Tender for Refrigeration system - Gogave - Gokul for Refrigeration system.pdf · 11)Sealed Tender...

TENDER NOTICE

Sealed Tender offers are invited for design, supply, installation & commissioning of Refrigeration System for proposed expansion & revamping of existing Refrigeration System, at our Gogave Chilling Centre. Tender details alongwith scope of work, technical specifications & Terms conditions are availble on web site www.gokulmilk.coop and also at our Gokul Shirgaon office at B-1, M.I.D.C., Gokul Shirgaon, Kolhapur. Sealed Tender offer duly marked as " TENDER FOR REFRIGERATION SYSTEM" is to be submitted at our Gokul Shirgaon, Kolhapur office on or before 18.05.2018. Right to accept or reject any or all Tenders is reserved.

Managing Director ChairmanKolhapur Zilla Sahakari Dudh Utpadak Sangh Ltd., B-1, M.I.D.C., Gokul Shirgaon, Kolhapur – 416 234

TENDER DOCUMENTS

(FOR REFRIGERATION SYSTEM AT GOGAVE CHILLING CENTRE

KOLHAPUR ZILLA SAHAKARI DUDH UTPADAK SANGH LTD., KOLHAPUR

GENERAL TERMS & CONDITIONS OF TENDER( Expansion & revamping of existing Refrigeration System)

1) The Bidder should have design back up to carry out such jobs on Turn Key basis and must have executed in the last three years at least 3 contracts of similar nature having equivalent or more value.

2) The job should be treated as ' TURN KEY' excluding Civil work. Details as regards scope of work, technical details of required equipment are given in the Annexure – I given herewith .

3) The Bidder should submit the offer in a prescribed format on their letterhead. Commercial bid ( price details) and Technical bid ( Technical details, ) are to be given in separate envelops & both envelops are to be submitted in a sealed envelop marked as "TENDER FOR REFRIGERATION SYSTEM".

4) The offer should be valid atleast for 90 days from the date of submission.

5) The bid must be accompanied by Earnest Money Deposit of Rs. 1,50,000/- in the form of demand draft issued in favour of Kolhapur Zilla Sahakari Dudh Utpadak Sangh Ltd. Bids not accopanied with EMD will be summarily rejected . EMD amount may be forfeited if bidder withdraws it's bid during period of bid validity or if successful bidder fails to sign the contract.

6) No escallation in the price will be given once the order is finalised.

7) Successful bidder will have to keep Security Deposit with us.

8) Work is to be carried out without hampering routine work of our milk chilling centre.

9) Interested Bidder should visit the work place to know the exact working condition before submitting their offer.

10) Payment Terms-a) 30% advance of total contract value (Excluding GST) will be given as an advance

after getting order acceptance and on submission of Bank Guarantee of equivalent amount.

b) Next 40% payment of supply items alongwith GST will be released on safe receipt of equipment / material at site. This payment will be released on submission of progressive Invoices.

c) Next 20% payment of supply items will be released after satisfactory installation & commissionig of ordered Refrigeration System.

d) 60% payment of installation alongwith applicable GST on progression of installation as per joint inspection / measuremant.

e) Final 10% amount of total contract value (excluding GST) will be released after satisfactory completion of job on submission of Performance Bank Guarantee for equivalent amount valid for a period of 1 year

11) Sealed Tender offer should reach our office at B-1, MIDC, Gokul Shirgaon, Kolhapur on or before 18.05.2018.

12)We reserve the right to accept or reject any bid and rejection of all bids at any time priorto award of contract

13) Subject to Kolhapur Jurisdiction.

Managing Director

Specifications Scope of Supply for design, supply, installation, testing & commissioning of refrigeration system for proposed expansion & revamping at Gogave Chilling Center of Gokul Diary.

Specifications Scope of Supply for design, supply, installation, testing & commissioning of refrigeration system for proposed expansion & revamping at Gogave Chilling Center of Gokul Diary.

INDEX

Sr. No

Item Page No

1 General information 3 to 4

2 Basis of Design, refrigeration load summary 5 to 11

3 Scope of supply 12 to 31

4 Annexure-I Technical data to be furnish by bidder 32 to 37

5 Annexure-II price break up format 38 to 38

Specifications Scope of Supply for design, supply, installation, testing & commissioning of refrigeration system for proposed expansion & revamping at our Gogave Chilling Center

1. GENERAL

We propose expansion and revamping of existing refrigeration system into state of the art energy efficient, safe, sustainable, and easy to operate /maintain Refrigeration system at Gogave chilling center of Kolhapur Zilla Sahakari Dudh Utpadak Sangh Ltd. Kolhapur.

We are inviting Tender offer for the Design, Supply, Installation, Testing and Commissioning of the above refrigeration system as per following Specifications.

Prices: The Price quoted shall be all inclusive till site basis covering below:

i. GST : To be quoted separately

ii. Transit and Site Insurance : To be included in Price

iii. Packing and Forwarding: To be included in Price.

iv. Freight: To be included in price.

v. Validity for Price: 60 days

vi. Completion Period: total Four months for supply and one month for installation from date of work order / LOI

vii. Price to be quoted on lumsum basis. No extra cost on any account will be paid to bidder.

viii. Bidder to visit site, verify and satisfy with the quantity mentioned in tender. Bidder to add any quantity if required.

1.2 List Applicable standards to follow:

Sr. No Standard / Requirement to Follow

A System related Standard

1 AAR 1 -2016

2 ASME B-31.5 -2013 : Refrigeration Piping & heat transfer component :

3 ASME Sec VIII DIV -1 : Pressure vessels :

B Reference Books

1 ASHRAE System 2014 volume,

2 ASHRAE Fundamental 2013

3 IIAR piping Hand Book.

C Indian Requirement to follow

1 Indian Electricity acts and rules framed there under

2 Fire insurance regulation

3 Regulation laid down by the chief electrical inspector of state/ state electricity board

4 Regulation laid by factory inspector of the state

5 Regulation of local authorities

6 Installation and operation manuals of OEM

D Indian applicable standards

1 IS 2825 : code for unfired pressure vessels

2 IS 660 : Safety code for mechanical refrigeration

3 IS 662 : un-hydrous ammonia

4 IS 661 : Code and practice for thermal insulation of cold storage

5 IS 702 : Industrial Bitumen

6 IS 4544: code for safety for ammonia

7 IS 14164 : Measurement of pipe and vessel insulation work

2. Proposed Scheme & basis of design.

The scheme and basis of design for proposed refrigeration system is as defined in the following sections under the contract which includes design, engineering, supply, installation, testing and commissioning of Refrigeration system as required for the successful and satisfactory completion and handing over of the contract.

Existing refrigeration system at Gogave consists of following:

1. Existing system is more than 20 year old.

2. It is designed to cater to 50,000 LPD milk

3. Designed Milk in/out temperature is 35 to 4 Deg C 4. Existing compressor 2 x Frick 7 x 7 with 45 kW motor each

5. Atmospheric condenser

6. Receiver7. IBT 8. Chilled water pumps and piping

9. 1 x 10,000LPH IDMC RM chiller

10. 1 X 20,000 LPH GEA RM chiller

11. System is manually controlled and operated.

Proposed revamping of the refrigeration system is as follow:

• System to be expanded from present milk handling capacity of 50,000 LPD to 200,000 LPD milk with designed outlet milk temperature 3 Deg C instead of present design of 4 Deg C using 1 x 10000 LPH + 1 x 20,000 LPH Raw Milk (RM) chillers.

• System to be energy efficient, sustainable, safe, easy to operate and maintained along with improved life of plant for next 20 years.

• Remote Monitoring and controlling with PLC + PC based system to be installed. The monitoring and controlling of system should be from PC and data to be seen on local PC as well on remote PC located in Main Gokul Dairy plant at Kolhapur.

• Present 10,000 LPH RM chillers required 30,000 LPH chilled water flow. This chilled water flow to be reduced to 20,000 LPH. Revised Designed Milk in/out temperature should be 35 & 3 Deg C respectively. This is not possible with modifying existing 10,000 LPH RM chillers. This 10000 LPH RM chiller to be replaced by new chiller as per parameters specified in this tender. The bidder to buyback this old milk chiller and quote reduction in price on this account.

• Present 20,000 LPH RM chiller of GEA make: In order to get 3 Deg C milk temperatures we proposed to add 37 plates to this chiller. The revised required operating parameters are specified in this tender.

• Add new Falling film chiller with SS tank to cool 16.7 Deg C water to 0.5 Deg C chilled water @ 40000 lph water flow and -3 Deg C evaporation temperature to cater to 20,000 LPH milk chilling requirement. This chiller to be installed above

IBT

• Add new Falling film chiller with SS tank to cool 16.7 Deg C water to 0.5 Deg C chilled water @ 20000 lph water flow and -3 Deg C evaporation temperature to cater to 10,000 LPH milk chilling requirement. This chiller to be installed above IBT.

• Main objective is to eliminate IBT, and entire milk chilling load is to be taken care by falling film chiller. Bidder to guarantee the same.

• Modify chilled water piping in order to ensure desired chilled water flow through each RM chiller.

• Replace old atmospheric condenser with rusted coils by evaporative condenser to make energy efficient , trouble free & safe operation of the system

• Bidder to design system in such a way that we should be able to operate old Frick compressors and IBT along with new system. Piping and evp. Condenser to be designed considering 2 x KC-6 + 2 x Frick 7 x 7 comp (each Frick 7 x 7 compressor gives 30 TR @-10/40 deg C evaporation and condensing temperature with ,total compressor capacity = 60 TR) along with new proposed new compressors.

• Bidder to design plant in such a way that we should be able to operate IBT and frick compressors in case water temperature at out let of falling film chiller increases beyond 1 Deg C.

• Bidder to give total performance guarantee of the plant as per parameters given in basis of design.

The Basis of design of refrigeration system is as below given in Table -1

TABLE – 1 BASIS OF DESIGN: Design parameters for RM chillers

SR. NO ITEM UNIT

1 USE EXISITNG OR MODIFY EXISITNG MILK

PHE

2 MAKE

3 MILK WATER MILK WATER

4 FLOW CUM/HR 10000 20000 20000 40000

5 IN DEG C 35 1.5 35 1.5

6 OUT DEG C 3 16.7 3 16.7

7 NO OF PLATES TO BE ADDED 37

8 SURFAE AREA AAFTER ADDING 37 PLATES 62.1

9 TOTAL NUMBER OF PLATES AFTER

ADDITION OF 37 PLATES

137

10 SURFACE MARGIN % 26.3

11 PRESSURE DROP BAR 0.18 0.054

12 QTY 1 1

13 PLATE MATERIAL AISI316L

14 GASKET NBR GLUE LESS

RM CHILLER 10000 LPH RM CHILLER 20000LPH

EXISITNG PHE TO BE

REPLACED WITH

FOLOWING PARAMETERS

WITH BYBACK

ARRANGEMENT

USE EXISITNG WITH

MODIFICATION

IDMC GEA

The basic design parameters of refrigeration system are given below in Table: 2

Sr. No

Item UOM DATA

1 Refrigerant Ammonia

2 Refrigeration system Gravity feed

3 Type of compressor to be selected Single stage Reciprocating Compressor

4 Defrosting system °C Not Applicable

5 Dry Bulb (DB) temperature to be considered for design of condenser

°C 40

6 Wet Bulb ( WB )Temperature to be considered for design of condenser

°C 28

7 Electric Supply 415V +/- 10%, 3 Phase, 50 Hz +/-5%, AC combined variation 10%

8 Control supply 220V, 1 Phase, 50 Hz, AC.

9 List of Recommended suppliers - Please note no deviation to makes is acceptable.

Compressor and accessories Kirloskar / Mycom

Motor , high energy efficient IE3 Siemens / ABB

Evaporative condenser Evapco

Falling Film Chiller Omega / Buco

RM Chiller of 10000 LPH milk capacity

GEA / IDMC

Modification of 20,000 LPH RM chiller

GEA

Refrigerant controls Danfoss / Manik

Refrigerant angle / straight globe valves

Danfoss SVA type valves / Dhiren(Vimal) Engineers

Expansion valves / Stop Check valve Danfoss SVA type / Manik/ Dhiren( Vimal)

SA 106 GR B Seamless pipes Maharashtra Seamless

GI class B Pipe TATA

Automatic Air Purger Manik

Ammonia Leak detection system Manik

Ammonia Reflex level gauges Dhiren

Water line digital flow meters TELELIN INSTRUMENTS (INDIA)/ ABB

Ammonia Pressure and temperature gauges

Wika

Ammonia Pressure transmitter Danfoss / Manik

Insulated PUF pipe supports and PUF saddle for Surge Drum

Omkar PUF / Lloyd Insulation

PUF Pipe section and vessel insulation

Omkar Puf / Lloyd

Eye wash/ shower Euronics Industries Pvt. Ltd

Ammonia PPE Honey well / Joseph Lesley Dragger

Water line butterfly valves, swing check valves, strainers

Leader/Intervalve/ Audco

Water line flow switch JCI

PLC Siemens

Electrical switchgear L & T / Siemens

Temperature Scanner Manik

Duplex PT 100 sensors Danfoss / Manik

Thermowell, Digital temperature indicators

Manik

Ammeter AE

Current Transformer Reco/Nippen

kWh Meter Schneider / Conserve

Terminal Connectwel

Water line solenoid valve Manik / Danfoss

Water line level control for condenser sump

Minilec

Table 3: Design parameters for Water chiller and Refrigeration Load summary

Sr. No

Item Unit 10,000 LPH system

20,000LPH system

A Falling film Water chiller. Gravity feed system

1 Water to cool from 16.7 to 0.5 Deg C using falling film chiller

Deg C 16.7 to 0.5 16.7 to 0.5

2 Evaporation temperature for selection of falling film chiller

Deg C -3 -3

3 Chilled water flow rate Cum/hr 20 40

4 Ammonia Chilled water load kW 378 753

5 Refrigerant Ammonia Ammonia

6 Evaporation & condensing temperature for selection of compressor

Deg C -3/40 -3/40

7 Each Compressors required capacity to cater to both RM chiller load

kW 565

8 Number of working compressors no 2

9 Standby compressor no 0

• Based on the above basis of design and parameters given in TABLE 1, 2, 3 bidders to design the refrigeration system.

• P & I diagram for refrigeration circuit indicating line sizes, insulation thickness valves and controls is given in this section

• P & I diagram for water circuit line sizes, insulation thickness valves and controls is given in this section

• Location of Major Equipments:

• The compressor is located in plant room.

• Evaporative condenser to be located near existing atmospheric condenser.

• New Receiver and Air purger to be located near existing Receiver and to be equalized with existing receiver

• Falling Film chillers to be installed above existing IBT by installing appropriate structure, platform, ladders etc.

• Control panel, MCC to be located in control room located at plant room. Control room will be created by Gokul diary

• Bidder to visit site before quoting to understand requirement and calculation of all variable items such as Refrigerant and chilled water piping, Power and control cabling, structure platforms etc. No extra charge on any account will be paid during execution of the contract.

Proposed system schematic drawing is as below:

Refrigerant and chilled water P & I is given below. Suggest bidder to study the same. If bidder wants to add any valve, control, equipment, or increase any pipe sizes, they can do so as system performance guarantee is of bidder. However it should be highlighted in the bidder offer.

Scope of supply

The detail technical scope / specifications for the refrigeration system as follows. Bidder to include all as specified with any deviations. The detailed scope of supply & equipment specifications is as below:

Sr. No. Item Qty.

1 Compressor Reciprocating compressor operating at -3 /40 evaporative condensing temperatures, giving minimum 565 kW capacities, with capacity control solenoid valve mounted on it. Compressor to be selected with 3 Deg C suction superheat. KCX -6 compressors with 950 rpm, -3/40 giving capacity of 560.78 kW & shaft power of 133.34 kW is acceptable. Compressor jacket cooling must be air-cooled

Accessories to be provided along with each compressor:� Compressor capacity, shaft power, RPM, motor kW to be furnish by the bidder in data sheets attached in annexure-I� Common Base Frame.� Tools Kit� Set of Gaskets� HP side Demister Oil Separator with Float valve and oil return arrangement along with QDV valve.� Pipe & Ferrules� Powder coated box type panel fitted with Danfoss make HP, LP OP Cut out, & Glycerin filled Wika make Gauges with wiring & stainless Steel piping (Panel Colour –Siemens Gray, Panel will be manufactured out of 14/16 CRCA sheet along with power coated after 7 tank process.)� Drive set consisting of Flywheel, Motor Pulley & V belt, belt guard� Dhiren make Suction and discharge stop valves for LS & HS for compressor isolation� Pressure transmitter to be provided on suction line header. This pressure transmitter to be use for lead, lag sequencing and capacity control of all compressor through PLC.

� Minimum 160 kW, Siemens / ABB make TEFC, IP 55 , 4 Pole , sq. cage, high energy efficient motor ( IE3 type) to be coupled with the each above compressors . The motor should be suitable for electric supply of 415 V +/- 10%, 3 Phase, 50 Hz +/- 5%, and combined variation of +/- 10%. Motor should have facility to measure winding temperature and bearing temperature at DE and NDE. The cooling fans should be of low noise.

� Tools such as set of torque wrench, filler gauge, and other tools required to assemble and dismantling of compressors to be supplied by the bidder.

2 Nos

2 Evaporative Condensers.

• Evaporative Condensers, each having minimum a heat rejection capacity 1000 kW. Evapco Model ATC-258E giving capacity of 1021 kW to be selected with 1 fan x 7.5kW+ 1 pump x 1.5 kW

• 28 / 40°C DB /WB Temperature to be considered while selecting the evaporative condenser.

• The evaporative condensers will be installed near present atmospheric condenser. Civil platform will be constructed by Gokul. However platform and ladder to operate and maintain the evp condensers to be supplied and installed by bidder. Platform with Chquered plates, ladder and structure to be painted with 2 coats of red oxide primer + two coats of epoxy paint.

2 no

• Condenser to be supplied with galvanized coil and galvanized casing, water Tank and structure.

• Name plate as specified in AAR-1 standard to be provided

• The condenser to be supplied with Minilec level switch model WLC D1 and 25 NB water line solenoid valve. Level in sump increases water line solenoid valve to close. Bypass line with valve to this solenoid valve to be provided

• Additional valves to be provided on discharge header, liquid header to connect 3rd evaporative condenser of similar capacity in future.

• Evp. Condenser GA drawing to be submitted for our approval before startup of manufacturing of equipment.

• The condenser must be factory assembled factory tested.

• Test pressure must be 26 kg/sq. m.

• Capacity, size, operating weight, Fan kW x number of fans, water pump flow , head ,kW and qty, Material construction casing , basin, tubes, Air Flow Evaporation loss, Bleed rate, make up water quantity to be furnish by the bidder in their offer.

• All nozzles, valves and controls to be provided as per attached P & I diagram.

• Platform to be constructed with Chquered plate to operate and maintain condenser, platform shall be epoxy painted.

• 1 x 80 NB valve at each evp condenser inlet and 1 x 80 NB at discharge header near condenser to be provided to connect existing atm condenser header to the new evp condenser.

• 1 x 80 NB valve to be provided at liquid header to connect liquid line from header from atmospheric condenser.

• Existing atm condenser discharge and liquid header to be connected to new discharge and liquid lines from atmospheric condensers.

3 Automatic Air Purger: Fully automatic, six point air-purger with its accessories & controls to be supplied by bidder. Name plate as specified in AAR-1 standard to be provided. Two receivers and two condensers to be connected to this automatic air purger.

1 No

4 High Pressure Receiver

• Minimum size 1200 mm dia x 6000 mm Shell length. The minimum Shell & dish end thickness shall be 12/12 mm

• Receivers to be manufactured as ASME SEC VIII DIV –I.

• Material construction shall be SA516 Gr 70. The minimum test pressure for the vessel shall 26 kg/sq. cm.

• Spare Valves/ nozzles to be provided on vessel to connect future liquid inlet / outlet connection.

• Receiver should be provided with water spray system which covers both receivers entire length.


• 100% Joints must be Radiography and its plan and corresponding plates to be submitted along with the test certificate before dispatch of vessel for our approval.

• GA drawing of vessel to be submitted before startup of manufacturing of vessel for our approval.

• Receiver to be stress relieved after fabrication and certificate of the same to be submitted before dispatch of vessel.

• Vessel size, shell and dish end thickness to be mentioned in your offer.

• All nozzles, valves & controls to be provided as per attached P & I

• 1 x 32 NB valve to be provided for liquid equalizing for the old receiver to new receiver.

• Receiver to be provided with MS saddle welded to the

1 No

vessel and fabricated at manufacturer works.

• Receiver to be painted with 2 coats of red oxide + 2 coats of epoxy paint

5 Horizontal accumulator (Surge drum) for 10,000 LPH systems.

• Minimum size 1000 mm dia x 2500 mm shell length.

• Shell and dish end thk as per data sheet given in Annex –I (12 / 12mm thick. respectively.)

• The vessel to be manufactured as ASME SEC VIII DIV –I. Material construction shall be SA516 Gr 70.

• The minimum design Pressure for the vessel shall 18 kg/sq. cm. and test pressure must be 21 kg/sq. cm

• Name plate as specified in AAR-1 standard to be provided.

• Proper insulated barrier to be provided of PUF material 300 kg/cum density, between vessel & stand / platform.



• Vessel to be stress relieved after fabrication and certificate of the same to be submitted before dispatch of vessel.

• QDV valves to be provided at drain. Vessel size, shell and dish end thickness to be mentioned in your offer.

• Platform with Chquered plates, ladder and structure to be painted with 2 coats of red oxide paint + two coats of epoxy paint.

• Surge drum to be provided with MS saddles ( fabricated at manufacture works ) and below saddle provided 300 kg/cum flat PUF insulation barrier

1 no

6 Horizontal accumulator (Surge Drum) 20000 LPH systems.

• minimum size 1200 mm x 2500 mm shell length

• Shell and dish end thk as per data sheet given in Annex –I ( minimum 12/12 mm thk to be provided)

• The vessel to be manufactured as ASME SEC VIII DIV –I. Material construction shall be SA516 Gr 70.

• The minimum design Pressure for the vessel shall 18 kg/sq. cm. and test pressure must be 21 kg/sq. cm


• Proper insulated barrier to be provided of PUF material 300 kg/cum density, between vessel & stand / platform.



• Vessel to be stress relieved after fabrication and certificate of the same to be submitted before dispatch of vessel.

• QDV valves to be provided at drain. Vessel size, shell and dish end thickness to be mentioned in your offer.

• Platform with Chquered plates, ladder and structure to be painted with 2 coats of red oxide paint + two coats of epoxy paint.

• Surge drum to be provided with MS saddles ( fabricated at manufactures work ) and below saddle provided 300 kg/cum flat PUF insulation barrier

1 no

7 Ammonia Falling Film Chiller for 10,000 LPH system

• Capacity 378 kW to chill water from 16.7 Deg C to 0.5 Deg C CHW flow 20000 LPH with SS tank, Evp temperature -3 Deg C

• All data to be furnish as per Annexure-I. Platform to be constructed to operate and maintained this chiller. Platform to be epoxy painted.

• MOC of plate, casing & tank shall be SS 304.

1N0

8 Ammonia Falling Film Chiller for 20,000 LPH system

• Capacity 753 kW to chill water from 16.7 Deg C to 0.5 Deg C with SS tank, CHW flow 40000LPH Evp temperature -3 Deg C

• All data to be furnish as per Annexure-I Platform to be constructed to operate and maintained this chiller. Platform to be epoxy painted

• MOC of plates casing and tank shall be SS 304.

1 No

9 Modification of existing 20,000 LPH RM chillers. Add 37 plates. And please see other parameters in annexure –I data sheet. Bidder to guarantee all parameters mentioned in data sheet. Bidder to include all necessary required material such as gasket etc. along with required tools and tackles to carry out modification of this RM chiller. Bidder to check and confirm whether adding 37 plates, we will achieve desired parameters or not. Bidder to carry out this from authorized GEA service agency only.

1 lot

10 Replace 10,000 LPH RM chiller as per parameters mentioned in data sheet annexure-I. Bidder to guarantee all parameters mentioned in data sheet. Bidder to buy back this PHE and give reduction in price accordingly. Bidder to buy back old 10000 LPH milk chiller

1 No

11 Refrigerant Piping: - P & I diagram indicating pipe sizes, valves, controls; insulation thickness is attached with this tender. Bidder to quote strictly as per the same without any deviation. Bidder can add or increase line sizes, add valves & controls if necessary to achieve desired performance.

• The Refrigerant & oil (ammonia piping) piping should be as per A 106 Gr. B seamless pipes.

• 1 x 125 NB angle valve to be install in suction header to connect standby compressor in future

• 1 x 80 NB stop check valve to be installed on discharge header to connect standby compressor in future

• 100 NB valve to installed on new suc header to connect suction header of old frick compressor

• 80 NB valve to be installed on discharge header near compressor to connect discharge header of old Frick compressor.

• 2 x 80 NB valve to be connected to each inlet line of evp. Condenser to connect old discharge header near evp condenser + 1 x 80 NB valve in old header.

• 1 x 80 NB + 2 x 40 NB valve to be installed on discharge header and liquid line at evp. Condenser to connect one evaporative condenser in future

• 1 x 80 NB valve to connect to new liquid header to connect existing liquid line from atm condenser.

• The schedule of pipe must be: Size 15 to 40 NB SCH 80, 50 to 250 SCH 40 and above 250 SCH 20.

• While designing the piping, please consider the following.

• New receiver to connect and equalize with old receiver.

• Safety valves, Gauges, Reflex level gage to install on old receiver also.

• All the above headers to be designed to connect future equipment of similar capacity.

• All dry suction/ liquid & discharge headers should be provided with 2 Nos. 15 NB Stop valve for purging or pump down purpose. One valve to be installed in the field and one to be installed in the plant room.

• The pipe sizing to be designed based on velocities mentioned in IIAR piping hand book as a guideline, the distance of the pipe line, pressure drop in pipe line and energy saving perspective. The minimum required pipe sizing is given in P & I. if bidder wishes to increase the line sizes he may do so.

• Elbow size 50 mm and above: Carbon Steel 90 degree long radius as per A 234 GR WPB ANSI B 16.9 butt welded.

• Elbow size 40 mm and below: Carbon Steel 90 degree long radius as per A -105 ANSI B 16.9 socket welded

• Concentric reducer Carbon Steel as per A 234 GR WPB ANSI B 16.9

1 Lot

butt welded.

• Eccentric reducer Carbon Steel as per A 234 GR WPB ANSI B 16.9 butt welded. To be used for evaporative condenser liquid outlet connection.

• End Cap size 50 mm and above: Carbon Steel as per A 234 GR WPB ANSI B 16.9 butt welded.

• End cap size 40 mm and below: Carbon Steel as per A -105 Socket welded ANSI B 16.9

• All tubing for instruments, controls must be SS.

• All Pipes, pipes supports, platforms are in bidder scope, Pipe bridges, and walkways will be in bidder scope.

• All piping, platforms, ladders, walkway, all supports to paint with two coats of red oxide paint + 2 coats of epoxy paint.

• Safety valve piping to be designed and installed as per EN 13136 – 2013. The pipe header to be laid 10 m higher than the nearest tallest building height.

• All piping must be in plum, aesthetically well designed. We reserve right to ask bidder to cut and re do the piping if not installed accordingly.

• Piping to be designed with minimum bends.

• Wherever possible angle valve must be used and avoid using elbow.

• Stop check valve inlet pipe must be vertical and outlet pipe must be horizontal.

• Proper slops to be maintained wherever required.

• Contractor is required to furnish BOM for lot items.Bidder to visit site and calculate the pipe quantity before quoting. Piping to be quoted on lumsum basis & No extra cost on any account will be paid in case of any variation in piping and valve qty.Bidder to study in detailed P & I diagram enclosed and included all as per the same.

12 Refrigeration controls and valves.

• All valves must be weldable angle type valves.

• The equipment wise list of valves / controls to be furnished by the bidder in their offer.

• The controls / instruments, sensors to be selected to fulfill automation mentioned in the scope given in the tender.

• All temperature sensors (PT100) must be duplex type.

• Shielded cable to use to connect sensors. This shielded cable must be laid in separate conduit / tray and away from power cable.

• Please note calculation of quantity of valves and controls is bidder responsibility.

• The list of controls given below is minimum required controls, any additional controls required for monitoring and controlling of the refrigeration system through PLC is to include in bidder scope. No extra cost on any account will be paid. Bidder to attached list of controls included in offer for evaluation and confirms all valve and controls are included in his offer as stated in P & I and as below.

Proposed list of minimum refrigeration controls required. Bidder to add to list if required. Bidder to include all required controls and instrument required for automation system, monitoring and controlling. No extra cost on any account will be paid if any additional controls and instrument supplied extra than the list given below.

Sr. No

Item Description line size Total Qty

1 Compressor : 2 No x KCX-6

2 Quick drain valve 1

3 Pressure transmitter for capacity control through PLC scada system

150 NB 1

4 Evaporative Condenser 2 Nos

5 Dual Manifold Type with Safety Valve SFV15 with Indicator inlet with flange

32 NB 2

6 Pressure Gauge inlet / outlet Wika make Glycerin filled

80 NB 3

13 Insulation of refrigerant piping and vessels.The insulation for refrigerant pipe and vessel, pipes should PUF pipe section or slab. Covered with 20/22 G Aluminum cladding with 20 micron anodizing depending upon pipe & vessel diameter. Oil pot also to be insulated

• PUF pipe support for insulated pipes shall be of minimum 150 kg/cum density. PUF flat with Density 300 kg/cum to be provided between surge drum MS saddle and the frame.

• PUF pipe section must have density 40 kg/cum• No negative tolerance on PUF density is acceptable. Material / lot

will be rejected if density is observed less than 40 kg/cum.The minimum required PUF insulation thickness are given below:

SR. NO. PIPE SIZEThickness for -2 deg C ( mm)

1 15 NB 30

2 20 NB 30

3 25 NB 30

4 32 NB 40

5 40 NB 40

6 50 NB 40

7 65 NB 40

8 80 NB 40

9 100 NB 40

10 125 NB 50

11 150 NB 60

12 200 NB 60

13 250 NB 60

14 300 NB 60

15 Surge Drum 100

1 Lo

14 First charge of unhydrous ammonia. Please note the bidder will have to charge required ammonia into the system as per system requirement and top up the ammonia quantity as and when required till handover of the system to client. No extra cost for ammonia will be paid on any account for ammonia charge till the system is handed over.

lot

15 Two charges of compressor lube oil. Oil type, brand name and name of the oil company to be specified in the offer. The oil should be available in India. Oil charged in the entire system should be suitable for -20 systems. Minimum quantity to be included in the bidder offer is 200 lit. Please note the quantity of oil mentioned is indicative, bidder will have to charge required lub oil into the system as per system requirement and top up the same as and when required till handover of the system to client. No extra cost for lub oil will be paid on any account till the system is handed over. The lub make and parameters to be approved by us before procurement.

200 lit

16 Chilled water piping: The existing chilled water pipes along with the chilled water pump, up to pump discharge header to be used. Pump discharge header to be modified in such a way that pump installed at center can be used as standby pump for other two pumps as shown in attached P & I diagram. Bidder to check condition of existing chilled water pipe along with the insulation. If condition is not suitable to use then new piping with Insulation to be supplied and installed by the bidder. The make of valves and piping should be as specified in tender. Bidder to check condition and suitability of existing chilled water pumps. If according to bidder they are not suitable then bidder to quote optional additional price for new pumps. Bidder to include existing chilled water pumps in new MCC / control panel supplied the bidder. Monitoring and controlling, start / stop of these chilled water pumps must be prom new MCC/ control panel/ PLC/PC.Bidder to include following water line valves in their scope: these are minimum quantity required. Bidder to supply and install any additional valves and other controls required as per system requirement. No extra cost on any account will be paid for this additional requirement.

Water line valves Qty

15 NB globe valves with flanges , gaskets , nut bolt 34

25 NB globe valve flanges gasket nut bolts 6

50 NB butterfly valve flanges gasket nut bolts 3




80 NB Check valve with flanges , nut bolts and gaskets

3

100 NB pot strainer with SS mesh flanges , nut bolts and gaskets

2

80 NB pot strainer with SS mesh flanges , nut bolts and gaskets

1

1 lot

17 Structural material: For pipe installation and construction of platform with Chquered plates, pipe supports, and falling film chiller supports are in bidder scope. All platforms, ladders as per site condition to be supplied and installed by the bidder as per safety requirement and emergency evacuation requirement. Pipe supports to be provided as per requirement and as per AAR standard and also to ensure safety and prevention of vibration of pipe.Contractor is required to furnish BOM for lot items. All pipe supports must epoxy painted.

1 lot

18 Ammonia Leakage detection system. You will have to provide minimum six sensors suitable for plant room + sensors near condenser + at safety release system top point of piping. The controller will be located in main control panel. Spare testing bottles to be provided. The hooter to be provided for Alarm. Cabling from sensor to controller is included in bidder scope. Shielded cable to be used for the same. Contractor is required to furnish BOM for lot items. Each sensor indication to be given in controller to identify which sensors is giving alarm. There should be a possibility to connect Ammonia leak detection controller to PLC to get indication on PLC which sensor is giving alarm. Alarm and SMS/email to 3 designated persons to be generated by PLC also in case of Ammonia leak.

1 lot

19 Ammonia safety Personal protective equipment (PPE)to be supplied as below:

� Make Honeywell / Joseph Lesley Dragger � Breathing apparatus set suitable for 45 min with cylinders : 2 sets� Full face mask : 4 Sets� Spare ammonia canister : 10 pairs� Ammonia Suit full protection : 2 sets� Hand gloves suitable for ammonia : 2 pairs� Ear Muff: 10 Nos.� Helmet: 10 Pairs� Safety Goggles: 10 Pairs� Safety shoe: of various sizes. Total 10 pairs.� Eye wash (SS construction) / eye Shower as per make specified.

1 sets

20 Electrical MCC (starter panel) & power distribution board (PDB): Required for all Refrigeration system with aluminum power cable, copper control cable, cable tray, shielded screen cable for sensors, earthing to be included in bidder scope. MCC should have provision to record / monitor energy consumed by each compressor. Energy meter to be also installed in main incomer of the MCC and to be connected PC. All power and control cables are to be lead in galvanized cable tray. MCC / control panel to have top cable entry. No cable trenches will be provided. MCC must be provided with forced cross ventilation. Energy meter to be connected to PC. Capacitor bank to be provided for automatic maintenance of power factor as per regulation. 2 No + 2 NC auxiliary contactors to be provided for each starter for control action.Controls scheme:

• Entire control action start stop of equipments, pumps etc. will be from PLC based panel located in control room.

• power cable: 1 power cable 3 -1/2 core

• GI strip earthing will be for all Panels.

• Ammeter is to be installed for Evaporative condenser fan motors and pump motors to monitor current.

• Earthing pit will be provided by electrical agency.

• Entire control action will be from PLC based panel located in control room.

• Local lockable start stop push buttons to provide near motor located outside plant room, (Construction IP 65)

• Power supply for Air purger supply to be provided from Control panel

• Supply for PLC panel to provide from MCC panel.

• All control supply to PLC , solenoid coils etc. should be through UPS

• 4 CT for power factor and energy measurement to be installed in main panel.

• 1 MCCB, 3 pole thermal magnetic for capacitor bank to provide in MCC panel. To provide in separate compartment.

• MCC panel top entry. PLC panel top entry.

• Each feeder will be provided with 2 NO + 2 NC auxiliary contactor for each starter.

Reference Standards:-a) IS 8623: Factory built assemblies.b) IS 2147: Degrees of protection provided for enclosures.c) IS 13947: General requirements for switchgear d) IS 375: Marking and colour coding for bus bars.

• Construction: Metal enclosed, cubicle type, dust & vermin proof floor mounted, Single Front, Cable entry from bottom, fixed type semi-compartmentalized construction as per IP 52 degree of protection.

1 Set

• Fabrication: Panels will be fabricated out of 14/16 SWG. (2.0/1.6mm) CRCA Sheet Steel. Gland Plate will be 14 SWG. Base Frame will be 10 SWG. All cover plate will be with Neoprene Rubber gasket and will be bolted.

• Painting: The panel will be pre-treated with seven tank process i.e. Degreasing De-rusting acid prickling, phosphating, and final powder coated structure finish epoxy based paints as per IS-5, Shade – 7032. (Interior & Exterior)

• Bus bar: Bus bar will be Aluminium E91E grade with PVC heat shrinkable sleeves. (Clearance between – Phase to Phase – 25mm & Phase to Earth – 20mm)

• Busbar Rating: 1sq.mm = 1Amps

• Wire: Current circuits wire will 2.5sq.mm and control wire 1.5sq.mm. Flexible PVC Copper wires. Power wire will be as per rating.

• Hardware: Zinc yellow passivated will be provided.

• Earthing: Earth Alu. Bus/stud will be provided, and Door will be earthed

• Terminal: 10% spare control terminal will be provided.

• Name Plates: Name plates will be aluminium anodized.

• Routine Test: Insulation Test on 1000V meggar between earth, neutral and phase.

--H.V. Test: For Power 2.5KV for 1 min.-- For Neutral 1.5KV for 1min.-- Operational Test at no load.

The spare feeder of each kW rating to be provided in the MCC. Each compressor to be provided with energy meter to be facilitates to connect to PC. Also MCC incomer to have energy meter to note energy consumed by all refrigeration equipment and with facility to connect to PC.MMC to have feeders for 2 + 1 x 160 kW compressor motor, condenser fans and pumps, Each evp condenser fan and water pump to have separate starter and we want to start condenser each fan and pump independently . Starters for old chilled water pumps also to be provided in the new MCC.

21 CONTROL SCHEME FOR THE REFRIGERATION SYSTEM

The main control panel shall be kept in the plant room.

The control panel is fully automatic standalone control system with

possibility to run the entire refrigeration system in manual mode.

Compressor shall have PLC based lead lag sequencing system, capacity

control system compressor.

• For manual operation of compressors, condensers, chilled

water pumps RM chillers etc. should be possible from control panel

without PLC also. All safety interlock must be functional in manual

mode also. Necessary arrangement with switches, lamps and hard

wiring is to be provided.

• Different security levels are incorporated in the system to

change the set points by persons at different levels.

• PC is provided along with above control panel for operating and monitoring of the plant.

• Data to be possible to transfer from Gogave to Gokul main plant PC via internet.

• Programmable Logic Controller (PLC) is used for measurement and control of the entire refrigeration system. Dynamic Mimic Screens to create on PC and plant to operate from PC as well as from PLC panel. PLC will be in operation only in auto mode. In manual mode, signals from PLC shall be disabled and plant will work based on the inputs given from the control desk. We should be able to operate all equipment in manual or in auto mode. All equipment to have A-O-M stop mode selector switch to select desired type of operation.

• Control panel will house PLC and its components, various switches, contactors, push buttons, lamps, timers, interconnecting wiring, Data logger, ammonia leak detection system etc.

• The control panel is to be sized considering sufficient operating space between switches/push buttons / switch gear mounted on the desk and also the sufficient space is provided for the internal wiring.

• For future expansion, there should be a provision of appropriate space in the panel for mounting hardware/push buttons/ indicating lamps / internal cable terminations PLC rack etc. The control supply to PLC and compressor controllers will be through UPS. UPS is to be designed considering compressor crank case heater load. UPS is in bidder scope.

• Incase PLC or I/O cards etc. fails then we will be able to run the entire plant in manual mode with all safety interlock, without any problem.

• PLC to be supplied with 20% spare I/O of each type.

• All the necessary hardware such as contactors and relays are to be provided in the control panel. Control desk is to be fabricated out of CRCA sheet, powder coated, free standing type panel of suitable size to house the PLC and I/O modules with relays, exhaust fan, illumination, The panel has cable entry from top.

• Remote monitoring and controls along with energy calculation has to be included in PLC panel.

• Bidder has to incorporate any controls , hardware , software and other logic suggest by client during detail engineering without any additional cost to client.

The main components of each control system are as follows: We should be able to control and monitor following from PC and PLC panel:

1) Compressor: to controls from control panel , PC ( 2 Nos comp with 160 kW motor)

• Start / stop compressors from control panel, provide PB and indicating lamp for the same. A-O-M- selector switch.

• Compressors capacity control is based on suction pressure sensed by suction pressure transmitter installed in main dry suction header.

• HP / LP/OP pressure switch to be provided on each compressor gauge board for safety interlock through control panel for each compressor safety.

• The Glycerin field Pressure gauges and Danfoss cut outs for oil pressure are also to be provided.

• Lead-lag sequencing, on / off, capacity control to be designed for all compressors. First compressor to start manually

other compressor to start as per load based on suction pressure.

• If one compressor fails to start, other compressor to start after time lag.

• There should be a facility to operate this compressor and load & unload these compressors manually from PC and by switches on gauge board.

• All safety interlocks of compressors to be taken care by PLC and must be in operation even if PLC fails.

• There should be facility to change sequence of compressor. Stand by compressor will be always operated on manual mode.

• PC to log each Compressor running hours, Each Compressor energy consumed. Calculate COP and kW / lit of milk per day. Qty of milk process to feed to PC manually.

2). Evaporative condenser: 2 Nos. (Each condenser 7.5 kW x 2 fan + 1.5 kW x 1 Pump tentatively it may change)

• Indicate Discharge Pressure (header) in PC by pr. Transmitter, in PLC.

• Based on Discharge pressure decide start /stop of condensers at set pressure of 12 bar

• Provide start stop, A-O-M switch for each Fan and water pump start stop, A-O-M switch.

• Provision to control inlet make up water level through level controller and 25 NB water line solenoid valve for each condenser.

• Provision for one future evp condenser to be made in panel and in PLC & PC.

• We should be able to start / stop each fan and each pump of each condenser from control panel and from PC. On/off indication must be available on control panel and in PC. Including running hours of the fan and pump.3. Ammonia chiller for 20000 LPH water chilling: ( 1 N0 )

• Provide A-O-M switch,

• PLC / PC to show in/out water temperature and water Flow, and to calculate actual capacity of chiller

• based on CHW Outlet temperature trip LLSV and Solenoid valve on BPRV,

• Based on low flow signal from Flow switch LLSV and BPRV solenoid valve to be closed,

• Based on float level action LLSV to be on/off.

• LLSV & BPRV installed on dry suction of each chiller is to set in such a way that pressure in surge drum will be always corresponding to -3 Deg C.

• Solenoid valve on / off indication must be available in PC.

• We should be able to make on/off of solenoid from panel & and from PC.4. Ammonia Chiller for 40,000 LPH water chillers: ( 1 No)

� Provide A-O-M switch, � PLC / PC to show in/out water temperature and water Flow, and to calculate actual refrigeration capacity.� based on CHW Outlet temperature trip LLSV and Solenoid valve on BPRV, � Based on low flow signal from Flow switch LLSV and BPRV solenoid valve to be closed, � Based on float level action LLSV to be on/off.� LLSV & BPRV installed on dry suction of each chiller is to set in such a way that pressure in surge drum will be always corresponding to -3 Deg C. � Solenoid valve on / off indication must be available in PC. � We should be able to make on/off of solenoid from desk and from PC.

5. All solenoid valves installed in plant must have facility for manual on/ off from panel & from PC / PLC.6. IBT: water temperature to indicate in PLC / PC. IBT level controller to start and stop water pump 2 No. + 1 S7. Chilled water pump ( 3 No - 2 W + 1 S ) : � Start / stop with indication shall be from control panel and PC.� Indication of on/off of chilled water pumps to be given in control desk and in PC. � Running hours of the pumps to be recorded and indicated in the PC8. PLC/ PC should also show all operating parameters of plant as stated above.9. Facility to enter Maintenance data.10. PC with 18 inch monitor and printer to be provided for monitoring and controlling. PI and various screens to be created on PC to indicate data.11. UPS of adequate capacity is included in bidder scope including 1kW heater of each compressor crank case . Entire supply to control panel shall be through UPS.12. Panel to have forced ventilation.

22 Complete power and control cabling including cable trays, conduits etc. for all refrigeration system supplied by the bidder. Selection and installation should follow Indian standards and local electrical authority’s standard.

• Power for 415 V system shall be 1100 V Grade Aluminium Conductor XLPE insulated PVC sheathed, Armored IS 7098 (Part-I). No power cable of aluminum conductor having less than 4 sq. mm shall be used. No copper power cable to be used less than 2.5 sq. mm shall be used.

• Control cable shall be 415 V 1100 V grade, copper conductor XLPE insulated PV sheathed IS per IS 7098 Part –I. The minimum size of copper control cable shall be 1.5 sq. mm

• Screen cable for instruments and controls shall be multi stranded, based annealed, copper conductor, PVC insulated, cores colour coded lay-up, screened by braiding with ATC copper wire and finally overall PVC Sheathed.

• Cable glad must be of same material of cable, and crimped by proper tools.

• Contractor is required to furnish BOM for lot items.

1 set

23 Requirement of drawingsFollowing drawings to be attached along with the bid 1. P & I diagram with line sizing, indicating all valves and controls included in scope.2. Electrical load list.3. List of controls & valves with model4. Filled data sheet as given in Annexure-I Data mentioned against each equipment and item.5. Submit manufacturer selection printout for compressor, condenser, RM chillers and falling film chiller.Following Drawings are required after order finalization for approval before startup of work

• P & I diagram with valves, controls with models, equipment sizing, line sizing.

• Equipment layout drawings for plant room and evaporative condensers with plan and sections.

• Equipment foundation drawings.

• All pressure vessel GA drawings

• Evaporative condenser GA drawing

• RM chiller and ammonia chiller GA drawings , manufacturer selection print out and data sheets as per format given in annexure-

I

• Equipment wise refrigerant controls list with part number and qty.

• List of valves with manufacturer part numbers, model, quantity.

• MCC GA drawing with BOQ / make / Qty

• Control panel GA drawing and control logic with BOQ / make /Qty

• MCC and control panel Power and control wiring diagram

• Isometric Safety valve relief piping diagram with line size, pipe qty in meters.

Following as built manual / drawings in 6 sets are required along with 3 sets of soft copy.

• O & M of refrigeration plant

• O & M with spare part list and part numbers for compressor with motors

• All vessels test certificates , stress relieving certificate ,with 100% radiography plates and plan

• P & I diagram with valves, controls with models, equipment sizing, line sizing.

• Equipment layout drawings with plan and sections

• Equipment Foundation drawings

• All Pressure vessel GA drawings

• Evaporative condenser GA drg

• RM chillers and ammonia chillers GA drawings manufacturer selection print out and data sheet.

• O & M of manufactures of compressors, condensers, RM chillers, ammonia falling film chillers.

• Equipment wise Refrigerant controls and valve list with part number model and Qty.

• MCC power and control wiring diagram with as built ferrule numbers along with GA drawing with BOQ / make / Qty.

• Control panel power & control wiring diagram with as built ferrule numbers, GA drawing , control logic, with BOQ / make /Qty

• Safety valve relief piping diagram.

• Pressure test , vacuum test , loop checking report jointly signed by bidder site in-charge and authorized Gokul dairy person.

24 General Specifications.1. Bidder will be responsible for technically correct installation

and include in his scope as per requirement of automation and system basis of design. Bidder will not be paid extra cost on any account if he has to add any material or redo the installation if necessary to achieve the requirement

2. Refrigeration contractor to furnish all equipment foundation drawing consisting of pocket dimensions, static / dynamic load details, inserts bolts etc. at appropriate time during the execution. Any delay in providing these details which will cause delay in project will be attributed to refrigeration contractor. Refrigeration contractor has to closely coordinate with civil agency for the same.

3. Fixing of insert plates, structure for supporting operating equipment, pipe lines etc. to be supplied and installed by the bidder. The structural material to be used should be of TATA or SAIL make only.

4. All pipe lines and structures / platforms , ladders should be thoroughly cleaned and painted with two anti-corrosive red oxide primer followed by two coats of epoxy paint as per the standard colour code and instruction by client.

5. From all Safety valve, piping should be provided up to outside of the plant room and at a height 10 feet above the nearest height

building. Ammonia sensors to be provided at top most point with alarm in plant room indicate ammonia leak from safety valve. Each Safety valve to be provided with mechanical indicator, indicating release of each safety valve. Safety valve pipe sizing shall be as per EN 13136:2016, no deviation accepted. Bidder to submit safety valve piping P & I for approval before installation.

6. Refrigerant pipe welding is, route run by tig and final by arc. Pipe should be thoroughly cleaned by CTC / wire brush before installation. Pipe should be flushed properly before charging of ammonia.

7. All pipe ends must be closed by end cap only.8. Pressure testing (21 kg) for 48 Hours by nitrogen. Vacuum testing at

735 mm to hold for 48 hours. For vacuum test proper vacuum gauge to be used. Joint inspection report to be submitted and test will be witness by our site in charge. Vacuum to be taken by vacuum pump and not by compressor.

9. All exposed outside pipe supports and platforms should be galvanized and bolted type.

10. Pipe labeling / marking shall be carried out as IIAR standard.11. All uninsulated pipes must be epoxy painted as specified12. The Platform with Chquered plates and ladders should be

provided to access valve and controls, near evp. Condensers, water chillers, surge drums and wherever required.

13. Once the contract is awarded bidder has to co-ordinate other agencies such as electrical, firefighting, civil agency and ensure the committed dates are archived.

14. All tools & tackles, crane, hoisting equipment etc. to be provided by the bidder.

15. The rigging and placement of the equipment at site, unloading of equipments (imported & Indigenous ) at site will be carried out by the bidder.

16. All safety measures such as safety shoes, helmet, and proper safety arrangement to work above certain height; movable scaffolding must be with lockable wheel and appropriate plat form to work.

17. Proper crane to be arranged and used by bidder to install evp condensers, water chillers etc. , Crane with appropriate boom to be used to install evaporative condensers and pressure vessels, and equipments to be arranged and paid by the bidder.

18. Lodging, Boarding, Transport etc. of the erection crew would be arranged by the bidder.

19. Transit Insurance of all the supplied materials from supplier’s ware house up to Site shall be covered by the bidder. The storage cum erection ( all risk ) Insurance to be covered by the bidder. The risk covered should be valid up to handing over the plant to us.

20. The prices should be inclusive of local taxes & duties , import duties if applicable, now and as and when made applicable in future.

21. Unloading equipment at site including, lifting shifting positioning of the equipment of the same is included in bidder scope. Bidder to take at most care of these equipments while installation and commissioning. In case of any damage to these equipments while installation & commissioning, the equipment to be repair/replacement by the bidder. Custom clearance of imported equipments equipment and transportation to site is included in bidder scope.

22. Bidder should inspect the site of the work to familiarize themselves with the site conditions before finalization of the order.

23. Income tax according to Government of India regulations and any other local taxes, as required statutorily will be deducted, and prescribed certificates shall be issued to the

bidder. If works contract tax, trade tax is applicable, then it will be to bidders account.

24. Provident Fund, ESIC or any other statutory benefits if applicable now and/or as and when made applicable to the erectors/worker employed by the bidder would be borne by the bidder.

25. The prices shall remain firm till the satisfactory completion of the entire scope of work. No extra claim will be entertained.

26. Performance trail will be conducted for period of two weeks as per mutually agreed plan.

27. Since this is running dairy entire work has to be carried out meticulously , with proper planning and with minimum shutdown

25 Any other terms and conditions, if not agreed by us in writing would not be acceptable to us.

26 Bidder to supply & install and commission Chilled water fan coil unit along with necessary piping, valves and controls to maintain 20 Deg C room temperature of control room located in plant room. The capacity to be decided by refrigeration contractor. Chilled water tapping to be taken from IBT outlet and return to IBT. Appropriate room temperature control to be also provided.

1 set

27 Client will provide following:

• All civil work, foundation work, floor water drain arrangement in plant room and on terrace.

• All foundations, such as compressor, condenser receivers, chillers etc. will be provided by client.

• Water will be provided near condenser. Bidder to take piping with valves from one point to condenser and drain piping to nearest drain point. Bidder to take from this point water piping to Receiver spray shower system and also for eye wash and eye shower with required valves

• Making holes in walls and repairing of the same. Bidder to provide marking and coordinate with designated person.

• Power & water for erection: Power & water will be provided at one point. You will have to make your own arrangement for further connection of power supply to your machinery. Any other supports required for refrigeration system is in refrigeration contractor scope.

• Incoming power cable supply up to bidder MCC. Termination of the same at bidder’s MCC by bidder. Further distribution by bidder.

• Make up RO water at all condenser sumps. Further distribution to eye wash, receiver shower is in bidder scope.

• Construction of control room

• If required removal and reinstallation of roof above IBT , to accommodate Falling film chiller.

Annexure I -- Data sheet to be furnished by the bidder:*Data to be furnish by bidder

ANNEXURE -- I

TECHNICAL DATA SHEET REQUIRED TO BE FURNISHED BY THE BIDDER AND SUBMIT ALONG WITH THE OFFER FOR REFRIGERATION SYSTEM FOR GOGAVE DAIRY

SR. NO

ITEM UNITS SPECIFIED REQUIRED DATA

DATA TO BE FILLED BY BIDDER

1 Compressor

2 Make Kirloskar/ Mycom

Kirloskar

3 Type Reciprocating *

4 Model KCX-6 Air-cooled jacket cooling

*

5 RPM rpm 950 *

6 Evp/cond temperature deg c .-3/40 *

7 Refrigerant Ammonia *

8 Capacity kW 560 *

9 shaft power kW 133.34 *

10 motor kW kW 160 *

11 Qty no 2 *

12 Bidder to confirm that all bidder has included accessories as specified in tender

confirmed yes/ no

*

13 Attached compressor selection print out

attached

attached

14 Compressor motor *

15 Make Siemens *

16 Frame size *

17 Rating kW 160 *

18 RPM RPM 1440 *

19 Type IE 3 *

20 Efficiency % *

21 Power factor at supply voltage of 415V +/- 10%, 3 Phase, 50 Hz +/-5%, AC combined variation 10% , confirm winding thermistor as per specification provided

*

22 Control supply voltage 220 V , 1 Phase AC

23 Qty 2 *

24 Evaporative condenser

25 Make Evapco *

26 Model ATC -258E *

27 Heat rejection capacity kW 1021 *

28 Qty NO 2 *

29 Condensing Temp DEG C

40 *

30 WB temperature DEG C

28 *

31 Refrigerant Ammonia *

32 Casing, water sump galvanized *

33 Attached Evapco selection print to be attached attached

out

34 HP Receiver

35 Diameter mm 1200

36 Shell Length mm 6000

37 MOC SA 516 Gr 70

38 Shell / Dish End thickness mm .12/12

39 MS Saddle fabricated and welded to vessel at manufacturers works

to be provided included

40 radiography of joints % 100

41 Paint 2 coats of red oxide + two coats Epoxy

42 lifting hooks to be provided

43 name plate to be provided

44 design & mfg standard ASME SEC VIII DIV :1 & AAR-1

45 Qty 1

46 Design Pr / Test Pressure kg/sq. cm g

.21/26

Automatic air purger manik make to include included

New 10000 LPH milk chiller Existing PHE to buyback by bidder and quote price after deducting by back price

New 10000 LPH milk chiller

Make GEA

milk side water side milk side

flow rate kg/hr 10000 20000 *

inlet temp DEG C

35 1.5 *

outlet temp DEG C

3 16.7 *

Pressure drop bar a * less than 0.7

*

Heat transfer area sq. m * * *

safety margin on heat transfer area % * * *

Fouling factor * * *

no of plates * * *

no of effective plates * * *

no. of passes * * *

Plate material / thickness

Alloy 316 /0.6mm

*

Ring gasket * * *

Sealing material * * *

Connection material * * *

connection diameter * * *

nozzle orientation * * *

pressure vessel code * * *

flange rating bar * * *

Design pressure bar * * *

test pressure bar * * *

design temperature deg c * * *

Overall dimensions ( L X W x H) mm * * *

liquid vol. lit * * *

net weight kg * * *

Operating weight kg * * *

milk PHE 20,000 LPH

Existing PHE to be modified by adding 37

plate

milk side water side milk side

Make GEA GEA

flow rate kg/hr 20000 40000 *

inlet temp DEG C

35 1.5 *

outlet temp DEG C

3 16.7 *

pressure drop bar a less than 0.7

*

Heat transfer area sq. m 62.1 *

safety margin on heat transfer area % 26..3 *

Fouling factor *

NUMBER OF PLATES TO BE ADDED 37

*

no of plates FTER ADDING 37 PLATES 137

*

no of effective plates *

no. of passes *


Alloy 316/0.6mm

*

Ring gasket *

Sealing material *

Connection material AISI316L *

connection diameter *

nozzle orientation *

pressure vessel code *

flange rating bar *

Design pressure bar 15 *

test pressure bar 13 *

design temperature deg c 120 *

Overall dimensions ( L X W x H) mm *

liquid vol. lit *

net weight kg *

OPERATING WEIGHT kg *

Ammonia water Falling Film chiller for 10,000 LPH milk processing

water side ammonia side

*

Make Omega / Buco *

capacity kW 378 *

flow rate lph 20000 *

inlet temp DEG C

16.7 *

outlet temp DEG C

0.5 .-3 evp temp

*

Heat transfer area sq. m *

safety margin on heat transfer area % *

Fouling factor *

no of plates *

Plate material / thickness *

Tank , plate casing material SS304

Connection material *

connection diameter *

pressure vessel code *

flange rating bar *

Design pressure bar *

test pressure bar *

design temperature deg c *

Overall dimensions ( L X W x H) mm *

liquid vol. lit *

net weight kg *

Operating weight kg *

Pressure dropbar less than 0.5

less than 0.5

*

Submit data sheet and selection print out of supplier

to be attached

Ammonia Falling film chiller 20000 LPH milk processing

water side ammonia side

Make

Omega / Buco *

capacity kW 756 *

flow rate lph 40000 *

inlet temp DEG C

16.7 *

outlet temp DEG C

0.5 .-3 evp temperature

*

Heat transfer area sq. m *

safety margin on heat transfer area

%

*

Fouling factor

*

no of plates

*


Alloy 316/.60mm

*

Tank , plate casing material

SS304

*

Connection material

*

connection diameter

*

pressure vessel code

*

flange rating

bar

*

Design pressure

bar

*

test pressure

bar

*

design temperature

deg c

*

Overall dimensions ( L X W x H)

mm

*

liquid vol. lit *

net weight kg *

Operating weight kg *

Pressure dropbar less than 0.5

less than 0.5

*

Submit data sheet and selection print out of supplier

to be attached *

Surge Drum for 378 kW capacity ammonia PHE

Diameter mm 1000 *

Shell Length mm 2500 *

MOC SA 516 Gr 70 *

Shell / Dish End thickness mm .12/12 *

Insulation thickness 100 *

PUF Insulation thickness mm 100 mm *

radiography of joints % 100 *

Paint Epoxy *

lifting hooks to be provided *

name plate to be provided *

design & mfg standard ASME SEC VIII DIV :1 & AAR-1

*

Qty 1 *

Design Pr / Test Pressure kg/sq. cm g

18/21 *

Surge drum to be provided with MS saddles ( fabricated) and below saddle provide 300 kg/cum flat PUF insulation barrier

included included

Surge Drum for 758 kW capacity ammonia PHE

*

Diameter mm 1200 *

Shell Length mm 2500 *

MOC SA 516 Gr 70 *

Shell / Dish End thickness mm .12/12 *

Insulation thickness 100 mm with minimum density 40 kg/cum with no negative tolerance

*

Surge drum to be provided with MS saddles ( fabricated) and below saddle provide 300 kg/cum flat PUF insulation barrier

included included

PUF Insulation thickness mm 100 mm with minimum density 40 kg/cum with no negative tolerance

*

radiography of joints % 100 *

Paint Epoxy *

lifting hooks to be provided *

name plate to be provided *

design & mfg standard ASME SEC VIII DIV :1 & AAR-1

*

Qty 1 *

MCC, Control panel, power and control cabling , scada system and automation included as per specifications

to include included

bidder to conform they have included all as specified in tender with out any deviation

to confirm

confirmed

========================================================================

(COMMERCIAL OFFER)

Format(To be given on the Letter head of Tenderer)

Date :

To,

The Managing Director,Kolhapur Zilla Sahakari Dudh Utpadak Sangh Ltd.,B-1,, MIDC., Gokul Shirgaon, Kolhapur-416 234.

Sub : Commercial offer for Refrigeration System.Ref : Your Tender Notice Published on

Dear Sir,

With reference to the Tender Notice published in , I/We submit commercial offer for the work of design, supply, installation & commissioning of Refrigeration System for proposed expansion & revamping of your Gogave Milk Chilling Centre. We have thoroughly studied the details of work tobe done and agree upon the following.

1) Equipment specifications, make, quantity, work place, standard and required skill for execution of job.2) Terms & conditions of the Tender.

A) OUR TOTAL BID PRICE FOR THE WORK :- Rs.

(Amount in Words Rs. )

B) REQUIRED PERIOD FOR COMPLETION OF JOB -

Place :

Date :

Encl : Price Break up sheet -

Seal & Signature of Tenderer.

PRICE BREAK UP FORMAT

Sr. No

Item TotalQty

Unit Rate ( Rs)

Total Price (Rs.)

A) Supply of Equipment

1 Compressor with Accessories common base frame, dimister oil separtor, ss tubing, special gauge

2

2 160kW siemens / ABB make IE 3 motor 2

3 Evaporative condenser 1000 kW Evapco 28/38 WB/DB

2

4 Receiver as per Tender specification 1

5 4 point air purger 1

6 Ammonia dehydrator 1

7 Falling film chiller 755 kW with SS tank 1

8 Surge drum size 1200 x 2000 1

9 Falling film chiller 378 kW with SS tank 1

10 Surge drum sixe 1000 x 2000 with PUF supports 1

11 RM chiller 10000 LPH with byback of old PHE 1

12 Modification of existing 20000 LPH RM chiller 1

13 Ref controls & valves 1

14 Ref piping, fittings and insulation 1

15 CHW water piping with PUF insulation and valves

1

16 Structural material platforms, ladders etc. 1

17 MCC, control panel, Power and control cables earthing etc.

1

18 Ammonia Gas 1

19 Lub oil 1

20 Ammonia leak detection system

21 Safety equipment as per tender 1

22 Additional cost for remote monitoring, additional control, scada system including PC & printer ,UPS

1

Total price (A) =

B) Installation and commissioning charges (B) =

Total Bid Price i.e. A + B = Rs.

( Total Bid Price In Words Rs. )

Seal & Signature of Authorised signatory

TECHNICAL OFFER

FORMAT(To be given on the Letter head of Tenderer)

To,

The Managing Director,Kolhapur Zilla Sahakari Dudh Utpadak Sangh Ltd.,B-1, MIDC., Gokul Shirgaon, Kolhapur-416 234.

Sub : Technical offer for Refrigeration System.

Dear Sir,

With reference to the Tender Notice published in Daily , I/We submit the Technical offer for carrying out work of Refrigeration system for proposed expansion & revamping of existing refrigeration system at your Gogave milk chilling centre. I/We have thoroughly studided the details of this Tender and have studied Technical specifications and nature of entire work. We agree upon the technical specifications and details of equipemnt/material (No deviation with respect to Tender).

Thanking you,

Yours faithfully,

Seal & Signature of Tenderer.

Encl :1) D/D towrads EMD2) Company profile3) Technical details 4) Details of similar jobs executed during last three years.

( FORMAT )

COMPANY PROFILE

Name of the Tenderer

Address

Telephone Nos.

Web site

E. mail

GST Registration No.

Name of Authorised signatory

Desigantion of Authorised signatory

Tender for Refrigeration system - Gogave - Gokul for Refrigeration system.pdf · 11)Sealed Tender...

Documents

Transcript of Tender for Refrigeration system - Gogave - Gokul for Refrigeration system.pdf · 11)Sealed Tender...