Request for Quotation - Naboro Prison Biogas Plant...Drawn by Manjunath V B, NIE-CREST Approved by...

5 Maafu Street Suva

Fiji 8th March 2017

Dear Sir

Request for Quotation - Naboro Prison Biogas Plant

The International Union for the Conservation of Nature (IUCN) is assisting the Fiji Correctional Services to install a biogas plant at the Naboro Prison’s piggery in order to clean up the waste water coming out from the piggery and polluting nearby waterways. The biogas plant consist of a holding steel tank (the digester) about 5.5 meters in diametre and 5m high and a steel gas holder 4.3 m in diameter and 1.8 m width that inverts into the biogas digester and thus traps the gas generated from pig wastes. The specific details are attached. When completed the unit would look like this:

Quotes should be e-mailed to [email protected] or to [email protected] or sent via mail to Energy Programme, IUCN ORO, 5 Maafu Street, Suva. Contact number is 7733715. Yours sincerely, Varea Romanu Energy Programme Assistant IUCN ORO

mailto:[email protected]

Crusher/Macenator

Tank 2

Tanks 3

Tanks 2

Tank 1

Tanks 1

Tank 4

Water line 3

Water line 1

EB 1

EB 3

3Ø Electric pole

ROAD

ROAD

ROAD

3Ø Electric pole

GROWER SHED

BREEDER SHED

PLANT AREA

(Existing Building)

Mixing tank 3

Mixing Tank 1

600 kg Pig Waste

Co

okin

g sh

ed

Co

okin

g sh

ed

Slu

rry L

in

e 2

Slurry Line 1

C 1

C 2

EB 1

Mixing Tank 2

600 kg Pig Waste

Water line 2

Tanks 5

Slurry Line 3

Resting Shed

Resting Shed

CV 1

CV

1

CV

2

CV 1

CV 2

MT 1

MT 2

Gas Line 1

Gas Line 2

55m

52m

25m

15m

No part of this drawing may be copied, stored in a retreival system or transmitted, in any form or by anymeans-electronic, mechanical, photocopying, recording or otherwise without prior permission of NIE-CREST The Drawing is site specific and cannot be generalised and replicated for projects of similar kind The fabricator shall carryout fabrications in compliance with Industrial Standards The fabrication shall ensure good quality of materials and good workmenship The details have been given for all the components, in case of unforeseen items, the fabricator shall contactNIE-CREST for clarification The changes may be suggested during fabrication of the plant, but the fabricator shall not claim suchchange/modifications as "additional works" Detailed guideline for painting will be provided in due course Name board shall be painted on the biogas plant as per the text which will be provided by NIE-CREST in thedue course

DETAILSDrawing No.

Draft Drawing 1

Title

Fiji Biogas Plant Layout

Scale

Not to scale

Dimensions

All Dimensions are in Metre

Designed byNIE-CREST, Mysore

Drawn byManjunath V B, NIE-CREST

Approved by

Prof. S Shamsundar, Chief Coordinator and

Head, NIE-CREST

NOTE

Bio Filtration

RP

Details of the Parts

Sl.No.Parts Dimention Material

Quantity

1

Digester

Ø5500 & Ø4600 and

2700, 500 & 1250 Length

Sheet Steel 10mm

Thickness

1

2 Gas Holder

Ø4300X1400 length

Sheet Steel 6mm

Thickness

1

3

Inspection Chamber with

gas outlet

Ø500

Sheet Steel 6mm

Thickness

2

4

FlangeØ600, 6X15mmX10mm

10mm MS Plate 2

5

Nut, Bolt and Plate

Washers

Ø15mm Stainless Steel

6 nut & Bolt, 12 Plate

Washers

6

Collers and End Plug

Ø100mm Mild Steel 5

7 Ball Valve Ø160mm Stainless Steel / MS 4

8 Gusset Plate

Given in Drawing

10mm Thick MS Plate 8

9

Handles for Digester

Lifting huck for gas holder

Given in Drawing

10mm Thick MS Plate 4 Handles and 2 Hucks

10

Digester Traversing Pipe Ø100 & 5200 length 5mm Thick MS Pipe

1

11

Gas holder Supporting

Pipe

Ø125 & 1800 length 5mm Thick MS Pipe

1

12

L- angle

65X65X10mm Mild steel

As per Drawing

requirment

13

Coating

Inside and outside the

Digester and Gas holder

FRP 2mm -

14

Painting

Inside and Outside the

Digester and Gas holder

One Coat anti-corrossive

paint Duco and enamel

Paint

-

DETAILS

Drawing No. Biogas Plant/Detailed Drawing/1

Title

Detailed drawings of 1000kg per day kitchen waste biogas

plant

Scale Not to scale

Dimensions All Dimensions are in mm

Designed by NIE-CREST, Mysore

Drawn by Manjunath V B, NIE-CREST

Approved byProf. S Shamsundar, Chief Coordinator and Head, NIE-CREST

NOTE1.No part of this drawing may be copied, stored in a retreival system or transmitted, in any form or by any means-electronic, mechanical, photocopying,

recording or otherwise with out the prior permission of NIE-CREST2. The Drawing is site specific and cannot be generalised and replicated for projects of similar kind3. The fabricator shall carryout fabrications in compliance with Industrial Standards4. The fabrication shall ensure good quality of materials and good workmenship5. The details have been given for all the components, in case of unforeseen items, the fabricator shall contact NIE-CREST for clarification6. The changes may be suggested during fabrication of the plant, but the fabricator shall not claim such change/modifications as "additional works"7.Detailed guideline for painting will be provided in due course8.Name board shall be painted on the biogas plant as per the text which will be provided by NIE-CREST in the due course

4600

4300

500

5500

1600

450

1250

2700

500

1150

125

1400

600

ASSEMBLY

1

2

3

4

7

6

10

11

12

NIE-CENTRE FOR RENEWABLE ENERGY AND SUSTAINABLE TECHNOLOGIES [NIE-CREST]The National Institute of Engineering (NIE), Manandavadi Road, Mysore-570008, Ph: 0821-4004914, Email: [email protected], Web:

www.niecrest.in

1350

Supporting Plate

10mm thick

9

150

500

5.50

500

Ø160

80m3

300X300X10

Base Plate

65X65X10

L Anglers (8 no.)

800

1950

660

1600

2700

500

1.2500

4600

1400

4300

630

1520

Ø4300

65X65X6

L Anglers (8 no.)

A

DETAILS


Title

Detailed drawings of 1000kg per day kitchen waste biogas plant

Scale Not to scale




Approved byProf. S Shamsundar, Chief Coordinator and Head, NIE-CREST

NOTE1.No part of this drawing may be copied, stored in a retreival system or transmitted, in any form or by any means-electronic, mechanical, photocopying, recording or

otherwise without the prior permission of NIE-CREST2. The Drawing is site specific and cannot be generalised and replicated for projects of similar kind3. The fabricator shall carryout fabrications in compliance with Industrial Standards4. The fabrication shall ensure good quality of materials and good workmenship5. The details have been given for all the components, in case of unforeseen items, the fabricator shall contact NIE-CREST for clarification6. The changes may be suggested during fabrication of the plant, but the fabricator shall not claim such change/modifications as "additional works"7.Detailed guideline for painting will be provided in due course8.Name board shall be painted on the biogas plant as per the text which will be provided by NIE-CREST in the due course

NIE-CENTRE FOR RENEWABLE ENERGY AND SUSTAINABLE TECHNOLOGIES [NIE-CREST]The National Institute of Engineering (NIE), Manandavadi Road, Mysore-570008, Ph: 0821-4004914, Email: [email protected], Web: www.niecrest.in

600

Ø5500

Ø4500

65X65X10

L angle stiffners ( 8 no.)

Radial Elements along C -C

Ø5500

Ø4600

65X65X6

L angle elements

160

1350

D

D

Cross Sectional view along D - D

Radial Elements along A - A and B - B

Ø5500

Ø4600

65X65X10

L angle stiffners ( 8 no.)

A

B

CC

B

150

150

Ø4300

Digester Steel Structure

Gas Holder Steel Structure

DETAILS


Title


plant

Scale Not to scale




Approved by

Prof. S Shamsundar, Chief Coordinator and Head,

NIE-CREST

NOTE1.No part of this drawing may be copied, stored in a retreival system or transmitted, in any form or by any means-electronic, mechanical, photocopying,

recording or otherwise without the prior permission of NIE-CREST2.The Drawing is site specific and cannot be generalised and replicated for projects of similar kind3. The fabricator shall carryout fabrications in compliance with Industrial Standards4.The fabrication shall ensure good quality of materials and good workmenship5. The details have been given for all the components, in case of unforeseen items, the fabricator shall contact NIE-CREST for clarification6. The changes may be suggested during fabrication of the plant, but the fabricator shall not claim such change/modifications as "additional works"7.Detailed guideline for painting will be provided in due course8.Name board shall be painted on the biogas plant as per the text which will be provided by NIE-CREST in the due course

Details of Digester Details of Gas Holder

NIE-CENTRE FOR RENEWABLE ENERGY AND SUSTAINABLE TECHNOLOGIES [NIE-CREST]The National Institute of Engineering (NIE), Manandavadi Road, Mysore-570008, Ph: 0821-4004914, Email: [email protected], Web: www.niecrest.in

Details of Handle (made of 10mmthick Sheet Steel)

215

450

Ø100

Ø4600

Ø5500

1600

2700

500

1150

125

600

2100

1250

Details of Gusset plate

Gusset Plates Made of

10mm thick Sheet Steel

330

330

460

950

710

R150

Slurry level

Ø10

200

1350

(8)

(7)

65X65X6

Radial support

Supporting Plate

10mm thick

A

A

Inner surface of Digester shall becoated with 2mm thick FRP Black

Outer surface of Digester be coated with2mm FRP, one coat of primer, one coat ofanticorrosive paint (Duco) and one coat ofenamel paint

150

Ø150

Lifting Hook made of

16mm Rod

1400

Ø4300

400

Ø125

500 500

Base Plate 300X300X10

Inspection

Chamber 1

Inspection

Chamber 2

Inner surface of gas holder shall becoated with 2mm thick FRP Black

Outer surface of gas holder be coated with2mm FRP, one coat of primer, one coat ofanticorrosive paint(Duco) and one coat ofenamel paint.

Ø4300

Gas holder made up of

6mm thick sheet steel

Ø600

Ø5500

Ø4500

65X65X6

L angle Radial stiffners ( 8 no.)

Radial Elements view along C - C

15mm Hexagonal nuts(6No.)

10mm Thick Plate Flange-2No.

7.5mm Outlet for biogas

Ø600

Body of the Gas Holder

Handle 6mm MS Rod

15mm HexagonalBolts (6No.)

Spring Washers (6No.)

Plate Washers (12No.)Rubber Gasket/washer

500

400

Outlet for biogas (7.5) one side threaded

150mm long above top corner

65X65X10 Angle Iron (Welded to the top of

the baffle plate)

10mm thick Baffle Plate

Welded to Bottom

Plate of Digester

Welded to lateral surface of

the Baffle Plate

Welded to

Bottom Plate

65X65X10 L-angle

(Stiffener)

View

alo

ng A

-A'

65X65X10 L-angle

(Stiffener) Welded to the

internal surface of the

bottom sheet of digester

Bottom plate of

digester (3.15mm thick)

Stiffener (65X65X10) welded to

the lateral internal surface of

digester and gas holder

Continuous Weld

Co2 Lap Welding 10mm shall beadopted for welding of Sheetsteel

B

B

C

C

Radial Elements view along A - A and B - B

1600

Baffle plate 10mm thick welded to side lateral

surface and bottom plate of Digester

2mm FRP coating to the Bottom

Plate is done at initial stage of

fabrication

Details of Inspection chamberDetails of Partition Wall

Edge View of Baffle Plate

Details for welding 65X65X10 L-angles -8No.

Welded to

Digester

600

200

4800

600

600

Made out of 10mm

thick sheet steel

200

INLET

2700

10X10 mm rod

Welded to top

edge of inlet chamber

4500

450

To Slurry Tank

Welded to

Digester

500

450

Made out of 10mm

thick sheet steel

200

OUTLET

2700

100mm MS

Coller

10X10 mm rod

Welded to top

edge of outlet chamber

500

500

3000

1000

750

500

450

500

1200

500

500

3100

600

600

600

Ø100mm

MS coller

Ball Valve

Ø160mm

Details of Inlet and Outlet chambers

500

Ø5500

Ø4700

65X65X10


Handles/Huck for lifting (4No.s)

to be provided at equal

intervals

600

600

500

500

Digester made up of


300X300X10

Base Plate

Handle

4 numbers

Ball Valve

Ø160mm

Details of Digester

Details of Handle (made of 10mmthick Sheet Steel)

215

450

Ø100

Ø4600

Ø5500

1600

2700

500

1150

125

600

2100

1250

Details of Gusset plate

Gusset Plates Made of

10mm thick Sheet Steel

330

330

460

950

710

R150

Slurry level

Ø10

200

1350

(8)

(7)

65X65X6

Radial support

Supporting Plate

10mm thick

A

A

Inner surface of Digester shall becoated with 2mm thick FRP Black

Outer surface of Digester be coated with2mm FRP, one coat of primer, one coat ofanticorrosive paint (Duco) and one coat ofenamel paint

BB

C

C

Radial Elements view along A - A and B - B

2mm FRP coating to the Bottom

Plate is done at initial stage of

fabrication

Ø5500

Ø4700

65X65X10


Handles/Huck for lifting (4No.s)

to be provided at equal

intervals

600

600

500

500

Digester made up of


300X300X10

Base Plate

Details of Gas Holder

150

Ø150

Lifting Hook made of

16mm Rod

1400

Ø4300

400

Ø125

500 500

Base Plate 300X300X10

Inspection

Chamber 1

Inspection

Chamber 2

Inner surface of gas holder shall becoated with 2mm thick FRP Black

Outer surface of gas holder be coated with2mm FRP, one coat of primer, one coat ofanticorrosive paint(Duco) and one coat ofenamel paint.

Ø4300

Gas holder made up of


Ø600

Outlet for biogas (7.5) one side threaded


Handle

4 numbers

Biogas Plant/Detailed Drawing/1


plant

Not to scale

All Dimensions are in mm

NIE-CREST, Mysore

Manjunath V B, NIE-CREST

Prof. S Shamsundar, Chief Coordinator and Head,

NIE-CREST

Welded to

Digester

600

200

4800

600

600

Made out of 10mm

thick sheet steel

200

INLET

2700

10X10 mm rod

Welded to top

edge of inlet chamber

4500

450

To Slurry Tank

Welded to

Digester

500

450

Made out of 10mm

thick sheet steel

200

OUTLET

2700

100mm MS

Coller

10X10 mm rod

Welded to top


500

500

3000

1000

750

500

450

500

1200

500

500

3100

600

600

600

Ø100mm

MS coller

Ball Valve

Ø160mm

Details of Inlet and Outlet chambers

500

Ball Valve

Ø160mm

TOR FOR THE NABORO BIOGAS WORK 1. In consultations with the Fiji Correctional Services and Consultants for the Project (Subbarao

Consultants) the Contractor will a. Fabricate a biogas plant at the Naboro Piggery. The fabricated plant will be coated with

anti-corrosion paint as per the specifications given in the table below and in the detailed designs.

b. Source specific items as outlined below for the biogas plant including meters, pumps, blowers, etc.

2. Entry on to the Naboro piggery will be facilitated by the Fiji Correctional Services. Please contact Mr. Junior Bali at the FCS HQ or officers at Naboro

3. All quotations should be received by April 30th 2017. Quoted amount should be in Fiji dollars 4. This expression of interest is managed by a team comprising representatives from the Fiji

Department of Energy, the Fiji Correctional Services and the International Union for Conservation of Nature. Extension of time to get a proper quotation worked out may be entertained on discussion

5. For any clarification pleae consult [email protected] and copy [email protected]

Specifications for the biogas plant

Particulars Qty

1 Main digester: Mild steel (BIS 2062)main digester of capacity 80m3 without water jacket, fabricated out of 10mm thick with necessary circumferential, tangential, radial, lateral support frames made of MS Angle iron (L-angle) 65mmx65mmx10mm MS fats, flanges, bolts, nuts, guide pipe etc., complete inclusive of one primer coat, Including fabrication of inlet pipe, outlet pipe, supporting stands, ladder) as per approved drawing NIE-CREST

1

2 Construction of a concrete base to Fiji Construction standards or similar for sitting the Mild steel (BIS 2062)main digester of capacity 80m3

3 Materials for FRP coat (1mm thick) and Anticorrosive Paint with FRP Coating and painting to be done on site

4 Gas Holder: Mild steel (BIS 2062) Gas holder of capacity 20m3 fabricated out of 8mm thick with necessary circumferential, tangential, radial, lateral support frames made of MS Angle iron(L angle) 65mmx65mmx10mm MS fats, flanges, bolts, nuts and guide pipe inclusive of one primer coat, as per approved drawing NIE-CREST. Materials for FRP coat (1mm thick) and Anticorrosive Paint to be sourced and FRP Coating and painting done on site

1 Set

5

Supply of Feeder Pumps: 3HP, 3phase submersible pump, Make: M/s Sharp Pumps Pvt. Ltd. , Coimbatore, Tamilnadu Model: 80PDS-12-17-3.0 Submersible Drainage Pump – 415 Volt, 50HzLiquids: water, sludge, slurry Motor: electric motor Rated Flow: 12 m3/h Rating/rpm: 2.2 kW/2880 rpm Rated Head: 17 m Nominal current: 6 A Motor start: Star / Delta General Specifications Protection:IP68 Discharge connection: 80 mm Insulation class: F Weight (pump):50 kgs Volt/Phase: 415v-3p Solids handling: 72 mm Cable length: 6mtrs(standard) Dimensions L x B x H: 269x118x570 mm Material Specifications Details Pump Castings: FG200 Max.sub. depth: 10 m Impeller: FG200 Max. Liquid Temp: 40° C Seal: Sic – Sic / car-cer Shaft Material: S S 4 3 1 for Pumping Swine manure/Vegetable Waste/Digested Slurry.

Feeder Pump 1 @ Grower Shed to pump swine manure + Water Mixture to Plant area 1

Feeder Pump 2 @ Plant area to pump swine manure + Cassava Waste+Vegetable Waste +Water Mixture to Biogas Plant

1



Feeder Pump 3 @ Grower Shed to pump swine manure + Water Mixture to Plant area 1

Feeder Pump 4 @ Slurry tank to pump slurry to utility 1

Total 4

6 Crusher/Maccerator: to crush 150kg of cassava waste, 150kg of vegetable waste, inclusive of 3HP, 3Phase electric motor, belt drive, belt and sink (Model: CD 3050 Make: M/s Point Industries)

1

7 Supply of Blower 1: Make: M/s Kulkarni Power Tools Ltd. Pune, Maharashtra Model: SR010 Biogas blower with 2HP, 3phase electric motor, belt drive, belt, pulleys, shaft, pressure release valve, silencer for blowing biogas for recirculation of biogas with a pressure of 400millibar, maximum discharge of 18cu.m/hr

1

8 Supply of Blower 2: Make: M/s Kulkarni Power Tools Ltd. Pune, Maharashtra Model: SR015 Biogas blower with 3HP, 3phase electric motor, belt drive, belt, pulleys, shaft, pressure release valve, silencer for blowing biogas for recirculation of biogas with a pressure of 1bar

1

9 Supply of Solar water heater comprising of solar fat plate collector of required size and stainless steel hot water storage tank with stainless steel heat exchanger absorber made of copper sheet and copper tube of500L capacity aluminium box collector with appropriate capacity electrical back up arrangement including inlet and outlet pipes, SS Model with 100mm thick of 48kg/cu.m density rock wool insulation with 22SWG aluminium cladding with necessary stand/supporting frame complete

1

10 Supply of stand/terrace, Three layered PVC Tank of capacity 2500Lwith manhole, lid, and suitable locking arrangements, making holes of suitable diameter for inlet, outlet and overflow pipes. (Custom Made, fabricated by local fabricator referred by NIE-CREST)

1

11 Supply of Mild Steel Stand for Over Head Tank to a height of 6m with necessary Angle iron, I Sections (inclusive of installation) for placing 2500L capacity PVC Tank

1

12

Supply of Mixer tank with stirrer : of net volume 1000L made of mildsteel sheet of 3mm thick, mild steel stirrer with solid shaft 75mmdiameter, curved blades of 5mm thick, 1HP/0.75kW, 3 phase electric motor (Custom Made, fabricated by local fabricator referred by NIECREST)

Mixer Tank with Stirrer tank 1 @ Grower Shed 1

Mixer Tank with Stirrer tank 3 @ Breeder Shed 1

2

13

Supply of Mixer tank with stirrer: of net volume 3000L made of mild steel sheet of 3mm thick, mild steel stirrer with solid shaft 75mmdiameter, curved blades of 5mm thick, 1HP/0.75kW, 3phase electric motor(Custom Made, fabricated by local fabricator referred by NIECREST)

Mixer Tank with Stirrer tank 2 @ Plant Area 1

14 Supply of Gas Meter: electronic/mechanical gas meter with accessories for measuring biogas from along pipeline for a nominal flow of 18cu.m per hour at nominal pressure of 400millibar for measurement of biogas generated

1

15 Supply of Weighing scale: electronic weighing scale for measuring mass up to 1000kg 1

16 Supply of Moisture Trap: for removal of moisture 8

17 Supply of Essential spares for repair of machineries like blower and slurry pumps 1

18 Supply of Tools and tackles: spanners and wrench 1

19 Supply of Flare apparatus: for testing fire 1

20 Supply of Stainless Steel Biogas burner with discharge of 32cft per hour 2

IUCN/20th March 2017

Request for Quotation - Naboro Prison Biogas Plant...Drawn by Manjunath V B, NIE-CREST Approved by...

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