Techno-Commercial Offer

OSM ENGINEERING Pneumatic Conveying Pvt. Ltd. An ISO 9001 : 2008 Company

OSM House, Sec, 59, Plot No.53, Pragati Vihar, Ballabgarh, Distt, Faridabad (Hr.)Tel. : +91-129-4275101–20 Fax No. : 4275151Mob. : 9811322996, 9911335414,9891989292

Ref: OSME/AIL/EH/2009-10/3334 November 27, 2009

M/S AARTI INDUSTRIES LTD.PLOT NO.285, 286/1, GIDC ESTATE,PHASE-II, VAPI-396195,GUJRAT.

KIND ATTN. : MR. C.C.PATEL. (MANAGER-MAINTENANCE)

SUBJECT : Techno-commercial Offer for Ash Handling System for 30 , 18 & 13 TPH FBC Boiler.

REFERENCE : Site Visit Dated 13/11/09.

Dear Sir,

We thank you for the courtesy extended to our Mr. Deepak Kumar – Engineer Marketing during his visit to your site. Based on the discussions held and details collected at site, we hereby take pleasure in submitting our “Techno - Commercial Offer” for your kind perusal.

We hope you will find our offer in line with your requirement. Should you need any additional information/clarification, do contact us.

Thanking you

Yours Faithfully,For OSM ENGINEERINGPNEUMATIC CONVEYING PVT. LTD.

EJAZ HABIB (General Manager - Marketing)


WORKS : Sikri Industrial Area, Village – Sikiri, Main Mathura Road, Faridabad – 121004 (Haryana) E-mail : [email protected], [email protected], [email protected], http:www.osmindia.com

mailto:[email protected]





List of Annexures

1. Annexure - 1 : Design Basis2. Annexure - 2 : Considerations/Assumptions/Deviations3. Annexure - 3 : Brief System Description4. Annexure - 4 : Utility Requirements5. Annexure - 5 : Scope of supply6. Annexure - 6 : Exclusions7. Annexure - 7 : Electrical write up 8. Annexure - 8 : Terminal points.9. Annexure - 9 : Price schedule.10. Annexure - 10 : Commercial terms & conditions11. Annexure - 11 : Technical data sheet.12. Annexure - 12 : List of major bought out items.

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Annexure : 1Ref: OSME/AIL/EH/2009-10/3334 November 27, 2009

DESIGN BASIS

No. of Boiler 3 Nos.

Fuel 100 % Indian coal

Boiler Capacity 1x30 TPH 1x18 TPH 1x13 TPH

DESCRIPTION ESP-I ESP-II ESP-III Cyclone Cyclone

No. of Hopper 1 1 1 2 2

Total Ash Collection Rate per Hopper (TPH)

- Actual 0.325 0.166 0.166 0.166 0.175

- Design 0.65 0.332 0.332 0.332 0.35

Ash Temp. (deg C) for Design 150 150 150 200 200

Bulk Density(kg/m3) 700

No. of bends in conveying line(max. considered)

5 Nos. (90 deg) in each line.

Particle size distribution (Assumed to be 100 % less than 300 microns)

Moisture content Nil

Ash discharge to 1 No. Fly Ash Silo

Headroom available in Mtr. Between 1.0 to 1.2

Conveying distance in M (H+V)

40 35 30 100 60

essel inlet Valve200 NB 200 NB 200 NB 200 NB 200 NB

Note : We have designed the system based on the details mentioned in the above Proposal Basis. In case of any change please intimate as change in any of the above parameters may result in change in design.

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Annexure : 2








CONSIDERATIONS / ASSUMPTIONS / DEVIATIONS

We have considered / assumed / taken deviations of the following while preparing our offer.

1. Our offer is based on the details furnished in the “Design Basis” of our offer.

2. The particle size is not mentioned in your email enquiry so we have assumed the sameto be 100 % less than 300 microns. Kindly note & comment.

3. With reference to our discussions at plant the ash temperature was given by you as mentioned in our design basis.

4. With reference to our discussion at plant the headroom availability was given by you as mentioned in our design basis. As the headroom is less a small pit of suitable size may need to be provided by you below the ash hoppers to accommodate the conveying equipments.

5. For the control of the system we have considered a common PLC based control panel with mimic. This PLC shall be provided with communication facility with plant DCS.

6. The control / signal cables shall be provided from the field instruments to the local pneumatic panel provided on each vessel which act as Junction Box. The cables from these JB’s to the PLC panel shall be provided by you. Also the communication cable from the PLC to plant DCS shall be provided by you.

7. We are assuming that instrument air required for the ash handling system shall be given at one point near any of the boiler by client. Please clarify.

8. We have considered the ash silo in our scope of supply.

9. We have considered 2 Nos. (1W+1SB) Oil Injected Screw Type Conveying Air Compressors common for all the boilers.

10. The fluidizing air for the silo shall be met from the compressed air system.

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Annexure : 3


BRIEF SYSTEM DESCRIPTION

1x30 TPH ASH HANDLING SYSTEM :

ESP ASH HANDLING SYSTEM :

There are 3 fields of ESP hoppers. Beneath these ash hoppers we propose to provide suitable M.S. adopter / chute with a manually operated plate valve for isolation purpose, flexible joint to take care of any undue stress caused through thermal expansion and ash conveying vessels.The ash conveying vessels provided below the hoppers of ESP 1ST field shall be provided with independent conveying pipeline, whereas the ash conveying vessels provided below the hoppers of ESP 2nd & 3rd fields shall be provided in series in master slave arrangement (1 master +1 slave) & provided with common conveying pipeline.

The conveyed material shall be discharged into the Fly Ash Storage Silo with the help of an end receiver provided at the end of conveying pipeline.

Suitable fluidizing pads shall be provided in ESP hoppers to facilitate free flow of ash in the conveying vessels.

Suitable nos. of Level Probes shall be provided at the ESP hoppers to initiate the conveying cycle.

1x18 TPH ASH HANDLING SYSTEM :

CYCLONE ASH HANDLING SYSTEM :

There are 2 hoppers for cyclone. Beneath these ash hoppers we propose to provide suitable surge hoppers with a manually operated plate valve for isolation purpose, flexible joint to take care of any undue stress caused through thermal expansion and ash conveying vessels. The ash conveying vessels below the cyclone hoppers shall be provided in series in master / slave arrangement (1master +1slave). The proposed pneumatic transporters shall convey the fly ash at specified rate through a common heavy duty MS conveying pipeline to the Fly Ash Storage Silo. The conveyed material shall be discharged into the Fly Ash Storage Silo with the help of an end receiver provided at the end of conveying pipeline.

Level Probe is provided at the surge hopper of conveying vessel to initiate the conveying cycle.

The same scheme shall be followed for 13 TPH FBC Boiler

.

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Annexure : 4


UTILITY REQUIREMENTS

CONVEYING AIR

To meet the conveying air requirements all the boilers we propose to provide 2 Nos. (1W+1SB) Oil Injected Screw Type Conveying Air compressors of suitable capacity at 4.5 - 5.5 bar (g).

INSTRUMENT AIR

The total requirement of instrument air shall be about 0.5 M3/min. FAD at 6-7 bar(g).

SPRAY WATER

The spray water requirement shall be about 2 M3/hr. at 2.0 kg/cm2.

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Annexure : 5







Ref: OSME/AIL/EH/2009-10/3334 November 27, 2009SCOPE OF SUPPLY

Our Scope of work consists of Design, Engineering, manufacturing, Painting, testing and supply of following equipments.

S No. DESCRIPTION Quantity

A) ESP ZONE FOR 1X30 TPH BOILER

1. Suitable MS adopter / chute 3 Nos.

2. 200 NB Manually operated plate valve 3 Nos.

3. 200 NB Expansion Joint 3 Nos.

4. Level probe for cycle initiation To suit

5. Ash conveying vessel with local controls 3 Nos.

6. MS Black ERW (Heavy as per IS:1239) conveying pipeline with MS flanges, fasteners, gaskets and clamps

2 Lot.

7. Long radius Cast Basalt Bends in segments of 450 or to suit.

2 Lots.

8. Terminal Box 2 Nos.

FOR 1X18 & 1&13 TPH BOILER

B) CYCLONE HOPPER Quantity / boiler

TOTAL QTY. FOR BOTH BOILERS

1. Suitable MS surge hopper 2 Nos. 4 Nos.

2. 200 NB Manually operated plate valve 2 Nos. 4 Nos.

3. 200 NB Expansion Joints 2 Nos. 4 Nos.

4. Level Probe for cycle initiation To suit. To suit.

5. Ash Conveying vessels with local controls 2 Nos. 4 Nos.

6. MS Black ERW (Heavy as per IS:1239) conveying pipeline with MS Flanges, fasteners, gaskets and clamps

1 Lot. 2 lots.

7. Long radius Cast Basalt bends in segments of 450 or to suit.

1 Lot. 2 lots.

8. Terminal Box 1 No. 2 Nos.







C) Equipments For Silo Area

1. Vent Filter (Reverse pulse jet type) 1 No.

2. Level Probe for high level indication 1 No.

3. Pressure Relief Valve 1 No.

4. 10 TPH Single Shaft Ash Conditioner with Rotary Vane Feeder and manually operated plate valve

1 Set.

5. Fluidizing pads at the conical portion of silo 1 Set.

D) COMMON ITEMS

1. Oil Injected Screw Type Conveying Air compressors with drive 2 Nos.(1w+1s))

2. Air Receiver in MS construction of suitable capacity and necessary attachments for conveying air

1 No.

3. Air / Water Pipeline with manual valves required for the system and as mentioned in the terminal points.

1 Lot.

4. Mating flanges & fasteners for complete system. 1 Lot.

E) ELECTRICALS

1. PLC based control cum mimic panel 1 No.

2. Cables from field instruments up to junction box / pneumatic panels and from pneumatic panel to the PLC panel

1 Lot.

3. Local silo unloading panel 1 No.

F) STRUCTURALS

1. Common M.S. ash silo of capacity 50 M3 with supporting structure, platform, staircase and roof cover.

1 No.

2. Pipe rack with supporting structure. The pipe rack shall be without walkway but with maintenance platform at the bends area

1 Lot.

3. Foundation bolts & packers for pipe support columns. 1 Lot.







Annexure : 6


EXCLUSIONS

1. All Civil work, buildings & foundations.

2. Water for spray at required rate and pressure within an area of 5-10 M from the silo.

3. Instrument air at 6 Bar within an area of 5-10 m from the boiler.

4. All electrical and instruments like DOL/RDOL starters, DCS, UPS, Power Cables, control / signal cables with cable trays from local pneumatic panel of vessel (JB’s) to PLC and communication cables from PLC to DCS, plant illumination, lightning arrestor, underground earthing with grid/pit.

5. Any other equipment /services not specifically mentioned in our scope of supply.

6. Any dismantling/rectification of the existing system.

7. Any mechanical handling equipment including cranes / hoists etc.

8. Any modification /rectification /dismantling if /as required.

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Annexure : 7


ELECTRICAL WRITE – UP

PLC BASED CONTROL CUM MIMIC PANEL

One No. common PLC based control cum mimic panel has been considered for the ash handling system for both boilers. PLC based control cum mimic panel shall be vertical type, freestanding floor mounted with bottom cable entry. Allen Bradley or equivalent PLC of the other makes has been considered for the system.PLC will be mounted inside PLC based control cum mimic panel. The PLC based control cum mimic panel shall be fabricated with 2 mm thick CRCA sheet as per manufacturer's standard design practice.

The PLC system complete with non-redundant processor, Power supply, and 1/0 Cards has been considered for the offered system. The 24 V DC bulk power supply shall also be non-redundant. Each digital input and output card shall be 16/32 Channels as per manufacturers' standard. Digital inputs shall be potential free, which shall be interrogated by 24V DC. All digital outputs from PLC shall be 24V DC which drive interposing relays (these shall be used for energization of solenoid valves having coil voltage 1 10 / 220 VAC).

Purchaser shall provide stabilized, uninterrupted control power supply for PLC system.No graphic software has been considered in our scope of supply

Make of panel shall be :

RYB Switchgear / System House of Siemens / Radha Krishna Controls / Vidyut Control/ And Electrical

Make of PLC shall be Allen Bradley /GE Fanuc /ABB /Siemens.

Local Silo Unloading Panel :

1 No. Local Silo unloading panel shall be provided for silo and the same shall be placed on the silo operating platform. These shall be wall/column mounted type and shall be fabricated from CRCA sheet. All push buttons/indications for unloading system shall be carried out from this local panel. This unloading panel shall not be hooked up with Purchaser's DCS panel. All the cables from silo top equipments shall also be terminated in the Silo unloading panel. As such we are not envisaging any separate Junction box on silo top for the purpose.

Make of Silo unloading panel shall be:

RYB switchgear/ Vidyut Control / Advance panel & swgr/ TricotWORKS : Sikri Industrial Area, Village – Sikiri, Main Mathura Road, Faridabad – 121004 (Haryana)

E-mail : [email protected], [email protected], [email protected], http:www.osmindia.com






Power Cables :Power cable shall be 1.1 KV grade, PVC insulated, PVC sheathed, armoured type, with stranded

Aluminium conductor confirming to IS-1554.

Control Cables :

Cables shall be 1.1 KV grade, PVC insulated, FRLS PVC sheathed, arm round type, multi core with copper conductor of 1.5 sq. mm size.

Signal Cables :

Signal cables shall be multi pair, color coded, PVC insulated, arm round type with 1.5 sq. mm size annealed copper conductor.

Note : We have included Control / signal cables field instrument to our junction boxes only in our scope of supply.

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Annexure : 8


TERMINAL POINTS

Ash : Inlet of surge hopper below ESP / cycloneOutlet of Ash Conditioner

Instrument Air: Required quantity at 6-7 bar(g) within an area of 5 M from boiler.

Spray Water : Required quantity at 2.5 kg/cm2 within an area of 5 M from Silo.

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Annexure : 9


PRICE SCHEDULE

Sr.

No.

Description Amount in Rs.

1. Our prices towards Design, Engineering,

Manufacture, Supply, Site Fabrication, Erection and

Commissioning of the equipments enlisted in our

scope of supply.

(The above price is on FOR site packed basis and

exclusive of Excise Duty, Sales Tax, Octroi and

Service charges. The same shall be extra at actual at

the time of delivery.

Rs.65,50,000/-

(Rupees Sixty Five

Lacs Fifty Thousand

Only)

TAXES & DUTIES

• PACKING & FORWARDING - Included• EXCISE DUTY - @ 8.24% • CST - @ 2% AGAINST FORM “C”• TRANSPORTATION & - Buyers Scope

INSURANCE • SERVICE TAX - @ 10.30% wherever applicable.

**************

Annexure : 10WORKS : Sikri Industrial Area, Village – Sikiri, Main Mathura Road, Faridabad – 121004 (Haryana)

E-mail : [email protected], [email protected], [email protected], http:www.osmindia.com







COMMERCIAL TERMS & CONDITIONS

1. TERMS OF PAYMENT FOR SUPPLY :

30% Advance along with Purchase Order 10% against submission of drawings. . 60%+ all Taxes and Duties against Performa Invoice before dispatch

2. TAXES & DUTIES :

All taxes and duties as applicable shall be charged extra

3. CENVAT SCHEME :

E.D shall be Charged Extra as applicable at the time of dispatch

4. DELIVERY :

The entire scope of supply shall be completed within 12-16 weeks from the date of acceptance of your technically and commercially clear order and receipt of advance.

5. VALIDITY :

Our offer shall be firm and remain valid up to 30 days from the date of this offer.

6. WARRANTY :

a) The stores offered shall be free from all defects in design, material, workmanship and

manufacture in full conformity with standards, specifications and the contract.

b) The warranty shall be valid for a period of 18 months from the date of delivery of thelast consignment or 12 months from the date of commissioning which ever is earlier.

c) Our liability under the contract shall be limited free replacement / repair of defective parts / components. However, this guarantee doesn’t cover replacement of parts whose service life is less than 12 months or defects arising from mishandling, negligence, overloading etc.

Annexure : 11








TECHNICAL DATA SHEET

MS SURGE HOPPERS :

1. Quantity : 04 Nos.

2. Size & Volume : To Suit

3. Material of Construction : MS ( As per IS : 2062)

4. Water Cooling Arrangement : NA

KNIFE GATE VALVES :

1. QUANTITY : 1 No. below each surge hopper/adopter and at the outlet ofsilo.

2. TYPE AND SIZE : Knife edge type, 200 NB

3. METHOD OF VALVE OPERATION : Manual / chain wheel / pneumatic

4. ARE WORN OUT PARTS EASILY REPLACEABLE? : Yes

5. AIR QUANTITY AND PRESSURE NEEDED FOR VALVE OPERATION (M3/HR) : Very nominal for pneumatically

Operated.

6. MATERIALS CONSTRUCTION AND HARDNESS (BHN) :

a) BODY : CI as per IS – 210 / MS as per IS – 2062

b) SLIDE PLATE : SS as per IS - 304

7. IS VALVE CROSS SECTION DRAWING ENCLOSED? : No

8. ARE ALL SPECIFIED AND/OR NEEDED INTERLOCKS PROVIDED? : Yes

SS EXPANSION JOINT :







1. QUANTITY : 7 Nos.

2. TYPE, SIZE AND MAKE : Bellow type, 200 NB

3. MATERIALS OF CONSTRUCTION :

a). BODY : MS

b). BELLOW : SS

c). INNER SLEEVE :

ASH INLET VALVE :


2. TYPE AND SIZE : Dome / 200 NB

3. METHOD OF VALVE OPERATION : Pneumatic

4. QUANTITY, TYPE AND MAKE OF LIMIT SWITCH :

5. TYPE AND CONNECTIONS : Flanged

6. VALVE WORKING PRESSURE (MWC) : 6-7 bar(g).

7. ARE WORN-OUT PARTS EASILY REPLACEABLE : Yes

8. CONSTRUCTION MATERIALS & HARDNESS :

a). BODY : CI

b). FLAP PLATE :

c). SHAFT : SS

9. IS VALVE CROSS SECTION DRAWING ENCLOSED? : No.

ASH TRANSMITTAL VESSEL :


2. TYPE : Bottom discharge type







3. LOCATION & SIZE : Below each ash hopper size to suit.

4. NO OF CYCLES/HR FOR DESIGN CAPACITY : Later

5. MAXIMUM NO OF CYCLES ALLOWED : Later

6. EFFECTIVE ASH REMOVAL CAPACITY FOR MAX. NO OF CYCLES (TONNES) : Please refer Proposal Basis for ash Rates.

7. ARE NEEDED PRESSURE RELIEF

VALVES ARE PROVIDED? : Not required for such vessels.

8. ARE NEEDED GATES ARE PROVIDED? : Provided

9. MATERIAL OF CONSTRUCTION HARDNESS & THICKNESS :

a) BODY : MS

b) INLET SEGMENT :

c) WEAR SEGMENT :

10. IS DETAILED DRAWINGS FURNISHED? :

ASH DISPOSAL TRANSPORT PIPE :

1. LENGTH OF EACH CONVENG PIPE LINE : 6 M standard length

2. TOTAL LENGTH OF ASH DISPOSAL PIPE LINE : Please refer Proposal Basis

3. DIA OF PIPE LINE (mm) : 80/100 NB

4. CODE OF PIPE LINE : IS:1239 Heavy

5. VELOCITY THRU PIPE CONSIDERED : 5-7 m/s.

6. TYPE OF JOINTS : Flanged

7. WEIGHT OF PIPE PER METER (Kg) : As per standards

a) EMPTY WEIGHT : As per standards







b) WITH ASH :

8. MATERIAL OF PIPE : MS ERW

9. TYPE OF SUPPORT FOR LINES : Structural

10. NO.OF PIPE BENDS : 5 – 6 Nos. considered for each pipelines

11. MATERIAL OF PIPE BENDS : Cast Basalt

12. RADIUS OF PIPE BENDS : 3D & 5D in segments of 450 or to suit.

FLUIDIZING PADS :

1. QUANTITY : 1 set for Fly Ash Silo.

2. SIZE : To suit. 3. MATERIALS OF CONSTRUCTION :

a) FRAME WORK : MS

b) ELEMENT : Cloth

4. AIR QUANTITY NEEDED PER PAD (NM3/hr) AND PRESSURE (MWC) : Very nominal for ESP’s.

SILO VENT FILTER :

1. TYPE OF VENT FILTER : Reverse Pulse Jet Type

2. QUANTITY : 1 No. at silo top

3. MAKE : OSME

4. LOCATION : Above Silo

5. DESIGNED STANDARD :

a) CAPACITY (Cu. m/hr AIR FLOW PER hr) : later

b) MAXIMUM ASH CONTENT OF THE AIR COMING OUT FROM THE VENT FILTER (mg/M3/net) : 75

6. MATERIAL OF CONSTRUCTION :







a) BODY : MSb) FILTER ELEMENT : Polyester needle felt / PTFE Coated

7. FILTERING AREA OF BAGS

PREVENT FILTER m2 : To Suit

8. NET CLOTH TO AIR RATIO : 1.5:1

9. CLEANING ARRANGEMENT OF BAGS : Pulsing

10. MOTIVE FORCE TO CLEAN VENT FILTER : Instrument Air

11. IN CASE OF COMPRESSED AIR USED FOR CLEANING OF FILTER :

i) QUANTITY OF AIR : Very nominal

ii) QUANTITY OF AIR PER VENT FILTER (NET Cu. m/hr) :

iii) PRESSURE OF COMPRESSED : 6-7 bar (g)

ASH CONDITIONER :

1. DIAMETER : As per our standard

2. LENGTH : As per our standard

3. TYPE : Double Shaft Rotary Paddle type

4. CAPACITY : 10 TPH for Ash Silo.

5. POWER : Later

6. BULK DENSITY OF ASH : As mentioned in the Design Basis of offer.

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Annexure : 12


LIST OF MAJOR BOUGHT OUT ITEMS

Sl. No.

DESCRIPTION OF EQUIPMENT

NAME OF MANUFACTURERS

(A) MECHANICAL EQUIPMENTS:

1. Screw type conveying air compressors

Chicago Pneumatic / Kaeser / Elgi / Ingersoll Rand / Atlas Copco

2. Gear Box Radicon / Elecon

3. Bag Filter OSME / ACCO / FMI / Alsthom

4. Level Probes:

4.1 RF type E-TEK (EIP) / SAPCON / SBEM / FLOWSTAR

4.2 Capacitance type NIVO / SAPCON

(B) PIPING & VALVES:

1. M.S. ERW (Black / Galvanised) SAIL / Jindal / TISCO

2. Butterfly Valve (Air line) Inter Valve / Audco/ Leader

3. Water / Air Line Valves (C.I.)

- Gate / Globe / Check

Leader / Crescent / BDK / KSB

4. Water / Air Line Valves (G.M.) Leader / GG / BDK

5. Ball Valves BDK / Hawa / Uniflow/ Flowcon

6. Y-Strainers Spirax / Drayton (Greaves)

(C) ELECTRICAL & INSTRUMENTATION:

1. Control Panels, Lighting Panels, Misc. Panels, JBs, LPBs

Rittal / Equivalent

2. LT Motors Siemens / ABB / Crompton

3. Geared Motors SEW /IC Bauer /Power Built /Crompton / Bonfiglioli

4. Power/ Control & Signal Cables Universal /Torrent / Asian / Polycab / Lapp / BCH

5. Cable Trays Venus Steel / Metalite Industries / Indiana / Graeatfeb Engg. & Fabricators / Bharti Export /







Technofab/ Equiptech/ APT

6. Filter / Lubricator / Regulator Shavo Norgren / SMC / Camozzi

7. Solenoid Valves:

7.1 For Denseveyor System Schrader / Rotex / Festo

7.2 For Bag Filter Manik / Rotex / ASCO / Avcon

8. Pressure Gauge MASS / WIKA / A.N. Instrument / H. Guru / General Instruments

9. Temperature Gauge General Instruments / H. Guru

10. Pressure Switch Indfoss / Switzer / Orion Instrument

11. Pneumatic Cylinder Festo / Schrader / Nucon / Camozzi / Rotex

12. Rotary Pneumatic Actuator El-o-matic / Rotex / Virgo

13. Electrical Actuator Rotork / Auma

14. Safety Relief Valve Spirex / LEADER

15. Drain Trap:

15.1 Mechanical type Spirex / Drayton (Greaves) / Rotex

15.2 Auto type Trident / Rotex / GORC / Jucomatic

16. Electrical Limit Switch:

16.1 Lever type Jai Balaji / BCH / Telemecanique / Siemens

16.2 Rotary type Virgo / Rotex / Keystone

17. Silencer:

17.1 Sintered Bronze Kulkarni

17.2 Plastic Fluoroquip / FESTO

18. Polyurethane Tubing FESTO / PARKER/ Cammozi

19. Selector Switch / Push button Siemens / Teknic / L & T

20. Proximity Switch P & F / Telemechanic / AB/ Jayashree

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