| Reference | SDG5495P12/08 |
| Date | 4/24/2012 |
| Location | Asia |
| Scope | 1.0 Design. Manufacture, unitization and supply of a Truck Mounted Horizontal Mobile Steam Generator (MSG) unit as per following specifications: QTY: 4 Nos. 2.0 The successful bidder shall have to carry out the following works for supply of the Mobile Steam Generator. - To design and manufacture the Mobile Steam Generator. - To procure and supply truck chassis as per specification furnished in para 4.0 to 4.2 for mounting the Mobile Steam Generator Unit. - To unitize and install the steam generator unit on the truck chassis and to construct a weatherproof housing on the truck platform. 3.0 Technical Specification: Detailed technical specifications of the Mobile Steam Generator is as under. 3.1 Boiler / Steam Generator: The boiler shall have the following features. 3.1.1 Duty Condition: The boiler shall meet the following duty and working condition. Steam output capacity: 600-Kg/Hr dry and saturated steam at 100 Deg C Max. Working pressure: 42.2 kg/sq.cm (600 psig) Max. Steam temperature: 253 Deg C. Max. Time allowed to generate steam at the rated output and pressure of 42.2 kg/sq.cm from cold start: 3 to 5 minutes Design code: IBR 1950 / ASME 3.1.2 Type: Once through, water tube, coil type, laterally wound, force circulation, forced draft, 3 pass design horizontal type. 3.1.3 Design Code of Pressure Parts: The pressure parts must be designed and made as per latest edition of ASME/IBR code. 3.1.4 Coil Tube Design: The pressure parts including inner and outer coils must be made out of seamless boiler quality alloy steel tube suitable for high temperature and pressure service. The coil shall be technically wound with closed pitch except at the entrance of each pass. The winding shall be done in cold condition and the ovality of the tubes shall be within tolerable limits. The tubes shall be 100% radiographed at all circumferential welds before winding and the coils are fully stress relieved at elevated temperature as per IBR code requirement. The coil ends shall be flanged joined and independent of the feed water and main steam header. That is, replacement or maintenance of the tube bundle shall be independent of the headers. 3.1.5 Shell Design: The shell assembly comprises of a double shell arrangement containing the pressure parts as described above and to preheat the combustion air between the shells along with suitable radiator to reflect radiant heat to the convection zones. Necessary refractory work at the burner and far end shall be provided, using proper quality materials. The far end shell must be independent of the coil bundle. That is, the far end wall should be easily removable without disturbing the coil for maintenance. The shell shall be provided with a peephole for visual inspection of fire. 3.1.6 Fuel: The fuel for generating steam should be high-speed diesel (HSD). The bidder shall indicate the gross calorific value of the fuel and fuel consumption per hour at rated output. 3.1.7 Feed Water Quality: The bidder shall specify the feed water quality for smooth and efficient operation of the unit. 3.1.8 Prime Mover: The unit shall be equipped with an air cooled diesel engine of suitable HP of reputed manufacturer like KIRLOSKAR / RUSTON / CUMMINS / CATERPILLAR, complete with dynamo, charging alternator, electrical self starter with suitable maintenance free battery, clutch, drive pulley for power take off, air cleaner, fuel filter and speed regulator to run (a) air blower (b) fuel pump, (c) feed water pump and (d) Alternator of the Mobile Steam Generator. All the above units shall be direct belt driven. Belt guard shall be provided on all the V - belt assemblies. Suitable spark arrestor with silencer shall be provided at the engine exhaust and the engine exhaust shall be provided outside the boiler hut and it shall be suitably insulated. The engine shall have minimum 20% reserve HP. Power balance for the unit i.e. generation and consumption of power shall be clearly indicated in the bid. Alternative arrangement shall be provided for manual starting of the engine. The engine shall be firmly anchored to the skid, using vibration isolator of reputed make like DUNLOP. The minimum requirements for the engine shall be as below – a. Suitable air cooled diesel engine of adequate power and conforming to min. EURO-III emission norms. (Engine Emission Norms Certificate shall be submitted along with documents as mentioned in 7.0 (iii) by the supplier). b. The engine shall be complete with Tachometer & Hour meter in addition to all standard gauges & meters, Filters, Spark Arrester, etc., Emergency/ Safety Engine Shutdown system and anti vibration mountings. c. Electric engine starting mechanism (Lucas or Delco Remy Make) with heavy-duty maintenance free battery enclosed in a safety enclosure. d. Fuel tank capacity for minimum 12 Hrs. continuous full load operation. e. The engine with all other accessories, tanks, etc. shall be installed on a suitable skid with removable type steel protective frame cage equipped with lifting lugs for lifting of the complete unit. The skid shall have provision to facilitate installation of the same on a truck platform. In case of above system the alternator, its control panel, lighting scheme, earthing scheme, Electrical works & cabling etc. will be as per clause (3.1.9) - A/B/E/F/G below. 3.1.9 Alternative System All Pumps And Blower Will Be Electrical Motor Driven. The Details Of Electrical System And Devices Are As Under: A. Alternator: Power for all electrical equipment shall be provided by an air-cooled diesel engine driven (as mentioned in 3.1.8 above) acoustically enclosed 3- phase alternator. Air blower, fuel pump, feed water pump shall be driven by directly coupled electric motors. The alternator prime mover/engine shall have all the features of the engine stated above. The continuous Alternator KVA output at 40 deg C ambient shall be more than the sum of starting KVA of the biggest motor and the maximum running KVA of other electrical equipment. The engine shall be able to provide the required KW during motor starting & running. The engine output rating shall be on continuous basis at 40 deg C ambient and at rated alternator output KW. The engine & alternator rated output on continuous basis shall be at least 20% more than the continuous running electrical load. The bidder shall submit detail calculations for KVA rating of alternator & KW rating of the engine along with the bid. The ALTERNATOR Shall Meet the Following Technical Specifications: 1. Rated voltage: 415V (+/-) 6%AC 2. Rated frequency: 50 Hz (+/-) 3% 3. Phase: 3 phase, 4 wire system 4. Power factor: 0.8 lagging 5. Class of insulation for stator, rotor: F 6. Phase sequence: UVW 7. Rating: Continuous 8. Connection: Star 9. Alternator Internal Protection (enclosure): IP 23 10. Alternator cable terminal box protection: IP 54 11. Excitation system: Self excited & auto regulated. 12. The automatic voltage regulator shall ensure that voltage dip during starting of highest size motor with other electrical loads running at rated output shall not be more than 10% of the alternator rated voltage. 13. Mounting: Foot mounted 14. Suitable cable termination box for four core, copper conductor, steel armoured PVC insulated cable connection. 15. Alternator is to be mounted on anti-vibration pads. 16. Alternator shall have two external grounding terminals. 17. The following information in respect of the alternator shall also be provided: (i) Rated output, (ii) Motor starting ability, (iii) Voltage swing when rated load is suddenly switched on, (iv) Overload capacity, (v) Short circuit withstand capacity, (vi) Automatic voltage regulation, (vii) Unbalanced current withstand capacity, (viii) efficiency of alternator at 25%, 50%, 70% and 100% load (0.8 PF). 18. Alternator make shall be Stamford, KEC or CGL. Alternative make if offered will be subject to the company’s approval. 19. Alternator shall be guaranteed for a period of one year from date commissioning of the unit. 20. The alternator along with the Prime Mover shall be housed in an acoustic enclosure. B. Control Panel: Suitable Industrial type Control Panel shall be provided for the alternator. The panel shall comprise of the following: I. Four Pole, 415V MCCB, continuous current rating (AC23 duty) 25% higher than the genset full load current, adjustable thermal- magnetic overload & short-circuit release, breaking capacity of 25kA, with shunt trip coil. Qty - 1 No. Make: Merlin Gerin/ Legrand/ Siemens. ii. Earth-leakage relay with Core Balance Current Transformer. Range- 0.3 Amp to 3.0 Amp with adjustable time delay, indication LEDs, test and reset push button; Qty- 1 No. ELR shall trip the MCCB in case of an earth leakage. Make: Merlin Gerin/ Legrand. iii. Multifunction Digital meter for V, I, KW, Freq, KWH shall be provided. Current Transformer, type BPL, 5 amp output at rated primary current. Burden-15 VA, Class-I; Qty - 3 Nos.; Make of Meter: HPL-Socomac/ Merlin Gerin. Make of CT: Kappa/A.E./L&T. iv. Control fuses for protection of voltmeter and earth leakage relay v. LED indication lamp for indication of incoming 3 phase power supply; Qty-3 Nos C. Electric Motor: Induction motors of suitable rating (with adequate reserve HP) & RPM shall be provided for running the air blower, fuel pump and feed water pump. The motors shall have the following minimum specification: (a) Voltage: 415V (-+/-) 6%AC (b) Frequency: 50 Hz (+/-) 3% (c) Duty: S-l (Continuous) (d) Enc1osure : Tota11y enc1osed Fan Coo1ed (TEFC) (e) Class of insulation: F but limited to temperature rise of B class insulation. (f) Degree of protection: IP 55 (g) Suitable cable termination box (h) 2 Nos. suitable earth terminals shall be provided (i) Standard: Motor should confirm to IS-325 for performance. (j) Motor shall be guaranteed for one year from date of commissioning of the unit. (k) Make: KEC or CGL or BHARAT BIJLEE. The motors shall be directly coupled through direct, flexible couplings and complete with coupling guards. D. Motor Control Center: A suitable MCC panel shall be provided for starting the above motors. The MCC panel shall have the minimum technical specification as under: (a) INCOMER: Qty -1 No. It s shall comprise of the following: (a1) TPN combination switch fuse unit with current rating as per CFS unit of control panel. Make: Siemens/GEPC/L&T. (a2) Multifunction Digital meter for V, I, KW, Freq, KWH shall be provided. Current Transformer, type BPL, 5 amp output at rated primary current. Burden-15 VA, Class-I; Qty - 3 Nos.; Make of Meter: HPL-Socomac/ Merlin Gerin. Make of CT: Kappa/A.E./L&T (a7) Control fuses for protection of meter - 3 Nos. (b) BUSBAR: A suitable length of 4 Nos. (Three phases and one neutral) electrolyte grade high conductivity tinned copper busbar shall be provided. Continuous current rating of the busbar shall be two times the current rating of the incomer CFS unit. Busbar support shall be provided with SMC (sheet moulding compound) material. Busbar shall be insulated with heat shrinkable PVC sleeves. (iii) Outgoing Motor & Lighting Feeder: Direct on line (DOL) starter for motors up to 5 hp and star/ delta for motors above 5 hp shall be provided along with one no. spare starter for highest sized motor. Besides starters one no. lighting feeder (Fitted with fuses and switch) and one no. spare feeder (Fitted with 25 amp TPN CFS unit) shall be provided. Starters shall have following components. (c1) TPN switch fuse unit, panel mounted type with HRC Fuses, Make: Siemens/GEPC/L&T. (c2) TP power contactor with auxiliary contacts. Make : Siemens/L&T. (c3) Thermal Overload relay with in built single phasing preventer. Qty – 1 No.; Make: Same as contactor. (c4) Start & Stop push button; Qty - 1 set; Make: Siemens/L&T. (c6) ON/OFF/Trip Indication; Qty - 1 set; Make: Siemens/L&T. (c7) 2 Nos. control fuses for control circuit E. Lighting Detail: Sufficient nos (minimum 2 nos) of industrial type, 125W, MV, 240V, IP55 well glass fittings shall be provided inside the unit for achieving illumination level as per NEC code. Make: Philips/Bajaj/GE. F. Earthling Details: The entire earthing work shall confirm to IS-3043. Two nos. 25x5 mm galvanized GI straps shall be mounted suitably inside the unit. Two nos. earth connections from alternator, motors, control panel & MCC shall be connected to these straps so as to ensure two earth connections for each device. The generator neutral shall be earthed to the earth straps with suitable sized insulated copper cables. Bidder shall specify the neutral cable size. Earthing scheme shall be as per IS-3043. G. Electrical Works & Cables Entire electrical installation work will be as per BIS, IE Rules & NEC Codes. All items used shall conform to relevant IS. The layout plan & electrification work shall be planned considering safety of operating staff, equipment & maintenance aspect. All cables will be terminated through suitably sized Heavy duty single compression glands and connections will be made through properly rated terminal strips and tinned copper sockets crimped rigidly to the copper conductors. H. Illumination: Interior of the unit shall have sufficient illumination with Metallic conduit wiring/ Armoured cable wiring using stranded copper conductor cables approved by ISI. Light fittings shall be industrial type fluorescent fittings, protected with acrylic , transparent cover. MCB shall be used as Switches for illumination system and shall be housed in Metallic enclosure. One no. Industrial type socket outlet of 10 amp with 10 amp MCB shall be provided inside the unit. Make: Philips/ Baja/ Crompton/ GE I. Documents: Complete scheme for detail of electrical system including genset, conrol panel, earthing, illumination, MCC, Motor, wiring scheme shall be submitted with the offer. Three sets of above scheme along with test report, inspection report and all drawings of electrical system and guarantee certificate for electrical items shall be submitted with the unit. 3.1.10 Fuel Burning Combustion System: The Fuel Burning System Of The Boiler Shall Comprise Of The Following – (a) Burner: The burner shall be pressure jet, direct electric spark ignition type using spark electrodes/plugs and high tension power supply from inverter/magneto of a well proven design comprising of burner gun, electrode, air fuel mixing devices, ignition transformer and other accessories if any, all rated for continuous duty service. The burning system shall be adequate to produce heat required for generating steam at the desired rate within 3 to 5 minutes of cold start. Make – Monarch. Manual describing combustion principle for steam generation is to be submitted. (b) Combustion Air Blower: Centrifugal type air blower of suitable capacity is to be driven directly either by the diesel engine through belt drive or by directly coupled electric motor complete with all the accessories for power transmission. It shall also be provided with an over pressure relief valve. (c) Fuel Pump: Gear type fuel pump suitable for pumping HSD or any second grade fuel oil, either mounted on the same shaft as that of the air blower driven by the diesel engine through belt drive or by directly coupled suitable electric motor. The fuel pump shall be complete with all accessories required for power transmission. It shall also be equipped with internal over pressure relief arrangement / automatic by-pass control valve. Make – Sofag, Sunstrand or Neel. The position of the pump should be easily accessible for maintenance. (D) Diesel Oil Tank: HSD tank of suitable capacity, based on the feed water tank capacity and fuel consumption rate, for continuous full load operating time made of MS sheet, complete with inlet and drain nozzles fitted with valves, graduated level gauge shall be firmly anchored to the skid to withstand severe wrenching and shocks. Necessary MS pipings up to the diesel engine and boiler fuel pump should be provided. (e) Manual Hsd Filling Pump: One (1) no. hand operated HSD filling pump (gear type) complete with suction and discharge flexible rubber hoses for filling HSD tank shall be mounted near the tank. While the length of the discharge hose shall be as per assembly requirement, the length of the suction hose shall not be less than 40 ft. 3.1.11 Feed Water Pump: Triplex reciprocating plunger type positive displacement pumps of suitable capacity of a reputed manufacturer like SPECK etc. to be driven either by the diesel engine through belt drive or by directly coupled suitable electric motor complete with all accessories for power transmission. The pump shall be complete with fluid over pressure relief valve, suction stabilizer and pulsation dampener. The bidder shall clearly specify volumetric capacity, pump HP and other technical details. Pipings shall be provided for connecting the water pump to the coil inlet. A suitable strainer shall be provided at the suction of the pump to remove foreign materials. The position of pump should be easily accessible for maintenance. 3.1.12 Feed Water Tank: Tank/s made of MS sheets with suitable anti-corrosive paint of capacity not less than 4000Litre, fitted with inlet, outlet, drain and vent nozzles (in each tank) fitted with valves, level indicator/gauges shall be provided. The tank shall be properly designed to reduce water surging on turns and withstand violent wrenching and shocks. It shall be firmly anchored to a skid mounted above the chassis as shown in the attached layout diagram. The tanks shall be easily detachable from main unit for cleaning and maintenance without dismantling other units. If the tanks are made in several sections, then each section shall have isolating valve and individual tank drainage facility. Suitable air vent nozzle shall be provided in each tank to eliminate air pockets while filling up. Proper care shall be taken that the tanks are suitably connected to the feed water pump and there is no starvation of water to the pumps. 3.1.13 Steam Header: The steam header for mounting safety relief valves, steam pressure indicator, high steam pressure switch, coil blow down valves including steam stop, auxiliary and check valves. The steam header shall have flanged ends for mounting all the valves. 3.1.14 Ducting: Ducting shall be provided for the flue gases from outlet of the boiler complete with a rain head outside the boiler housing. 3.2 Piping: Piping to connect water pump, boiler as well as steam outlet shall be of boiler quality duly certified by the competent authority. Suitable insulation shall be done up to the rear of the boiler housing. Drain piping for fuel, feed water and steam coil shall be suitably provided. 3.3 Steam Hose/Pipe: 25mm (1") NB 12 metre long flexible metal braided high pressure hose for steam working pressure of 70 kg/sq.cm (1000 Psig) at 100 Deg C. complete with quick release coupling at each end shall be provided. Or Alternatively: A set of 25 mm (1") NB pipes of 70 kg/sq.cm (1000 Psig) working pressure duly insulated with quick release couplings at each end shall be provided. The far end of the pipe shall be 12 m away from the steam outlet of the boiler along the ground. Accordingly, necessary elbows/bends and short joints with quick release couplings shall be provided. 3.4 Valves: The boiler shall be equipped with 2 nos. each of coil blow down valves (at suitable position for easy operation), safety relief valves, steam stop valves (suitably covered for safe operation) and feed check (non-return) valves for coil blow down, over pressure release, steam shut off and preventing reverse flow respectively. These valves are minimum requirement for the unit. All the valves shall be IBR quality flanged type valves. The bidder has to provide necessary document in support of this along with the quotation. 3.5 Msg Control Panel and Instrumentation: A. The control panel shall be designed based on state of the art technology PLC/SLC system suitable for Mobile Steam Generation (MSG) operation. The fault functions shall be both visually and audibly indicated on the unit’s control panel and shall remain ‘ON’ until manually reset. It will have sequence starting system to ensure that all functions associated with starting operation are performed in correct sequence. The initiation shall be by means of a switch of push type, on the unit control panel. Provision shall also be incorporated for emergency shutdown of the MSG unit. The MSG units shall be provided with automatic safety shutdown devices and annunciation system with fuel cut-off. Shutdown Devices with Audio-Visual Alarm for the Following Conditions Should be Offered i. Flame failure ii. Steam Pressure high iii. Steam Temperature high iv. Low feed water pressure v. Low fuel oil pressure vi. Blow down valve open Sequence and Control for the Following Conditions Should be offered i. Primary safety checks ii. Start of blower fan and fuel pump iii. secondary safety checks iv. Start ignition and fuel supply v. Prove Pilot Flame establishment vi. Continue operation till high steam pressure reached vii. On-off operation set pressure failure viii. Safety lock out for flame or any other safety shutdown condition as mentioned above B. Field and panel mounted indicating instruments shall also be available to monitor various process parameters. Panel mounted indicating meter (Analog type, preferably 4–20 mA) i. Steam temperature Panel mounted Indicating lamp & Switches Indicating Lamp: ii. 230 V AC ON iii. Safety Lockout Internal iv. Start v. Flame ON vi. Water Pump On vii. Water Pump Off viii. Water Pump Trip ix. Fuel Pump ON x. Fuel Pump OFF xi. Fuel Pump Trip xii. Air Blower ON xiii. Air Blower Off xiv. Air Blower Trip xv. Steam Temperature High xvi. Steam Pressure High xvii. Low Steam Pressure xviii. Low Air Pressure xix. Low Fuel Pressure xx. Low Fuel Oil level xxi. Low Feed Water level xxii. Blow down valve open status Switches (Push Buttons): xxiii. Start Push Button xxiv. Stop Push Button xxv. Alarm Test Push Button xxvi. Alarm Accept PB xxvii. Alarm Reset PB xxviii. Start PB for water pump xxix. Stop PB for water pump xxx. Start PB for fuel pump xxxi. Stop PB for fuel pump xxxii. Start PB for air blower xxxiii. Stop PB for air blower xxxiv. Auto/Manual water pump selector switch xxxv. Auto/Manual fuel pump selector switch xxxvi. Auto/Manual air blower selector switch xxxvii. 230 V AC power ON/OFF switch Field mounted instruments (Analog type) xxxviii. Steam Pressure gauges xxxix. Feed water pressure gauge xl. Steam temperature gauge xli. Indicating thermostat or temperature switch for steam temperature, with a set point for high temperature(superheat alarm) xlii. Steam pressure switch for both high & low xliii. Air pressure switch xliv. Pressure switch for fuel oil xlv. Pressure switch for feed water xlvi. Level switch for fuel oil level xlvii. Level switch for feed water level xlviii. Limit switch for blow down valve xlix. Alarm rest, engine start and main switch l. Tachometer, lube oil pressure indicator, temperature indicator for the diesel engine. C. Ignition of burner should be carried out using ignition transformer and ignition electrodes operating at 230 V AC, 50 Hz. D. Steam temperature controller function shall be incorporated in the PLC programme. E. A low voltage/under voltage( less than < 180 V AC) indication of Instrument Panel incoming power(230V AC, 50 Hz) to be provided. F. All three phase (415V, 3PH, 50Hz) motor starter relays, overload relays, current transformers etc should be placed in the control panel in such a way that no high voltage interference will occur in the PLC side. Therefore , the control panel should be designed like that upper half of the panel should include all instrumentation items and lower half of the panel should include all three phase electrical component including ignition transformer with proper isolation. G. The control panel shall be mounted in such a way that it can absorb maximum shock/vibration. Rubber pads of suitable size shall be used for this purpose. H. The control panel shall have an entry for easy access and shall be suitable for use in IP-65 environment. The control system shall be designed in such a way that failure of portion of the system shall not jeopardize the health of the MSG unit i.e. the health of various auxiliaries as well as the steam generation availability shall be always ensured. I. All the indication as well as sequence, interlock, startup and safety shutdown through PLC using analog / digital I/O cards. Also preferred analog / digital indication in the panel as mentioned in Para 2.0. J. The control panel shall include a programmable logic controller (PLC) with the following features to cater the operational need of the boiler. i. Indication of status of inputs and outputs for easy debugging ii. Expandable inputs/outputs iii. Program memory held in EPROM iv. Communication port for connection to PC or laptop computer v. Designed to work in boiler environment vi. Battery backup for retaining memory in case of power failure 4.0 Truck Unit Brand-new Truck Chassis of Make: Tata, Leyland, MAN, Volvo / Eicher with Factory Built sleeper type driver’s cabin and having following specifications, in general. The make and model of the truck chassis offered is to be clearly indicated in the bid. – (A) Chassis i. Drive 6 x 2 drive – (To note para 4.1.b.), Right Hand Drive - steering on Right Hand side of the vehicle ii. Cowl Full Forward Control. iii. Engine Suitable Water-cooled diesel engine delivering not less than 140 HP - To note para 4.1.b. iv. Emission norms Minimum EURO - III / BS - III compliant. v. Gearbox Minimum 5 forward speed & 1 reverse speed. vi. Steering Hydraulic power assisted. vii. Wheelbase Min 4600 mm - To note para 4.1.b. viii. Overall length 8500 mm – 9500 mm ix. Maximum width (With MSG cabin) 2400 mm x. Suspension Semi-elliptical multi-leaf springs in all axles with shock absorbers. xi. Maximum permissible GVW Not less than 20,000 Kg. The maximum permissible GVW should be such that the total laden weight is not more than 75% of that GVW (note para 4.1.b). xii. Rear Overhang (ROH) ROH should be as per original chassis; extension of chassis to accommodate Steam Generator unit/rear housing is not acceptable. xiii. Brake Duel Circuit Full Air Service Brake and Spring Actuated Parking Brake acting on rear wheels. xiv. Wheels & Tyres Tyre Size min. 10.00 x 20. xv. Electrical system 12/24 Volt system preferably with Lucas-TVS make starter, alternator, etc. xvi. Ground clearance Minimum 250 mm. (B) Driver’s Cabin Factory Built sleeper cabin with following specification/accessories - i. All steel structure construction with non-slippery Chequered Plate flooring. ii. 2(two) lockable doors with glass window (moving up & down). iii. Side windows on both sides with lockable sliding glass. 1(one) No. fulllength rear window with sliding lockable glass and steel wire mesh guard. iv. Adjustable driver’s seat with shock absorber. v. 1(one) No. Co-driver’s seat on the left side of the driver’s seat. Additional 1(one) bench type seat made of foam rubber cushion with full backrest suitable for minimum 3 (three) persons at the back of drivers’ seats. Total seating capacity of the cabin is to be for min. 5 persons. vi. Suitable roof lamps and fan(s). vii. Windscreen of laminated non-splinter glass. Sliding window glasses of toughen type. (C) Other Fitments & Accessories a. All standard equipments, gauges and meters, air horn, lightings, reflectors, sunshades, lockable fuel tank with strainer, standard tool kit, lockable toolbox (inside the cabin), hydraulic jack of capacity min. 30MT, handle & wheel wrench, mud flaps, etc. b. One additional lockable toolbox of size min. 1.00m x 0.50m x 0.50 m under the truck platform at suitable location. c. 2(two) Nos. large rectangular rear view mirrors on each side of the cabin. d. Well-covered lockable Battery Box preferably outside the driver’s cabin, suitable mounting arrangement for the spare wheel and towing hooks at rear and front. e. Audio visual alarm ((Reversing Horn with blinking light) at reversing of the vehicle. f. First Aid Box, Glove Box, Fire extinguisher(s) and all other statutory fittings/accessories. (D) Platform a. A suitable platform is to be constructed on the truck chassis to mount the skid(s) with all the items of the Steam Generator Unit (SGU) described at para. 3.0 to 3.5 above and to construct a weatherproof housing as detailed at para 5.0 below. The skid (two layer skid- bottom layer for the water storage tanks & above layer for the platform housing) shall be properly mounted in the chassis and for the same, adequate number of cross members in the skid is to be provided. Width and length of the platform should be as per original width of cowl/driver’s cabin and length of chassis. Extension of chassis to accommodate the skid(s)/housing of SGU or any additional overhang of the housing is not acceptable. b. The platform is to be made out of MS channels with min. 5(five) mm thick MS chequered plate flooring. c. It should be strong enough to carry the load of all the equipments as well as shock load during movement. d. For aesthetic look, extended paneling of the canopy housing is to be made to cover the tank portion of the unit. This extended portion shall either be screwed with the main paneling or is to be fixed with hinge with the main housing frame. In case of hinge, proper anchoring is to be made to hold the lifted panel. 4.1 Special Note on Selection of Truck Chassis a. The total weight of the Stem Generator Unit with full capacity water, housing (rear cabin of SGU), all fittings, etc. as described at para. 3.0 to 3.5 above & 5.0 below is to be indicated in the bid. Approx. weight of the truck with driver’s cabin & platform is also to be indicated. b. The maximum permissible GVW of the truck should be such that the total laden weight (mainly weight of the truck chassis with driver’s cabin & platform + Weight of SGU with water and housing) is not more than 75% of that GVW. Accordingly, the truck chassis specifically with respect to GVW, Engine HP & Wheelbase is to be selected and offered/quoted. c. Positioning of the items of the SGU on the platform should be such that the load is distributed evenly on the platform. 4.2 Painting Exterior of Driver’s Cabin - Deluxe Imperial Crimson. Interior of Driver’s Cabin - Light Shade as per standard. Chassis & undercarriage - Rustproof painting. 6. Spares: a) COMMISSIONING SPARES: The Supplier has to supply all the spare parts required for initial commissioning of the unit. b) Operational critical spares: Supplier shall supply the following operational critical spares along with the supply of the EACH UNIT: I. 1 ˝” Globe type valve – 2 Nos II. 1” globe type valve – 3 Nos III. Fuel pump (Suntec/Danfos) – 1 No IV. Water pump -1 No V. 1 ˝” non-return valve- 2 Nos VI. Ignition transformer – 1 No VII. Spray nozzle – 1 No VIII. Safety valve – 1 No IX. Steam coil – 1 No X. Blower – 1 No XI. Alternator – 1 No XII. Ignition Electrodes 3/8”- 1 No XIII. ˝” Non-return valve - 1 No XIV. 1” Flange type globe valve – 3 Nos XV. 1” check Valve – 2 Nos XVI. 1 ˝” Flange check valve – 1 No XVII. 1 ˝” flange type Globe valve- 2 Nos XVIII. Cont RPM shall be provided for running the air blower, fuel pump and feed water pump.’s control panel and shall remain ‘ON’ until manually reset. It will have sequence starting system to ensure that all functions associated with starting operation are performed in correct sequence. The initiation shall be by means of a switch of push type, on the unit control panel. Provision shall also be incorporated for emergency shutdown of the MSG unit. The MSG units shall be provided with automatic safety shutdown devices and annunciation system with fuel cut-off. Shutdown Devices with Audio-Visual Alarm for the Following Conditions Should Be Offered i. Flame failure ii. Steam Pressure high iii. Steam Temperature high iv. Low feed water pressure v. Low fuel oil pressure vi. Blow down valve open Sequence and Control for the Following Conditions Should Be Offered i. Primary safety checks ii. Start of blower fan and fuel pump iii. secondary safety checks iv. Start ignition and fuel supply v. Prove Pilot Flame establishment vi. Continue operation till high steam pressure reached vii. On-off operation set pressure failure viii. Safety lock out for flame or any other safety shutdown condition as mentioned above B. Field and panel mounted indicating instruments shall also be available to monitor various process parameters. Panel mounted indicating meter (Analog type, preferably 4–20 mA) i. Steam temperature Panel mounted Indicating lamp the motors shall have the following minimum specification: (a) Voltage: 415V (-+/-) 6%AC (b) Frequency: 50 Hz (+/-) 3% (c) Duty: S-l (Continuous) (d) Enc1osure : Tota11y enc1osed Fan Coo1ed (TEFC) (e) Class of insulation: F but limited to temperature rise of B class insulation. (f) Degree of protection: IP 55 (g) Suitable cable termination box (h) 2 Nos. suitable earth terminals shall be provided (i) Standard: Motor should confirm to IS-325 for performance. (j) Motor shall be guaranteed for one year from date of commissioning of the unit. (k) Make: KEC or CGL or BHARAT BIJLEE. The motors shall be directly coupled through direct, flexible couplings and complete with coupling guards. D. Motor Control Center: A suitable MCC panel shall be provided for starting the above motors. The MCC panel shall have the minimum technical specification as under: (a) INCOMER: Qty -1 No. It s shall comprise of the following: (a1) TPN combination switch fuse unit with current rating as per CFS unit of control panel. Make: Siemens/GEPC/LT. (c3) Thermal Overload relay with in built single phasing preventer. Qty – 1 No.; Make: Same as contactor. (c4) Start actors – 1 Set XIX. Overload relays – 1 Set XX. Fuses – 1 Set XXI. Lamps- 1 Set a. All spares in specified quantity as indicated above shall be supplied along with each unit. b. Specific description, Part Nos., Make etc. and Unit Price of each and every item shall clearly be indicated in the bid. c. Bidder shall also quote separately for any additional spares with similar details as felt necessary for 2 (two) years trouble free operation and maintenance. However, cost of the spares will not be considered for bid evaluation. c) Recommended spares: The bidder is to furnish a list of spares & components that will be required for regular operation and maintenance, overhauling etc. throughout the life of the equipment complete with price of each item. Annual consumption of each spare should be furnished. The bidder should also provide detailed spare list of all the items including bought out items in the operation and maintenance manuals. The list should include a spare parts list along with OEM part numbers, make & model of the equipment and contact postal address of OEM for all items of the whole unit. d) The bidders must submit a written undertaking (along with the bid) that they would be able to supply all the requisite spares and consumables (including bought out items) for a minimum period of 10 (ten) years from the Certified date of completion / successful field commissioning of the unit. |
| Documents Price | USD 100.00 |
