2.5.Performance and Guarantee Tests (AHP)

(a) Performance and Guarantee tests shall be conducted in accordance with the conditions specified in ‘General Technical Conditions’ of Technical Specifications

(b) The performance guarantee tests shall be conducted for Seven (7) days continuous operation of the boiler at 80% to 100% load. In case, the boiler trips during the test duration the interpretation of performance test shall be mutually agreed between OWNER  and bidder. In case of any major breakdown in any of the equipment disrupting the operation of Ash Handling Plant, the breakdown period shall be added to the testing period of 7 days.

 (c) The performance guarantee test shall be conducted to prove uninterrupted operation of ash handling plant of each unit separately as they are completed and all units simultaneously when they are completed. The ash handling plant shall be operated with its normal auxiliaries, (as applicable commensurate with the number of boiler units in operation) without using standby pumps or any other standby equipment. During the performance guarantee test, the guarantee parameters of the various equipments as detailed below shall be demonstrated by the Contractor. In addition to above shop and site tests, the test requirement specified in subsequent section for Mechanical, Electrical, Civil and Structural items shall also be complied with by the bidder.

2.5.1 Guarantees and Liquidated Damages Guarantees

The performance and guarantee test shall be conducted in accordance with the conditions specified in General Technical conditions, and in Clauses above. The parameters guaranteed by the Bidder shall have no tolerance value whatsoever. The equipment and systems offered under this specification shall be guaranteed to meet the following performance.

 (a) Bottom Ash Handling System

 (1) In case the Bidder offers intermittent type bottom ash removal system employing W-type water impounded hopper and jet pumps, the system shall be guaranteed to meet the following performance. (i) Continuous effective extraction, crushing and conveying of bottom ash generated during various modes of boiler operation to the ash slurry sump and the continuous effective pumping of combined slurry from this sump to the ash slurry dump area. The extraction of bottom ash and economiser ash shall be done twice in every shift of eight (8) hours. The total time for evacuating the 4 hours collection of bottom ash and economiser ash corresponding to maximum collection rates specified shall not exceed 1 hour 30 minutes (90 minutes) including the time required for starting, stopping, sequential changeover from one unit to second unit and water flushing of the system for the following two conditions and with 25mm wear on the diameter of the throat section of the jet pumps : – Maintain water level by allowing the make up valve to remain open. – Complete draw down by totally emptying the hopper of all water and ash with the make up closed. (ii) Power consumption (KW) as measured at motor input terminals for ash crusher/clinker grinder operating during continuous effective ash extraction rate as outlined in 1 (i) above. (2) In case the Bidder offers continuous type bottom ash removal system employing submerged scrapper chain conveyors, the system shall be guaranteed to meet the following performances. (i) Continuous effective discharge, crushing and sluicing of bottom ash generated during various modes of boiler operation to the bottom ash slurry sump and the continuous effective pumping of slurry from this sump to the main slurry sump in ash slurry pump house for onward effective pumping from main sump to the ash slurry dump area. (ii) (a) Continuous normal extraction capacity (50 T/hr or 25 T/hr as the case may be) of the submerged scrapper chain conveyors with the linear speed of chain not exceeding 2.0 m/min. (guaranteed extraction rate). (b) Dead start capability of submerged scrapper chain conveyor i.e. it shall be able to start and discharge the bottom ash with water filled trough full of bottom ash upto maximum water level. (iii) Power consumption (KW) as measured at motor input terminals for submerged scrapper chain conveyor operating at the guaranteed extraction rate. (iv) Power consumption (KW) as measured at motor input terminals for ash crusher operating at the guaranteed bottom ash extraction rate. (v) Rated capacity at Rated Head of each bottom ash slurry transportation pumps/bottom ash overflow water pumps, sludge pumps etc. (vi) Power consumption (KW) of each bottom ash slurry transportation pumps/bottom ash over flow water pumps/surge tank over flow transfer pump above as measured at motor input terminals when operating at the rated capacity and head as stated in 2(v) above. The performance test listed at 2(iv), 2(v) & 2(vi) above shall be performed on test rig at the vendor’s works and actual motor shall be used for this purpose. (3) The continuous effective conveying and pumping as stated above shall be established by no stagnation of ash or slurry at any point in the complete system and with all interlocks, protections and sequential operation working satisfactorily.

 (b) Economiser and Air preheater

 Ash Handling System Continuous effective extraction and conveying of ash collected in economiser, economiser bypass duct, primary air preheater and secondary air preheater hopper from hoppers to economiser/air preheater slurry trench; from economiser/air preheater slurry trench/pipe line to ESP fly ash slurry trench; from ESP fly ash slurry trench to sump of combined ash slurry pump house. The continuous effective extraction and conveying of ash as stated above shall be established by no stagnation of ash or slurry at any point in the complete system and with all interlocks, protections working satisfactorily.

 (c) Fly Ash Handling System

(i) Continuous effective extraction and conveying of fly ash from all fly ash collection hoppers i.e. ESP and duct hoppers, generated during various modes of boiler operation upto collector tank/ buffer hoppers, from buffer hoppers to ash storage silo and from collector tank to the ash slurry sump and the continuous effective pumping of ash slurry from this sump to dyke area. The fly ash collected in each unit in every shift of eight (8) hours corresponding to maximum ash collection rates shall be extracted in six (6) hours. (ii) The continuous effective extraction conveying and pumping as stated above shall be established by no stagnation of ash or slurry at any point in the complete system and with all interlocks, protections and sequential operation working satisfactorily. (iii) Rated capacity at rated discharge pressure of each air compressor/blower/vacuum pump as applicable. (iv) Power consumption (KW) of air compressors/Blowers/vacuum pumps, as applicable, as measured at motor terminals when operating at the rated capacity and pressure as stated in b(iii) above. (v) The performance listed in c (iii) & (iv) above shall be performed on test rig at the vendor’s works and actual motor shall be used for this purpose.

 (d) Ash water and Seal Water Pumps

 (i) Rated capacity at rated head of each ash, seal and flushing water and other water pumps. (ii) Power consumption (KW) of each ash, seal and flushing water pump and other pumps as measured at motor input terminals when operating at the rated capacity and head as stated in c (i) above. (iii) The performance listed in c (i) & (ii) above shall be performed on test rig at the vendor’s works and actual motor shall be used for this purpose.

 (e) Ash slurry Disposal Pumps

(i) Rated capacity at Rated Head of each ash slurry disposal pump. (ii) Power consumption (KW) of each ash slurry disposal pump as measured at motor input terminals when operating at the rated capacity and head as stated in d (i) above. The power consumption figure shall be corrected to take into account ash slurry as the pumping medium. (iii) The performance listed in d(i) & (ii) above shall be performed on test rig at the vendor’s works and actual motor shall be used for this purpose.

 (f) The value of the various performance guarantee parameters stated above shall be as per the requirements specified in the equipment specifications. Where not specified, these shall be as per guarantees furnished by the Bidder.

2.5.2 Liquidated Damages Should the results of the performance and guarantee tests show that the equipments has failed to meet the guaranteed parameters, the Contractor shall carry out modifications considered necessary within 90 days of the notification by the Owner. If the equipment fails to meet the guarantee (except the power consumption) at the end of the above specified period of 90 days, the Owner may at his discretion reject the equipment. The total power consumption for the complete ash handling plant of two (2) units shall be worked out by using the following formula: P =  (p × n × f) P = Total power consumption. p = Power consumption of the Individual drives listed below, at motor input terminals without any negative tolerance n = No. of drives in operation f = weighting factor for the various drives as listed below The guaranteed power consumption for the package shall be worked out by using the guaranteed 'p' value indicated by the Bidder in relevant Schedule (Guarantee Declaration Schedule) of 'Bid Proposal Sheets'. The actual power consumption for the package shall be worked out by using the measured 'p' value during PG tests (at shop or site as the case may be). Using the above computation method, if the actual power consumption exceeds the guaranteed power consumption, liquidated damages shall be payable by the Contractor at the rate of Rs.1,24,000/- per KW excess power consumption, over the base guaranteed figure indicated by him in his bid. Such liquidated damages may be recovered by the Owner by deduction from the contract price or by enforcing the contract performance guarantee or in any other manner deemed fit by the Owner. For this purpose, the drives of standby equipment shall not be considered. List of drives with guaranteed power consumption and weightage factors thereof.

Drive Weightage Factor

 1. Bottom Ash Crushers 0.3125 for jet pump system & 1.0 for submerged scrapper conveyor system.

 2. Bottom Ash H.P. 0.3125 for jet pump system Water Pump

 3. Bottom ash L.P. Ash 1.0 Water Pumps

 4. Fly ash water pumps 1.0

5. Bottom Ash Slurry 1.0 Transportation pumps

6. Submerged scrapper 1.0 chain conveyor

7. (i) Fly ash extraction 1.0 air compressors with air drying plant (ADP) (ii) Fly ash extraction 1.0 vacuum pumps (iii) Buffer hopper aeration 1.0 Blower alongwith heater (iv) Silo aeration blower 1.0 with heater (v) Transport air 1.0 compressor with air drying plant

8. BA hopper cooling water 1.0 over flow pumps/sludge pumps

9. Ash slurry disposal 1.0 pumps

10. Seal/cooling water pumps 1.0

11. Instrument air compressor 1.0 with air drying plant

2.6.0 Spares(AHP)

2.6.1 General

The Contractor shall indicate and include in his scope of supply all the start-up commissioning spares. The contractor shall further separately indicate the prices of recommended spares necessary for three (3) years continuous operation, in addition to mandatory spares. The Contractor shall also identify the total population of each item of spares both mandatory, and recommended, and their service life expectancy under normal operation conditions, with his bid in the form of Schedules. All spares supplied under this contract shall be strictly interchangeable with the parts for which they are intended for replacement. The spares shall be treated and packed for long storage under the climatic conditions prevailing at the site e.g. small items shall be packed in sealed transparent plastic bags, with desiccator packs as necessary. Each spare part shall be clearly marked or labeled on the outside of the packing, together with the description. When more than one spare part is packed in single case, a general description of the contents shall be shown on the outside of the case, and detailed list enclosed. All cases, containers and other packages must be suitably marked and numbered for the purpose of identification. All cases, containers or other packages are liable to be opened for examination, as may be considered necessary by the Engineer.

 2.6.2 Mandatory Spares Parts The list of mandatory spares which are considered essential by the Owner shall be indicated and the Bidder shall quote prices for all these spares. The Bidder shall furnish the itemized and total price for these spares mentioned in the above annexure . Further, wherever the spares are indicated as a percentage, and result in a number plus fraction, the same shall be converted to the next whole number. In compliance with the requirements of ITB, the prices for mandatory spares must be given separately, and shall be used for bid evaluation purposes. All mandatory spares shall be delivered to site alongwith corresponding main equipment.

2.6.3 Recommended Spares In addition to the mandatory spares, the Contractor shall also provide a list of recommended spares giving unit prices, and total prices for 3 years of normal operation of the equipment, in the relevant schedule of the BPS, This list shall take into consideration the mandatory spares specified in Annexure-GO-VI, and should be a separate list. The Owner reserves the right to buy any, or all the recommended spares. The recommended spares parts shall be delivered to the project site atleast two months before the scheduled date of trial operation of the system.

The list of recommended spares to be furnished by the successful bidder should contain the following :

 (i) Population of each item installed alongwith reference drawing number. (ii) Service life expectancy of each item.

(iii) Offer validity period

 (iv) Price justification Prices of recommended spares will not be used for evaluation of the bids. The prices of these spares will remain valid for a period of not less than 1 year after the date on which the validity of main Bid expires. Whenever, recommended spares are the same as mandatory spares, then the prices of the mandatory spares and such common recommended spares shall be the same. Further, the prices of any recommended spares, which are not common with mandatory spares listed in this volume, shall be subject to review by the Owner and shall be finalised after mutual discussions.

2.6.4 Start-up Commissioning Spares Start-up commissioning spares are those spares which may be required during the start up and commissioning of the equipment/system. All spares used until the plant is handed over to the Owner shall come under this category. The Contractor shall provide for an adequate stock of such start up commissioning spares to be brought by him to the site for the plant erection and commissioning. They must be available at site before the equipment are energized and the unused spares, if any, should be removed from there only after the issue of taking over certificate. All start up spares which remain unused at that time shall remain the property of the Contractor. The list of commissioning spares to be brought by the Contractor to ensure smooth commissioning of the plant will be subject to Owner’s approval. Contractor shall submit a complete list of all such start up spares. The cost of commissioning spares if any and consumed before the handing over of the plant shall be deemed to have been included in the lumpsum proposal price of the package and the Contractor shall have no claim on this account to the Owner. No mandatory or recommended spares will be used during startup and commissioning of the equipment/plant.