View
2
Download
0
Category
Preview:
Citation preview
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of 2.8
TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 1 of 82
Tender Specification Document
Scope of the work: Design, Manufacturing, Testing, Erection &
Commissioning of 2.8 TPH (1 No.) and 1.1 TPH (1 No.) Steam
Boiler Systems with Accessories
Delivery Place : Propellant Complex, Rasayani, ISRO (PCRI),
Dept. Of Space, Govt. of India, Dist.: Raigad, Maharashtra -
410207
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of 2.8
TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 2 of 82
Tender Specification Document
Scope of the work: Design, Manufacturing, Testing, Erection &
Commissioning of 2.8 TPH (1 number) and 1.1 TPH (1 number) Steam
Boiler System with Accessories
1.0 General Specifications
Purpose: Steam Boilers are meant for the supply of steam for various
process operations of CNA / N2O4 production plant at Propellant
Complex, Rasayani, ISRO, (PCRI) Dept. Of Space, Govt. of India, Dist.:
Raigad, Maharashtra – 410207.
2.8 TPH capacity boiler is planned to be operated whenever bleaching
process is active and 1.1 TPH boiler will be operated during rest of the
process operations.
Steam Boiler Parameters :
a. Boiler Quantity : 2 nos.
b. Capacity, TPH (F&A 100 degC) : 2.8 TPH - 1 No.
1.1 TPH - 1 No.
c. Steam pressure, kg/cm2(g) : 10.54 kg/cm2(g)
d. Type of Boiler : Smoke Tube, 3Pass Wet Back
e. Fuel to be Fired : Furnace Oil (FO)
f. Thermal Efficiency, NCV of fuel oil : 89% on FO as per BS-
845 part I on NCV basis.
1.1 SCOPE OF WORK
A. The Scope of work includes detailed Engineering design,
manufacturing, testing at works, inspection, supply, transportation,
unloading and receiving the material at site, storage and safe custody
at site, handling at site, erection, testing, commissioning, guarantee
test run and handing over of boiler and connected accessories with all
statutory approvals as per technical parameters mentioned under 1.0,
Detailed Scope of Work under 2.0, Design requirements under 3.0 and
technical specifications & all other requirements as detailed from 4.0
to 33.0 of this document and the Annexures.
B. The successful bidder shall submit detailed design calculations and
proposal within 4 weeks after release of Purchase Order to IBR
Authority and Purchaser and after approval and clearance from IBR
Authority & Purchaser, actual fabrication work shall be taken up.
C. Supply of spares for 2 years of trouble free operation.
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of 2.8
TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 3 of 82
1.2 The Steam Boiler shall be fabricated and inspected as per drawings &
QAP, both approved by IBR authority.
1.3 At the time of submitting the offer, party shall quote the names of
IBR authority that will be engaged during the course of entire work in
the technical bid.
1.4 At the time of submitting the offer, party shall attach documentary
evidence indicating IBR approval of the fabrication shop in the technical
bid.
1.5 The bidder’s scope shall also include any other services, etc. if called for
in the succeeding sections of the specification. The successful bidder shall
be responsible for providing all material, equipment & services, which
are required to fulfil the intent of ensuring operability, maintainability,
reliability and complete safety of the complete work covered under this
specification, irrespective of whether it has been specifically listed
herein or not. Omission of specific reference to any component /
accessory necessary for proper performance of the equipment shall not
relieve the bidder of the responsibility of providing such facilities to
complete the supply, erection and commissioning of Boiler and accessories
as per this document within quoted price.
1.6 It is not the intent to specify herein all the details of design and
manufacture. However, the equipment / system shall conform in all
respects to high standards of design, engineering and workmanship
and shall be capable of performing the required duties in a manner
acceptable to purchaser who will interpret the meaning of drawings
and specifications and shall be entitled to reject any work or material
which in his judgement is not in full accordance herewith.
1.7 Items though not specifically mentioned but needed to make the
system complete as stipulated under these specifications are also to be
furnished unless otherwise specifically excluded.
1.8 Bidder shall submit all the details of the proposed boilers,
accessories, tanks, instrumentation & control system, etc. confirming to
the specifications of this document in the technical bid itself, without
which offer will not be considered.
2.0 Detailed Scope of work by Vendor:
a) All activities related to obtaining approval and clearance by the IBR
and other statutes shall be the responsibility of the Vendor.
b) All necessary certificates in the required form as approved by the
Boiler Inspectorate shall be forwarded to PURCHASER. Responsibility
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of 2.8
TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 4 of 82
of the purchaser with respect to the boiler Inspectorate is limited
to paying the registration fee and forwarding of necessary
application forms only. All other fees and expenses in connection
with IBR approval shall be borne by the Vendor.
c) All equipments and parts covered under Indian Boiler Regulation shall
be designed, fabricated, tested and erected as per the requirement of
this regulation, and necessary statutory approvals are to be obtained
before the commencement of the work.
d) The Scope of work shall include complete refractory insulation and
lagging including material for the complete boiler units.
e) All hot water, steam lines, air ducts, furnace oil lines shall be
insulated.
f) Dampers are to be provided for isolation of FD fan.
g) All exposed carbon steel/structural steel parts of equipment, pipes,
ducts etc. shall be given two external coats of approved primer before
dispatch.
h) All equipment after erection shall be given two coats of primer
wherever required and two external coats of final painting as per
standard.
i) All civil work for foundation are excluded from Vendor’s scope.
However, grouting of equipments/structurals including supply of
grouting materials and anchor bolts are included in Vendor’s
scope. Anchor bolts shall be dispatched to site sufficiently in
advance.
j) Vendor shall furnish detailed foundation data and loading diagrams
for the boilers, stack etc. Vendor shall provide floor plan of
equipments, piping, etc.
k) Bidder shall provide proposed P&ID of the system along with the offer.
For all such components / equipments like pumps, pipelines, tanks,
etc. sizing shall be finalized as part of detailed engineering phase.
l) The Quality Assurance Plan (QAP) identifying all stages of inspection
shall be approved by IBR as well as Purchaser.
m) The stack shall be designed and fabricated to meet the Maharashtra
Pollution Control Board (MPCB) norms. The expected emission
levels from the proposed boilers shall be specified in the offer.
n) All piping items, valves, pumps, control valves, instruments like
pressure gauges, level gauges, flow meters, transmitters, motors etc.
shall be procured from reputed vendors and manufacturers test
certificate for chemical compositions, mechanical properties, hydro
test etc. shall be furnished.
o) For IBR covered items, IBR certificate in relevant forms shall be
furnished.
p) Preservation method during idle period shall be recommended by the
successful bidder for drum internals, water headers, smoke tubes,
outer surface of boiler tubes and furnace.
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of 2.8
TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 5 of 82
q) Material of construction for major boiler parts as per table - 1, boiler
feed water lines, steam lines and all such applicable items shall meet
IBR requirements.
Table – 1: Material of Construction of major Boiler Parts
Sl. No. Material of Construction of major Boiler
Parts
Boiler Drum
1 Shell Plate SA 515/516 Gr 70
2 Tubes BS 3059 ERW
3 Manhole/Hand hole SA 515/516 Gr 70
4 Pipes SA 106 Gr B
Furnace
5 Plates SA 515 / 516- 70
6 Header/Pipe SA 106 Gr B
7 Tubes BS 3059 ERW 320
r) Successful bidder has to impart necessary training to the personnel of
PURCHASER without any financial implications.
s) Successful bidder shall provide lightning protection for equipments of
the boiler system as applicable. Vendor shall also provide earthing to
all electrical equipments.
t) Successful bidder shall provide the data sheets and drawings of all
equipments, valves, instruments etc. of the system with isometric
drawing.
u) 3 sets of all the documentation involved in this scope of work shall be
submitted by the successful bidder.
v) Party shall submit data as per xxii) in soft format also after placement
of P.O.
w) List of Tentative Spares to be supplied for each boiler as per following
Table – 2
Table – 2: List of Tentative Spares
Sr.
No.
Description Qty.
(a) Spares of Boiler
1. Manhole Gasket 1
2 Mudhole Gasket 1
3 Tube changing Brush 2
4 Magnet Switch for Water Level Controller 1
5 S.S. Float, Rod & Magnet Assembly 1
6 Boiler Pressure Gauge 0-25 Kg/Cm2 1
7 Feed Water Pressure Gauge 0-16 Kg/Cm2 1
8 Fusible Plug 2
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of 2.8
TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 6 of 82
9 Inspector Test Gauge Cock 1
10 Toughened Glass for Flame Observation 1
(b) Spares of Burner
1 Photocell 1
2 Mechanical Oil Seal 1
3 Ignition Electrode 2
4 Heater Gasket 2
(C) Other Spares
1 10% (min. 1No.) spares shall be provided
for all manual valves, steam traps, gaskets,
bolts, nuts etc. for each type and size
1 lot
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of 2.8
TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 7 of 82
3.0. Design Requirements (Boilers & Accessories)
3.1 Boiler shall be horizontal, shell type fully packaged 3- pass smoke
tube design, automatically controlled, tested and proven under
rigorous conditions and subject to the strictest quality control
procedures.
3.2 The boiler shall be of genuine three pass flue path. Flue gases
shall pass through the furnace (first pass) whereas second and
third passes shall be formed by nests of smoke tubes. At the end of
the furnace the flue gas reverses into second pass tubes.
3.3 All the common systems shall be suitably designed for either
individual or combined operation of both the boilers
simultaneously.
3.4 The boiler shall be complete with all mountings, accessories,
controls etc.
3.5 Boiler construction shall be in accordance with the latest
revision of Indian Boiler Regulations Act 1950 and in conformity
with AOTC requirements for unattended boilers. All materials used
shall be approved and tested as per relevant existing codes. All the
welded joints shall be as per code requirement.
3.6 The boiler shall be of modern compact design and be genuinely
packaged design. The design source shall confirm to international
design. The boiler and the burner design must be from single
manufacturer to ensure perfect matching of burner and boiler.
Relevant details shall be attached with the offer as part of
technical bid.
3.7 The fire tubes in the tube nest shall be plain without any
restriction inside. These tubes shall be easily accessible both from
inside as well as outside for inspection and maintenance. These
tubes are to be tightly expanded in the tube plate and seal welded.
The required number of stay tubes and stay bars are to be fitted in
the boiler. The stay tubes shall be seamless & strength-welded to
tube plates.
3.8 All working parts of the boiler shall be accessible for ease of
inspection and maintenance. On the shell, one elliptical man-door
and on tube plate one mud hole must be provided. Access to the
combustion chamber shall be through bolted refractory lined access
door whereas tube nest shall be exposed through hinged mounted
front door.
3.9 Boiler front door shall be lined with ceramic fiber blanket with
SS sheeting on the tube side of the door.
3.10 The boiler mountings, supporting systems and accessories shall
be as per the Scope of Supply as mentioned in Sl. No. 21.
3.11 The boiler shall be designed and constructed to generate steam
at efficiency of 89% on net calorific valve (NCV) basis. Efficiency
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of 2.8
TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 8 of 82
shall be demonstrated as per standard BS – 845 Part 1 Indirect
method.
3.12 The insulated cylindrical shell of the boiler shall be cladded with
aluminum sheets. A movable ladder shall be provided which can be
moved as per convenience.
3.13 Boiler and accessories shall be mounted on a single base frame.
Individual systems such as feed water pump etc. may be on
separate base plates welded to the boiler base frame.
3.14 It shall not require any special foundation for the boilers and
for its mountings/fittings. It shall be able to be mounted on
simple PCC foundation.
3.15 The proposed Boiler House civil requirements with the
anticipated size of the boiler is enclosed as figure no. 1. Boilers &
accessories shall be designed to meet / not to exceed the
dimensions given in the sketch.
4.0 Fuel oil system : This shall be suitable for handling furnace oil
fuel. Burner shall be mono-bloc type. The electric heater with
required number of elements shall be provided for ensuring the
conditioning of furnace oil for firing in the boiler. The electrical oil
pre-heating system shall be 100% pre-heating for the rated boilers
capacity.
5.0 Combustion system: This system shall consist of a forced draft
combustion air blower with motor, mechanical atomizer, burner
assembly, photocell operated safety device, ignition electrodes,
transformers etc. Burner assembly shall be bolted on combustion
chamber and that the burner is lit only when the entire burner
assembly is fitted and is in a closed position, ready for operation.
Pressure jet atomisation shall be provided. The burner shall be
capable of firing furnace oil of viscosity upto 3500 rad-sec. at 35 deg.
C. Dead weight explosion door & fusible plug shall be provided for
ultimate safety. The entire assembly shall be engineered in such a way
that burner moves along with the door when the door is opened for
tube cleaning.
The burner shall be of stepless modulation compatible for
firing oil. The controlling of the air and fuel damper shall be done
by means of individual servomotors sending electronic signals.
Burner must be with turn down ratio of 1:4 for oil. Burner shall be
equipped with pneumatic arm control for maintaining the A/F
ratio with changes in air density compensation.
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of 2.8
TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 9 of 82
Type of Burner Pressure Jet
Construction Monobloc
Modulation Stepless
Load Regulation Electronic Compound Regulation (ECR) Technology
Turndown Ratio 1:4 without loss of efficiency.
Stack Emissions Shall meet Maharashtra Pollution Control Board specified
allowable limits for the proposed boiler & chimney design
The burner and the boiler design shall be compatible with each other
and that both the burner & boiler manufacturer shall be same.
Construction of Burner:
The burner shall be of monobloc construction and directly mounted on the
furnace of the boiler. No civil foundation shall be required for installing the
burner. Burner shall have hinged construction for easy maintenance
ensuring reduced downtime. The flame geometry shall be such that there is
no flame impingement on the surface of the furnace.
Electronic/Digital Compound Regulation:
The burner shall be equipped with Electronic Compound Regulation with the
air damper, oil regulating valve connected to servomotor. The signal from
the pressure transducer mounted on the steam drum is taken to the
controller which provides the necessary signal to the servomotor and
control the air to fuel ratio to avoid the hysteresis losses typical for burner
operation with mechanical linkages.
For oil firing, the burner shall ensure smooth start up with reduced thermal
stresses on the furnace. It shall have facility to flush out the vapours or
contaminants from the oil circuit in case the oil of poor quality or when the
moisture content of the oil is high. The burner shall have provision for
localised oil heating for reducing the viscosity of oil and ensuring proper
atomization of the oil.
It shall be provided with touch screen display and PLC based software to
precisely control the air to fuel ratio. The parameter settings on the burner
shall be easy to ensure optimal combustion throughout the burner operating
range. Provision for changing the settings shall be done by means of a user
friendly touch screen display.
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of 2.8
TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 10 of 82
The burner shall have provision for online display of percentage opening of
air dampers and fuel valve/dampers corresponding to burner load. The
setting and tuning of the burner parameters shall be user-friendly with
computer interfacing.
Burner shall be provided with digital manager for burner fault detection.
The fault shall be displayed in readable english format along with necessary
diagnostic instructions ensuring ease of troubleshooting. It shall have
provision for storing fault data.
For safety of burner operation, the burner shall be equipped with photocell
for detecting the flame. The burner management system shall control the
entire sequence of burner operations including safeties.
Burner Refractory:
Refractory shall be provided along with the Burner to mount the same in the
boiler.
Cabling:
The interconnecting cabling between the panel and the burner along with
linking it to the other safety interlocks.
6.0 Day Feed Water Tanks, 25000 liters – 2nos. : The feed water tanks
shall be with a capacity of 25000 liters each. The feed water tanks (2.2 m
Diameter x 7.0 m Length) shall be manufactured as a horizontal cylindrical
tank with minimum 6 mm thick plate material of IS 2062 Gr.B. The feed
water tanks shall be complete with the following accessories.
(a) Level Gauge
(b) Atmospheric Deaerator Head with inlets for make-up
water, flash steam and condensate.
(c) Level Control System consisting of 3 level switches for
high, low and extra low level of water.
(d) Insulation & Cladding
Feed water tanks – 2nos. of 25000 liters capacity shall be placed at an
elevation of 4 m on available RCC columns at site as shown in figure - 1. The
successful supplier shall make suitable interfacing of the supplied tanks
with these columns.
7.0 Feed Water System Pumps: 2 nos. of electrically driven vertical
centrifugal multistage pumps with motor capable of using feed water at
maximum temperature of 120 deg C with all SS internals, interconnected
pipe work between pumps and feed check valves shall be supplied.
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of 2.8
TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 11 of 82
8.0 Blowdown system: Total Dissolved Solids (TDS) based Automatic
Blowdown Control System based on conductivity principle with
pneumatically actuated valve for efficient control of TDS level within the
boiler shell. This system shall be installed in parallel to the manual
blowdown valve.
9.0 Instrumentation & Controls: The electro-mechanical control
system shall be provided. The following controls / indications shall
be ensured:
a. The relay based control panel shall be mounted in the control
room.
b. Interlocking of the feed water pumps and water level in the boiler
c. Audio–visual alarm for high, low & very low level of water in the
boiler and also for flame failure.
d. Programmer controller to ensure sequence of boiler start-up after
ensuring required temperature and pressure of oil, air etc.
e. MCB’s and contactors shall be provided for all electrical drives for the
boiler
f. Pilot lamp to indicate operating status of the various equipments.
g. Complete internal wiring to ensure power supply at a single point on
the panel.
h. Indicating lamps/ Audio alarm shall be provided for the following
parameters -
1) Low water level in the boiler and very low level trip
provision
2) Burner flame failure
3) Feed water pumps failure
4) Damper closed position
i. Pressure switch shall be provided for burner interlock.
j. Microprocessor based single loop Controller shall be provided for
Steam drum level, oil pressure, degasifier Level and Ratio controller
for Air Fuel ratio, Furnace Box pressure. One controller shall be
provided as spare. (Preferably ABB commander C500 or equivalent)
k. Both boiler shall have separate control systems and interlocks.
l. Differential pressure Transmitter shall be provided for deareator,
boiler level with PID Controller, ABB commander C500 controller or
equivalent. Smart positioners shall be provided for control valve
operation. Dampers for operation of ID and FD.
m. Control panel shall be mounted in control room for ease of operation
and maintenance.
n. Instead of side level gauges top mounted level indication shall be
provided with float and rollers magnetically coupled for Level of
storage tanks and deareator.
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of 2.8
TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 12 of 82
o. Boiler Drum water Very High Level and Very low level Switches
shall be provided for trip interlocks. Boiler level shall be controlled
by providing level transmitter PID controller and feed water control
valve.
p. Alarms shall be provided for High and low level of boiler drum level,
flame failure, box pressure high, BFW pump trip, Oil temp high low
etc. Interlock for BFW pump trip shall be provided in case of boiler
level V high. Boiler shall trip with flame failure , Box pressure Very
High, Boiler Level Very low etc .
q. Steam, Oil, BFW Flow meter shall be of two wire transmitter type and
indication of flow and total flow to be provided in control room.
r. Vendor shall provide interlock logic diagram.
s. Vender to provide list of Spares for 2 years. Mandatory spares shall
include - One set of candles for air filters, smart positioners, indicator
totaliser.
t. Vendor to provide SS air header with ¼ ‘’ needle valves for
distribution of pneumatic supply.
u. Vendor to provide line mounted Air filters of required size at battery
limits. Two sets of Fine ( 20 Microns) and Coarse filters (50 Microns)
parallel to each other shall be mounted on the header assembly with
isolation valves as standby arrangement.
v. Wetted parts for all transmitter shall be SS316.
w. Vendor shall provide specifications of each instruments with
operation and Maintenance manuals.
10.0 Chemical Dosing System: Feed water side softener along with
necessary pumping skid mounting & piping shall be supplied along with
ONE standby set of pump & motor.
11.0 Furnace Oil Supply related Piping with heating arrangement:
Furnace oil tanks are NOT in the scope of supplier. However,
necessary piping arrangement shall be realized by the vendor. There will
be 2 Day Oil Tanks of 20 m3 capacity & 2 oil storage tanks of 30m3
capacity for which bidder shall consider piping arrangements. Tentative
distance between FO storage to actual boiler will be ~40m. Successful
Bidder shall supply suitable electric heater for satisfactory operation of
the boilers (Overall for 4 TPH capacity). The built in electric heater with
required number of elements shall ensure the conditioning of furnace oil
for firing in the boiler. The electrical oil pre-heating system shall ensure
100% pre-heating for the rated boiler capacity. 6 nos. of Oil pumps as
detailed under scope of supply under 21.4 shall also be supplied.
• Arrangement of common drain line with individual bottom drain
valves is required to be done for removing water (moisture) from the
tanks. Drained furnace oil shall be collected for proper disposal;
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of 2.8
TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 13 of 82
taking care that dyke area will remain clean and there will not be any
soil or drain water contamination
12.0 Structural Supports: Shall be provided for the following:
(a) Boiler House Piping
(b) Ducting
(c) Also wherever applicable as per site conditions
13.0 Boiler House Piping: The following boiler house piping (for 2
boilers, Overall for 4 TPH capacity) shall be delivered by the
vendors.
(a) Feed Water Piping from the Feed Water Tank to the
individual feed water pumps complete with inlet Isolation
Valves – 2 Nos and Strainers – 2 Nos. Inclusive of
Insulation & Cladding.
(b) Furnace Oil Piping from the Day Oil Tank to the Burner
complete with Duplex Filter, Recirculation Header and
return oil piping to Recirculation Header. The piping shall
be complete with Insulation & Cladding.
(c) Steam Piping from Main Steam Stop Valve to the Main
Steam Header & from Header to the Pressure Reducing
Station complete with Insulation & Cladding as approved
by IBR. And also up to existing steam header located
approximately 50m away from boiler house.
(d) Steam Header shall be as per IBR with inlet & outlet
isolation valve, safety relief valve, steam trap module,
insulation & cladding.
(e) Safety Valve Exhaust Piping from the outlet of the Safety
Valves to outside of the boiler house, complete with
insulation & cladding.
(f) Blowdown piping from the outlet of the blowdown control
system to the blowdown pit as approved by IBR.
(g) Drain Piping from the boiler drain points, drain from the
feed water tank and the day oil tank shall also be
delivered by the Vendor.
(h) Any other piping & valve arrangements for overall smooth
operation of both the boilers.
14.0 Pressure Reducing Station – 1 number each for each steam flow rate
of 2800 kg/ hr & 1100 kg/hr for pressure reduction from 10.54
kg/cm2(g) to 3.5 kg/cm2(g) with bye-pass and isolation valves provision.
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of 2.8
TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 14 of 82
15.0 Flue Gas Ducting: MS flue gas ducting from boilers to Chimney
complete with expansion bellows, insulation & cladding.
16.0 Condensate Recovery System: A suitable condensate recovery system
shall be supplied to optimize the consumption of Furnace oil.
17.0 Feed Water Dosing System: Vendor shall supply suitable Feed Water
Dosing system as required for satisfactory boiler operation. Available DM
water is of following specifications :
pH value in range : 7 ± 1
Conductivity : ≤ 5 µS/cm
Total Hardness : < 3ppm
Chloride content : < 0.5ppm
Silica : < 0.04ppm
Dissolved Salt : < 5ppm
18.0 Boiler Efficiency Monitoring Package: Boiler efficiency monitoring
system to improve the boiler efficiency and monitor boiler parameters on
real time basis. Shall be provided as detailed under -
(a) Steam Flow Meter, Vortex Type with density compensation
(b) Oil Flow Meter
(c) Booster Pump Skid for Oil Flow Meter
(d) Temperature transmitters for Feed Water & Steam
(e) Software for online Trend analysis
19.0 Boiler House Electricals : Shall be complete with
- Power cables from the control panel to the various consumers
- Control cables from the panel to the various instruments
- Utility Panel from mounting the Efficiency Monitoring Panel
- Cable trays & Accessories as required
20.0 MS Self Supported Chimney : Shall be Designed as per IS 6533
with a height of 30 meters minimum. The chimney shall be designed
for a boiler capacity of 4.0 TPH. Chimney shall have the provision for
sampling point. The corrosion allowance to be considered shall be 1.5
mm and shall be complete with
(a) Aviation Lamps
(b) Lightening Arrestor
(c) Earthing Strips
(d) Inlet for ducting coming from 2.8 TPH boiler
(e) Inlet for ducting coming from 1.0 TPH boiler
(f) Ladder & Platforms at suitable heights
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of 2.8
TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 15 of 82
(g) Insulation & cladding of the Bottom 2 meters
(h) Dampers as applicable
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of 2.8
TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 16 of 82
21. Scope of Supply
21.1 The boilers for specified duty shall be designed & supplied complete
with all accessories in all respects, but not limited, to the following, within
vendor’s battery limit.
- Oil fired package boilers complete with all accessories as specified
such as fuel oil system, FD fan, oil heating system, boiler mountings,
motors, starters, etc.
- Foundation bolts for all items to be supplied.
- 2 nos. of 25m3 feed water tanks of 2.2m Diameter & 7 m length
- Two feed water pumps of adequate capacity and rating complete with
motor, starters etc.
- All necessary instrumentation complete with pre-wired control panel
- Inter connecting piping, fittings etc.
- Inter connected power & control wiring and instrument tubing etc.
- Items required for installation, commissioning & start up of boilers
The following items, but not limited to those mentioned, shall be supplied
with the boilers.
21.2 Pressure Parts for each boiler
a. Boiler Shell 1 no.
b. Tube Plates 2 nos.
c. Furnace Flue 1 no.
d. Combustion Chamber 1 no.
e. Boiler Tubes 2 lots
f. Stays (Tubes, Bars, Gussets) 1 lot
g. Mud door on tube plate 1 no.
h. Man door 1 no.
i. Stand Pipes for Stop, Feed check, Safety and
Blowdown Valves
1 lot
j. Stand pipes for gauge glass and level controller 1 lot
21.3 General Construction Parts for each boiler
a. Front casing with hinged door 1 no.
b. Rear casing with removable doors, Flue outlet 2 lot.
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of 2.8
TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 17 of 82
flange
c. Insulation and sheeting for boiler shell 1 lot.
d. Refractory for front & rear access doors with
support base frame. Refractory for furnace ring /
burner ring
1 lot.
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of 2.8
TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 18 of 82
21.4 Accessories of reputed make for each boiler:
a. Oil firing equipment Pressure jet, automatic, with necessary
valves, fittings & mountings – 1 set
b. Oil pump with drive motor 2 nos. – for transfer from Day oil tank to
Boiler (s) located 40m apart
2 nos. – for transfer from oil Storage tank
to Day Oil tank
2 nos. – for transfer from oil unloading
station to storage tank
c. FD fan with drive motor 1 no.
d. Multistage feed pumps with
motors
2 nos.
e. Electric pre-heater 2 nos.
f Pumps along with electric
motor required for softner
plant operations
2 nos.
21.5 Mounting & Fittings for each boiler:
a. Main steam stop valve 1 no.
b. Safety valve 2 nos. (with each
capable of 50% venting
capacity)
c. Feed check valve 2 nos.
d. Auxiliary valve 1 no.
e. Blowdown valve with Automatic Blowdown
Control System
1 no.
f. Isolating valve for water level controllers 2 nos.
g. Isolating valve for pressure switches and
pressure gauge
2 nos.
h. Drain valve for water level controller 2 nos.
l. Sight glass assembly 2 set
j Isolation valve for sight level gauge glass
assembly
2 nos. for each level
gauge glasss
21.6 Instrumentation for each boiler:
a. Water level
controllers
2
nos.
for feed pump operation and low water
level alarm
b. Over-ride controller 1 no. for lockout under extra low water level
alarm
c. Steam pressure gauge
with cock
1 no. For display of boiler steam pressure
d. Water level gauge
assembly
2
nos.
For display of water level in the boiler
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of 2.8
TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 19 of 82
c. Switch gears, relays,
connectors
1 set For individual controls of equipment
through control panel
d. Audio / visual alarm 1 set In case of unsafe operation for lockout
under extreme conditions
e. Pressure and temp
gauge with
thermostat
1 set for burner operation
f. Control panel 1 no. For housing above instruments and
switchgears
g. Steam to fuel ratio
monitoring system
1 no. To monitor and display the boiler efficiency
on-line, using necessary meters,
instrumentation and hardware.
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of 2.8
TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 20 of 82
21.7 Controls & Safeties for each boiler:
a. Oil temperature
indicator
1 no. Local cum panel mounted to indicate oil
temperature
b. Pressure switch 3 nos. For firing positions of burner
c. Photo resistant cell 1 no. Flame failure and audio visual alarm
d. Temperature
controller
1 no. To control oil temperatures in burner
heater before nozzle with audio visual
alarm and burner trip
e. Sequence controller 1 no. To control sequence of firing, pre-purging
etc.
f. Modulating
mechanism
1 no. Stepped / Three stage modulation
g. Low oil pressure
switch
1 no. To trip burner with audio visual alarm
h. Level controller 2 nos. To regulate feed water pump operation
and to trip burner in case of very low
level with audio visual alarm.
21.8 General Terms for Instrumentation & Control system
A. The Instrumentation & Control System configuration of the proposed
system shall be provided along with the proposal.
B. Successful bidder shall provide the specification and details of the
components, instruments proposed along with their makes and data
sheets for department approval.
C. Successful bidder shall provide the details of the range of the
instrument, nominal values, minimum, maximum values, alarm values
and trip values (Software and Hardware) shall be provided for review.
D. The Wiring diagram of the hardware components shall be provided for
approval after PO placement.
E. The details (Soft and Hard copy) of the hard wired interlocks/logic
implemented using the switches shall be provided for approval after
PO placement.
F. As built drawings (03 numbers) of the ICS configuration, instrument
ranges, alarm values, trip values, parameters of the programmable
controllers shall be provided after successful commissioning of the
system.
G. The programmable controllers shall be powered using 24 V DC only
and all the relay logic shall be implemented with 24 V DC power. Dual
redundant DC power shall be provided with Diode O ring where ever
applicable.
H. All the test certificates for the instruments and components like
material test certificates, calibration certificates, etc shall be
provided.
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of 2.8
TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 21 of 82
I. The supplied system shall have end to end spare capacity of at least 20
% for future use.
J. Each Boiler shall be Independent with its own control and MCC.
K. The Low voltage switchgear panels (MCC) shall be metal clad, totally
enclosed, CRCA sheet steel cubicle compartmentalized. The Motor
starter unit shall be fixed type and shall be combination of SFU,
Magnetic contactor, Bimetal overload relay, auxiliary contactor and
CTs for metering.
L. The make of switch gear components shall be Siemens/Schneider.
M. The make of Electrical Motors shall be Siemens/Bharat
Bijlee/Crompton/NGEF or Kirloskar.
N. Operational and Maintenance document consisting of the
troubleshooting steps shall be submitted by successful bidder
O. All the items required for satisfactory commissioning of the system
shall be considered and if any required during commissioning time for
satisfactory demonstration shall be provided without any cost
increase to the department.
P. Following make of the different instruments are acceptable:
Description Make
1 Pressure Transmitter Rosemount, Yokogawa, SMAR
or Boiler Manufacturer own
make
2 Temperature Sensor with
Transmitter
Rosemount, Yokogawa, SMAR
or Boiler Manufacturer own
make
3 Level Sensor & Transmitter Magnetrol, Rosemount, Vega
or Boiler Manufacturer own
make
4 Pressure Switch Switzer, Wika, Cella, ITT
Neodyne & Festo or Boiler
Manufacturer own make
5 SMART Positioners Siemens, Emerson, SMAR or
Boiler Manufacturer own
make
6 Contactors, Auxiliary Contactors Siemens,
Schneider/Telemechanique,
Stahl or Boiler Manufacturer
own make
7 MCB’s Merlin Gerin, Siemens, L&T,
Stahl
8 Standalone Controllers Honeywell, Eurotherm, Jumo,
Digitrenic, ABB or Boiler
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of 2.8
TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 22 of 82
Manufacturer own make
9 Relays (DC) Finder, Omron, OEN
10 Connectors Amphenol, Deutsch, Souriau or
Boiler Manufacturer make or
Boiler Manufacturer own
make
11 PLC and I/O Schneider, Siemens,
Mitsubishi
12 MCC, Motors & Switchgear Siemens/Schneider or Boiler
Manufacturer own make
13 Electrical Drives Siemens/ Schneider/Danfoss
or Boiler Manufacturer own
make
Q. MCC Related:
i. All the MCC panels should have LED lamps for indicating the
availability of three phase power, Voltmeter and Ammeter and
Multiplication meter for recording the various electrical parameters.
ii. Emergency STOP provision shall be provided on all the starter
Modules
iii. All the Motor starter Modules shall be provided with ON/OFF/Trip
indicating lamps, Local/Remote mode , reset PB for BMR and ammeter
. These shall be provided on the front door of the panel.
iv. The power contactor shall be three, pole, double break
electromagnetic air break with AC-3 category of duty. The rated coil
voltage shall be 230 V AC.
v. The cable entry shall be from the bottom.
vi. Successful bidder shall provide the details of the MCC components,
Motors proposed along with their selection criteria, makes and data
sheets for department approval.
vii. All the wiring diagrams shall be submitted for approval before
realization. Standard/Good Engineering practices shall be followed
during wiring of the panels with cross feruling.
viii. Any other make other than the above specified makes shall be used
subject to prior approval from department.
R. Tentative List of Analog I/O instruments for each Proposed Boiler
Sl.
No.
Type of Instrument Nos of
Instruments
1 Electronic programmable dual loop PID 4 Nos
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of 2.8
TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 23 of 82
controller with 2 DIs and 2 DOs
2 Electronic Indicators single loop with Totaliser 2 Nos
3 Control valves with HART positioner 4 Nos
4 Level switch, Mobrey make for drum level LL
and HH
2 Nos
5 Relay interlock Panel 1 Set
6 Positioner for ID and FD Fan 2 no.
7 Alarm Annunciator with first out sequence, 12
windows ( 4X3 ), LED lamps and Hooter.
1 Set
8 Flame failure detector. 1 Set.
9 Two sets of air filter assembly in parallel,
primary 50 micron and secondary 20 micron.
2 Sets
21.9 Safety Interlocks:
Unsafe condition Instrument Action
High water level Level controller No. 1 Feed water pump trip.
Low water level Level controller No. 1 Alarm & Burner Shut
down
Extra low water level Level Controller No. 2
(Overriding controller)
Alarm & lock-out
Flame failure Photocell Alarm & burner trip
Boiler high pressure Safety valves Lift & discharge
21.10 Tanks
Day Feed Water Tanks : 25 KL – 2nos. tank as detailed in specification
21.11 MS Self Supported Chimney
As detailed in the specifications
21.12 Flue Gas Ducting
As detailed in the specifications
21.13 Structural Supports
As detailed in the specifications
21.14 Piping
Feed water : Feed Water Tank to Boiler
Oil : Day Oil Tank to Burner, oil storage tank to day oil tank
Steam : From Main Steam Stop Valve to Header (IBR) and
from Header to
Pressure Reducing Station and up to existing steam piping
header
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of 2.8
TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 24 of 82
which is approximately 50 m away from boiler house
Safety Valve : From Exhaust to outside of Boiler House
Blowdown : From blowdown control system to Blowdown Pit
Drain : Interconnecting drain piping within battery limits
Any other piping & valve arrangements as required for smooth operation of
both the boilers
21.15 Pressure Reducing Station – 2nos.:
As detailed in the specifications
21.16 Electricals:
• It shall contain all necessary switchgears, safety alarms/interlocks
and burner management system and is to be mounted in the control
room for ease of maintenance and comfort of working peoples.
• Boiler shall be complete with all necessary electrical cabling from the
control panel till burner / FW pumps etc. Power cables shall be 1100 V
grade, PVC insulated & PVC overall sheathed.
• Control cables shall be multi-strand copper conductors of minimum
2.5 sq.mm.
• All motors shall conform to squirrel cage induction motors, TEFC, IP-
55, class ‘F’ insulation. IE-2 efficiency class motors shall be of
BBL/Siemens/NGEF/Crompton make and shall be painted with
anticorrosive paint.
21.17 MCC Cum Control Panel :
• A MCC cum control panel, complete with main isolator switch,
starters, auxiliary contactors, relays, fuses, rotary switches,
indicating lamps, isolator, hooters with programmer and combustion
safety relay.
• The panel shall be completely pre-wired and factory tested. It shall be
installed in MCC room with suitable foundation. All switch gears shall
be of Siemens or other reputed make.
21.18 Insulation & Cladding for each boiler:
The boilers shall be completely insulated in the factory itself and there
shall not be any site work involved for insulation and electrical cabling.
The cylindrical shell of boiler must be insulated with glass wool / Rock wool
mattresses of required thickness and shall be cladded with Aluminium.
21.19 Refractory for each boiler:
Suitable refractory material shall be provided for all required parts as
follows :
Front door : Ceramic fiber blanket with SS sheeting
Rear door : Hysil blocks with Kynex HG / Insulyte 7
Furnace ring / burner ring : Hysil blocks with Insulyte 7
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of 2.8
TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 25 of 82
22. Battery Limits for the bidder:
Feed Water : Inlet flange of Feed Water Tank
Fuel oil : Inlet Flange of Day Oil Tank located approx.
40m away from
boiler house and piping involved for oil circulation
with day oil tank
Blow down water : At the Blowdown Pit
Steam : Outlet of Pressure Reducing Station and
up to approximately
50 m steam line to be provided to connect to the
existing
piping rack
Power : At the Control Panel/ Utility Panel
Flue gas : At the outlet of chimney
• All battery limit flanges for low pressure (3.5 kg/cm2) steam shall be
as per ANSI B 16.5 150# and that for high pressure (10.5 kg/cm2)
steam shall be as per ANSI B 16.5 ASA 300#.
Following utilities will be available at battery unit
a. Electricity (Power & cables) : 415V, 3 Ph, 3 wire, AC
b. Instrument Air :4.0 to 5.5 kg/cm2(g)
- 40deg.C dew point, oil free
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of 2.8
TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 26 of 82
23.Detailed Technical Inputs to be provided by the bidder as per
following table
Description Units Remarks
Boiler type Smoke tube, 3-pass wet back boiler
Design Code IBR 1950 with latest amendment
Steam output F&A 100 0 C Kg/Hr 2800 & 1100
Design Pressure Kg/cm2 g 11.5
Working Pressure Kg/cm2 g 10.54
Actual Steam output Kg/Hr Vendor to specify
Steam consumption for steam oil Kg/Hr Vendor to specify
preheater
Rating of Electric oil heater and KW Vendor to specify
type
Net steam output at B/L Kg/Hr Vendor to specify
Dryness Fraction % 98 % (Min)
Heat output 106 Kcal/Hr Vendor to specify
Volumetric heat Release rate
106 Kcal/Hr.m3 Vendor to specify
Heating Surface M 2 Vendor to specify
Water holding Capacity up to NWL M 3 Vendor to specify
Steam Space M 3 Vendor to specify
M O C and type of boiler tube Vendor to specify
and diameter
M O C of Shell and diameter Vendor to specify
FUEL
Type Furnace oil
NCV of Furnace Oil Kcal / Kg 9650
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of 2.8
TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 27 of 82
Description Units Remarks
BURNER
Type Vendor to specify
Light up Vendor to specify
Furnace oil supply pressure Kg/cm2 g Vendor to specify
Turn down (Oil) 1:4 Atomizing medium and pressure Vendor to specify
Modulation type (Oil) Vendor to specify
F D FAN
Type Vendor to specify Flow M 3 /Hr Vendor to specify
Head (At 20 0 C & at Sea level) mm wc Vendor to specify
Arrangement Vendor to specify
Speed rpm Vendor to specify Break Kw KW Vendor to specify
Motor Kw KW Vendor to specify
Material of Construction Vendor to specify Motor Connection Starting Vendor to specify
FEED WATER PUMP
Type Vendor to specify
Flow M 3 /Hr Vendor to specify
Head MLC Vendor to specify
NPSH required MLC Vendor to specify
Speed rpm Vendor to specify Break KW KW Vendor to specify
Motor KW KW Vendor to specify
Motor connection Starting Vendor to specify
Material of Construction
Impeller Vendor to specify
Outer Sleeve Vendor to specify
Shaft Vendor to specify
Type of seal Vendor to specify
Casing Vendor to specify
Type of coupling Vendor to specify
FUEL OIL PUMP
Type Vendor to specify
Flow LPH Vendor to specify Discharge Pressure Kg/cm2 g Vendor to specify
Suction Pressure required Kg/cm2 g Vendor to specify
Speed rpm Vendor to specify
Motor KW KW Vendor to specify
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of 2.8
TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 28 of 82
Motor Connection Starting Vendor to specify
Material of Construction
Gears Vendor to specify
Casing Vendor to specify
Coupling type Vendor to specify
DETAILS OF SAFETY FEATURES OF Vendor to specify
THE BOILER
SYSTEM
DETAILS OF INSTRUMENTATION AND
CONTROL SYSTEM OF
THE BOILER Vendor to specify
Manual valves, gauges,
and other mechanical
items
Vendor to specify along with
minimum 2-3 proposed
makes
Any other items which is
not mentioned in the
above list Vendor to specify
24. Scope of Supply by PURCHASER
Description Unit Remarks
D M WATER DM Water as Boiler Feed Water located as shown in figure - 1
Size of the DM water
line mm Vendor to specify
INSTRUMENT AIR Instrument air at a suitable point 20 meter away from boiler house at 5.5 Kg/cm2 g and ambient temperature
Size of the Instrument
air line
mm
Vendor to specify
POWER SUPPLY At boiler MCC incoming terminal 415 V, three phase, 50 Hz and neutral power supply.
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of 2.8
TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 29 of 82
25. Delivery
a. Transportation, Erection and commissioning shall be
carried out by the bidder at Propellant Complex Rasayani, A Unit
of SDSC, ISRO, Tal.: Panvel, Dist.: Raigad, PIN-410207,
Maharashtra.
b. All necessary Equipments like welding machine, Gas cutting
set, Grinding M/C, etc, and Consumables like Welding Electrodes,
Gases, Grinding Wheels, paints, brushes, etc., including material
handling support, skilled and semi-skilled manpower required for
carrying out the above work shall be in the scope of the bidder.
c. The supply scope of work as per this specification
document shall be completed within maximum period of 6 months
from the date of placement of Purchase Order and erection and
commissioning within maximum period of 2 months from the date
of site clearance after receipt of items.
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of 2.8
TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 30 of 82
26. Performance Test and guarantee:
A. Steam blow out for the new boiler and interconnecting pipes
shall be carried out using suitable target plate to ensure steam
purity to the satisfaction of PURCHASER.
B. As soon as the boiler system is commissioned the Vendor shall
conduct a Performance Guarantee test of the system. All
parameters listed below are to be proved/demonstrated to the
complete satisfaction of PURCHASER. The duration of test run shall
be for a period of 24 hours continuous operation after
stabilization. Performance guarantee runs shall be conducted as
per BS 845 part I – 1987 indirect test method – after one month of
continuous trouble free operation.
C. The following parameters are to be guaranteed by the Vendor at
the system outlet Battery limit. In the event of not achieving the
same, the Vendor has to set right the system to achieve these
figures without any extra cost with in a period of three weeks. If
the vendor fail to achieve even after this, PURCHASER shall be free
to get it done by themselves or through other agencies at the risk
and cost of the vendor.
Quantity of Steam
- 2.8 T/Hr F& A 100 0 C
- 1.1 T/Hr F& A 100 0 C
Steam pressure
- 10.54 Kg/cm2g (Tolerance +0.5-0.0
Kg/cm2g)
Steam temperature - Saturated steam
Dryness factor - 98 %(Min)
Emission
level
Shall be lesser than MPCB allowable
limits for the proposed boiler & chimney
design.
a. The guaranteed noise level at 1M from the equipment shall be
85 db(A) b. Gas temperature at outlet of stack (top opening) shall be
175oC (Min). c. Vendor shall guarantee the equipment and the components
of boiler against all defects in design, use of defective
materials or bad workmanship for a period of 12 months
from the date of commissioning or 18 months from the date
of supply whichever is earlier. Any such defect shall be set
right by the Vendor at his own cost during the period.
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of 2.8
TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 31 of 82
27. Mandatory Documents to be submitted along with offer:
Technical:
i. General Arrangement drawing of the system.
ii. Detailed list of Instrumentation items to be supplied. iii. Detailed list of mechanical items to be supplied.
iv. Detailed list of Electrical items to be supplied. v. Detailed list of spares for 2 years operation shall be
submitted for each boiler.
vi. PERT chart for supply and Site activities. vii. Proposed P&I Diagram.
viii. Equipment data sheet. ix. Quality and quantity of Steam generated.
x. Quality and quantity of dozing chemicals, if any.
xi. Annexures – 1 to Annexure – 10 shall be filled, signed and
to be uploaded on the portal
xii. Utility requirements like DM water, Instrument Air,
Power, Furnace Oil, etc at battery limit with line size.
Commercial:
i. Firm establishment certificate indicating nature of work.
ii. Details of work of similar type – minimum 3 nos. completed by
providing copies of purchase orders during the preceding three years.
iii. Satisfactory work Completion certificates from the clients
iv. Documentary proof shall be submitted with the offer indicating
execution of at least one order of value of Rs. 95 lakhs or two orders
of value of Rs 50 Lakhs each or three orders of Rs. 30 Lakhs each
during preceding three Audited financial years.
v. IT/ TDS certificate shall be submitted with Profit & Loss statement for
preceding three financial years.
vi. Bidder shall submit audited statement of financial status for preceding
three years.
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of 2.8
TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 32 of 82
28.Compliance statement to be submitted as per Annexure - 4 The offer shall contain as an integral part of the same the following
statement.
“We have read, understood and accepted the details contained in this
Tender Specification Document, Instructions to Bidders, Standard
terms and Conditions of Purchase and technical procurement
specification attached along with your enquiry and conform our
acceptance to the same.”
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of
2.8 TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 33 of 82
29. The Offer
Vendor to ensure that the offer is complete in all respect
covering all points in the enquiry as per this tender specification
document.
30. Exclusions
- Civil work
- Power supply cable wiring upto the incoming switch of the control
panel
31. Inspection & Approvals
a) The boilers shall be subject to inspection and testing in accordance
with latest IBR codes.
b) Boilers fabrication shall be subject to inspection & testing in
accordance with latest revision of IBR code. Manufacturer shall
ensure that the boiler meet the requirements of the Inspectorate of
boilers.
c) Simulation test of boiler control panel shall be carried out in
presence of customer’s representative at the place of manufacture
before delivery.
d) Boilers/ piping shall be hydro-tested at works as per IBR
guidelines.
e) All piping items, valves, pumps, control valves, instruments like
pressure gauges, flow meters, transmitters, motors etc shall be procured from reputed vendors and manufacturer’s test certificate for chemical compositions, mechanical properties, hydro test etc. shall be furnished.
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of
2.8 TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 34 of 82
32.0 TWO PART BID: Bidders shall quote the tender in two part bid
basis. Technical bid shall be evaluated first, only technically suitable
bidders shall be allowed for price bid. The price bid will be evaluated
based on overall single lowest offer and splitting of order is not
envisaged.
32.1 Technical BID QUALIFICATION CRITERIA
Bidders who are qualifying / meeting following Technical and financial
criteria are eligible to participate in the bid for supply of items. Bidder
shall furnish all the information mentioned in the criteria with
documentary proof and submit along with quotation. Bids of the parties
which are not meeting the following criteria will not be considered for
evaluation and will be rejected without seeking any further clarifications.
32.1.1. Technical Qualification Requirements:
a. The bidder shall meet the technical specification and other
requirements and shall submit relevant certificates to establish the
credentials.
b. The Bidder shall be a party who has manufactured steam boilers
and executed similar / identical works with minimum 5 years of
experience.
32.1.2. Financial Qualification Requirements:
a. The Bidder shall have executed at least one order of value of Rs. 95
lakhs or two orders of value of Rs 50 Lakhs each or three orders of
Rs. 30 Lakhs each during preceding three Audited financial years.
Documentary proof shall be submitted with the offer in this regard.
b. IT/ TDS certificate shall be submitted with Profit & Loss statement
for preceding three financial years.
c. Bidder shall submit audited statement of financial status for
preceding three years.
32.1.3 Following documents shall be submitted along with the bid for
prequalification of Bidder.
a. Firm establishment certificate indicating nature of work.
b. Details of work of similar type - minimum 3 nos. completed by
providing copies of purchase orders during the preceding three
years.
c. Satisfactory work Completion certificates from the clients, with the
work / purchase order copies
32.1.4 Bid Selection Procedure and Process of Pre-Qualification
a. Short listing based on documents submitted, satisfying all the
eligibility criteria given above by the firm along with their Bid.
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of
2.8 TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 35 of 82
(Non-submission of any document as given in above list within
stipulated time leads to rejection of Bid).
b. Subsequently Bidder's competency, their technical achievements
and financial status will be evaluated suitable for this work.
Feedbacks from Bidder's clients will be verified, if required.
32.1.5 Evaluation criteria for bidders:
a. After receipt of bids from the bidders, their credentials will be
evaluated by the purchaser and their offers will be considered
only after evaluation.
b. Visit to earlier executed work sites, if required, where similar
works have been carried out, erected and commissioned by the
party, to ascertain their complete suitability for the jobs
described above.
c. Purchaser reserves the right to reject the offers not complying to
conditions mentioned in this tender specification document. No
communication from the rejected parties / bidders will be
entertained by the purchaser
d. Technical bids submitted by the bidder will be opened first and
evaluated for fulfilling the Pre-qualification criteria and other
conditions in NIT/Tender documents, based on documentary
evidences submitted along with the offer.
e. In case the qualifying experience is claimed by private
organizations based on work order and completion certificates
from another private organization, PCRI reserves the right to ask
for further proofs including submission of TDS certificates for
the said job.
f. Visit to vendor’s premises by our technical team for accessing
the technical capabilities of bidder, if required.
g. The documents listed in Sl No. 32.1.1 to 32.1.4 of this section
will be reviewed by the purchaser during factory visit, if
required.
h. It is proposed to evaluate the bidder based on the previous
experience in execution of the similar nature of works. The
supplier has to furnish/confirm the details as enclosed in the
vendor evaluation format as per Annexure – I.
i. Financial bids of shortlisted bidders (qualified in technical bid)
shall only be opened.
j. Financial bids of unqualified bidders shall not be opened.
k. Conditional bids may be rejected by PCRI. The technical
evaluation shall be made strictly on the basis of the documents
submitted by the bidders in support of the eligibility, the
technical and commercial response. All the required information
shall be furnished strictly in prescribed schedules/Annexure
only. Any information indicated other than prescribed
schedules/Annexure shall not be entertained. The financial
evaluation shall be made on the basis of the total price/charges
as indicated in the schedule of rates. PCRI is not bound to accept
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of
2.8 TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 36 of 82
the lowest quoted offer. Conditions, if any, on any document
enclosed with financial Bid shall not be considered. PCRI’s
decision in this regard shall be final and binding.
32.1.6 General Terms & Conditions:
a. Successful bidder shall make their own arrangements
towards lodging, boarding & conveyance during Erection &
commissioning activities at Propellant Complex Rasayani,
ISRO.
b. Liquidated Damages - Delivery schedule indicated in the
Purchase Order/Contract is the essence of the contract and if
the party fails to deliver the material within the delivery
schedule, Liquidated Damages will be levied @ 0.5% per
week or part thereof subject to a maximum of 10% of total
order value.
c. Performance Bank Guarantee - Performance Bank Guarantee
for 10% of the order value shall be furnished in the form of
Bank Guarantee from nationalized/scheduled bank or by
Demand Draft valid till warranty period plus sixty days as
claim period.
d. Security Deposit – Security Deposit for 10% of the order
value is mandatory. Party shall furnish the Security Deposit
in the form of Bank Guarantee from nationalized/scheduled
bank or by Demand Draft valid till completion of the contract
period plus sixty days towards claim period for faithful
execution of the contract.
e. In case, if parties are unable to provide two separate BGs,
i.e., one for SD & one for PBG, they can submit a combined BG
for SD & PBG for 10% of the Order value valid till the
completion of total contractual obligation (i.e., Supply period
+ warranty period + 60 days).
f. Force Majeure:
The following shall amount to Force Majeure:
i. Acts of God, act of any Government, War, Sabotage, Riots,
Civil commotion, Police action, Revolution, flood, Fire,
Cyclones, Earth quake and Epidemic and other similar
causes over which the Supplier has no control.
ii. If the Supplier suffers delay in the due execution of the
contractual obligation due to delays caused by force
majeure as defined above, the agreed time of completion
of the job covered by this contract or the obligations of
the Supplier shall be extended by a period of time equal
to period of delay, provided that on the occurrence of any
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of
2.8 TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 37 of 82
such contingency, the Supplier immediately reports to
PCRI in writing the causes of delay and the Supplier shall
not be eligible for any compensation.
g. Arbitration & Reconciliation:
i. In case amicable settlement is not reached in the event of
any dispute of difference arising out of the execution of
the contract or the respective rights and liabilities of the
parties or in relation to interpretation of any provision by
the Supplier in any manner touching upon the contract,
such dispute or difference shall (except as to any matters,
the decision of which is specifically provided for therein)
be referred to the sole arbitration of the arbitrator
appointed by PCRI. ii. The award of the Arbitrator shall be binding upon the
parties to the dispute.
iii. Subject as aforesaid, the provisions of Arbitration and
Reconciliation Act 1996 (India) or statutory modifications
or re enactments thereof and the rules made there under
and for the time being in force shall apply to the
arbitration proceedings under this clause. The venue of
the arbitration shall be held at Mumbai and the language
of the proceedings shall be in English. Subject to the
above, the Courts at Mumbai alone shall have the
jurisdiction to deal any disputes between the Parties
pertaining to the contract.
iv. The cost of arbitration shall be borne equally by both the
parties.
v. Work under the contract shall be continued during the
arbitration proceedings.
vi. Failure to comply with any of the above conditions can
result in termination of the contract, forfeiture of the
security deposit, penalty as may be decided by PCRI and
future blacklisting of the Supplier.
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of
2.8 TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 38 of 82
32.1.7 Special Instructions to the bidders for quoting prices in
the on-line price bid
A. Purchaser reserves the right to order all the items as listed in this
specification document or excluding 1.1 TPH boiler unit alone.
B. Accordingly, a separate line item has been identified for bidder to
quote for 1.1 TPH boiler unit alone against sl. No. 3 of Price bid.
C. Under sl. No. 1 of price bid, bidder shall quote lumpsum amount
towards Design, Manufacturing, testing, Packing & Forwarding and
transportation of 2.8 TPH Steam Boiler along with all systems and
all accessories required for both (2.8 TPH & 1.1 TPH) boilers as per
detailed requirements as a single package offer as specified in
tender specification document (sl.no. 1 to 32), but excluding 1.1 TPH
Steam Boiler unit alone
D. Under sl. No. 2 of price bid, bidder shall quote lumpsum amount
towards Erection & Commissioning of items against sl. No. 1 at
Propellant Complex Rasayani, ISRO (PCRI)
E. Under sl. No. 3 of price bid, bidder shall quote lumpsum amount
towards Design & manufacturing of 1.1 TPH Steam Boiler alone
F. Under sl. No. 4 of price bid, bidder shall quote lumpsum amount
towards Erection & Commissioning of item against sl. No. 3 at
Propellant Complex Rasayani, ISRO (PCRI)
G. Under sl. No. 5 Supply of Two Years Essential Operating spares for
2.8 TPH Boiler boilers shall be quoted.
H. Under sl. No. 6 Supply of Two Years Essential Operating spares for
1.1 TPH Boiler boilers shall be quoted.
I. Under sl. No. 7 to 10, IBR Authority Charges will be paid on actuals
or quoted price, whichever is lower against documentary proof of
payment by the Successful bidder to IBR authority.
J. GST as applicable will be paid extra. For ISRO 5% IGST is
applicable.
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of
2.8 TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 39 of 82
33. Schedule of Prices
(To be filled in on-line bid only at specified place under Price Bid)
Sl.
No.
Description Amount, in INR
1 Design, Manufacturing, testing, Packing
& Forwarding and transportation of 2.8
TPH Steam Boiler along with all systems
and all accessories required for both (2.8
TPH & 1.1 TPH) boilers as per detailed
requirements as a single package offer as
specified in tender specification
document (sl.no. 1 to 32), but excluding
1.1 TPH Steam Boiler unit alone
*************
2 Erection & Commissioning, etc. of items
against sl. No. 1 at Propellant Complex
Rasayani, ISRO (PCRI)
*************
3 Design, Manufacturing, testing, Packing
& Forwarding and transportation of 1.1
TPH Steam Boiler alone
************
4 Erection & Commissioning, etc. of items
against sl. No. 3 at Propellant Complex
Rasayani, ISRO (PCRI)
**************
5 Supply of Two Years Essential
Operating spares for 2.8 TPH Boiler
*****************
6 Supply of Two Years Essential
Operating spares for 1.1 TPH Boiler
*************
7 Indicative IBR Authority Inspection
Charges towards sr. No. 1 as above
*************
8 Indicative IBR Authority Inspection
Charges towards sr. No. 2 as above
*************
9 Indicative IBR Authority Inspection
Charges towards sr. No. 3 as above
*************
10 Indicative IBR Authority Inspection
Charges towards sr. No. 4 as above
*************
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of
2.8 TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 40 of 82
Annexure - 1
VENDOR EVALUATION FORMAT
The Bidder must submit the following table with documentary proof to
confirm his acceptance to meet the requirements detailed above, without
which the offer will not be considered.
SR.
NO.
DESCRIPTION To be filled / confirmed
by the bidder
1. Name of Company
2. Address of Company
3. Type of Company (Proprietary/Pvt.Ltd
/Public Ltd/Joint Venture/Consortium)
4. Registration number
5. Year of inception of the company
6. Registered address
7. Name & address of the office of the Chief
Executive of the company
8. Name & Designation of the officer of the
Bidder to whom all correspondence shall
be made for expeditious technical/
commercial co-ordination.
Telephone number
Fax number
E-mail address
9. Bidder’s previous track record: The
Manufacturer shall be a
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of
2.8 TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 41 of 82
SR.
NO.
DESCRIPTION To be filled / confirmed
by the bidder
Company/Society/Firm registered since
last 5 (five) years or more.
10. Locations of the Branches of Company (if
any)
11. Annual turn-over of the company for the
last three years
12. IT returns for the last 3 years
13. Enclose copies of the similar Purchase
Orders executed in last five years
14. Customers feedback on the services which
is in writing (Pl. enclose copies)
15. Quality certification of the company
16. PAN Card Copy
17. The Profit & Loss Account details for the
last 3 years which is duly audited and
Submitted as part of the Annual Report
18. Acceptance for Scope of work as detailed above
19. Acceptance of QAP & Inspection Clauses mentioned in the respective annexure
20. Acceptance for Sequence of Design, Manufacturing, Testing, Transportation, Erection & Commissioning of 2.8 TPH & 1.1TPH Steam Boilers along with accessories as mentioned in the tender specification document
21. Details of purchase orders executed under IBR to be submitted
22. The bidder shall not have been blacklisted
by Central Government or any State
Government organization / department in
India at the time of submission of the Bid
(Self-declaration has to be attached)
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of
2.8 TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 42 of 82
SR.
NO.
DESCRIPTION To be filled / confirmed
by the bidder
23. Confirm acceptance of the Delivery
schedule as per the contract
24. Visit by Purchaser: During the Technical
evaluation of the Tender, if required the
purchaser has right to visit the bidder’s
facilities to Clarify / confirm the
documents /claims submitted by him. It is
the responsibility of the bidder to submit
necessary supporting documents / to
evaluate technical competency to meet the
specifications of this document
25. Supplier shall agree to all the terms and
conditions of the tender specifications
26. TWO PART BID: Bidders shall quote the
tender in two part bid basis. Technical bid
shall be evaluated first, only technically
suitable bidders shall be allowed for price
bid.
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of
2.8 TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 43 of 82
Annexure – 2
Check-list to be filled by the bidder and to be uploaded under vendor solicited documents
Sl. No.
Description / Specification Bidder Response / Compliance information
1 Design, Manufacturing, Testing, Erection &
Commissioning of 2.8 TPH (1 No.) and 1.1 TPH (1No.)
Steam Boiler System with Accessories
2 Steam Boiler Parameters :
a. Boiler Quantity : 2 nos.
b. Capacity, TPH (F&A 100 degC : 2.8 TPH - 1 No.
1.1 TPH - 1 No.
c. Steam pressure, kg/cm2(g) : 10.54
kg/cm2(g)
d. Type of Boiler: Smoke Tube, 3Pass
Wet Back
e. Fuel to be Fired : Furnace Oil (FO)
f. Thermal Efficiency, NCV of fuel oil: 89% on
FO as per
BS- 845 part I
on
NCV basis
3 SCOPE OF WORK
A. The Scope of work includes detailed Engineering
design, manufacturing, testing at works,
inspection, supply, transportation, unloading and
receiving the material at site, storage and safe
custody at site, handling at site, erection, testing,
commissioning, guarantee test run and handing
over of boiler and connected accessories with all
statutory approvals as per technical parameters
mentioned under 1.0, Detailed Scope of Work under
2.0, Design requirements under 3.0 and technical
specifications & all other requirements as detailed
from 4.0 to 33.0 of this document and the
Annexures.
B. The successful bidder shall submit detailed design
calculations and proposal within 4 weeks after
release of Purchase Order to IBR Authority and
Purchaser and after approval and clearance from
IBR Authority & Purchaser, actual fabrication work
shall be taken up.
C. Supply of spares for 2 years of trouble free
operation.
4 The Steam Boilers shall be fabricated and inspected as
per drawings & QAP, both approved by IBR authority.
5 At the time of submitting the offer, party shall quote
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of
2.8 TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 44 of 82
Sl. No.
Description / Specification Bidder Response / Compliance information
the names of IBR authority that will be engaged
during the course of entire work in the technical bid. 6 At the time of submitting the offer, party shall attach
documentary evidence indicating IBR approval of the fabrication shop in the technical bid.
7 The bidder’s scope shall also include any other services,
etc. if called for in the succeeding sections of the
specification. The successful bidder shall be responsible
for providing all material, equipment & services,
which are required to fulfil the intent of ensuring
operability, maintainability, reliability and complete
safety of the complete work covered under this
specification, irrespective of whether it has been
specifically listed herein or not. Omission of specific
reference to any component / accessory necessary for
proper performance of the equipment shall not relieve
the bidder of the responsibility of providing such
facilities to complete the supply, erection and
commissioning of Boiler and accessories as per this
document within quoted price
8 It is not the intent to specify herein all the details
of design and manufacture. However, the equipment /
system shall conform in all respects to high
standards of design, engineering and workmanship
and shall be capable of performing the required
duties in a manner acceptable to purchaser who will
interpret the meaning of drawings and specifications
and shall be entitled to reject any work or material
which in his judgement is not in full accordance herewith
9 Items though not specifically mentioned but needed to
make the system complete as stipulated under these
specifications are also to be furnished unless otherwise
specifically excluded.
10 Bidder shall submit all the details of the proposed
boilers, accessories, tanks, instrumentation & control
system, etc. confirming to the specifications of this
document in the technical bid itself, without which
offer will not be considered.
11 Detailed Scope of work by Vendor:
a) All activities related to obtaining approval and
clearance by the IBR and other statutes shall be the
responsibility of the Vendor.
b) All necessary certificates in the required form as
approved by the Boiler Inspectorate shall be
forwarded to PURCHASER. Responsibility of the
purchaser with respect to the boiler Inspectorate
is limited to paying the registration fee and
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of
2.8 TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 45 of 82
Sl. No.
Description / Specification Bidder Response / Compliance information
forwarding of necessary application forms only.
All other fees and expenses in connection with IBR
approval shall be borne by the Vendor.
c) All equipments and parts covered under Indian
Boiler Regulation shall be designed, fabricated,
tested and erected as per the requirement of this
regulation, and necessary statutory approvals are
to be obtained before the commencement of the
work.
d) The Scope of work shall include complete
refractory insulation and lagging including
material for the complete boiler units.
e) All hot water, steam lines, air ducts, furnace oil
lines shall be insulated.
f) Dampers are to be provided for isolation of FD fan.
g) All exposed carbon steel/structural steel parts of
equipment, pipes, ducts etc. shall be given two
external coats of approved primer before dispatch.
h) All equipment after erection shall be given two
coats of primer wherever required and two
external coats of final painting as per standard.
i) All civil work for foundation are excluded from
Vendor’s scope. However, grouting of
equipments/structurals including supply of
grouting materials and anchor bolts are included
in Vendor’s scope. Anchor bolts shall be
dispatched to site sufficiently in advance.
j) Vendor shall furnish detailed foundation data and
loading diagrams for the boilers, stack etc. Vendor
shall provide floor plan of equipments, piping, etc.
k) Bidder shall provide proposed P&ID of the system
along with the offer. For all such components /
equipments like pumps, pipelines, tanks, etc. sizing
shall be finalized as part of detailed engineering
phase.
l) The Quality Assurance Plan (QAP) identifying all
stages of inspection shall be approved by IBR as
well as Purchaser.
m) The stack shall be designed and fabricated to meet
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of
2.8 TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 46 of 82
Sl. No.
Description / Specification Bidder Response / Compliance information
the Maharashtra Pollution Control Board (MPCB)
norms. The expected emission levels from the
proposed boilers shall be specified in the offer.
n) All piping items, valves, pumps, control valves,
instruments like pressure gauges, level gauges,
flow meters, transmitters, motors etc. shall be
procured from reputed vendors and manufacturers
test certificate for chemical compositions,
mechanical properties, hydro test etc. shall be
furnished.
o) For IBR covered items, IBR certificate in relevant
forms shall be furnished.
p) Preservation method during idle period shall be
recommended by the successful bidder for drum
internals, water headers, smoke tubes, outer
surface of boiler tubes and furnace.
q) Material of construction for major boiler parts as
per table - 1, boiler feed water lines, steam lines
and all such applicable items shall meet IBR
requirements.
Table – 1: Material of Construction of major
Boiler Parts
Sl. No. Material of Construction of major
Boiler Parts
Boiler Drum
1 Shell Plate SA 515/516 Gr 70
2 Tubes BS 3059 ERW
3 Manhole/Hand
hole SA 515/516 Gr 70
4 Pipes SA 106 Gr B
Furnace
5 Plates SA 515 / 516- 70
6 Header/Pipe SA 106 Gr B
7 Tubes
BS 3059 ERW
320
r) Successful bidder has to impart necessary training
to the personnel of PURCHASER without any
financial implications.
s) Successful bidder shall provide lightning protection
for equipments of the boiler system as applicable.
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of
2.8 TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 47 of 82
Sl. No.
Description / Specification Bidder Response / Compliance information
Vendor shall also provide earthing to all electrical
equipments.
t) Successful bidder shall provide the data sheets and
drawings of all equipments, valves, instruments
etc. of the system with isometric drawing.
u) 3 sets of all the documentation involved in this
scope of work shall be submitted by the successful
bidder.
v) Party should submit data as per xxii) in soft format
also after placement of P.O.
w) List of Tentative Spares to be supplied for each
boiler as per following Table – 2
Table – 2: List of Tentative Spares
Sr.
No.
Description Qty.
(a) Spares of Boiler
1. Manhole Gasket 1
2 Mudhole Gasket 1
3 Tube changing Brush 2
4 Magnet Switch for Water Level Controller 1
5 S.S. Float, Rod & Magnet Assembly 1
6 Boiler Pressure Gauge 0-25 Kg/Cm2 1
7 Feed Water Pressure Gauge 0-16 Kg/Cm2 1
8 Fusible Plug 2
9 Inspector Test Gauge Cock 1
10 Toughened Glass for Flame Observation 1
(b) Spares of Burner
1 Photocell 1
2 Mechanical Oil Seal 1
3 Ignition Electrode 2
4 Heater Gasket 2
(C) Other Spares
1 10% (min. 1No.) spares shall be provided
for all manual valves, steam traps,
gaskets, bolts, nuts etc. for each type and
size
1 lot
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of
2.8 TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 48 of 82
Sl. No.
Description / Specification Bidder Response / Compliance information
12 Design Requirements (Boilers & Accessories)
o Boiler shall be horizontal, shell type fully
packaged 3- pass smoke tube design,
automatically controlled, tested and proven
under rigorous conditions and subject to the
strictest quality control procedures.
o The boiler shall be of genuine three pass flue
path. Flue gases should pass through the
furnace (first pass) whereas second and third
passes should be formed by nests of smoke
tubes. At the end of the furnace the flue gas
reverses into second pass tubes.
o All the common systems shall be suitably
designed for either individual or combined
operation of both the boilers
simultaneously.
o The boiler shall be complete with all
mountings, accessories, controls etc.
o Boiler construction shall be in accordance
with the latest revision of Indian Boiler
Regulations Act 1950 and in conformity with
AOTC requirements for unattended boilers.
All materials used shall be approved and
tested as per relevant existing codes. All the
welded joints shall be as per code
requirement.
o The boiler shall be of modern compact design
and be genuinely packaged design. The design
source should confirm to international
design. The boiler and the burner design
must be from single manufacturer to
ensure perfect matching of burner and
boiler. Relevant details shall be attached
with the offer as part of technical bid.
o The fire tubes in the tube nest should be plain
without any restriction inside. These tubes
should be easily accessible both from inside
as well as outside for inspection and
maintenance. These tubes are to be tightly
expanded in the tube plate and seal welded.
The required number of stay tubes and stay
bars are to be fitted in the boiler. The stay
tubes should be seamless & strength-welded
to tube plates.
o All working parts of the boiler should be
accessible for ease of inspection and
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of
2.8 TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 49 of 82
Sl. No.
Description / Specification Bidder Response / Compliance information
maintenance. On the shell, one elliptical
man-door and on tube plate one mud hole
must be provided. Access to the combustion
chamber should be through bolted refractory
lined access door whereas tube nest should
be exposed through hinged mounted front
door.
o Boiler front door shall be lined with ceramic
fiber blanket with SS sheeting on the tube
side of the door.
o The boiler mountings, supporting systems
and accessories shall be as per the Scope of
Supply as mentioned in Sl. No. 21.
o The boiler shall be designed and constructed
to generate steam at efficiency of 89% on net
calorific valve (NCV) basis. Efficiency shall
be demonstrated as per standard BS – 845
Part 1 Indirect method.
o The insulated cylindrical shell of the boiler
shall be cladded with aluminum sheets. A
movable ladder shall be provided which can
be moved as per convenience.
o Boiler and accessories shall be mounted on a
single base frame. Individual systems such as
feed water pump etc. may be on separate
base plates welded to the boiler base frame.
o It shall not require any special foundation
for the boilers and for its
mountings/fittings. It should be able to be
mounted on simple PCC foundation.
o The proposed Boiler House civil requirements
with the anticipated size of the boiler is
enclosed as figure no. 1. Boilers & accessories
shall be designed to meet / not to exceed the
dimensions given in the sketch. 13 Fuel oil system : This shall be suitable for handling
furnace oil fuel. Burner shall be mono-bloc type. The
electric heater with required number of elements shall be
provided for ensuring the conditioning of furnace oil for
firing in the boiler. The electrical oil pre-heating system
shall be 100% pre-heating for the rated boilers capacity.
14 Combustion system: This system shall consist of a
forced draft combustion air blower with motor,
mechanical atomizer, burner assembly, photocell
operated safety device, ignition electrodes, transformers
etc. Burner assembly shall be bolted on combustion
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of
2.8 TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 50 of 82
Sl. No.
Description / Specification Bidder Response / Compliance information
chamber and that the burner is lit only when the entire
burner assembly is fitted and is in a closed position,
ready for operation.
• Pressure jet atomisation shall be provided. The
burner should be capable of firing furnace oil of
viscosity upto 3500 rad-sec. at 35 deg. C. Dead
weight explosion door & fusible plug shall be
provided for ultimate safety. The entire assembly
should be engineered in such a way that burner
moves along with the door when the door is opened
for tube cleaning.
• The burner shall be of stepless modulation
compatible for firing oil. The controlling of the
air and fuel damper shall be done by means of
individual servomotors sending electronic
signals. Burner must be with turn down ratio of
1:4 for oil. Burner should be equipped with
pneumatic arm control for maintaining the A/F
ratio with changes in air density compensation.
Type of Burner Pressure Jet
Construction Monobloc
Modulation Stepless
Load
Regulation
Electronic Compound Regulation
(ECR) Technology
Turndown
Ratio
1:4 without loss of efficiency.
Stack
Emissions
Shall meet Maharashtra Pollution
Control Board specified allowable
limits for the proposed boiler &
chimney design
• The burner and the boiler design shall be
compatible with each other and that both the
burner & boiler manufacturer shall be same. 15 Day Feed Water Tanks, 25 KL – 2nos. : The feed water
tanks shall be with a capacity of 25000 litres each. The
feed water tanks (2.2 m Diameter x 7.0 m Length) shall
be manufactured as a horizontal cylindrical tank with
minimum 6 mm thick plate material of IS 2062 Gr.B. The
feed water tanks shall be complete with the following
accessories.
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of
2.8 TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 51 of 82
Sl. No.
Description / Specification Bidder Response / Compliance information
(a) Level Gauge
(b) Atmospheric Deaerator Head with
inlets for make-up water, flash steam
and condensate.
(c) Level Control System consisting of 3
level switches for high, low and extra
low level of water.
(d) Insulation & Cladding
Feed water tanks – 2nos. of 25m3 capacity shall be placed
at an elevation of 4 m on available RCC columns at site as
shown in figure - 1. The successful supplier shall make
suitable interfacing of the supplied tanks with these
columns.
• 16 Feed Water System Pumps: 2 nos. of electrically driven
vertical centrifugal multistage pumps with motor capable
of using feed water at maximum temperature of 120 deg
C with all SS internals, interconnected pipe work
between pumps and feed check valves shall be supplied.
17 Blowdown system: Total Dissolved Solids (TDS) based
Automatic Blowdown Control System based on
conductivity principle with pneumatically actuated valve
for efficient control of TDS level within the boiler shell.
This system shall be installed in parallel to the manual
blowdown valve.
18 Instrumentation & Controls: The electro-mechanical
control system shall be provided. The following
controls / indications shall be ensured:
a. The relay based control panel shall be mounted
in the control room.
b. Interlocking of the feed water pumps and water
level in the boiler
c. Audio–visual alarm for high, low & very low level
of water in the boiler and also for flame failure.
d. Programmer controller to ensure sequence of boiler
start-up after ensuring required temperature and
pressure of oil, air etc.
e. MCB’s and contactors shall be provided for all
electrical drives for the boiler
f. Pilot lamp to indicate operating status of the
various equipments.
g. Complete internal wiring to ensure power supply at
a single point on the panel.
h. Indicating lamps/ Audio alarm shall be provided for
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of
2.8 TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 52 of 82
Sl. No.
Description / Specification Bidder Response / Compliance information
the following parameters -
1. Low water level in the boiler and very low
level trip provision
2. Burner flame failure
3. Feed water pumps failure
4. Damper closed position
i. Pressure switch shall be provided for burner
interlock.
j. Microprocessor based single loop Controller shall
be provided for Steam drum level, oil pressure,
degasifier Level and Ratio controller for Air Fuel
ratio, Furnace Box pressure. One controller shall be
provided as spare. (Preferably ABB commander
C500 or equivalent)
k. Both boiler shall have separate control systems and
interlocks.
l. Differential pressure Transmitter shall be provided
for deareator, boiler level with PID Controller, ABB
commander C500 controller or equivalent. Smart
positioners shall be provided for control valve
operation. Dampers for operation of ID and FD.
m. Control panel shall be mounted in control room for
ease of operation and maintenance.
n. Instead of side level gauges top mounted level
indication shall be provided with float and rollers
magnetically coupled for Level of storage tanks and
deareator.
o. Boiler Drum water Very High Level and Very low
level Switches shall be provided for trip
interlocks. Boiler level shall be controlled by
providing level transmitter PID controller and
feed water control valve.
p. Alarms shall be provided for High and low level of
boiler drum level, flame failure, box pressure high,
BFW pump trip, Oil temp high low etc. Interlock for
BFW pump trip shall be provided in case of boiler
level V high. Boiler shall trip with flame failure ,
Box pressure Very High, Boiler Level Very low etc .
q. Steam, Oil, BFW Flow meter shall be of two wire
transmitter type and indication of flow and total
flow to be provided in control room.
r. Vendor shall provide interlock logic diagram.
s. Vender to provide list of Spares for 2 years.
Mandatory spares shall include - One set of
candles for air filters, smart positioners, indicator
totaliser.
t. Vendor to provide SS air header with ¼ ‘’ needle
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of
2.8 TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 53 of 82
Sl. No.
Description / Specification Bidder Response / Compliance information
valves for distribution of pneumatic supply.
u. Vendor to provide line mounted Air filters of
required size at battery limits. Two sets of Fine (
20 Microns) and Coarse filters (50 Microns)
parallel to each other shall be mounted on the
header assembly with isolation valves as standby
arrangement.
v. Wetted parts for all transmitter shall be SS316.
w. Vendor shall provide specifications of each
instruments with operation and Maintenance
manuals. 19 Chemical Dosing System: Feed water side softener along
with necessary pumping skid mounting & piping shall be
supplied along with ONE standby set of pump & motor.
20 Furnace Oil Supply related Piping with heating
arrangement: Furnace oil tanks are NOT in the scope
of supplier. However, necessary piping arrangement
shall be realized by the vendor. There will be 2 Day Oil
Tanks of 20 m3 capacity & 2 oil storage tanks of 30m3
capacity for which bidder shall consider piping
arrangements.
• Tentative distance between FO storage to actual
boiler will be ~40m. Successful Bidder shall
supply suitable electric heater for satisfactory
operation of the boilers (Overall for 4 TPH
capacity). The built in electric heater with required
number of elements shall ensure the conditioning
of furnace oil for firing in the boiler. The electrical
oil pre-heating system shall ensure 100% pre-
heating for the rated boiler capacity.
• 6 nos. of Oil pumps as detailed under scope of
supply under 21.4 shall also be supplied.
• Arrangement of common drain line with individual
bottom drain valves is required to be done for
removing water (moisture) from the tanks. Drained
furnace oil shall be collected for proper disposal;
taking care that dyke area will remain clean and
there will not be any soil or drain water
contamination
21 Structural Supports: Shall be provided for the following:
• Boiler House Piping
• Ducting
• Also wherever applicable as per site conditions
22 Boiler House Piping: The following boiler house piping
(for 2 boilers, Overall for 4 TPH capacity) shall be
delivered by the vendors.
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of
2.8 TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 54 of 82
Sl. No.
Description / Specification Bidder Response / Compliance information
a) Feed Water Piping from the Feed Water Tank to the
individual feed water pumps complete with inlet
Isolation Valves – 2 Nos and Strainers – 2 Nos.
Inclusive of Insulation & Cladding.
b) Furnace Oil Piping from the Day Oil Tank to the
Burner complete with Duplex Filter, Recirculation
Header and return oil piping to Recirculation
Header. The piping shall be complete with
Insulation & Cladding.
c) Steam Piping from Main Steam Stop Valve to the
Main Steam Header & from Header to the Pressure
Reducing Station complete with Insulation &
Cladding as approved by IBR. And also up to
existing steam header located approximately 50m
away from boiler house.
d) Steam Header shall be as per IBR with inlet &
outlet isolation valve, safety relief valve, steam
trap module, insulation & cladding.
e) Safety Valve Exhaust Piping from the outlet of the
Safety Valves to outside of the boiler house,
complete with insulation & cladding.
f) Blowdown piping from the outlet of the blowdown
control system to the blowdown pit as approved by
IBR.
g) Drain Piping from the boiler drain points, drain
from the feed water tank and the day oil tank shall
also be delivered by the Vendor.
h) Any other piping & valve arrangements for overall
smooth operation of both the boilers. 23 Pressure Reducing Station – 1 number each for each
steam flow rate of 2800 kg/ hr & 1100 kg/hr for pressure
reduction from 10.54 kg/cm2(g) to 3.5 kg/cm2(g) with
bye-pass and isolation valves provision.
24 Flue Gas Ducting: MS flue gas ducting from boilers to
Chimney complete with expansion bellows, insulation &
cladding.
25 Condensate Recovery System: A suitable condensate
recovery system shall be supplied to optimize the
consumption of Furnace oil.
26 Feed Water Dosing System: Vendor shall supply suitable
Feed Water Dosing system as required for satisfactory
boiler operation.
27 Boiler Efficiency Monitoring Package: Boiler efficiency
monitoring system to improve the boiler efficiency and
monitor boiler parameters on real time basis. Shall be
provided as detailed under -
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of
2.8 TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 55 of 82
Sl. No.
Description / Specification Bidder Response / Compliance information
(a) Steam Flow Meter, Vortex Type with
density compensation
(b) Oil Flow Meter
(c) Booster Pump Skid for Oil Flow Meter
(d) Temperature transmitters for Feed
Water & Steam
(e) Software for online Trend analysis 28 Boiler House Electricals : Shall be complete with
- Power cables from the control panel to the
various consumers
- Control cables from the panel to the various
instruments
- Utility Panel from mounting the Efficiency
Monitoring Panel
- Cable trays & Accessories as required
29 MS Self Supported Chimney : Shall be Designed as per
IS 6533 with a height of 30 meters minimum. The
chimney shall be designed for a boiler capacity of 4.0
TPH. Chimney shall have the provision for sampling
point. The corrosion allowance to be considered shall be
1.5 mm and shall be complete with
(a) Aviation Lamps
(b) Lightening Arrestor
(c) Earthing Strips
(d) Inlet for ducting coming from 2.8 TPH
boiler
(e) Inlet for ducting coming from 1.0 TPH
boiler
(f) Ladder & Platforms at suitable heights
(g) Insulation & cladding of the Bottom 2
meters
(h) Dampers as applicable
30 Total scope of supply items as detailed from 21.1 to
21.19 of the tender specification document
31 Electricals:
• It shall contain all necessary switchgears, safety
alarms/interlocks and burner management system
and is to be mounted in the control room for ease
of maintenance and comfort of working peoples.
• Boiler shall be complete with all necessary
electrical cabling from the control panel till burner
/ FW pumps etc. Power cables shall be 1100 V
grade, PVC insulated & PVC overall sheathed.
• Control cables shall be multi-strand copper
conductors of minimum 2.5 sq.mm.
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of
2.8 TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 56 of 82
Sl. No.
Description / Specification Bidder Response / Compliance information
• All motors shall conform to squirrel cage induction
motors, TEFC, IP-55, class ‘F’ insulation. IE-2
efficiency class motors shall be of
BBL/Siemens/NGEF/Crompton make and shall be
painted with anticorrosive paint. MCC Cum Control Panel :
• A MCC cum control panel, complete with main
isolator switch, starters, auxiliary contactors,
relays, fuses, rotary switches, indicating lamps,
isolator, hooters with programmer and combustion
safety relay.
• The panel shall be completely pre-wired and
factory tested. It shall be installed in MCC room
with suitable foundation. All switch gears shall be
of Siemens or other reputed make.
32 Insulation & Cladding for each boiler:
The boilers shall be completely insulated in the
factory itself and there shall not be any site work
involved for insulation and electrical cabling. The
cylindrical shell of boiler must be insulated with glass
wool / Rock wool mattresses of required thickness and
shall be cladded with Aluminium.
33 Refractory for each boiler:
Suitable refractory material shall be provided for all
required parts as follows :
Front door : Ceramic fiber blanket with
SS sheeting
Rear door : Hysil blocks with Kynex HG
/ Insulyte 7
Furnace ring / burner ring : Hysil blocks with
Insulyte 7
34 Battery Limits for the bidder:
Feed Water : Inlet flange of Feed
Water Tank
Fuel oil : Inlet Flange of Day Oil Tank
located
approx. 40m away from
boiler house and piping involved
for oil circulation with day oil
tank
Blow down water : At the Blowdown Pit
Steam : Outlet of Pressure
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of
2.8 TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 57 of 82
Sl. No.
Description / Specification Bidder Response / Compliance information
Reducing Station
and up to approximately
50 m steam line to be provided to
connect to the existing piping
rack
Power : At the Control Panel/
Utility Panel
Flue gas : At the outlet of chimney
• All battery limit flanges for low pressure (3.5
kg/cm2) steam shall be as per ANSI B 16.5 150# and
that for high pressure (10.5 kg/cm2) steam shall be
as per ANSI B 16.5 ASA 300#.
35 Detailed Technical Inputs to be provided by the bidder
for the proposed items as per table under sl. No. 23 of
the tender specification document
36 Delivery
a. Transportation, Erection and commissioning
shall be carried out by the bidder at
Propellant Complex Rasayani, A Unit of SDSC,
ISRO, Tal.: Panvel, Dist.: Raigad, PIN-410207,
Maharashtra.
b. All necessary Equipments like welding
machine, Gas cutting set, Grinding M/C, etc, and
Consumables like Welding Electrodes, Gases,
Grinding Wheels, paints, brushes, etc., including
material handling support, skilled and semi-skilled
manpower required for carrying out the above
work shall be in the scope of the bidder.
c. The supply scope of work as per this
specification document shall be completed
within maximum period of 6 months from the
date of placement of Purchase Order and erection
and commissioning within maximum period of 2
months from the date of site clearance after
receipt of items.
37 Performance Test and guarantee:
a) Steam blow out for the new boiler and
interconnecting pipes shall be carried out using
suitable target plate to ensure steam purity to
the satisfaction of PURCHASER.
b) As soon as the boiler system is commissioned
the Vendor shall conduct a Performance
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of
2.8 TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 58 of 82
Sl. No.
Description / Specification Bidder Response / Compliance information
Guarantee test of the system. All parameters
listed below are to be proved/demonstrated to
the complete satisfaction of PURCHASER. The
duration of test run shall be for a period of 24
hours continuous operation after stabilization.
Performance guarantee runs shall be conducted
as per BS 845 part I – 1987 indirect test method
– after one month of continuous trouble free
operation.
c) The following parameters are to be
guaranteed by the Vendor at the system outlet
Battery limit. In the event of not achieving the
same, the Vendor has to set right the system to
achieve these figures without any extra cost
with in a period of three weeks. If the vendor
fail to achieve even after this, PURCHASER shall
be free to get it done by themselves or through
other agencies at the risk and cost of the
vendor.
Quantity of Steam
- 2.8 T/Hr F& A 100 0 C
- 1.1 T/Hr F& A 100 0 C
Steam pressure
- 10.54 Kg/cm2g
(Tolerance +0.5-0.0
Kg/cm2g)
Steam temperature - Saturated steam
Dryness factor - 98 %(Min)
Emission
level
Shall be lesser than
MPCB allowable limits
for the proposed boiler
& chimney design.
d) The guaranteed noise level at 1M from the
equipment shall be 85 db(A)
e) Gas temperature at outlet of stack (top opening)
shall be 175oC (Min).
f) Vendor shall guarantee the equipment and the
components of boiler against all defects in design,
use of defective materials or bad workmanship for
a period of 12 months from the date of
commissioning or 18 months from the date of
supply whichever is earlier. Any such defect shall
be set right by the Vendor at his own cost during
the period.
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of
2.8 TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 59 of 82
Sl. No.
Description / Specification Bidder Response / Compliance information
38 Mandatory Documents to be submitted along with
offer:
Technical:
1) General Arrangement drawing of the system.
2) Detailed list of Instrumentation items to be
supplied.
3) Detailed list of mechanical items to be supplied.
4) Detailed list of Electrical items to be supplied.
5) Detailed list of spares for 2 years operation shall
be submitted for each boiler.
6) PERT chart for supply and Site activities.
7) Proposed P&I Diagram.
8) Equipment data sheet.
9) Quality and quantity of Steam generated.
10) Quality and quantity of dozing chemicals, if any.
11) Annexures – 1 to Annexure – 10 shall be filled,
signed and to be uploaded on the portal
12) Utility requirements like DM water, Instrument
Air, Power, Furnace Oil, etc at battery limit with
line size.
Commercial:
13) Firm establishment certificate indicating
nature of work.
14) Details of work of similar type – minimum 3
nos. completed by providing copies of purchase
orders during the preceding three years.
15) Satisfactory work Completion certificates
from the clients
16) Documentary proof shall be submitted with
the offer indicating execution of at least one order
of value of Rs. 95 lakhs or two orders of value of Rs
50 Lakhs each or three orders of Rs. 30 Lakhs each
during preceding three Audited financial years.
17) IT/ TDS certificate shall be submitted with
Profit & Loss statement for preceding three
financial years.
18) Bidder shall submit audited statement of
financial status for preceding three years.
39 Inspection & Approvals
a) The boilers shall be subject to inspection and
testing in accordance with latest IBR codes.
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of
2.8 TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 60 of 82
Sl. No.
Description / Specification Bidder Response / Compliance information
b) Boilers fabrication shall be subject to inspection &
testing in accordance with latest revision of IBR
code. Manufacturer shall ensure that the boiler
meet the requirements of the Inspectorate of
boilers.
c) Simulation test of boiler control panel shall be
carried out in presence of customer’s
representative at the place of manufacture before
delivery.
d) Boilers/ piping shall be hydro-tested at works as
per IBR guidelines.
e) All piping items, valves, pumps, control valves,
instruments like pressure gauges, flow meters, transmitters, motors etc shall be procured from reputed vendors and manufacturer’s test certificate for chemical compositions, mechanical properties, hydro test etc. shall be furnished.
40 TWO PART BID: Bidders shall quote the tender in two
part bid basis. Technical bid shall be evaluated first, only
technically suitable bidders shall be allowed for price
bid. The price bid will be evaluated based on overall
single lowest offer and splitting of order is not
envisaged
41 T Technical Qualification Requirements:
a. The bidder shall meet the technical specification
and other requirements and shall submit relevant
certificates to establish the credentials.
b. The Bidder shall be a party who has
manufactured steam boilers and executed
similar / identical works with minimum 5 years
of experience.
42 Financial Qualification Requirements:
a. The Bidder shall have executed at least one order of
value of Rs. 95 lakhs or two orders of value of Rs
50 Lakhs each or three orders of Rs. 30 Lakhs each
during preceding three Audited financial years.
Documentary proof shall be submitted with the
offer in this regard.
b. IT/ TDS certificate shall be submitted with Profit &
Loss statement for preceding three financial years.
c. Bidder shall submit audited statement of financial
status for preceding three years.
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of
2.8 TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 61 of 82
Sl. No.
Description / Specification Bidder Response / Compliance information
43 T Following documents shall be submitted along with
the bid for prequalification of Bidder.
d. Firm establishment certificate indicating nature of
work.
e. Details of work of similar type - minimum 3 nos.
completed by providing copies of purchase orders
during the preceding three years.
f. Satisfactory work Completion certificates from the
clients, with the work / purchase order copies
44 Bid Selection Procedure and Process of Pre-
Qualification
a. Short listing based on documents submitted,
satisfying all the eligibility criteria given above
by the firm along with their Bid. (Non-
submission of any document as given in above
list within stipulated time leads to rejection of
Bid).
b. Subsequently Bidder's competency, their
technical achievements and financial status will
be evaluated suitable for this work. Feedbacks
from Bidder's clients will be verified, if required.
45 Evaluation criteria for bidders:
a) After receipt of bids from the bidders, their
credentials will be evaluated by the purchaser and
their offers will be considered only after
evaluation.
b) Visit to earlier executed work sites, if required,
where similar works have been carried out, erected
and commissioned by the party, to ascertain their
complete suitability for the jobs described above.
c) Purchaser reserves the right to reject the offers not
complying to conditions mentioned in this tender
specification document. No communication from
the rejected parties / bidders will be entertained by
the purchaser
d) Technical bids submitted by the bidder will be
opened first and evaluated for fulfilling the Pre-
qualification criteria and other conditions in
NIT/Tender documents, based on documentary
evidences submitted along with the offer.
e) In case the qualifying experience is claimed by
private organizations based on work order and
completion certificates from another private
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of
2.8 TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 62 of 82
Sl. No.
Description / Specification Bidder Response / Compliance information
organization, PCRI reserves the right to ask for
further proofs including submission of TDS
certificates for the said job.
f) Visit to vendor’s premises by our technical team
for accessing the technical capabilities of bidder,
if required.
g) The documents listed in Sl No. 32.1.1 to 32.1.4 of
this section will be reviewed by the purchaser
during factory visit, if required.
h) It is proposed to evaluate the bidder based on the
previous experience in execution of the similar
nature of works. The supplier has to
furnish/confirm the details as enclosed in the
vendor evaluation format as per Annexure – I.
i) Financial bids of shortlisted bidders (qualified in
technical bid) shall only be opened.
j) Financial bids of unqualified bidders shall not be
opened.
k) Conditional bids may be rejected by PCRI. The
technical evaluation shall be made strictly on the
basis of the documents submitted by the bidders in
support of the eligibility, the technical and
commercial response. All the required information
shall be furnished strictly in prescribed
schedules/Annexure only. Any information
indicated other than prescribed
schedules/Annexure shall not be entertained. The
financial evaluation shall be made on the basis of
the total price/charges as indicated in the schedule
of rates. PCRI is not bound to accept the lowest
quoted offer. Conditions, if any, on any document
enclosed with financial Bid shall not be considered.
PCRI’s decision in this regard shall be final and
binding. 46 General Terms & Conditions:
a. Successful bidder shall make their own
arrangements towards lodging, boarding &
conveyance during Erection & commissioning
activities at Propellant Complex Rasayani, ISRO.
b. Liquidated Damages - Delivery schedule indicated
in the Purchase Order/Contract is the essence of
the contract and if the party fails to deliver the
material within the delivery schedule, Liquidated
Damages will be levied @ 0.5% per week or part
thereof subject to a maximum of 10% of total order
value.
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of
2.8 TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 63 of 82
Sl. No.
Description / Specification Bidder Response / Compliance information
c. Performance Bank Guarantee - Performance Bank
Guarantee for 10% of the order value shall be
furnished in the form of Bank Guarantee from
nationalized/scheduled bank or by Demand Draft
valid till warranty period plus sixty days as claim
period.
d. Security Deposit – Security Deposit for 10% of the
order value is mandatory. Party shall furnish the
Security Deposit in the form of Bank Guarantee
from nationalized/scheduled bank or by Demand
Draft valid till completion of the contract period
plus sixty days towards claim period for faithful
execution of the contract.
e. In case, if parties are unable to provide two
separate BGs, i.e., one for SD & one for PBG, they
can submit a combined BG for SD & PBG for 10% of
the Order value valid till the completion of total
contractual obligation (i.e., Supply period +
warranty period + 60 days).
Force Majeure:
The following shall amount to Force Majeure:
i. Acts of God, act of any Government, War,
Sabotage, Riots, Civil commotion, Police action,
Revolution, flood, Fire, Cyclones, Earth quake and
Epidemic and other similar causes over which the
Supplier has no control.
ii. If the Supplier suffers delay in the due
execution of the contractual obligation due to
delays caused by force majeure as defined above,
the agreed time of completion of the job covered
by this contract or the obligations of the Supplier
shall be extended by a period of time equal to
period of delay, provided that on the occurrence of
any such contingency, the Supplier immediately
reports to PCRI in writing the causes of delay and
the Supplier shall not be eligible for any
compensation.
Arbitration & Reconciliation:
i. In case amicable settlement is not reached in the
event of any dispute of difference arising out of the
execution of the contract or the respective rights
and liabilities of the parties or in relation to
interpretation of any provision by the Supplier in
any manner touching upon the contract, such
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of
2.8 TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 64 of 82
Sl. No.
Description / Specification Bidder Response / Compliance information
dispute or difference shall (except as to any
matters, the decision of which is specifically
provided for therein) be referred to the sole
arbitration of the arbitrator appointed by PCRI.
ii. The award of the Arbitrator shall be binding upon
the parties to the dispute.
iii. Subject as aforesaid, the provisions of Arbitration
and Reconciliation Act 1996 (India) or statutory
modifications or re enactments thereof and the
rules made there under and for the time being in
force shall apply to the arbitration proceedings
under this clause. The venue of the arbitration shall
be held at Mumbai and the language of the
proceedings shall be in English. Subject to the
above, the Courts at Mumbai alone shall have the
jurisdiction to deal any disputes between the
Parties pertaining to the contract.
iv. The cost of arbitration shall be borne equally by
both the parties.
v. Work under the contract shall be continued during
the arbitration proceedings.
vi. Failure to comply with any of the above conditions
can result in termination of the contract, forfeiture
of the security deposit, penalty as may be decided
by PCRI and future blacklisting of the Supplier. 47 Special Instructions to the bidders for quoting prices
in the on-line price bid
A. Purchaser reserves the right to order all the items
as listed in this specification document or
excluding 1.1 TPH boiler unit alone.
B. Accordingly, a separate line item has been
identified for bidder to quote for 1.1 TPH boiler unit
alone against sl. No. 3 of Price bid.
C. Under sl. No. 1 of price bid, bidder shall quote
lumpsum amount towards Design, Manufacturing,
testing, Packing & Forwarding and transportation
of 2.8 TPH Steam Boiler along with all systems and
all accessories required for both (2.8 TPH & 1.1
TPH) boilers as per detailed requirements as a
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of
2.8 TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 65 of 82
Sl. No.
Description / Specification Bidder Response / Compliance information
single package offer as specified in tender
specification document (sl.no. 1 to 32), but
excluding 1.1 TPH Steam Boiler unit alone
D. Under sl. No. 2 of price bid, bidder shall quote
lumpsum amount towards Erection &
Commissioning of items against sl. No. 1 at
Propellant Complex Rasayani, ISRO (PCRI)
E. Under sl. No. 3 of price bid, bidder shall quote
lumpsum amount towards Design & manufacturing
of 1.1 TPH Steam Boiler alone
F. Under sl. No. 4 of price bid, bidder shall quote
lumpsum amount towards Erection &
Commissioning of item against sl. No. 3 at
Propellant Complex Rasayani, ISRO (PCRI)
G. Under sl. No. 5 Supply of Two Years Essential
Operating spares for 2.8 TPH Boiler boilers shall be
quoted.
H. Under sl. No. 5 Supply of Two Years Essential
Operating spares for 1.1 TPH Boiler boilers shall be
quoted.
I. Under sl. No. 6 to 10, IBR Authority Charges will be
paid on actuals or quoted price, whichever is lower
against documentary proof of payment by the
Successful bidder to IBR authority.
J. GST as applicable will be paid extra. For ISRO 5%
IGST is applicable.
48 Signed & stamped copies of Annexures 1 and 3 to 10 shall be uploaded
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of
2.8 TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 66 of 82
Annexure 3
EXCEPTIONS AND DEVIATIONS
In line with Proposal Document, Bidder may stipulate Exceptions and
deviations to the Proposal conditions if considered unavoidable.
SL.
NO
Reference in
Specification
Purchaser
Spécification
Offered
Spécification DEVIATION
PAGE
NO
CLAUSE
NO
NOTE :
Only deviations are to be written in this Annexure.
Any deviations taken by the Bidder to the stipulations of the Proposal
document shall be brought out strictly as per this format and enclosed
along with the bid.
Any deviations not brought out as per this Proforma and written
elsewhere in the Proposal document shall not be recognized and the same
is treated as null and void.
Any willful attempt by the Bidder to camouflage the deviations by giving
them in the covering letter or in any other documents that are enclosed
may render the Bid itself non-responsive.
(SIGNATURE OF BIDDER)
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of
2.8 TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 67 of 82
Annexure -4
TENDER ACCEPTANCE LETTER (To be given on Company Letter Head)
Date:
To,
SPSO, SDSC SHAR
Sub: Acceptance of Terms & Conditions of Tender. Tender Reference No: ________________________
Name of Tender / Work: - . Dear Sir,
1. I/ We have downloaded / obtained the tender document(s) for the
above mentioned ‘Tender/Work’ from the web site(s)
namely:……………………………….. as per advertisement, given in the
above mentioned website(s). 2. I / We hereby certify that I / we have read the entire terms and
conditions of the tender documents of all pages (including all
documents like annexure(s), schedule(s), etc.,), which form part of the
contract agreement and I / we shall abide hereby by the terms /
conditions / clauses contained therein. 3. The corrigendum(s) issued from time to time by department/
organization too has also been taken into consideration, while
submitting this acceptance letter. 4. I / We hereby unconditionally accept the tender conditions of above
mentioned tender document(s) / corrigendum(s) in its totality /
entirety. 5. I / We do hereby declare that our Firm has not been blacklisted/
debarred by any Govt. Department/Public sector undertaking/Private
organization. 6. I / We certify that all information furnished by the our Firm is true
& correct and in the event that the information is found to be
incorrect/untrue or found violated, then department/ organization
shall without giving any notice or reason therefore or summarily reject
the bid or terminate the contract , without prejudice to any other rights
or remedy including the forfeiture of the full said earnest money
deposit /Security deposit or both absolutely.
Date:
Place:
Signature of authorized person Full Name & Designation: Company’s Seal
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of
2.8 TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 68 of 82
Annexure -5
OFFER FORWARDING LETTER/TENDER SUBMISSION LETTER (To be typed submitted in the letter Head of the Company/firm of Bidder) _______________________________________________________________
_________
Offer Reference No…………………………… Dated:…………………….
To,
SPSO, SDSC SHAR Dear Sir,
Sub: Submission of Offer against Tender Specification
No:……………………………….
I/We hereby offer to carry out the work detailed in the Tender
Specification issued by PCRI, ……………………………………………, in
accordance with the terms and conditions thereof. I/We have carefully perused the following listed documents connected
with the Tender documents and shall abide by the same.
i) Amendments/Clarifications/Corrigenda/Errata/etc issued in
respect of the Tender documents by PCRI. ii) Notice Inviting Tender (NIT)/ (Technical Bid)
iii) Financial Bid
iv) Documents referred to in tender document
v) Forms and Procedures
Shall our Offer be accepted by PCRI for Award, I/we further agree to
furnish ‘Security Deposit’ for the work as provided for in the Tender
Conditions within the stipulated time as may be indicated by PCRI. I/We further agree to execute all the works referred to in the said
Tender documents upon the terms and conditions contained or referred
to therein and as detailed in the appendices annexed thereto. I/We have deposited/depositing herewith the requisite Earnest Money
Deposit (EMD) as per details furnished in the tender document, as
applicable.
Authorised Representative of
Bidder Signature:
Name:
Address:
Place: Date:
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of
2.8 TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 69 of 82
Annexure -6
DECLARATION BY AUTHORISED SIGNATORY OF BIDDER (To be typed submitted in the letter Head of the Company/firm
of Bidder) _______________________________________________________________
________
To,
SPSO, SDSC SHAR
Dear Sir,
Sub:
Declaration by Authorised
Signatory
Ref:
i) NIT/Title of the work. Name of Tender
No………………………………..,
ii) All other pertinent issues till date
I/We hereby certify that all the information and data furnished by me
with regard to the above Tender Specification are true and complete to
the best of my knowledge. I have gone through the specifications,
condition, stipulations and other pertinent issues till date, and agree to
comply with the requirements and Intent of the specification. I further certify that I am authorized to represent on behalf of my
company/firm for the above mentioned tender and a valid Power of
Attorney/Authorisation letter to this effect is also enclosed.
Yours faithfully,
(Signature, Date & Seal of
Authorized Signatory of the Bidder)
Date:
Enclosed: Power of Attorney/Authorization letter
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of
2.8 TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 70 of 82
Annexure -7
DECLARATION CONFIRMING KNOWLEDGE ABOUT SITE CONDITIONS (To be typed submitted in the letter Head of the Company/firm of Bidder)
To,
SPSO, SDSC SHAR
Dear Sir,
Sub: Declaration confirming knowledge about Site conditions Ref: i) NIT/Tender No………………………………..,
ii) All other pertinent issues till date
I/We ______________________________hereby declare and confirm
that we have visited the site as referred in PCRI Tender Specifications
and acquired full knowledge and information about the site conditions
including Wage structure, Industrial Climate, the Law & Order and
other conditions prevalent at and around the site. We further confirm
that the above information is true and correct and we shall not raise
any claim of any nature due to lack of knowledge of Site conditions. I/We, hereby offer to carry out works, if awarded to us, as detailed in
above mentioned Tender Specification, in accordance with Terms &
Conditions thereof.
Yours faithfully,
(Signature, Date & Seal of Authorized
Representative of the Bidder)
Date: Place:
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of
2.8 TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 71 of 82
Annexure -8
DECLARATION FOR RELATION IN PCRI (To be typed and submitted in the Letter Head of the Company/Firm of
Bidder failing which the offer of Bidder is liable to be summarily
rejected)
------------------------------------------------------------------------------------------
-------------------
To,
SPSO, SDSC SHAR
Dear Sir,
Sub: Declaration for relation in PCRI
Ref: NIT/Tender No.______________________
I/We hereby submit the following information pertaining to
relation/relatives of Proprietor/Partner (s)/Director(s) employed in
PCRI Tick(√)any one as applicable:
1. The Proprietor, Partner(s), Director(s) of our Company/Firm DO
NOT have any relation or relatives employed in PCRI
OR
2. The Proprietor, Partner(s), or Director(s) of our Company/Firm
have relation/relatives employed in PCRI and their particulars
are as below:
(i)
(ii)
Signature of the Authorised
Signatory
Note: 1. Attach separate sheet, if necessary.
2. If PCRI Management come to know at a later date that the
information furnished by the Bidder is false, PCRI reserves the
right to take suitable action against the Bidder/Supplier.
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of
2.8 TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 72 of 82
Annexure
-9
NON DISCLOSURE UNDERTAKING (INTEGRITY PACT) (To be typed and submitted in the Letter Head of the Company/Firm of
Bidder) -------------------------------------------------------------------------------------------
-----------------
NON DISCLOSURE UNDERTAKING (INTEGRITY PACT)
I/We understand that PCRI ____ is committed to Information Security
Management System as per their Information Security Policy. Hence, I/We
M/s___________________________________________________________
_
who are submitting offer for providing services to PCRI ___ against
Tender Specification No. ___________________________________________________________
hereby undertake to comply with the following in line with Information
Security Policy of PCRI _____, ____________
µ To maintain confidentiality of documents & information which
shall be used during the period of the work.
µ The documents & information shall not be revealed to or shared
with third party which shall not be in the business interest of
PCRI
(Signature, date & seal of Authorized
Signatory of the bidder)
Date:
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of
2.8 TPH (1 No.) and 1.1 TPH (1 No.) Steam Boiler Systems with Accessories
Page 73 of 82
Annexure -
10
DECLARATION
(TO BE TYPED ON A LETTER HEAD OF THE COMPANY/ FIRM) Ref: 1) NIT/Tender No.______________________
Dear Sir,
1. We have carefully read and understood all the terms and
conditions of the tender and hereby convey our acceptance to the
same.
2. The information / documents furnished along with the above
offer are true and authentic to the best of my knowledge and
belief. We are well aware of the fact that furnishing of any false
information / fabricated document would lead to rejection of our
tender at any stage besides liabilities towards prosecution under
appropriate law.
3. We have apprised ourselves fully about the job to be done
during the currency of the period of agreement and also
acknowledge to bear consequences to of non performance or
deficiencies in the services on our part.
4. We have no objection, if enquiries are made about the work
listed by us.
5. We have not been blacklisted by any other organization where
we have worked. Further, if any of the partners/directors of the
organization /firm is blacklisted or having any criminal case
against them, our bid shall not be considered. At any later point of
time, if this information is found to be false, PCRI may terminate
the assigned work immediately.
6. We have not been found guilty by a court of law in India for
fraud, dishonesty or moral turpitude.
7. We agree that the decision of PCRI in selection of Bidders will
be final and binding to us.
Date: Place:
Signature of authorized person Full Name & Designation: Company’s Seal
N.B: The above declaration, duly
signed and sealed by the authorized
signatory of the company, shall be
enclosed with Technical Bid.
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of 2.8 TPH (1 No.) and 1.1 TPH (1 No.) Steam
Boiler Systems with Accessories
Page 74 of 82
Annexure –11
Proposed Quality Assurance Plan (to be updated and finalised after placement of P.O)
SR
.
NO
.
MANUFACTURING/QUAL
ITY ACTIVITIES
CHARACTERISTIC
TO BE
VERIFIED
METHO
D OF
CHECK/
FORMAT
OF
RECORD
ACCEPT
ANCE
CRITER
IA
REFERE
NCE
DOCUM
ENT
EX
TE
NT
OF
CH
EC
K
INSPECTION BY Inspected
by
Vend
or Client
IBR
Authority
BOILER
1
Review of Mechanical
Design
Design calculations
Engineer
ing
drawing
Require
d design
code
100
%
H
R
W
2 PRESSURE PARTS
2a Identification of the
material for following
pressure parts
Verification of MTC
with design code,
drawing
requirements.
Verification of raw
material engraving
in line with Test
certificate
MTC
JOB Card
GA
Drawing
,
Manufa
cturing
code,
100
%
H
R
Plates
Tubes R
Pipes
Flanges
2b Welding procedure and WPS, PQR and WPQ
Review
Manufa
cturing
code
100
%
H
R
R
Welders Qualification
2c Stage wise inspection
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of 2.8 TPH (1 No.) and 1.1 TPH (1 No.) Steam
Boiler Systems with Accessories
Page 75 of 82
SR
.
NO
.
MANUFACTURING/QUAL
ITY ACTIVITIES
CHARACTERISTIC
TO BE
VERIFIED
METHO
D OF
CHECK/
FORMAT
OF
RECORD
ACCEPT
ANCE
CRITER
IA
REFERE
NCE
DOCUM
ENT
EX
TE
NT
OF
CH
EC
K
INSPECTION BY Inspected
by
Vend
or Client
IBR
Authority
Longitudinal seams set up Dimensions, Weld
edge preparation &
Test plates
Measure
ment,
Visual
and
template
/Job card
Manufa
cturing
code &
Drawing
100
% H R
W
Circumferential seams set
up
Tube plates ground
inspection Visual &
Measurement,
Minimum Ligament
& hole size
GO -
NOGO
Gauge
passing/
Inspectio
n report
Manufa
cturing
code &
Drawing
100
% H R
after drilling
W
Welding inspection
Visual, Dye
penetration test and
Interpretation of
the films
Visual
inspectio
n report
, RT
reports
Vendor
Standar
d
procedu
re
100
% H R
W
Attachments set up
Dimensions,
Orientation, Weld
edge preparation &
Test plates
Measure
ment,
Visual
and
template
Manufa
cturing
code
Drawing
100
% H ---
W
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of 2.8 TPH (1 No.) and 1.1 TPH (1 No.) Steam
Boiler Systems with Accessories
Page 76 of 82
SR
.
NO
.
MANUFACTURING/QUAL
ITY ACTIVITIES
CHARACTERISTIC
TO BE
VERIFIED
METHO
D OF
CHECK/
FORMAT
OF
RECORD
ACCEPT
ANCE
CRITER
IA
REFERE
NCE
DOCUM
ENT
EX
TE
NT
OF
CH
EC
K
INSPECTION BY Inspected
by
Vend
or Client
IBR
Authority
/
Inspectio
n report
Attachments welding
inspection
Weld visual, Fillet
sizes
Visual
inspectio
n and
inspectio
n report
Drawing
, Weld
visual
standar
d SOP
100
% H ---
W
2d Final inspection
All components as per PP
BOM
Verification on the
Boiler
Visual ,
Photos
Drawing
BOM
100
% H --
Overall weld visual
inspection Weld visual
Visual ,
Photos Drawing
100
% H R
W
Overall dimensional
inspection
Overall interfacing
dimensions
Measure
ment,
Inspectio
n report
Drawing 100
% H --
Temporary attachments Surface visual after
removal
Visual ,
Photos
Vendor
Standar
d
100
% H --
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of 2.8 TPH (1 No.) and 1.1 TPH (1 No.) Steam
Boiler Systems with Accessories
Page 77 of 82
SR
.
NO
.
MANUFACTURING/QUAL
ITY ACTIVITIES
CHARACTERISTIC
TO BE
VERIFIED
METHO
D OF
CHECK/
FORMAT
OF
RECORD
ACCEPT
ANCE
CRITER
IA
REFERE
NCE
DOCUM
ENT
EX
TE
NT
OF
CH
EC
K
INSPECTION BY Inspected
by
Vend
or Client
IBR
Authority
procedu
re
Hydro static test surface cleaning Visual
Vendor
Standar
d
procedu
re
100
% H
W
W
pressure Visual,
Inspectio
n report
Manufa
cturing
code
100
% H
leakage No
leakage
100
% H
stamping on shell Visual,
Rub off
Stampin
g
100
% H
3 Non pressure parts
structural steel Dimensions
Measure
ment Drawing
100
% H -
fabrication Dimensions
Measure
ment Drawing
Insulation & cladding as
per PO terms
Overall visual
inspection Visual
Vendor
Standar
d
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of 2.8 TPH (1 No.) and 1.1 TPH (1 No.) Steam
Boiler Systems with Accessories
Page 78 of 82
SR
.
NO
.
MANUFACTURING/QUAL
ITY ACTIVITIES
CHARACTERISTIC
TO BE
VERIFIED
METHO
D OF
CHECK/
FORMAT
OF
RECORD
ACCEPT
ANCE
CRITER
IA
REFERE
NCE
DOCUM
ENT
EX
TE
NT
OF
CH
EC
K
INSPECTION BY Inspected
by
Vend
or Client
IBR
Authority
procedu
re
Orientation
Visual,
Photos,
Inspectio
n report Drawing
4
Painting of Boiler Shell
surface cleaning, Visual
Vendor
Standar
d
procedu
re 100
% H -
painting
Measure
ment
(DFT)
Vendor
Standar
d
procedu
re
5
FINAL INSPECTION
Complete assembly
of
pressure parts and
non
pressure parts
Documents review
Visual,
Photos,
Inspectio
n reprot
Drawing
100
% H -
W
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of 2.8 TPH (1 No.) and 1.1 TPH (1 No.) Steam
Boiler Systems with Accessories
Page 79 of 82
SR
.
NO
.
MANUFACTURING/QUAL
ITY ACTIVITIES
CHARACTERISTIC
TO BE
VERIFIED
METHO
D OF
CHECK/
FORMAT
OF
RECORD
ACCEPT
ANCE
CRITER
IA
REFERE
NCE
DOCUM
ENT
EX
TE
NT
OF
CH
EC
K
INSPECTION BY Inspected
by
Vend
or Client
IBR
Authority
6
MOUNTINGS
Mountings
assembly with
boiler. Mountings
as per required
specifications/BOM
Phycical
verificati
ons &
photos.
Mountin
gs
Manufac
turers
test
certificat
es.
Standar
d
mountin
gs list
100
% H R
W
7
BURNERS
Verification of
burner and
component
certificates with
material
specifications
Visual,
Inspectio
n check
sheet
Burner
BOM
specific
ations
100
%
H R
W
8
Control Panel &
electrical and Testing of
CP
Control panel
inspection
Supplier
s
Inspectio
n check
sheet
Drawing
specific
ations 100
%
H R
Overall dimensions
W
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of 2.8 TPH (1 No.) and 1.1 TPH (1 No.) Steam
Boiler Systems with Accessories
Page 80 of 82
SR
.
NO
.
MANUFACTURING/QUAL
ITY ACTIVITIES
CHARACTERISTIC
TO BE
VERIFIED
METHO
D OF
CHECK/
FORMAT
OF
RECORD
ACCEPT
ANCE
CRITER
IA
REFERE
NCE
DOCUM
ENT
EX
TE
NT
OF
CH
EC
K
INSPECTION BY Inspected
by
Vend
or Client
IBR
Authority
Verification of
operation of
Relays, Switches,
Lights
Operatio
nal Test
Wiring
Diagram
100
%
H -
9 Single element
Verification of
single element
Manufac
turers
TC
Specific
ation,
BOM
100
% H R
W
10
Economizer,
Deaerator,
Chemical dozing,
Softener,
Chimney,
Feed water tank,
(As applicable)
Final inspection (As
applicable)
Dimensi
onal
report
Final
inspectio
n/Hydro
test
report
Approve
d
drawing
s, BOM
&
Specific
ations
100
% H R
Verification of all
items as per
drawing BOM,
Specifications
W
Final dimensional
inspection
Final weld visual
inspection
NDE Completeness
Hydro testing
11 Dispatch clearance Dispatch clearance MDCC - 100
% H H
H HOLD POINT PROCEED FURTHER UNLESS CLEARED BY
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of 2.8 TPH (1 No.) and 1.1 TPH (1 No.) Steam
Boiler Systems with Accessories
Page 81 of 82
SR
.
NO
.
MANUFACTURING/QUAL
ITY ACTIVITIES
CHARACTERISTIC
TO BE
VERIFIED
METHO
D OF
CHECK/
FORMAT
OF
RECORD
ACCEPT
ANCE
CRITER
IA
REFERE
NCE
DOCUM
ENT
EX
TE
NT
OF
CH
EC
K
INSPECTION BY Inspected
by
Vend
or Client
IBR
Authority
AUTHORISED INSPECTOR
W WITNESS POINT
"W" INDICATES THAT AUTHORISED INSPECTOR SHALL BE
NOTIFIED AND MAY EXERCISE HIS OPTION
R REVIEW POINT
WHEN THE INSPECTOR DOES NOT VALIDATE HIS OPTION
MDCC
MATERIAL DISPATCH CLEARANCE CERTIFICATE
Tender Specification Document for Design, Manufacturing, Testing, Erection & Commissioning of 2.8 TPH (1 No.) and 1.1 TPH (1 No.) Steam
Boiler Systems with Accessories
Page 82 of 82
Figure – 1 Boiler House Civil layout sketch
Recommended