Supply, erection and commissioning of Steam Boilers of 3 TPH capacity for steam boiler section at MTVAC, Tirumala

Supply, erection and commissioning of LPG fired steam boilers of capacity 3 TPH of make – Forbes Marshall (F and A 100 Deg. C) with Design Pressure of 10.5 Kg/sqcm. The supply of steam boiler is including components of ECR Pressure Jet Monobloc burner, Feed Water Pumps, HP Gas Train, MCC cum ICP Panel, Boiler with Pre-wired Electricals and Pre-insulated boiler. The rate is including cost of supervision, Packing and Forwarding, loading and unloading, 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) BOILER SPECIFICATIONS : Boiler Type : Three Pass Wet Back Type of mounting : Skid mounted Number of Boilers : 1 a) Model : Marshall B Steam Generation : 3000 kg/hr (F and A 100 Deg C) Boiler Design Pressure : 10.5 kg/sqcm b) Steam Pressure Safety valve Set Pressure : 10.2 / 10.5 kg/sqcm Operating Steam Pressure : 9.5 kg/sqcm c) Mechanical Details for Boiler Tubes Thickness - 3.25 mm Tube Inner Diameter : 38.1 mm Material of Construction : SA 515/516 Gr 70 / IS 2002 Gr II

d) Material of Construction : i) Boiler Drum : Shell Plate : SA 515/516 Gr 70 Tubes : BS 3059 ERW Manhole / Hand hole : SA 515/516 Gr 70 Pipes : SA 106 Gr B ii) Furnace Plates : SA 515 / 516- 70 Header / Pipe : SA 106 Gr B Tubes : BS 3059 ERW 320 e) Electrical power : Voltage level for Motors : 415 V +/- 10% Frequency : 50 Hz +/- 5% Combined variation on voltage and frequency : 10% Type : 3 phase

f) For Instrumentation : Voltage for solenoid valves etc. : 230 V AC Voltage for transmitters : 24 V DC Emergency drives : 230 V DC g) Instrument air : Pressure : 5 Kg/sqcm (g) Temperature : 20 Dec C Quality : Dry and Oil free Dew point : -40 Dec C h) Compressed air : Pressure : 6 Kg/sqcm (g) Temperature : Ambient Dec C Quality : Dry and Oil free Duty : General purpose

B) DESIGN BASIS a) Major codes Design : IBR Pressure parts : IBR Piping : IBR Boiler performance testing : BS 845 Part I b) INSPECTION Stage wise inspection : As per FM QAP Final dispatch inspection : FM Non-pressure parts and Bought out equipment : As per agreed QAP

C) SCOPE OF SUPPLY : The steam boiler consisting of : - a) Three Pass, fully fusion welded boiler shell, fully wet back with stiffens ring plain furnace, convection smoke tubes, hinged doors with 75 mm insulation and aluminium cladding with Stucco finish sheets, Manhole, Mud hole, ladder, platforms and set of nozzles for mountings Pressure parts and accessories shall be mounted on a single base frame. Individual systems such as feed water pumps etc., may be on separate base plates welded to the boiler base frame.

b) LPG Fired ECR Pressure Jet Monobloc type Burner (1 No) mounted on combustion chamber Each Burner consists of : Force Draught combustion fan - 1 No Oil Pump and motor - 1 Set Ignition transformer - 1 No HP and LP Gas train - 1 Set Ignition Electrode - 1 No Flame sensor - 1 No

c) Boiler Feed Water Pump and Motor - 2 Nos Centrifugal multistage Pump and motor assembly - 2 Nos Outlet isolation valves - 2 Nos NRVs - 2 Nos Pressure gauges - 2 Nos

d) MCC Cum ICP - 1 No of make - Forbes Marshall Boiler mounting, non-compartmentalised confirming to ingress protection class of IP54, made out of 14/16 SWG CRCA sheet. The power section shall be provided with Power Isolator.

e) Boiler Electricals – Pre Wired - 1 No of make - Forbes Marshall Power cables and control cable supply from panel to motor and instruments GI perforated cable trays

D) BATTERY LIMITS : a) Combustion Air : Inlet of FD fan b) Feed water : At the inlet of Feed water pump c) Fuel : At the inlet of HP and LP Gas train d) Instrument air : At the Instruments/ valves e) Atomization air for burners : Not Applicable f) Service air : Not Applicable g) Compressed Air : At the Instruments / valves h) Power : At the inlet of the MCC cum ICP

i) Control cabling : By FMPL j) Power cabling : From Panel to motors by FM Pvt. Ltd., k) Construction power : By Customer l) Construction water : By Customer m) Instrument signals : Upto local junction boxes n) Drinking Water : By Customer o) Flue Gas : Upto Outlet of Boiler p) Steam : Upto Outlet of MSSV Valve q) Safety Valve and Air vents : At the respective outlets

E) EXCLUSIONS : a) All Civil work activity i.e., for the Bed Concrete, Boiler house, lighting etc., b) Electrical cabling support to Boiler panel. c) Structure and support required for Feed Water line from Feed Water tank to Boiler. d) Structure and support required for Steam Line from MSSV (Main Steam Safety Valve) to Boiler Header e) Flue gas ducting from Boiler Outlet to Chimney f) Gas pipeline from Gas Yard to HP Gas train inlet. g) Feed Water Bulk Storage tank, Feed Water Transfer Pumps and Water treatment plant. h) Bulk Oil Storage Tank and and Oil Transfer Pumps.

i) Boiler House Piping other than that indicated in offer. j) Fuel, water instrumentation and accessories required for performance testing. k) Steam, water and fuel piping beyond terminal points. l) Erection electrical cables and cable trays apart from any other indicated in the offer. m) Any specific item not indicated in our scope of supply. n) Water treatment plant o) Statutory approvals at site. p) Free construction power and water. q) Earth Pit preparation and Earthing from panel to earth pit. r) Boiler Operation and Maintenance team.

F) PERFORMANCE PARAMETERS Maximum Steam Output (F and A 100 Deg C) : 3000 Kg/hr Maximum Design pressure : 10.5 Kg/sqcm (g) Steam dryness Fraction : 98% Efficiency on 100% load (On NCV Basis) as per BS 845 Part I without heat recovery : 89% +/- 2 % ECR burner Turndown ratio : Gas 1:5

G) MAKE OF COMPONENTS a) Boiler : Forbes Marshall b) Feed Water Pump : Wilo / Grundfos / Forbes Marshall Std. c) Fuel oil pump : Madas / Entees / Forbes Marshall Std. d) Burner : Forbes Marshall e) Blower : Crompton Greaves / Forbes Marshall Std. f) Sequence controller : Forbes Marshall Std. g) Photocell : Forbes Marshall Std. h) Fuel Filter : Madas / Forbes Marshall Std. i) Motors : Crompton Greaves / LHP Motors / Forbes Marshall Std. j) Piston valve : Forbes Marshall k) Gate / Globe valve : Forbes Marshall l) Non-Return valve : Forbes Marshall m) Safety valve : Forbes Marshall

n) Blow down valve : Forbes Marshall Std. o) Level indicator : Forbes Marshall p) Level controller : Forbes Marshall Std. q) Pressure switches : Danfoss / Forbes Marshall Std. r) Pressure gauges : Forbes Marshall s) Electrical Control Panel : Forbes Marshall Std. t) Electrical Switch Gears : Siemens / Forbes Marshall Std. u) Cables : Polycab / Forbes Marshall Std. v) Temperature Gauge : Forbes Marshall

H) FEED WATER PUMP SKID consists of : a) Feed Water Pumps (2 Nos) : Wilo / Grundfos / as per FM Standard – Flowrate 3.7 cu.m/hr, 120m Head b) Motor : Wilo / FM Approved - 3 KW Capacity c) Outlet Isolation Valves : Forbes Marshall make Piston Valves – 40 NB / as per Forbes Marshall Std. d) NRV : Forbes Marshall Spring Loaded Disc Check Valve – 40 NB / as per Forbes Marshall Std. e) Pressure Gauge : 15 NB - Forbes Marshall make Bourdon sensing Pressure Gauges - 0 to 25 bar / as per Forbes Marshall Std

I) HP GAS TRAIN SKID consists of : a) Gas PRV – Mechanical Type – 50 NB size ASA150# - Madas / Forbes Marshall Std. b) Isolation Valves : 2 Nos – 50 NB size - Ball Valve type – Madas / Forbes Marshall Std. c) Gas Filter : 1 No - 50 NB size – Madas / Intervest/ Forbes Marshall Std. d) Pressure Gauges : 2 Nos – Madas / Forbes Marshall Std. e) Slam Shutoff Valve : 1 No - 50 NB size - Madas / Forbes Marshall Std. f) Pressure Relief Valve : 1 No - 50 NB size - Madas / Forbes Marshall Std.

J) BURNER : a) Consists of Electronic Compound regulation Pressure Jet Burner for proper mixing of Air and Fuel leading to enhanced Boiler Efficiency – Forbes Marshall Make b) Casting and Fabrication : Forbes Marshall c) Ignition Electrodes : Forbes Marshall d) Pressure Gauges - Forbes Marshall e) Burner Atomiser : Fluidics / Forbes Marshall Std. f) Blower Motor : Crompton Greaves / Forbes Marshall Std. – 7.5 KW

ECR Pressure Jet Monobloc Burner : The supply of ECR burner should perform the following features : a) Individually Solenoid valve operated Multi Nozzle Design at the tip of lance. b) Constant Fuel Oil Pressure results in best quality atomisation at all loads. c) Fixed Air Damper setting for corresponding firing positions i.e. High, medium, or Low, leading to constant air flow rate. Thus, accurate setting of O2/CO2 can be done. d) The Oil & air control is properly achieved ensuring superior quality combustion, since flow of oil is controlled by atomizer size and not by any actuated valves. e) Burner Performance at low Load - In case of a stage burner, since the oil pressure is always constant at all loads, combustion efficiency is at its peak even at low loads. Hence, a higher turn-down ratio (1:5) is possible in case of a stage burner.

Note : a) The contractor is to submit the all drawings and documents to the Department such as GA Drawing (General arrangement drawings), Piping and Instrumentation Diagram, Electrical Drawings, IBR folder, 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 confirming to as per norms of IBR standards.

The rates are exclusive of GST but inclusive of all other taxes.No reimbursement whatsoever will be made by TTD for taxes (EXCEPT GST) recovered by TTD from the contractor or taxes paid by the contractor.