Design Supply Erection and Commissioning of Augmentation of Dry Fly ash Handling system PDFACS Dense phase pneumatic conveying system 1 set

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 nos. RF admittance type permissive level switches, • 16 nos. Adopter cum downcomer pipes to suit ESP hoppers outlet, • 16 nos. Manual Hand wheel operated knife Gate Valves, • 16 nos. Expansion joint cum spool pieces, • 16 nos. Pneumatic conveying Vessels each with inlet valve Complete With Pneumatic panels & electro Pneumatic controls, • Fluidizing Blowers are required for 16 Nos. of frontline ESP hoppers & fluidizing air supply for Intermediate SILO. (Heaters + Piping + Pads)

Supply Portion A) STAGE-I (From ESP 1st & 2nd field hoppers to New intermediate fly ash storage silo) A2 - 4 lots MS ERW conveying pipe line along with Hardwares like Flanges, Gaskets, Fasteners & U-Clamps as per IS 1239/3589, • 4 Nos. 2 / 1 way switch over valves for clubbing the pipe lines of ESP fields • 4 lots 90˚ / as required long radius MS Fabricated Cast Basalt /DRC lined Flanged bends • 4 Nos. Terminal End Boxes. • The Fly ash filter materials quality should be 50mg/Nm3 with temperature resistant of 140 Degree C. • The material quality of Dome valves are alloy C.I with 250BHN hardness, Disc with 10mm thick SS ( 350BHN), Seat of replaceable type SS smooth finish with a hardness of 250BHN minimum. • The fly ash conveying pipe’s material should be of MS as per IS. 3589 of 9.5mm wall thickness.

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 – MS structures with RCC supports

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, • 1no. Vacuum cum pressure Air Balance valve. • 1 no. RADAR type continuous level monitoring for silo, • 1 no. 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/Oil free Screw type New Air Compressors having discharge pressure and capacity to handle and evacuate an ash quantity of not less than 135 TPH complete with accessories and 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 air pipe & Piping work and controls with Instrument air receivers. • Two No’s - (1W+1SB) Instrument 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 For each conveying line from intermediate SILO to the main SILO. 2 Nos. of working and 1 No. of Stand by transport air Compressors (All the 3 nos. of compressors each having same capacity) (2W+1 S/B) water cooled, skid mounted, oil free screw type new air compressors having adequate discharge pressure and capacity to handle and convey the ash quantity of not less than 90 TPH complete with accessories and drive motor unit, each compressors O/L connected to the air receiver of the respective conveying line. Hence for 2 conveying lines this transport air Compressors sets are (2W+1 S/B) x 2 accordingly with air pipes & piping work. (OR) For each conveying line from intermediate SILO to the main SILO. 1 No. of working and 1 No. of Stand by transport air Compressors (Both the 2 nos. of compressors each having same capacity) (1W+1 S/B) water cooled, skid mounted, oil free screw type new air compressors having adequate discharge pressure and capacity to handle and convey the ash quantity of not less than 90 TPH complete with accessories and drive motor unit, each compressors O/L connected to the air receiver of the respective conveying line. Hence for 2 conveying lines this transport air Compressors sets are (1W+1 S/B) x 2 accordingly air pipes & piping work. 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 (or) 1working+1standby 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. • Mixing apparatus provision (but not consisting the slurry disposal pumps and lines), have to be provided. Fly Ash unloading Chute provision at intermediate SILO to facilitate the Bulker loading has to be provided. • Provision of Direct Loading facility of fly ash, from the proposed intermediate fly ash silo to the bulk ash conveying vehicles

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 Draw out, 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 – 11 kV/6.6 kV 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 Hardwares, 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 - Earthling 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 earthling

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 ODB 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. 7. Welding supply can be availed from our existing welding transformer but welding DB 63A SFU module is at contractor scope. All cables (HT/LT/Control) under contractor scope. 8. Suitable capacity hoist shall be provided for motor (HT/LT) lifting. 9. Empty 630Amps SFU module- 2 Nos will be provided from our existing LT MCC. The contractor have to provide new 630 A SFU module- 2 Nos. in existing empty module and new ACB- 2 Nos is to be provided with newly formed LT MCC incomers. The maximum load in LT MCC should be within 630A only and there should not be any more additional loads. 10. Spare HT Breaker with compartment with HT breaker is to be provided in 3.3KV HT switchgear and spare module 1no. For each rating is to be provided in LT switchgear.

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 forebay by providing suitable pumps 2 Nos. and complete piping, supply and circulation systems for the equipments as per the design requirements.

Supply Portion G.Miscellaneous G2- One Lot - Mandatory spares

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. Two storied building, bigger size suitable for 3 no. Conveying air compressors, 6 no. Transport air compressors, 2 nos. air dryers, 4 nos. fluidizing blowers at Ground floor and 3 nos HT Panels, 1 no. LT MCC, battery, JBs, DBs, SCADA based PLC system, Control desk, UPS at first floor

(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 much higher foundation works for the compressors, Fluidizing Air Blowers, Air receivers & the pipe racks, with related building / structural provisions and additional equipments. 2. Required civil modification works, rerouting of existing pipelines, and other connected works in compressor Room and intermediate Silo. 3. Any deviation during the execution of work, the contractor should get perior approval from the Board officials, and any additional work is required may be on the part of contractor.

Erection, Testing & Commissioning of the entire DPPCS (Integrated System) H1- Design, Supply, Erection of the entire Augmentation of Dry Fly ash Handling system (PDFACS -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.

Erection, Testing & Commissioning of the entire DPPCS (Integrated System) H2 - Testing, Commissioning and Performance Guarantee Testing of the entire Augmentation of Dry Fly ash Handling system (PDFACS -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