B.V.F.C.

L, NAMRUP
MATERIAL PURCHASE REQUISITION
INDENT NO: N-III/Mech/2014/66AINDENTED BY:
NAME : P K Barkataki
DESGN. : APE (M)
DEPT. : Mechanical
PLANT : Ammonia-III

215.

(Signature of Indentor)

Date: 05-04-2014
1. NATURE OF MATERIAL (ITEM)
A. (
) EQPT/MECH. B. ( ) SPARES
C. (
) CONSUMABLE
2. NAME OF EQPT./MECH : SGC HE-3,HE-4 and
HE-5 of A-III plant
3. NO. OF SUCHEQPT/MCH IN PLANT:- 03

(TO BE FILLED UP IN CASE OF B & C ITEMS ONLY)

1. MATERIAL CODE

2. V.E.D. CATEGORY: Essential

4.

NO. OF SPARES REQD FOR EACH EQPT/MECH

5.

STATIC OR DYNAMIC: Static

3. UNIT OF MEASUREMENT: As per Annexure-I 6.

CATEGORY :( ) RST ( ) SST ( ) INSURANCE

( ) INDIGENOUS ( ) IMPORTED
( ) PROJ/CONS. ( ) PROPRIETORY

1. DESCRIPTION & DETAILS : S.S. U-Tubes for 3rd stage cooler(HE-3), 4th stage cooler( HE-4)
and By pass cooler( HE-5) of Synthesis Gas Compressor of A-III plant as per our scope of supply
enclosed at Annexure-I
2. COST ESTIMATE
3. LIFE IN RUNNING HRS

: ` 23,96,000.00
: -----

4. AVERAGE ANTICIPATED CONS RATE

(PLANT WISE)

: N/C

5. WHETHER SIMILAR OR EQV. MATERIAL

IS AVAILABLE IN STORES/ AS SURPLUS
IN OTHER UNIT/DIVISION.

: NIL

JUSTIFICATION AND TIME OF CONSUMPTION:

These tubes are required for replacement of
existing damaged tubes of above critical condenser. Also, the subject item is not available in store
hence emergency.
COMMENTS OF DGM-I

INVENTORY CONTOL CELL

REMARKS:

COMMENTS OF GM (O & M) / OSD

APPROVAL OF CMD:
( ) APPROVED
( ) NOT APPROVED

INDENT TO BE FORWARDED TO PURCHASE: YES/NO

IF YES, ENSURE:
1. BIN CARD OPENING

) DONE

2. MASTER CREATION IN COMPUTER ( ) DONE

DATE :

(Signature )

(To be submitted in duplicate along with every indent for items other then inventory controlled)

Brahmaputra Valley Fertilizer Corpn. Ltd.,

Namrup
(To be filled by the Indentor)
Indentors Ref. : N-III/Mech/2014/66A- 215.
Date : 05/04/2014
Budget Head:
Main Head
R & R (Sl. No )
a) Sub Head
b) Cost Code
3052

MATERIALS INDENT
SEAL
(Emergency)
(To be filled by Inv. Control Section)
M.I.No.
Date.

To

1. Annex.-I (Total scope of Supply)

2. Annex.-II (Technical terms
conditions)
3. Drawings 05 (five) nos.
4. Annex-III-Justification for
procurement
5. Annex-IV-Payback period analysis
6. Annex.-V (Cost Estimate)

51

&

Prev
P.O.
ref

23/08/2013AN/2013/66A-2065/8866/JB/0417 Dt.

3
For Amm-III Plant
Seamless S S U-tubes for 3rd stage
cooler(HE-3), 4th stage cooler( HE4) and By pass cooler( HE-5) of
Synthesis Gas Compressor as per
our scope of supply enclosed at
Annexure-I
Encl.:

As per Annx.-I

2
Adhoc

basis. These items will be

` 23,96,000.00

Materials Manager (Inventory Control)

Please arrange to purchase the following items on emergency
consumed immediately after the materials are available in stores.
Delivery required: By an early date
S Code Description of the Item
Unit Qnty. App
l
/
Rqd.
Cos
N Folio
t
0 No.
(`)

*Av
mtl
y
con
pn
8

Present stock
with
Indr.
Stores

N/C

NIL

10

NIL

Justification for the Emergency Purchase: These tubes are required for replacement of existing
damaged tubes of above critical condense. Also, the subject item is not available in store hence
emergency.
Countersigned with Seal by:
Forwarded to Materials Manager
Signature of the Indentor:
(P) to procure the materials on
Emergent basis as per Delivery
Schedule.
ACE(M), A-III & CPP
..
Name:
P.K. Barkataki
Materials Manager (I.C.)
CE(M), N-III

Designation: APE (M), A-III

Department: Mechanical

Notings: 1 ) Enquiries to be sent only to reputed heat exchanger tube manufacture

2) Along with other parties, following parties may please be contacted for procurement of
the item:1) M/s Ratnamani Metals and Tubes Limited
2) M/s Choksi Tube Company Limited
3) M/s REMI Tubes
4) M/s Sandvik Tubes
5) M/s Ratnadeep metal & tubes Limited, Mehsana.
6) M/s Heavy Metals & Tubes Limited, Mumbai

7) M/s Jindal Saw Limited, Chennai.

8) M/s Shekasa

Annexure-I
Ref: N-III/Mech/2014/66A-215.

SCOPE OF SUPPLY
A. Complete U-tube for Synthesis Gas Compressor (1.41CR1/HE3)of A-III plant
(Drawing NO- N/III/Mech/722)
Code
Adhoc

B.
C.
D.
E.
F.
G.
H.
I.
J.
K.
L.
M.
N.
O.
P.

Description
Seamless S S U-tubes
Material: ASTM SA-213 TP 304 ( OD x Thk x Deviation length)

Qty. Reqd.
Mean bend
Radius

nos.

Size: 19.05

+0.05
+ 3.00
+0.10
(OD) mm x 3.0 mm(thk.) x 13518+ 0.00 (length) mm

30

17

+0.05
+ 3.00
+0.10
(OD) mm x 3.0 mm(thk.) x 13574+ 0.00 (length) mm

48

16

Size: 19.05
Size: 19.05

+0.05
+ 3.00
+0.10
(OD) mm x 2.77mm(thk.) x 13631+ 0.00 (length) mm

66

17

+0.05
+ 3.00
+0.10
(OD) mm x 2.77mm(thk.) x 13687+ 0.00 (length) mm

83.80

14

Size: 19.05
Size: 19.05

+0.05
+ 3.00
+0.10
(OD) mm x 2.77mm(thk.) x 13743+ 0.00 (length) mm

101.80

17

+0.05
+ 3.00
+0.10
(OD) mm x 2.77mm(thk.) x 13820+ 0.00 (length) mm

119.80

16

Size: 19.05
Size: 19.05

+0.05
+ 3.00
+0.10
(OD) mm x 2.77mm(thk.) x 13876+ 0.00 (length) mm

137.80

15

+0.05
+ 3.00
+0.10
(OD) mm x 2.77mm(thk.) x 13933+ 0.00 (length) mm

155.80

14

Size: 19.05
Size: 19.05

+0.05
+ 3.00
+0.10
(OD) mm x 2.77mm(thk.) x 14045+ 0.00 (length) mm

173.60

15

+0.05
+ 3.00
+0.10
(OD) mm x 2.77mm(thk.) x 14122+ 0.00 (length) mm

191.60

14

Size: 19.05
Size: 19.05

+0.05
+ 3.00
+0.10
(OD) mm x 2.77mm(thk.) x 14178+ 0.00 (length) mm

209.60

13

+0.05
+ 3.00
+0.10
(OD) mm x 2.77mm(thk.) x 14235+ 0.00 (length) mm

227.60

12

Size: 19.05
Size: 19.05

+0.05
+ 3.00
+0.10
(OD) mm x 2.77mm(thk.) x 13518+ 0.00 (length) mm

245.60

Q. Complete U-tube for Synthesis Gas Compressor (1.41CR1/HE4)of A-III plant

(Drawing NO- N/III/Mech/723)
Code
Adhoc

Description
Seamless S S U-tubes
Material: ASTM SA-213 TP 304 ( OD x Thk x Deviation length)

Mean bend
Radius

Qty.
Reqd.
nos.

Size: 19.05

+0.05
+ 3.00
+0.10
(OD) mm x 3.0mm(thk.) x 13518+ 0.00 (length) mm

30

19

+0.05
+ 3.00
+0.10
(OD) mm x 3.0mm(thk.) x 13574+ 0.00 (length) mm

48

18

Size: 19.05
Size: 19.05

+0.05
+ 3.00
+0.10
(OD) mm x 3.0mm(thk.) x 13631+ 0.00 (length) mm

66

19

+0.05
+ 3.00
+0.10
(OD) mm x 3.0mm(thk.) x 13687+ 0.00 (length) mm

83.8

18

Size: 19.05
Size: 19.05

+0.05
+ 3.00
+0.10
(OD) mm x 3.0mm(thk.) x 13743+ 0.00 (length) mm

101.8

17

+0.05
+ 3.00
+0.10
(OD) mm x 3.0mm(thk.) x 13820+ 0.00 (length) mm

119.80

16

Size: 19.05
Size: 19.05

+0.05
+ 3.00
+0.10
(OD) mm x 3.0mm(thk.) x 13876+ 0.00 (length) mm

137.80

17

+0.05
+ 3.00
+0.10
(OD) mm x 3.0mm(thk.) x 13933+ 0.00 (length) mm

155.80

16

Size: 19.05
Size: 19.05

+0.05
+ 3.00
+0.10
(OD) mm x 3.0mm(thk.) x 13989+ 0.00 (length) mm

173.60

15

+0.05
+ 3.00
+0.10
(OD) mm x 3.0mm(thk.) x 14045+ 0.00 (length) mm

191.60

16

Size: 19.05
Size: 19.05

+0.05
+ 3.00
+0.10
(OD) mm x 3.0mm(thk.) x 14122+ 0.00 (length) mm

209.60

15

+0.05
+ 3.00
+0.10
(OD) mm x 3.0mm(thk.) x 14178+ 0.00 (length) mm

227.60

14

Size: 19.05
Size: 19.05

+0.05
+ 3.00
+0.10
(OD) mm x 3.0mm(thk.) x 14235+ 0.00 (length) mm

245.60

13

+0.05
+ 3.00
+0.10
(OD) mm x 3.0mm(thk.) x 14291518+ 0.00 (length) mm

263.40

10

Size: 19.05

R. Complete U-tube for Synthesis Gas Compressor (1.41CR1/HE5)of A-III plant

(Drawing NO- N/III/Mech/896)
Code
Adhoc

Description
Seamless S S U-tubes
Material: ASTM SA-213 TP 304 ( OD x Thk x Deviation length)

Mean
bend
Radius
20

Qty.
Reqd.
nos.

Size: 19.05

+0.05
+ 3.00
+0.10
(OD) mm x 3.0mm(thk.) x 9518+ 0.00 (length) mm

17

Size: 19.05

+0.05
+ 3.00
+0.10
(OD) mm x 3.0mm(thk.) x 9574+ 0.00 (length) mm

48

16

+0.05
+ 3.00
+0.10
(OD) mm x 3.0mm(thk.) x 9610+ 0.00 (length) mm

66

17

Size: 19.05
Size: 19.05

+0.05
+ 3.00
+0.10
(OD) mm x 3.0mm(thk.) x 9667+ 0.00 (length) mm

83.8

14

+0.05
+ 3.00
+0.10
(OD) mm x 3.0mm(thk.) x 9723+ 0.00 (length) mm

101.8

17

Size: 19.05

Size: 19.05

+0.05
+ 3.00
+0.10
(OD) mm x 3.0mm(thk.) x 9779+ 0.00 (length) mm

119.8

16

+0.05
+ 3.00
+0.10
(OD) mm x 3.0mm(thk.) x 9836+ 0.00 (length) mm

137.8

15

Size: 19.05
Size: 19.05

+0.05
+ 3.00
+0.10
(OD) mm x 3.0mm(thk.) x 9892+ 0.00 (length) mm

155.8

14

+0.05
+ 3.00
+0.10
(OD) mm x 3.0mm(thk.) x 9949+ 0.00 (length) mm

173.6

15

Size: 19.05
Size: 19.05

+0.05
+ 3.00
+0.10
(OD) mm x 3.0mm(thk.) x 10005+ 0.00 (length) mm

191.6

14

+0.05
+ 3.00
+0.10
(OD) mm x 3.0mm(thk.) x 10122+ 0.00 (length) mm

209.6

13

Size: 19.05
Size: 19.05

+0.05
+ 3.00
+0.10
(OD) mm x 3.0mm(thk.) x 10178+ 0.00 (length) mm

227.6

12

+0.05
+ 3.00
+0.10
(OD) mm x 3.0mm(thk.) x 10235+ 0.00 (length) mm

245.6

Size: 19.05

Note:i)

ii)
iii)

These seamless SS U tube are for high pressure critical exchangers, only reputed
parties like M/s Ratnamani Metals and Tubes Limited,M/s Choksi Tube Company
Limited,M/s REMI Tubes,M/s Sandvik Tubes,M/s Ratnadeep metal & tubes Limited,
Mehsana.,M/s Heavy Metals & Tubes Limited, Mumbai,M/s Jindal Saw Limited,
Chennai,M/s Shekasa
may be contacted along with the others who have
manufactured and supplied such type of tube to other PSUs and other reputed
companies with design pressure not less than 200 kg/cm2 can only participate in
the bidding. In this regard following details are required to be provided
a) Name of the organization
b) Reference work order no. & relevant drawings
c) Name & address of the person so that performance can be verified
Party shall stand guarantee for good workmanship and material.
Party shall submit two part bid in two separate envelopes subscribing as
A) Technical and un-price bid
B) Price bid

(P K Barkataki)
APE (M), A-III

Annexure-II
Technical terms & conditions
1) The size and material of tubes shall be strictly as per specification given and no
deviation shall be acceptable. Tubes shall be manufactured as per ASTM A334 Gr-1
and shall meet all relevant requirements of the slandered including testing in
conformance to ASME SA-450. Tubes shall be marked with manufactures name, size,
grade, heat no and surveyors stamp (electro etching) etc. The party shall confirm
compliance for all.
2) The tube shall be made by seamless process and shall be pickled free from scale.
The party should give compliance.
3) Tubes shall be in one piece and shall be formed from single length (with no welded
joints).
4) Party shall arrange stage wise third party inspection by LRIS during manufacturing
and testing shall submit all relevant test certificates along with dispatch documents.
5) All tests shall be in conformance to ASME SA-450. Party shall give compliance for
following shall be submitted.
i)

Tension test.

ii)

Flaring test.

iii)

Hardness test.

iv)

Hydraulic test (for 100 percent tubes).

v)

Flattening test.

vi)

Material of construction.

6) All the tubes shall be blind with plastic caps and packed in wooden crate to avoid
damage during transit. Party shall give compliance.
7)

The tubes shall be finished reasonably and have smooth ends free from burrs, and
shall be free from injurious defects.

NOTE: - In view of our urgent requirement, the parties shall quote minimum
delivery schedule.

(P K Barkataki)
APE (M), A-III

ANNEXURE V
Ref: N-III/ MECH/2014/66A-215.
COST

ESTIMATE

(Basis: Prev. P.O. AN/2013/66A-2065/8866/JB/0417 Dt. 23/08/2013)

Cost of
0.05

20.00

+0.10

+ 3.00

(OD) mm x 2.0mm(thk.) x 6000+ 0.00 (length) mm

Cost of per meter length of SS tube

= `1630.00

Volume of tube= 3.14/4(20x20-2x2) x6000 =1865160 mm3

Weight of SS tube= Sp. Weight x Volume = 8x 10-6 kg/mm3 x 1865160 mm
= 14.92 Kg
Therefore price per kg = `1630.00/ 14.92 = ` 109.24
For HE-3
Considering Maximum length and maximum thickness for 189 SS tubes
Size :
0.05

19.05

+0.10

+ 3.00

(OD) mm x 3.0mm(thk.) x 14235+ 0.00 (length) mm

Volume of tube= 3.14/4(19.05x19.05-3x3) x14235 =3954674.639 mm3

Weight of one SS tube= Sp. Weight x Volume = 8x 10-6 kg/mm3 x 3954674.639 mm
= 31.64 Kg
For 189 tubes
= 5979.96 Kg

Therefore price per kg = `109.24 x 5979.96 = ` 653251------ (A)

For HE-4
Considering Maximum length and maximum thickness for 189 SS tubes
Size :
0.05

19.05

+0.10

+ 3.00

(OD) mm x 3.0mm(thk.) x 14291+ 0.00 (length) mm

Volume of tube= 3.14/4(19.05x19.05-3x3) x14291 =3970232.193 mm3

Weight of one SS tube= Sp. Weight x Volume = 8x 10-6 kg/mm3 x 3970232.193 mm3
= 31.76 Kg
For 223 tubes
= 223x 31.76 Kg = 7082.48 Kg
Therefore price per kg = `109.24 x 7082.48 = ` 773690 ------ (B)
For HE-5
Considering Maximum length and maximum thickness for 189 SS tubes
Size :
0.05

19.05

+0.10

+ 3.00

(OD) mm x 3.0mm(thk.) x 10235+ 0.00 (length) mm

Volume of tube= 3.14/4(19.05x19.05-3x3) x10235 =2843416 mm3

Weight of one SS tube= Sp. Weight x Volume = 8x 10-6 kg/mm3 x 2843416mm3
= 22.74 Kg
For 189 tubes
= 189x 22.74 Kg = 4297.86Kg
Therefore price per kg = `109.24 x 4297.86= ` 469498 ------(C )
Total amount of HE-3, HE-4 & HE-5 = A+B+C =653251+773690+469498 = `1896439
Considering escalation @ 5% per year = `1991261
Considering fabrication cost for U tube bend and others @ 20% on total amount
=0.20 X `1991261
= 398252.20.
So, total estimated cost U- tubes of SS

= `1991261 + 398252.20
= ` 23, 895,13.2

Say, ` 23,90,000.00 (Rupees twenty three Lakh ninety thousand) only exclusive of taxes

(P K Barkataki)
APE (M), A-III

ANNEXURE III
Ref: N-III/ MECH/2014/66A-215.

Reasons for procurement of SS Tubes

Stage cooler HE-3, HE-4 & By pass cooler HE-5 are major accessories of the Syn
gas compressor and hence, trouble free operation of these Heat exchangers are
essential for energy efficient sustained running of Syn gas compressor.
The tubes of all the above three heat exchangers have started failing. In case of
failure of any of these heat exchangers, complete shutdown of Namrup-III plants
required to be taken. In 2013-2014, already 5 times failure has occurred and it is
anticipated that number of such failure may increase in coming time.
Based upon the above condition of the tubes, it has been decided to procure the
total SS tubes for those cooler to meet any exigency and reliable in all respect for
sustain operation of the plant in full capacity.
Considering above, for sustained running of Namrup-III plants, complete U tube
replacement with of existing HE-3, HE-4 & HE-5 U-tubes are urgently and
essentially require with new one.
Hence indent has been raised
(P K Barkataki)

APE (M), A-III

ANNEXURE IV
Ref: N-III/ MECH/2014/66A-215.

PAYBACK PERIOD ANALYSIS

Failure of Heat exchanger lead to complete halt of Urea production of Namrup-III plant.
The average production of Urea per day

: 1000 MT

The cost of Urea/ MT

: `. 10,809.00

Total cost of production of Urea per day

: ` 10,809.00 x 1000
= Rs. 1,08,09,000.00

Price of Heat exchanger

: ` 2,04,23,000.00

Payback period

: ` 2,04,23,000.00
1,08,09,000.00
= 2 days.

(P K Barkataki)
APE (M), A-III

A. Complete U-tube as per following dimensions

Code
Description
Adhoc

Seamless S S U-tubes
Material: ASTM SA-213 TP 304 ( OD x Thk x Deviation length)

Mean bend
Radius

Qty.
Reqd.
nos.

+0.05
+ 3.00
+0.10
(OD) mm x 3.0mm(thk.) x 13518+ 0.00 (length) mm

30

60

Size: 19.05
Size: 19.05

+0.05
+ 3.00
+0.10
(OD) mm x 3.0mm(thk.) x 13574+ 0.00 (length) mm

48

60

+0.05
+ 3.00
+0.10
(OD) mm x 3.0mm(thk.) x 13631+ 0.00 (length) mm

66

60

Size: 19.05
Size: 19.05

+0.05
+ 3.00
+0.10
(OD) mm x 3.0mm(thk.) x 13687+ 0.00 (length) mm

83.8

60

+0.05
+ 3.00
+0.10
(OD) mm x 3.0mm(thk.) x 13743+ 0.00 (length) mm

101.8

60

Size: 19.05
Size: 19.05

+0.05
+ 3.00
+0.10
(OD) mm x 3.0mm(thk.) x 13820+ 0.00 (length) mm

119.80

60

+0.05
+ 3.00
+0.10
(OD) mm x 3.0mm(thk.) x 13876+ 0.00 (length) mm

137.80

60

Size: 19.05
Size: 19.05

+0.05
+ 3.00
+0.10
(OD) mm x 3.0mm(thk.) x 13933+ 0.00 (length) mm

155.80

60

+0.05
+ 3.00
+0.10
(OD) mm x 3.0mm(thk.) x 13989+ 0.00 (length) mm

173.60

60

Size: 19.05
Size: 19.05

+0.05
+ 3.00
+0.10
(OD) mm x 3.0mm(thk.) x 14045+ 0.00 (length) mm

191.60

60

+0.05
+ 3.00
+0.10
(OD) mm x 3.0mm(thk.) x 14122+ 0.00 (length) mm

209.60

60

Size: 19.05
Size: 19.05

+0.05
+ 3.00
+0.10
(OD) mm x 3.0mm(thk.) x 14178+ 0.00 (length) mm

227.60

50

+0.05
+ 3.00
+0.10
(OD) mm x 3.0mm(thk.) x 14235+ 0.00 (length) mm

245.60

50

Size: 19.05
Size: 19.05

+0.05
+ 3.00
+0.10
(OD) mm x 3.0mm(thk.) x 14291518+ 0.00 (length) mm

263.40

40