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