NTPC Limited
(Domestic Competitive Bidding)
Bidding Document No: 100088519
NTPC invites on-line bids from eligible Bidders for aforesaid package, as per the scope of work briefly mentioned hereinafter:
Date:01.02.2014
NIT No: 40019032
1.0
(A Government of India Enterprise)
Badarpur Thermal Power Station
NOTICE INVITING TENDER (NIT)
FOR
PROCUREMENT OF WEAR COMPONENTS(HI-PERFORMANCE GRINDING ROLLS AND BULL RING
SEGMENTS) FOR XRP-783 BOWL MILL
2.0
Brief Details
01.02.2014 18:28:46
Source of IFB/NIT
Document Sale Commencement Date & Time
Last Date and Time for Bid submission
Document Sale Close Date & Time
Badarpur Thermal Power Station
NIT Date
40019032
01.02.2014
09.05.2014 17:00:00
NIT No.
22.05.2014
Pre-Bid Conference Date & Time (if any)
Cost of Bidding Documents in INR
Last Query Date (if any)
EMD in INR
Bid Opening Date & Time
2,363.00
10.06.2014 15:00:00
Contract Classification
Equipment Supply
23.05.2014 13:00:00
321000.00
Technical Opening Date & Time
23.05.2014 13:00:00
A complete set of Bidding Documents may be downloaded by any interested Bidder on payment (non-refundable) of the cost of
4.0
Bid Security and Integrity Pact (if applicable) shall be submitted in a sealed envelope separately offline by the stipulated bid
3.0
the documents as mentioned above in the form of a crossed account Payee demand draft in favour of NTPC Ltd., Payable at NEW
filled in questionnare for issue of vendor code and SRM user id/password.
submitting a questionnaire available at our SRM site as well as at NTPC tender site (
www.ntpctender.com). First time users not
submission closing date and time at the address given below. Any bid without an acceptable Bid Security and Integrity Pact (if
applicable) shall be treated as non-responsive by the employer and shall not be opened.
logging on to the SRM Site, the bidder would require vendor code and SRM user id and password which can be obtained by
allotted any vendor code are required to approach NTPC at least three working days prior to Document Sale Close date alongwith duly
DELHI or directly through the payment gateway at our SRM Site (https://etender.ntpclakshya.co.in/sap/bc/gui/sap/its/bbpstart). For
TOGETHER).
WEAR COMPONENTS FOR XRP-783 BOWL MILL (GRINDING ROLLS -3NOS. & 1 SET OF BULL RING SEGMENTS
5.0
ITEM DESCRRIPTION:
Brief Scope of Work & other specific detail
---------------------
THIS BIDDING FOR WEAR COMPONENTS IS FOR 120 THOUSAND RUNNING HRS.
WEAR COMPONENTS FOR XRP-783 BOWL MILL (GRINDING ROLLS -3NOS. and 1 SET OF BULL RING SEGMENTS
TECHNICAL SPECIFICATION FOR PROCUREMENT OF WEAR PARTS FOR XRP 783 COAL PULVERISERS
The intent of the specification is to procure #wear parts# (Grinding Rolls and bull Ring Segments etc.) for XRP # 783 type coal
pulverisers of BHEL Make operating at NTPC- Badarpur.
1.0.0 Intent Of The Specification
REVISED TECHNICAL DETAILED SPECIFICTION:
------------------------------------------
TOGETHER).
It is not the intent to specify completely herein, all aspects of material selection and manufacturing process, nevertheless, the wear
parts shall conform in all aspects to high standards of material quality, manufacturing process and workmanship and shall be capable
of performing in continuous commercial operation, in a manner acceptable to the owner, who will interpret the meaning of
specification, drawings and shall have right to reject or accept any work or material which in his assessment is not complete to meet
the requirement of this specification.
2.0.0 Project Information
Stage-2 : 2X210 MW
Name of the Station NTPC - Badarpur
No. And size of Units Stage-1 : 3 X 95MW
should not be conditional with respect to the Operation and Maintenance practices at the station.
to carefully examine and understand the specification and seek clarifications, if required, to ensure that they have understood the
Bidder is requested to visit NTPC Badarpur site to assess the operating conditions before submitting the offer. They are also requested
specification. The Bidder#s offer should not carry any sections like clarifications, interpretations and/or assumptions. Also, the offer
Stage 2 : 6
Stage 2 : XRP-783
Type of Coal Pulverisers Stage 1 : 300/579 Ball Mills
3.0.0 Applicable Drawings
No. of Coal Pulverisers per Unit Stage 1 : 3
Rated Capacity Of Bowl Mill : 36.6t/hr.
Mill Motor : 335 Kw,6.6 KV, 990 RPM
The drawing listed below and forming part of the specification are for Bidder#s information. All these drawings are only indicative of
Owner#s requirement to enable the Bidder to make a suitable offer. It shall, however, be responsibility of the Contractor to ensure
Any variation/alteration from the listed drawings shall be clearly brought out in the technical deviation schedule with implications, if
i. Drawing No. : BTPS-210-B-94-712 Grinding Rolls
ii. Drawing No. : BTPS-210-B-92-702 & BTPS-210-B-92-703M Bull Ring Segments
fitment of the supplied material.
The scope the proposal shall include manufacturing, testing, packaging, transportation, delivery on F.O.R (Badarpur) basis of wear
parts of XRP # 783 type coal Pulverisers installed in 2*210 MW Units comprising of the following:
any. Such variations may be acceptable, after assessment of its implication and shall be subject to Owner#s approval.
ii. Bull Ring Segment
4.0.0 Scope of the Proposal
i. Grinding Rolls
iii. Any other component necessary to meet guarantee requirements/performance
the guaranteed wear life of the grinding rolls and bull ring segments over stipulated period of pulveriser operation i.e. 10000 hrs., the
their adequate quantities and if same become necessary for installation and/or satisfactory operation of the pulveriser and/or to achieve
additional components for the same. In case Bidder's proposal does not include the additional components mentioned above and/or
familiarize himself with the design of specified pulveriser model, its grinding rolls and bull ring segments and requirement of
complete period of wear life guarantee of 10000 Hrs of pulveriser operation for each pulveriser. It 'is responsibility of the Bidder to
on the pulveriser or to ) replace some of the pulveriser components(other than grinding rolls and bull ring segments) with new
guaranteed wear life of wear parts require some additional components(other than grinding rolls and bull ring segments) to be installed
The scope of proposal shall also include supervision of installation of 1st set of wear parts.
design/material of components, same shall also be included in the scope of supply of the Contractor in such quantities that they last the
Note 1 :- In case the installation and fitment, commissioning, operation, grinding process optimisation and/or achievement of
Contractor will be required to supply the same without any cost implication to the Owner. Pulveriser components which are not
and/or achievement of guaranteed wear life of wear parts offered by the Bidder during stipulated period of 10000 Hrs shall, however,
segments for each of the 12 numbers of bowl mills XRP # 783 type) such that these wear parts are compatible with each other.
pulveriser.
4.1.0 The scope of supply of Contractor shall include supply of mill wear parts, (that is 3 nos.of grinding rolls and one set of bull ring
with adequate quantity of above mentioned additional mill. Components so as to last for 10000 Hrs of pulveriser operation for each
completed by the Contractor only on such date when all the wear parts(all sets of grinding rolls and bull ring segments) are supplied
required to undergo design/material change for installation and fitment, commissioning, operation, grinding process optimisation
be replaced by the Owner as per past established maintenance practice. The delivery schedule of wear parts shall be considered to be
4.2.0 The quantity of wear parts shall be such that 10000 running Hrs of operation of each mill can be achieved with pulverizer
Note 2: One set of wear parts include #3 nos. of Grinding rolls# and # One set of Bull Ring Segment#.
capacity not less than 90% of its maximum capacity at rated finess (refer note 3) for the specified range of coals. The Bidder shall
the set to next higher whole number.
is not less than the number of hours resulting from multiplications of #number of coal pulverisers for which wear part are being
based on guarantee provided by the Bidder for wear life of wear parts) for each set of wear part (i.e grinding rolls, bull ring segments )
procured# X #10000 operating Hrs#. The required Quantity/sets of wear parts shall be arrived at by rounding off the fractional part of
4.3.0 In the bid proposal the Bidder is required to offer the wear parts in such quantities that the cumulative wear life (adding all,
be the basis for calculating the quantity of wear parts. The guarantee for wear parts life shall be in accordance with the guarantee
requirement specified in subsequent sections.
guarantee the life for each type of wear part (i.e grinding roll, bull ring segments) and this guaranteed life of respective wear parts shall
Note 3: The rated fineness not is less than 70 % through 200 mesh.
4.4.0 The wear life guarantee for each type of wear parts shall be from within the range of 2000 Hrs. # 10000 Hrs.The quantity of wear
parts shall be calculated based on guaranteed wear life from within above range only. Life of grinding roll set and bull ring set shall be
the same. An example for arriving at number of sets of wears parts for the purpose of Bidder#s quotation given below at Table - 1:
5.0.0 Evaluation Criteria
The bids guaranteeing wear life less than 2000 Hrs. will not be considered for evaluation and shall be rejected. Further, no evaluation
Bidder in accordance with the clause 4 i.e. #Scope of the Proposal#.
The evaluation of the bids shall be based on the total price of (a) sets of bull ring segments and (b) sets of grinding rolls quoted by the
credit will be given for guaranteed wear life in excess of 10000 Hrs.
6.0.0 Material of Construction
The material of construction of wear parts shall be selected such that wear part offered are guaranteed for wear life.
S. No. Name of Wear Part Material
1. Bull Ring Segments Ni Hard, High Chrome etc.
The material selected by the contractor for the mill wear parts and additional mill components (if, required) must have been used
familiarize themselves with the detailed coal and ash characteristics, if required. No allowance will be given on wear part life on
account of change in coal and ash characteristics except for YGP index. (See clause 8.1 .2 & 8. 3.4)
The range of coal and ash characteristics, which is likely to be supplied to the mills, is enclosed at Annexure - 1. Bidder is requested to
Note 3: The Ni-Hard rolls shall be manufactured using centrifugal casting method.
2. Grinding Rolls Ni Hard, High Chrome, Carbide Insert, Sinter cast type etc.
satisfactorily in at least six(6) numbers of coal pulverizers having similar or higher rated capacity.
7.0.0 Coal Characteristics
The material of construction of wear parts shall be selected taking into account highly abrasive nature of coal resulting from coal
contamination with silica sand and Alpha-quartz. Bidders shall consider the effect of these shale, sand stone and alpha quartz content
Schedule # I
8.1.0 Guaranteed Wear Life
The #each set of wear parts#, i.e. each set of 3 grinding rolls, each set of bull ring segments shall be guaranteed for wear life in
8.0.0 Guarantees
The Bidder shall guarantee the wear life and the fitment of the wear parts in the existing mills and furnish these guarantees in
The quantity of wear parts shall be such that 10000 hrs of operation of each mill can be achieved.
for offering guaranteed wear life of Mill wear parts.
upto the wear as follows:
range of coals during this period (as mentioned by manufacturer in offer). The guaranteed life of wear components shall be considered
number of hours of mill operation with mill capacity not less than 90% of its maximum capacity at rated fineness for the specified
guaranteed wear life for each set of grinding rolls and each set of bull ring segments shall be from within the range of 2000 - 10000
8.1.1 The guarantee on wear life provided for each type of wear part (i.e. Grinding Rolls and Bull Ring Segments shall be same. The
#Operating Hours of mill#. Bidders offering wear life guarantee less than 2000 operating hours shall not be considered for evaluation.
A.. Hours of Mill operation for wear of Grinding Roll element -up to 50mm. at any portion of set.
If either A & B or A or B is not achieved both grinding roll set and bull ring set of the same mill shall be considered for penalty.
B. Hours of Mill operation for wear of Bull Ring segment set- up to 40mm. at any portion of set.
Note : No other factors whatsoever shall be considered for demonstration of wear life provided rated output parameters as in clause
4.2.0 are complied with.
Further, Bidders offering wear life guarantee higher than 10000 operating hours shall not be given any evaluation credit beyond 10000
hrs.
guarantee/warrantee on wear life shall be demonstrated on all the sets of pulverizers (wear parts).
8.1.2 The mill wear part guarantee shall be valid for complete range of coal and ash characteristics specified in this specification. No
correction in guaranteed wear life shall be allowed within the specified range of coal and ash characteristics.
8.2.0 Wear Part Warrantee: - The Bidder shall guarantee the wear life of wear parts in number of mill operating hours. The
maximum capacity but not less than 90% of maximum mill capacity at mill fineness not less than 70% through 200 mesh.
The material and design of bull ring segments shall be so selected by the Contractor that their replacement coincides with the
replacement of set of grinding rolls.
The Guarantee/warrantee for the life of mill wear parts shall be demonstrated by the Contractor during the Guarantee Trial
8.3.0 Demonstration of Pulverisers Wear Part Guarantee:-
Note 4 : -Operating Hours of mill for the purpose of wear parts warrantee are defined as hours of mill operation at or near to its
Period (GTP). The GTP shall commence after successful operation of the Pulverisers established continuously for a period of not less
than 12 hrs at or near to 36.6 tonnes/Hr capacity and fineness not less than 70% thru 200 mesh with the newly installed wear parts.
8.3.1
the practice in vogue at the station. The Mill loading will be monitored on daily basis, the Fineness on weekly basis and wear depth
during every Preventive Maintenance of the Mill. Each Type of wear part (i.e. set of grinding rolls & bull ring segments) shall be
considered to have completed their guaranteed/warranted wear life when any of the following conditions occur.
8.3.2 The performance of the pulveriser shall be monitored on regular basis w.r.t Loading, Fineness, Wear depth of wear parts as per
a) The actual wear depth reaches the guaranteed wear depth for Rolls (Average wear of 3 rolls in the set) and/or bull ring segments.
guaranteed wear life (whichever is earlier) in all the Pulverisers. However, in case the wear parts are supplied in more than one lot,
the Pulverisers Wear Part Guarantee demonstration as per the above shall be repeated for each lot of wear parts.
The GTP shall end as soon as first set of grinding rolls and first set of bull ring segments have completed their actual wear life or the
8.3.3 Further in case any of the wear parts has worn out to such an extent that either the normal or safe operation of the Pulverisers is
41.6 amps)
b) Mill loading capacity falls below 36.6 Tons/Hr due to restriction on Mill amperage . (Maximum allowable Mill motor current is
8.4.0 Liquidated damages shall be levied for shortfall in wear life of wear parts for each type of wear parts separately.
then the part shall be deemed to have outlived its wear life.
not meant for the purpose of checking the shortfall in wear life, even if there is no reduction in Pulveriser rated capacity or fineness,
Note: 5 No allowance will be given for Operation and Maintenance practices while applying this criteria under normal conditions.
jeopardized if this part is not replaced/ repaired or continuous use with this part may lead to exposure or wear of other parts which are
If it is found that any of the wear parts viz. Grinding Rolls & Bull Ring segments have achieved life of 50% or less than the
successful fitment & trial operation clearance will be given for bulk supply
SAMPLE CLAUSE :- Bidder has to supply Two sets of wear components as sample for fitment at site. After getting clearance of
9.0.0 Quality Assurance & Inspection
guaranteed wear life the vendor shall replace the wear parts free of cost .For wear life between 50 % and 100% the penalty of one and
Bidder.
half time the pro-rota landed cost of short fall in duration will be charged.
8.6.0 Fitment Guarantee
Fitment of the supplied material in the identified Pulverisers is the responsibility of bidder and same shall be guaranteed by the
out by the manufacturer, during various stages of manufacturing, for NTPC approval. The quality Plan shall be accompanied with all
shall also submit a detailed manufacturing quality plan in the format enclosed at Annexure # II detailing out the tests/checks carried
9.1.0 Bidder shall provide the necessary information on Quality Assurance Program containing the overall Quality management and
Procedures, which the Bidder proposes to follow during various stages of manufacturing of the specified wear parts. The contactor
the entire plan standards, reference documents, acceptance norms, procedures and specifications. The indicative tests/checks, which
iii. Wear # resistant parts shall be UT/RT tested to check soundness after suitable heat treatment. In case of bi-metallic castings, UT
shall necessarily form part of the Quality plan, are as follow:
v. Surface defects of the wear resistant parts shall be examined by DPT.
ii. Mechanical properties and measurement of hardness.
shall be carried out for ensuring the proper bonding.
iv. Metallurgical test: Micro-structure examination will be carried out on samples selected at random.
i. Chemical Composition and heat treatment.
case of bull ring segment trial assembly shall be carried out for each set on the test bowl.
9.2.0 The approved Quality Plan shall indicate NTPC witness points ( customer hold points) for which the contractor shall give 15
Schedule # I : Guarantee Declaration, Schedule # II : Technical Data Sheets, Schedule # III : Information Regarding Quality
days inspection advance notice for undertaking inspection.
vi. To ensure proper fitment at site each grinding roll shall be subjected to blue-matching check for proper bore surface contact. In
Assurance Plan, Schedule # IV : Schedule of Rates and prices, Schedule # V : Delivery Schedule.
QUALITY CHECKS :
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Note: The technical specification includes following forms which need to be duly filled by the Bidder and submitted along with the
bid:
4. During PDI / Stage Inspection, all the material having chemical composition of Alloy steel / Stainless Steel / Non Ferrous metal,
2. Detailed QAP (NTPC format) along with acceptance norms, to be submitted along with the offer for approval from BTPS (FQA)
1. Detailed Drawing/ Data-sheet/ Specifications along with detailed Bill of material (if applicable) to be got approved from indenter.
6. All material should bear manufacturer identification including part no/catalogue no/model etc.
5. Vendor is to submit Test, Guarantee & Fitment certificate during inspection.
shall be checked for chemical composition using XRF Analyzer and the same shall be arranged b the vendor. After receipt of material
and Indenter.
3. Material to be checked at vendor's works as per approved QAP, Drawing, Data-sheet & Specifications.
at BTPS Store, one again shall be checked using XRF Analyzer and same shall be arranged by NTPC / BTPS.
EARNEST MONEY DEPOSIT (EMD) : Bid Security in the amount of Rs. 3,21,000/- (Rupees Three Lac Twenty One Thousands
No Interest shall be paid on EMD. Offers without EMD are liable for rejection.
In case of DD/Banker#s cheque, same should be payable at Delhi in the favour of NTPC Ltd.
DELIVERY SCHEDULE : Supply shall be taken in four lots i.e. one every quarter within 01 year.
100/-non judicial stamp paper.
In case of Bank Guarantee, the same should be valid for 225 days from the date of Bid Opening and BG should be executed on Rs.
Only).
Or
Contract Performance Bank Guarantee (CPBG): 10% of order value to be deposited by the firm which valid till the end of guarantee
period of last set plus 03 months claims time.
Security Deposit (SD) : S.D.
@5% of order value to be deposited by the firm and shall be released after completion of supplies.
Reverse Auction Rules : Reverse auction shall be done in this case for which base price & decrement with other details shall be
decided after price bid opening.
FOLDER.
6.0
Prospective bidders from U.P. State are compulsorily required to provide TIN number at the time of purchase of bidding
1.4 OR 1.3 & 1.4:
Qualifying Requirements for Bidders:
7.0
documents.
ALL OTHER DETAILED DOCUMENTS OF TENDER ENQUIRY ARE ATTACHED IN COLLABORATION FOLDER.
QUALIFYING REQUIREMENT
REVISED TECHNCIAL DETAILED SPECIFICATION ARE ATTACHED IN COLLABORATION FOLDER ---> AMENDMENT
1. Qualifying requirement: The bidder should meet the qualifying requirements stipulated here under in clause 1.1 & 1.4 OR 1.2 &
1.1 The bidder should be regular manufacturer of vertical type coal pulverizers and should have supplied such pulverizers to at least
two coal fired units, each of 200 MW or higher capacity, located at two different power stations and which are in successful operation
---------------------------
chrome type) offered by him and should have supplied at least 150 nos. of 36 inch or higher size such type grinding roll for
ii) Bidder should either himself or through a company / agency in which he has controlling stake, own following manufacturing &
chrome type or sintered cast type rolls / weld overlay) as well as bull ring segments (cast Ni-hard type or carbide insert type or high
XRP/Raymond bowl type of coal pulverizer during last three years.
AND
testing facilities for use by the bidder for manufacturing of the grinding rolls as well as Bull Ring segments, (Bidder to furnish proof
for at least two years as on date of bid opening with the same type of grinding rolls (Centrifugally Cast Ni Hard type or carbide insert
1.2 i) The Bidder should be a manufacturer of the type of grinding rolls (Centrifugally cast Ni hard type or carbide insert type or high
OR
type or weld overlay / high chrome type or sintered cast type rolls, using one or more grinding roll sets) as offered by the Bidder.
b. Centrifugal Casting machine (in case manufacturing process involves centrifugal casting)
c. Machining facility for inside bore.
of ownership of the facilities along with his bid):
Manufacturing Facilities
c) Micro structure testing
Other Facilities
a. Induction / Cupola / Induction Arc Furnace for melting iron of capacity 1.0 Ton and above.
a) Chemical Composition testing (Spectrometer / Spectrogram)
Testing Facilities:
b) Magnetic particle testing machine.
b) Ultrasonic testing machine to check tread to core bond
c) Inside Micrometers to check inside taper measurements.
Ni-hard or Carbide insert or hi-chrome type) for which his collaborator is qualified. In such a case bidder along with his collaborator
cast Ni-hard or Carbide insert or weld-overlay or high chrome type or sinter cast type) as well as Bull Ring Segments (i.e. Cast
should have manufacturing and testing facilities as per 1.2(ii) above and shall offer only the type of grinding rolls (i.e. Centrifugally
a) Hardness testing
d) Check Bowl / Test Bowl to check the ring bull ring segments of XRP -783.
1.3 The Bidder should be a regular manufacturer of grinding rolls as well as Bull Ring Segments for vertical type coal pulverisers and
OR
should have supplied 50 (fifty) numbers of grinding rolls for vertical type coal pulverisers and should have an ongoing collaboration /
license agreement with a manufacturer who meets the qualifying requirements as stipulated at Clause 1.2 (i) above. Further Bidder
Performance Security to be furnished by the bidder.
submitted along with the bid, failing which the bidder shall be disqualified and his bid shall be rejected. In case of award, the
offered by him jointly and separately, as per the format enclosed in the bid documents. The joint deed(s) of undertaking shall be
shall furnish a Joint Deed of Undertaking (JDU) for successful supply and performance of the Grinding Rolls and Bull Ring Segments
collaborator will be required to furnish on demand, Bank Guarantee for 1.5% of the total contract price in addition to the Contract
1.4 The average annual turn-over of the bidder in the preceding three (3) financial years as on date of bid opening shall be not less
than Rs. 480.80 lacs and must have experience of having completed / executed similar work of single order value not less than Rs.
128.21 lacs OR Two orders each of value not less the Rs. 80.13 lacs OR Three orders each of value not less than Rs. 64.11 lacs in the
last seven years.
vertical type coal pulverisers and of the type bidder is going to quote for the present bid.#
the preceding seven (7) years period even if the contract has been started earlier and / or is not completed / closed.
b) The clause # 1.4 above the #Completed / executed# means the bidder should have achieved the criteria specified in the QR within
Issuance of Bidding Documents to any bidder shall not construe that bidder is considered qualified.
8.0
9.0
a) The clause # 1.4 above the word #Similar Work# shall be defined as #The supply of Grinding Rolls and Bull Ring Segments for
Note:
Sr. Manager(Pur)
Gireesh Kumar
Badarpur Thermal Power Station
Badarpur, New Delhi - 110044
NTPC reserves the right to reject any or all bids or cancel/withdraw the NIT for the subject package without assigning any
reason whatsoever and in such case no bidder/intending bidder shall have any claim arising out of such action.
10.0 Address for Communication
011-26949161, 26941358, 26943495
9650994011
011-26944493
NTPC Limited