sludge drier specs

Extract from Tender Document

The following summary of work is extracted from thetender document.

2 SUMMARY OF WORKS

2.1 The Scope of Works of Contract EP3 comprises, but is not necessarily limited to,the supply of personnel, labour, plant, materials, equipment, tools, services andeverything necessary for the design, sizing (where not specified), factory testing,finishing, painting, packing, transportation, loading and unloading, insurance,taxes/duties, storage, installation, testing and commissioning including operationand maintenance training for the Sludge Drying Systems and all associated worksfor the CWRP as detailed on the Drawings and in the Specifications as may bereasonably inferred from the Contract Documents.

2.2 The Drawings show the conceptual general arrangement of the major equipmentto be used as a guide by the Contractor. This arrangement is not intended to depictthe construction details of the final installed system, but to provide guidelines forthe Contractor's design, manufacture and installation of the Sludge DryingSystems. The Contractor may submit variations from the equipment layout shownin the Drawings subject to the conditions and requirements set out in theSpecifications.

2.3 The Works shall include but not necessarily be limited to:-(a) Five (5) dryer feed systems complete with de-watered cake bin, wet

material dosing and transfer screws, recycle bins and dosing screws, andmixers, and dryer feed screws.

(b) Five (5) dryer thermal systems comprising furnaces, burners, rotary drums,saturators, exhaust fans, and regenerative thermal oxidisers.

(c) Five (5) dry solids separation and classification system comprising pre-separator/polycyclones, induced draft fans, rotary valves, vibratingscreens, surge bins, roller mills and dumpster.

(d) Five (5) dried product cooling and conveyance systems comprisingproduct coolers, recycle coolers, recycle and recycle transport screws,recycle bucket elevators, rotary valves, recycle feed screws, and productdense phase pneumatic conveyance systems.

(e) Five (5) ACMV exhaust fans.

(f) Three (3) chilled glycol and dehumidification systems.

(g) Dried product storage and load-out system comprising four (4) productstorage silos complete with screw conveyors and load-out chutes, andmineral oil storage, feed, and unloading systems.


(h) Dewatered cake transport, storage and unloading systems comprising maintransport screw conveyors, centrifuge collection screw conveyors, cake binfeed screw and distribution screw conveyors, dewatered cake storagehoppers and dischargers.

(i) Dust control system comprising process bag-house with rotary valves andexhausters, silo bag-house with rotary valves and exhausters, and dustdense phase pneumatic conveyance system.

(j) Dry vacuum system comprising exhausters, separator/bag-house/ rotaryvalve and bulk bag loader.

(k) Interconnecting piping and ductwork between Sludge Drying Systemequipment and process and utility piping to connect to the Sludge DryingSystem from designated interface points, including pipe support systems,valves, insulation, and piping specialities.

(l) Electrical systems from designated feed locations, including completemotor controls with adjustable frequency drives and double-ended MCCswith power for each application provided from each side of the busbreaker. All interconnecting electrical work from electrical supply sourcesto equipment, to include power and control cabling, conduit as requiredand raceways.

(m) Instrumentation and control systems for monitoring and control of thesludge drying systems and for interface with Plant Monitoring and ControlSystem. Includes local instrumentation, panels and control stations whereappropriate, communication hardware and cabling and all ancillarymaterials to comprise a complete control system.

(n) Steel floor and platforming systems to provide contiguous floor systemsthroughout the designated drying area of the Solids Building, matchingconcrete floor levels designated for construction by the C4B Contractor,and to provide and facilitate equipment maintenance access for allequipment requiring servicing.

(o) Equipment maintenance hoisting systems throughout the drying area of theSolids Building to serve all critical lifting functions as designated in theSpecifications.

(p) Lighting systems, ACMV ductwork, fire sprinkler system and hose reelsystems throughout the dryer area of the Solids Building and where notedin the Specifications.

(q) Personnel safety systems, including explosion suppression systems for theSludge Drying Systems.


(r) Concrete plinths for equipment bases including the supply and installationof connectors, such as anchor bolts (cast in-situ or grouted), expansionbolts, base plates, connection bolts, nuts and washers, supports, brackets,spacers, wedges, shims and spacers including all grouting or othermaterials necessary for levelling, alignment and securing all plant andequipment installed under this Equipment Supply and InstallationContract.

(s) Installation, factory testing, site testing and performance testing andoperation during the commissioning period of all plant and equipmentfurnished and installed under this Equipment Supply and InstallationContract.

(t) Supply of all essential spare parts and special tools, including consumableitems and spares as specified under this Equipment Supply and InstallationContract.

(u) Fulfil Defects Liability obligations for all plant and equipment installedunder this Equipment Supply and Installation Contract for a minimumperiod of two (2) years.

(v) Provision of Servicing & Maintenance Services and Operation Services toall plant and equipment installed under this Equipment Supply andInstallation Contract for a minimum period of two (2) years with an optionto be exercised by the Employer to extend the period for a maximum oftwo (2) more years.

(w) Provision of Shop Drawings, As-constructed Drawings and Operation andMaintenance Manual.

(x) Provision of necessary classroom and hands-on training to Employer'spersonnel.

(y) Provision of professional services (including fees) and submissions, whererequired, for application and obtaining necessary approvals by theQualified Person employed by the Employer from relevantgovernment/statutory authorities to comply with local requirements.

(z) Co-ordination and co-operation with other onsite contractors in liaisonwith the S.O., including, but not limited to, the contractors for ContractsC1A (Foundation Works, Site Development and Management), C4B(Solids Building, Civil and M&E Works), C4C (Digesters, Civil and M&EWorks), C5A (Monitoring and Control Systems), and EP7 (Centrifuges).

2.4 The scope of the Contractor's design for the Sludge Drying Systems shall includebut not be limited to the following:


(a) Process and mechanical design of all systems that make up the SludgeDrying Systems, including preparing mass and heat balances, processdescriptions, process and control narratives and process flow diagrams.Mechanical equipment design shall be in accordance with Specifications inDivision 15 Mechanical.

(b) Complete and systematic evaluation of potential hazards and safetyrequirements and implementation of measures to mitigate these hazardsand meet the safety requirements. A safety report shall be prepared, whichshall list all hazards and safety requirements identified in the evaluationand identify how these are addressed in the designs. The hazardevaluation and safety report shall be prepared by a consultant (or firm)who is:(i) qualified for and normally engaged in hazard evaluations(ii) a Singapore Professional Engineer(iii) knowledgeable in Singapore codes and standards(iv) conversant with Ministry of Manpower safety compliance

requirementsThe Contractors design shall incorporate the recommendations andrequirements of the safety report.

(c) Sizing and selection of all equipment.(d) Final layout of all equipment. The general equipment configuration shall

be as shown on the Drawings but equipment locations may be adjusted tocompensate for differences between the equipment to be supplied and thatshown on the Drawings, to adjust for process differences that may existfrom that shown and to optimise the operability and maintainability of theprocess.

(e) Sizing of equipment pads and design and layout of equipment anchor boltsand anchoring systems.

(f) Design and layout of supports for, but not limited to, equipmentappurtenances, conduit, piping, ductwork, cable trays and stacks.

(g) Routing of all associated piping and ductwork, and cable trays within thesystem. Routing shall interface with the piping, ductwork, conduit, cabletrays, etc. not included as part of the Sludge Drying Systems anddesignated on the Drawings as system interface locations and as identifiedin the supplement of Section 01040 Co-ordination.

(h) Insulation of hot surfaces to limit heat rejection to the space as specifiedhereinafter.

(i) Noise abatement provisions to limit facility noise to specified levels.

(j) Confirmation of sizing for wall, floor, and roof penetrations required forpiping, ductwork, stacks, conduit and cable trays.


(k) Structural design of all metalwork to include structural steel, platforms,stairs and points of interface with the building structure. Design completeequipment access platforming systems to include stairways, grating andhandrailing. Equipment-specific access platforms must be at least 1.5metres wide and must be accessible from the concrete or steel primaryfloors or by stairs. Design of equipment and platforming systems shallallow adequate access for operations and maintenance in accordance withSection 11100 - Rotary Dryer System.

(l) Design for equipment maintenance provisions for disassembly, hoisting,and subsequent movement of equipment for maintenance purposes.Schedule of Major Equipment Maintenance Requirements, provided as asupplement in Section 01750 Servicing and Maintenance, describesminimum maintenance functions requiring permanently installedprovisions for hoisting and movement of equipment and components.Provisions for hoisting and movement of equipment may include bridgecranes, monorails, jib cranes and lifting eyes with hoists.

(m) Complete electrical system design, including design of motor controlcentres, transformers, distribution panels, switchboards, panelboards,raceways, all required wiring and cable tray sizing and layout and supportthe overall harmonic interference study with requested data on equipmentsupplied. Electrical system design shall be in accordance with Section16000 Electrical.

(n) A complete instrumentation and control system design, including processand instrumentation diagrams (P&IDs), Input/Output (I/O) lists for allphysical and virtual values utilised, instrument lists for all monitoring andcontrol devices (including ranges and settings), control panel layouts,control panel elementary diagrams, control wiring diagrams, controlsystem block diagrams, configuration of all programmable controllersoftware, conforming HMI software configuration and interfacinghardware and software to the plant-wide Monitoring and Control System(MCS) per specified methods & protocols.

(o) Complete design for the fire sprinkler system located within the areasdescribed in these Specifications. The sprinkler system design shall beendorsed by the Professional Engineer Board, Singapore in the mechanicaldiscipline.

(p) Final engineering drawings for structures included in the Sludge DryingSystems shall be designed by the Contractors Professional Engineer. Thedesign shall be certified by an Accredited Checker employed by theEmployer.

2.5 The Contractors design, supply and installation work shall specifically complywith Singapore Standard CP 27 : Code of Practice for Factory layout.


2.6 The Contractors equipment system shall comply with Singapore Standard CP 27 :Code of Practice for Factory layout, Section 2.4. Where a person maybe exposedto excessive noise exceeding 85 dBA, the Contractor shall be responsible todesign, supply and install one or more of the measures listed in Section 2.4.2 ofthe Standard.

2.7 The Contractor shall ensure that all plant, equipment, materials and goods areprovided in a new condition. They shall be stored, installed, applied, connected,erected, protected, used, cleaned and conditioned in accordance with theSpecifications and instructions of the applicable suppliers and manufacturers.

2.8 In addition to the Contractors normal obligations during construction, he shallalso be responsible for:

(a) Use of the 3D Model and Database, including updating the 3D Model andDatabase to as-constructed condition

(b) Updating drawings not extracted from the 3D Model including process andinstrumentation diagrams (P&ID) and single line electrical drawings

(c) Using the 3D Model layout tools provided by the S.O. to maintain theModel

(d) Using the 3D Model to perform interference checks against all objectswithin the 3D Model including checking for interferences with othercontract package 3D models related to the Contractors Works as providedby the S.O.

(e) Complying with and using the Project CAD standards(f) Complying with electronic submittal requirements as defined in the 3D

Model and Database Project Instructions(g) Conforming to Project defined Document Management Practices

2.9 The Contractor shall undertake all other activities specific to the Contractincluding:

(a) Additional data and information acquisition(b) Agency liaisons(c) Design approvals(d) Temporary works(e) Other ancillary work as may be required for the completion of the work as

shown on Drawings or specified