Scope of Work
Consultancy service for modification of existing Pond ash
dryer system for reject handling from furnace & Ash hoper
including vibrating screen at crusher house for pond ash
Tulsigam
1. PREAMBLE:
WCL intends to do followings.
a. Modification in existing Pond ash dryer system for reject handling &
vibrating screen at crusher house:
i) In the existing system, the discharge from the furnace and ash hopper is
directly released onto the ground.
ii) Use of screw conveyors/ belt conveyors/chain conv. to transport ash from
discharge to a designated storage or disposal area.
iii) Designated ash storage silos or bins to safely contain the material until
disposal or reuse.
iv) In the current setup, pond ash is fed directly into the pond ash hopper
without any preliminary screening. To improve the quality and
consistency of the material, it is proposed to install a vibrating
screen within the existing crusher hopper.
v) Integration of sensors and control systems for efficient operation and
maintenance.
The concept /proposal drawing showing requirement is attached.
b. Technical feasibility study for reject handling through new proposed system
1.1 It is proposed to appoint a consultant for providing comprehensive
engineering service for followings.
a) Equipment Layout, Flow sheets and Single line diagram and GA
drawings.
b) System design
c) Basic Engineering
d) Procurement Assistance
e) Detailed engineering including integration with existing
system/process
i) Cost Estimation
j) Technical feasibility study for point
3.0 SCOPE OF SERVICES FOR BATTERY LIMIT
3.1 Engineering, Procurement & Project Management:
3.1.1. General
a. Evaluation & acceptance of Basic Engineering
3.2 Acceptance Of Basic Engineering:
a. Participation in take -off meeting for preparation of Basic Engineering of
system design & scheme with maximum utilisation of existing facilities
available.
b. Provide assistance for adoption of Basic engineering to conform to Indian
regulations, operating conditions and standard engineering practices.
c. Participation in design conference to finalise the design criteria and
design documents as BIS code/ European code/American code
3.3 Engineering Services:
a. Plant Engineering including integration with existing systems /process
along with retrofit works.
b. Prepare system layout / GA Drawings and Process Flow Sheets.
c. Finalisation of the equipment’s and Civil & structural design as per
approved design criteria.
d. Undertake design based on information / Review from equipment
supplier(s) with proper integration for completeness of system /process.
e. Review / Checking and approval of the Suppliers drawings.
3.4 Mechanical Engineering:
a. Finalization of System layout based on basic engineering.
b. Preparation of flow sheets for process plant and material handling
sections.
c. Preparation of GA drawings, Elevations, Cross sections, Floor plans
showing equipment levels & co-ordinates etc.
d. Shop floor Fabrication drawings for ducting, chutes, Hoppers etc.
with bill of materials not falling in the scope of the Supplier will be
prepared by consultant.
e. Detail specifications of equipment’s & machinery.
f. Preparation of the utility pipe routing & sizing, single line drawings
(water & air) with bill of materials of pipes, valves & Fittings etc.
g. Review and approval of GA drawings /interface/ interconnection
detail.
h. Finalisation & providing inputs for civil and structural design of
building, equipment foundations/equipment supports/mounting
arrangement and retrofit works etc.
i. Checking and giving concurrence to Civil drawings for levels, pocket
details, insert plates, clearances etc. required for equipment based on
supplier Mech. Drawing & Electrical drawings.
j. Preparation of final as-built Drawings based on final construction
and erection.
k. Any other miscellaneous work related to the project within battery
limit.
3.5 Electrical Engineering
a. Fault level calculations, including Relay settings for 11KV/0.433 KV
circuits.
b. Design criteria and detailed specification for Earthing System.
c. Review of the vendor drawings for the equipment.
d. Prepare the following detailed layout drawings:
Single Line Diagram & Complete SLD along with its Hook up to existing
plant SLD.
Unit Sub-stations (USSs) & its complete equipment layout.
Cable Trench underground or overhead (inside and outside plant
sections)
Supply of drawing for approval from electrical inspectorate as
required.
Upgradation & modification in SLD, System architecture, DCS, CRD
etc. for proposed system.
Cable trays (inside and outside plant sections)
Lighting
Cable routing
Cable schedule
Field mounted electrical equipment
Control schematics
e. Finalization and providing inputs for civil and structural design of
buildings /equipment's foundations/retrofit works/mounting
arrangements etc.
3.6 Process Control & Instrumentation
3.6.1 System Design
Prepare control concept of the system, type of microprocessor controls,
control loops for optimized operation of the plant, system architecture for
central control based on latest programmable controllers available.
3.6.2 Preparation of Technical Specifications
Prepare detailed technical specifications for the following:
Micro-processor-based colour graphic control system comprising CPUs.
Input/ Output rack both for plant and supervisory level controls, including
uninterrupted power supply system.
Field sensors and process instruments for temperature, pressure, level, flow
etc.
Instrument power distribution boards/junction boxes/instruments panel and
erection hardware’s & accessories.
3.6.3 Scrutiny of Vendor's Drawing and Documents
Scrutinize the GA drawings, control schematics, interface/inter-connection
diagrams; I/O addresses etc., to check conformity with the technical
specifications.
3.6.4 Control & Instrumentation Engineering Drawings
Review detailed design and schemes as per the details given below:
Process & Instrumentation diagrams (based on recommendations of
suppliers & main machinery Supplier )
Block Interlocking diagrams for material handling sections (complete
section).
Cabling concept for control & instrumentation cables
Interfacing diagrams for PC controlled drives
Interfacing diagrams for sub-control systems to be supplied by main
machinery suppliers
Details of close loop controls for optimizing plant operation in various
process departments
Control cable schedules and termination details for electrical drives (Control
& Instrumentation cable schedules for microprocessor-based control systems
shall be prepared).
Mimic diagrams
Layout of local control rooms & local control rooms (If any)
Typical mounting arrangement of process instruments to be mounted in the
field
GA drawings showing location of field mounted instruments.
Cable routing details for control & instrumentation cables.
Preparation of tender enquiry documents for instrumentation supply &
erection work of the plant and floating the tender documentation to various
reputed contractors.
SCS list signal list , final IO list to be prepared along with its interfacing with
existing system & plant controller & DCS.
E&I BOM to be prepare by consultant if anything needs to be purchase from
WCL side.
3.7 Civil and Structural design and drawings
a. Building, Structures and foundations will be designed on the load data provided
by different suppliers of the machinery.
b. Construction Drawings – Structural
i. Detailed civil and structural design work including RCC details for
foundations of hoppers, ramps, conveyors structures (trestles, galleries
etc.), Transfer towers for entire unit in totality within the battery limit. All
retrofit & existing Civil/structural strengthening works for which required
Civil design drawing shall be provided , which is part of system process.
ii. Preparation of detailed RCC working drawings including BOM.
iii. Drawings for civil work will include:
Civil general arrangement drawing with plans and elevations.
RCC details of columns, beams, slabs with insert plates , anchor bolts etc.
along with BOM and Bar Bending Schedule drawings
iv. Preparation of detailed GA drawings of structural steel, conveyors
structures (trestles, galleries) ,Transfer towers , take up towers, , shed
ladders, stairs, platforms etc. & shop floor drawings with BOM including
development drawings.
v. Shopfloor fabrication drawings for structural steel works with detailed bill
of material.
vi. Bill of materials of steel / cement.
3.8 General for Civil Work
a. Prepare final working drawings and insert plate schedule for
construction.
b. Provide final and as built drawing for reference purpose and submit soft
copy of the drawing prepared for WCL.
c. Prepare detailed architectural drawings with plans, elevations, cross-
sections with detail of finishing.
3.9 Other Services:
a. Other services as may be required for complete implementation within
battery limits.
b. Based on final construction and erection at site . preparation &submission of
final “AS BUILT” GA drawings for records in soft copies. Provide final as built
drawing for records in soft copy based on inputs provided by WCL.
3.10 Procurement Services:
a. Prepare detailed specifications and tender document for Mechanical –
Electrical – C&I for Suppliers & Contractors.
b. Prepare specifications, sizes and bill of quantity and tender document for
procurement of:
1. Steel and Cement
2. Electrical / Instrument / Câblés / Cable trays etc.
3. Piping & fittings, valves etc.
c. Evaluate offers, give recommendations, participate in negotiations, and
assist in placement of order with all conditions and guarantee clauses.
3.11 Construction Supervision:
a. Supervision to ensure adherence to drawings, specifications, and quality.
b. Provide clarification/solutions for discrepancies in design /drawings/ give
alternate section etc.
c. Participate in commissioning and guarantee test runs for individual/ systems to
ensure the performance qualitatively and quantitatively.
Above scope is only illustrative but Consultant will be overall responsible for all the
services/engineering required to build project to achieve the objective in totality
within battery limit
