60 klpd capacity ethanol plant village sugauli, district...

Doc No. : GDP/EPC-BID-E/09-10/026 (F)Date : June 8, 2009Assign No. : GPD/SDE/HPCL/08-09/045Date : September 12, 2008

ENGINEERING, PROCUREMENT & CONSTRUCTION (EPC) BID DOCUMENT

60 KLPD Capacity Ethanol Plant Village Sugauli, District East Champaran, Bihar

Technical Specifications

Prepared For

Hindustan Petroleum Corporation Ltd. (HPCL)(A Govt. of India Enterprise)

Petroleum House, 17, Jamshedji Tata Road,Mumbai – 400 022

Prepared By

MITCON Consultancy Services Ltd. (MITCON)Kubera Chambers, Shivajinagar

Pune - 411 005

June, 2009

EPC Bid Document for Ethanol Plant at Sugauli, Dist. East Champaran, Bihar, Technical Specifications

Doc No. : GDP/EPC-BID-E/09-10/026 (F)Date : June 8, 2009 Assign No. : GPD/SDE/HPCL/08-09/045Date : September 12, 2008

EPC BID DOCUMENT

60 KLPD Capacity Ethanol PlantVillage Sugauli, District East Champaran, Bihar

CONTENTS

Chapter No. Title Page No.1. Intent of Specifications 12. Project information 23. Design Basis, Scope of Supply, Services & Terminal

Points 5

3.1 Design Basis 53.2 Scope of Supply 123.3 Services 153.4 Terminal Points 154. Technical Specifications 184.1 Juice Concentration 184.2 Syrup Bulk Storage 194.3 Juice Handling & Pasteurization 194.4 Continuous Fermentation 204.5 Multi-pressure Vacuum Distillation 234.6 Molecular Sieve Dehydration 284.7 Alcohol Storage 294.8 Utility 314.9 Water Treatment Plant 324.10 Condensate Polishing Unit 324.11 Piping & Fittings 33



EPC BID DOCUMENT


CONTENTS (CONTD.)

Chapter No. Title Page No.5. Spent Wash Treatment 355.1 Bio-methanation 355.2 Evaporation 365.3 Composting 396. Electrical Distribution System 446.1 General Design Basis 446.2 Scope of Work 496.3 Diesel Generating Set 507. Control & Instrumentation System 527.1 Process Control Philosophy 527.2 Parts Interchangeable 527.3 Security 537.4 Spare Philosophy 537.5 System Specifications 537.6 Operator Interface 557.7 Operator cum Engineering Station 557.8 Other Hardware Requirements 567.9 Instrument List 58



EPC BID DOCUMENT


CONTENTS (CONTD.)

Chapter No. Title Page No.8. Civil Works 638.1 Major Civil Works 638.2 Design Data 648.3 System Description & Specification 648.4 Design Criteria 658.5 Foundations 668.6 Machine Foundations 668.7 General Design Considerations 698.8 Design of Miscellaneous Items 738.9 Architectural Concepts & Design 748.10 Construction 778.11 Effluent Treatment Plant 828.12 Buildings & Civil Works 838.13 Important & Common Notes 909. Fire Fighting & Protection 929.1 General 929.2 Basic Fire Fighting System 929.3 Fire Water Piping 969.4 Valves 96 10. Spares 9711. Inspection & Testing 9812. Drawings, Data & Information 9913. Guaranteed Performance Parameters 100



LIST OF APPENDICES

Appendix No. Title

I Process Flow Diagram

II Product Specifications

III Design Basis

IV Scope of Work

V Other Inputs & Specifications

VI List of Approved Makes

VII Drawings to be Submitted by the Tenderers

VIII General Guidelines for Erection & Commissioning

IX General Construction Specifications

X Data Sheets for Electrical Distribution System to be submitted by Tenderers

XI List of Workshop Equipment

XII Preliminary Plant Layout, Integrated Sugar, Ethanol & Cogen Power Project

XIII Terms & Conditions for Erection & Commissioning

EPC Bid Document for Ethanol Plant at Sugauli, Dist. East Champaran, Bihar, Technical Specifications 1

Chapter – 1

Intent of Specifications

The main intent of the specifications has been to define the equipment, electrical, auxiliaries and civil works for the proposed 60 KLPD capacity ethanol plant including spent wash treatment with bio-methanation / evaporation & bio-composting, envisaging latest and commercially proven technologies, being set up co-extensively with 3500 TCD capacity sugar plant and 20 MW high efficiency grid connected cogen power plant, at Sugauli in East Champaran district of Bihar State.

The ethanol plant component will include all equipment, associated systems, electrical distribution system, instrumentation and control, piping and auxiliaries, civil works, treatment of spent wash including biogas digesters / evaporation and bio-composting, etc.

The intent of the specifications also has been to achieve continuous and efficientoperations throughout the operation of the ethanol plant for 270 days, 130 season days and 140 off season days based on own molasses and 50% mixed juice transferred from the sugar plant.

The main goals set are as under:

(a) Providing specific equipment, associated systems, electrical distribution system and associated civil works, mainly to achieve the targeted production rate, optimum fermentation / distillation / dehydration efficiencies and lowest steam and power consumption of the ethanol plant, as well as achieve continuous operation.

(b) The design basis for selection of all equipment will consider average 60 KLPD, on 24 hr basis and 270 days annual operation, based on own molasses and 50% mixed juice transferred from the sugar plant (The provision for adding on ENA plant later on should be considered).

(c) Achieving targeted electricity consumption for the ethanol plant and associated spent wash treatment facility of 400 kWh / KL and total steam consumption of 8TPH / KL during cane crushing season.

(d) Ensuring targeted biogas generation from the digesters (for supply of biogas to cogen power plant of 16.67 Nm3/KL ethanol manufacture), 250 / 100 BOD / COD after evaporation and targeted bio-composting production, meeting the BSPCB / CPCB / MoEF norms.


Chapter – 2

Project Information

Name and Address : DGM (Pipeline Projects)M/s. Hindustan Petroleum Corporation Ltd. (A Govt. of India Enterprise)8, Shoorji Vallabhdas MargBallard Estate, Mumbai – 400 001Ph : 022 – 2263 7153, 2265 4110 (D)Fax : 022 – 2263 7184 E-mail : [email protected]

Project Site : Near Village Sugauli,District East Champaran, Bihar

Constitution & Type : A Government of India Enterprise

Project Title : Engineeri n g , P r o c u r e m e n t , C o n s t r u c t i o n & Commissioning of Ethanol Plant & spent wash treatment / bio-composting facility at the Project Site

EPC Consultant : MITCON Consultancy Services Ltd. "Kubera Chambers", 1st FloorShivajinagar, Post Box No. 923, PUNE-411005, (INDIA)Ph. No.: 020 – 2553 3309 / 2553 4322Fax No.: 020 – 2553 0305 / 2553 3206

Products : Absolute alcohol or ethanol (co-extensively with 3500 TCD sugar & 20 MW Co-generated Power plants)


Project overview : This EPC bid is invited for design, engineering, manufacture, procurement, supply, transportation to site, transit and storage, insurance, storing at site, project management, civil works, mechanical works, e lec tr ical works and I & C works , erect ion, installation, testing, commissioning, performance testing, putting into successful commercial operation and handing over of 60 KLPD ethanol plant, associated spent wash treatment through digesters and evapora t ion , fo l lowed by b io-composting facility as specified.

Installed Capacity : 60 KLPD ethanol for 270 days operation on 50% mixed juice and molasses available from the sugar plant

Site location : Near Sugauli town Distance from nearest town / city

: Sugauli, 2 Km

D i s t a n c e f r o m n e a r e s t railway station

: Sugauli, 0.5 KmMotihari, 25 Km

Distance from nearest airport : Patna, 185 KmDistance from nearest water source

: Gandak River, 2 km

Distance from nearest BSEB EHV substations

: Sugauli, 33 KV (2 Km) & Motihari (132 KV), 25 Km

Annual Rainfall : 1241 mmAmbient air temperatureMaximumMinimum

::

460C 50C

Data for Seismic Design : Zone IV

Relative Humidity : 70% (average)

Climatic Conditions : Tropical, dry & arid


Design wind pressure : In accordance with provisions of Indian Standards IS:875.

Design c o o l i n g w a t e r temperature

: 320 C

Soil characteristics at site :Iso-ceramic level (No. of stormy days/year)

: 20

Construction power & water : Construction power and water is in the scope of EPC vender.


Chapter – 3

Design Basis, Scope of Supply, Services & Terminal points

3.1 Design Basis (Also refer Appendix – III)

3.1.1 The proposed ethanol plant will have manufacturing capacity of 60 KLPD, with 99.8% purity by volume and 1.6 KLPD impure spirit of 95% purity by volume. The ethanol plant will be provided required steam and power from cogen power plant for 270 operating days, 130 season days & 140 off-season days.

3.1.2 Ethanol plant will operate on 50% mixed juice diverted from the sugar plant & available molasses during season & on stored concentrated syrup & saved molasses during off-season. The required quantity of mixed juice will be used for ethanol manufacture during season & the balance will be converted into concentrated syrup & stored for off-season requirements.

3.1.3 Out of 1750 TPD mixed juice diverted to ethanol plant, 50% or 875 TPD will be used for ethanol manufacture during season & balance 50% or 875 TPD will be concentrated & stored for off-season requirement. One MT of mixed juice will generated about 56.81 Ltrs of ethanol, hence with 875 TPD mixed juice about 49.71 KL of ethanol per day will be manufactured.

3.1.4 With 95% maximum utilization of the ethanol plant, 57 KL per day ethanol will be manufactured both during 130 season days & 140 off-season days.

3.1.5 Hence, for balance requirement of ethanol manufacture of 7.29 KL per day, molasses available from sugar process during season will be used. With 40% fermentable sugar in molasses, one ton of molasses will yield 227.24 lit of ethanol. Hence, for 7.29 KLPD balance ethanol manufacture, molasses requirement will be 32.08 TPD.

3.1.6 Out of total molasses generation of 84.88 TPD (1750 TCD x 4.85%) will yield required per day, 32.08 TPD will be used for ethanol manufacture in season & 52.8 TPD or 6864 MT of molasses will be saved for off-season operation.


3.1.7 The concentrated syrup of 875 TPD or 113750 MT during 130 season days will be used for 140 off-season days. Hence, based on 56.81 ltrs ethanol manufacture per MT of concentrated syrup, 46.16 KLPD ethanol will be manufactured from stored concentrated syrup for 140 off-season days. The balance quantity of 10.84 KLPD (57 KLPD @ 95% maximum utilization – 46.16 KLPD) ethanol will have to be manufactured from saved molasses.

3.1.8 For 10.84 KLPD ethanol manufacture, 47.70 TPD molasses will be required. For 140 off-season days, total molasses requirement will be 6678 MT. Wi th saved molasses o f 6864 MT, the o f f -season molasses requirement will be easily met.

3.1.9 The overall design parameters of the ethanol plant are given in the following table:

Sr. No.

Item Ethanol Plant (on Mixed Juice /

Own Molasses during season &

Conc.Syrup / saved molasses during off-

season)1 Cane crushing, TCH 1462 No. of hrs. per day 243 Cane Crushing per day, TPD 35004 No. of gross season days 1305 Annual Cane crushing, MT 4550006 Screened mixed juice to Ethanol (50%),

TPD1750

7 Screened mixed juice used during season, TPD (50% of diverted mixed juice)

875

8 Screened mixed juice concentrated per day during season, TPD (50% of diverted mixed juice)

875


Sr. No.




season)9 No. of days of operation of Ethanol

Plant- Own molasses & Cane juice- Saved molasses & Con. Syrup

270

130140

10 Fermentable sugar content, % W by W 1011 Fermentable sugar concentration in

juice, % W by W10

12 Ethanol capacity, KLPD 6013 Maximum capacity utilization, %

(KLPD)95

(57)14 Molasses Generation, % cane 4.8515 Molasses Production, TPD (MT) 84.88

(11034)16 Filter cake, % cane 3.517 Filter cake production, TPD (MT) 61.25

(7963)18 Ethanol recovery, liters / MT of

molasses227.24

19 Ethanol recovery, litres /MT of cane juice

56.81

20 Steam requirement, TPH (@ 8 Kg/cm2)- Season (ethanol manufacture & syrup concentration)

- Off-season (ethanol manufacture)

20.00

10.2521 Power requirement, MW

- Season- Off-season

1.000.90

22 Water requirement, KL/ KL of Ethanol - Season - Off-season

15.0020.00


Sr. No.




season)23 Spent wash generation per lit of Ethanol

with evaporation, Ltr/KL3.00

24 Total spent wash generation per annum, KL (270 days)

48600.00

25 Annual Compost Production, MT (at 1:2 ratio of press mud / filler material)

16200.00

3.1.10 The ethanol manufacture from diverted mixed juice & molasses will involve state of the art technologies like continuous / batch fermentation, multi pressure vacuum distillation & molecular sieve dehydration system. These systems will ensure optimum utilization of raw materials i.e. mixed juice / concentrated syrup & molasses, highest yields & lowest steam, power & water consumptions. The in-built automation system will ensure optimum manpower required for operation of the plant.

3.1.11 The ethanol plant will involve different sections including juice pasteurization & concentration, syrup & molasses bulk storage, continuous fermentation, multi pressure distillation, molecular sieve dehydration, effluent & water treatment plant, ethanol storage, misc. laboratory & workshop, etc.

3.1.12 The mechanical design basis is indicated below:

x For design of static equipment like fermentors, pre-fermentors etc.the following factors have been taken into consideration:

(a) Wind pressure = 150 Kg/m2(b) Seismic factor = 0.04 As per Indian Standards

x The Seismic factor Alpha = 0.04 corresponds to Zone 4 as per Indian Standards 1893


x The static equipment like SS fermentors will be designed generally as per API 650.

x All equipment will be supported laterally to the structural members and no direct load due to wind and seismic forces have been considered. All tanks like Fermentors, Beer well etc will be supported / rested using civil foundations.

x Specifications of the material of construction for the equipment will be as per generally ASTM 240 for stainless steel sheets and coils. Material of construction for Copper column trays, body flanges for columns.

x The material of construction of all body flanges and bolts will be CS and gaskets will be EPDM.

x All pressure vessels like distillation columns, condensate pot, etc. will be generally designed as per ASME Sec. VIII Div. I.

x All distillation columns will be supported laterally to the structural members and no direct load due to wind and seismic forces have been considered.

x All shell & tube type heat exchangers will be generally designed as per TEMA C.

x The baffle thickness in case of above heat exchangers is restricted to2/ 3 mm.

x Hydro testing of critical equipment wherever applicable will be carried out at our fabrication facility before dispatch.

x Piping and valves specification will be generally as per ANSI standards.

x Pipes - CS ANSI B 36.10 SS 304 ANSI B 36.19

x Flanges - ANSI B 16.5, 150 # and Stubend - MSSP 43 TYPE

x Instrumentation specification will be generally as per ISA.


x The following are the design standards used for the equipment for design.

- Pressure Vessels and distillation columns as per ASME - Storage tanks as per API - Heat Exchangers as per TEMA- Piping and valve as per DIN/JIS- Instruments as per ISA.

3.1.13 Design consideration for selection of electrical equipment, power supply & power distribution are indicated below:

x Ambient temperature : 50° C

x Humidity : 90%

x Altitude : >1000 M above MSL

x System Fault Level :

: 50 kA for 1 Sec. for 415V system

: 9 kA for 1 Sec. for lighting circuits

x 415 V + 10%, 50Hz + 5 %, 3 Phase for power distribution available from cogen power plant to ethanol plant

x 415 V + 10% , 50Hz + 5 %, TPN for plant load operating at 415V supply

x Control voltage 110V AC, 50Hz for MCCs and PCCs

x Power Supply for Tripping and Closing Circuits of Circuit breakers : 110 V, D.C.

x 415 V power supply will be given to Ethanol Plant Switchboardlocated at cogen power plant. Further downstream power distribution will be in the scope of EPC contractor for ethanol plant

x 230 V Single phase power supply shall be derived through Phase & Neutral for single phase power consumer in the ethanol plant, if any


3.1.14 Effluent Treatment

The spent wash generated in the ethanol plant will be treated in following stages, to meet the BSPCB / CPCB / MoEF norms. :

1) Bio-methanation – The spent wash from the ethanol plant will be passed through bio-methanation process to generate bio-gas and reduce the BOD / COD to the targeted levels.

2) 4 effect evaporation - The spent wash after bio-methanation will be passed through a multiple effect evaporator system in which heat recovered from one effect is used to concentrate spent wash in second effect evaporator with continuous recirculation of concentrated spent wash with in the system until desired concentration is obtained. This entire concentration process will be carried out under vacuum leading to less consumption of steam and maximum concentration of spent wash with in less period of time.

3) Bio-composting - Composting is a biological process in which organic matter is degraded under controlled conditions. It involves microbial mineralization.

The mixing of concentrated spent wash from evaporation plant and press-mud (50-70% moisture) will be carried out in trenches with the help of excavator-cum–loader for mixing, turning, loading and unloading of compost material. Addition of cow dung will provide bacterial culture required for composting.

3.1.15 Fire Fighting & Protection

Fire protection system to be offered based on site plan. The system is designed as per International rules (NFPA) & equivalent standards. List of Reference:

x NFPA-10- Standard for portable Fire Extinguishers.x NFPA -11 - Standard for Low expansion foam systemx NFPA-13 – Standard for sprinkler system installation.x NFPA -14 - Standard for the installation of Standpipe, Private Hydrant

& Hose System.x NFPA -15 Standard for water spray systemx NFPA -24 Private Fire Service mains & their appurtenances.x NFPA -30 Flammable & combustible Liquids Code x NFPA -72 National Fire Alarm Code


3.2 Scope of Supply (Also refer Appendix – IV)

3.2.1 General

The scope of work will include design, engineering, manufacture / procure, supply, erection and commissioning of equipment, associated systems, internal electrical distribution system and associated civil works for the entire ethanol plant and associated spent wash treatment / bio-composting facility, as detailed hereunder for achieving the guaranteed performance parameters specified for each section and for steam & power consumptions. The Contractor will also need to complete all associated electrical, mechanical and instrumentation work required for installation, commissioning of the entire equipment, and proving the performance at site.

The Contractor will be responsible for providing an efficient, reliable and state of art technology equipment. The specifications in this section, attempt to define the scope and specifications. However, the onus of providing the appropriate equipment and auxiliaries for successful commissioning, performance proving and operation, entirely rests with the Contractor.

The scope of work for the equipment, associated systems and civil works covered under the specifications will include, but not limited to the following.

(a) Design, engineering, supply, fabrication, manufacture / procure, assembly, shop testing and inspection at manufacturer's works, erection and commissioning

(b) Providing all labourers, materials and equipment for testing at shop / site,as required.

(c) All spare parts required for the commissioning.

(d) Spare parts required for two (2) years of trouble free operation

(e) Special tools and tackles required for operation and maintenance, inspection, and repair of the equipment / systems offered.


The specifications are intended to cover the design, engineering, manufacture / procure, supply, erection, testing and commissioning of the entire ethanol plant and associated spent wash treatment / bio-composting equipment, associated systems, electrical distribution system, necessary piping / supports / valves / instruments, DCS based control & instrumentation system, necessary structures and civil works.

Supplies and services shall be rendered in conformity with proven engineering principles, taking into account the current state of the art technology. The requirements of the contract must be fulfilled in its entirety.

The supplies and services within the scope shall be rendered inclusive of all appliances and interconnecting arrangements with other supplies, necessary for installation of all accessories and for satisfactory operation, maintenance and repair.

The scope of supply and services shall include all necessary work and supply of equipment and material whether mentioned in these specifications or not, but which are necessary for the satisfactory, reliable, safe operation, maintenance and required for achieving guaranteed performance parameters.

Any equipment, devices or material even if not included in this EPC bid, but found necessary for the safe and satisfactory functioning of the unit under this EPC bid, shall be supplied, erected and commissioned by the Contractor at no extra cost to the Owner, as though, such equipment, material or work were originally specified and formed part of the scope of work.

3.1.2 Major Equipment

(a) Juice concentration plant, syrup bulk storage, juice pasteurization plant, continuous fermentation section, multi-pressure distillation section, molecular sieve dehydration plant, water treatment plant, alcohol storage section, interconnecting piping & accessories and miscellaneous like weigh bridge, laboratory, workshop, etc.

(b) Bio-methanation plant including bio-gas digester, de-gasing pond, lamella clarifier, gas holder, central agitator, lateral agitator, over / under pressure release device, flare burners, safety & security devices, spent wash pumps, sluge recycling pumps, bio-gas blowers, interconnecting piping & accessories, electrical control panel and cabling, instrumentation, etc.

(c) Evaporation plant for spent wash after bio-methanation including evaporator calendria, flash vessels, vacuum / feed / recycle-cum-forward pumps and motors, pre-heaters, surface condensers, internal piping & valves, electrical panel & cabling, instrumentation, etc.


(d) Composting plant for treatment of spent wash after evaporation to meet the BSPCB / CPCB / MoEF norms including aerotillers, tractors with hydraulic blades, trolley with creeper gear box, HDPE piping & spraying unit , JCB machines, pumps, motors, electrical panel & cabling, interconnecting piping & accessories etc.

(e) Steam and power consumption reduction equipment for achieving the related guaranteed performance parameters.

3.1.3 Electrical Distribution System

11 KV feeders from cogen power plant, all internal electrical distribution system within the ethanol plant for 1 1 K V , 440 V systems including distribution transformers, power & control cables, accessories, earthing & lightening protections, all mandatory safety devices, instrumentation, illumination, etc. will be included in the contractor’s scope.

3.1.4 Control & Instrumentation

All necessary control & instrumentation equipment for efficient operation of the proposed ethanol plant and associated spent wash treatment / bio-composting equipment, associated systems and electrical distribution system or otherwise for the entire ethanol plant, will be in the scope of the Contractor.

3.1.5 Civil Works

All necessary civil works including foundations, structural, earth work, etc. required for installation of the proposed ethanol plant equipment, associated systems and electrical distribution system will be in the scope of the Contractor.

3.1.6 Fire Fighting & Protection

Fire protection system shall be provided for the above plant as per the design basis. Scope of work includes design, engineering, supply of equipments and components required for fire protection system for all areas as per system mentioned below. Following works are also to be included in the scope.

x Construction of firewater storage tanksx Construction of fire pump housex Earthing of equipmentsx Erection of fire fighting piping & equipmentx Any type of civil work


3.3 Services

3.3.1 Design and Engineering

(a) Preparation of design calculations and detailed drawings (b) Preparation of BOQ (c) Preparation of manufacturing drawings (d) Preparation of quality assurance and inspection plans and implementation

schedule.(e) Preparation of schedule for site testing and commissioning.

3.3.2 Erection and Commissioning

(a) Inspection of civil work in foundations, trenches and allied jobs.(b) Unloading, unpacking, shifting to locations, positioning, aligning and

fixing of equipment which are included in contract (c) Pre-commissioning checks. (d) Commissioning , testing and trials runs and performance proving(e) Completion of documentation and records.

3.3.3 Statutory Approvals

(a) Obtaining approvals on drawing and designs from local authorities, as required.

(b) Arranging inspections and approvals for commissioning of plant electricalfrom Local authorities and Chief Electrical Inspector.

(c) All approvals from Government agencies are in the scope of the Tenderer.

3.3.4 Inspections / Review Meetings

(a) Making the arrangements for periodical and final inspection of all major equipment at own or sub-contractor’s works.

(b) Attending the periodical review meetings at site or at the agreed locations.

3.4 Terminal Points

3.4.1 Screened & Mixed Juice

From the discharge end of juice mass flow meter (after proportioning device & juice transfer pumps, including valve), located in the milling section of the sugar plant for transfer of 50-45% of juice to ethanol plant

3.4.2 Raw water


At the specified intake point at the raw water storage tank outlet header located in the sugar plant

(Contractor’s scope covers suitable raw water transfer pumps & accessories, pipeline from main reservoir up to ethanol plant, spent wash treatment / bio-composting facility and internal water storage / distribution, including all fittings / supports / valves, etc.)

3.4.3 Steam supply

At the LP header of cogen power plant located at 1.5 m level beside the powerhouse building, towards the sugar plant side.

(Contractor’s scope covers LP steam pipeline from LP header of cogen power plant up to ethanol plant / spent wash distribution and bio-composting facility and internal distribution pipelines, including all flanges, valves, accessories, supports, etc.)

3.4.4 Power supply

At 2 nos. 11 KV feeders identified in 11 KV switchboard in cogen plant TG building

(11 KV (UE), XLPE insulated Aluminium conductor cables from cogen power plant up to the ethanol plant, 11 KV / 440 V distribution transformers and 440 V internal power distribution system including related panels / switchboards / starters / cables / protections, and related distribution system including panels / switchboards / starters / cables / protections, etc. & all earthing will be in the contractor’s scope).

3.4.5 Compressed air

Necessary size compressor & accessories, distribution header & pipelines, valves, fittings, etc. required for the sugar plant included in the contractor’s scope.

3.4.6 Molasses

At the delivery header of the molasses transfer pumps, near the molasses storage tank located in sugar plant, for transfer of molasses to ethanol plant (the contractors scope covers pipeline, fittings, valves, etc. from molasses transfer pumps up to storage tanks in ethanol plant and further distribution within).


3.4.7 Steam Condensate

At the outlet header of steam condensate transfer pumps, including valve, located in the ethanol plant.

3.4.8 Filter Cake

At the discharge chute end, below the vacuum filters located in the sugar plant,for transfer to bio-composting facility

3.4.9 Ethanol

At the outlet of positive displacement flow meter of ethanol bulk storage tanks

3.4.10 Effluent

Bio-composting facility based on treated spent wash in the bio-methanation & evaporation plants meeting the BSPCB / CPCB / MoEF norms.

3.4.11 Civil Works

Entire civil works & structural in the ethanol plant and spent wash treatment / bio-composting facility area will be in the Contractor’s scope.


Chapter – 4

Technical Specifications

4.1 Juice Concentration Section For Off-Season Storage

Sr.No.

Item of Equipment Outline Specifications

Material of Construction

Qty.

1. 5 Effect Evaporators Shell & Tube and forced circulationtype, with 200 m2 heat transfer area

SS 304 1 Set

2. Vapour- Liquid Separator

Cylindrical vertical type, 4 m3capacity

SS 304 1 Set

3. Recirculation cum Transfer Pump

Centrifugal type, with 150 m3/hrcapacity

Wetted parts SS 304

1 for each

4. Final Condenser Shell & Tube type, with 300 m2 heat transfer area

SS 304 1

5. Syrup Intermediate Storage Tank

Cylindrical vertical type, with 20 m3 capacity

SS 304 1

6. Syrup Transfer Pump Centrifugal type, with 35 TPHcapacity

Wetted parts SS 304

1+1

7. Condensate Collection Tank

Cylindrical vertical type, with 2 m3 capacity

SS 304 1

8. Condensate Transfer Pump


Wetted parts SS 304

1+1

9. Vacuum Pump Water Ring type, with 350 m3/hrcapacity

CI 1+1

10. Piping & Valves,Instrumentation

Suitable As required Lot


4.2 Syrup Bulk Storage Section

Sr. No.



Qty.

1. Syrup / Molasses tank with accessories like Cooling system, Vent, Drain, etc.

Vertical Cylindrical type, with 8000 m3 capacity

M.S. 7

2. Molasses Pit Rectangular Underground type, with 100 MT capacity

RCC 1

3. Syrup/Molasses Pump

Gear / Lobe type, with 35 TPHcapacity

C.I. 1+1

4. Syrup/Molasses Filter Basket strainertype

SS 304 1+1

4.3 Juice Handling & Pasteurization

Sr.No.



Qty.

1. Juice Holding Tank Cyl i n d r i c a l /Verti c a l t y p e , w i t h 4 0 m 3capacity

SS 304 1

2. Juice Transfer Pump Centrifugal type, w i t h 3 5 T P H capacity

Wetted Parts :

SS 304

1+ 1

3. Juice pasteurizer PHE type Plates: SS316 1+1

4. Juice Cooler PHE type Plates: SS316 1+1


4.4 Continuous Fermentation Section

4.4.1 Syrup Handling Section

Sr. No.



Qty.

1. Syrup Receiving Tank Cylindrical / vertical, conical bottom type, with 3 m3 capacity

MS 1

2. Weighed Syrup Tank Cylindrical, vertical, flat slopping bottomtype, with 60 m3capacity

MS 1

3. Syrup Weighing System

Load cell type, with 3 MTcapacity

-- 1

4. Weighed Syrup Pump Gear type, with 15 TPH capacity

CI 1+1

4.4.2 Yeast & Fermentation Section

Sr. No.



Qty.

1 Culture VesselsCV– I CV – II CV – III With air sparger, heating & cooling system

Cylindrical,vertical & jacket type, with capacities 0.2 m3, 1 m3 & 5.5 m3

SS 304 1 Set

2 Culture Vessel Transfer pump

Trolley Mountedtype, with 5 m3/hrcapacity

Wetted Parts SS

1

3 Pre Fermenter along with Air Sparger & Broth Mixer

Cylindrical,vertical, conical bottom type, with 50 m3 capacity

SS 3042


Sr. No.



Qty.

4 Pre Fermenter Recirculation pump


Wetted Parts SS

2

5 Fermenter with Sparger, & safety system, Broth Mixer

Cylindrical,vertical, Conical Bottom type, with 350 m3 capacity

SS 304 Minimum 4

6 Fermented Wash Coolers

PHE type Plates: SS 316

Minimum 4

7 Fermenter Re circulation Pump

Centrifugal type, with 250 m3/hr capacity

Wetted Parts SS

4+1Spare in

store

4.4.3 Wash Clarification Section

Sr. No.



Qty.

1 Wash Settling Tank Cylindrical,vertical, Conical Bottom type, with 225 m3 capacity

SS 304 1

2 Sludge Settling Tank Cylindrical,vertical, Conical Bottom type, with 60 m3 capacity

SS 304 1

3 Sludge Trough Cylindrical, vertical type, with 0.5 m3 capacity

SS 304 2

4 Sludge transfer Pump 2 m3/hr capacity Wetted Parts SS

2+2

5 Wash Holding Tank Cylindrical, vertical, conical bottom type, with 350 m3 capacity

SS 304 1

6 Fermented Wash Feed Pumps


Wetted Parts SS

1+1


4.4.4 Utility & Chemical Dosing Section

Sr. No.



Qty.

1. Air Blowers Water Ring type, with 350 Am3/hr capacity

SS 304 2 + 1

2. Air Filter HEPA type SS 304 13. CO2 Scrubber Sieve trays type,

with 800 mmdiameter having 6 nos. trays

SS 304 1

4. Acid Dosing tank Cylindrical, vertical type, with 1 m3 capacity

MS 1

5. Acid Dosing pump Centrifugal type, with 1 m3/hrcapacity

Alloy 20 1+1

6. Antifoam dosing tank Cylindrical, vertical type, with 1 m3 capacity

SS 304 1

7. Antifoam dosing pump

Gear type, with 1 m3/hr capacity

SS 304 1+1

8. Nutrient Dosing Tank with Agitator

Cylindrical, vertical type, with 2 m3 capacity

SS 304 1

9. Nutrient Dosing Pump Centrifugal type, with 2 m3/hrcapacity

Wetted Parts SS

1+1

10. PF & Fermenter cleaning nozzles

-- SS 304 6

11. CIP Tank Cylindrical, vertical type, with 10 m3 capacity

SS 304 1

12. CIP Pump Centrifugal type, with 15 m3/hrcapacity

SS 304 1+1

13. Piping, Valvesand instrumentation

-- -- LOT


4.5 Multi-pressure Vacuum Distillation

Sr. No.



Qty.

1. Analyzer Column(Vacuum)

Rh Grid Traystype, with 2000 mm diameter, 20 no. of trays and 750 mm tray spacing

ShellSS 304Trays

SS 304

1

2. Degasifying Column(Vacuum)

Sieve Trays type, with 1250 mm diameter, 6 no. of trays and 750 mm tray spacing

ShellSS 304Trays

SS 304

1

3. Rectifier Column(Pressure)

Bubble Cap Trays type, with 1500 mm diameter, 72 no. of trays and 250 mm tray spacing

ShellSS 304Trays

SS 304

1

4. Aldehyde Column(Vacuum)

Bubble Cap Trays type, with 1600 mm diameter, 30 no. of trays and 300 mm tray spacing

ShellSS 304Trays

SS 304

1

5. Analyser Condenser-I(Beer Heater)

Shell & Tube, Horizontal type, with 75 m2 heat transfer area having 25.4 mm OD tube, 3000 mm long

ShellSS 304TubesSS 304

1

6. Analyser Condenser-II

Shell & tube, Horizontal type, with 75 m2 heat transfer area having 25.4 mm OD tube, 3000 mm long


1


Sr. No.



Qty.

7. Analyser Condenser-III

Shell & Tube, Horizontal type, with 7 m2 heat transfer area having 25.4 mm OD tube, 3000 mmlong


1

8. Analyser Reboiler Shell & Tube, Vertical type, with 230 m2 heat transfer area having 25.4 mm OD tube, 3000 mm long


1+1

9. Aldehyde Condenser–I



1

10. Aldehyde Condenser–II



1

11. Analyser Reboiler Vent Condenser



1


Sr. No.



Qty.

12. Rectifier PCV Condenser



1

13. Rectifier Reboiler Shell & Tube, Horizontal type, with 180 m2 heat transfer area having 25.4 mm OD tube, 3000 mm long


1

14. Analyzer Condenser Tank

Cylindrical, vertical type with 1 m3 capacity

SS 304 1

15. Rectifier Reflux Tank Cylindrical, Vertical type, with 1 m3 capacity

SS 304 1

16. RS Intermediate tank Cylindrical, Vertical type, with 1 m3 capacity

SS 304 1

17. Steam Condensate Tank

Cylindrical, Vertical type, with 2 m3 capacity

SS 304 1

18. FW Preheater PHE type SS 316 Plates 1+1

19. Rectifier Feed Preheater

PHE type SS 316 Plates 1


Sr. No.



Qty.

20. RS Cooler Shell & Tube, Vertical type with 35 m2 heat transfer area having 25.4 mm OD tube, 3000 mm long


1

21. IS Cooler Shell & Tube, Vertical type with 3 m2 heat transfer area having 25.4 mm OD tube, 3000 mm long


1

22. FO Coolers Double Pipe type SS 304 2

23. FO Decanter Cylindrical, vertical type

SS 304 1

24. Analyser Bottom Pump


SS 304 1+1

25. Analyzer Condensate Pump


SS 304 1+1

26. Rectifier Bottom Pump


SS 304 1+1

27. Rectifier Reflux Pump Centrifugal type, with 18 m3/hr capacity

SS 304 1+1

28. Steam Condensate Pump

Centrifugal type, with 7 m3/ hr capacity

SS 304 1+1

29. RS Transfer Pump Centrifugal type, with 3 m3/hrcapacity

SS 304 1+1


Sr. No.



Qty.

30. Vacuum Pump Centrifugal type, with 350 Nm3/hr capacity

CI with SS 304 internal

1+1

31. Cold Water Overhead Tank

Cylindrical, Vertical type, with 40 m3 capacity

M.S. 1

32. Hot Water Tank Cylindrical, Vertical type, with 2 m3 capacity

M.S. 1

33. Siphon, Manometer Bottles, Vapour Bottles, Mixing Bottles

Standard SS 304 Lot

34. Piping & Valves W i t h s t a n d a r d specs

SS 304 & MS Lot

35. Instrumentation PLC system with control valves, pressure & Temperature transmitters

Standard Lot


4.6 Molecular Sieve Dehydration

Sr. No.



Qty.

1. Molecular Sieve Bed With desiccant- 3A and Internals

4.25 m3 capacity SS 304 2/3

2. Evaporation Column

900 mm dia. with 25 no. of trays

SS 304 1

3. Regeneration Condenser

127 m2 heat transfer area having 25.4 mm OD tube, 3000 mm long

SS 304 1

4. Feed Preheater 14 m2 heat transfer area having 25.4mm OD tube, 3000 mm long

SS 304 1

5. Product Condenser 40 m2 heat transfer area having 25.4mm OD tube, 3000 mm long

SS 304 1

6. Regeneration Preheater

6 m2 heat transfer area having 25.4mm OD tube, 3000 mm long

SS 304 1

7. Regeneration Cooler

PHE type SS 304 1

8. Dry Ethanol Cooler 28 m2 heat transfer area having 25.4 mm OD tube, 3000 mm long

SS 304 1

9. Superheater 11 m2 heat transfer area having 25.4 mm OD tube, 3000 mm long

SS 304 1

10. Evaporation Column Reboiler

44 m2 heat transfer area having 25.4 mm OD tube, 3000 mm long

SS 304 1


Sr. No.



Qty.

11. D r y E t h a n o l Product Drum

0.8 m3 capacity SS 304 1

12. Regeneration Drum 0.8 m3 capacity SS 304 1

13. Vacuum Eductor/vacuum pump

Standard SS 304 1 or1+1

14. Regeneration Pump 45 m3/hr capacity CF8 1+1

15. Product Pump 3 m3/hr capacity CF8 1+1

16. P r o c e s s P i p i n g , V a l v e s a n d Instrumentation

--- SS 304 Lot

4.7 Alcohol Storage Section

Sr. No.

Item of Equipment

Outline Specifications


Qty.

1 Ethanol Storage Tank

Vertical Cylindricaltype of 700 m3 capacity

M.S. 3

2 Rectified Spirit Storage Tank


M.S. 1

3 Impure Spirit Storage Tank


M.S. 1

4 Fusel oil Storage Tank


M.S. 1

5 Ethanol Day Receiver


M.S. 3


Sr. No.



Qty.

6 SDS Tank Vertical Cylindricaltype of 100 m3 capacity

M.S. 1

7 Vent condenser Shell & Tube Heat Exchanger type, with heat transfer area of 3 m2

M.S. 4

8 Fire Arrester Standard type SS 304 9

9 Ethanol transfer Pump

Centrifugal type of 40 m3/hr capacity

Wetted part SS 2+2

10 RS Transfer Pump Centrifugal type of 20 m3/hr capacity

Wetted part SS 1+1

11 IS Transfer Pump Centrifugal type of 20 m3/hr capacity

Wetted part SS 1+1

12 FO Transfer Pump Centrifugal type of 10 m3/hr capacity

Wetted part SS 1+1

13 SDS Tank Transfer Pump

Centrifugal type of 15 m3/hr capacity

Wetted part SS 1+1

14 Ethanol Flow Meter Positive displacement typeflow meter of 40 m3/hr capacity

SS 304 1

15 IS Flow Meter Positive displacement typeflow meter of 20 m3/hr capacity

SS 304 1

16 Piping & Valves As per standard -- Lot17 Instrumentation Local instruments

like pressure gauges Lot


4.8 Utility

4.8.1 Cooling Water System

A) For Fermentation & Pasteurization Section

Sr. No.

Item of Equipment



Qty.

1. Cooling Tower for Fermentation( Delta T= 2 deg C)

500 m3/hr capacity Wood 1

2. Cooling water Recirculation pump


C.I 1 + 1

3. Piping & valves As per Design MS Lot

B) For Distillation & Dehydration Section

Sr. No.

Item of Equipment



Qty.

1. Cooling Tower( Delta T= 6 deg C)

300 m3 capacity Wood 1

2. Cooling waterRecirculation pump

300 m3/hr capacity C.I 1 + 1

3. Piping and valves As per Design MS Lot

C) For Juice Concentration Section

Sr. No.

Item of Equipment



Qty.

1. Cooling Tower( Delta T = 10 deg C)

725 m3 /hr capacity Wood 1

2. Cooling water Recirculation pump

725 m3/hr capacity C.I 1 + 1

3. Piping and valves As per Design MS Lot


4.8.2 Instrument Air System

Sr. No.

Item of Equipment



Qty.

1. Instrument Air Compressor

With adequate capacity

CI 1+1

2 Air Dryer for compressor

With adequate capacity

Silica / refrigerant type

1

4.9 Water Treatment Plant

Sr. No. Description Qty .

1. Chemical Dosing System 2 Nos.

2. Raw Water Pump 2 Nos. 3. Sand Filter 1 No. 4. Activated Carbon Filter 1 No. 5. Softener 1No.

6. Inter Connection Piping 1 Lot 7. Rota meters 3 Nos.

4.10 Condensate Polishing Unit

Sr. No. Description Qty .1 Screen for Separation 1 No.2 Settling tank 1 No.3 Equilization Tank 1 No.

4 Feed Pump 2 Nos. 5 Reactor with Flare Stack & Sludge recirculation system 1 No. 6 Secondary Aeration system with Tank & Agitator 1 No.7 Clarifier 1 No.

8 Clorination / Ozonation Dosing System 1 No.9 Sand Filter 1 No.

10 Activated Carbon Filter 1 No. 11 Inter Connection Piping 1 Lot

12 Instrumentation & MCC & electricals Lot


4.11 Piping & Fittings

4.11.1 Piping MOC For Fermentation Section

Sr. No. Service MOC1. Antifoam solution AISI 3042. Enzymes and Chemicals AISI 3043. Carbon dioxide AISI 3044. Concentrated Sulphuric acid MS5. Cooling water MS 6. Flour Slurry AISI 3047. Fermented Wash AISI 3048. Instrument air AISI 3049. Low pressure steam (Non IBR) MS – Heavy Class10. Nutrient Solution AISI 30411. Process air AISI 30412. Process water MS

4.11.2 Piping MOC For Distillation Section

Sr. No. Service MOC1 Fermented Wash line to distillation AISI 3042 Analyzer, Pre – Rectification vapor

/ reflux lineAISI 304

3 Purifier, Rectification, v a p o r , / reflux line

AISI 304

4 Fusel Oil Conc. Column vapor / reflux line

AISI 304

5 ENA Copper6 Impure Spirit / Technical Alcohol SS 3047 Fusel Oil SS 3048 Liquid Separator SS 3049 Gas Separator SS 304

10 Column Siphon AISI 30411 Vapor bottles Copper (for Copper

Column)SS 304 (for SS

Column)12 Water & Steam MS (as per ASTM A

106B)13 Instrument air SS 304


4.11.3 Piping Specs For Fermentation & Distillation Section

Sr. No. Pipe MOC Sch. No /Class / Thk

1 SS 304 (upto 50 NB) Sch 10

2 SS 304 (above 50 NB) Sch 5

3 Mild Steel (upto 150 NB) B-Class (IS 1239)

4 Mild Steel (150 NB - 450 NB) 4.8 mm

5 Copper 1.2 mm


Chapter – 5

Spent Wash Treatment

5.1 Bio-methanation

Sr. No.



Qty.

1. Raw Spent Wash Settling Tank (5 Day Storage Tank)

Civil Pit type with 250 micron HDPE and brick lining on earthen embankment

Earthen embankment with Brick

lining

1

2. Biomethanated Spent Wash Holding Tank (2 Day Storage Tank)



lining

1

3. Concentrated Spent Wash Holding Tank (2 Day Storage Tank)



lining

1

4. Raw Spent Wash feed Pump

Centrifugal type SS 304 1+1

5. Bio-methanated Spent Wash feed Pump

Centrifugal type SS 304 1+1

6. Degassing Pond Cylindrical / vertical type

MS + Epoxy 1

7. Clarifier Pack of plates type MS + Epoxy 18. Biodigester with

Agitators, safety systems, support, ladders etc.

Cylindrical / vertical type

MS + Epoxy 1

9. Gas Holder Cylindrical / vertical type with RCC Tank

MS 1

10. Biogas Blower Twin Lobe type - 1+111. Flare Burner Mechanical type - 112. Flame Arresters - 2

13. Sludge recycle Pump

Suitable SS 316 1+1


Sr. No.



Qty.

14. Process Water Pump Centrifugal type SS 304 1+1

15. Piping, Valvesand instrumentation

- - LOT

16. MCC & Electricals with Plant & Yard Lighting

- - LOT

5.2 Evaporation

Sr. No.



Qty.

1. Heat exchanger for Effect – I

Falling Film Type AISI 304 Shell with AISI 316 ERW Tubes & C.S. Flanges

1

2. Heat exchanger for Effect – II


1

3. Heat exchanger for Effect – III

Forced Circulation Type

AISI 304 Shell with AISI 316 ERW Tubes & C.S. Flanges

1

4. Heat exchanger for Effect – IV


1

5. Heat exchanger for Effect – V

Suitable AISI 304 Shell with AISI 316 ERW Tubes & C.S. Flanges

1

6. Surface condn. For Evaporator

Shell & Tube Type AISI 304 Shell with AISI 316 ERW Tubes & C.S. Flanges

1


Sr. No.



Qty.

7. V a p o u r L i q u i d Separator I

Vertical Type AISI 304 1

8. V a p o u r L i q u i d Separator II


9. V a p o u r L i q u i d Separator III

Flashing Type AISI 304 1

10 V a p o u r L i q u i d Separator IV


11 V a p o u r L i q u i d Separator V

Suitable AISI 304 1

12 Pre-heaters Shell & tube type AISI 304 Shell with AISI 316 ERW Tubes & C.S. Flanges

2

13 Re-heaters Shell & tube type AISI 304 Shell with AISI 316 ERW Tubes & C.S. Flanges

1

14 Thin Slop Holding Tank cum Evaporator Feed Tank

-- AISI 304 1

15. Product Tank -- AISI 304 116. Process Condensate

Tank-- AISI 304 1

17. CIP Tank -- AISI 304 118. Insulation As per standard

design guidelinesMineral Wool with 22 gauge Aluminium Cladding

LOT

19. Feed Pump Centrifugal type with motor

Wetted Part CF8

1

20. E f f e c t – I R e c i r c u l a t i o n / Transfer pump.

Centrifugal type with motor

Wetted Part CF8

1

21 E f f e c t – II R e c i r c u l a t i o n / Transfer pump.


Wetted Part CF8

1


Sr. No.



Qty.

22 E f f e c t – III R e c i r c u l a t i o n / Transfer pump.


Wetted PartCF8

1

23. E f f e c t – IV R e c i r c u l a t i o n / Transfer pump.


Wetted Part CF8

1

24 Process Condensate Pump


Wetted Part CF8

1

25. Vacuum pump Water ring type with motor

C.I. Body Wetted Part CF8

1+1

26. CIP Pump Centrifugal type with motor

Wetted Part CF8

1

27. Piping, Valves and Fittings.

Standard Standard LOT

28. CIP Nozzles Standard Standard LOT29. Instrumentation

A. Steam Control Loop

B. Vacuum Control Loop

C. Level Control Loop

D. Feed Flow Meter

E. Product Control Loop

F. Temp Indicators/Scanner

G. Temperature Gauges

H. Pressure Gauges

PLC based Control system with SCADA software.PLC Distillery Scope.(Included in PLC-SCADA offered with Main Plant and Machinery)

1 No.

1 No.

4 Nos.

1 No.

1 No.

1 No.

LOT

LOT


Sr. No.



Qty.

30. Insulation (Wherever required from process point of view)

50 mm thick Mineral Wool with 22 SWG AL cladding

LOT

31. MCC & Electrical for evaporation

Standard Standard LOT

Note: 1. The material of construction of flanges and nut bolts for heat

exchangers will be Carbon Steel & Gaskets will be NBR / EPDM / CAF.

2. All tubes will be Electric Resistance Welded types.3. The equipment specifications given are tentative and the exact

specifications will be confirmed only after discussion with client as per his requirement & detailed engineering.

5.3 Composting

5.3.1 Land Preparations & Formalities

a) Preparation of Plan and demarcation of Land.b) Contour Survey of Land with 1.0 meter interval.c) Location map showing Identification of the proximity of other water

bodies with in 1 KM radius from proposed Area.d) Map with Wind direction.e) Soil testing report containing.

x Co-efficient of Permeability.x Angle of Repose.x Hydraulic Gradient.x Sieve analysis.

f) Process flow sheet along with input of spent wash and characteristic of compost material after treatment.

g) Approval of BSPCB/ CPCB for the drawing.


5.3.2 Composting Yard

a) Cleaning, leveling and compaction of soil.b) Providing spraying and pipe line network as per design, using HDPE pipe

(max pressure 6kg/cm2) inclusive of all accessories (i.e. Tees, Joints, Flanges, Valves, Reducers and Non return valves etc.)

c) Excavation of trenches to lay the pipes up to optimum required depth.d) Providing and laying of 250 micron thick HDPE sheet inside the prepared

surface.e) Laying of pipe line with proper cushion.f) Backfilling and compaction of excavated earth after laying the pipes. g) Providing brick on edge lining over HDPE sheet for bottom surface &

joints will be filled in with fine sand. The bricks are laid in blocks of 5 mtr square. There will be gap of 150 mm between two blocks which will be filled with PCC 1:3:6 proper curing is required.

h) Providing and laying Main header – 110 mm OD, HDPE pipe of 6kg/cm2pressure.

i) Providing and Laying Distribution line of 110 mm OD, HDPE pipe of 6kg/cm2 pressure.

j) Providing and fixing Chamber outlets 63 mm OD HDPE pipe of 6kg/cm2

pressure with butterfly/ Ball valve and quick release coupler.k) Provision of 30m long fire hose ( ISI mark) with SS 304 adaptor hose

shank at both ends for auto spraying, suitable for above Quick release coupling for online filling.

l) Providing and constructing Round / Square chambers pre cast / in situ as per design. (Chamber dia of 800 mm and depth as required as per ground level.)

5.3.3 Leachate Management System

a) Excavation for Gutter and leachate collection pit.b) Design the profile of Gutters and construction of collection pit in flat

brick in Cement mortar in 1:5 ratio and maintain slope as required.c) Formation of bunds as per design.d) Providing pathways in flat brick lining in between gutter and bund.e) Net f inished plaster in cement mortar 1:4 for the collection pit

internally.f) Green belt will be developed all along the boundary of compost yard and

lagoon to control the issue of “foul odor”.


5.3.4 Lagoons (30 Days Storage Capacity)(Consider production of spent wash as 350 m3 per day)

a) Excavation of Soil and preparation of land.b) Providing impervious soil bund wherever necessary as per design.c) Preparation of embankment in Black cotton soil for all four sides in 1:2

slopes, while preparation of embankment proper compaction will be done.d) Providing and laying of 250 micron thick HDPE sheet inside the prepared

surface.e) Providing brick lining over HDPE sheet for bottom and slopes, lining will

be filled in cement mortar 1:5 with pointing.f) Construction of toe wall to avoid underscoring of the embankment during

heavy rains.g) Lagoon bottom and embankment top will be provided with bricks on edge

and joint to be filled in fine (sieved) sand.h) Two coat of tar epoxy paint (120 micron total) will be provided at the

bottom of the lagoon.i) Provision of fencing around the Lagoon to prevent trespassers and

wandering animals, with RCC poles and barbed wires.

5.3.5 Laboratory Shed (4m X 4m size)

a) The Laboratory shed will be provided to facility for maintain the check over the samples of spent wash and compost.

b) It will have 2.5 mtrs height brick wall, plastered from both sides and remaining height will be provided with suitable grill. The sizes of this should be 4 mtrs x 4 mtrs and height of 3.75 mtrs.

c) Shed should have locking arrangement.

5.3.6 Garage Shed (5m x 4m size)

a) The Garage shed will be provided for parking and work shop facility. The size of this shed should be 5mtrs x 4 mtrs and height of 4.5 mtrs.

b) It will have brick wall of 230 mm thk up to 1 meter height, plastered from both side and above wall grill or sheet cladding will be provided, roofing with GI sheet will be considered.

c) It should have one side open and three sides closed.


5.3.7 Shed for Compost Enriching & Packing

a) Providing of shed of 8m x 4m with height of 4.5 meter in size for production of Enriched compost manure and packing facility.

b) The shed should have wall of 230 mm thick up to 1 meter height andabove the wall with sheet cladding and grills, the floor of shed should have plane finish surface in Plane cement concrete.

c) The supplier should provide bagging and packing machinery required for the packing of enriched compost manure.

d) Providing and fixing pulverizer and screens for grading of manure.e) Any other facility required for the effective packing of the manure.

5.3.8 Specification For Wind Row Turner Machine

a) A Machine to be supplied for effective mixing of press mud and spent wash. This machine should provide adequate aeration for mixture.

b) A separator tractor driven machine should be considered.c) The machine should have following minimum parts such as,d) A rotary Drum made out of M.S. seamless pipe having proper

arrangement of blades. It should be provided with epoxy paint.e) Stainless steel pipe with nozzles of exact size for effective spraying of

spent wash. (Minimum nozzles should be 12-14 no.)f) Stainless steel (SS304) tank of 4 m3 capacity for storage of spent wash

mounted on M.S. frame with machine. g) Specify the mixing capacity of machine. (Min 1000MT/hr is must.)h) Specify type and capacity of tractor required for drive of the machine. A

cost should be mentioned separately, so, factory may supply this on there own.

i) Specify diesel consumption per hour.

5.3.9 General Note

a) All the drawings will be approved by Factory or their consultant before starting of work. The responsibility to get approval from Govt. Authority will be with contractor.

b) The structural & RCC design should be made by renowned structural designer and it should be made on STAD III Program. If required the contractor may have to provide the design calculations.

c) The contractor / supplier will have to follow all safety norms on site. They must provide safety equipment to their workers, engineers like safety shoes, helmets, safety nets, safety belts etc. Contractor will also provide adequate facility for workers accommodation like toilets, drinking water, crèche etc.


d) Contractor / Supplier will also have to provide information on WCA, Insurance Policy for material, equipment, P.F etc.

e) Contractor / supplier will give operation and trial of machine with spraying system at least for continuous 60 days.

f) Contractor / supplier should provide manual for running of the plant. He will also give training to factory workers for minimum period of 15 days.

g) It will be sole responsibility of contractor / supplier to satisfy BSPCB officials about the effective management of spent wash.

h) The plant should be able to consume minimum of 350m3 spent wash produced in a day.

i) The contractor / supplier should provide a pump and a spent wash (HDPE) pipe line from the 5 days lagoons located near the distillery plant at a distance of 800 meters. Also quote cost of this pipe line per running meter basis in case of any decrease or increase of length of the pipe line.

j) The contractor / supplier should provide compost culture free of cost during 60 days trial operation. They should also quote rate and consumption per day of culture separately.


Chapter – 6

Electrical Distribution System

6.1 General Design Basis

6.1.1 Design Criteria in Equipments / Power Distribution

a. All Busbars shall be Air insulated and of ALUMINIUM. Busbar size shall be selected based on Temperature limit of 85 ºC at Busbar for the rated current.

b. Power Cables (HV & LV) shall be XLPE armoured ALUMINIUM conductors above and including 6 sq. mm. size. Power cables including and less than 4 sq. mm. shall be copper conductor.

c. Squirrel Cage Motors up to 15 KW shall have automatic DOL Starter suitable for operating from MCC, DCS and PB Station near Motors.

d. Motor rating above 15 KW up to 200KW shall be with Automatic Star Delta Starter suitable for operating from MCC, DCS and PB Station near Motors.

e. Motor rating above 200KW shall be operated with Soft Starter suitable for operating from starter, DCS and PB Station near Motors. Starter shall have bypass contactor with AC3 rating.

f. VFD shall be provided as per the functional requirement.

g. Following spare feeders shall be considered in Power Distribution

- In 11 KV Switchboard - 1 No. Transformer feeder

- In Cogen Aux. L. T. Panel - As per SLD

- Panels in other areas including PCC / MCC / DB - 1 No. of Each Rating

h. MCC shall be floor mounted self supporting, dust and vermin proof, fixed type construction.

i. Power Control Center (PCC) shall have Switch Disconnector Fuse up to 630A and above 800A these shall have Manually operated Draw Out (MDO) type ACB.’ON’ indication shall be provided on outgoing feeders.


j. Motor Control Center (MCC) shall have Switch Disconnector Fuse unit, Contactor and Bimetallic Over Load (O/L) relay for starters. Starters on MCCs shall have ‘ON’ & ‘TRIP’ indication. The selection of switchgear components shall be minimum with one stage higher than Type II co ordination as per IS 13947

k. Motor protection shall be provided in ACVF Drives & Soft Starters, as inbuilt protection functions.

l. Rating of Switchboard incomer ACB/SDF shall be 1.2 times the operating load current. Protection & Indication (For HV Switch board)

m. Flameproof equipments such as Push Button Stations, junction boxes, Lighting Switches, L lighting Fixtures etc shall be considered with hazardous area classification in Ethanol plant.

n. Push Button Station with Shrouded type actuator for ON push button, Lockable Mushroom type actuator for OFF Push button with Aluminum die cast enclosure shall be provided. Push Button Station for Motors above 15KW rating shall be provided with suppressed scale Ammeter. Push Button Station for VFD shall have SpeedSetting Potentiometer and speed indicator in addition to Push Buttons and Ammeter

6.1.2 Power & Distribution Transformer

The following criteria shall be applicable for the sizing of Transformer

a) Total Connected Load shall be calculated based on Motor List.b) Operating Load shall be calculated excluding Standby Loads and

equipment for maintenance such as Crane.c) Load Factors shall be considered on Operating Loads according to

Load Factor to consider shall be as below:- Motor Loads with DOL / S/D Starter / Soft Starters :

0.85- Motor Loads with VFDs 0.75- Lighting Loads : 1.0- Utility Plug Sockets : 0.5- Cranes, winches etc. : 0.1

d) Average Power Factor 0.8 shall be considered to arrive at KVA.e) Equipment Efficiency shall be considered 90% as average.f) On such Calculated load + 20% Margin shall be considered.g) If necessary percentage impedance shall be increased more than the

impedance indicated in IS to limit 415 V side Fault Level to 50KA for 1 sec.


6.1.3 Power Factor Improvement

a) Plant PF shall be required to improve above 0.95b) This is achieved by providing:

Capacitors across HV Motors as per recommendation of manufacturer. Provide Automatic Power Correction Panel with required no. of APP type capacitor banks in 415V PCC in Cogen Plant, Sugar Plant and Distillery plant. In Sugar Plant fixed type capacitors can be connected additionally near MCC with appropriate capacitor duty contactor and FSU feeder in MCC.

c) To determine number of capacitors following consideration be givenOperating KW & Average operating P.F.Drive with VFD shall maintain P.F. above 0.95. These loads shall not to be considered for deciding capacitor rating.

6.1.4 LV Power Control Centre (PCC)

The following points shall be considered while designing and selection of components.

a) TYPE OF FEEDERS :Incomers : D.O. – 3-Pole ACB Emergency Power Supply Feeder

: D.O. – 4-Pole ACB

Outgoing Feeders : SDF up to 630 A: MDO Type ACB Above 800A

b) BUSBARS Color Coded Sleeved Aluminum Bus bar Size shall be selected as per following norms:Continuous current carrying capacity as per the Rated Current of IncomerTemperature Rise LimitShort Circuit Withstand Capacity

6.1.5 Motor Control Centre (MCC) :

The following points shall be considered while designing & selecting components.

a) Incomer Feeder

- MDO ACB above 800 A up to 2000 AFixed Switch Fuse Disconnector up to 630 A


b) Outgoing Starter Feeder

Feeders shall be comprising of:Switch Fuse Disconnector ContactorsThermal Overload RelayTimer in case of Star Delta StartersPush ButtonsIndicating Lamps

c) Bus bar Above 125A rating

d) Control Logic

- Plant shall be capable of operation from MCC, DCS located at Central Control Room or locally from Push Button Station near motor.

- It will be possible to start the Motor locally through enable command from PLC.

- P.F. and KW parameter of Incomer shal l be communicated to PLC.

- ON/ OFF Status of the Motor shall be communicated to PLC.

e) Provision o f Spare feeders

In MCC total 10% spare feeders shall be provided, depending on feeder ratings in MCC following feeders shall be provided.

6.1.6 LV Bus Ducting

Bus duct up to 3200A shall be CRCA enclosure with color coded sleeved Aluminum bus bar. Short circuit rating shall be 50KA, 1 sec.

6.1.7 Battery & Battery Charger

a) Battery: - VRLA Maintenance Free - Capacity shall be determined by total operating load

& 20% margin- AH shall be determined for 8 hour backup time

b) Battary :Charger

Float and Float cum Boost with 20% capacity

c) DCDB : Built in with Battery charger panel with Incomer as MCCB & Outgoing as MCB


6.1.8 Grounding / Earthing System & Lightening Protection

a) Earthing shall be done according to IS 3043 – 1987.b) Earthing shall be carried out by G.I. Strips & Wires. Earth Electrodes

shall be G.I. Plate type & Pipe type as per requirement. However, Transformer Neutral will be connected to G.I. Earth Electrode through Copper Strip.

c) Total Resistance of Earthing system shall be Less than one ohm.d) Plant shall be protected against lightning according to IS 2309-1989.

6.1.9 Cables

The following consideration shall be given for Cable Sizing and Selection on Nominal Current Capacity

a) Ambient Temperature in Air/Groundb) Continuous Load Currentc) Short Circuit Withstand Capacityd) Voltage Drop at the Starting of Motor limited to 15% & 5% at Steady

state up to motor terminals.e) Deration Factor due to type of Laying & Grouping.f) Generally Power and Control cables shall be stranded.g) XLPE insulated cables upto & including 4 sq.mm shall be with stranded

copper conductors. Cables of 6 sq.mm & above size shall be with Al. conductor

6.1.10 Cable Trays, Accessories & Support

a) Generally Cable trays shall be prefabricated Hot Dip Galvanized Ironb) Cable Trays shall be run in Vertical formation as far as possible.c) HV & LV Power Cables shall have separating distance of 300mmd) Separating distance between Power and Control cable shall be

300mm.e) Instrument cables & screened shall run on perforated cable tray having

300 mm separating distance of 300 mm.

6.1.11 Illumination System

a) The Lux Level in various indoor areas shall be as per IS. In plant areas, the lighting shall be provided as per functional requirement.


b) HPMV Well Glass with integral control gear box fittings (IP55) shall be provided in plant areas. Industrial FL. Lamp fittings will be provided in sub station and other indoor areas. Mirror Optic fixtures shall be provided in CCR. In outdoor areas HPSV Lamp fixtures (IP 55) shall be provided.

c) The lighting shall be catered by Main Lighting DB. LDB & SLDB connected by Al. conductor cables. The Emergency power supply from 415V DG set will be made available to lighting transformer in case of failure of power

6.1.12 HV & LV Motors

Motors shall be as per IS 325. LV motors shall be IP 55 degree of protection and for HV motors the degree of protection shall be IP 55 (CACA). Motors shall have insulation of class F and temperature rise limit of class B. Motors shall be designed with 50 ºC ambient. Flame proof Enclosure shall beprovided for motors where ever required.

6.2 Scope of Work

In line with the overall battery limits for the ethanol plant and associated spent wash treatment / bio-composting facility and particularly for the electrical power, the Tenderers will have to consider following in the scope of work for electrical distribution system:

x 415 V Cable from cogen power plant 415 V distribution board up to ethanol plant 11 KV switchyard.

x 415 V panel comprising of VCB, CTs / PTs, meters, protective relays, required cables and terminations, etc.


x 415 V distribution network withi n t h e ethanol plant including main distribution panel, incoming / out going cables / bus bars, CTs / PTs, protection relays, annunciator, indicating lamps, push buttons, DCDB, battery & charger, safety devices, distribution boards, incoming / outgoing cables, indicating lamps, push buttons, etc. for all drives.

x Provision of flame proof equipment including flame proof push button stations, junction boxes, lighting fixtures, starters, etc. wherever needed as per the statutory requirements will be provided.

x High mast lighting fixture with 30 m high tower including cradle, motor operated mechanism, 8 nos. – 400 W, metal halide lamps – total 2 nos. to be installed at designated places as advised by Owner with all electrical connections.

x Lightening protection for buildings in ethanol plant area as per IS 2309.

6.3 Diesel Generating Set For Emergency Electrical Power Supply

One No: 150 kW rating diesel set with 0.80 power factor shall be installed for the ethanol plant.

The diesel generating set shall be continuously rated comprising multiple cylinder diesel engine having necessary protections such as low lube oil pressure trip, high engine temperature trip, over speed trip etc. and shall be fitted with speed control knob speedometer, hour meter battery charging meter, oil pressure and temperature gauges, radiator etc.

The diesel engine shall be coupled with suitable alternator capable of developing continuously the rated power at 3 phase, 4 wire, 50 Hz at normal voltage of 440 V AC. Alternator to be suitable for voltage range of 440 V AC and conforming to IS-4722 specifications. The alternator shall be fitted with minimum one ETD in each phase for thermo protection of the alternator windings. The alternator shall be designed for an ambient temperature of 45 deg. C. The alternator shall be self excited and self regulated.

The diesel set shall be complete with base frame, couplings, one M.S. fabricated, diesel service tank of 10 HL capacity, inter-connecting piping, D.C. storage battery and self starting mechanism for starting of engine.


One 2 mm thick for the back side and 1.6 mm thick for the other sides cold rolled sheet steel fabricated floor mounted, dust and vermin proof panel for the diesel set shall be provided. The panel shall be fitted with air circuit breaker, over current relay, earth fault relay, reverse power relay, over voltage relay, reed type frequency meter, neutral isolating switch, three phase 4 wire unbalancedenergy meters, kW meter, 3 phase power factor meter, 3 nos. ampere meters, one no voltmeter with selector switch, ON-OFF indicting lamps.

The panel shall have neutral and phase bus bars of electric grade (EC-91E) aluminum and shall be designed to withstand symmetrical short circuit current of 35 KA (RMS) for one second. The panel shall be designed for an ambient temperature of 45 Deg C’ the operating temperature of the bus bars shall not exceed 85 Deg. C. All the meters shall be class 1.50 per cent accuracy and shall conform to IS-1248 specifications. All the meters shall be square type of 100 mm sq. with 90 per cent deflection Inter connecting electrical cable 3½ cores from the diesel set to the main distribution panel and to the auxiliary panel changeover switch shall be provided.


Chapter – 7

Control & Instrumentation System

7.1 Process Control Philosophy

PLC is a microprocessor/micro controller based system having functional distribution, data base distribution associated with software and hardware. PLC system is used widely in industrial automation where we have to monitor the process and control as per our need. The system is equipped with following processing modules connected to it. The automation indicated below will have DCS connectivity.

Control system

The closed loop control, interlock, sequence controls and data acquisition are performed in the control system.

Communication system

Pentium computer (IV as a minimum) is used to download the software, ladder logic, and other programs to communicate with PLC on proprietary network. These computers will also act as an operator station for man machine interface. Computers shall be provided with monitors, printers, mouse and keyboard and standard peripherals.

7.2 Parts Inter-changeability

In order to minimize spare part-stocking requirements the PLC may offer high degree of interchange ability.

The system incorporates modular design using plug in assemblies.

It may be possible to modify application software on line.

Universal removable terminal strips shall be used to connect field wiring to individual circuit board assemblies.


7.3 Security

Password security is provided for at least for three different level of access.

Memory protect key switch is there to prevent alteration of program and configuration data through interface device.

7.4 Spare Philosophy

Provision of connecting I/O cards as spare.

Provision of spare wired slots to accommodate I/O modules for future expansion.

7.5 System Specification

System hardware

The system offers following subsystems connected to it.

- Communication within PLC system- The system is reliable, high speed, and peer-to-peer communication.- Cyclic redundancy check (CRC) used for all data communication on this link. - The BUS of IEEE standard and of latest version.- The BUS system capable of being extended through a connection of Modem.- PLC is provided with Ethernet port to communicate with any other third party

device.- Ethernet card of 32-bit PCI card- Communication with external device through TCP / IP protocol.

Power supply module

The system power supply suitable for 220 V AC UPS, 50 Hz, Single-phase operation. Power supply module are having fuses rated suitably for the nominal current requirements. Power supply is of SMPS type and delivers DC voltage levels required for the system operation.

Digital input module

Digital input module is used to convert external binary signal (potential free) from field to internal signal level of PLC.

Each input is isolated and be provided with individual fuse.


All cards is reported on computer monitor

LED indications are provided for fault status indication on the front of individual module (channel wise).

Digital output modules

Digital output module converts the internal voltage level of PLC in to external binary signal level required to operate actuating / indicating devices.

Digital output module sources current while energizing field outputs. Potential free contacts made available for start / stop signal.

DO is protected with short circuit protection.

Each output is isolated and provided with individual fuses.

All cards status is reported on computer monitor

Analog input module

Analog input modules are used to accept field analog signals.

Modules is accepting 4-20 ma, 1-5 V DC signals and provide power to field transmitter.

Analog output module

Analog output modules are used to give input to the final control elements.

AO modules provide isolation to all channels.

Processor module

The processor module is data acquisition and control processor system. The processor is of microprocessor based (Intel 80486/equivalent/better) and CPU shall be of 32 bits with floating point arithmetic calculation with math co-processor.

Processor unit access system I/O modules through local I/O bus. This module shall have capability to implement logic scheme.

Long life lithium battery can be used to maintain the contents of CMOS RAM. 30% memory shall be provided for application I/O after final commissioning of system. CPU can be programmed by external PC via communication bus.


7.6 Operator Interface

The operator interface with PLC is through PC. The PC can also be used for control and monitoring of plant.

PCs can be provided with following peripherals

- Monitor (Monitor shall be of 17” size and Pixel resolution shall be 1024 x 768 or better)

- Printer (One no. for logging of alarm and shall be 132 column dot matrix)- Key board (104 keys keyboard shall be provided)- Mouse (three-button mouse shall be provided)

7.7 Operator Cum Engineering Station

Operator cum engineering station can be used for engineering as well operator function in addition to the operator stations specified above. Selection of operator / engineering function can be selectable by password. The engineering station offered may have provision for performing the following engineering functions.

x Database configuration including configuration of all displays and loops system.

x Automatic downloading of the configurations in each system.x Configuration of various control functions or control blocks to implement

various control strategies and downloading the same into the control stations.

x Configuration/reconfiguration of alarm sett ings, their values, addition/deletion of alarm from groups, controller tuning like changing P,I,D values, dead time values etc.

x Defining the key lock functions or engineer keyboard functions.x On-line compilation of all types of dynamic graphic displays.x Plant/group alarm inhibits function.x Start/stop of each system, including printers.x Enabling/disabling of different instruments/ peripheral connected to the

system.x Preparation and compilation of logs/reports/ historical trend points.x Calling of detailed self-diagnostic displays for maintenance aid.x Loading, editing, compiling and executing of all programs written using

high level languages supported by the system.


7.8 Other Hardware Requirement

System cabinets

Control cabinets shall be free standing type with dimensions as required. The vendor shal l ensure that al l the equipment specif ied can be properly accommodated in the respective cabinets and if necessary offer cabinets with higher dimensions. All cabinets shall be of Rittal make.

Control Cabinet shall be completely metal enclosed. Control cabinet enclosures shall provide a degree of protection not less than IP 40.

Control cabinet shall be free standing, floor mounting type and shall comprise of rigid welded structural frames enclosed completely with specially selected smooth finished, cold rolled sheet steel of thickness not less than 2.5 mm all around. There shall be sufficient re-enforcement to provide level surfaces, resistance to vibration and rigidity during transportation and installation

All doors and removable covers shall be gasket all around with neoprene gaskets. Ventilating louvers, if provided, shall have screens and filters. The screens shall be made of either brass or SS wire mesh.

Control cabinets shall be suitable for floor mounting. Metal sills in the form of metal channels properly drilled shall be furnished along with anchor bolts and necessary hardware for mounting the cabinets. These shall be dispatched in advance so that they may be installed and leveled when concrete foundations are poured. Cabinets shall have additional rolled channel plinth at the bottom with smooth bearing surface. Control cabinets shall be fixed on the embedded foundation channels with intervening layers of anti-vibration strips of at least 15mm thickness and made of shock absorbing materials

Cable entries to the cabinets shall be from the bottom. The bottom plates of the cabinets shall be fitted with removable gland plates of adequate size for fixing the cable glands. Cable glands shall be made of brass and shall be suitable for PVC armored cables.

Mounting

Equipment is mounted such that removal and replacement can be accomplished individually without interruption of service to adjacent equipment. Equipment mounted inside the cabinets is so located that terminals of adjacent devices are readily accessible without the use of special tools.


Interior lighting & receptacles

Each cabinet is provided with a fluorescent lighting fixture rated for 240V, 1 phase, 50 Hz supply for the interior illumination of the cabinet during maintenance. The fitting shall be complete with switch-fuse unit and the respective cabinet door switch shall control the switching of the fitting.

Each cabinet shall be provided with a 240 V AC, 1 phase, 50 Hz, 5 Amps, 3 pin receptacle switch mounted inside, at a convenient location.

OS shall perform the following functions.

- Operators functions- Plant graphic display- Alarm display- Plant control/Operation display- Logs and report generation- Real time and historical trend display

All relay logics, mathematical functions, Relational operations, Control station operations, and Logical operations.

Electrical:-

Complete electrification of plant including design, manufacture, procure, supply, erection, testing & commissioning of MCC, electrical motors, all flameproof equipments, power cables, control cables, instrument cables, lightening arrestor, cable trays, local push button station for each & every pump, blower, vacuum pump, agitator etc., lighting of all section of plant including light fitting, earthing pits etc. It also includes cable laying, earthing of motors, MCC, push button station etc.

In MCC, 3 No. vacant compartments suitable for HP starters shall be provided. Panel MCC boxes should be as per Indian Electric Rule (thickness) switch, starter, relays, conductors, ACB etc. should of L&T/Siemens, Volt, Ampermeter & energy meter for each panel should be of AE make. Copper thimbles only is to be used. Earthing should be as per Indian Electrical Rule Standard only.

Make:1. All the cables used for electrification shall be of Finolex/Asian/C.C.I. make only.2. All lighting (Distillation & Warehouse) material should be flame proof and of Philips or Crompton Greaves make only.


Insulation & Painting

Insulation:Insulation for distillation columns & other related equipments & piping, CIP tank etc. with Aluminium cladding if 22 G(As per IS code)Painting:Painting as per the relevant code to all MS equipments, CS piping, Supports etc.

7.9 Instrument List

7.9.1 Fermentation Section

a) Temperature Senser & Transmitter

1 Fermentor 2 Fermentor 3 Fermentor 4 Fermentor 5 Fermentated Wash Out Temperature6 Fermentated Wash Out Temperature7 Fermentated Wash Out Temperature8 Fermentated Wash Out Temperature9 Prefermenter 10 Prefermenter 11 Cooling Water Supply Temperature

b) Magnetic Flow Meter with Transmitter

1 Fermented wash feed2 Molasses To Fermenter 3 Molasses To Fermenter 4 Molasses To Fermenter 5 Molasses To Fermenter 6 Molasses To PreFermenter & Culture Vessels

c) Flow Indicator

1 Air to Culture vessels2 Air to Pre-Fermenter3 Air to fermenter 14 Air to fermenter 25 Air to fermenter 36 Air to fermenter 4


7 Process Water to fermenter 18 Process Water to fermenter 29 Process Water to fermenter 310 Process Water to fermenter 411 Process Water to co2 scrubber12 Process Water to blower 113 Process Water to blower 214 Fermented Wash to Wash Settling Tank

d) Load Cell For Transmitter

1 Weight of molasses

e) Pressure Guages

1 Fermenter Recirculation Pump 12 Fermenter Recirculation Pump 23 Fermenter Recirculation Pump 34 Fermenter Recirculation Pump 45 Antifoam Dosing Pump 18 Antifoam Dosing Pump 29 Nutrient Dosing Pump 110 Nutrient Dosing Pump 211 Acid Dosing Pump 112 Acid Dosing Pump 213 CIP Pump 114 CIP Pump 215 Sludge Transfer Pump 116 Sludge Transfer Pump 217 Beer Feed Pump 118 Beer Feed Pump 219 Weighed Molasses Pump 120 Weighed Molasses Pump 221 Pre-fermenter Pump 122 Pre-fermenter Pump 2


7.9.2 Distillation Section

Pressure Gauges / Vacuum Gauges

1 Analyzer Bottom Transfer Pump2 Analyzer Bottom Transfer Pump3 Rectifier Reflux Pump4 Rectifier Reflux Pump5 Ana Cond Pump6 Ana Cond Pump7 RS Transfer Pump8 RS Transfer Pump9 Rectifier Bottom Transfer Pump

10 Rectifier Bottom Transfer Pump

Pressure Transmitter

1 Analyzer Column Bottom

2 Analyzer Column Top

3 Aldehyde Column Top

4 Rectifier Column Bottom

5 Rectifier Column Top

Temperature Sensors & Transmitters

1 Analyzer Column Bottom2 Analyzer Column Top3 Degasser Top4 Aldehyde Feed Plate T-25

5 Aldehyde Column Top6 Aldehyde Column Bottom7 Rectifier Cum Exhaust column Bottom8 Rectifier Cum Exhaust Column HFO 9 Rectifier Cum Exhaust Column LFO

10 Rectifier Cum Exhaust Column Top11 Rectifier cum Exhaust column RS Draw

12 Fermented Wash Feed Temperature


Flow Meter with Transmitter

1 FW feed to distillation2 Steam to rectifier reboiler3 Rectifier reflux flow4 RS Draw5 RS feed to MSDH6 IS To storage7 Ethanol Draw

Level Transmitter

1 Analyzer column bottom2 Rectifier column bottom3 Rectifier reflux Tank4 Analyzer condensate Tank5 RS Draw Tank

Safe and testers for ethanol, RS & Is control loops : 2 Nos.

7.9.3 Distillation Section

1 Analyzer column bottom level controller2 Reflux tank level controller

3 Purifier bottom level controller4 Rectifier cum exhaust column bottom level controller5 Steam Flow Controller for Reboiler for Rectifier column6 Fermentated Wash Flow controller

7 Steam flow Controller for Reboiler for Purifier Column

8 Rectifier column pressure controller9 Analyzer column pressure controller

10 Rectifier column temperature controller

7.9.4 MSDH Section

1 Evaporation Column Bottom level controller

2 Super heater Steam Flow Controller3 Regeneration Tank level Controller

4 Molecular Sieve Bed ON/OFF valves – 8 nos.


7.9.5 Utility Section

Pressure Gauges

1 Cooling Water Recirculation Pump for Fermentation2 Cooling Water Recirculation Pump for Fermentation3 Cooling Water Recirculation Pump for Distillation4 Cooling Water Recirculation Pump for Distillation5 Water Header6 Steam Header

Temperature Sensors with Transmitter

1 Analyzer cond.-I cooling Water Out2 Analyzer cond.-II cooling Water Out3 Analyzer cond.-III cooling Water Out4 Aldehyde condenser –I cooling water out5 Aldehyde condenser –II cooling water out6 Analyzer reboiler vent condenser cooling water out7 Rectifier PCV Condenser8 Steam Header

Note: There will be a common PLC to operate fermentation, distillation, and MSDH.


Chapter – 8

Civil Works

Design philosophy and criteria for civil and structural construction at the project site for ethanol plant and associated spent wash treatment / bio-composting facility area has been indicated in the ensuing paragraphs.

8.1 Major Civil Works

a) Site clearance by removing & disposing any impediments for commencing construction

b) Contour survey, soil testing, tests for ascertaining the soil bearing capacity, water tables at site, wind direction etc.

c) Back filling and levelling, if requiredd) Chain link/barbed wire fencing, gates, entrance arches etc., for ethanol

plant and other non-plant buildings within e) Foundations for cooling system for ethanol plantf) Foundations for equipment for 60 KLPD Ethanol plant and associated

spent wash treatment / bio-composting facility g) Workers rest rooms, panel rooms, worker’s rest room, first aid facility,

fire fighting facilities including sheds for fire tenders, foundations for fire fighting equipments, pipe lines for fire fighting/fire hydrants etc. and other auxiliary buildings

h) Buildings and structures i) Non plant buildings such as canteen, laboratories, toilet blocks, effluent

treatment scheme j) Water reservoir of adequate capacityk) Foundations for molasses / treated mixed juice / ethanol storage tanks,

pumps, fuel conveyors, pipe racks, electrical equipment, pipe / cable racks, water treatment equipment, etc. in ethanol plant area

l) Spent wash ponds, day collection sumps, composting yard, composting field, HDPE pipe lines, panel rooms, sheds for equipments, sheds for DG set

m) All internal roads to be of RCC and RCC approach roads to be provided for all building / structures including green areas, road side drains, culverts, pipelines and other provisions for street lighting, yard lighting, area lighting, etc. within ethanol plant and associated spent wash treatment / bio-composting facility area

n) Drainage channels, storm water drains, within ethanol plant o) Underground cable & bus ducts, tunnel for fuel handling, trench for CW

piping, etc.p) Earthing pits and earthing mats


q) Required plumbing and sanitary fittings & equipments.r) Rain water harvesting, sewage treatment plant and green belt within

ethanol plant areas) Pile foundation to be provided, if required, based on soil investigationt) Landscaping for the total area available at siteu) All building and civil work commencement certificates, building

completion certificates, stability certificates, any other certificates as perstatutory requirements of the Bihar and the Central Government, NOC of the BPCB, NOC of Airport Authority etc., all necessary permissions from the statutory authorities.

v) All electrification and lightingw) Fire fighting

8.2 Design Data

The following basic design criteria are used in the designs of various structures.

Soil bearing capacity (to be verified : 12 ton/m² at 2 m from NGLby bidder, prior to civil design)Min grade of concrete for RCC works : M20Grade of reinforcement steel : IS : 1786Type of Cement : 43 grade Portland cementAll structural steel members : As per IS 800Seismic zone of factory area : As per IS 1893-2002Wind velocity & direction : Velocity : As per IS : 875South-West (May- Sep), North – East (Oct – Apr)

8.3 System Description & Specifications

8.3.1 Site Grading and Levelling

The site clearance and grading work has been considered only of the area for the plant. The grading work will be done by cutting-filling balance method and no earth will be transported from outside. All excavation and back filling shall be in Contractor’s scope. The contour survey and all necessary surveys of the total area for the integrated plant shall be carried out by the EPC Contractor.


8.3.2 Plant Internal Roads & Culverts

Internal roads within the plant boundary and roads for access to equipment and buildings will have to be provided. Layout of the roads will be based on Plot Plan. Adequate turning space for vehicles will have to be provided and bend radii will be set according to maximum vehicle speed of 20km/hour. Roads to be as short and straight as possible. All internal roads shall be well designed RCC roads. All roads shall be designed as per IEC 58. Wherever drains or other underground facilities cross the roads, concrete pipe culverts class NP2 or NP 3 as required or RCC box culverts shall be provided. Roads shall be provided with kerb stones and the same shall be painted as per specification.

All plant roads will be constructed so as to permit transportation of all heavy equipment. Internal roads will be minimum 6.0m wide.

8.3.3 Soil Investigation

Soil investigation will be done by EPC Contractor for the determination of safe bearing capacities for the design of foundations for various structural elements. Earth resistivity will be determined. If required and necessary, pile foundation design shall be adopted for the major and critical foundations.

8.4 Design Criteria

The design criteria for various structures and structural elements will be as follows:

8.4.1 Steel Framed Structures

The design of steel framed structures will be done by linear elastic method as per the provision of IS: 800.

8.4.2 Reinforced Concrete Framed Structures

All reinforced concrete structures will be moment resisting frames along both longitudinal & transverse directions. The suspended slab will be considered as continuous over secondary beam and will not form part of the framing system. However it will be considered to be transferring the shear to the framing system. RCC structures/members will be designed as per IS:-456 using limit state method.


8.5 Foundations

Introduction

All main plant structures i.e. Transformer Foundations, buildings and foundations for the distillery/ethanol plant and machinery, all plant and non-plant buildings for the integrated plant and other Misc. Buildings will be supported on RCC foundation - isolated, combined or raft and/or pile foundations. Machine foundations for Compressors, BFP and misc. pumps and equipment foundations will be supported on RCC foundations - Isolated or Block foundations and/or pile foundations. Pile foundations will be provided, if required, by the soil investigation report.

Design

The foundations will be designed for the most critical combination of forces and moments, resulting from all the possible combinations of the various loading from the structural system. The effect of water table will be considered and the foundation will be checked for overturning for minimum and maximum vertical loads. There should be no uplift under any portion of the foundation for any loading condition. The foundation sections will be sized and reinforced adequately for bending moments and shear stresses. A levelling course of plain cement concrete will be provided before casting the foundation.

8.6 Machine Foundations

Introduction

This section outlines the design philosophy & construction aspect for foundations for large equipment as follows:

a) All major foundations for the distillery and ethanol plantb) Compressor foundationsc) All Miscellaneous machine foundations

General

A necessary requirement for all rotating machinery is that it should be properly supported. Thus the foundation becomes an important element of machine installation. It has to resist both static and dynamic forces exerted by the machine and transmit these to the ground. In doing so, it is responsible for smooth running of the machine by ensuring that amplitudes are limited to values that are permissible for the machine and for local environment, including structures and people.


The foundation must have sufficient structural strength to withstand all applicable forces and most severe combination of individual load cases that result in the maximum foundation loading for any conceivable set of normal or abnormal circumstances. Spring supported foundation shall be provided for low frequency machines, wherever the same are required from technical consideration.

Design Parameters

The data required for the analysis and design of machine foundations may be listed as under:

a) Loading diagram showing static and dynamic loads on the foundations, points of application of loads, area over which these loads will be distributed etc.

b) Operating speed of the machinec) Capacity or rated output of machined) Critical speeds of the machinee) Geometric limitationf) Opening limitations, depressions, projections etc.g) Details including sizes and locations of anchor bolts, pipe sleeves, inserts,

embedded parts etc.h) Layout and distribution of pipe lines, ducts etc. and their supporting detailsi) Temperatures in various areas during operationj) Mass moment of inertiak) Allowable amplitudes at the machine bearing points, etc.l) Tolerance in bearing and clearances of various components

Loads

The loads to be considered for analysis and design are:

a. Static loads of the stationary components of the entire assembly along with the static weight of rotating parts.

b. Dynamic loads from start-up torque.c. Loads on foundation resulting from admissible forces and moments of pump

nozzles.d. Loads on pedestal top due to installation and maintenance.e. Any other forces/loads which equipment EPC Contractor considers

applicable.


Analysis & Design

The analysis and design of machine foundations will be carried out to ensure the following:

a) Compliance with the manufacturer’s requirements.b) No resonance phenomenon of a disturbing nature to machine operation should

exist at the normal running speed.c) Calculations to be performed for dynamic as well as static cases for reinforced

concrete block type pedestal.

Foundation Sizing

The outline plan dimensions of foundations will be given by the machine EPC Contractor. The height of foundation will be selected after taking into consideration soil strata and operating level of the machine. The eccentricity of common CG of machine and foundation with respect to the centroid of base area/pile group should not exceed 3% of the corresponding base dimensions of the foundation.

In order to reduce the horizontal amplitudes, the height of foundation should be selected as small as possible. A larger base dimension should be selected in the direction of rocking moment, if any, acting on the foundation.

Compressor Foundation

The Compressor is a machine of reciprocating type. This is a low speed machine and produces unbalance forces during operation, causing vibration in the foundation. Excessive foundation vibrations may cause settlement or damage to the foundation-machine system and also a feeling of discomfort and uneasiness to the personnel. Compressor foundation shall be isolated from the close slab and other foundations

Vibrations are also transmitted through the ground. Ground vibrations may be minimized by providing trenches all around the foundation up to a suitable depth.

Miscellaneous Machine Foundations

For the large variety of other types of machines there are numerous foundation designs and the most suitable one will depend on the particular application.

Foundations for pumps, etc. are usually in the form of solid block foundations, resting on the undisturbed strata.


At machine supports supported on the finished floors, floor may be thickened and extra reinforcements provided. Also, the machines, which are almost vibration free and are very light to moderately heavy, may be supported in the above manner. Rubber or neoprene pads may have to be used under some of these machines to reduce transmission of vibrations to the supporting floor.

8.7 General Design Considerations

The design of various civil and structural works will be done as per relevant Indian Standard and sound engineering practices to meet the system and functional requirements.

Design Loads: Design loads for all structures will be determined according to the criteria described below.

Dead Loads: - Dead loads will consist of the weights of the structure and all equipment of a permanent or semi-permanent nature including tanks, wall panels, partitions, roofing, piping, drains, electrical trays, bus-ducts. Dead loads will be determined using the weight from IS-875 (Part -1).

Live Loads:- Live loads will consist of uniform live loads and equipment live loads. Uniform live loads are assumed unit loads which are sufficient to provide for movable and transitory loads, such as the weight of people, portable equipment and tools, equipment, or parts which may be moved over or placed on floors during maintenance operations. These uniform live loads will not be considered on floor areas which will be permanently covered with equipment.

Equipment live loads are calculated loads based upon the actual weight and size of the equipment and parts to be placed on floors during dismantling and maintenance or to be temporarily placed on or moved over floors during installation. Floors and supporting members which are subject to heavy equipment live loads will be designed on the basis of the weight of the equipment in addition to a uniform load of 500 kg/m², or specifically defined live loads, whichever is greater. Each member in the floor which may carry these loads will be designed for the heaviest piece or pieces of equipment arranged in the most critical position. For loads caused by moving equipment over the floor for installation, consideration will be given to the shoring of beams and floor from floors below. When moving equipment over floors for installations are considered, stress increases of 25 percent are permitted in beams and columns.

Wind Speed: The design wind speed will be based on IS: 875 (Part - 3). This design wind speed will be used to determine wind loads for all structures.

Seismic Zone: As per IS: 1893-2002


Design Loads

Dead Loads

Dead load will comprise of the following and will be computed as per IS: 875 (Part-1). Following will be considered for evaluation of dead loads:

i) An uniform 150/200 mm thick RCC slab wherever concrete floors are provided

ii) An uniform floor finish of 50 mm laid over RCC slabiii) Other area flooring will consist of removable grating/chequered plate or

50 IPS.iv) Beams & columns as per actual sizev) Wall/cladding loadsvi) Self weight of supporting structure/facilities

Imposed Loads

Imposed loads will include minor equipment loads, cable trays, small pipe racks/hangers (not exceeding 250 Kg/m²) and also loads during erection, operation & maintenance.

Actual plant loads coming on the floor area occupied by the equipment will be calculated and compared with the superimposed loads given above. Higher of the two will be adopted for analysis and design.

Steam Piping Load

As per static/dynamic analysis for steam piping, the loads superimposed on structure by piping hangers and at the restraint points will be considered as advised by piping Contractor. However, pipe dynamic forces at hanger location/restraint points will be considered not to act simultaneously with seismic forces in that plane.


Crane Loads

The frames will be analyzed for the maximum wheel loads when the lifted weight is nearest to ‘A’ row in one case and ‘B’ row in another load case. The impact fac tor for ver t i ca l l oad w i l l be 25% for c rane g i rder and 10% for columns/foundations as per provision of IS: 875 and lateral crane surge of 10% of lifted weight and trolley weight will be considered in the analysis of the frame. The longitudinal surge will be 5% of the static wheel load. Each of the crane girders will be analyzed for the moving loads and for half the total surge loads on each gantry girder.

Wind Loads

The basic wind pressure will be taken as IS: 875(Part-III) and combination of wind loads with other types of loading will be done according to provision of IS:875 (Part-V). The basic wind speed of 50m/sec. up to height of 10metres above ground level.

Earthquake Load

As per IS: 1893, the seismic zone and basic horizontal seismic coefficient for this plant location will be decided. The importance factor of not less than 1.50 will be used to calculate base shear coefficient. The coefficient of soil-foundation interaction will be not less than 1.0. Reduction in live loads is to be considered for analysis according to IS: 875. In view of the asymmetrical nature of main powerhouse, response spectrum method will be used for analysis.

Temperature Loads

The effect of temperature loads will be considered for design of the structural frames. For temperature loading calculation the total temperature variation will be considered as 2/3rd of the average annual variation in temperature. The structure will be designed to withstand stresses due to 50% of the total temperature variation. The structures will also be analyzed/checked for temperature effects in the areas where the temperature rise is expected to be high.


Load Combinations

The following load combinations will be considered for finding out the critical forces, moments and torsion on the structural elements.

i) DL + LLii) DL + LL + CLA + DLC ± CSiii) DL + LL + CLB + DLC ± CSiv) DL + LL + CLA + DLC ± CS ± TLv) DL + LL + CLB + DLC ± CS ± TLvi) DL + 0.5LL + K1(DLC) + K2(CLA)vii) DL + 0.5LL + K1(DLC) + K2(CLB) + EL ± TLvii) DL +LL + DLC + K3(CLA) ± K3(CS)+ WL1+TLviii) DL +LL + DLC + K3(CLB) ± K3 (CS)+WL1+TLix) DL +LL + DLC + K3 (CLA) ± K3 (CS) ± WL2+TLx) DL +LL + DLC + K3(CLB) ± K3(CS) ± WL2 ± TLxi) DL +LL ± WL1 ± TLxii) DL + LL ± WL2 ± TL

The following load combinations will be used for getting max. tension at column base which will be used for the design of holding down bolts

i) 0.9DL ± ELii) 0.9DL ± WL1iii) 0.9DL ± WL2

NomenclatureDL Dead load (comprising of only dead weight of structural members,

side cladding etc.)LL Live load (including imposed load, plant loads & equipment loads)TL Temperature loadDLC Dead load of crane bridge with impactCLA Crane trolley + lifted weight nearest to A row column with impactCLB Crane trolley + lifted weight nearest to B row column with impact.CS Crane surgeEL Earthquake loadWL1 Wind load with internal suction of 0.2pWL2 Wind load with internal pressure of 0.2pK1 (DLC)Dead load of crane bridge without impactK2 (CLA)Crane trolley without lifted weight with impact or (CLB)K3 (CLA)Crane trolley + ½ lifted weight with impact or (CLB)K3 (CS) Crane surge for ½ lifted weight.


Permissible Stresses

The permissible stresses will be as per relevant IS Code. An increase of 33.3% in permissible stresses will be made wherever wind or earthquake load has been considered with dead load and appropriate amount of live load. For secondary effects without wind or earthquake load, permissible stress will be increased by not more than 25%.

8.8 Design of Miscellaneous Items

8.8.1 Cable Trenches

The cable trenches and pre-cast removable RCC cover (with lifting arrangement) will be constructed using RCC/Masonry work. The cable trench walls will be designed for the following loads:

a. Dead load of 155 Kg/m length of cable support and 75 Kg on one tier at the end.

b. Triangular earth pressure + uniform surcharge pressure of 2T/m².c. Cable trench covers will be designed for self-weight of top slab and

concentrated load of 200 Kg at center of span on each panel.d. Cable trench crossing the road/rails will be designed for class AA loading

of IRC/relevant IS code and should be checked for transformer loading.

Suitable drainage arrangement will be provided to drain water from cable trenches. Cable trenches will not be used as storm water drains. The top of trenches will be kept at least 50mm above the finished ground level. Trench wall will not foul with the foundation. Suitable clear gap will be provided.

A clear (vertical) space of at least 200-mm will be available for each tier in cable trench. From trench bed to lowest tier, a minimum clearance of 150 mm will be available. The trench bed will have a slope of 1/500 along the run and 1/250 perpendicular to the run. All the construction joints of cable trenches i.e. between base slab to base slab, the junction of vertical wall to base slab, from vertical wall to wall and all the expansion joints will be provided with approved quality PVC water stops of approx. 230 x 5 mm size for those sections where the ground water table is expected to rise above the junction of base slab and vertical wall of cable trenches.

Cable trenches will be blocked at the ends if required with brick masonry in cement sand mortar 1:6 plaster with 12mm thick 1:5 cement sand mortar.


8.8.2 Drains

Adequate surface drainage system will be provided within the plant area. Design will be done with obtained rainfall data and the storm water drainage system designed, (Culverts, ditches, drains etc.) to accommodate the most intense rainfall that is likely to occur over the catchments area in one hour period on an average of once per ten year. The surface of the site will be sloped to prevent the ponding of water.

The maximum velocity for pipe drains and open drains will be limited to 2.4m/ sec and 1.8m/ sec respectively. However, minimum non-silting velocity of 0.6 m/sec will be ensured. Longitudinal bed slope will not be milder than 1 in 1000.

Invert of the drainage system will be decided in such a way that the water can easily be discharged above the High Flood Level (HFL) outside substation boundary at suitable location and approved by Owner. Pumps for drainage of water (if required) will be provided.

8.9 Architectural Concepts & Design

An Architectural Design Basis Report will be submitted to the Owner including proposals for the following scheme components: shape, form, color, and basic materials for interior and exterior architecture along with an appropriate landscaping scheme. All schemes will be supported by architectural statement explaining the factors considered in the design.

EXTERIOR ARCHITECTURE General design criteria for the exterior architectural systems will be as follows:

8.9.1 Wall / Cladding System

All external walls of the building shall be 230 mm thick brick walls and internal walls 230/115 mm thick brick walls as per requirement in CM 1:5. Internal plastering shall be 12 mm thick using CM 1:4 and external wall with CM 1:4., 20/25 mm thick and/or sand faced plaster or any other special finish if required, 115 wall shall be plastered with CM 1:3, 12 mm thick. Ceiling plastering shall be 6 mm thick with CM 1:3. Damp proof course 40 mm thick in PCC 1:2:4 using 6 mm down stone shall be provided in the external brick walls at grade level.

In order to quickly erect / complete the Distillery and Ethanol buildings, wall cladding with Galvalume sheets may be examined above 5.0 m from ground level and up to 5.0 m brick work can be adopted. Where ever advised, self supported galvalume roofing could also be provided for the main plant buildings and other non-plant buildings.


8.9.2 Roof

As per details given in relevant sections.

8.9.3 Flooring & Floor Finish

The floor slabs will be designed as cast-in-situ RCC slabs with removable shuttering unless mentioned otherwise. The nominal thickness of RCC slabs will be 150/200 mm.

Floor finish of 50mm thickness will be provided over the RCC Slab as per finish schedule wherever applicable. Type of floor finish will be as per the functional requirements of different areas and facilities.

8.9.4 Roof Water Proofing Treatment Above RCC Roofs

Over the cast-in-situ roof slab, 50mm thick screed concrete (blended with water-proofing admixture) will be laid. The final treatment will be heavy-duty type with bitumen felts. For the provision of handling of equipment on the roof and movement of personnel, tiles will be provided in place of pea gravel.

Roof slope of 1 in 75 will be provided in one direction in A-B bay and sloping towards A-row. For other bays, roof slope of 1 in 100 will be provided in two directions.

For rainwater down comers, heavy duty UPVC pipes will be used. Number and sizing will be as per the relevant Indian Standard.

8.9.5 Windows, Ventilators

Window and Ventilator frames will be made of extruded aluminium, steel, or other tried and proven material as per the schedule given earlier. Frames will have a minimum depth of 38 mm and a minimum thickness of 3 mm. Ventilation sections will be compatible with the frames providing a weather tight seal.

All aluminium windows shall be provided with MS grills of approved design and all glazed windows to be provided with sun control film. All steel windows to be provided with 12mm sq MS safety bars @ 100 mm c/c

All windows will be fully flushed and sealed for weather tightness.


8.9.6 Doors

Pressed steel doors/ Aluminium doors will be provided as per the schedule given earlier. Steel doors will be the hollow metal type, flush, 46 mm thick, insulated, with formed hollow metal frames. The doors will be constructed from 1.3 mm steel with an internally reinforced, insulated core. Frames will be constructed of 1.6-mm steel, welded, and ground smooth. Both doors and frames will be factory galvanized or field painted.

Doors will have a glazed vision panel when required by door function. Glazing will consist of tempered safety glass or wired glass.

Fire barrier doors, if any, shall be specifically designed steel doors with required fire rating. The door, frame, and hardware will bear a certification label for the class of opening and rating. Doors for fire exits will be secured with panic bars.Solid core flush doors with both side veneer finish to be provided for housing and other non-plant buildings as advised and specified.

8.9.7 Equipment Access Doors

Large access exterior doors will be vertical lift rolling shutter type, with weather seals and windsocks. Components will be formed from galvanized steel, factory primed, and field painted. Doors at high traffic areas will be motor-operated. Doors will be manually operated where access is infrequent.

INTERIOR ARCHITECTURE: Interior architectural systems will conform to the following general design criteria. Fire rated architectural system will be provided when required by building or fire codes. All normal occupied areas will be finished areas.

8.9.8 Painting

Inside masonry walls and ceilings of all buildings will be provided with white wash, color wash, oil bound distemper, acrylic emulsion paint as per schedule given earlier. Steel structures, doors, windows, steel rolling shutters, gangways, stairways railing, grating rain water pipes etc. will be painted with synthetic enamel paint.

8.9.9 Lighting

Lighting fittings and fixtures will be provided for proper illumination in all buildings as per good engineering practice.


8.9.10 Sanitary Facilities

Toilet and shower facilities will be provided for personnel in finished areas of all major buildings and in other areas as determined by project requirements. Sanitary facilities fixture types will be so selected to provide a balance of local and Western fixtures. Towel and waste receptacles will be recessed to the extent possible. Janitor closets and cleaning material storage areas will be provided in finished areas of all major buildings. The sewage from various locations will be collected in septic tank. The capacity of the sewerage system, septic tank, required gutters, air vents, PVC piping, etc. will be calculated based on manpower deployment of 500 personnel per shift.

All Architectural, Structural and RCC drawings and design calculations, shall be supplied in triplicate to the Client and their Consultants, minimum 15 days prior to construction of works at site, for approval purposes and only after approval, the works shall be taken up at site. A soft copy of all such drawings and designs, either by E-mail or by CD/DVD, shall also be provided along with the hard copies.

8.10 Construction

8.10.1 Concrete:

Reinforced concrete structures will be designed in accordance with the latest version of IS: 456 Code of Practice for Plain and Reinforced Concrete.

Water retaining RCC Structures will be designed in accordance to IS:3370: Code of practice for concrete structures for the storage of liquids.

The grade of concrete for various structures will be as follows:

PCC below Foundations/Plinth Beams 1:4:8PCC in base slabs for drains, water retaining structure etc. 1:3:6PCC/RCC in grade slabs, pavements, plinth protection, etc M20RCC in foundations and super structures M20RCC for liquid retaining structures M25RCC for T. G. Foundation M20

Minimum cement content shall be as follows:

M15 : 324 kg/m³M20 : 360 kg/m³M25 : 400 kg/m³1:3:6 : 216 kg/m³


1:4:8 : 216 kg/m³1:5:10 : 130 kg/m³

Grouting :

Non-shrink flowable grout shall be used for grouting below base plate of columns. For grouting of base of machine foundation high flowable strength ready mixed non shrink grout shall be sued.

Type and grade of grouting for structural columns and equipment base shall be as indicated. Crushing strength of the grout shall generally be one grade higher than the base concrete. Minimum grade of grout shall be M30.

Nominal thickness of grouting shall be at least 50 mm for building columns and pedestals of major equipments. For secondary posts, stair & ladder base, etc, grouting shall not be less than 25 mm thick.

Reinforcing Steel:

Reinforcing steel will be High, Yield Strength Deformed bars conforming to IS-1786 (Grade Fe 415).

Cement:

Cement used in all concrete mixes will be Ordinary Portland cement/ Portland Slag cement 43-Grade unless design requires a different type.

Aggregates:

Fine aggregates will be clean natural sand. Coarse aggregates will be crushed gravel or stone. All aggregates will meet the requirements of IS:383 - 1970.

Admixtures:

1. Plasticizers and retarders will be used to control setting time and to obtain optimum workability, if required.

2. Water: Clean water of potable quality will be used in all concrete mixes.3. Mixes: A table will be supplied with the Design Intent Memorandum, which

classifies the proposed mixes into a general range of classes. The minimum cement provided in concrete mixes will be as per the stipulations laid down in IS: 456.

4. Secondary reinforcement : Polyester fibres will be used in cement mortar, PCC, RCC, etc. to enhance / improve the performance of mortar / PCC / RCC


Design Mix Tests:

1. Two sets of compression test samples, three samples per set, will be made from each proposed concrete mix. One set of three samples will be tested at an age of 7 days, and the other set will be tested at an age of 28 days. Tests will be in conformity with IS:4031-1968.

2. Grade Slab: The existing earth fill will be thoroughly compacted, and provided with 150 mm of boulder soling or brick aggregates, interstices filled with small stones and sand. Floor paving will be of 100/150 mm thick in M-20 grade laid over the prepared surface.

Finishing Formed Surfaces:

1. Fins and other surface projections will be removed from all formed surfaces except exterior surfaces that will be covered with earth back fill. Exterior surfaces that will be exposed above grade and all interior surfaces, except those not usually exposed to view, will be cleaned and rubbed. Rubbing will produce a smooth, uniform surface free of marks, voids, surface glaze, and discoloration. Rubbing will be done by hand with a carborandum stone using only the mortar produced by the rubbing action and the application of water.

2. Projecting ends of all form ties will be removed. The resulting recesses will be cleaned, wetted, and filled with patching mortar. Patches on rubbed surfaces will match the texture of the adjacent concrete.

3. Plinth Protection: All buildings will be provided with 1000 mm wide and 100 mm thick plain cement concrete paving all around on the outside. The plinth protection will be laid over prepared sub-grade and base formed with broken bricks or rubble laid to a thickness of 75 mm.

Structural Elements :

Minimum thickness of structural element to be as follows:

Suspended flow slab / roof slab / walkways / canopy slabs, etc

: 100 mm

Ground floor slab (non-suspended) : 150 mmWater retaining slab / walls : 150 mmCable / Pipe Trenches / Under ground pit / Launder walls and base slab

: 100 mm

All footing (including raft foundation) : 250 mmTapered footing : 150 mm

(Min. at edges)Parapets / Chajjas : 75 mmPre-cast louvers / fins : 50 mm


Pre-cast trench cover slabs / floor slabs / louvers : 75 mmPaving : 150 mmBasement walls and base slab : 150 mm

Curing:

1. Concrete will be protected from loss of moisture for not less than 7 days after the concrete is placed. Trowelled surfaces, except those that receive a separate finish or coating, will be cured with a membrane curing compound. Float finished surfaces, except those that receive a separate finish, may be cured with either a membrane-curing compound or with water. Only water curing will be used if the surface receives a separate finish.

2. Water Curing: Water saturation of concrete surfaces will begin as quickly as possible after initial set of the concrete. Water curing will begin within 12 hours in dry weather and within 24 hours in damp weather. The rate of water application will be regulated to provide complete surface coverage with a minimum of runoff The application of water may be interrupted for surface rubbing. The concrete surface will not be permitted to dry.

3. Damp proofing: Damp proof course in a thickness of 40mm and consisting of cement concrete 1:2:4 with admixture of approved water proofing compound, will be provided at plinth level for masonry walls in super structure.

4. Waterproofing: A waterproofing seal will be provided for structures where applicable. Water-proofing will be carried out by a system duly approved by the Owner/Engineer.

8.10.2 Steel

Structural Steel:-

Steel framed structures will be designed in accordance with IS:-800- Code of Practice for Construction in steel adopting allowable stress design and plastic design. In addition steel framed structures will be designed in accordance with the criteria discussed in the following subsections.

Materials:

Structural steel shapes, plates, and appurtenances for general use will conform to Indian Standards IS:800 with a minimum yield strength of 250 MPa. Connection bolts will conform to IS:-1367. Connections will conform to the latest version of the Specification for Structural Joints. Welding electrodes will be as specified by the AWS.


Tests:

Mill test reports or reports of tests made by the fabricator will be required certifying that all material is in conformance with the applicable standards and specifications. In addition, the fabricator will provide an affidavit stating that all steel specified has been provided at yield stresses in accordance with the drawings and the specification.

Minimum Heights for pedestals of Steel Columns :

Top of RCC foundation (pedestals) shall normally be kept at a height of 300 mm above the floor level.

Other Pedestals and Foundations

Stairs and ladder pedestal : 200 mm above the finished floor level

Equipment in open area : As required (300 mm min.)Equipment in covered area : As required (150 mm min.)Structures / Equipment supplied : As per vendors data subject to

minimum as specified above

In case the top of pedestal is kept at a lower level so that the column base plates together with gussets and stiffener remains below finished floor level (FFL), the column base as well as column section shall be encashed in concrete above FFL as below:

Open area : 300 mm above FPL / FGL, whichever is higherCovered : 150 mm above the FFL

8.10.3 Miscellaneous Metal Items

Steel Grating:

Steel gratings will be pressure locked grating manufactured with 40mmx 5mm MS strips as longitudinal bearing strips (spanning the supports) and 25mm x 3mm strips in transverse direction. The grating will be provided with a 40mm x 5mm band all-round. The grating will be designed for 500kg/m2 loading and spans up to 1500mm. Stair treads will also be made of steel grating with nosing.


Guard rail /Handrail:

Guard rail will be a two-rail system with the top rail 1000 mm above the walkway surface and the intermediate rail 500 mm below the top rail. Guard rail post spacing will be proportioned to the length of the protected horizontal opening, but will not exceed 1200mm centre-to-centre of posts. Guard rail will be shop fabricated for specific locations and field welded or bolted to the erected structural steel. Steel pipe will conform to IS-1151, Medium grade.

Anchor Bolts and Embedded Shapes:

Anchor bolts will conform to IS:-5624. Embedded shapes and plates will be galvanized where required. Anchor bolt assemblies will be galvanized where required. Steel, which is not galvanized and will remain exposed, will be primed with a primer paint.

8.10.4 Data to be submitted by Contractor with the bid

The Contractor to submit the integrated plant layout and sections, all plant and non-plant buildings, layouts for the cooling systems, designs for the water supply schemes etc., layout and sections for the distillery and ethanol plant including areas designated for the effluent disposal and the schemes for the same, areas designated for nursery etc. Contractor to also reflect water collection schemes, water harvesting schemes, collection systems etc. Landscaping details shall also be reflected by the Contractor on the layout. Contractor shall also reflect provisions for future expansion for all sections. The Contractor to also submit the sizes considered for all buildings in the scope.

8.11 Effluent Treatment Plant

The distillery and ethanol project will have its own effluent treatment plant. Effluent will be discharged by the Contractor at identified exits of the integrated plant area. The discharged effluent will be oil free and meet or better the BPCB norms. Part of the treated effluent will be pumped back to the Contractor to be utilized for ash quenching and gardening in the integrated plant area. The ETP will include the required storage area, aerators, dosing systems, sludge drying beds, etc. based on the expected effluent quality and BPCB norms. The expected quantity of effluent is to be detailed by the Contractor.


8.12 Buildings & Civil Works

8.12.1 Juice Concentration Plant

The Juice Concentration Plant Building shall be approximately 12.00 meters wide x 20.00 meters long with required eave height with multiple floor elevations and a sloping roof. The building will have metallic siding for the roof and walls and translucent fiberglass panels shall be provided as sky lights in the roof and a light band (vertical/horizontal) around the perimeter of the building. The metallic siding shall extend down to within 5 meters of grade and terminate. The remaining 5 meters shall be brick masonry/concrete block with louver panels installed. The roof is to be provided with suitable gravity vent to insure adequate natural ventilation of the building. The building shall be designed to carry all equipment loads and supports, to enable proper and safe operation. All floor levels shall be galvanized steel grating/chequered plates (as required). Walkways and platforms shall be provided for operational access to the sides, back and top. The building shall be designed for installation of future equipments and for future expansion. FFL shall be vaccum dewatering system flooring 150mm thk. M.S railings shall be provided for all cut-outs, accesses and for the perimeter of the plant at all levels.

8.12.2 Juice Pasteurization Plant

The Juice Pasteurization Plant Building shall be approximately 10.00 meters wide x 10.00 meters long with required eave height with multiple floor elevations and a sloping roof. The building will have metallic siding for the roof and walls and translucent fiberglass panels shall be provided as sky lights in the roof and a light band (vertical/horizontal) around the perimeter of the building. The metallic siding shall extend down to within 5 meters of grade and terminate. The remaining 5 meters shall be brick masonry/concrete block with louver panels installed. The roof is to be provided with suitable gravity vent to insure adequate natural ventilation of the building. The building shall be designed to carry all equipment loads and supports, to enable proper and safe operation. All floor levels shall be galvanized steel grating/chequered plates (as required). Walkways and platforms shall be provided for operational access to the sides, back and top. The building shall be designed for installation of future equipments and for future expansion. FFL shall be vaccum dewatering system flooring 150mm thk. M.S railings shall be provided for all cut-outs, accesses and for the perimeter of the plant at all levels.


8.12.3 Syrup Storage Section

The Syrup Storage Section shall be approximately 50.00 meters wide x 100.00 meters long with required eave height with single/multiple floor elevations and a sloping roof. The building will have metallic siding for the roof and walls and translucent fiberglass panels shall be provided as sky lights in the roof and a light band (vertical/horizontal) around the perimeter of the building. The metallic siding shall extend down to within 5 meters of grade and terminate. The remaining 5 meters shall be brick masonry/concrete block with louver panels installed. The roof is to be provided with suitable gravity vent to insure adequate natural ventilation of the building. The building and foundations shall be designed to carry all equipment loads and supports, to enable proper and safe operation. All floor levels shall be galvanized steel grating/chequered plates (as required). Walkways and platforms shall be provided for operational access to the sides, back and top. The building shall be designed for installation of future equipments and for future expansion. FFL shall be vaccum dewatering system flooring 150mm thk. M.S railings shall be provided for all cut-outs, accesses and for the perimeter of the plant at all levels. Chain Link fencing to the designated areas shall be provided as per proper excisable norms. Levelled platform for loading, unloading shall be adjacent to the storage section.

8.12.4 Fermentation Section, Panel Rooms, Laboratory, etc.

The Fermentation Section shall be approximately 28.00 meters wide x 60.00 meters long with required eave height with single / multiple floor elevations and a sloping roof. The building will have metallic siding for the roof and walls and translucent fiberglass panels shall be provided as sky lights in the roof and a light band (vertical/horizontal) around the perimeter of the building. The metallic siding shall extend down to within 5 meters of grade and terminate. The remaining 5 meters shall be brick masonry/concrete block with louver panels installed. The roof is to be provided with suitable gravity vent to insure adequate natural ventilation of the building. The building and foundations shall be designed to carry all equipment loads and supports, to enable proper and safe operation. All floor levels shall be galvanized steel grating/chequered plates (as required). Walkways and platforms shall be provided for operational access to the sides, back and top. The building shall be designed for installation of future equipments and for future expansion. FFL shall be vaccum dewatering system flooring 150mm thk. M.S railings shall be provided for all cut-outs, accesses and for the perimeter of the plant at all levels.


A brick masonry/concrete block with RCC slab at various levels, Electrical Equipment/Panel/MCC panel room building shall be incorporated adjacent to the fermentation section building, which will be air conditioned. This building shall also house the laboratory at the upper levels and the compressors etc.at the FFL. Floor heights for the panel room shall not be less than 6m and the remaining floors not less than 4m. The building shall also house the offices for the distillery/ethanol plant.

8.12.5 Distillation & MSDH Section

The Distillation and MSDH Section shall be approximately 25.00 meters wide x 25.00 meters long with required eave height with multiple floor elevations and a sloping roof. The building will have metallic siding for the roof and walls and translucent fiberglass panels shall be provided as sky lights in the roof and a light band (vertical/horizontal) around the perimeter of the building. The metallic siding shall extend down to within 5 meters of grade and terminate. The remaining 5 meters shall be brick masonry/concrete block with louver panels installed. The roof is to be provided with suitable gravity vent to insure adequate natural ventilation of the building. The building and foundations shall be designed to carry all equipment loads and supports, to enable proper and safe operation. All floor levels shall be galvanized steel grating/chequered plates (as required). Walkways and platforms shall be provided for operational access to the sides, back and top. The building shall be designed for installation of future equipments and for future expansion. FFL shall be vaccum dewatering system flooring 150mm thk. M.S railings shall be provided for all cut-outs, accesses and for the perimeter of the plant at all levels.

A walkway connecting the fermentation section and the distillation/MSDH section shall be provided.

8.12.6 Alcohol Storage Section

The Alcohol Storage Section shall be approximately 35.00 meters wide x 60.00 meters long with required eave height with single/multiple floor elevations and a sloping roof. The building will have metallic siding for the roof and walls and translucent fiberglass panels shall be provided as sky lights in the roof and a light band (vertical/horizontal) around the perimeter of the building. The metallic siding shall extend down to within 5 meters of grade and terminate. The remaining 5 meters shall be brick masonry/concrete block with louver panels installed. The roof is to be provided with suitable gravity vent to insure adequate natural ventilation of the building. The building and foundations shall be designed to carry all equipment loads and supports, to enable proper and safe operation. All floor levels shall be galvanized steel grating/chequered plates (as required).


Walkways and platforms shall be provided for operational access to the sides, back and top. The building shall be designed for installation of future equipments and for future expansion. FFL shall be vaccum dewatering system flooring 150mm thk. M.S railings shall be provided for all cut-outs, accesses and for the perimeter of the plant at all levels. Chain Link fencing to the designated areas shall be provided as per proper excisable norms.

8.12.7 Workshop, Store Room, Weigh House Cabin

Workshop shall be approximately 10.0 meters wide x 10.0 meters long x 8.0 meter eave height with sloped roof. The building should be adjacent to the distillation plant. The building is designed to be a structural frame building with one line of interior columns that shall serve as a crane column for the 10 meter span overhead traveling crane on the building. Crane beams and crane rails shall be installed on wall columns. The roof shall be either of truss or single beam rafter construction. Adequate bracing is to be provided on all sides and roof of the building for wind and equipment loads.

Store Building shall be approximately 10.0 meters wide x 10.0 meters long x 8.0 meter eave height with sloped roof. The building shall be designed as a portal frame or rigid frame structure with no interior columns.

The Workshop and Store buildings will have metallic siding for the roof and walls and translucent fiberglass panels shall be provided as sky lights in the roof and a light band around the perimeter of the buildings. The metallic siding shall extend down to within 5 meters of grade and the remaining 5 meters shall be brick masonry/concrete block with louver panels installed. The roof is to be provided with proper gravity vent to ensure adequate natural ventilation of the building during operation and in the out of crop season.

The buildings shall have inbuilt racks for storage of materials, files, nuts/bolts etc.

Weigh br idge cab in o f s i ze 5m x 5m x 3m sha l l be prov ided a t the distillery/ethanol plant entrance near the weigh bridge. The structure shall be RCC slab, brick/block masonry, aluminium doors and windows, industrial flooring, inbuilt rack facilities for record storage, ease of operation for recording and issuing necessary slips etc. Sufficient storage space for records shall be provided.

Excise and allied offices shall be provided at the entrance to the Distillery /Ethanol Plant as laid down and as per the norms of the Factory Inspector and Excise Department.


8.12.8 Water Treatment Plant, Water Reservoir, etc.

This will consist of a partly underground/partly above ground water reservoir (1 no. approximately of required working capacity including fire water storage). The water reservoir will be of RCC or masonry construction with adequate waterproofing & strength. PCC (1:3:6) paving will be provided in water treatment area all around 1m. The raw water reservoir will have a partition for fire water storage. Capacity of the water storage tank shall be finally confirmed before construction as per the requirements for the Distillery/Ethanol plant. The waterreservoir shall be designed as an independent reservoir for the distillery/ethanol plant and the capacity for the same shall be confirmed. The water reservoir shall be designed for at least 4 days capacity.

8.12.9 Cooling Towers

Cooling towers (separate for each section) of required sizes and capacities shall be provided for the distillery/ethanol plant. The structure could be masonry/RCC structure. Required pump house with gantry facilities shall be provided adjacent to the cooling tower. Epoxy waterproofing shall be adopted for the water holding areas and the structures shall be made fully water-proof. Cooling towers shall be designed for minimum dead water storage. Proper levels and slopes shall be maintained at all locations. Location and orientation of the Cooling Towers shall be such as to provide maximum contact with wind or to provide proper natural aeration.

8.12.10 Spent Wash Pipe Lines, Pipe Racks, Cable Trays, etc.

All molasses, steam, spent wash etc. pipe lines including piping and supporting structures for the distillery/ethanol plant are covered under this section and shall be considered by the EPC Contractor. The molasses pipe line from the molasses tank to the distillery/ethanol plant including their foundations and supporting structures are to be considered as also the steam, water pipe lines from the boiler/water reservoir.

All piping pipe rack and misc. pipe racks will be latticed steel structure on RCC foundations. At road crossing, the minimum clearance will be 7.5 m. Sleeper way will be RCC foundation protruding 500 mm above finished grade level for support of piping and cable trays. The layout and sizing of the pipe racks and sleeper ways to be based on the system requirements. Cable trays to be designed above the pipe racks and suitable walkways for inspection, maintenance and repairs to be provided for all pipe racks and cable trays. Design of the pipe racks shall be suitable for ease of erection of the various piping.


8.12.11 Effluent Treatment Scheme (Composting Field, Bio-Gas Plant, etc.)

Suitable effluent treatment and disposal scheme for the Distillery/Ethanol plant shall be submitted in detail along with the EPC tender documents. Details for the development of the composting yard and field, area required as per BPCB norms,wind rows, piping, nozzles, spraying facilities, leach collections pits, drains, panel rooms, DG set and shed, all HDPE/PVC piping, pumping machineries etc. are to be included in the EPC bid document and submitted along with the tender. Details of the Bio-Gas plant alternatively should also be submitted along with the EPC bid.

8.12.12 Internal Roads & Culverts

Internal roads shall be concrete/bitumen topped of sufficient widths as required, one way/two way with proper s treet l ighting arrangements and green zone/plantation in the centre/ along the sides, with proper road side drains, culverts, provision of pipes/ducts to carry storm water in separate ducts and cables/pipes in separate ducts. Crossings, cul-de-sacs and dead ends shall be properly planned for and provided. No roads shall be less than 6m in width. Roads shall follow the specifications provided with the tender documents.

Drains and culverts shall be designed as per requirements and as specified in the other sections. Side water drains and storm water drains shall be connected to the water harvesting scheme. Proper provisions shall be carried out especially at crossings, cable crossings etc. Drains shall as far as possible be trough type RCC, with sufficient depths and proper slopes in conjunction with the total scheme worked out for the site. Pipes for drains could also be used with provision for proper inspection and maintenance at regular intervals. As far as possible, drains and cable trenches shall not be planned side by side.

8.12.13 Fencing & Gates

Fencing for the distillery/ethanol plant shall be as required as per excise norms with openings as required by excise norms. Fencing shall be masonry wall upto 600mm above NGL with barbed wire/chain link fencing above and of a minimum height of 2.1m above NGL. “Y” shaped angles with barbed wire rounds shall be provided at the top of the fencing necessarily. Gates to be sliding type electrically operated and all gates to have provision of man gates within the gates. Gates shall be minimum 2m height. Gates shall be of various widths as per requirement, however not less than 6m in width.

Main gate will be provided at the plant entry and will be of minimum 2 m height and 6 m width. The main gate will be motorized and operated through the security cabin.


8.12.14 All Machinery Foundations

Foundations for the distillery/ethanol plant would comprise of foundations for the various tankages, foundations for the various equipments in all the sections, pumps, compressors, DG sets, pipe rack foundations, water treatment plant etc. required for the 60 KLPD ethanol plant.

8.12.15 Evaporation Section

The Evaporation Section (if required) shall be of appropriate size with multiple floor elevations and a sloping roof. The building will have metallic siding for the roof and walls and translucent fiberglass panels shall be provided as sky lights in the roof and a light band (vertical/horizontal) around the perimeter of the building. The metallic siding shall extend down to within 5 meters of grade and terminate. The remaining 5 meters shall be brick masonry/concrete block with louver panels installed. The roof is to be provided with suitable gravity vent to insure adequate natural ventilation of the building. The building and foundations shall be designed to carry all equipment loads and supports, to enable proper and safe operation. All floor levels shall be galvanized steel grating/chequered plates (as required). Walkways and platforms shall be provided for operational access to the sides, back and top. The building shall be designed for installation of future equipments and for future expansion. FFL shall be vaccum dewatering system flooring 150mm thk. M.S railings shall be provided for all cut-outs, accesses and for the perimeter of the plant at all levels.

8.12.16 Spent Wash Ponds, Day Holding Tanks, etc.

Spent wash ponds as required by the BPCB norms and other settling tanks including the day holding tank shall be of required capacity and as laid down in the specifications along with this tender. Brick on edge to be preferred for the floor and side walls of the ponds.

8.12.17 Lighting & Electrification

All yard and other areas lighting and electrification shall be considered within the EPC Contract. Electrification and lighting for the plant and all areas covered under the ethanol plant including street lighting are to be included. Lighting and electrification shall be as per proper accepted norms of illumination and as per IS.


8.12.18 Cable Trenches / Drains

Cable trenches for the MCC panel rooms and at other locations will be rectangular reinforced concrete structures of approx. 1m width and 1m depth (sizes may vary as per sections). They will be covered either by pre-cast concrete covers or by chequered plate covers. Cable pull pits of approx. 1x1x2m deep will be provided at suitable locations.

All paved and unpaved surface in the distillery/ethanol plant area will be adequately drained with drainage system for effluent/ rain water/ fire water/ washing water. Open surface drains will be provided with bricks of class designation 50 or locally good quality brick in cement mortar 1:4 including 100 mm thick bed concrete of grade 1:3:6 and 12 mm thick cement plaster 1:4 with a floating coat of neat cement inside the drains without any cover. Manholes will be made of reinforced concrete and contain silt traps. Storm water drains will collect all surface water from roofs of the buildings and from paved and unpaved areas as applicable. The drains from proposed plant area will be connected to the main drains running all along the roads and or to the effluent treatment plant, as required.

8.12.19 Fire Fighting

EPC Contractor shall include all provisions for fire fighting including providing the water lines (preferably along the roads and in the storage areas etc.) as per proper norms and as required by the Factory Inspector and Excise Department. This shall include all provisions required for the same.

8.13 Important & Common Notes

x The sizes of buildings and areas are tentative and may vary as per the final engineering and machinery layouts and requirements of the EPC Contractor, which shall be got approved from the Client and their Consultants prior taking up any work at site.

x Landscaping details shall be submitted along with the layouts and got approved from the Client and their Consultants prior taking up any work at site.

x EPC Contractor to verify availability of land as per the records of the Client and carry out their independent surveys for the land as per the Land records statement.

x The FFL/Plinth levels shall be verified by the EPC Contractor and shall necessarily be above the HFL at site.


x Water harvesting details and scheme shall be worked out and approved from the Client and their Consultants for all sections and shall necessarily be incorporated in the integrated plant.

x Sites in possession of the Archeological department shall be identified and shall be protected and maintained in proper manner as per the Statutory norms of the Archeological Department.

x Places of worship within the site need to be identified and shall be properly protected and maintained at all locations. The layout shall reflect all such locations and the means of protection to be adopted for these locations.

8.14 The construction specifications have been given in Appendix - VIII.


Chapter – 9

Fire Fighting & Protection

9.1 General

The Plant is considered as (Extra hazard group –II ) as per NFPA -14 classifications.

9.2 Basic Fire Fighting System

1. Hydrant System2. Hose reel system3. Portable fire extinguishers4. Medium Velocity water spray system5. Foam Protection System6. Fire Detection & Alarm system

9.2.1 Hydrant System

9.2.1.1 Hydrant System shall be provided for the areas as mentioned under clause 2.0. Hydrant system consists of a large network of pipe laid underground (min. 0.8 M below grade for general area & 0.9 mtr. for road crossing area), which feeds pressurized water to number of hydrant valves or hydrant with monitor.

9.2.1.2 The hydrants will be located above ground & type of hydrant should be wet barrel type with 6” connection to the fire main. No block valve is considered above ground at the base of hydrant.

9.2.1.3 Monitor are specified in accordance with NFPA & mounted above the wet barrel hydrant with 4” connection to hydrants. Foam cum water type monitors are considered for Alcohol storage area protection.

9.2.1.4 Spacing & location of hydrants will be as per NFPA 24 or local authority rules. Maximum distance between two hydrants is considered 45 mtr. as per standard practice.

9.2.1.5 Hose box near field hydrant shall store 1 nos. of 2 ½” X 30 mtr. Length Fire hoses, 1 Nos. of 1 ½” dia x 30 mtr. Fire hose, one no 1 ½” adjustable fog & straight stream nozzle, 2 ½” & 1 ½” adaptor, 2 nos. universal hose spanner wrench for 2 ½” & 1 ½” & 2 nos. of coupling gasket.


9.2.1.6 Hose box are signed with safety signs in accordance with BS 5499 part-1.

9.2.1.7 For protection of column, High structure, & storage tank area, suitable master stream or hydrant with water monitor are considered.

9.2.1.8 For protection of upper floor areas inside the Distillation MSDH unit standpipes system are considered. Standpipe shall be provided near the staircase with internal house box, suitable for storing two nos. of 15.0 mtr. 38mm dia hose pipes, one no. of branch pipe with solid stream nozzle equipped with shutoffs, two house wrench, two hose wrench, two hose coupling qasket.

9.2.1.9 Each standpipe is to be sized for a minimum flow of 380 ipm at 6.9 bar (g) inlet pressure.

9.2.1.10 The fire water network shall be designed on the basis of following:

A. The firewater network around a risk area shall be sized for the maximum firewater flow demand for the risk area i.e. combined water requirement for all water based extinguish system.

B. Velocity in the pipeline shall not exceed 5 m/s. Pipe friction shall be determined on the basis of Hazen and willians formula.

C. Post indicator type cut of valves shell be located in the network in such a way that a pipe run can be insolated for maintenance and at the same time ensuring that fire water is available on at least two sides of any risk area through the pressurized network.

D. Hydrant –monitors guards are to be considered for hydrants where these are subject to vehicle damage or mechanical damage near roadways, access ways.

E. The guards are to be section of 4” sch 40 pipes, filled with concrete & set in concrete. The top of the pipe is to be at least 0.9 mtr, above grade & the bottom at least 1.2 mtr. below grade.

F. Guards are to be painted with a reflective paint (Yellow & Black stripes).

G. The design pressure of pipeline shall be 12.0 bar (g).


H. The minimum pressure required at each hydrant point shall be 6.9 bar (g).

I. One no. of El. Motor driven pump capacity 273 M3/hr (1250 GPM), Head 70 mtr. head is considered as main fire pump & similar capacity of diesel engine driven pump is considered as standby fire pump.

J. One no. El. Motor pump capacity 10.8 M3/Hr, 70 mtr. head is considered for pressurization of system.

K. As per NFPA-14, 2 hrs of firewater storage required for the system, hence total 550 M3 water storage shall be provided by the client. The storage shall be exclusively for fire fighting system & shall be stored in two equal compartment type reservoirs.

9.2.2 Hose Reel System

First aid hose reels shall be provided inside process area & service floor area for internal protection. Tapping for hose reels shall be taken from standpipe system.

9.2.3 Portable Fire Extinguishers

a. Adequate number of portable fire extinguishers of dry chemical (ABC –powder) type, carbon-dioxide type & foam type are to be consider for the open plant area & inside building at places where the fire hazards could potentially arise.

b. NFPA – 10 code are used to finalize the type, accessories, size, number & location of fire extinguishers.

c. All the portable fire extinguishers used to be listed & approved type.

d. Fire extinguishers located outdoors is kept by cabinets. The location of all fire extinguishers is signed with safety signs in accordance with BS 5499 part 1.

e. In portable type extinguishers (hand held type) 4.5 Kg capacity Co2 type extinguisher, 9 ltr. capacity Foam type & 5.0 kg. Capacity DCP type fire extinguishers are considered.


f. For trolley mounted DCP type fire extinguisher capacity is considered 22.5.7 Kg.

9.2.4 Medium Velocity Water Spray System

For exposure protection of anhydrous Alcohol storage tanks, manual medium velocity spray system shall be provided on each alcohol storage tank as per NFPA – 15.

Water spray shall be applied to vessel surface at a net rate of not less then 0.25 gpm/ft2 (10.2 ipm/m2) of exposed surface

A typical medium velocity water spray system consist of:

A quick opening valve located at suitable distance from the hazard area.

GI CS piping on down stream of quick opening valve, branched off into rings, branches etc.

Medium velocity spray nozzles on GI piping and located in such a way that the desired spray pattern is obtained and the protected area is wetted with the required flow rate per sq. m of area.

Tapping for MVWS systems piping shall be taken from firewater hydrant mains.

For process unit area in MSDH section automatic type medium velocity water spray system is considered to exposure protection of all those area where alcohol is flowing liquid.

For automation of MVWS system electric operated deluge valves is considered. The automatic MVWS system includes:

Detection nozzles (QBD) for detection of fire or any other detection system shall be designed in accordance with NFPA 72.

Electrical trim kit of deluge valve for automatic operation of deluge valve.

Deluge valve control panel with associated cabling.


9.2.5 Foam System

Manual foam systems are considered for anhydrous Alcohol Storage tank.

Foam pourer & foam solution piping are considered for all the storage tanks asper NFPA – 11.

Individual foam piping is considered for each foam pourer at each tank. Foam inlet couplings are considered at near road edge by which foam solution are to be supplied inside the tank through Mobile foam tender or mobile foam units.

9.2.6 Fire Detection & Alarm System

Fire detection & alarm system shall be microprocessor based with addressable detectors as per NFPA – 72 requirements. The system shall transmit one common signal to emergency control panel located in the main fire station. Addressable manual call points shall be provided at suitable location in the plant area to activate the alarm signal in case of fire.

Detection system shall be capable to automatically operate MVWS system.

Addressable smoke detectors are considered for the all process area i.e. Fermentation, Distillation & MSDH section admin. Building etc. Manual call points are considered at all strategic points (entry / exit areas) & anhydrous Alcohol storage section.

9.3 Fire Water Piping

i. Underground firewater mains are considered as per ASTM A53 Gr. B with coating-wrapping.

ii. Firewater main size is to be not less 6” (152 mm) dia. However connection to hydrant or fire monitor lateral are considered at least 4” dia.

iii. Above ground fire water pipes required for standpipe system, hose reel system & MVMS systems are considered of A53 Gr.B Galvanised.

iv. For Standpipe system pipe size shall be considered to be 4” dia.

9.4 Valves

The cut off valves shall be butterfly valves, generally conforming to API 609 and shall be listed & approved type. All cutoff valves are considered as post-indicator type.


Chapter – 10

Spares

The spares required for erection & commissioning will be made available by the appointed EPC contractor. List of spares required for 2 years of operation will be submitted along with the EPC bid and the cost will be included.


Chapter – 11

Inspection & Testing

The Contractor will submit Quality Assurance Plan (QAP) and inspection schedule for the equipment covered in this bid for approval, w1thin 15 days of Letter of Intent (LoI). The Owner or representatives of the Owner will attend these inspections at the Contractor’s or sub-contractor’s works and / or give waiver.


Chapter – 12

Drawings, Data & Information

The Contractor will submit list of documents, data & drawings to the Owner for the equipment covered under this section, defining the category like approval or information, within 15 days of LoI. The Owner or representatives will approve the list accordingly.


Chapter – 13

Guaranteed Performance Parameters

Distillery capacity

Ethanol

:

:

65 KLPD Total Spirit (95%V/V)

60 KLPD Ethanol (99.8% V/V)

PlusImpure spirit ( 2.5 %) : 1.6 KLPD (95% V/V)

Sr. No.

Inputs Qty. Specifications

During season

1 Efficiencies & Yield Fermentable Sugar : 10% w/w

A Fermentation Efficiency : 90.0%

B Distillation efficiency : 98.5%

C Dehydration Efficiency : 99.5%

D Yield per Ton of Juice : 60 Litres Total spirit of 95.0 % v/v

56.81 Litres Ethanol of 99.8 % v/v

2 Steam (Total) Dry, Saturated @ 3.5 kg/cm2 (g)At the inlet of respective header

A Juice Pasteurization 24TPD

0.4 Kg/Lit of Ethanol

B Wash to RS Multipressure Distillation

115 TPD 1.9 Kg/Lit of Ethanol

C RS to Ethanol Mol. Sieve Dehydration

36 TPD


D Juice Concentration 210 TPD 3.5 Kg/Lit of Ethanol

E Spent Wash Evaporation 108 TPD 1.8 Kg/Lit of Ethanol


3 Raw Water (Total) M 3/day Raw water will be treated to get process & soft water

A Process Water for fermentation & other utility purpose

100 M3/day

Filtered, Free from sludge, sand, algae, E coli

B Soft Water for Cooling Tower Make-up, Vacuum Pump etc

400 M3/day

Hardness less than 5 ppmTDS less than 50 ppm. Chloride content less than 25ppm.

4 Electricity 960 KW 415 V, 50 Hz, 4 wire supply

A Syrup Storage ---

B Juice Conc. Plant 120 KW

C Juice handling 10 KW

D Fermentation 200 KW

E Distillation 40 KW

F Mol. Sieve Dehydration 15 KW

G Alcohol storage 15 KW

H Utility section 225 KW

I Bio-methanation 75 KW

J Evaporation 150 KW

K Condensate Polishing Unit 80 KW

L Water Treatment Plant 30 KW


Sr. No.

Inputs Qty Specifications

During off-season

1 Efficiencies Fermentable Sugar : 35% w/w

A Fermentation Efficiency : 90.0%

B Distillation efficiency : 98.5%

C Dehydration Efficiency : 99.5%

D Formula for Yield Sugar Content in kg X 0.511 X Eff F X EffD X Effm

____________________________________

0.795 X Alcohol Concentration in v/vWhere,EffF – Fermentation Efficiency in %EffD – Distillation Efficiency in %Effm – Dehydration Efficiency in %

2 Steam (Total) Dry, Saturated @ 3.5 kg/cm2 (g)At the inlet of respective header

A Wash to RS Multipressure Distillation

115 TPD 1.9 Kg/Lit of Ethanol

B RS to EthanolMol. Sieve Dehydration

36 TPD


C Spent Wash Evaporation 108 TPD 1.8 kg/lit of Ethanol

3 Raw Water (Total) M 3/day Raw water will be treated to get process & soft water

A Process Water for fermentation & other utility purpose

800 M3/day

Filtered, Free from sludge, sand, algae, E coli

B Soft Water for Cooling Tower Make-up, Vacuum Pump etc

550 M3/day

Hardness less than 5 ppmTDS less than 50 ppm. Chloride content less than 25ppm.


4 Electricity 845 KW 415 V, 50 Hz, 4 wire supply

A Syrup Storage 15 KW

B Juice Conc. Plant ---

C Juice handling ---

D Fermentation 200 KW

E Distillation 40 KW

F Mol. Sieve Dehydration 15 KW

G Alcohol storage 15 KW

H Utility section 225 KW

I Bio-methanation 75 KW

J Evaporation 150 KW

K Condensate Polishing Unit 80 KW

L Water Treatment Plant 30 KW

Parameters for Condensate Polishing Unit :

Quality of water required after treatment which is to be used as cooling tower make-up water:

PH 7 to 7.5Temperature Deg.C Ambient COD PPM < 100 BOD PPM < 10

60 klpd capacity ethanol plant village sugauli, district...

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