ROTARY KILN ELECTROSTATIC PRECIPITATOR (ESP) OR BAG FILTER RETROFIT TURNKEY PROJECT 

 

1 SCOPE OF WORK

 

This document details the Vendor’s role in the project, including the scope of services and the scope of supply. The Vendor should quote for ESP and or Bag Filter separately.

 

1.1  Scope of Supply

 

1.1.1        All equipment shall be supplied complete and operational including all necessary accessories and the incorporation of all miscellaneous material, minor parts and other such items whether or not the items are indicated in the specification, where it is clearly the intention that they should be supplied or where they are obviously required and necessary to complete and commission the work.

1.1.2        Safety features

Temperature sensors

CO2 monitor

1.1.3        The battery limits are from the Rotary Kiln Smoke Chamber to the last Textile Compensator immediately after the ESP discharge Hood. (Refer to attached sketch for Existing Structure to be Replaced)

1.1.4        The design shall be retrofitted within the available space. (Refer to attached sketch for the plan of structure to be replaced)

 

 

1.2  Scope of Services Included

 

1.2.1        Detailed mechanical, electrical design and engineering based on the details specified in this document, the datasheet provided.

1.2.2        Procurement and expediting of all material

1.2.3        Fabrication/manufacturing of equipment.

1.2.4        QA/QC to ensure that all manufacturing processes comply with the design requirements

1.2.5        Insulation, Lining

1.2.6        Delivery to site, Ndola Lime Company,

1.2.7        All erection materials such bolts,

1.2.8        Supply of all documentation as detailed

1.2.9        Vendor to supply 12 months warranty for the equipment and workmanship subjected to the service.

1.2.10              Erection of all equipment, Supervision during commissioning and start-up of equipment within battery limits on site including travelling and accommodation.

1.2.11    Supply of electrical transformers and all electrical accessories

1.2.12    Supply of field instruments and lists with tender, including the manufacturer and model number of the equipment.

1.2.13    Lagging.

 

1.3  Scope of Services Excluded

 

1.3.1        All electrical cabling from the MCC up the terminal points of the Supplier’s equipment.

1.3.2        All instrumentation cabling up the terminal points of the Supplier’s instrumentation.

1.3.3        Mobile/Tower Crane

1.3.4        Scaffolding.

 

 

2        DESIGN AND CONSTRUCTION

 

2.1  Design Details

 

2.1.1    The Vendor shall submit a tender for the ESP and or Bag Filter, the following is a applicable: All design specifications, drawings and test procedures.

2.1.2        No deviations from listed standards and specifications shall be accepted, except those clearly stated and agreed upon deviations in Vendor’s initial quotation. Any deviation shall only be accepted where an approved concession has been obtained beforehand.

2.1.3        The ESP design emission of dust shall be < 50 mg/Nm3.

 

2.2      Materials

 

2.2.1        Materials used in the fabrication of all components shall be new.

2.2.2    Defects in any material shall not be repaired by welding without the prior written approval by NLC.

 

2.3      Codes, Standards and Specifications

 

2.3.1        The ESP/Bag Filter design will conform to the requirements of all relevant BS standards,  Mine & Minerals Act (1995) (Zambia) and all national, state, provincial and local codes and regulations applicable to the plant and equipment.

2.3.2                     Typically BS reference codes, standards and specifications that shall be applicable (not restricted to) in the design of the ESP /Bag Filter are listed below as per categories & sub- categories:

Occupational & Personal

 

 

 

 

 

2.4               Site Data - Ndola Lime Company

 

2.4.1        Site elevation: 1 286 m sea level

 

2.4.2    Air temperatures: Max. 40 ºC

 Min.  0 º C

 

2.4.2        Wind:   < 100 km/h

2.4.3        Relative Humidity: < 80 %

2.4.4        Electrical Supply - Ndola Lime Company

o   Medium voltage : 11kV

o   Low voltage: 550 V

o   Frequency: 50 Hz

o   Control voltage:

2.4.5    Instrumentation: 230 V - AC; 24 V – DC

Measuring transducers: 230 V 

 

 

2.7   QA and QC Inspection

 

2.7.1    NLC shall reserve the right to inspect, examine and /or test all material and services at any and all reasonable times and places of manufacture/ fabrication.

2.7.2        The Vendor shall prepare a Quality Control Plan for supply of the ESP as per the requirements of this engineering requisition.

2.7.3        The Vendor and their sub-Vendors shall operate a quality system in accordance with ISO 9001, as a minimum and is responsible for quality control inspections.

 

2.8      Fabrication

 

2.8.1        All fabrication tolerances shall be as per the relevant BS standard.

2.8.2        All welding shall be done and qualified in accordance with the relevant BS standard.

2.8.3        Flame cutting of anchor bolt holes is not acceptable. These shall be drilled.

2.8.4        The ESP shall be free of geometric irregularities resulting from poor manufacturing practices and careless handling.

2,8.5    All load bearing supports or items subject to impact or oscillating loads such as baffles, if welded directly to the shell, shall be attached by means of full penetration welds.

 

2.9      Documentation

 

2.9.1        All documents shall be signed off by the Vendor’s originator and competent checker prior to submission.

2.9.2        All documentation shall be submitted to the NLC, clearly stating the reason for the submission and the intended recipient.

 

 

2.10        Identification

 

2.10.1   The equipment shall be clearly identified by painting or dye stencilling the purchase order number and tag number on the shell, head or supports.

2.10.2 The ESP/Bag Filter shall be equipped with securely attached stainless steel nameplates

 

2.11  Drawings and Data Requirements:

 

2.11.1 The Vendor shall submit drawings and data in accordance with the requirements of the “Vendor’s Drawings and Data Commitment” form attached.

2.11.2 All data shall be provided in the English language.

2.11.3 Certified drawings to be submitted are not limited to those indicated herein. The Vendor shall add to the “Vendor’s Drawing and Data Commitment” as he deems necessary to cover all aspects of engineered equipment for design evaluation purposes.

2.11.4 The Vendor shall be required to add drawings, any reasonable notes, clarifications or other data required by NLC. Standard drawings will normally not be acceptable without changes.

 

 

2.12  Standardising of Equipment

 

2.12.1 The listed vendor brands are preferred by Ndola Lime Company to be used in the ESP/Bag Filter.

 

Type of Equipment Brands

Electric Motors Siemens Soft Starters Siemens, Varispeed Gearboxes Flender, FL Smidth (FLS) Rigid Couplings John Crane Powerstream Bearings SKF, FAG Instrumentation ABB, Honeywell & Foxboro

 

2.12.2 If the Vendor proposes an alternative brand in their tender, the brand must be totally locally supported in South Africa and/or Zambia.

 

2.13  Process, Design & Operating Performance

 

2.3.1       A process guarantee shall be provided as per emission level as stated in the design  

                specification.(See VDRL)

2.3.2    ESP/Bag Filter design life as per process conditions shall at least 20 years or more.

2.3.3    ESP/Bag Filter operations shall be 365 days continuous with a plant availability of 97 % at least.

 

 

 

 

 

3.  VENDOR DATA REQUIREMENTS LIST (VDRL)

 

 

Item	Description	Parameter	Unit
1	Volumetric Gas Flow Rate	3750	Nm3/min
2	Gas Temperature	375	° C
3	Inlet Dust Burden	22	g/Nm3
4	Emissions	< 50	mg/Nm3
5	Water Content	18.9	Vol.%H2O
6	Dew Point	55	DP deg C
7	Operating Pressure	-100	mmWG