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Summary of the scope of the inquiry
The bidder is to quote a waste heat recovery boiler or a total waste heat recovery power plant for kiln gas line. The budget quotation must include the engineering, supply and supervision of the erection of equipment according to the descriptions and specifications presented later in this inquiry. The technical scope has to be considered as functional complete concept within the given borderlines.
Location and address of the site:
Bid due date:
November 19th, 2008
Acknowledgement:
The bidder is requested to acknowledge the receipt of this Inquiry by e-mail, and to indicate the intention to submit a tender.
Basic information about the plant and project
LGroup is a diversified construction company founded in 19 and operating in a number of complementary market segments. Its core business areas are building materials, construction and real estate development. The Group includes enterprises for extraction and processing of aggregates, production and transportation of building materials, and housing construction �?from mass market large-panel housing to elite property built after designs made by leading domestic and foreign architects.
ABC “Cement�?was established by LGroup to implement a cement project. The new plant will meet the demand of the cement market. The plant will use raw materials supplied from lime and clay quarries and waste resulting from oil shale extraction and processing.
Cement plant of ABC “Cement�?is located in the town 170 km and close to the Estonian border. The cement plant is a new green field factory. The clinker manufacturing capacity is of 5000 t/d and all produced clinker is grinded to cement. The contract of the cement plant is signed with ABC on October 24, 2007 and the civil work is started on the site. The commissioning is planned in June, 2010.
1.2 Project organization and schedule
The pre-feasibility study of the waste heat recovery of the kiln gases will be carried out in co-operation with the Cement Ltd.
The plan is to have the Heat recovery power plant connected to kiln exhaust gas line as soon as possible.
The start of the clinker production is planned in June, 2010. The heat recovery boiler is to be built as near as possible the cyclone tower. The connecting shall be done during the kiln erection time or during a rather short kiln stop.
Tender is to be sent as follows:
Location:
The plant is located in country. Plant elevation is less than 40 m above sea level.
Operating circumstances
The heat recovery boiler will be installed in the kiln exhaust gas line after cyclones. The minimum outdoor temperature is - 40 ºC (during complete stand by conditions) and the maximum temperature + 30 ºC.
The planned process concept of the cement plant is designed without any waste heat recovery of the flue gases but the temperature after the cyclones is so high that the waste heat recovery of flue gases is possible. Please see the basic data for dimensioning in Appendix No. 2.
2.2.2 The General Requirements
According to Appendix �?1
The scope of delivery consists of the equipment and devices described in this inquiry and its Appendices. The attached flow sheet, Appendix 3, presents preliminarily the process scheme and the equipment needed.
Please note that it is the bidder’s obligation and responsibility to survey the flow sheet and make / propose necessary corrections / changes to the new machinery part of the flow sheet to ensure that the heat recovery process is state of art and that all equipment is included to make a functionally operating complete system.
The delivery shall include
- Mechanical and process engineering according to the requirements
- Process description for electrification, instrumentation and automation engineering and/or the specification of the included equipment
- Precise description of the equipment not included in the Suppliers delivery but to be purchased by buyer
- The supplier is responsible for his sub supplier’s equipment as if they were his own delivery
- documents (drawings, equipment list, installation, operating and maintenance)
- guarantees (mechanical, process, performance)
The quotation should include the price of supervision, commissioning. This scope will be agreed on separately.
Civil engineering, electrification and installation belong to the buyer’s responsibility / costs if not otherwise agreed later between the buyer and supplier.
3. Scope of Quotation
The waste heat is recovered only from the kiln gases. The recovered waste heat is taken after the cyclones and returned to gas duct before the raw mill. The tender must include one or both of the following alternatives:
Alternative 1: Complete waste heat recovery boiler plant delivery designed in accordance with the basic data for dimensioning
Alternative 2: Turnkey waste heat power plant delivery designed in accordance with the basic data for dimensioning.
Quotation includes the complete delivery and erection supervision of the offered alternative. The delivery includes all needed loads data for construction. The documentation should be delivered in Russian and English language.
The Bidder is asked to quote
- Mechanical supervision for the erection of the equipment with the estimated duration of the erection and number and qualification of the erection labour.
- Supervision for the commissioning of the machinery following the completion of the erection; please, estimate the duration of the commissioning.
- Pre-Commissioning training of local staff for operation and maintenance of the system and the duration of the training
The layout of the waste heat recovery power plant is still open but the preliminary scope of the plant is that the waste recovery boiler is located beside of the cyclone tower and the rest of the power plant near the switchyard or the control building. However, supplier’s comments and proposals are welcome.
The quotation must include the following information:
- The detailed scope of the delivery
- Technical data of the quoted equipment
- Data for project planning, dimensions, loads etc.
- Possible bidder’s technical preconditions
- Precise description of the equipment not included in the supplier’s delivery but to be purchased by the buyer
Please give information about the following:
- An estimation of spare part costs for the first twenty-four (24) months of operation.
24 months from accepted commissioning or 30 months from delivery.
The supplied equipment must be capable of the operation as specified in Appendix �?1.
The material is delivered in accordance with standards and regulation valid in Russia. All equipment should follow all existing Codes.
If the standards and regulations are unknown the bidder should inform in the offer which standards and regulations are the followed.
The considered bidder should have Authorized support service centers in for all equipment included in the delivery.
Together with the bidder:
- Technical specifications of quoted equipment.
- General arrangement drawings with dimensions
The quotation should not include any taxes, fees or custom duties, which the authorities may levy on the importation of goods.
4.2 Prices
The Prices must be in Euro’s and have to be specified separately in the quotation as follows:
- Equipment prices according to Appendix No 1 supported with the flow sheets and general arrangement drawings
- Process engineering
- Bidder’s price estimate of the equipment / entities to be specified by Bidder but purchased by Buyer
- Adapting the documentation to meet the Russian standards and requirements. The equipment for the project should be subject to get all needed Certificates, permissions to use from Authorities and documents needed for import purposes and start of operation. The costs should be clarified in the proposal
- Price for supervision of local manufacturing, erection supervision, commissioning, and training
- Price for other possible services
- certificate:
- Price basis:
To be proposed by the bidder.
Bidders are expected to accept. In the event exceptions are taken they must be detailed in an attachment to the tender. Bidder's "Conditions of Sale" is not acceptable.
The estimated delivery time for the equipment as well as for the necessary documents for project planning in normal situation are to be included in the quotation.
No.1 Engineering and Technical Requirements
No.2 Technical specifications for the equipment of the plant
No.3 Preliminary process schema of the WHRP-Plant
No.4 Site plan of the cement factory
No.5 Connection of the generator to the plant electric network
Appendix No.1
Cement Plant Waste heat recovery
This document presents the general specifications for the technical scope, requirements, information for the design and basic data.
The technical delivery scope of the flue gas waste heat recovery system has to be in accordance with the basic concept presented in Appendix No, 2 and with supporting schemes and drawings. However, the bidder may also propose technically more simple and better/lower priced solutions as an option within the basic concept. It is to be noticed that the bidder �?supplier is solely responsible for the proper function of the heat recovery process and that all the equipment is specified / selected to fill the given terms and requirements.
The following items are fixed:
Location of the cyclone tower
Location of the raw mills
The bidder is asked to present his proposal(s) for the optimal technical and economical solution(s) for the waste heat recovery of the cement plant kiln gases.
The main equipment and the basic idea are shown on the flow sheet but not restricted to it. The equipment must form a functional complete system within the border limits.
The waste heat recovery boiler will be installed outdoors. All other equipment and processes will be installed indoors.
All the electrical components which are needed to operate the process will be included with their specifications to the scope of delivery such as:
- Electric motors and gear motors (frequency controlling taken into consideration), actuators etc.
- Rotation monitoring device
- Position limit switches, level switches, pressure switches etc. instruments with needed transmitters
1.3 Power distribution
The generator will be connected to the main 10 kV switch gear
- The medium voltage of the plant is 10 kV and the low voltage 400 V
- The delivery of the medium voltage includes all equipment needed between the generator and the main switch gear. This means e.g the control and synchronizing equipment. The main switches by the switch gear include not in the delivery
- All electrical power needed for the power plant is taken from the main 400 V feeding and the own use is double secured, see appendix No. 5
The control and automation system will be integrated with the new kiln automation system. The new automation system is a delivery of
1.5 Kiln gas specifications
The basic data of the kiln gases is listed in Appendix No.2.
1.6 Gas connections
The delivery includes all needed connection flanges, flue gas valves and additional gas ducts between the cyclone tower and the raw mills.
The waste heat boiler should be furnished with a by-pass gas duct.
The bidder is responsible to calculate and guarantee the pressure drop of the waste heat recovery boiler. The pressure drop between the inlet and outlet flanges should be calculated in normal operation conditions.
The plant layout must be such that
- there is easy access to all pumps, dampers, nozzles �?meters �?sensors , manholes and inspection locks and all other maintenance targets
- lifting beams, structures and equipments must be seen
- the channel and pipe routings ensure low pressure drop
- the waste heat boiler and steam and feed water piping from and to the boiler are installed outdoors.
The enclosed site plan, Appendix no. 4, shows a possible location of the new kiln and buildings and their relations to each other. The Bidder is obliged to survey the lay out and confirm - comment and / or change it according to his experience to ensure the state of art design and lay out of the waste heat recovery of the plant.
1.8 Options and additional equipment
The bidder is asked to propose alternative entities of equipment and process based on the specifications if needed.
If the bidder considers that additional equipment or changes to the equipment presented in this Appendix or the inquiry text part, for the optimal operation of WHRP plant are required, the bidder is asked to make a notice of it and add / modify the needed devices to the scope of his quotation / delivery.
The supplier will be responsible for various engineering services. The Quotation has to contain information on / pricing for different engineering services which are the responsibility of the supplier:
- mechanical engineering and design of the process itself and its equipment
- information for the electrical �?automation engineering, to be made by the buyer
- information for the civil engineering, to be made by the buyer
- position numbering of the equipment final documentation, as built drawings
- the main documentation should be both in Russian and English language.
The bidder is asked to take into consideration that the Supplier’s responsibilities will include:
- General flow sheets and equipment list
- General Arrangement drawings of the WHRPP process equipment.
- General arrangement drawings and work shop drawings of the steel structures for the local supply.
- Load data for all machines and drives.
- Installation drawings and manuals
- Information to procure needed lifting devices for maintenance
- All drawings must be provided in electronic CAD compatible form.
- Engineering / initial data and documentation for the civil design and engineering
- Schemes of all ventilation (HEVAC) systems with design/measured airflows, velocities, under pressures etc. in table form
- Utility list and place of consumption
The engineering is excluded from the scope supply, but the supplier has to submit to ABC Cement all the information which is required to:
- Design and implement the electrical power system.
- A functional description of the system for process control design
- Design and implement the process control system.
- A final motor list
- All the main and auxiliary machinery numbered
- P&I diagram and flow sheet containing the following information
The delivery includes “physical�?devices, valves and fittings (=field instruments)
- All monitoring devices (e.g. level switches, pressure switches, etc.)
- All control devices (e.g. manual and automatic flaps and valves).
- Instrument List and the list of all measurement equipment and switches
Civil engineering is excluded from the scope delivery but the Supplier has to supply to and support ABC Cement with all information required to enable the buyer to:
- Design and implement the civil constructions
The Supplier must be ready to use in flow sheet and GA drawings the equipment numbers given by Buyer after contract.
The term “final document�?means the so called as built-documents. The following final documents are included in the delivery:
- Final general arrangement and detail drawings
- Final flow sheet �?Pi diagram
- Operation and maintenance manuals
- Complete spare parts lists
- Complete electrical/instrumental documentation including software installed
- Final schemes of all de-dusting and ventilation systems with measured airflows, velocities, under pressures etc. in table form
3.1 In general
The material is to be delivered in accordance with standards and requirements.
3.2 Quality assurance
Applicable Directives:
If the bidder is not able to clarify the quality assurance procedure valid in Russia the bidder is responsible to inform the buyer of the procedure followed.
3.3 Surface treatment
All the steel constructions must be properly protected against corrosion and surface treatment of steel parts must be made according to the specification:
- prior to painting the parts have to be shot or sand blasted to Sa 2½ according to the standard ISO 8501
- primer dry film thickness 40 μm + Finish 40 μm parts which will be located inside
- primer dry film thickness 40 μm + Finish painted 2 x 40 μm parts which will be located outside
- painting according to the standard ISO 2944, primer painting has to be done within 2 hours after the shot or sand blasting.
NOTE! The bidder is asked to present his own surface treatment procedure if it deviates from the above and if it is necessary from corrosion point of view based on the bidder’s experience. The used color codes of the steel parts, maintenance platforms and handrails should be specified.
4. Site Conditions and utilities
Site conditions:
Altitude above sea level 40 m
Ambient temperature: Max. +30 ºC
Min.: - 40 ºC
Site utilities:
Medium Voltage: 10 kV
Low Voltage: 400 V
Control Voltage: 24VDC / 230 VAC
Water Pressure: 3 bars or 6 bars
Compressed Air Pressure: 6 bars (not dried)
Raw/cooling water
The raw and cooling water is taken from the river or lake and it is mechanically purified. The delivery includes all needed equipment and accessories for processing the needed cooling water for the condenser and for processing the make-up water.
5.1 Civil works
- dismantling the existing equipment and machinery and disposal of the dismantled material
- excavation and foundations of new structures and machines
- modifications and changes to the existing buildings
- permissions from the authorities for civil works
5.2 Electrification
- switch gear, transformers, main distribution board (MDB), low voltage distribution board (MCC), lightning distribution board (LDB)
- HVAC of the electrical room or substations
- fire alarm system and equipment
- cables, cable trays etc. and their installation from MCC to individual equipment (the supplier is in charge of all the internal cabling of the delivered equipment),
- lightning equipment, cables, cable trays etc. and their installation from LDB to the equipment
Appendix No. 2
Cement Plant, Waste heat recovery Equipment specifications
This document presents the general equipment specifications for the technical scope, requirements, information for the design and basic data.
The technical delivery scope of the flue gas waste heat recovery system has to be in accordance with the basic concept presented in Appendix No, 2 and with supporting schemes and drawings. However, the bidder may also propose technically more simple and better/lower priced solutions as an option within the basic concept. It is to be noticed that bidder �?supplier is solely responsible for the proper function of the heat recovery process and that all the equipment is specified / selected to fill the given terms and requirements.
The following items are fixed:
Kiln line and its accessories
Location of the cyclone tower
Location of the raw mills
The bidder is asked to present his proposal(s) for the optimal technical and economical solution(s) for the waste heat recovery of the cement plant kiln gases.
1. Technical specifications
This preliminary project/equipment specification is made for the waste heat recovery of the new cement kiln. The heat recovery is planned only from the flue gases of the kiln. The heat recovery of the cooling gases of the clinker cooler is not included in the scope of this project.
The flue gases are planned to be cooled between the cyclone tower and the raw mill. The recovered waste heat is used so that the heat is recovered as high pressure steam with a new waste heat boiler. The aim is to produce electric power with high pressure steam. The electric power is produced with the condensing steam turbine.
The main equipment and the idea of the basic process are shown on the flow sheet, Appendix No. 3. The plant and equipment always form a functional complete system within the border limits.
1.1 Basic data for the heat recovery
The heat recovery and the dimensioning of the power plant should be made in accordance with the following data:
The gas analyses and gas data after cyclone are in accordance with the simulation made by FLS:
CO2 31,3 %
O2 3,5 %
H2O 9,0 %
N2 56,2 %
Gas mass flow 462 t/h
Gas volume flow 100 m3n/s (calculated)
Temperature 603 ºC
Dust content 63 g/kg-gas
Dust content 90 g/m3n (calculated)
After the boiler the gases are led back to the cement plant process. The main part of the gases is used as drying gases of the raw meal grinding.
The gas temperature before the raw mill should always be over 345 ºC.
The preliminary recovered heat power is about 42 MW. The bidder is responsible to calculate the recovered heat power in accordance with the specified data.
1.2 Steam values
The bidder can decide on the steam values in accordance with his own practice. One of the comparison values is the guaranteed electric power (MW).
The minimum feed water temperature before the economizer is 135 ºC so that the sulfur corrosion of the economizer tubes can , be avoided. This temperature is valid also in the feed water tank.
2. Specification
2.1 Waste heat boiler
The boiler is a horizontal or a vertical type waste heat boiler without any additional primary fuel. The boiler can be either a natural circulated or forced circulated boiler.
The bidder decides the type and furnishes the delivery with all the necessary equipment.
The bidder is responsible to calculate and guarantee the pressure drop of the flue gas side in the boiler. The pressure drop between the inlet and outlet flanges should be calculated in normal operation conditions with a full load.
The waste heat boiler will be installed outdoors. This means that all the equipment and fittings should be furnished with necessary heating elements.
2.2 Turbine
The turbine is a normal condensing turbine with one extraction steam connection. The extraction steam pressure should be 0,3 MPa.
The extraction steam is used for heating of feed water in the feed water tank and for heating of the cement plant. The maximum plant heating capacity is 3,5 MW.
The preliminary steam values are the normal design values of one Russian manufacturer and the condensing power capacity is calculated in accordance with those turbine values. The steam values of the turbine used in preliminary power calculations are the following:
Steam pressure 4,2 MPa
Steam temperature 435 ºC
Outlet steam pressure 9,8 kPa
2.3 Generator
The generator voltage is 10 kV. The supply includes a complete delivery of the generator as follows:
- oil system including pipes, tank and cooler
- all medium voltage needed switches for operation and protection
- control and protection system as well as synchronizing equipment
2.4 Condenser
The condenser is water cooled. The water cooling process is closed and the water is cooled with the air coolers. The water temperature to the condenser should be +30 ºC and the maximum temperature after the condenser +55 ºC.
The air/water cooler should be dimensioned as follows or the bidder can make his own dimensioning of the condenser:
Maximum cooling capacity 45 MW
Maximum cooling air temperature +25 ºC
Water temperature, in +55 ºC
Water temperature, out +30 ºC
2.5 Demineralization plant
The delivery includes a complete deminerazation plant for the plant. This plant is located in the turbine house.
The plant should be designed and dimensioned in accordance with the process and the pressure level of the boiler. The raw water is river or lake water and mechanically purified.
2.6 Feed water tank
The delivery includes a complete feed water tank with accessories. The minimum tank volume is dimensioned for one hour operation without any make-up water feed to tank.
2.7 Dimensioning of the pumps
All pumps should be furnished with reserve pump. The capacity of the pumps is 2x100% plus the dimensioning reserve (15%).
The delivery of the feed water pumps includes 3x100% pumps. One of the pumps is a steam turbine driven pump.
The delivery of the pump always includes all necessary valves and fittings.
2.8 Steam pressure reduction valve
The delivery includes a pressure reduction valve. This valve should be dimensioned so that all steam flow from the boiler can pass the turbine direct to the condenser.
2.9 Options and additional equipment
The bidder is asked to propose alternative entities of equipment and process based on the specifications if needed.
If the bidder considers that additional equipment or changes to the equipment presented in this Appendix or the inquiry text part are be required for the optimal operation of WHRP plan, the bidder is asked to make a notice of it and add / modify the needed devices to the scope of his quotation / delivery.
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