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| 1 | Supply, installation and commissioning of PRETREATMENT SYSTEM AND MONITORING EQUIPMENT FOR PYROLYSIS UNIT |
| 2 | Belt Conveyor- To feed waste to shredder - Belt conveyor system with trays to transfer the fibrous waste such as banana peduncle, tender coconut etc., to the shredder.• Motor rating not less than 3 HP, IP65• Belt width not less than 500mm• Rubber belt thickness not less than 10mm• Length and height to suit the site conditions (Min 6.0m length)• Belt material – synthetic rubber belt (MRF/Dunlop/Duro/Equivalent)• MoC – MS Epoxy coated • SS 316 Cleat arrangements in the belt have to be provided. • Energy efficiency of motor - IE2, Perferable Makes Motor: Bharat Bijlee / Marathon /CGL Gear Box: Premium greaves / Power build /ShanthiSuitable civil foundation to be provided. Equipment basement level with required machine foundation (as per supplier requirements) should be atleast 1 feet above the road adjacent to site |
| 3 | Primary Shredder - To shred the bigger waste materials (75mm thick wood materials-The equipment should be capable to shred fibrous organic waste (75 mm thick wood materials, Banana peduncle, and full tender coconut) with the capacity of 250 kg per hour with suitable MS-FRP coated hopper.The shredded Particle size should be less than75mmMaterials of Construction• Housing: MS Epoxy coated and plate thickness not less than 16mm• Internal housing should not be less than 600x450mm (length x width)• Shaft MoC: D2/4140 hexagonal hardened Steel• Cutters MoC: D2/4140 hardened steel• Cutter blade plate thickness: 16mm• Cutters Arrangement: Cartridges / single piece• Cutters Type: 3 to 5 teeth • Each shaft drive should have separate gear box and separate motor• Mechanical Seal: Tungsten • Motors rating – not less than 5 HP each, IP65, Energy efficiency - IE2• Provision for VFD to adjust the RPM from 40 to 80• D2/4140 Hardened steel cleaning comb arrangement has to be provided.• Suitable hopper in MS with FRP coated.• Provision for auto reverse and forward operation• Corrosion resistant structural framework has to be provided for placing both primary and secondary shredders (top and bottom respectively).• Platform, ladder arrangement and handrail have to be provided.Perferable Makes Cutter and Housing Make: Shreddo / Ecoster/ / AlphathermMotor Make: Bharat Bijlee / Marathon / CGL Gear Box: Premium greaves / Power build /Shanthi |
| 4 | Secondary Shredder - For further size reduction - The equipment should be capable to shred fibrous organic waste with the capacity of 250 kg per hour with suitable MS with FRP coated hopper.The shredded Particle size should be less than 25 mmMaterials of Construction• Housing: MS Epoxy coated and plate thickness not less than 16mm• Internal housing should be not less than 600 x 400 mm• Shaft MoC: D2/4140 hexagonal hardened material• Cutters: D2/4140 hardened steel• Cutters Arrangement: Cartridges / single piece• Cutter blade plate thickness: 10 mm• Cutters Type:13 to 16 teeth• Mechanical Seal: Tungsten • D2/4140 Hardened steel cleaning comb arrangement has to be provided.• Motor rating – not less than 7.5 HP, IP65, Energy efficiency - IE2• Provision for auto reverse and forwarding operation• Suitable structural framework has to be provided to integrate with primary shredder.• Platform, ladder arrangement and handrail have to be provided for supervision and maintenance of the equipment.Perferable Makes • Cutter and Housing Make: Shreddo/ Ecoster / Alphatherm • Motor Make: Bharat Bijlee / Marathon /CGL • Gear Box: Premium greaves / Power build / SanthiSuitable civil foundation to be provided for primary above and secondary shredder. Equipment basement level with required machine foundation (as per supplier requirements) should be atleast 1 feet above the road adjacent to site |
| 5 | Screw Conveyor -1 - To convey the shredded waste from shredder to the dewatering system. • Screw conveyer system with suitable hopper. The bottom of the hopper has to be connected with screw conveyor inlet.• Inclined - U type screw conveyor with removable lid• U plate thickness – 3mm• Screws MoC – SS304• Screw diameter – 350mm• Screw thickness – 3mm• Screw Pitch – 150mm to 200mm• Shaft diameter – 60mm• Motor rating – not less than 3 HP, IP65, Energy efficiency - IE2• Hopper size – 800x 800 mm, MS with FRP coated• Length and height to suite the site conditions (Length: 5 minimum)Perferable Makes • Motor Make: Bharat Bijlee / Marathon /CGL • Gear Box: Premium greaves / Power build /ShanthiSuitable civil foundation and basement to be provided for integrating screw conveyor, primary and secondary shredders. Equipment basement level with required machine foundation (as per supplier requirements) should be atleast 1 feet above the road adjacent to site |
| 6 | Dewatering system - To dewater the fibrous organic waste - • To dewater the fibrous organic waste for a capacity of 250 kg per hour • Capable of dewatering the fibrous materials• Continuous discharge wedge type screw press• Equipped with adjustable RPM• Provision for VFD to adjust the RPM from 10 to 30• All parts MoC – SS304• Pneumatics adjustable back pressure for moisture control• Suitable compressor for pneumatic system• Motor rating not less than 7.5 HP, IP65, Energy efficiency - IE2• The height of the dewatering system has to be raised so that the dewatered waste should fall directly into the pan mixer with weighing load cell.Perferable Makes Dewatering system make: Jash / Geeli / Shree Engineers Motor Make: Bharat Bijlee / Marathon /CGL Gear Box: Premium greaves / Power build /ShanthiCompressor Make: Anest Iwata /Elgi /Ingersoll rand Suitable civil foundation to be provided. Equipment basement level with required machine foundation (as per supplier requirements) should be atleast 1 feet above the road adjacent to site |
| 7 | Solid Mixer- To mix the fibrous organic waste and sewage sludge - • Mixer for homogenization of dewatered fibrous waste and sewage sludge • Type – Pan type, open type mixer, Pan MoC – MS FRP• Dia/size – 1200mm, Height – 500mm, free board – 100mm• Min. distance above tank – 100mm• Total shaft length – 300 mm• Bottom clearance – 100 mm• Shaft dia – 90 mm• MoC shaft – SS304• Minimum No of vanes – 6• Propeller type - Plough Type with adjustable blades• MoC propeller - SS304• MoC Lantern support – MS/CI• RPM @ full load - 30 rpm +/- 10%• Bottom Guide – 1, Gear box type – Helical • Motor – not less than 7.5HP, IP 65Energy efficiency - IE2 Perferable Makes Motor Make: Bharat Bijlee / Marathon /CGL Gear Box: Premium greaves / Power build / ShanthiSuitable civil foundation to be provided. Equipment basement level with required machine foundation (as per supplier requirements) should be atleast 1 feet above the road adjacent to site |
| 8 | Screw conveyor - 2 - To transfer the dewatered sludge to the mixer -• Screw conveyer system with suitable hopper of size 800x800m (Hopper - MS FRP coated)• Inclined - U type screw conveyor with removable lid• MoC of all the components – Mild Steel with epoxy coated• U plate thickness – 3mm• Screw diameter – 300mm, Screw thickness – 3mm• Screw Pitch – 150mm • Shaft diameter - 60mm• Motor rating – not less than 2 HP, IP65, Energy efficiency - IE2• Hopper size – 800 x 800mm• Length and height to suit the site conditions (Min. length 2.0 m)Perferable Makes Motor Make: Bharat Bijlee / Marathon /CGLGear Box: Premium greaves / Power build/Shanthi |
| 9 | Weighing Load cell - To fix below the mixer for the weight calculation. Load cell – 4 Nos • To suit the size of mixer equipment (Approx. 2.00m x 2.00 m)• Rated capacities 200 kg to 5.0 ton capacities• “Thru or “threaded load hole configurations• Low sensitivity to axial loads• Sealed to IP67 standards• Factory Mutual System Approved for Classes I, II, III; Divisions 1 and 2; Groups A through G. Also, non-incentive ratings (No barriers).• Trade certified for NTEP Class III: 5000d, IIIL: 10000d and OIML R-60 3000d availableFour Load Cell Junction box – 1 No• With Surge Protector• MOC: Stainless Steel 316Digital weight Indicator• Serial Communication: RS232 (automation ON/OFF system has to be provided in the panel board based on the set value)• Analog output: 4-20mA (or) 0 -10V• Two Opto – Isolated set Point• Display: 6 Digit/ 7 Segment LED, Digital Height: 14mmSuitable civil foundation to be provided. Equipment basement level with required machine foundation (as per supplier requirements) should be atleast 1 feet above the road adjacent to site |
| 10 | Screw Conveyor - 3 - To transfer the waste from solid mixing system to solar dryer. • Screw conveyer system with suitable hopper • Inclined - U type screw conveyor with removable lid• MoC of all components – MS with Epoxy coated• U plate thickness – 3mm• Screw diameter – 350mm• Screw thickness – 3mm• Screw Pitch – 150mm to 200mm• Shaft diameter - 60mm• Motor rating – not less than 2 HP, IP65, Energy efficiency - IE2• Hopper size – 800x 800 mm• Hopper MoC – MS FRPLength and height to suit the site conditions (Length: 4metre minimum) Perferable Makes • Motor Make: Bharat Bijlee / Marathon /CGL • Gear Box: Premium greaves / Power build / ShanthiSuitable civil foundation to be provided. Equipment basement level with required machine foundation (as per supplier requirements) should be atleast 1 feet above the road adjacent to site |
| 11 | Screw Conveyor - 4 - To transfer the dried waste from solar drier to silo hopper. • Screw conveyer system • Inclined - U type screw conveyor with removable lid• MoC of all components – MS with Epoxy coated• U plate thickness – 3mm• Screw diameter – 350mm• Screw thickness – 3mm• Screw Pitch – 150mm to 200mm• Shaft diameter - 60mm• Motor rating – not less than 3 HP, IP65, Energy efficiency - IE2Length and height to suit the site conditions (Length:6 metre minimum) Perferable Makes • Motor Make: Bharat Bijlee / Marathon /CGL • Gear Box: Premium greaves / Power build / ShanthiSuitable civil foundation to be provided. Equipment basement level with required machine foundation (as per supplier requirements) should be atleast 1 feet above the road adjacent to site |
| 12 | Portable Flue Gas Analyzer - To identify the composition of gas liberated during the pyrolysis. The following parameters have to be measured on sensor based.• CO – 0 to 10000 ppm and CO in percentage upto 10%, if the conc. of CO higher than 10000 ppm• CO2 – 0 to 40% (IR bench based)• NO – 0 to 5000 ppm• NO2 – 0 to 1000 ppm• SO2 - 0 to 5000 ppm• HC- 0 to 5000 ppm (IR triple bench sensors for CO, CO2 and HC)• NOx – calculative method• Pressure measurement for temperature upto 1000oC• Dual pumps for pumping of gas • Filtering systems for chemicals, dust, water and air traps filters needs to be provided.• Sampling Probe: 1 metre, Sampling Hose: Min 6metres (to match the site conditions).• 25 or more lines of data have to be displayed.• Software for data logging &downloading and Transfer live analyzer readings has to be recorded in the PC/data acquisition system.• In-built Printer to print the data shall also be included for remote operation and submission of report.• TUV Certification should be provided for the quoted model.Perferable Makes Make: Testo / Nova / Kane / Geotech / Fujitstu. |
| 13 | Electrical Control panel- Electrical power supply and distribution for the pilot plant. - • Supply, fixing, testing and commissioning of MCC panel board (indoor system with exhaust arrangements) with control switches, contactors, VFD drives (for primary shredder, dewatering system, for one existing screw conveyor (3HP)), voltmeter, Ammeter, selector switch, phase LED indicators, energy meters (2 Nos for main panel and Pyrolysis Unit), suitable electrolytic copper bus bar, cable entry shall be from bottom or top etc., with all accessories as required for the complete plant.• Panel MoC: 2.0 mm cold rolled (CRCA) sheet with powdered coated metal etc., conforming to IS standards.• All electrical materials should be of suitable flame proof.• Local push buttons should be provided for all the Mechanical equipment• Two number of copper earthing system to be providing with appropriate earthing arrangement.• Contactor preferable makes: Schneider, ABB and L&T (for control switches, MCCB, MCB) • VFD preferable makes: Danfoss / ABB / Schneider • Cable preferable makes: polycab/ finolex/ orbit• Supply and Laying of 3.5C x 70 sq.mm XLPE power cable of 1.1 kV grade (Approx. length 100m) of following size direct in ground including excavation, sand cushioning, protective covering and refilling the trench etc. as required (along with test certificate).• Supply and laying of cable for pyrolysis unit panel (18kW) and existing screw conveyor (3 HP) for the proposed panel will also be scope of the bidder.• Appropriate electrical items are also to be provided for the pyrolysis unit and existing screw conveyor in the proposed panel.• Supplying and making end termination with brass compression gland and aluminium lugs for selected cable size as required.• Before fabrication of panel, GA drawing may be obtained approval from CLRI.• Automatic ON and OFF provision for equipment has to be provided based on the output of load cell (weight basis).Digital Clamp Meter with following specifications with test certificate • AC Current: 200, 1000A • AC Voltage: 250V, 750VAC• DC Voltage: 200, 1000V DC• Resistance: 2MOhm• Frequency: 2KHz• Continuity buzzer and diode checking. |
| 14 | Personal Protection Equipment (PPE) - Personal safety - • The PPE such as gloves, goggles, masks, safety helmets, Toe PVC Safety Shoe should be provided (4 numbers each). |
| 15 | 20 feet container- To fix the electric control panels and monitoring systems- • 20 feet length x 8 feet x 8.6 feet• Age – Not more than 12 years old with date of manufacturing / certificate• Used container without any damage and properly painted with primer and enamel.• High quality steel / corrosion resistant corten steel with corrugated two end fixed walls • Lifting hooks - 4 Nos.Interior Works• 35mm wooden frame• 25 mm thick rock wool or glass wool insulation (compressed size)• 8 mm MDF paneling• Door: 7 ft x 3 ft Aluminum Flush Door – 1No.• Window: 3 ft x 3ft aluminium siding windows 3Nos.Electrical Works• Supply and installation of prewired electrical fittings with15/5A sockets, switch boards and all accessories.• 28 wattsLED slim fit tube light - 3 Nos.• 1.5 Ton split A/C (four star rated) with metal coat socket & top with MCB (Make: Voltas, Haier and blue star) - 1No.• 400 mm sweep wall mounted fans - 2Nos. • 18 watts LED bulket fitting – 1No.• 40A MCB, DP-1No, 16 A and 10 A MCB – each 2Nos., Distribution Board with earthing to connecting 8 SWG GI earthing wire• Suitable civil foundation to be provided. Equipment basement level with required machine foundation (as per supplier requirements) should be equal to top of road adjacent to site |
| 16 | Buffer Water tank for pyrolysis system -• Water Tank capacity – 3000 litres• MoC – rectangular FRP tank to withstand maximum temperature of 100oC. |
| 17 | Shed for storage- To store the sewage sludge -• Shed Size 3.0m x 3.0m with Galvalume sheeting• Appropriate structural support has to be provided |
| 18 | Plant lighting system- For night operation of the pilot plant-• Supply, installation, testing and commissioning of prewired 60watts LED street light fitting complete with all accessories. IP65• Light Make: Crompton, Havells, Philips / Equivalent• Providing and fixing of 6m single arm street light pole, bottom side 150mm dia and top side 70mm dia, thickness 3mm MS powder coated pipe with suitable base including SMC box, MCB controller and pole earthing. Cylindrical pole is preferable.• Suitable foundation with min 400mm dia and 800mm depth plain cement concrete foundation should be provided.• LED light fittings (36W) inside the plant at the machineries at higher elevation and outside containers (3 Nos).• Interconnecting cables for the street light will be the scope of the supplier.• Single ON or OFF switch for each street light with Dinrail, MCB and Sintex box of IP65.Number of Street Lighting with pole – 4 Nos Number plant light fittings inside the plant– 3 Nos with Switches |
| 19 | Data acquisition and Processing system - To store the data from the monitoring systems- • Processor – i7, 10th Gen or Latest with 2.9 GHz to 4.7 GHz or higher, 16 MB Cache, 8 Cores or more • RAM – 16 GB, DDR4@2933MHz SDRAM (1 x 8GB) with expandability of 64 GB• Memory Slots – 2 DIMM• Hard Drive – 4TB 7200 RPM HDD SATA III 6Gbps• Network – Onboard Gigabit 10/100/1000 Mbps LAN• WLAN - Onboard Wi-Fi and Bluetooth Combo card• Ports – Front: Minimum 2 super speed Type-A; Minimum 2 USB Super Speed, Type – A; 1 VGA; 1 HDMI 1.4; 1 Display port 1.4; 1 audio-out; 1 power connector; 1RJ-45• Expansion slots – As per OEM specifications • Drive bays – Minimum 3 Base Bays • Form factor - As per OEM specifications • Optical drive – Integrated slim DVD-Writer• Keyboard – USB Keyboard, Mouse – USB optical mouse • Monitor – 27-inch Monitor FHD (1920 x 1080 @ 60Hz)• Aspect Ratio – 16:9• Webcam: HD Webcam with audio • Ports: 1 Display Port 1.2; 1 VGA; 1 HDMI 1.4(with HDCP Support) or higher, Minimum 3 USB 3.0, 1 Microphone; Graphics – Integrated Intel UHD Graphics 630• Audio – Integrated audio with internal speakers mounted in cabinet• Power supply – 180W or higher • Security Management – Trusted platform module TPM 2.0 embedded security chip with windows 10; Serial, USB enable/disable (via BIOS); Power-on password (via BIOS); Set up password (via BIOS);• Operating system – Genuine windows 10 Pro 64bit with recovery partition or recovery media • Warranty – 3 Years onsite comprehensive warranty Perferable Makes • Dell/HP/ Lenovo |
