Corrigendum 2 SMR-MED1-CP109-2021L-PT - SAMEER

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Society for Applied Microwave Electronics Engineering & Research

IIT Campus, Hill Side, Powai, Mumbai 400 076

CORRIGENDUM

TENDER NO.: SMR/MED1/CP109/2021L/PT

SUB. : Supply, Installation, testing & Commissioning (SITC

Basis) of HYDROGEN BRAZING/ANNEALING FURNACES

Qty: 02 Nos.

DUE ON : 16/03/2021

Sd/ Purchase officer

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Contents

SECTION - II : TECHNICAL SPECIFICATION ........................................................................................ 3

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SECTION - II : TECHNICAL SPECIFICATION

SCOPE: supply, installation, testing & commissioning (SITC Basis) of Hydrogen Brazing/Annealing

Furnaces and buyback offer for SAMEER old existing H2/Vacuum Furnace at actual for item NO.2

Item No. 01 : Hydrogen Brazing/Annealing Furnace

Size: 200 mm diameter x 300 mm height

Qty: 01

Heating Retort

Sr. No. Required Specifications State

Complied/Not Complied

Mention Deviation if any

1. Configuration Vertically Mounted Cylindrical

Construction

2. Retort (Working

Hot Zone)

200 mm diameter x 300 mm height

3. Material of

Construction

Inconel 600

4. Top Side Welded with dish end

5. Bottom Side Welded with mild steel flange which

will achieve sealing with bottom base

plate.

6. Lifting Hook Retort on the top should provide

with a lifting hook to lift the retort

whenever required.

7. Bottom Plate Bottom plate made of stainless Steel

SS304 with water cooling

arrangement with Viton 'O' ring

provided to achieve sealing with

retort flange

8. Pressure Relief

Valve

Pressure Relief Valve should provide

with a extended Inconel 600 Pipe to

release the excess pressure during

operation.

9. Max Charge 10 Kgs

10. Max. Design

Temperature

1200 C

11. Maximum

Operating

Temperature

1100 C

12. Number of Hot

Zones

03

13. Heating Rate 5-10 C/Min

14. Time to attend

Max. Temp.

110 mins@10 C/Mins

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Item No 02: Hydrogen Brazing/Annealing Furnace:

(300 mm diameter x 750 mm height)

Qty: 01

Heating Retort

Sr. No. Required Specification State

Complied/Not Complied

Mention Deviation if any

1. Configuration Vertically Mounted Cylindrical

Construction

2. Retort (Working

Hot Zone)

300 mm diameter x 750 mm height

3. Material of

Construction

Inconel 600

4. Top Side Welded with dish end

5. Bottom Side Welded with mild steel flange which

will achieve sealing with bottom base

plate.

6. Lifting Hook Retort on the top should provide with

a lifting hook to lift the retort

whenever required.

7. Bottom Plate Bottom plate made of stainless Steel

SS304 with water cooling

arrangement with Viton 'O' ring

provided to achieve sealing with

retort flange

8. Pressure Relief

Valve

Pressure Relief Valve should provide

with a extended Inconel 600 Pipe to

release the excess pressure during

operation.

9. Max Charge 40 Kgs.

10. Max. Design

Temperature

1200 C

11. Maximum

Operating

Temperature

1100 C

12. Number of Hot

Zones

03

13. Heating Rate 5-10 C/Min

14. Time to attend

Max. Temp.

110 mins@10 C/Mins

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ITEM NO.03: BUYBACK OFFER/CHARGE FOR SAMEER EXISTING VACUUM CUM

HYDROGEN FURNACE FOR ITEM NO.02 (H2 FURNACE)

Note: Above buyback offer for item No.2 (H2 furnace) is mandatory and should be

quoted in price bid, failing which tender may be rejected. Bidder may visit SAMEER

IIT Campus Powai Mumbai to inspect old furnace before submitting the offer.

BUYBACK work includes: Dismantling, Packing and Taking away in suitable

transportation old vacuum cum H2 furnace from SAMEER IIT Campus Powai Mumbai

premises.

Technical specifications for Item No.01 & Item No.02

S.N. Required Specifications State whether

Complied/Not

Complied,

Mention

Deviation if any

01 Method of Heating

Heating Bell

Heating Bell should be consisting of Kanthyal APM heating

elements (Strips/rods) arranged in suitable fashion

supported on fibrothal insulation in the heating bell to

achieve maximum operating temperature of 1100 C on the

retort. The heaters should arrange in three zones for

uniform temperature distribution on the retort. Make

proper arrangement to shifting heating bell at rest station

when furnace is OFF. Keep diameter of Heating bell as

smaller as per retort diameter.

02 Heating Insulation

Heat insulation should be of FIBROTHAL Vacuum formed

Board insulation arranged in a circular fashion to avoid

heat loss to the atmosphere. The entire insulation should

be supported on a metal structure, outer case

temperature should be room temperature during

operation of furnace..

03 Furnace Input Power

415 V +/- 10%, 3 Phase, 5 Wires, 50 HZ (Total Power

should be given by party for both the furnaces)

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04 Furnace Casing

The Furnace casing should be fabricated form 6 mm thick

commercial quality MS Plates duly reinforced structural

members make the casing rigid and strong so as to

withstand operational stresses, roof thrust and thermal

expansion. Bottom of the bell should provided with 20 mm

thick MS ring to support the bell while resting on the legs.

05 Temperature Measurement and Control

The temperature measurement and control should be

done by temperature programmable Controller of reputed

make like M/s. EUROTHERM/YOKOGAWA and by 3 Nos. of

PID controller (Salve Controller) to control the hot zone

independently. Each Zone should provide with "K" type

thermocouple to feed the signal to the programmer for

control purpose.

An over temperature controller with "K " type

thermocouple should also provided for over temperature

protection in case of heater failure or Thyristor power

failure for each zone. In total 3 Nos. of over temperature

controllers should provide.

The heating bell should be dividing into three zones of

control. The heating should be through a programmable

controller of reputed make like Eurothem, Honeywell etc

using three phase Thyristor control circuit with isolation

transformer. Provision for manual heating should also

exist. The process controller should be able to compare

the temperature set points with the thermocouple

readings and send appropriate signals to the power

controllers, Digital display of temperature with a

resolution of +/- 1 degree should be incorporate. Provision

for over temperature protection should be available i.e.

over temperature controller to be incorporated.

A process controller should take care of the automatic

sequence of operations and safety interlocks like over

temp, water, gas flow etc.

Also list out the safety interlocks that are proposed to

incorporated in the normal mode of operation.

Proper interlock should work at failure of any of the input.

The time to attend the Max operating temp 1100

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Centigrade should be around 110 mins. however provision

for varying the heating rate to say about 5 to 10 Deg

centigrade per minutes should also be available. The ramp

& soak should be controlled.

The schematic of the proposed electrical wiring form the

mains to the furnace should be indicated.

06 Support Structure

Support Structure made of Mild Steel should provide to

support the Retort and heating bell. The top support plate

made of chequered plate should have approx. dimension

to supported with mild steel channels.

07 Job Hearth Support/Plate

1) Job hearth plate should be mount on rod made Incone-

600l and 200 mm dia plate made Inconel-600 to take job

load 10 Kg. should be provided, It should be easily

demountable. Max Charge 10 Kgs. (FOR ITEM NO.01 Small

Furnace)

2) Job hearth plate should be mount on rod made Inconel-

600 and 300 mm dia plate made Inconel-600 to take job

load 40 Kg. should be provided, It should be easily

demountable. Max Charge 40 Kgs. (For ITEM NO.02 Big

Furnace)

for both furnaces below the support plate heat radiation

shields made of Molybdenum of 1 mm thick 3 Nos and 2

Nos. SS shield should be provided. ((Additional shields may

be provided the temperature of base plate, based on

thermal calculation)

Proper clamping arrangement should be provided

between Retort and base flange to avoided leak during

operation.

The entire Hearth Support should be support on the

bottom plate. Provision should be made to adjust the job

support plate with bottom radiation shields.

An Inconel-600 tube should be provided to introduce

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Hydrogen/Nitrogen into the Retort. Also Flexible "K" type

thermocouple should provide to check the job

temperature. Also provision to made on Control Panel to

monitor mili-volts signals to monitor temperature during

operation.

08 Atmosphere Control

The furnace should have provisions for the flow of

nitrogen and hydrogen gases through

programmed/manual valves and preset flow meters ( 5 to

100 Ltrs/mins) . The sequence of operation in case of

N2 floe: 5 to 60 Ltrs/Mins for purging

H2 Flow: 5 to 45 Ltrs/Mins during Operation

1) Loss of Hydrogen pressure in the chamber or

2) Power failure during operation should be clearly

mentioned

The furnace should have a N2 purge, H2 purge followed

brazing operation again N2 purge And power OFF.

The Ignition sequence for the hydrogen burn-OFF should

given.

The safety precautions to be mentioned, should the flame

be inadvertently extinguished. The Igniter should be

automatically tested to assure proper operation each time

run is started.

All gas plumbing and components should be of stainless

steel, high quality, and high-pressure standard fitting.

09 Furnace Control Panel

The control panel should be an independent unit which

should house PID controllers, Process controllers,

Ammeters, Voltmeters, Mimic Diagram, fault indicating

lamps, Ckt breakers, Fuses, Thyristor Ckt, audio alarms,

visible indications for furnace ON etc. The components in

the control panel should be reputed make like Siemens,

ABB or equivalents.

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10 MONO Rail System (Hoist Crane)

Suitable weight capacity Monorail System for both the

furnaces should consists of horizontal and vertical structures

fabricated from "C" channels and vertical channels should

grout to the ground. On the horizontal channels motor with

brakes and two speed arrangement (Micro & Normal speed

controlled on hand paddle switch). Overhead chain hoist pulley

block should provide for upward and downward movement

and also for the horizontal movement to lift and move the

heating bell to rest station and also to lift the retort up & down

for job loading and unloading.

Refer As per attached Drawing

11 JOB REST STATION

Rest Station for both the furnaces should be provided to keep

heating bell during job loading in furnace.

12 Gas Inlet System

Gas Inlet System should consist of SS Manifold, Which should

be connected to the Hydrogen and Nitrogen Cylinders with 2

Stage regulators (SAMEER Scope). The outlet of the manifold

should provide with manually operated isolation valves,

solenoid operated valve, flow meters (adjustable) for

Hydrogen and Nitrogen having flow range 5-100 ltrs/mins. All

stainless steel plumbing lines and fittings with pressure gauge,

pressure switch should be connected to the bottom base plate.

13 Hydrogen Flow System:

At the outlet end glass bowl should be provided with

resistance heater igniter & thermocouple. The resistance

heater ignites the output coming hydrogen and burns it. The

temperature of the hydrogen flame should be sensed by the

thermocouple & indicated on a digital temperature

indicator/controller. If flame gets OFF, the temperature given

signal & alarm start with H2 inlet solenoid valve to close, and

immediately the emergency N2 line solenoid valve to open

automatically to purge the Retort with N2 to dilute the H2

concentration.

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14 Power Supply

This whole furnace should be wired to operate on 415 VAC, 3

Phase, 50 HZ with Power neutral & Ground connections. The

maximum power consumption should be informed by vendor

for both the furnaces. A suitable triple pole mains fuse isolator

should be provided between the furnace & mains power

supply.

Isolation Transformer should be provided in heating Circuit.

15 Water Supply

Water cooling connections should be provided for electrical

feed through, flanges, O-Rings, Bottom plate, and other

components wherever required. with water pressure 3 to 4

Kgs/cm2

16 Emergency automatic solenoid valve operated N2 supply

During power failure there should be provided an automatic

solenoid valve operated N2 pursing for furnace. Automatically

H2 Supply stop and N2 Supply start during Power failure. After

Power resume again H2 line should open & N2 line stop.

17 SAFETY ISSUE

1) The Furnace shall be in conformance with all applicable

electrical, fire & safety standards.

2) The furnace shall be fitted with alarm devices for over

temp/any input failure. The Maximum temp should be settable

from the control panel.

3) The various safety interlocks incorporated should be listed

out.

4) The event of power failure during brazing operation, the

precautions that should be taken shall be listed out. The

sequence of operation after resumption of power should be

mentioned.

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18 Bidders are required to furnish following technical documents

1) Detailed description of furnace with drawing (Technical Bid)

2) General arrangement drawings of the furnace.

3) A picture of similar furnace

3) Detail descriptions of each component and sub components

5) Footprint of the entire furnace system.

6) Detailed descriptions of SAMEER's responsibilities for the

site preparation

7) Detailed descriptions of the safety issues addressed and

suggested by the vendor.

8) Testing plan

9) Maintenance & service

11) Shipment plan

State Yes/No

Special Terms & Conditions

The work consists of design, fabrication, delivery, installation, commissioning (SITC

Basis) of furnaces at SAMEER IIT Campus, Powai Mumbai as per specifications

given in this document.

1) Only after approval of the engineering drawings from SAMEER for both the

furnaces, the fabrication of furnace should commence.

2) The entire furnace operation should be demonstrated to the rated specifications

and for proper functioning of all the subsystems as per design. Only after this, the

furnace will be cleared for dispatch to SAMEER, IIT Campus, Powai, Mumbai.

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3) Delivery, unloading at SAMEER, Installation & commissioning of the furnace is to

be done at SAMEER, IIT Campus, Powai Mumbai, also clearly indicate installation

time after delivery of furnaces at SAMEER IIT Powai Mumbai.

4) The entire furnace operation should be demonstrated again at SAMEER IIT

Campus, Powai Mumbai.

5) Two sets of operating instructions & maintenance manuals should be provided.

Training to operate the furnace should be provided to at least three Engineers from

SAMEER at vendor site.

6) Please quote for minimum critical spares, which may be procured to meet

contingencies.

7) Quotation should be clear and wherever necessary options may be quoted.

8) All Govt levies & taxes and any other charges should be clearly indicated.

9) Indicative drawing of both furnaces attached for reference.

For any technical clarifications , you may contact following SAMEER Officials.

1. Mr. Chandrakant Nainwad, Scientific Officer-SE 022-2572 7204

2. Mr. R Krishnan, Scientist & HOD MED1 022-2572 7125

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Information required for Vendor Evaluation – To be submitted with Technical Bid

The Vendors will be evaluated by the team of experts from SAMEER based on the

essential requirements of vendor’s qualification as laid down below. Only on

satisfactory conditions of evaluation the bid will be considered. It is important to

note that this is one of the qualifying criteria.

Bidders are required to indicate whether the required information is furnished by

stating Yes / No in the remarks column.

The detail information as asked is to be furnished on the separate sheets.

A. Company Profile REMARKS

1 Name of the Organization:

Website:

2 Name of the Contact Person:

Name:

Address:

Telephone:

Fax:

E-Mail:

YES/NO

3 Year of Incorporation:

YES/NO

4 Type of Organisation

(Public Sector/Limited/Private Limited / Partnership / Propritery

/Society / Any Other):

YES/NO

5 Address of the Registered Office:

YES/NO

6 Number of Offices with addresses (Excluding Registered Office):

India

Abroad

YES/NO

7 Certificate of registration as a manufacturing unit

YES/NO

8 Permanent Account Number

YES/NO

9 GSTN:

YES/NO

10 Status of ISO9001/IS013485 Certification

YES/NO

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VENDOR QUALIFICATON: ESSENTIAL REQUIREMENTS REMARKS*

A. Vendor should have adequate manpower to undertake this work

The manpower strength at various levels to be furnished

a. B.E. / B.TECH.

b. DIPLOMA

c. SKILLED TECHNICIANS

d. UNSKILLED

YES/NO

B. Vendor should have adequate manufacturing facilities for part and subassembly

fabrication related to this work.

The list of machine tools and other electrical/electronic equipments available

to be furnished.

YES/NO

C. Vendor should have adequate inspection and quality control facilities for this work.

The list of quality control instruments available to be furnished.

YES/NO

D. Vendor should have adequate space for undertaking this work.

Available space – Covered & Open to be furnished.

YES/NO

E. Vendor should have sound financial back ground and a proven record. They should

have taken up similar or more complicated jobs and executed successfully.

List of five assignments done in last three years to be enclosed.

Enclose copies of purchase orders.

Audited Balance sheet of last three years to be furnished.

YES/NO

F. List of minimum 5 customers to be furnished by the Vendor for whom similar work

has been satisfactorily completed.

Give complete address & Telephone Number of the contact person

YES/NO

G.The industry should have service engineers to attend service calls for this

unit. The service network to be furnished.

*Strike out which is not applicable

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1) PHOTO OF H2 FURNCACE (EXISTING IN SAMEER)

2) JOB LOADING HERTH PLATE WITH LIFTING DOME

Corrigendum 2 SMR-MED1-CP109-2021L-PT - SAMEER

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