)

Parameter Value

Flow, m3/day 50

Ph 5 – 11

BOD, mg/l 2500 – 3000

COD, mg/l 5000 – 6000

TSS, mg/l 1000

TDS, mg/l 1500

Temperature, deg C 30 – 40

Oil & Grease, mg/l 600-700

Treated Effluent Characteristics:

The treated effluent parameters after UASB process followed by Aerobic Process shall be as indicated below in Table 2

Table 2 – Ex Aerobic Process Parameter Value

pH 6.5 – 8.5

BOD, mg/l < 30

COD, mg/l < 250

TSS, mg/l < 50

TDS, mg/l < 2100

O & G, mg/l < 10

The design selected for ETP is based on UASB process followed by aerobic process for which following minimum sizes / specifications would have to be taken into consideration.

380



PROCESS DESIGN CONSIDERATIONS

Effluent Treatment plant is designed for the dairy plant effluent and will consist of preliminary system, primary anaerobic system followed by aerobic system.

The preliminary system includes screening, equalisation, surge and oil & grease removal. The primary anaerobic system includes buffering (acidification), neutralisation, UASB Process and biogas handling system. The aerobic system includes aeration, secondary clarification and sludge dewatering system which includes Sludge drying beds.

As pH of the raw effluent varies between 5.0 – 11.0, either alkali or acid will have to be used for neutralization during process stabilization and commissioning and the consumption of the same can be reduced gradually. The dosing tanks for dosing of alkali or acid by gravity to the buffer tank.

The treated effluent parameters Ex – Aerobic System will be guaranteed for the raw effluent parameters mentioned above in the Table 1.

PROCESS DESCRIPTION

The following section provides a brief description of the process flow diagram and the unit operations involved in the proposed treatment:

The raw effluent from the dairy plant will enter into Inlet channel, which is provided with

baffles and screen to remove free floating fat and coarse material in the effluent manually. The effluent from inlet channel will enter into Equalisation Tank where any hydraulic as well

as organic variations will be dampened. The equalised effluent will be then pumped Oil & Grease Trap for removal of free oil and

grease. The floated free oil & grease will be removed by oil skimmer and will be disposed off. The effluent will be bypassed to Surge Tank in case of a surge. The outlet will again

collected into equalisation tank for further treatment. The effluent from oil & grease trap will enter into Buffer Tank where caustic/Lime or acid will be dosed by gravity from dosing tanks if required. The effluent from buffer tank will then be pumped to the proposed UASB Reactor through a

series of distribution pipes. The multiple distribution ensures a uniform flow of liquid throughout the sludge blanket making maximum use of available high bacterial population. The liquid rises to the top of UASB reactor alongwith the biogas generated and also some sludge particles. A unique three phase separator, separates out the biogas, liquid and the sludge particles. The biogas is allowed to leave through collecting domes and is carried through a gas header, sediment trap and flame arrestor to gas burner for ultimate flaring to atmosphere. The liquid overflows through the gutters and the suspended solids then separated are allowed to settle down in the sludge blanket thereby retaining valuable bacterial population (attached to the suspended solids).

381



The anaerobically treated effluent from UASB Reactor shall then enter by gravity into Aeration Tank. The aeration is achieved by means of submersible aerator which also help in

the complete mixing of the contents of the aeration tank. The activated sludge generated from the A.T will be settled in the Settling Tank. A part of the settled activated sludge is recycled back to the aeration tank for maintaining a desired MLSS concentration, while the excess sludge is pumped on to the Sludge Drying Beds for necessary dewatering. The treated effluent from settling tank can be collected in the Treated Effluent Tank where

bleaching powder / hypochlorite can be added for desired disinfection. The treated effluent can be discharged for final disposal or for the gardening purpose from the treated water tank.

382



LIST OF CIVIL UNITS

1. Inlet Channel Length, m Width, m SWD, m Free Board, m MOC

5.0 0.5 0.5 0.3 RCC M30

1 No.

2. Equalisation cum Buffer Tank Length, m Width, m SWD, m Free Board, m MOC

4.0 3.0 3.0 0.3 RCC M30 with partition wall and pipe railing

1 No.

3. Oil & Grease Trap Length, m Width, m SWD, m Free Board, m MOC

4.0 1.5 1.0 0.15 RCC M30 with Baffles & Oil Collection Trough

1 No.

4. UASB Reactor Diameter, m SWD, m

Free Board, m MOC

3.25 6.0 0.3

Foundation with RCC Raft, PCC Raft, Rubble Soling and Compacted Sand Filling and Superstructure in RCC M30 with 1 m wide walkway around the reactor with Pipe Railing of 1m height and connecting gutter to buffer tank

1 No.

5. Aeration cum Settling Tank Length, m Width, m SWD, m Free Board, m MOC

4.25 3.00 3.00 0.50 RCC M30 with partition wall

1 No.

6. Sludge Drying Beds Side, m Total Height, m MOC

1.5 1.0 Brickwork In C.M (1:5) with Sand & Gravel Filling

2 Nos.

7. Treated Effluent Tank Length, m

3.00

1 No.

383



Width, m SWD, m Free Board, m MOC

3.00 3.00 0.30 RCC M30 with pipe railing

384



8. Surge Tank Length, m Width, m SWD, m Free Board, m MOC

2.5 2.5 2.5 0.3 RCC M30

1 No.

9. Other Foundations For

a. Feed Pumps b. Biogas Burner c. Filtrate Pit, V Notch Chamber d. Dosing Tanks e. Inserts required in civil structures f. Cable trenches, pipe supports

1 Lot

10. MCC / Lab Room and chemical storage room & Toilet Block

1 No.

CIVIL CONSTRUCTION SPECIFICATIONS

The scope of civil engineering works will be carried out as per proposed drawings submitted by erector & approved by Salient features are however mentioned below:- Provisions for excavation & back filling for construction of ETP is to be made by contractor and surplus excavated material shall be disposed in consultation CONCRETE MIXES : The following mixes/grades of concrete shall be used in places specified:- M-300 Grade Concrete : In reinforced concrete members in direct contact with liquid using 20mm and nominal size stone aggregates and having cement content not less than the minimum specified in IS:3370:1965. M-150 Grade concrete : In reinforced concrete members not in direct contact with liquid using 20mm and nominal size stone aggregated. 1:4:8 Concrete : In 100mm thick under various footings / foundations and RCC base slabs of structures using 40mm and down size stone aggregate. 1:3:6 Concrete : (i) In 150mm thick foundations for various masonary structures using 40mm down size stone aggregate. (ii) In 100mm thick base slabs of oxidation ditches and aerated lagoon if proposed by the erector using 40mm and down size stone aggregate. Crusher broken stone aggregate used.

NOTES ON CONCRETE CONSTRUCTIONS

All concrete will be volume batched. All reinforced will be mechanically mixed and vibrated. All RCC structure will be lift straight from shutters with reasonable rendering of shuttering joint marks only. RCC structure will be suitably plastered wherever necessary. Construction joints in RCC members shall be formed in accordance with the provision of IS:3378. Reinforcement shuttering work For shuttering ply woods / steel plate shuttering as consider suitable for particular place will be provided.

385



Design should be based on Tor Steel reinforcement basis conforming to IS:1768/1139 MASONARY WORK Stone / Brick masonary work for all walls partitions etc. shall be constructed with best quality of brick/RR stone / sand etc. in cement sand mortar mix 1:4 as per the drawings to be supplied by erector and approved by the Milk Union. FINISHING

Exposed faces of R.C. walls shall be given two or more coat to give an even shade of cement paint of approved shade. 20mm thick and 12mm thick cement plasters in 1:4 cement sand mortar shall be provided at the rough faces of the brick panel walls of the pump house / blower room. However the ceiling of the roof shall be provided with / average 6mm thick cement plaster in cement sand mortar and 100mm thick water proofing be done in Brick Ballast and CM (1:3) as per specifications. DESIGN OF STRUCTURES The design of structures will be based on the following IS codes of practice unless specified by us: (i) IS-456-1964 : For plain and reinforced concrete work. (ii) IS-3370 : For structural members in part I, II, IV direct contact with liquid. (iii) Other relevant IS codes. Covers to main reinforcements shall be as per IS 56 3370 whichever is applicable. The thickness of wall foundation of machinery etc. should be structurally safe and sound and the same will have to be got approved before execution. Equipment-wise specification for civil work 1 INLET CHANEL : 1 NO.

This will be constructed with RCC M-300 and plaster on both sides. The side of screen chamber would be 5.0m x 0.5m x 0.5m, free board 0.3 mtr.

2 EQULISATION CUM BUFFER TANK : 1 NO.

The construction will be RCC M-300 with partition wall with internal plaster with water proof compound. The size of tank would be 4.0m x 3.00m x 3.00m, free board 0.3 mtr with pipe railing.

3 OIL AND GREASE TRAP : 1 NO. The construction will be RCC M-300 with internal plaster with water proof compound. The size of tank would be 4.0m x 1.5m x 1.0m, free board 0.15 mtr with baffles and oil collection trough.

4 UASB REACTOR : 1 NO.

The construction will be RCC M-300 with internal plaster with water proof compound. The size of reactor tank would be dia 3.25m x depth 6.00m, free board 0.3 mtr with pipe railing. Foundation with RCC Raft, PCC Raft, Rubble Soling and Compacted Sand Filling and Superstructure in RCC M30 with 1 m wide walkway around the reactor with Pipe Railing of 1m height and connecting gutter to buffer tank.

386



5 AERATION CUM SETTLING TANK : 1 NO.

The construction will be RCC M-300 with partition wall with internal plaster with water proof compound. The size of tank would be L 4.25m x W 3.0m x D 3.00m, free board 0.5 mtr.

6 SLUDGE DRYING BEDS : 2 NOS.

The construction will be Brick work in C.M. (1:5) with sand and gravel filling with internal plaster with water proof compound. The size of tank would be L 1.5m x W 1.5m x Total Height 1.00m.

7 SURGE TANK : 1 NO.

The construction will be RCC M-200 with internal plaster with water proof compound. The size of tank would be L 2.5m x W 2.5 m x D 2.5m, free board 0.3 mtr.

8 TREATED EFFLUENT TANK : 1 NO.

The construction will be RCC M-200 with internal plaster with water proof compound. The size of tank would be L 3.0m x W 3.0 m x D 3.0m, free board 0.3 mtr with pipe railing.

9 OTHER FOUNDATIONS : 1 LOT

a. Feed Pumps b. Biogas Burner c. Filtrate Pit, V Notch Chamber d. Dosing Tanks e. Inserts required in civil structures f. Cable trenches, pipe supports

SPECIFICATIONS FOR PIPING WORK :

1 Effluent Piping: MS B class piping. 2. Sludge Line: Suitable size MS B class piping. 4. Gas Line: Suitable size MS B class piping. 5. Water & Other Lines: Suitable size MS B class piping.

The above piping will be of reputed make, ISI marked, complete with suitable size of valves, bends, flanges, headers and other auxiliary materials. All valves will be of flanged type.

387



LIST OF MECHANICAL, BOUGHT OUT, ELECTRICAL & INSTRUMENTATION ITEMS FOR ETP

A. UASB System, Biogas Handling System:

Sr. No. Unit Specifications Quantity

1. UASB System comprising of: UASB Reactor alongwith ladder a. Influent Header b. Bottom Distribution System c. Three Phase Settler d. Supporting Structure d. Distribution Line Valves e. Baffles, Effluent, Gutters etc. f. Sampling Ports g. Inspection Manhole

In M.S of suitable size

HDPE- 10 kg/cm² MSEP MS with anticorrosive painting As per Design In MSEP 40 NB size, 6 nos. 1 No. 1200 mm

1 Lot

2. Biogas Handling System comprising of: a. Sediment Trap b. Flame Arrestor c. Gas Burner

1 No.

B. Mechanical, Bought Outs & Instrumentation:

Sr. No.

Unit Specifications Quantity

1. Bar Screen Bar Width, mm Bar Depth, mm Cleaning Mode MOC

10.0 10.0 Manual MSEP

1 No.

2. Oil & Grease Trap Feed Pumps Flow Rate, m3/hr Head, MWC Motor Rating / Speed Type MOC

3.0 10.0 1.0 HP / 2900 RPM Horizontal Centrifugal Non Clog C.I.

2 Nos. (1+1)

3. Oil Skimmer Type

Trolley Type auto moving in both forward and backward side complete with collection hopper plate with suitable capacity motor and gearbox, FRU panel and limit switch for movement in automation.

1 No.

4. Dosing Tanks for Acid & Caustic Capacity, lits MOC

100.0 HDPE

2 Nos.

388



5. UASB Feed Pumps Flow Rate, m3/hr Head, MWC Motor Rating / Speed Type MOC


2 Nos. (1+1)

389



6. Aerator in Aeration Tank

Rating, HP Type Air blower.,

Submersible capacity 65m3/hr, pressure 0.4 kg./cm2, 3 HP qty. 2 nos. (1W+1S) with non clog type membrane diffuser, air grid system suitable for 65m3/hr. with lifting arrangement for Aerator in Aeration Tank

1 No.

7. Sludge Recycle Pumps Flow Rate, m3/hr Head, MWC Motor Rating / Speed Type MOC


2 Nos. (1+1)

8. Process Piping, Valves and Fittings within battery limits

Piping – M.S. Class B Valves – C.I Butterfly Wafer

1 Lot

9. “V” Notch for flow measurement MOC

MSEP

1 No.

10. Electricals: Starters for UASB Reactor Feed Pumps, Aerator, Sludge Recycle Pumps

Associated Cabling and Earthing.

1 Lot

SPECIAL CONDITIONS FOR EFFLUENT TREATMENT PLANT

1. The make of items here in covered should be well reputed. 2. The ETP is to be treated as a turnkey project as per the lay out to be submitted by

suppliers and final drawing to be approved by Concerned Milk Union/RCDF. 3. All necessary mechanical, electrical equipments controls machinery and other items,

which may be required for the erection of the entire plant falls in the scope of supply though specifically mentioned. The plant also is guaranteed for the performance parameters.

4. All the taxes and duties are included and rates are FOR site. 5. The price is inclusive of unloading charges at site of the equipments and your

representative will unload the same safety at site. 6. Complete erection, testing and commissioning of the plant comprise of the following:

Shifting and placing of the equipments on the respective foundations. Electrical wiring of the complete plant including power and control, lubrications, testing, commissioning and handing over of the plant in satisfactory working condition after satisfactory trial runs for 15 days including capacity test.

7. The services/utilities to be made available to the erector shall be arranged upto the battery limits and it will be the erectors responsibility to tap these service / utilities from the battery point to the different places of requirement. All necessary fittings, mountings and all other items required for tapings and transmitting the services shall be supplied and installed by the erector.

390



8. The necessary quantities of cleaning chemicals, make up lubricants etc. required for the installation, commissioning, testing and start up of all the equipments are to be supplied by erector free of cost.

9. Initially the plant will be on commissioning and will be commissioned on the flow of effluent available at point of time subject to delivery mentioned in the order. However, supplier will be required to demonstrate satisfactory performance of the plant during full flow conditions to be made available during peak season.

10. The performance guarantee period will start from the date of successful commissioning of plant.

11. The tendrer has to stabilize the plant to required parameter and will inform Milk Union/RCDF for 15 days on load trial. During trial period required chemical and lubricants to be arrange by tendrer.

12. The supply system should be under one year performance guarantee period after successful installation and commissioning.

13. The one year performance guarantee period includes deputation of one technical person for supervision of plant operation during general shift. The general maintenance will be carried out by concerned milk union in direction/supervision of deputed technical person by the party.

14. It will be the sole responsibility of the suppliers to ensure performance of the plant to give desire results of treated water as specified by the water pollution board of Rajasthan and as given in the tender. In case any changes, modifications, alterations etc. are required at the time of commissioning by Board, the same will have to be carried out by the supplier free of cost.

15. ZDUSS will reimburse any statutory fee payable for the plant on submission of receipt / vouchers etc.

16. Approval from various Agencies like RPCB/Electrical Inspectorate etc. which are connected with the ETP plants supply, installation, testing and commissioning will be obtained by the suppliers.

17. The oil and grease trap, equilisation tank, Aeration tank etc. will be RCC M-300 construction. The detailed civil drawings will be got approved by supplier prior to construction.

18. All interconnecting pipe lines will be of MS as mentioned. 19. ZDUSS will lay cables up to ETP which is to be connected therein by contractor. 20. The plant layout will be such as to facilitate expansion in future. The expansion

possibilities and directions should be down dotted in the layout. 21. Tenderer should have execute three ETP projects of similar or above capacity in India. 22. Tenderer should furnish the details of the chemicals / power consumption per ltrs of

effluent treatment at rated capacity. 23. Tenderers should visit the site for complete analysis of work involved in the project

and S/I/C of ETP should be as per site condition (considering site ground lavels etc.) 24. The consent to establish and consent to operate is in the scope of tenderer.

391



MAKES OF EQUIPMENTS:

Sr. No. ITEM MAKE

1. Centrifugal pumps Jyoti/Johnson / KSB / Kirloskar

2. Motors Bharat Bijlee / kriloskar / ABB / Siemens Crompton

3. Air blowers Kay / Usha / Everest / Eq.

4. Flow meters / Instruments E&H / Emerson / Eq.

5. Level Probes / switches Pune Techtrol / SBEM / E&H / P&F/ Waree

6. Electrical switchgear L&T / Siemens

7. Cables Gloster / CCI / Nicco/ Finolex/Havells

8. Pressure gauges Fiebig / Forbes / H Guru / Waree / Wika

9. Structural steel SAIL / TISCO / Jindal

10. MS / GI pipes Tata / Jindal

11. HDPE Pipes Finolex / Godavari / Supreme / Dutron

12. DAF Krofta / DAFTECH / Dew /Ionex

13. Decanter Centrifuge Humboldt Wedag / Alfa Laval / Eq.

14. PSF / ACF Thermax / Water Treatment / Ionex

15. PVRV Fainger / Eq.

16. Limit Switch Jayashree / Sirnens /Honeywell/L&T

17. Aerator, Clarifier, Agitator - Gear Box

Redicon/Elecon / Greeves

18. Dosing Pumps Milton Roy / ProMinent / Eq.

19. PH Meter E&H/Emerson/HACH

20. Diffuser Rehau/OTT/Eq.

21. Butter Fly valves Audco/ CRI

392



393



TECHNICAL SPECIFICATION FOR FOUR TANK AUTOMATIC SINGLE CIRCUIT CIP MODULE

Functional Requirement: The automatic CIP unit will be required to clean all milk handling equipments and interconnecting pipes and fittings to dairy standards. The CIP system shall be single circuits, automatic type, suitable to meet the CIP requirement of the milk processing. All circuits of the CIP system shall be capable of functioning independently and simultaneously. In the CIP System, the cleaning media of desired temperature and concentration shall be prepared and the cleaning process/cycle shall be initiated, controlled & monitored from a central location through a PLC control panel. However the operator will connect the field level connection/distribution and return of the CIP piping manually. The CIP system shall have following operations

A. Filling: In this mode adequate quantity of raw water will be taken into the Tanks as per

the requirement. The high level of the tanks will be maintained by an electromagnetic

float switches provided on the tank. This will be functional only during the filling mode

only.

B. Preparation: 1. During the preparation mode the required quantity of cleaning detergent solution will

be added in the tank automatically. Then the CIP solution will be circulated through

the heat exchanger to achieve the desired temperature. Once the desired/set temperature is achieved and the detergent solution is prepared

recirculation will be stopped.

2. The stored water in both the tank will be circulated through the heat exchanger and

stored in the tank as per the set temperature for the CIP system. The heating will be

made by hot water or/steam to the heat exchanger by controlling the hot

water/steam control valve operated automatically through PID controller and Electro

pneumatic controller.

3. During the preparation mode the required quantity of dilute Nitric Acid solution will

be added in the tank automatically. Then this solution will be circulated through the

heat exchanger to achieve the desired temperature. Once the desired/set temperature is achieved, and the Nitric Acid solution is prepared, recirculation will be

stopped.

Once Preparation is completed and the system is ready for cleaning sequences.

394



C. Cleaning : The sequence of the cleaning procedure will be as follows:

1. First water flush: During this mode water from the recirculation tank will be

circulated through the supply pump with heating to the selected equipment and the

same will be returned back to the CIP module and flush it before the filter.

2. Acid rinse: The detergent solution prepared in the Tank will be circulated through

the supply pump through heat exchanger to the selected equipment and the return

will be collected and send back to the system through the filter of the same tank.

After circulating the solution, the system can be changed over to the next mode.

3. Hot water rinse: In this mode, the water will be circulated through the supply

pump through the heat exchanger to the selected equipment and the return will be

collected back to the Acid tank and after timer operated will go to recuperation

tank. After completing the pre-rinse, the system can be switch over to the next

mode.

4. Detergent rinse: The detergent solution prepared in the Tank will be circulated

through the Supply Pump through the heat exchanger to the selected equipment

and the return will be collected and send back to the system through the filter of

the same tank. After circulating the solution, the system can be changed over to

the next cleaning process.

5. Hot water rinse: In this mode, the water will be circulated through the

supply pump through the heat exchanger to the selected equipment and the

return will be collected back to the Detergent tank and after timer operated

will go to recuperation tank. After completing the pre-rinse, the system can be

switch over to the next mode

6. Hot water Sterilization: In this mode, the hot water stored in the Tank will

be circulated through the supply pump through heat exchanger to the

selected equipment a part of return will be collected back to the recirculation

tank. After completing the pre-rinse, the system will be changed over to the

395



next mode.

7. Fresh water cooling: During this mode, fresh water will be circulated

through the supply pump without heating to the selected equipment and the

same will be returned back to the CIP system for drain or recuperation tank.

The CIP system will be “Automatic’ to the extent that it will comprise programmed

cleaning cycles having preset controls for cleaning and flushing. The CIP tank supply and

return valves including the forward/diversion valve and water fill up valve shall be

pneumatic and operated automatically depending on the set programme by rotary switch

in panel. The system will also monitor parameters like air pressure, steam pressure etc. It

will be possible to repeat uniform cleaning operations and to ensure efficient and constant

performance with maximum operating economy.

i. Technical specification and scope of supply:


1. CONCENTRATE LYE/ACID TANK 100L 2Nos

Vertical, cylindro-conical in design, made of 3 mm thick SS 316

sheet complete with all accessories

Finish:

All visible inner as well as outer surfaces should be finished

to

180 grits. All welded joints are to be ground smooth and

finished to 180 grit finish.

2. DOZING PUMP STD 2No

The dosing pump is pneumatic, double diaphragm, plastic type,

suction pipe with foot valve is included.

3. C. I. P TANK FOR LYE/ACID/HOT WATER 1000L 3No

Vertical, cylindro-conical in design, made of SS 316 sheet duly insulated with 100 mm thick mineral wool and cladded with SS 304 sheet, complete with all accessories water inlet connection, CIP inlet and outlet connection.

STANDARD ACCESSORIES:

1. Foam free inlet for CIP return

2. Water inlet from side towards bottom

396



3. Drain arrangement with two way valve

4. Overflow pipe

5. Man hole on top

6. Level switches-2No

7. Temperature probe

Finish:

All visible inner as well as outer surfaces should be finished

to

180 grits. All welded joints are to be ground smooth and

finished to 180 grit finish.

4. WATER RECOVERY TANK 2000L 1NO

Vertical, cylindro-conical in design, made of SS 304 sheet,

complete with all accessories water inlet connection, CIP

inlet and outlet connection.

STANDARD ACCESSORIES:

1.Foam free inlet for CIP return

2.Water inlet from side towards bottom

3.Drain arrangement with two way valve

4.Overflow pipe

5.Man hole on top

6.Level switches-2No

7.Temperature probe

Finish: All visible inner as well as outer surfaces should be finished to 180 grits. All welded joints are to be ground smooth and finished to 180 grit finish.

5

CIP SUPPLY PUMP

Type: Centrifugal MOC: SS 316 Capacity: 12000lph Head: 35MWC Electrical connection : Standard TEFC motor with 3 phase connection 12KLPH 1No

397



6 CONDUCTIVITY METER Make: E & H / Equivalent. STD 1NO

7

TUBULAR FILTER

Sanitary type design made of SS 304

sheet with suitable pore size will be

used to filter the CIP solution

continuously.

12KLPH 1NO

8

CIP RETURN PUMP Type:Centrifugal MOC:SS 316

Capacity:12000lph Head:15MWC

Electrical connection: Standard TEFC motor with 3 phaseconnection 12KLPH 1No

9

SHELL AND TUBE HEAT EXCHANGER

The shell and tube heat exchanger Shell will be stainless steel confirming to S.S.304 and inner tubes will be

S.S.316 seamless

corrugated. Final stage of heating will be done with steam

heated water. The hot water generation system will

be all stainless steel construction, efficient silent and rugged unit with all necessary accessories.The shell

and tube heat exchanger will be complete with

steam setup with steam ball valves, steam control valve, condensate outlet with steam trap (float

type), pipes and fittings and temperature controller

with 20 DEG C temp rise 12KLPH 1No

10 VALVES AND FITTINGS: STD 1LOT

Pneumatically actuated butterfly valves MOC 316 shall be provided for the CIP circuits and manually operated butterfly valves will be provided for the drain,

11 SS CONTROL PANEL WITH PLC TOUCH SCREEN STD 1No

The panel will be made out of SS 304, It will be provided with

PLC, touch screen. The entire sequence of Filling,

Preparation,

and CIP followed by Raw water flush, Hot water rinse and

Caustic with Pneumatically operated steam control valve will maintain the temperature in the system. Through the

398



PLC and the I/P converter based on the flow rate required

for the object to be cleaned. Except the drain valves of the

Individual tank, all other valves will be pneumatically

operated and all pneumatic components and accessories will be mounted in the panel and duly piped internally.

12 SS SKID STD 1NO

The above process equipment except tanks will be mounted

on SS 304 skid.

13 SS 304 PIPES AND FITTINGS STD 1LOT

One lot of SS 304 pipes and fittings will be provided to

interconnect the process equipment in this section.

14

Floor Plates STD 2 Nos.

399



LIST OF EQUIPMENT





suitable 1 lot.



500 Kg 1 lot.







Suitable 1 No.















400









Suitable 1 No.


Suitable 1 No.










100 ltrs 1 No.


100-400 ltrs 1 No.




700-3000 cup per hr

1 No.


1 No.





401




10 Moulds size

1 Lot.


1 No.









5.0 MISCELLANEOUS



Suitable 1 Lot






500 L 2 Nos.



3.10 m x 4.4 m x 3.5 m

1 Lot


3.10 m x 4.4 m x 3.5 m

1 Lot


5.2 m x 6.7 m x 3.5 m

1 Lot


3.5 m 1 Lot

402



5.13


6.7 m x 2.10 m + 6.23 x

3.10 m

1 Lot














6.12



500 bottles per hr

1 No.


per hr 1 No.


500 bottles per hr

1 No.


6.17



per hr 1 No.


500 bottles per hr

1 No.


25-50 tray per hr.

1 No.



403







1 KLPH 01

set


hr. 01

set



1000 ltrs. 02

set


per hr. 01

set


per hr. 02

set




200 ltrs. 01

set

8.0 PANEER





8.05



01

set







1000 ltrs 01 set


404





10.00 SERVICES





1 Set.







1,00,000 Kg/hr

1 Set.


11. ELECTRICAL


11.01


1 Set.

12. GENERAL


12.01 D.G. Set 160 KVA 1 lot.


1 lot.

405








406



Sub section-2

Project Information

407



Project Information “Supply, Erection, Testing and Commissioning of Plant & Machinery for Setting up Indigenous Product Plant on Turn Key Basis” at Malpura (Tonk) Raj.

Introduction: The scope of the tender shall include the following:- Scope of Work: The scope of work includes supply, installation, testing & commissioning

of plant and machinery for setting up indigenous product plant as per list detailed below:-





suitable 1 lot.



500 Kg 1 lot.







Suitable 1 No.








408
















Suitable 1 No.


Suitable 1 No.










100 ltrs 1 No.


100-400 ltrs 1 No.




700-3000 cup per hr

1 No.

409




1 No.






10 Moulds size

1 Lot.


1 No.









5.0 MISCELLANEOUS



Suitable 1 Lot






500 L 2 Nos.


410




3.10 m x 4.4 m x 3.5 m

1 Lot


3.10 m x 4.4 m x 3.5 m

1 Lot


5.2 m x 6.7 m x 3.5 m

1 Lot


3.5 m 1 Lot

5.13


6.7 m x 2.10 m + 6.23 x

3.10 m

1 Lot














6.12



500 bottles per hr

1 No.


per hr 1 No.


500 bottles per hr

1 No.


6.17 Bottling labelling, printing & Packing

411



Section


per hr 1 No.


500 bottles per hr

1 No.


25-50 tray per hr.

1 No.







1 KLPH 01

set


hr. 01

set



1000 ltrs. 02

set


per hr. 01

set


per hr. 02

set




200 ltrs. 01

set

8.0 PANEER





8.05



01

set


412








1000 ltrs 01 set




10.00 SERVICES





1 Set.







1,00,000 Kg/hr

1 Set.


11. ELECTRICAL


11.01


1 Set.

413



12. GENERAL


12.01 D.G. Set 160 KVA 1 lot.


1 lot.






Note:-

1. The plant & machinery, shall be supplied as per respective specification detailed at Annexure - X

2. The supplied Plant & Machinery shall be efficiently installed at site, same should be connected electrically and mechanically. The associated (SS,GI,MS) pipes and pipe fittings (valves, flange, nipple, bend etc), insulation wherever required, electrical wire and cables, cables trays, mimic control panels etc. We have mentioned the tentative quantity of same in respective technical specification, the quantity may vary as per actual site condition.Tenderer has to supply the aforesaid item as per site condition and no additional charges shall be paid.

3. Tenderer has to include steam control valve and its allied circuit with provision of bypass arrangement control valves, steam trap assembly etc. wherever control of steam supply is needed . Example :- Milk Pasteurizer, Multi Purpose pasteurizer for curd and paneer, retort for flavored milk sterilization etc.

4. S.S service tables of suitable size where ever needed to be included in the scope of supply .

5. Wherever mimic control panel is required for the ease of plant operation need to be considered and scope of supply .

6. The platform and overhead sheds need to be provided for outdoor refrigerator units. The suitable capacity of Cooling tower should be considered in case of water cooled compressors used in refrigeration units for Candy Tank, Candy Hardener etc.

7. Suitable capacity of Milk Pump / Water Pump etc. need to be installed in Milk / CIP / Water circuit etc. accordingly same should be considered in the scope of supply.

8. Tenderer has to carry out Supply, Erection, Testing and Commissioning of supplied Plant & Machinery as per site condition.The plant layout is hereby enclosed with tender document for the analysis of quantam of work involved .

9. Following approvals are required from RCDF before fabrication of equipment and for the execution of awarded work:- General arrangement drawing for the plant and

414



machinery layout , defining inter-connection of equipment and flow of milk and milk products, water, steam etc.

10. Complete electrical work: The scope of electrical covers complete electrical connection, earthing and controls to supplied plant and machinery, electrical panel with required switch gears i.e MCCB, MCB, ampere meter, volt meter, relay, single phase preventer, earth fault relay, contractors, push buttons etc., mimic control panels where ever required along with control wiring, related cables, cable trays, suitable structure for support of cable tray etc. need to be provided. The drawing of electrical panel and controls and cable layout etc. shall be get approved before execution of electrical work.

11. In addition to the standers mentioned, all works shall also conform to the requirements of the following for which necessary certifications of the concerned departments are to be obtained and submitted to the concerned Milk Union/RCDF :- a. Indian Electricity Act and rules framed there under. b. Fire, Insurance and Regulations Act. c. Regulations laid down by the Chief Electrical Inspector of the State/State

Electricity Board. d. Regulations laid down by the Chief Inspector of the Factories & Boilers of the

State. e. Regulations laid down under the Explosive Act. f. Regulations as per Weight and Measure Act. g. Pollution Control Board of Rajasthan (i.e. consent to established , consent to

operate. h. Bureau of Indian Standards i Any other regulations laid down by the local authorities.

Applications under various Acts should be moved through MD, Union well in advance so that operation of the plant could be started as per rules and regulations from the day one after handing over the plant. However, actual fee and other charges deposited with the government authorities will be reimbursed to the Contractor after production of receipt. 1. The Tenderer shall be responsible for developing the conceptual layout and flow diagram

to ensure successful operation of the plant with minimum investment. 2. Since this will be Turnkey Job it will be the full responsibility of the Tenderer to carry

out all minor works necessary to achieve the rated capacity of the plant even though they might not have been expressly mentioned in the tender document.

3. All the equipment to be supplied will have to be manufactured and supplied as per the standard specifications adopted by the Milk Plant manufacturer/dairy industry in the country.

4. This contract will be “Fixed Rate Contract” and the contractor will have to supply the equipment and complete the erection and commissioning within the agreed contract value and no escalation of prices will be allowed.

5. It is absolutely essential to complete the job of supply, installation, testing & commissioning of plant and machinery for setting up indigenous product plant within 08

months from the date of issue of purchase order.

6. The tenderer is advised to visit to site so as to apprise himself of actual site condition and quantum of work involved.

415



SUB SECTION - 3

Design Basis

416



BASIS OF DESIGNS

1.1 The “Supply, Erection, Testing and Commissioning of Plant & Machinery for Setting up Indigenous Product Plant on Turn Key Basis” at Malpura (Tonk) Raj “ need to be as per tender.

We have provided the technical specification of plant machinery covered under the scope of tender. It is a turnkey project, accordingly tenderer has to carry out shifting lifting of supplied equipment as per site condition and necessary connection of electricity, water (soft water / hard water), air, steam, need to be provided for successful installation and commissioning of supplied system.

In addition to aforesaid, all works shall also conform to the requirements of the following for which necessary certifications of the concerned departments are to be obtained and submitted to the concerned Milk Union/RCDF :-

a. Indian Electricity Act and rules framed there under. b. Fire, Insurance and Regulations Act. c. Regulations laid down by the Chief Electrical Inspector of the State/State Electricity

Board. d. Regulations laid down by the Chief Inspector of the Factories & Boilers of the State. e. Regulations laid down under the Explosive Act. f. Regulations as per Weight and Measure Act. g. Pollution Control Board of Rajasthan. h. Bureau of Indian Standards i. Any other regulations laid down by the local authorities.

Applications under various Acts should be moved through MD, Union well in advance so that operation of the plant could be started as per rules and regulations from the day one after handing over the plant. However, actual fee and other charges deposited with the government authorities will be reimbursed to the Contractor after production of receipt. The technical specification of plant and machinery will provide the information regarding the capacity, quality, and the analysis of quantum of work involve within the project. Tenderer may analise the associated cost. The supplier shall require to be ensure that no damage occur to any of the structure/building of plant. If any existing structure/line is required to be removed from the job the contractor has to make it good and restore to its existing state at his cost. The tenderer is advised to visit the site so as to apprise himself of actual site conditions & quantum of work involved. The plant building layout is hereby enclosed, accordingly tenderer may assess the volume of work involved in the project for providing connection to supplied plant and machinery.i.e electrically and mechanically , the total required pipe line, valves and fittings, electrical panel, wire and cables etc. are covered under the scope of work of project.

417



Tenderers are hereby informed that the scope of work and related statutory formalities covered under this turn key project shall be completed within the total FOR quoted price as per BOQ, no extra payment shall be made for successful completion of the project.

418



SUB SECTION - 4

RESPONSIBILITIES

419



1.0 RESPONSIBILITIES OF BIDDER

1.01 Developing the process design, complete engineering design, manufacturing and/or supply of goods and service and ensuring best performance of individual equipment/systems/process plant as a whole. The bidder shall avail the assistance of reputed specialists in the respective field wherever required as well as past experiences gained during installation/ commissioning of the of projects.

1.02 Providing technical data, technical literature, production and service load calculations. 1.03 Arranging for approvals from various statutory authorities on behalf of the Purchaser .

The statutory fees will be reimbursed by Purchaser on production of receipt. 1.04 First charge of oil/lubricants. 1.05 Execution of project in accordance with prevailing Indian standards IER & IBR,

wherever applicable & relevant to the project. 1.06 Testing and commissioning satisfactorily and performance of all equipment in bidder’s

scope and after sales service at mutually agreed terms. 1.07 Test equipment, test kits, instrumentation and materials required for establishing

performance parameters. However laboratory equipment required for testing milk quality etc. shall be provided by the Purchaser to establish product quality.

1.08 Provide necessary manpower during erection, testing and commissioning along with tests.

1.09 Testing, commissioning of the system under scope as per agreed performance parameters and utility consumption.

1.10 Training Purchaser 's personnel in the field of instrumentation automationplant operation & control, maintenance & repair of systems & equipment.

1.11 Distribution of water,chilled water, steam, electricity within the proposed Indigenous section at Malpura is the scope of bidder. It includes all necessary MS / GI, required insulation on chilled water line / steam pipe, SS pipes, fittings, structure, electricals, automation & control etc.

420



1.1 RESPONSIBILITIES OF PURCHASER

1.1.1 Electric power and water will be made available for use by RCDF free of cost. These supplies will be made, where available at one central point in the site convenient to RCDF and all piping for service water to work area shall be furnished, installed and maintained by erector at his own expense. He shall also furnish, install and maintain at his cost the power lines, junction boxes and any other electrical receptacles, apparatus or equipment from the central point of his work area.

1.1.2 Lighting and domestic wiring system and internal telephone system including the switch boards for lighting. Engineering personnel to liaison with the supplier, Project Manager and the execution team.

1.1.3 Permanent water and power supply at the time of pre-commissioning of the plant.

1.1.4 Adequate staff including operators, supervisors and engineers for product trials.

1.1.5 Provision to provide services, raw products, packaging materials & chemicals etc.

1.1.6 Timely provision of personnel for training.

1.1.7 Provide open storage area, lockable store and office space during erection and commissioning of project.

1.1.8 Suitable Site fabrication yard

1.1.9 Telephone and fax on chargeable basis.

1.1.10 Payment as per agreed terms and conditions.

1.1.11 Approval of drawing within 10 days from date of submission and decision within a week on any issue which will come up.

1.1.12 Project manager with team throughout the implementation.

1.1.13 Availability of required quantity of milk for the designed product to conduct the first run of product trials at the rated plant capacity.

421



SUB SECTION - 5

BATTERY LIMIT

422



BATTERY LIMITS

Supplier will be responsible to undertake all the works involved in completing the project within the battery limits prescribed below

The battery limits for Setting Up Indigenous Product Plant on Turn Key Basis at Malpura are as follows:

Raw Milk Raw Milk with required quality, quantity shall be made available at RMRD (raw milk reception dock), through milk tankers or milk canes. Transfer of milk from RMRD onward for processing of milk is in scope of bidder.

Raw Water, Soft Water The bidder should take tapping of soft water, hard water from the soft water hard water circuit .The bidder shall be responsible for the distribution of the water to all points of consumption, within Setting Up Indigenous Product Plant on Turn Key Basis at Malpura. LT Power Milk Union to provide three phases LT power (four wire) at one point within plant premises, bidder will arrange the extension of same up to work site. Temporary Site Office and Store The bidder shall be responsible for the construction of the temporary site office and store. Civil The purchaser shall be responsible for Civil works. However, the bidder shall provide for the supply of foundation bolts along with template / sub- base, motor slide rails etc. for erection and alignment of the equipment. Raw Material Packing Material and Consumable. Purchaser shall provide raw material, consumable, CIP detergent or milk etc. As required for trail run commissioning and performance demonstration etc.

423



Sub Section 6

Drawing, Data and Documents

424



Drawings enclosed with the tender.

1. The plant layout defining space available for placement for plant and machinery for

Setting up Indigenous Product Plant on Turn Key Basis at Malpura is hereby enclosed with tender document. The prefab cold store for ice-cream, milk and milk products shall be placed on the platform made available by purchaser.

2. Tenderer should submit the proposed plant and machinery, equipment, layout as per building layout plan of Malpura Plant.

3. Tenderer should submit the proposed pipe-line (steam, hard water, soft water, milk & milk product circuit etc. layout as per building layout plan of Malpura Plant.

4. Tenderer should submit fabrication drawing of equipment for approval from RCDF,

before start of fabrication. 5. Tenderer should submit foundation drawing of supplied equipment of Malpura Plant. for approval from RCDF, before installation and commissioning of machinery. 6. Tenderer should submit electrical panel drawing, cable route drawing, electrical panel

layout drawing etc. For approval from RCDF, before start of installation and commission of electrical cable, laying of cables etc.

425



Sub Section 7

Bidders Meetings

426



BIDDERS MEETINGS

1. This will be general meeting at which all purchasers of the tender

document may attend. 2. Bidders may also request technical discussions with the Dairy / clients

project team before the tender closing date. Subjects for discussion at the technical meeting may include:

Project management Technical clarifications Scope of supply Concept of the design Processes Equipment designs Equipment suppliers Automation Plant management Quality control Existing equipment to be utilized in the job Battery limits Acceptable alternatives This will be the only opportunity for bidders to discuss the project in detail with Dairy before the commercial bid opening, and all technical matters should be resolved at meetings.

427



RECOMMENDED MAKES OF MAJOR EQUIPMENT / BOUGHT OUT ITEMS

Sr N

Description of Item Name of tenderer

1. Plate Heat Exchangers i.e. Milk Chiller, Milk/Cream Pasteuriser,

GEA Ecoflex/Tetrapak/Goma/D-Laval/Alfa Laval/ IDMC/ Westfalia

2. Milk / Cream Separator Tetrapak/Alfa Laval/ Westfalia

3. SS fabricated items Milk Silo / HMST Ghee Kettal / Weigh Bowel / Butter Melting Wet / Paneer Press / CIP System / Butter Trolley / Butter Ghee Storage Tank / Ghee Settling Churn Cream Tank

GEA Process Engineering (India) Ltd./Tetrapak/D-Laval/Alfa Laval/ IDMC/ Goma/Westfalia/Swastik Enterprises/Food & biotech/ SS Engineering

4. Automatic Form Fill & Ceiling machine for milk

Nichrome/RMC/Samarpan

5. Automatic Form Fill & Ceiling machine for ghee

Nichrome/RMC/Samarpan/Paper Products/Tetra pak

6. Oil Fired Boilers with accessories Forbes Marshal/Thermax

7. Water Softening Plant Forbes Marshal/Thermax/Ion Exchange

8. Refrigeration plant and allied item like cold store, IBT etc.

Kirloskar/Frick India/GEA/Servotech

9. Reciprocating Ammoia compressor Kirloskar/Frick India

10. SS valves and fittings Swastika/IDMC/Sri Pumps & Fittings/Kspar

11. Curd Cup / Shrikkhad Cup Filling & Ceiling machine

Space Electricals/RMC/Samarpan/Goma /Nichrome

12. Desil Generator Set Kirloskar/Cummins/Greaves/Mahendra & Mahindra/Eicher

13. Continuous Butter making machine HMT/GEA Process Engineer (India) Ltd./Tetrapak/ IDMC

14. Automation Rockwell Automation/Tata Honeywell/ Emersion/ IIM/ Siemens

15. Dock Automation REIL

16. Electronic Weigh Bridge Avery India/Mettler

17. Ghee Clarifier Tetra Pak/Penwalt/Alfa Lavel/Westfalia

18. Can scrubbers Chaddha Sales/Swastik/IDMC/Anand Dairy machinery/BAAF/D-Mech/RPM Engineers

19. SS Pipes Apex Tubes/Bhandhari Foils & Tubes/Ratnaani/ Nika Tubes/Heavy Metals

20. Air compressor Elgi/Ingersol Rand

21. SS Pumps IDMC/Swastik/Sri Pumps/HMT/Alfa Laval/Tetra pak/Filtron/Fristam/Zeutec

22. Centrifugal fans ABB / FLAKT WOODS /AEROTECH / DUVENT/ ENGICON / RITZ / TLT / NADI / AIR CONTROL

23. Starter L&T/ ABB /SIEMENS / ALLEN BRADLEY / DANFOSS

24. Programmable Protection Relay MINILEC

25. Temperature / Pressure Transmitter E&H / ROSEMOUNT

26. RTD RADIX /PYROELETRIC / ALTOP / GIC / TOSHNIWAL

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27. PID Controller YOKAGAVA / CHINO / FOXBORO / TATA HONEYWELL/SIEMENS / ROSEMOUNT

28. Level Switch (float type for liquid & vibrating fork type for powder)

E&H / ROSEMOUNT / P&F / HONEYWELL / TECHROL / SB ELECTRONICS

29. Vortex / Magnetic Steam Flow meter FORBES MARSHALL / E&H / ROSEMOUNT / YOKAGAWA / MANAS MICROSYSTEMS

30. Process Control Valve FORBS MARSHALL /SAMSON / ROSEMOUNT

31. Butterfly Valve SAMSON /DANFOSS / DEMBLA / AVCON / TOSHBRO / FISHER XOMOX / MASONEILAN/AUDCO/CASTLE

32. Temperature sensors / digital indicator/ controller / recorder

YOKOGAWA / CHINO / TATA HONEYWELL / RADIX / PYROTECH

33. Energy Monitor L&T / SIEMENS / ABB / ALLEN BRADLEY

34. Voltage / Current / Energy / Power/factor Transducer

RISHABH / ENERCON

35. Printer HP/Canon

36. Automation System IIM / SIEMENS / ROCKWELL/ TATA HONEYWELL/ INVENSYS / EMERSION/ MELSS / TECHNOWEIGH

37. Electric Motors ABB / KIRLOSKAR / BHARAT BIJLEE / SIEMENS / NGEF / CROMPTON GREAVES

38. Air Circuit Breaker L&T / SIEMENS / ABB / SCHNEIDER

39. MCCB, MPCB L&T / MDS-LEGRAND / SIEMENS / ABB / MERLIN GERIN / GE / CROMPTON GREAVES

40. Contactors L&T / SIEMENS / ABB / SCHNEIDER

41. Starter, Overload Relays L&T / SIEMENS / ABB / SCHNEIDER

42. Timers (Electronic) L&T / SIEMENS / BCH / GE

43. Fuse Switch Units L&T / SIEMENS / ABB / SCHNEIDER / C&S/ GE

44. MCBs L&T-HAGER /SIEMENS/ MDS-LEGRAND / GE

45. Push Buttons TEKNIC / ESBEE / SIEMENS / GE / VAISHNO /

46. Indicating Lamps L&T / SIEMENS / VAISHNO / TEKNIC / BINAY

47. Digital Ammeter & Voltmeter L&T /ANERCON / HPL SOCOMEC / MECO

48. Analog Ammeter & Voltmeter RISHABH / IMP / MECO / AE

49. Digital Energy Meter L&T / ENERCON / HPL SOCOMEC / CADEL / AE

50. Analog Energy Meter GEC / UNIVERSAL / HAVE / JAIPUR

51. Power Factor Meter RISHABH / IMP / MECO / AE

52. Current Transformer KAPPA / MECO / AE / IMP / INDCOIL

53. LT Power Cables FINOLEX / FORT GLOSTER / CCI / INCAB / HAVELS

54. LT Copper Control Cables FINOLEX / FORT GLOSTER /CCI / RPG ASIAN / RR KABELS (UNILAY) / LAPP KABEL/ HAVELS

55. Signal & Instrument cable POLYCAB / LAPP KABEL / THERMOPAD

56. Power Capacitors EPCOS / MOMAYA / MEHER / KHATAU JANKAR / SIEMENS / UNISTAR

57. APFC Relay L&T / BELUKE / EPCOS / PHASITRON / MECO

58. Cable Tray INDIANA / MEK / SUNRISE / SUPER / PILCO

59. Isolating Switches L&T / SIEMENS / ABB / SCHNEIDER / C&S

60. HRC fuses L&T / SIEMENS / EE / C&S

61. IP 55 boxes for motor isolators, push buttons, junction boxes etc.

HENSEL / HANSU

62. Terminal Blocks WAGO / LAPP INDIA / CONNECT WELL / ELMEX

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63. Selector Switch L&T / KAYCEE / SALZER /

64. Cable Glands COMET / EX-PROTECTA / DOWELS / LAPP KABEL / BRACKO

65. Programmable Protection Relay MINILEC

66. Servo Voltage Stabilizer SUVIK / APLAB / NEEL / KRYKARD

67. MS Pipes TATA / JINDAL / KALYANI / MST / ISMT

68. LP Steam / condensate Valves AUDCO / LEADER / BDK

69. Steam relief valve, traps & strainers SPIRAX / SAMSON / THERMAX

70. Expansion bend for steam line JN MARSHALL / MAZDA

71. Steam Pressure Reducing Valve SPIRAX

72. Air Compressor (Reciprocating) INGERSOLL RAND / ELGI / KIRLOSKAR

73. Cables Gloster/ Nicco/ Finolex /Universal / Cci /Rpg Havells/

74. Capacitors Mehir / Unistar

75. Energy meter L&T / Siemens / Enercon

76. Hoist Indef / Consolidated Hoist/

77. Level switch E&H / P&F / Waree

78. Milk / CIP Hoses Gayatri / Saint Gobain/ Pearl/ Sainath

79. Milk / CIP Pumps Fristum / Alfa Laval / GEA / IDMC/Zutech

80. Motors ABB / Siemens / Crompton Greaves / Kirloskar

81. PRS JNM

82. Steam Flowmeter E&H / Rosemount / Yokagawa / Krone Marshall

83. Water pumps Grundfoss / Becon / Kirloskar / Jyoti

84. Pre-fabricated cold store Blue star, Carrier, Voltas, Ice maker

85. Homogenizer TETRA PACK /GEA/GOMA/REPUTE

86. Powder and sugar blender (ventury)

ZEUTECH/IDMC/Food and Bio Tech/SS Engineering/GOMA/REPUTE

87. Continuous Ice-Cream Freezer Tetrapack/Gea/ ISF/Goma/Repute

88. Fruit and nut feeder Tetrapack/Gea/ ISF/Goma/Repute/Synergy

89. Refrigerated Aging vat Goma/Repute/Food & Bio-Tech/Synergy

90. Ripple machine Tetrapack/Gea/ ISF/Goma/Repute/Synergy/PWS Engineers

91. Ice cream cup and cone filling machine

PWS Engineers/ ISF/Goma

92. Chocolate dozer PWS Engineers/ ISF/Goma

93. Conveyor and cartooning table PWS Engineers/ ISF/Goma

94. Candy tank with refrigeration plant

Synergy/Goma/ Ice maker

95. Candy hardener Synergy/Ice maker/Goma

96. Candy pouch packing machine Goma / E.C packtech or equivalent

97. Candy moulds King Ice Mould /Sara Engineering or equivalent

98. Chocolate melting vat Sarda or equivalent /Goma/Synergy

99. Kulfi mix preparation vat Sarda or equivalent/Goma

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100. Chocolate coating tank Goma /Sarda or equivalent

101. Thawing tank Goma / Sarda or equivalent

102. Evaporating cooling Aircone/ Symphony/Enviro tech/Star Enterprises

103. Ozonisation system Ozonetech or equivalent

104. Batch code machine with conveyor

Videojet/ Domino / Willet or equivalent

105. Cooling tower Kwality cooling towers and equivalent.

106. Metal Detectors Unique Equipment or equivalent

107. Flavoured Milk Bottle Rinsing and filling machine

Global / Bajaj./ Fill pack Or equivalent

108. Bottle cap induction sealing machine

Global / bajaj processpack / Fill pack or equivalent

109. Bottle Sterilizer Counter pressure retort

bajaj Processpack / MachineFabric or equivalent

110. Bottle drying machine

Bajaj Processpack/ Global or equivalent

111. Shrink Wrapping machine Bajaj Processpack/ Global or equivalent

112. Shrink Wrapping machine for Tray

Bajaj Processpack/ Global / Pragati/ Fillpack or equivalent

113. Bottle Batch printing machine Videojet or equivalent

Note: - Bidder may supply Equivalent make subject to purchaser approval.

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Transcript of E- TENDER FORMsarasmilkfed.rajasthan.gov.in/Tender/MalpuraTENDER-ID...406-414 415-417 418-420...