Supply, erection and commissioning of BIO Gas fired steam boiler of Sri Vakulamatha Centralized kitchen boiler section Tirumala

PART - A (OPEN TENDER)

Supply, erection and commissioning of Bio Gas fired steam boiler of make – Thermax, Model - Revomax RXA-06 of capacity 600 kg/hr (F and A 100 Deg. C), Gas train range 1-4 Bar with Design Pressure of 10.54 Kg/sqcm (g). The supply of steam boiler is including cost of Gas Train assembly, Steam Seperator, Economizer, heat optimizer, Control Panel, Supervision charges for Erection and Commissioning. The rate is including cost of Packing and Forwarding, loading and unloading, Freight, Transit Insurance, F.O.R at Tirumala, cost and conveyance to site of work and all other incidental charges etc., complete. (The rate is excluding GST). A) SCOPE OF SUPPLY : The steam boiler consisting of - a) BOILER : 1 set i) Pressure part assembly consisting of closely wound helical vertical membrane coil fabricated out of high temperature resistant ERW tubes and flats. ii) Double jacketed air casing with an aluminum radiator to enclose the Pressure parts and serve as an integral combustion air Pre-heater.

b) AUXILARIES : 1 set i)Diffusion type, down firing burner assembly suitable for Bio Gas firing ii) Blower coupled with motor, mounted on bottom chassis, duly connected to the Jacket iii) Water pump, with surge suppressor and relief valve, mounted on pumping module iv) Atmospheric economizer and heat optimizer to Pre-heat feed Water v) Dust protected Pre-wired control panel with necessary switch gear, power and control circuitry vi) Set of tool kit.

c) PIPING : 1 Set i) Feed water line between optimizer, economizer, feed pump and boiler ii) Flexible / Fixed connection from Gas train to burner

d) MOUNTINGS AND FITTINGS : 1 Set i) Set of isolating needle valves for indication instruments STEAM : 1 set i) One Main steam stop valve ii) One Auxillary steam stop valve iii) One Single port spring loaded safety valve WATER :1 set i) One Y Strainer ii) One Drain valve for economizer iii) One Relief valve on feed water pump iv) One Non-return valve on feed water line v) One Ball valve for coil blow down

e) INSTRUMENTS CONTROLS AND SAFETIES: 1 set i) One Burner programmer with matching flame detector ii) One Set Audiovisual alarms for abnormal conditions STEAM i) One Steam pressure switch for burner ON-OFF control ii) One Steam pressure gauge iii) One Steam temperature indicator-cum Switch for high alarm WATER i) One Low water leval alarm switch on economizer ii) One Blow down valve limit switch

f) BIO GAS FIRED GAS TRAIN ASSEMBLY- MADAS make of size 40NB consisting of i) Inlet Isolation valve: Full Bore, SS Body, SS304 Ball, PTFE seat ii) Needle valve: Needle valve, body-SS304 iii) Pressure Regulator, Slam shut-Off, Safety Relief Valve, 1st Safety SOV. 2nd Safety SOV, Pilot SOV: will be with Biogas + CAtaphorsis Treatment iv)Gas train inlet size 40 NB Note : Suitable for min/ max pressure of 1-4 bar at inlet of gas train

B) BATTERY LIMITS : Terminal Points a) STEAM i) Main steam stop valve outlet ii) Auxiliary steam stop valve outlet iii) Steam safety valve outlet b) WATER i) Heat optimizer inlet ii) Air vent outlet on economizer iii) Economizer drain valve outlet iv) Relief valve outlet on feed water pump v) Blow down valve outlet

c) FUEL i) Gas - Outlet of safety relief valve ii) Gas - inlet of gas train d) AIR and FLUE GAS i) Suction of Blower ii) Flue GAS outlet on economizer e) ELECTRICALS i) Terminal connectors on control panel f) Vent - Upto outlet of air vent / safety valve g) Power / signal - At the inlet of motor / instrument mounted on equipment h) Earthing - At the earhing node of each equipment i) Fuel gas - Inlet and outlet of the gas train assembly

C) CONTROLS & SAFETIES : Alarm and Interlock Schedule - Instrument \ Action a) Steam Pressure High - Pressure Switch \ Burner OFF b) Steam Temperature High - Temperature Switch \ Burner Trip c) Flame Failure - Flame Sensor \ Burner Trip d) Economizer water level low - Level Switch \ Burner Trip e) Blow down Valve open - Blow down Sensor \ Burner Trip f) Gas Pressure Low - Pressure Switch \ Burner Trip g) Gas pressure high - Pressure Switch \ Burner Trip

D) EXCLUSIONS : a) Main chimney and flue gas duct between boiler and chimney b) Raw water and soft water service tanks c) Steam, water, fuels oil and drain piping up to our terminal points d) All civil and structural work for installing the boiler e) Electrical works in boiler house up to our terminal points f) Labour, tools and tackles, utilities (water, power, air, gas, etc.) and consumables required for assembling, erecting and commissioning the boiler g) Spares for installation, operation and maintenance of boiler h) Water treatment plant i) Fuel, water, instruments and accessories for commissioning, operation and for performance testing of boiler j) All lagging / insulation wherever required

Note : a) The contractor is to submit the all drawings and documents to the Department such as Drawings, Terminal Point, GA Drawing (General arrangement drawings), foundation details (not foundation design), electrical wiring diagram and Piping and Instrumentation Diagram, Installation / Operations and Maintenance Manual etc., b) The contractor is to submit all the tested certificates at their own cost for the steam boiler and for all components as mentioned in the scope of work.

Supply and fixing of following valves / accessories etc., complete. The rate is including cost & conveyance to site of work, incidental charges and FOR at Tirumala. (The rate is excluding GST)

40 NB Globe Valve CS F/E (Audco make)

25 NB Ball Valve CS F/E (Audco Make)

25 NB Strainer CS F/E (leader Make)

40 NB NRV F/E CS (Audco Make)

15 NB Steam Trap TD3 (Trax Make)

Providing, laying, testing & commissioning of 25 NB SCH 80 Seamless pipe including fittings like elbows, tees, flanges, tapers, nuts, bolts, gaskets etc., complete. (The rate is excluding GST). Makes:- Jindal - Hissar / Tata pipes / Prakash/ MSL

Supply and erection of 50mm thick mineral wool with wire mesh and 24 SWG aluminium cladding (Measurements are IS Standard) including cost and conveyance of all materials etc., complete as directed during execution of work. (The rate is excluding GST)

40 NB Pipe Insulation

25 NB Pipe Insulation

Ducting and seperator insulation

PART -B SSR Items

Supply and fixing of M.S. pipe of 300mm dia for ducting / chimney / steam header including cost & conveyance to site of work, incidental charges etc., complete as directed during execution.

Providing, laying, testing & commissioning of following MS 'C' class pipes conforming to IS 3589 and 1239 including fittings like elbows, tees, flanges, tapers, nuts, bolts, gaskets etc., complete. Makes:- Jindal - Hissar / Tata pipes / Prakash Surya

250 mm dia MS 'C' Class pipes

80 mm dia MS 'C' Class pipes

50 mm dia MS 'C' Class pipes

40 mm dia MS 'C' Class pipes

25 mm dia MS 'C' Class pipes

Supply and fixing of MS structural steel i.e., angles, channels & 'I' sections for structural supports of pipe lines including labour charges for fabricating and fixing all heavy steel works like trusses, stanchions, heavy beams and girders by using chain pulley blocks, derek pole arrangements and cranes), cost of welding rods, power charges, painting one priming coat with ready mixed red oxide metal primer and two coats with ready mixed synthetic enamel paint in all shades grade-I (total 3 coats) of approved colour and make, cost and conveyance of all materials to site of work etc., complete as directed during execution.

Painting two coats with Aluminium paint grade-I over a Primary coat (Red oxide metal primer) (total three coats) of approved make including brushes to have an even shade including cost and conveyance of all materials as directed during execution complying with standard specifications, etc., complete for new work.

Painting two coats with Ready mixed Synthetic Enamel paint in all shades Grade-I having VOC (Volatile Organic Compound) content less than 50 grams/litre over a Primary coat (Red oxide metal primer) (total three coats) of approved colour and make including brushes to have an even shade including cost and conveyance of all materials as directed during execution complying with standard specifications etc., complete for new work.

Demolition including stacking of serviceable materials and Disposal of unserviceable materials within 100 meters lead---Unreinforced cement concrete upto 15 cm thickness

Supply of Rabbit wire mesh ( G.I. Chicken mesh) of not less than 24 Gauge

Providing High Yield Strength deformed (HYSD) / Thermo mechanically treated (TMT) steel bars of specified grade (as per IS 1786-2008) of different diameters for RCC works, including labour charges for straightening,cutting,bending to required sizes and shapes placing in a position with cover blocksof approved materials and size and tying and lap splicing with binding wire of 18 SWG, forming grills for reinforcement work as per approved designs and drawings, including cost and conveyance of steel bars including all wastages such as over laps,couplings,chairs, spacer bars including cost and conveyance of binding wires, cover blocks and all incidental, operational, labour charges such as cutting, bending, placing in position, tying including sales and other taxes on all materials etc., complete for finished item of work in all floors. (APSS NO.126) (In the absence of 18G binding wire, 2 nos of 20G binding wire in tandem are to be strictly adhered). Note: Unless otherwise fabrication and placement of steel, no pre-payment shall be made against the supply of steel reinforcement ---Below 36mm Fe500/Fe500D

Supply and placing of M 25 Design Mix Concrete corresponding to IS 456 using concrete mixer using of 20 mm HBG crushed metal 0.530 cu.m (707 kg),. 10 mm HBG crushed metal, 0.362 cu.m (471 kg) , sand 0.407 cu.m (616 kg.) and cement 380 kg with water cement ratio of 0.48 ( 182.40 ltrs/ cu.m of CC)etc., to site and including sales & other taxes on all materials including all operational, incidental and labour charges such as machine mixing, vibrating, laying concrete, curing etc., complete with cement from standard suppliers approved by the department but excluding cost of centering, shuttering charges and excluding cost of steel and its fabrication charges for finished item of work (APSS No. 402). - COLUMNS, LINTELS, WATER TANKS, RCC WALLS IN BUILDINGS

Note : The design mix shall be got designed by furnishing the information required as per clause 19.1.1 &19.1.2 of IS 456-2000 by the contractor at his own cost and get approved from the competent authority before execution. The cement considered for above M25 grade concrete is 380 kg/cu.m and the rate is arrived accordingly in the estimate. After the mix is designed and approved, if there is any variation in the quantity of cement, over the cement content adopted in the estimate, the same will be considered and paid/recovered at estimate rate + or - T.P ( Either increase or decrease in quantity adopted in the estimate). Payment will not be made for variation in the quantity of other materials such as coarse & Fine aggregates.

Providing impervious coat to exposed RCC roof slab surface with CM (1:3), 20mm thick with 500 ml of liquid concentrated micronized cement water proot compound/ 100 ml of Integral cement water proofing admixture complies with IS:2645-2003 of approved make per 50 kg bag of cement laid over roof when it is green including cost of all materials, conveyance charges of materials and all operational, incidental and labour charges for mixing mortar, laying, rendering smooth and thread lining, curing, rounding off junctions of wall and slab etc., complete for finished item

Hire charges for centring and scaffolding for VCC vertical walls of plane surface (Rate is for both sides centering including open drains)

Plastering in Cement mortar (1:3), 20 mm thick using best river sand from approved quarry including cost and conveyance of all materials, screening, curing, rounding of corners, incidental charges as directed during execution complying with standard specifications etc. complete