Delhi Jal Board Tender

Automatic Chemical Dosing System PART: I, CONCEPT OF ISASMAC : Provisioning, installation and commissioning and 1-year O&M of an Intelligent Self-Administered and Self-Monitored Automatic Chemical dosing system (ISASMAC) is required at 20 MGD Nilothi Sewage treatment plant (having designed parameters 30 TSS and 50 BOD) to achieve the BOD and TSS below 10-10 mg/ltr with the chemical dosing of Poly Aluminum Chloride solution/ coagulants. Concept of ISASMAC: It will be Intelligent Self-Administered and Self-Monitored Automatic Chemical dosing system to reduce the pollution load with Poly Aluminum Chloride or any other coagulant. The system is engineered that it will not only adjust the dosing of coagulant with the flow but also predict maintenance required in the system. The system will dose the coagulant in Raw Sewage (after grit chamber and before PST inlet) to reduce pollution load up to minimum desired levels as mentioned below and additional dosing in mixed liquor (After aeration and before FST) to get BOD and TSS levels below 10-10. The system will be integrated with software for real time monitoring of dosing, health of the system, predictive maintenance, integration with LIMS, pollution load reduction etcetera as per detailed of software available in the specifications. The software will be able to do AI based calculations in future to access best dosing patterns for better pollution load reduction. General Requirements The successful bidder will provide the equipment as per specifications and installed the dosing system as per drawing that will be approved by the DJB and commission the dosing system. Vendor will also operate and maintained the dosing system for 1 year as per conditions laid down in this document. The dosing system will include following features other than the reduction of turbidity, TSS and BOD 1. Quantified Chemical Receipt from Tanker 2. Real Time Chemical Stock reporting 3. Automated Chemical mixing facility 4. Automated Chemical transfer 5. Sewage Flow Monitoring 6. Chemical Dosing proportionate to the Sewage Flow 7. Dozer will have 5 dosing patterns to handle varying sewage quality 8. PLC based Control System supporting Auto and Manual mode of operation 9. HMI for local display and control 10. Monitoring Health and Condition of all Electrical devices in the System 11. Predictive maintenance of equipment 12. Necessary Redundancy supporting non-stop operation 13. Error Logging to self-introspect the issues and plan for corrective action 14. Cloud based Data Storage and Analytics 15. Provision to accommodate real time raw sewage and discharge quality input 16. Software featuring as per details and specifications attached 17. Integration of hardware and software to have AI based analysis for future dose planning and improvement in the STPs PART-II: Inventory List Intelligent Self-Administered and Self-Monitored Automatic Chemical dosing system (ISASMAC) Inventory List Dosing System After Aeration Before FST Item Qty 1 HP Pump - Chemical compatible 1 Chemical Flow Meter 1” 1 Chemical Tank 10000 Liters 10 Non-Contact Level Sensor 1 Dosing Pump 220 LPH - Chemical compatible 2 Channel Stirrer with 5 HP Motor 1 Panel Enclosure 1 Programmable Logic Controller (PLC) 1 Human Machine Interface (HMI) 1 Equipment Health monitoring device 2 IoT device 1 Cloud Service with SCADA and AI Software 1 Piping + Cable Tray 1 Cables and Accessories 1 Others · Automation System Programming · Cloud Service with SCADA and Artificial Intelligence Software · Civil Works · Installation and Commissioning · Training PART-III :SPECIFICATIONS: HARDWARE REQUIREMENT 1. Electromagnetic Flow meter Flow Sensor Coil housing : Fully welded SS316 Liner : PTFE Working Pressure : 14 bar Working Temp : 60 deg C Electrodes : Tantalum Grounding type : Rings Grounding MOC : SS316 Process connection : Flanged to ANSI#150 Flanges : SS316 Area classification : Safe Area Protection class : IP 67 Flow Transmitter Mounting : Wall Mounting Type : Microprocessor Based Communication : 4-20mA/HART + Pulse + Modbus RTU Accuracy : ± 0.5 % of measured value Max load : 500 Ohms Display : Large back lit graphic Display Parameters : Actual flow rate, totalized flow (8 digit), flow direction, flow velocity Diagnostics : Empty pipe detection, Noise, Flow profile Local indication : Programmable Power supply : 85 - 250 V AC, 50 Hz Housing : Die cast Aluminum Cable entry : M20 X 1.5 Area classification : Safe Area Protection class : IP 65 / IP66 2. Dosing Pumps · Nominal Flow Rate @ 50 Hz : Nominal Dosing Requirement x 2 · Number of dosing head : 1 · Non return valve type : Not spring loaded · Max Viscosity : 150 mPas · Dosing Head : PP · Type of inlet connection : Welding · Operation Voltage : 3 Phase · Pump Housing : Aluminium · Electrical Enclosure : IP65 · Stroke Control : Manual and Analog Input · Make : Grundfos / Milton Roy 3. Non Contact Level Sensor Measuring Principle : Radar (10 GHz) Frequency Modulated Continuous Wave Sensor Type : Antenna Material of antenna : PTFE Measuring distance : 5 mtr Accuracy : ± 5 mm max. Temperature range : -20 to 150 Deg C Process connection : G2 inch Threaded Display : 64 x128 pixels LCD with 4 button keypads display on side Power supply : 24 VDC Output : 4-20mA/HART Housing : Aluminium with PU Coating Cable entry : M20 x 1.5 Protection class : IP66/67 Area classification : Non-Hazardous area SIL2-compliant according to IEC 61508 for safety-related systems 4. Open Channel Flow Meter Flow Sensor Measuring Principle : Ultrasonic Level Sensing Area classification : Safe area Process connection : G 1.5 inch threaded Electronics : 2 wire 4 – 20mA Housing/Protection : Plastic / IP 66 Cable entry : ½” NPT Indication module : Top mounted LCD display Measuring Range : up to 15 meters Process Temperature : - 40 to 80 Deg.C. Process Pressure : up to 1 Bar Flow Transmitter Power supply : 230 VAC Input : 4-20mA Display : 5 Digit (Instantaneous), 8 Digit (Totalizer) Communication : Modbus RTU & 4-20mA Mounting : Panel mounted Transmitter Power supply : Available 5. Panel Enclosure · MOC : 1.5mm Sheet Steel · Surface finish : Dipcoat Primed, Powder coated · Mounting Plate : 3mm thickness with Zinc plated · Door : 2 mm thickness with Hinges and Lock · Gland plate : Bottom Entry · Protection Class : IP66 · Protection Category : NEMA4 6. PLC · Digital Input : 20 · Digital Output : 8 · Analog Input : 10 · Analog Output : 4 · Communication : Modbus · Network : TCP/IP · Power Supply : 24VDC · Memory : Integrated 100 Kb · Supporting Protocols : PROFINET / SIMATIC / Open IE / Web Server · S7 routing : Required · Ethernet Protocols : TCP/IP, SNMP, DCP, LLDP · Vibration Resistance : IEC 60068-2-6 · Shock Testing : IEC 60068-2-27 · Access Protection : Read, Write and Complete 7. Chemical Storage Tank · Cylindrical Shape · Vertical Placement · Closed Top · Flat Bottom · Chemical Resistant 8. Pipe and Pipe fittings · The pipe and fittings will be Chemical, High temperature resistant (up to 93 degree centigrade) of required sizes · The pipe material will be CPVC and as per schedule 40 & 80 of ASTM F441 and fittings as per schedule 80 of ASTM F439 · The OEM must meet requirement of cell class 24448 · The fittings must be high thermal resistant (up to 93 degree centigrade) · The pipe will be of low thermal conductivity and immune to galvanic and electrolytic attack 9. Auto On/Off Valve ACTUATOR APPROVALS : ISO 9001: 2008, CE, IEC, CMRI CHARACTERISTIC : ON‐OFF TYPE TRAVEL : 90° INDICATOR : CONTINUOUS POSITION INDICATOR PHASE : SINGLE PHASE POWER SUPPLY : 220V AC, 50HZ BODY MATERIAL : ALUMINIUM ALLOY AMBIENT TEMP : 0° C ~ 80° C MOTOR POWER : CLASS F PROTECTION CLASS : IP67 ‐ WEATHER PROOF LIMIT SWITCH : 1 NO + 1 NC OUTPUT OF 220V AC POSITION ON POWER FAILURE : STAY PUT VALVE VALVE BODY & BALL : FULL PORT, ON/OFF TYPE, 2 PIECE DESIGN, 2 WAY BALL VALVE BODY : SS 316 BALL : SS 316 WORKING TEMP : UP TO 180° C WORKING PRESSURE : 10 BAR MANUFACTURING STANDARD : BS – 5351 BASIC DESIGN COMPLIANCE : ASME / ANSI B 16.5 PRESSURE RATING : ASA 150 # TESTING CODE : BS – 6755 / ANSI B 16.5 END CONNECTION : FLANGE END 150# LEAKAGE CLASS : CLASS VI SEAT & SEAL : PTFE TEMP UP TO 180ᵒ C 10. Tank Stirrer with Gear and Motor Agitator Blade (MOC) : Alloy 926 Agitator Shaft : Rubber Lined Fastener : AISI 316L Motor : 3 Phase 440V Operated Motor Protection Class : IP55 Gear Box : Vertical Flange mounted Solid Shaft type 11. Chemical Pump Material : PVDE & PTFE Head : up to 10 meter Max Flow Rate : 70 LPM Power Supply : 3 Phase, 440 V Type : Magnetic drive 12. Channel Stirrer with Motor Agitator Blades (MOC) : Alloy 926 Agitator Shaft : Rubber Lined Fastener : AISI 316L Motor : 3 Phase 440V Operated Motor Protection Class : IP65 Gear Box : Vertical Flange mounted Solid Shaft type 13. Human Machine Interface Display Size : 7 inch Display Type : TFT Color widescreen display Resolution : 800 x 400 pixels Control Elements : Touch Screen User Memory : 12 MB Interface : RJ45, RS485, USB, SD Card Protection Class : IP65 14. Health Monitoring Device Temperature Sensing - Fast response surface sensing with Rugged lamination construction and Polyimide, silicone rubber or Mylar™ insulation Vibration Sensing - piezoelectric acceleration sensors Wired communication with PLC 15. IoT Device Analog Inputs : 4 Digital Inputs : 3 Digital Outputs : 2 Field Communication : RS232 / RS485 for Modbus Data Acquisition Server Communication : Supports HTTP, MQTT and FTP protocols Internet Connectivity : GSM / GPRS Remote Configuration : by SMS and Server Commands Firmware upgrade : Wired and Over the Air SOFTWARE REQUIREMENT As part of the complete project, the system will comprise of AI driven software to connect dosing system along with the health information of all the electrical & mechanical devices at a common platform. The software should be customized and or configured as per the requirements of the DJB, incorporating the features for its integration with the relevant modules of our upcoming systems at the plants and of laboratories such as OIML, LIMS etc. The selected vendor will provide technical support for the operation of the software too as per mutually agreed Terms and Conditions. The selected organization shall also be responsible for the complete turnkey operation of the system (including software) to ensure a minimum of 99% uptime availability of all the applications under this project and shall hand over the operation and management of it to the DJB in accordance with the time-frame and conditions whenever required to do so. The software shall have the following features: · The primary purpose of the software will be to bring together dosing system data including health condition of E&M devices, asset knowledge, and AI-based-analytics to help DJB get the most out of the system. · The software should allow monitoring the system units, health and utilization of the dozing system and critical assets with an intuitive, color-coded dashboard. · The software should show all the historical plant health and system utilization charts provide insights into how the system is performing over time. · The software should be designed in such a way that it is scalable for integration with multiple dozing systems at DJB plants as brought out under the folds of the DJB in future · The software will be exhaustive and specially designed for dosing system. It will monitor the dosing system and its equipments, show data, analyze and convert into applied results. · It will calculate the oxygen requirements in the aeration tank to neutralize the pollution load remain after the intervention of dosing and before dosing and thereby it will calculate the electrical savings. · Energy Savings Calculator · It will calculate the reduction in pollution load after intervention of dosing. · The software must also be able to fetch operational parameters like SVI, Sludge age etc on the basis of DJB’s Laboratory analysis and must also suggest measures for the better treatment required after dosing. · The software must calculate F/M ratio and auto-suggest MLSS for the better operation of the plant. · The software must be capable of AI. It may be capable of studding the dosing system and pattern and based on data may suggest best dosing. The software will also have entry system of Lab report of PAC supplied. · The software will have preventive maintenance plan and will keep all records of preventive maintenance and repairs done and also give advanced alarm. · Configurable for the coverage of new products & processes · The software should present the monitoring parameters to be received from dosing system: o Chemical Receiving Flow and Totalizer o Chemical Storage Tank Level o Transfer pump Run Status o Raw Sewage Flow and Totalizer o Dosing Pump-A Run Status o Dosing Pump-B Run Status o Dosing Quantity o Dosing Mode - Auto or Manual o System Operation Status o System Error Code o Energy Parameter values · History or log management (to ensure that all the actions or events are stored in the system and can be referred when required) · Web & Mobile App o Web enabled software, integrated workflow management with data-updating on centralized server o The software will be responsive web as well as be available on mobile app. The software should be accessible from any browser or mobile device. o Responsive solution capable of working on mobile platforms. · The Dashboard o There will be dashboard to the system and be able to show the important data in numeral-graphic. o The software must be such that it can be stitched to other dosing systems of DJB so at one platform all systems can be watched. o The dashboard will be specific to the hierarchy. · Reports o The software will generate reports and graphs on following § Laboratory Analysis reports for the parameters tested specific for dosing system § Operation data reports § Chemical Consumption report § Data of working, jerks, non-functional system/equipment § Maintenance done § Preventive/Predictive maintenance § Health data of E&M equipment § Complaint data and record § Non-functional history of each equipment and system § Pollution load reduction § Flow Vs Chemical Consumption § Flow Vs Chemical Consumption Vs BOD-TSS reduction § All other reports as required by Lab or engineering wing o Export tool to export or generate reports in other formats like csv, excel, etc. · Data Analysis o The software must be able to do data analysis and will also have AI tools for better run in future. o The software will analyze and perform analysis of chemical consumption and will show: § Per day consumption of dosing Chemical at average pollution load at average flow § Per month consumption at average pollution load at average flow § Total consumption at average pollution load at average flow § Consumption at peak flow § Consumption of dosing chemical at lean flow § Maximum, minimum consumption of dosing chemical o AI-driven Health Score and report generation o Data Analytics facility o The software will show real time animated visualization of the dosing system. o The software will also indicate all parameters like Heat Signatures, RPM, Voltage, Current, etc real time fetched from E&M equipment installed in the dosing system. o The software will also analyze health of various E&M equipment and in case any maintenance is required it must give alarm in advance based on data fetched from sensors put on electrical and mechanical devices. · Inventory Management o The software will have inventory management for chemical consumption. · Complaints Management o Provision for handling of Complaints o The software will also have complaint lodging and redressal management system. · User Management o The software should have User Management with various access levels. · Events & Notifications o The software will send SMS and e-mails of functioning of system and daily reports o The software should push automated alerts, track the health of the critical assets and notify incase of any unfavorable event from anywhere by regular automated notifications (sent through email or in-app notifications). · Security & Data Encryption o Security of data including encryption o All of the data paths – between the dosing system, cloud and applications – should be authenticated and fully encrypted. All the connection requests should always be initiated by the dosing system to prevent any type of inbound threats. · Technology o Technology used should be capable of being updated or aligned with advancements in future o Preferable open source solution · Connectivity o Provision to communicate through a reliable 3rd-party cellular gateway which uses the cellular network for data connection to the cloud server. · Integrations o The dosing system software should be capable to integrate with LIMS, IoT or OLMS. o APIs § The software should support REST APIs to enable storing and retrieving of dozing system. The APIs should have secure authentication to ensure that only authorized users or programs can access and update the data. · Hosting o Hosted on the cloud server or as decided by the DJB and able to meet all necessary security audits · The IoT devices mounted on the system should work together with the software in such a way that the remote configuration of the devices using SMS and server commands is possible · The same can be updates through over the Air firmware upgrade Platform: The Vendor will also construct a platform for storage tanks, wherever required. The platform will be made with reinforced cement concrete and will be designed to bear the load of 100 tons and the floor will be coated with chemical-resistant epoxy. The platform will have epoxy coated MS grill of around 5’ height and gate for entry to the storage platform. Firm will also make a control room to have an enclosed panel and on-site monitoring system. The room will be minimum of 10’X12’ and air-conditioned with 42” monitor. Firm will also be responsible for esteemed cleaning of premises and horticultural activity in and around its site.