MTPS II Design Supply Erection and Commissioning of Augmentation of Dry Fly ash Handling system DPPCS Dense phase pneumatic conveying system on turnkey basis

Design of Supply, Erection, Testing and Commissioning of Augmentation of Dry Fly ash Handling system (DPPCS-Dense phase pneumatic conveying system) on turnkey basis, for the first two rows of ESP fields to handle the Fly ash collection from 16 No’s of front line hoppers, Conveying to new intermediate Fly ash silo and transporting to the existing 2x4152 MT RCC Fly Ash silo by pressurized pneumatic system

Supply Portion A) STAGE-I (From ESP 1st & 2nd field hoppers to New intermediate fly ash storage silo) A1- System at ESP 1st& 2nd row field hoppers (16 Nos. hoppers) consisting of Complete set - Suitable for taking feed from 16 nos. ESP hoppers, consisting of 16 no. RF admittance type permissive level switches, 16no. Adopter cum down comer pipes to suit ESP hoppers outlet, 16no. Manual Hand wheel operated knife Gate Valves, 16no. Expansion joint cum spool pieces, 16no. Pneumatic conveying Vessels each with inlet valve complete with Pneumatic panels & electro Pneumatic controls

Supply Portion A) STAGE-I (From ESP 1st & 2nd field hoppers to New intermediate fly ash storage silo) A2- 2 lots MS ERW conveying pipe line along with Hardware’s like Flanges, Gaskets, Fasteners & U-Clamps as per IS 1239/3589, 2no.2/1 way switchover valves for clubbing the pipe lines of ESP fields (refer data sheet for details), 2 lots 90˚ / as required long radius MS Fabricated Cast Basalt / DRC lined Flanged bends, 2no. Terminal End Boxes

Supply Portion B.) STAGE-II (From intermediate Fly Ash Storage silo to main Fly ash storage silos #1 & 2) B1 - 300MT intermediate fly ash silo Top facilities & long distance conveying system up to existing Main storage silos

Supply Portion B.) STAGE-II (From intermediate Fly Ash Storage silo to main Fly ash storage silos #1 & 2) B2 - One Set consisting of , 1 no. Reverse Pulse jet Bag filter, 1 no. Vacuum cum pressure Air Balance valve, 1 no. RADAR type continuous level monitoring for silo, 1no. High level switch for back up protection

Supply Portion C)Utilities C1 - Conveying Air System for stage – I, Three No’s - (2W+1SB) Air/ Water cooled, skid Mounted, Oil injected screw type New Air Compressors having discharge pressure of 4.0-4.5 Kg./Sq.cm. (G) Complete with accessories & drive motor unit, Two No’s – New Conveying Air receivers complete with pressure Gauge, pressure Switch, pressure relief valve & Auto Drain Trap with Manual By-Pass Along with MS ERW Heavy duty conveying air pipes & piping work as Required, Two No’s - (1W+1SB) Water cooled, skid Mounted, Oil free screw type New Instrument Air Compressors having discharge pressure of 7-8 Kg/Sq.cm. (G)Complete with accessories & drive motor unit, along with the lines and controls, Two No’s - (1W+1SB) Air dryer, Two No’s - 1W+1SB twin lobe fluidizing air blowers with Electric air heater, Flow pads, fluidizing pads for fluidizing of pneumatic conveying vessels along with heat insulated MS ERW fluidizing air pipes & piping work

Supply Portion C)Utilities C2 - Transport Air System for stage-II, Six No’s. - (4W+2SB) water cooled, skid mounted, Oil free screw type New air Compressors having discharge pressure of 2.5 – 2.7 Kg./Sq.cm (G) Complete with accessories & drive motor unit, Two No’s – New Transport Air Receivers complete with pressure Gauge, Pressure switch, pressure relief valve & Auto drain trap with Manual by-pass along with MS ERW heavy duty conveying air Pipes & piping work as required, Two No’s. - (2W) Silo vent fan complete with accessories & drive motor unit. These new set of 4working+2standby new compressor sets and 2 New Transport Air receivers are to be installed for two streams (Stage II – A & B)

Supply Portion C)Utilities C3 - New 300MT intermediate fly ash silo fluidizing system, Two No’s - 1W+1SB twin lobe fluidizing air blowers with Electric air heater, Flow pads, fluidizing pads for fluidizing of intermediate fly ash Storage silos along with heat insulated MS ERW fluidizing air pipes & connected piping complete set , Provision of Direct Loading facility of fly ash, from the proposed intermediate fly ash silo to the bulk ash conveying vehicles, Provision of emergencies slurry operation arrangements from intermediate silo

Supply Portion D) Electricals D1 -One No. 3.3 kV HT Board with bus coupler and outgoing feeders with vacuum contactors for conveying air compressors and transport air compressors and spare feeder. One No - 415V,3 phase, 4 wire, Non Drawout, Free standing, floor Mounted LT MCC with ACB incomers & Outgoing feeder as required for intermediate silo fluidizing Blowers and LT loads power supply with feeders of each rating & type

Supply Portion D) Electricals D2 - One Lot – 11kV/6.6kV Grade XLPE – FRLS armoured multistrand aluminium power cable, One Lot - 1.1 kV (E) Grade FRLS PVC insulated, armoured aluminium power & Armoured multistrand copper control cable & cabling work as required for fluidizing Blowers and other LT loads in bidder’s scope of supply

Supply Portion D) Electricals D3 - One Lot - Cable trays & accessories as required for power, control &Instrument Cable in present scope of supply

Supply Portion D) Electricals D4 - One Lot - Power Distribution Boards, Lighting distribution Boards, Junction Boxes, Local push button stations, Local control panels, cable Hard wares,…etc as required for the system under present scope of supply.

Supply Portion D) Electricals D5 - One Lot - Lighting system along with accessories for lighting of new Compressor cum MCC room

Supply Portion D) Electricals D6 - One Lot - Earthing system around compressor room cum MCC room along With Earth pits including interconnecting with nearby power plant Earth grid riser for Transformer neutral & electrical equipment earthing

Supply Portion D) Electricals D7 - Electrical side provisions to be included additionally:- 1. On north & south side of 3.3KV HT Ash Handling switchgear in ESP building HT bus may be extended and 2 new HT outgoing breaker modules to be incorporated to form 3.3KV bus with 2 incomer breaker modules for the new system. The overall maximum possible load is 1.25MVA on each incomer, 2. LT supply 415V one incomer is to be taken from the existing LT switchgear ODA bus @ 12mtr (630A SFU empty module no.14RA) and the second incomer from the FWPH 0DB bus (630A SFU empty no.11RE). On both incomer LT supply can be availed but 630A SFU module 2 nos is in the scope of supply. The overall maximum possible load is 630A on each incomer. Also separate control transformer may be installed in DPPCS LT board to take care of AC control supply requirement, 3. 2 Nos 30KW empty module (6FA & 17FA) is available in Silo MCC but 30KW module 2 Nos is in the scope of supply, 4. Separate battery bank and charger may be provided for 3.3KV HT board to be formed newly for DPPCS as the existing DC bank is just adequate to cater to the present load, 5. Provision of DB 63A SFU modules for welding and for AC lighting utilization, 6. Provision of DC board for DC lighting

Supply Portion E. Control & Instrumentation E1 - One Lot - Field control, signal and instrumentation cable from field Instruments to LCP/ JB,

Supply Portion E. Control & Instrumentation E2 - One Lot - Impulse pipes and conduits

Supply Portion E. Control & Instrumentation E3 - C&I side provisions to be included additionally:-  Provision of Instrument cable laying and termination from the field end to new PLC panel,  Provision of Separate PLC rack panel with necessary PLC Controller, communication Modules & I/O Modules, etc.,  Provision of the necessary control logics and its GUI (mimics) – SCADA images with 1 No operator work station and 1 No Engineering work station for the new PLC,  Provision of existing PLC to the new PLC Interface in order to exchange the data to DCS like Intermediate Silo Level & Feedback Status,  Provision of separate UPS with Battery Bank needs to be provided for the New PLC & its Accessories,  For silo instrument, cable laying & termination along with necessary I/O Modules at the Existing Slurry Pump House PLC Panel Room,  Provision of silo logic and MIMICS at the existing PLC, Provision of level switches for 16 nos frontline hoppers

Supply Portion G.Miscellaneous G1.) Auxiliary Cooling water system The Auxiliary Cooling water system for augmentation works to be taken from the existing cooling water fore bay by providing suitable pumps and pipelines, supply and circulation systems for the equipments as per the design requirements

Supply Portion G.Miscellaneous G2- One Lot - Mandatory spares (20% of spares & part components)

Supply Portion G.Miscellaneous G3- One Lot - Commissioning spares as required for the system

Supply Portion G.Miscellaneous G4- One Lot - Consumables, testing appliances, tools & tackles as required for the System

Supply Portion G.Miscellaneous G5- One Lot - First fill of oil & lubricants

(F&H)Erection, Testing and Commissioning of the entire DPPCS(Integrated System)- F.Civil & Structural Work F1- One No - Two storied compressor room, ground floor for compressor sheltering with MCC room at first floor with intermediate floor for cable gallery near new intermediate silo area. This room shall house 3 nos. New conveying air compressors, 6 nos. of New Transport air compressors, 2nos of Instrument Air Compressors, 2 Nos intermediate Fluidizing air blowers and new LT MCC and connected equipments& Panels

(F&H)Erection, Testing and Commissioning of the entire DPPCS(Integrated System)- F.Civil & Structural Work F2 - One No - Intermediate storage silo of capacity 300MT of steel construction Complete with supporting structure

(F&H)Erection, Testing and Commissioning of the entire DPPCS(Integrated System)- F.Civil & Structural Work F3 - One Lot - RCC foundation as required for, intermediate silo and Intermediate pipe supports

(F&H)Erection, Testing and Commissioning of the entire DPPCS(Integrated System)- F.Civil & Structural Work F4 - One Lot - Intermediate pipe supporting columns with Bend Maintenance Platform but without walkways as required for new pipes. These supports shall be only for the section between ESP to new intermediate silo and from new intermediate silo to main existing pipe rack. Wherever possible all other pipe racks and ESP supports shall be used to the extent possible

(F&H)Erection, Testing and Commissioning of the entire DPPCS(Integrated System)- F.Civil & Structural Work F5- Civil side works to be included additionally:- 1. The foundation works for the compressors, Fluidizing Air Blowers, Air receivers & the pipe racks, with related building / structural provisions, 2. Required civil modification works, rerouting of existing pipelines, and other connected works in compressor Room and intermediate Silo

(F&H)Erection, Testing and Commissioning of the entire DPPCS(Integrated System)- H. H1- Erection of the entire Augmentation of Dry Fly ash Handling system (DPPCS-Dense phase pneumatic conveying system) on turn key basis, for the first two rows of ESP fields to handle the Fly ash collection from 16 No’s of front line hoppers, Conveying to new intermediate Fly ash silo and transporting to the existing 2x4152 MT RCC Fly Ash silo by pressurized pneumatic system

(F&H)Erection, Testing and Commissioning of the entire DPPCS(Integrated System)- H. H2- Testing, Commissioning and Performance Guarantee Testing of the entire Augmentation of Dry Fly ash Handling system (DPPCS-Dense phase pneumatic conveying system), to prove the conveyance of 3200 TPD., i.e., 135 TPH from the 16 Nos of frontline hoppers to the main silo & handling over of the augmentation system in full shape to MTPS -II