TENDER DOCUMENT

NIT No.: DLI/C&E/WI-665/284 FOR

Tender for Design, Engineering, Supply, installation, testing and commissioning of DUST SUPPRESSION PACKAGE AND ASSOCIATED WORKS for the project of Augmentation of Raw Material Handling Receipt and Handling facilities with new OHP Part B (Package- 061) of Bhilai Steel Plant, (SAIL).

VOLUME 2B

TECHNICAL SPECIFICATION

ENGINEERING PROJECTS (INDIA) LIMITED

(A GOVT. OF INDIA ENTERPRISE)

Core-3, Scope Complex, 7, Institutional Area, Lodhi Road, New Delhi-110003

TEL NO: 011-24361666 FAX NO. 011- 24363426

VOLUME - 2B
CONTENTS

Sl. No.

DESCRIPTION Documents/information to be furnished alongwith offer Scope of Supply

1.

2.

3.

Brief System Description

4.

Technical Specifications Dust Suppression Package Spares Technical data sheet (to be filled by the vendor)

5.

6.

GENERAL
The following Technical Specification shall be read in conjunction with General Technical Specification (GTS) of Bhilai Steel Plant, SAIL and General Specification. If there are any provisions in this Technical Specification, which are at variance with the provisions of General Technical Specification (GTS) of Bhilai Steel Plant, SAIL and General Specification, the provisions in this Technical Specification shall take precedence.

1.0

DOCUMENTS/ INFORMATION TO BE FURNISHED ALONGWITH OFFER.

(i) (ii) (iii) Clear Scope of supply. Type and quantity of oil, lubricants & consumables for initial fill till successful commissioning of equipment. List of Commissioning spares and start-up spares with unit rates.

(iv) List with unit rates of special tools and tackles, if any required. (v) Price Schedule for supply & erection work as per the format enclosed.

(vi) List of recommended spare parts for 3 years trouble free operation and maintenance alongwith unit rates as per the format enclosed in price schedule. (vii) Technical Data sheets duly filled by the vendor (blank data sheets enclosed).

(viii) Weight of the equipment in Kgs. (ix) Catalogues/ Leaflets and O&M Manuals. (x) Reference list of your Customers for the similar supply of items.

(xi) Unpriced Copy

2.0

SCOPE OF SUPPLY
The scope of the supply includes Design, engineering, manufacture, shop fabrication. assembly, testing and inspection at manufacturers works, packing , dispatch, transportation, delivery to site, receipt, required fabrication at site, installation, testing & commissioning completion of facilities, performance guarantee testing, final painting at site and handing over to Bhilai Steel Plant, SAIL / EPI of COMPLETE DUST SUPPRESSION PACKAGE and ASSOCIATED WORKS as per specifications and scope defined in tender documents complete with all accessories and drive, which are not mentioned specifically but are required for the efficient and trouble free operation of the equipment/system.

2.1 (i) (ii)

Following items are also included in bidders scope. Complete items as per the details given in the specifications. Consumables like first fill of lubricating oils etc. for the initial operation of the equipment till handing over.

(iii) Commissioning spares and start-up spare parts. (iv) Special tools & tackles, if any required. (v) Recommended spare parts for (3) three years trouble free operation and maintenance.

(vi) Painting of complete equipment (including final painting before handing over to the Employer). (vii) Installation, testing & commissioning at site. (viii) All drawings/documents along with operation and maintenance manuals as per requirement mentioned elsewhere in the tender document. (ix) Getting approval of design/drawings and any other design calculation related to the equipment from BSP/MECON/EPI. (x) 3 Ph, 415V +10% & -15%, 50Hz +4% & -6% power supply shall be provided at Power cum Control Panel of Ventilation at one point only through power cables. Other voltage levels, if required shall be arranged by the bidder itself. Installation, testing & commissioning of panel shall be in Bidders scope.

(xi) Carrying out any modifications/deletions/additions/alteration in design/drawings/documents as required by client & Clients consultant and EPI for proper execution of works at site till completion and handing over of the project to the client. (xii) Drinking Water & Construction Power shall be provided free of cost to the bidder at one point. However, further distribution shall be in the bidders scope. Bidder has to ensure the optimum and effective utilization of Construction Water & Construction Power. (xiii) Construction Water shall be arranged by the bidder themselves. Exclusions:

(i) Civil works including grouting.

2.2 1) 2)

Bidder to note the following: BSP approved preferred make list shall be followed for Hydraulics & Pneumatics. All HT and LT AC/DC motors, actuators, brakes etc. as per technological and process requirement. Generally Squirrel Cage Induction Motor with DOL starter / Soft Starter will be provided. Use of Slip ring motor in general will be avoided. Suitable Rotor contactor panels and SS-grid Resistance Boxes will be provided for slip ring motors if inevitable. Soft starter will be provided for LT motors of rating more than 75kW. All LT motors for conveyors will be S6 duty and will have class F insulation with temperature rise limited to class B. Equipment selection and dating will generally be based on ambient temperature of+50 Deg.C. For specific areas and shops, the ambient temperature conditions indicated above will be taken into consideration and equipment suitably derated wherever necessary. The equipment should be suitable for smooth, efficient and trouble free service in the tropical humid climate prevailing at plant site and under the ambient temperature conditions indicated above for the different shops and areas. In hot areas of higher temperature conditions, the equipment will be adequately protected against damage from radiant heat and hot air. Roller bearings will be provided at DE end for motor of rating 30KW and above.

3)

4) 5) 6)

7)

8)

3.0

BRIEF SYSTEM

DESCRIPTION

The turnkey package of this Contract Document comprises of the following subsystems: 1) New Ore Handling Plant (OHP-II) including receiving, unloading, Stacking & Reclaiming and finally transporting of Raw Material required for Blast Furnace #8, Sinter Plant-III. New conveyor line for New Lime Dolomite plant RMP3 and for proposed SMSIII. Modifications/ up-gradations of existing equipment, including: An additional series of conveyor from OHP I to JH-20 and JH42(Exstg) parallel to existing route. Up gradation of capacity of existing shuttle conveyors J9BRSC1.

2) 3)

3.1

New Ore Handling Plant (OHP-II) The raw material to be handled by the proposed system is mainly, Iron Ore Lump, Iron Ore Fines, Lime Stone (BF grade), Lime Stone (SMS grade), Dolomite (BF grade), Dolomite (SMS grade), Quartzite, Manganese ore. These raw materials are mainly required for Blast Furnace, Sinter Plant, Lime-Dolomite Plant, SMS. All the raw materials will be received at the plant boundary by rail. The type of Wagon will be BOXN, BOXNHA, BOY, BOBRN, BOST, BOBS, BOXNEL, BOYL,BOXN HS etc which will transport the raw materials depending upon the location of loading and type of raw materials.

(i)

Design Considerations The Ore Handling Plant (OHP-II) has been planned based on the following assumption: A. Size of Raw Material 1. Lump Iron Ore 2. Iron ore fines 4. Dolomite (BF/SP grade) 5. Quartzite 6. Lime Stone (SMS grade) 7. Dolomite (SMS grade) 8. Pellets 9. Manganese Ore 10. Coke Breeze : : : : : : : : : -40 mm - 8 mm -60 mm -60 mm -50 mm -25 mm -25 mm -18 mm -25 mm -25 mm 330 days

3. Lime Stone (BF/SP grade) :

B. No of Days of Working per year:

C. Maximum material carrying capacity of each wagon shall be as per IS: 100951982 reaffirmed 2001. Iron-ore-lump will be received in Track-Hopper & all other material in Wagon Tipplers. Two Track Hoppers have been considered for materials received in BOBS/ BOBRN wagons (mainly iron-ore), whereas wagon tippler with side arm charger has been considered for unloading the materials received in BOXN/BOST/ BOXNHA/BOY/BOBS, BOXNEL, BOYL wagons. (II) UNLOADING, STORAGE, BLENDING AND RECLAIMING IN OHP-II

One number Wagon tippler WT no.B1 along with a Track Hopper TH-B1 with two parallel tracks on it have been envisaged for unloading Iron ore (lump and fines), Limestone & Dolomite (both BF grade and Sinter Plant grade), Mn-ore, Quartzite etc. The Wagon Tippler shall be of Rota-side type capable of unloading BOXN and proposed BOXNHA ,BOXNHS, BOBS, BOY wagons as per IS:10095-1982, reaffirmed 2001. The rated unloading capacity shall be rated 20 Tips/hour. Adequate system of handling sticky rakes such as vibrator/ air blaster shall be provided. 25t wagon axle load and 110t gross weight of wagons (BOX, BOXN, BOXN HA, BOXN HS, BOXN EL, BOYEL) to be considered for design of Wagon Tippler and track hopper. 2 nos. Weighbridges included in contractor's scope. The location of Weigh Bridge shall presently be considered at entry of pre hopper yard. However as the total railway track is being engineered by RITES, the location of Weigh Bridge may undergo change in detailed engineering stage. The drawings of wagon tippler/track hopper shall be subjected to approval by RITES /SECR/RDSO as applicable. The placement of rakes shall be done by Side arm chargers capable of handling a full rake BOXN, BOXNHA, BOBS, BOY, BOXN EL, BOYEL wagons. Two nos. of track hopper each of length 210 m excluding maintenance bay and holding capacity of 6000 t each considering material of bulk density of 1.6 t/ cu.m. shall be included in contractor's scope. The side angle of hopper with vertical shall be minimum 60 deg. Each hopper shall have four compartments. Track hopper envisaged to accommodate minimum 18 BOBS wagons. Contractor to maintain sufficient height of the track hopper superstructure to take care of OHE. Total 4 nos. Electric hoist of 5 t capacity shall be provided for maintenance of Paddle Feeder at both ends of Track Hopper building. Two nos. double door pressurized cabin shall be provided for paddle feeder inside the track hopper tunnel. Antiderailment device/ check rail shall be provided in the track hopper subject to approval of RITES. Supply / Laying of 60 kg/ m rail with continuous MS insert plate within track hopper building only are in scope of contractor. In addition to the above, one dedicated compressor station at track hopper TH-B1for unloading of BOBRN wagons is to be provided. Compressed air connection to BOBRN wagons to be provided at 15 mts interval. The details of requirement of compressed air, the pressure and type shall be obtained from RDSO. Other points as applicable for compressed air station shall be considered as per CS for compressed air facilities indicated elsewhere. Provision of adequate illumination should be there on both pre & post tippler as well as on Merry Go Round circuit. Two belt feeders below Wagon Tippler shall discharge the raw material on either of two conveyors i.e. Z1-C1 or Z1-C2 which, in turn will discharge the material at Jn

House JH-Z1. From Jn House JH-Z1, conveyors Z3-C1 & Z3-C2 will carry the material and discharge at JH-Z3. There will be three incoming conveyors in Junction House JH-Z3. The tail end of two conveyors Z3-C1 & Z3-C2 will start from JH-Z1 and Belt conveyor Z3-C3 from JH-Z2. Junction house JH-Z2 shall be located in between the JH-Z1 & JH-Z3. The track hopper with four nos. paddle feeders of 1500 tph each, two on conveyors Z2-C1 and two on conv Z2-C2 has been envisaged. From Jn. House JH- Z2, either of three conveyors Z3-C1, Z3-C2 (coming from JH-Z1) & Z3-C3 (begin from JH-Z2) shall carry the material upto Jn house JH -Z3. Reversible shuttle conveyors Z2RSC1/2 at JH-Z2 will facilitate to discharge the material on either of any three conveyors. Therefore, JH-Z2 shall be designed suitably so as to receive material from any of the conveyors coming from Track Hoppers. Non sticky liners/ polymer liners are to be fixed in the track hoppers to improve flowability. Suitable interchangeability shall be provided below Wagon Tipplers and Track Hoppers for the conveyors by providing Diverter gates. In Jn House Z3, three nos. Reversible Shuttle conveyors no. Z3-RSC1,2&3 can feed any one of conveyor no. Z6C1, Z6C2 and Z6C3. Contractor to provide jumbo gallery suitable for three nos. mobile trippers up to JH-Z5 from JH Z4 over conveyors Z6C1, Z6C2 and Z6C3. Out of three trippers, two nos. (Over conv. Z6C2 and Z6C3) shall extend upto JH-Z6 and one no. shall have provision of extension up to junction house coming in future. Maintenance hoist of minimum 5t cap shall be provided for the trippers. Each of the three conveyors Z6C1, Z6C2 and Z6C3 shall be capable of feeding the stacking conv. Z4BC1 as well as itself in JH Z4 and stacking conv. Z5BC1 as well as itself in JH Z5. Each of the two conveyors Z6C2 and Z6C3 shall be capable of feeding the stacking conv. Z6BC1 as well as future conveyor in Junction House JH-Z6. The raw material can be either transported via. Jn House Z4, Z5 or Z6 to the respective stacking conveyors Z4B-C1, Z5B-C1 & Z6B-C1 for stockpiling or can be fed directly to the reclaiming conveyors Z7-C1/ Z7-C2 which means convey material directly from the WT/ Track Hopper to: (a) (b) To the Blast Furnace#8 Stock House To the Fuel & Flux crushing circuit of Sinter Plant-III.

Suitable interchangeability shall be provided at Junction house JH-Z4, 5 & 6 for the conveyors by providing 2-way chutes in mobile tripper. 5T Electric hoist each shall be provided at JH-Z5 & JH-Z6. Whereas, JH-Z4 shall be designed only as a transfer point. The Stacking conveyors Z4B-C1, Z5B-C1 & Z6B-C1 can form a stockpile 30m wide, 350m long and 10.5 m (maximum) high with the help of Twin boom stackers. Suitable number of electrically operated Under-Slung Cranes, Hoists etc. shall be provided in all floors of Junction Houses and building for maintenance of equipment. Electro-Magnetic Separators, In-Line Magnetic Separators, Metal Detectors, BeltWeigh-Scales, Air-Blasters/ Bin Vibrators shall be provided to make the system complete and the operation/ maintenance smooth.

(iii) STORAGE AND RECLAMATION OF ORE From the Wagon Tipplers WT-B1 and the Track Hopper TH-B1, the raw material may sometimes be fed directly to the consuming plant in case of emergency. However, this shall not happen under normal circumstances, when the three Twin-boom stackers over conveyors Z4B-C1, Z5B-C1 & Z6B-C1 store the raw material in the designated place of the yard in bed nos. 1 to 6. Flexibility shall be in built in the Jn Houses Z4, Z5, & Z6 to ensure stacking is trouble free. Bed blending system shall be possible with the stacker running to and fro on the length of the pile -or- on a length between two defined position in case more than one material is stored in a bed marked by travel limit switches, which through a relay sequencing circuit, with time control-reverses the traveling gear after the travel in each direction covering the desired length of the pile. After a layer of some pre determined amount is deposited in one traveling direction of the stacker, probes fitted on the stacker boom gives it a raise signal as soon as a net height of material is formed. The next layer is then formed. Iron ore may require stockpile formation as described above for blending and uniformity. However, the emphasis on blending shall be for iron ore fines which shall be blended while stacking. Four nos Bucket-wheel reclaimers have been envisaged for bed no. 1 to 6. All stacking line conveyors feeders and stackers etc. shall have a rated capacity of 1500 tph & a designed capacity of 1800 tph. All reclaim line equipment shall have a rated capacity of 1500 tph and a designed capacity of 1800 tph in the ore handling area. Reclamation takes place by the conveyors Z7-C3 (Bed no. 1), Z4A-C1 (Bed 2or 3), Z5A-C1 (Bed no.4 or 5) and Z6A-C1 (Bed no. 6) and the reclaimed material via Jn House Z4A, B, Z5A, B, Z6A and Z6B shall reach Jn House Z7. Two reclaim conveyors Z7-C1 and Z7-C2 between Z6A to Z7 will receive all the materials from yard for further transportation. Reclamation from OHP takes place for the following circumstances: Feeding of iron ore lump, dolomite, limestone, manganese, quartzite, pellet etc. to BF#8 stock house. Transporting Limestone/ Dolomite (SP grade) and iron-ore fines to fuel & flux crushing area for Sinter Plant-III.

Two streams of belt conveyors shall reclaim the material from new OHP-B yard to above places. Belt conveyor Z7-C1 & C2 shall carry the material and transport thru Z8-C1, C2, Z9-C1, C2, Z10-C1, C2 to Z11-C1& C2 to Junction house JH-Z11. Junction House-Z11 can discharge the material either to existing conveyors R103/ R104 of Sinter Plant-III or proposed conveyor Z12-C1/ C2 of BF#8, with the help of reversible conveyors. To receive the material from Z11-C1 & C2, suitable modification in existing gallery of R103 & R104 is required. Also a junction house JHZ11 with two reversible conveyors & tail end of belt conveyors Z12-C1 & C2 shall be erected above these conveyors. Further, conveyor Z12-C1 & C2 and then Z13-C1 & C2 shall move towards stock house of BF#8 and discharge at JH-Z15 onto reversible shuttle conveyors J15RSC1/2. The gallery from JH-Z14 to JH-Z15 shall have provision for installation of three identical conveyors i.e. Z15-C1, Z15-C2 and future conveyor Z15-C3. Suitable insert plate/ foundation bolts shall be provided for future conveyor Z15-C3. However, future conveyor Z15-C3 is not in scope of contractor.

Specification of future conveyor: Length - ~ 35 m: Lift 0.0 m: Capacity 1200 tph: Belt width 1400mm Centre to centre distance from Z15C2 3010 mm A junction house JH-Z14 shall be provided in between the junction houses JH-Z13 & JH-Z15. Two series of belt conveyors shall discharge the Sinter at the Junction House Z14 over belt conveyor Z15-C1 & C2. Junction House JH-Z14 and conveyors Z14C1/C2 shall be in the scope of Employer i.e. BSP. Suitable Junction houses with RCC floors, diverter gates & galleries shall be provided to transfer the material from one conveyor to another. The scope of contractor shall finish at JH-Z15 with complete drive and discharge (including reversible shuttle conveyor) facilities. The receiving belt conveyor below Z15-C1 & C2 shall be in the scope of Employer i.e. BSP. However, JH-Z15 shall have a provision (inserts/ foundation bolts) to erect outgoing conveyors to Stock House.

3.2

OTHER ADDITIONS/ MODIFICATIONS AND UPGRADATION IN EXISTING OHP (REF. DRG. NO. MEC/S/9101/11/17/0/00/00/061.B01) An Additional series of conveyor from OHP to J-20 and JH-42(Exstg) Another proposed conveyor No J9-C1 parallel to J9-C3/J9-C4, besides conveyors R102, shall start from Jn. House JH-9B and shall discharge the material in a proposed conveyor J9H-C1 in existing JH-9, which in turn feeds to conveyor J10-C2 in new Junction house JH-9H . Conv J10-C2 can feed proposed conveyor J11-C3, J11-RC2, J14-C2/J12-C2 (Exstg) , J15-C2. Conv J15-C2 shall feed new reversible conv. J15RC1 in junction house JH-15, which in turn can feed either existing SMS-II feeding conv. J15A-C1 or new conv. J15B-C1. Conv. J15B-C1 or another new conv. J15B-C2 which shall receive sinter from existing conv. SS-10 shall feed new conveyor J16-C3 in new junction house JH-15B which in turn shall discharge onto new conv. J16-C3A in new junction house JH-16A. Conv. J16-C3A shall discharge onto new conv. J17-C3 in JH-16A which shall convey material to conveyor J17A-C1 in JH-17(exstg). Conveyor J17A C1 (Capacity 1500tph) shall discharge to either of the two conveyors J20C3 or J17B-C1 through a adjustable flap gate in junction house J17A. further J17B-C1 shall discharge the material over J42-C2 in JH-17B. The capacity of the outgoing conveyors J20C3 and J17B-C1/J42C2 shall be 500tph and 1000tph respectively. Conveyor J20-C3 shall be provided with one no. belt weigh scale and have provision of discharging onto existing sinter carrying conveyor J27-C5 (Exstg) in junction house JH-20 (Exstg). Conveyor J42-C2 shall have provision of discharging onto existing conveyor J44-C5 in junction house J42 (Exstg). Necessary modification/strengthening shall be carried out in junction house J42 to take care of additional loads by new conveyor. Suitable electrical interlock shall be provided between the conveyors J27-C5 & J20-C3 in junction house JH-20 to trip all the incoming conveyors in case feed rate exceeds capacity (500tph) of the corresponding downstream conveyor J27-C5. Similar interlock shall also be provided between J44C5 & J44-C2 in junction house JH-42 to avoid any spillage/chute blockage. These additional conveyors with gate will facilitate a new additional route for 7. BF #

(i)

All above conveyor shall run adjacent to the existing conveyor/ galleries at same elevation. Junction houses JH-9H, JH-10A, JH-15B, JH-16A ,JH 17A and JH- 17B shall

be new Junction houses. For conveyor no. J11-C3, J11-RC2,J14-C2, J15-C2, J15RC1, J15B-C1, J15B-C2 , J17-C3, J17A-C1, J20-C3 & J42-C2, the existing junction houses (JH-10, JH-11, JH-14, JH-15, JH- 17, JH-20 and JH-42) shall be suitably modified to suit proposed conveyor transfer points/crossing over. (ii) Up gradation of Reclaiming conveyors The capacity up-gradation and utilization of reclaim conveyors are of utmost importance to ensure smooth operation in the OHP. The list of conveyors in the reclaiming circuit that shall be upgraded to are given in table 03.01. EXISTING BELT WIDTH mm 1 J9B-RSC1 1400 CAP 500 m3/hr PROPOSED BELT WIDTH mm 1400 CAP tph 1500 1500 tph Table 03.01 SL No CONVEYOR NO

The capacity of all Belt conveyors shall be 1500tph for all raw materials viz. iron ore, limestone, dolomite with 1400mm belt width and belt speed shall be 2.0 m/s with a troughing angle of 35o. (Bulk density of raw material shall be considered as 2.2 t/m3 for power calculation/load data of structures and 1.6 t/m3 for volumetric capacity calculation of conveyor)

3.3

NEW LIME DOLO PLANT (RMP III) AND SMS III CIRCUIT Existing conveyor R-101/R-102 shall be utilized to convey raw material required for Lime/Dolo Calcination plant RMP III and of SMS-III by tapping the conveyor from Jn house JH-N102 (With suitable modification in the Jn House) and taking a new route to the proposed Lime/Dolo calcination plant/SMSIII. Any civil work related to installation of new conveyors in existing junction house JN#102 shall be contractors scope. The SMS grade limestone, dolomite and iron ore in existing OHP-I shall be reclaimed via. Jn House N101, N102. Existing Belt Conveyors R101/102 coming from OHP-I shall now mostly carry Lime stone and dolomite. In JH-N102, two existing reversible conveyor R103A & R104A are having a provision for taking material to Sinter plant III as well as proposed Lime Plant. A discharge chute below R103A & R104A to feed at the tail end of proposed belt conveyor L1C1 shall be provided at Junction house JN102. Belt conveyor L1C1 shall discharge the material on L2C1 in junction house JHL2. Conv L2C1 discharges onto conveyor L3C1 which discharges onto L4C1 in JH L3.Conv L3C1 in turn discharge material at Junction House JH-L4 to any of the two conveyors i.e. L5C1 & L7C1 with the help of diverter Gate. Thereafter, conveyor L7C1 will carry the material and transfer onto conveyor L9C1. Conveyor L9C1 will carry the material up to Surge Bin building JHL9 through reversible shuttle conv. JL9RSC1. Surge bin building JHL9 shall have 3 nos. bunkers of minimum geometric capacity 190 cub m each for storing iron ore lump/limestone /bauxite. Suitable rod gate and motorized rack and pinion gates shall be fitted at the bottom of bunkers. Three (3) nos. VVF controlled vibro feeders of 420 tph capacity each shall withdraw material from bunker and discharge it onto conveyor L10C1

which shall convey up to Junction house JH L10 for onward transportation to Surge Bin Building for SMS-III (Surge bins with Vibro-feeder as shown in flow diagram at JH-L9 are in contractors scope.) through SMS feeding conveyor. Conveyor L10C1 complete with discharge facilities and junction house JH L10 shall be in the scope of contractor and SMS feeding conveyor shall be in the scope of employer. The other conveyor L5C1 shall receive material from conveyor L4C1 and discharge at JH-L5 on to conv. L6C1 which shall convey up to junction house JH-L6 and discharge onto lime plant feeding conveyor for onward transport to Lime & Dolomite calcination plant RMP III. Conveyor L6C1 complete with discharge facilities and junction house JH L6 shall be in the scope of contractor .However lime plant feeding conveyor shall be in the scope of employer i.e. BSP. Calcined lime/dolomite is received from the day bins of lime/dolo product storage building of RMP III onto conveyor L8C1.Conv. L8C1 discharges onto conv. L9C2 in JH L8 which in turn discharges onto conveyor L10C1 in Surge Bin building JH L9. This finished product of RMP III is transported to the junction house JH L10 by conveyors L10C1 which shall also carry limestone, bauxite, iron ore received directly from OHP I yard to SMS III. The scope of contractor starts from tail end on conveyor L8C1 including skirt boards. A fixed hopper of 8 cub m capacity on conveyor L10C1 near JH L9 with VVF controlled vibro feeder of 420 tph capacity shall also be used to transport coke fines as and when required in the storage bins of the bulk material charging system of SMS III. Any other material e.g limestone/ DRI can also be transported under emergency conditions through fixed hopper. Suitable ramp shall be provided to unload the material over hopper.

4.0

Technical Specifications of DUST SUPPRESSION PACKAGE

The scope of work of Dust Suppression package includes;

4.1 4.2 4.3

Dust Suppression System Compressed Air System Water Supply System

4.1.0 Dust Suppression System 4.1.1 Scope of work of Dust Suppression System
The scope of work of dust suppression system include (i) (ii) Plain water dust suppression (DS) system of track hopper & stock piles. Plain water dust suppression system for paddle feeders of track hoppers. The dust suppression system will be integral part of the paddle feeders and will be captive unit of these mobile equipment. Separate set pump (1W+1S) & water tank will be provided for dust suppression system of each plough feeder. (As dust suppression system will be integral part of the paddle feeders, dust suppression system for paddle feeders shall not be in the scope of bidder. However, the bidder has to provide Ring Header for DS of Paddle Feeders of the Track Hopper. The water requirement of paddle feeders shall be met out by the water pumps installed for dust suppression of Track Hopper Periphery) (iii) Dry fog dust suppression system (DFDS) at material transfer points in different junction houses, hoppers/bunker/ bin buildings and other dust generating areas. New OHP area: DFDS systems will be provided at wagon tippler bottom belt feeders & conveyors, JH-Z1, JH-Z2 (including the conveyors coming from existing track hoppers), JH-Z3, JH-Z4, JH-Z5, JH-Z6, JH-Z4A, JH-Z5A, JH-Z6A, JH-Z4B, JHZ5B, JH-Z6B, JH-Z7, JH-Z8, JH-Z9, JH-Z10, JH-Z11, JH-Z12, JH-Z13, JH-Z14, JH-Z15. Existing OHP area DFDS systems will be provided at all the new and upgraded conveyors at junction houses JH-9B, JH-9, JH-9H, JH-10A, JH-11, JH-14, JH-15, JH-15B, JH-16A, JH-17, JH-17A, JH-17B, JH-20, JH-42, JH-N102, JH-L1,JH-L2, JHL3, JH-L4, JH-L5, JH-L6, JH-L7, JH-L8, JH-L9, JH-L10

DFDS system will be divided in zones and each zone will have pumping station and consist of two pumps (1W+1S).

4.1.2 APPLICABLE CODES AND STANDARDS

The execution of the work covered under this specification will conform to the

latest Indian Standards specification where the same are available or the reputed standards acceptable to the owner / consultant. In case such specifications are not available, the work will be according to good engineering practice and norms acceptable to owner / consultant.

4.1.3 DESIGN CRITERIA

(1) (1a) (2) DS/DFDS system will be provided in all the new and upgraded areas Work zone dust concentration will be less than 5 mg/Nm3 (at 5m to 7 m distance from source) above ambient level. Water line velocity will will overflow connection will strainer will be maintained less than 1.5 m/sec. Water pipe line be included at each pump station tank. Duplex be used in the be supported at regular interval. Make-up water, quick fill, drains and be included at inlet to dust suppression system pumps. IS-1239

heavy class, ERW, G.I pipe line (for size up to 150 NB) will conforming to IS: 3589. supporting scheme will (wherever provided) will will (3) Water pipe line will

water line. The pipes above 150 NB will be MS, spirally welded, 6 mm thick & be preferably be laid over ground along conveyor gallery. In case of non-availability of same suitable be provided to suit site. Underground pipeline have wrapping and coating as per IS 10221 be coal tar based). Hume pipe protection be used in the compressed air be preferred be

(preferably wrapping coating will be laid at road crossing area.

IS-1239 heavy class, ERW, G.I pipe line will

line. Compressed air pipeline network over ground laying will

with a minimum slope of 10 mm in 1m (1: 100) along flow and moisture trap with drain provision at regular interval. Compressed air pipeline will preferably laid along conveyor gallery or can be supported from building supporting structure. In case of non-availability of same suitable supporting scheme to be developed by the Contractor to suit site.

(4)

Dust suppression system for stockpiles are to suppress the generated dust due to wind blowing. Sprinkler post of approx. 2m height will spray header along both sides of the stockpile. valve & solenoid valve will be installed on the Before each sprinkler ball

be provided for manual control and automatic be sized and be

control respectively. The sprinklers should be swiveling type. Water spray quantity will be minimum 1.6 litre/hr/m2 of area. Sprinklers will solenoid valve open/ close operation & water spray. spaced to ensure complete coverage of stock pile. Sequence timer will control Sprinkler will operated for a predefined time period at different location of stockpile. A bypass line (with pressure relief valve) from pump discharge line to water tank will be provided. In addition to above a bypass line with ball valve will also be provided. There will (5) be three water pumps (two working and one reserve). be selected be be mounted on each Spray Nozzles/Spray bar for DFDS systems at transfer points will so as to ensure complete coverage. Solenoid valves will

spray nozzle header at material transfer points. Solenoid valves will

interlocked with under belt switch and conveyor drives so that spray of water & compressed air take place when conveyor running with material. At reversible shuttle conveyor spray nozzles will The DFDS system nozzles will be provided at both side. have air driven acoustic oscillator capable of

producing super fine atomization of water droplets of size as that of dust particles & blanket of extremely fine fog. The approximate water addition will not be more than 0.2% of the weight of material being handled. In DFDS pumping station, 2 nos. pumps (1w+1s) will (7) be provided. be

Compressed air receiver and water tank at different pumping station will checking.

provided with connecting valve, pipe fitting, and instruments for quality (8) In track hopper, spray nozzles will be arranged in a no. of groups to cover the be through

entire track hopper. Water spray in each group of nozzles will push buttons. reserve). (9) In wagon tippler, spray nozzles will There will be two water pumps (one

solenoid valve. The operation (open/ close) of solenoid valves may be by local working and one

be arranged in three rows, at both side of

hopper and top of hopper to cover the entire hopper. Water spray in each

group of nozzles will of solenoid valves will There will (10) (11) (12)

be through solenoid valve. The operation (open/ close) be linked with the wagon tippler rotation, i.e wagon rotation. working and one reserve).

tippler position switches and timers be two water pumps (one Compressed air station will compressor will be provided.

be provided for DFDS systems. Standby be considered @ 16% of the

At each pump station air receiver capacity will

compressed air consumption in m3/min or 2 m3 capacity, whichever is higher. Adjacent to pump station of stock piles & track hopper, RCC water tank will be provided with minimum 30 minutes water storage capacity. For all other pump stations of DFDS system & wagon tippler dust suppression system, MS tank of 5 mm thick with stiffener for 1-hour storage capacity will by the Contractor. The inside surface of MS tank will (13) The Contractor will view. (14) Duplex strainer with SS filter element will micron (15) Monorail with chain pulley block will be provided for handling of equipment of weight more than 300 Kg (16) -The Contractor will pump operation. Spring loaded operated pressure release valve (adjustable) at pump discharge line for by passing water line to tank to avoid shut-off condition. Pressure gauge at all pump discharge line . Pressure gauge at air-receivers, safety valve and drain provision At consumer application points following instruments will be provided : be provided provide the following minimum instruments High level and low level switch in water tank. Low level switch interlocked with be provided at inlet to dust suppression system pumps to remove all suspended particles exceeding 100 be provided be epoxy painted.

provide platform, walkway, stair case adequate for the

necessary approach to the equipment for operation & maintenance point of

Independent pressure gauge & control valve (Ball valves) will for pressure regulation .This unit will construction.

housed in a steel cabinet of IP-55

-------

For flow activation, solenoid operated valves will airline. Belt conveyor load monitoring switch will running with material.

be provided in water and

be provided for sensing conveyor

Pressure switch in compressed air line to prevent spray operation at low pressure. Indication lamp in FAS to show ON/OFF operation of spray. Individual valve will have selection mode to run in Auto/Manual mode. be regulating by sequence timer. Sprinkler operation will

4.1.4 EQUIPMENT SPECIFICATIONS The equipment for "DFDS" dust control system is grouped into two main categories. Main Equipment The main equipment will include spray bar assemblies fitted with dual-fluid air driven acoustic oscillator atomizing nozzles, pressure regulating units, and flow activation stations for ON-OFF control of the system and instrumentation for auto operation. Auxiliary Equipment The auxiliary equipment will include water storage and pumping unit with duplex water filter and associate electrical works, air and water piping, enclosures, necessary hoods and skirt boards on belt conveyors / equipment to suit spray nozzle operation. Starter cum control panel will be provided at pumping station and local control panel will be provided at different application points.

Brief Specifications of various components of the system are given below Main Equipment Spray bar assemblies The spray bar assemblies will fluid atomizing nozzle will be manufactured from stainless steel tubing drilled and tapped for connection of nozzle adapters. A specially designed and selected dual be fitted into each of the adapters. These nozzles are be fitted with acoustic oscillators for atomizing the water into droplets of micronic size by passing them through a field of high frequency sound waves. The nozzles will

of stainless steel while the adaptors will pipeline. Pressure regulating units (PRU)

be of brass. Each spray bar will

be

provided with mounting brackets and flexible hoses for connection to the air & water

The performance of "Dry Fog" type dust control system is critically related to the size of water droplets. The nature and particle size of dust generated in the material handling system changes with change in size and characteristic of the material. In practice, the sizes of the dust particles have a very wide spectrum (1-800 microns). A careful control of air and water flow & pressure is therefore necessary to obtain optimum dust suppression results. For this purpose, pressure regulating units will be provided in the system. The pressure regulating unit will consist of diaphragm type pressure regulator with pressure gauge and ball valve for isolation of air and water line. The operator can adjust both the air and water pressures independently to change the fog characteristics to obtain optimum dust suppression results vis-avis the site requirements. The pressure regulators will be installed in a metallic enclosure with inspection door with rubber sealing arrangement. Flexible hose will be provided for connection of PRU to the air & water pipeline. The number of pressure regulating units will depend upon the position / elevation of be provided when

spray bars. Generally independent pressure regulating units will from one PRU should not exceed 6 ~ 8. Flow activation stations (FAS) The flow activation station will valves will hoses will

the elevation of spray bars exceeds 3 m. Further the number of nozzles operating

consist of solenoid valves in air & water line, be installed in

pressure switch in the airline, selector switch, and indication lamps. Isolation ball be provided in the air & water line. All the equipment will a metallic enclosure with inspection door with rubber sealing arrangement. Flexible be provided with each FAS for connection to air and water pipeline. be through the flow activation The "ON - OFF" control of the fogging system will will

stations with facility for both manual and auto mode. A three-position selector switch be provided to select the mode of operation. The switch when energized will

open the electric solenoid valves, which will

permit compressed air and water to

enter into the pressure regulating units and spray bars. In addition, a pressure switch will be installed in the airline to ensure that air and

water solenoid valves are energized only when sufficient air pressure is available in the line. This will ensure that the system cannot operate without sufficient air pressure to the nozzles and reduces the chance of un-atomized water to pour into the dust source. Flow activation will System ON System OFF due to lower air pressure have indication for: -

Auto operation The flow activation stations will have provision for both manual and automatic become operational with selector

operation. For manual operation, the system will

switch in manual mode and in auto mode, the fogging operation starts on receiving a signal either from a speed switch cum belt load monitor or limit switches installed at a strategic location in the material conveying line or potential free Contract from the drive motor of equipment as per requirements. Each dust suppression system location will be provided with requisite number of be spray bar assemblies with DFDS atomizing nozzles. Pressure regulating units will provided at each location to regulate the pressure of compressed air and water. The dust suppression system will be divided into independent circuits taking into account the flow diagram, operational requirements, distances between dust suppression locations etc. Flow activation stations with instruments for auto operation are provided for each circuit for ON/OFF control of the dust suppression system. Centrifugal Pump : Horizontal back pull out pump will split type. Impeller rpm will be provided. Pump casing will be vertically be coupled to

generally not exceed 1450. However, for pumps with be provided. Pump will

low capacity & high head may be provided with 2900 rpm. Pump will motor with flexible coupling. Spacer type coupling will conform to IS : 1520.

Pump will give satisfactory performance at any point on the H-Q curve over a range of 40% of rated flow to 120% of the rated flow. The maximum efficiency will preferably be within 10% of the rated design flow. The total head -capacity curve will be continuous rising towards the shut off without any zone of instability and with a minimum shut-off head of 15% more than the design head. Pumps will have shaft seal by gland packing. Pump will be fitted with double wearing rings, one is fitted in the front of the impeller on the casing and the other is fitted in the back of the impeller on the impeller itself. Impeller will be dynamically balanced. The magnitude of peak to peak vibration will be non overloading type. Impeller will

be limited to 75 micron. Pump impeller will be made in one piece & keyed to the shaft.

Material of construction
Casing Impeller Bearing Bracket Shaft protection sleeve Wearing ring Shaft Common base frame for pump & motor - C.I - Bronze - C.I - Bronze - Bronze - EN-8 - M.S

Common base plate for pump & motor will construction. Adequate space will

be in one piece & made of welded steel be

be provided between pump drain connection

and base plate for installation of minimum 15 mm drain piping. Pumps will connections. Critical speed of the shaft will Water Piping and Fittings Water piping up to 150 mm NB size will be at least 30 percent above the operating speed.

supplied with suitable drain pans or drain rim type base plates with tapped drain

be GI, ERW, heavy class and conforming to be MS, spirally welded, 6 mm thick be as per be beveled. Pipe fittings will

IS-1239 Part- 1. The pipes above 150 NB will and conforming to IS:3589. Pipe ends will

IS 1239, Part -2 for pipes of size up to 150 NB.

Fabricated fittings manufactured

from the pipes may be provided for pipes of sizes 200 NB & above. Plate type pipe flanges (as per IS 6392) will Pipes will be provided. be as per

be of welded joints. Welding (manual metal arc welding) will be employed.

relevant IS code and only certified welders will

All piping systems will

be hydro tested at 1.5 times the design pressure.

Auto air venting valves will

be provided at highest point of the pipe lines & drain

valves will be provided at lowest points of the pipelines in different segments. Pipe supports comprising pipe shoes, saddles, base plate, clamps & structural members like channels, angles etc. will be provided

Valves
Butterfly Valves will valve will be provided in water line of size 65 NB and above and ball be be provided for pipe size below 65 NB. However, ball valve will

provided in the pipe line (irrespective of sizes) when flow control is required.

Butterfly valve
Type : Wafer design, flange less Body : SG iron with nitrile rubber/ EPDM lining Disc : SG Iron with teflon (PTFE) coating Stem : High tensile stainless steel The valves will be provided with integrally moulded & bonded body liner to provide

perfect seating and complete isolation of body material from fluid. The body liner will provide the seating to valve disc, primary seal to the stem & gasket joint with mating pipe flanges. Valves will be provided with self locking lever operation from open to conform to BS : 5155 / IS : 13095. fully closed position with intermediate positions marked on the indicator plate mounted on the top flange. The valves will Extended valve shaft will be provided so that the lever can be operated without any

obstruction on the insulated pipes. Gear operated valves will more than 250 NB.

be provided for sizes

Ball Valve
Body : Cast steel Body liner : Nitrile rubber/ EPDM Ball : ASTM A351 Gr CF8 3 piece design Socket welded type Ball valves will be with 200 mm length welded joint pipes from manufacturer works.

Check valve
Type : Dual plate check valve with two springs hinged on a central hinge rod Body : SG iron Body liner : Nitrile rubber/ EPDM Disc : ASTM A351 Gr CF8 Wafer design

4.2.0 Compressed Air System 4.2.1 Instruction to Contractor

Dedusting system of RMH plant (Part-B) will require substantial quantity of compressed air. Also, compressed air will be required for track hopper poking. To meet these air requirements, one common compressed air station along with interconnecting inter-shop and in-shop piping facilities upto the individual consumers will be provided in the RMH area on turnkey basis. The compressed air station will be located suitably to ensure proper distribution of air to all the consumer points. The Compressed Air shall be supplied to the following Areas; A) B) C) D) E) Track Hopper Building Wagon Tippler Building Area Repair Shop All Water Pump Houses (5 Nos., PH-1 to PH-5) All Material Transfer Points where DFDS (Dry Fog Dust Suppression) system is to be installed in various buildings, Junction Houses, Trippers etc. Dry fog dust suppression system (DFDS) at material transfer points in different junction houses, hoppers/bunker/ bin buildings and other dust generating areas. New OHP area: DFDS systems will be provided at wagon tippler bottom belt feeders & conveyors, JH-Z1, JH-Z2 (including the conveyors coming from existing track hoppers), JH-Z3, JH-Z4, JH-Z5, JH-Z6, JH-Z4A, JH-Z5A, JH-Z6A, JH-Z4B, JHZ5B, JH-Z6B, JH-Z7, JH-Z8, JH-Z9, JH-Z10, JH-Z11, JH-Z12, JH-Z13, JH-Z14, JH-Z15. Existing OHP area DFDS systems will be provided at all the new and upgraded conveyors at junction houses JH-9B, JH-9, JH-9H, JH-10A, JH-11, JH-14, JH-15, JH-15B, JH-16A, JH17, JH-17A, JH-17B, JH-20, JH-42, JH-N102, JH-L1,JH-L2, JH-L3, JH-L4, JHL5, JH-L6, JH-L7, JH-L8, JH-L9, JH-L10 All Compressor Cooling Water Pumps, Cooling Towers, Make-up Water Pumps, Piping, Valves & Fittings, Instrumentation, Controls etc. are in the scope of Bidder. 4.2.2 The Contractor will furnish all the drawings, documents, data like fault diagnosis, operation and maintenance manuals, general details and layout drawings, design calculations and equipment specification of plant and equipment, together with `as built' drawings for all mechanical, electrical, civil, structural and instrument & control. Meteorological data The following meteorological data will be taken into account for design of plant and equipment. Site conditions will be assumed to be as follows:

4.2.3

Temperature Humidity Maximum Minimum Altitude above MSL 4.2.4 Selection Criteria a) b) c) d) e) 4.2.5

: : : :

500C 50C 100% 25% 307m

(Max) (Min)

Compressors will be designed at 500C temperature and 60% RH, 350C cooling water temp., 50 Hz frequency. Performance guarantee tests will be demonstrated at 350C temperature and 60% RH, 330C cooling water temp., 50 Hz frequency. Motor will be selected at 50C temperature and 100% RH, 50 Hz frequency. Design ambient temperature for Electrics will be considered as 500 C. Compressors will safely run in the frequency range of 50 Hz +3% to -6%.

Delivery Schedule Delivery schedule & commissioning schedule of compressors will be matched with the overall schedule of the package (OHP, Part-B).

4.2.6

In general the guidelines laid down in the TS, GTS and SBD will be followed.

4.2.7 Scope of Work The Scope of work will include design, engineering, manufacture, assembly, shop testing at manufacturers works, painting, supply, transportation and delivery F.O.R. site of all the plant & equipment and connected utilities of compressed air facility, handling and storage at site, erection, testing, commissioning, demonstration of performance guarantee tests and final handing over of all plant and equipment with connected accessories along with the following facilities. The compressors will be housed inside a building (compressed air station). The Air receivers will be installed outside but adjacent to the building. The building and equipment foundations including grouting and chipping works, structural works, etc. are also covered under the scope of this specification. The routing of inter-shop and in-shop compressed air piping system will be overhead. The compressed air station will comprise of the following main equipment : i) Five (5) sets (3W + 1S + 1MS) each of 36 Nm3/min (@ 8 kgf/cm2(g) discharge pressure after aftercooler) oil free, water cooled rotary screw packaged type air compressors with electric motor and all its accessories & auxiliaries including the following:

a) Intercooler, after cooler, moisture separator with trap station, b) Suction air filter cum silencer, c) Lube oil system. d) Cooling water system including duplex type filters in supply line. e) Acoustic enclosure along with exhaust fan and necessary illumination. Each Compressor will have dual type control system, which will permit operation of each compressor in either of the following way: (a) (b) ii) Continuous Variable Load /unload regulation Automatic Start-Stop Regulation.

2 no. of Air Receivers of 12 m3 water holding capacity at 8 kgf/cm2(g) operating pressure, complete with all fittings such as safety valves, drain connection with auto condensate trap and bypass valve, vent connections and all inlet and outlet connections with companion flanges, supporting arrangement, access platforms, instruments etc. The material of construction will be as per IS 2002 Gr. 2A . The air receiver will be designed, manufactured and tested according to IS 7938, 1976 (RA 1991). All necessary interconnecting pipes (from compressors outlet upto the consumer points including dedusting system and track hopper poking), valves, fittings including supports and supporting structures. Drain pipelines from compressed air station to nearest drain/drain pit. Miscellaneous structures, access platforms for operation and maintenance of equipment parts, valves, instruments, etc. forming part of the equipment. A complete new and unused set of all special tools & tackles required for operation and maintenance. Complete Electrics and C&I as required for the successful operation of the plant. Contractor has furnished list of itemwise spares for 2 years O&M along with unit rate. The item rates will be valid upto 12 months from last consignment at site All anchor bolts & nuts, washers, foundation bolts, shear lugs, counter flanges for inlet and outlet of each compressor, receivers and connected piping & base frame for equipment. Miscellaneous materials and services, if not otherwise specifically mentioned will be included, but not limited to nuts, bolts, washers, gaskets, necessary connections for hook up with employers pipe network and equipment. List of spare parts for 2 years operation & maintenance.

iii)

iv) v) vi) vii) viii)

ix)

x)

xi)

Supply of first fill of lube oil & consumables and also for testing, commissioning and performance guarantee. Specification of all consumables will be indicated. Commissioning spares (All spares used until the plant is handed over to the employer). Training of O&M staff of Employer for 10 mandays. Complete civil & structural works. Contractor will provide a separate compressor for track hopper poking and wagon tippler if required.

xii) xiii) xiv) xv)

4.2.8 PLANT ELECTRICS The Contractor will supply complete electrical equipment for compressors. All the technical specifications of the electrical equipment/system including LT switchgear, MCC, Metering and protection, cables, etc., shall be as per GTS/TS. The scope of supply for electrics shall include the following: i. ii. iii. iv. Drive motors for compressors & lubrication system as well as for motor operated valves. Control Cabinet/ Console: one for each compressor. Double compression brass cable glands and cable lugs for all electrical equipment supplied by the Contractor. For compressor motor bearing and winding temperature detection, monitoring, interlocking, signalling & annunciation, micro processor based temperature controller shall be provided for each motor by the Contractor. The scanner will be housed in an independent control panel. Contractor shall note that the HT Power for the Compressed Air Station shall be fed from the nearby HT sub-station through 5 nos. 6.6kV feeders. Supply, laying & termination of the incoming cables from the HT substation to the compressed Air station along with terminations at both ends shall be done by the Contractor. The cables shall be routed through underground trench. Further distribution of HT and LT power shall be done by the Contractor. All erection/installation accessories, cable trenches, cable support structures/cable gallery, cable termination at ends, cable fixing, and support materials etc. for all equipment within the scope of supply of Contractor within the plant area including cables from OHP HT switch board are in the scope of Contractor. Employer shall only provide the HT switch board at Ore handling plant substation. Further distribution of HT and LT power shall be done by the Contractor. Power and control cables from the control cabinets, for interlocking & inter connection to all motors, instruments, consumers etc.

v.

vi.

vii.

viii. ix. x. xi. xii.

Junction boxes with required number of terminals including 20% spare terminals. All other equipment, accessories, field devices, safety switch etc required for safety interlocks, process control & interlocking etc. The contractor shall include all power and control cables in adequate quantities in turnkey/lot basis as per actual requirement at site. Contractor shall include commissioning spares in their scope. They are also furnish the list of commissioning spares. Make of all the equipment shall be restricted to the list of preferred makes given in the TS. HT compressor motor shall be provided with Flux compensated magnetic amplifier (FCMA) type soft starter enclosed herewith. The HT soft starter to be designed considering the incoming feeder line distance from the supply feeder end. Motor soft starter to be connected in line side of motor. LT Power to the compressed air station shall be fed from a dedicated MCC cum PDB which shall have 2 incomers with bus-coupler arrangement. Local push button stations UPS as per requirement shall be provided with 60 minutes backup for compressed air station. LDBs / Junction Boxes etc(as per the requirement). Earthing for all equipment within the scope of supply. Cable trestle, supporting structures, conduits, prefabricated GI cable trays, cable racks, other associated accessories like cable glands, lugs, termination/jointing kits, ferrules, clamps including trefoil clamps for single core cables, cable markers, cable identification tags, and all other hardware material as per requirement. Fire sealing materials for laying termination and sealing of cables. Complete electrics of material handling equipment like cranes, lifts, hoists, etc (if any). Complete electrics of ventilation systems for area under battery limit. Water drainage pumps in required numbers with complete electrics including source feeders, pumps/motors, cable laying, etc. Fire protection system including Fire Detection and Alarm System for the complete plant, etc.

xiii.

xiv. xv. xvi. xvii. xviii. xix.

xx. xxi. xxii. xxiii. xxiv.

xxv. xxvi. xxvii. xxviii.

Welding sockets, 240 V power sockets and 24 volts AC sockets with transformers. Illumination for the entire plant and boundaries. Installation, erection accessories. Safety items.

SPECIFICATIONS OF MOTOR SOFT STARTER To avoid impact on electrical system due to heavy motor starting current, a soft start system limiting motor current to 2 to 2.5 times shall be provided to ensure voltage drop at motor terminals limited to 15% with a provision of DOL starting . Contractor to submit the voltage drop calculation, considering adequate fault level at 6.6 kV board. The soft start system shall be based on principle of flux compensated non-saturated magnetic amplifiers for control of motor starting current. Also, the starter should not introduce any harmonics into the system. The flux compensated magnetic amplifiers shall work on principle of flux opposition and operate in the linear non saturable zone of magnetic circuit. The system will work on constant mode in the starting zone so as to result in smooth start. The enclosure class shall be IP54. The Sheet steel thickness shall be 1.6 mm. The control circuit will utilize auxiliary contacts and timers for starting function. Lamp indication shall be provided using LED type lamps. Ammeter shall be provided on front door. The cubicle will have cable entry and exit from bottom through gland plate. Bypass device used shall be 6.6kV contactor. 4.2.9 CONTROL & INSTRUMENTATION General Electronic type instruments generally working on 4- 20 mA DC signal system will be used. The instrument panel will be suitably installed in the compressor room. All instrumentation items will be selected to function satisfactorily in shop floor environment.

List of measurements & controls For each compressor, the list of measurements & controls will include, but not limited to, the following: i) Equipment/ local panel mounted measurements i. ii. iii. iv. v. vi. vii. viii. ix. Indication of differential pressure across suction air filter for each compressor. Indication of pressure of compressed air after after-cooler and after compressor. Indication of temperature of compressed air after after-cooler and air compressor. Indication of pressure of compressed air in air receiver. Indication of pressure of lube oil before & after oil cooler. Indication of temperature of lube oil before & after oil cooler.

Indication of differential pressure across lube oil filter. Indication of temperature at the inlet & outlet of common header of compressor cooling water circuit. Indication of pressure at the outlet of common header of compressor cooling water circuit. Indication of flow of compressed air.

x. ii)

Alarms and interlocks 01 Following audiovisual alarms and interlocks will be provided for each compressor: 1) 2) 3) 4) 5) 6) 7) 8) Differential pressure of air across suction air filter high Alarm only. Temperature of air after air compressor high- Alarm only. Temperature of air after air compressor too high Alarm and trip. Pressure of air after after-cooler high - Alarm only. Pressure of air after after- cooler too high- Alarm & trip. Differential pressure across lube oil filter high - Alarm only. Pressure of lube oil to compressor low - Alarm only. Pressure of lube oil to compressor too low- Alarm & trip.

9) 10) 11) 12) 13) 4.2.10 1. 2.

Temperature of lube oil to compressor high- Alarm only. Cooling water supply pressure low - Alarm only. Cooling water supply pressure too low - Alarm & trip. Motor over load - Alarm & trip. Manual tripping- Alarm only

COMPRESSED AIR PIPES, FITTINGS & VALVES Pipe sizing will be done considering a velocity of 10 -12 m/s. The pipes will be hydro tested at shop as well as at site. All pipes and valves will be as per the following tables. Specification of Pipes & Fittings

Sl. 1.0

Service Compressed Air System

Size <50NB

Pipes A53 Gr.B or IS 1239, Heavy Grade A53 GR.B or IS 1239, Heavy Grade

Fittings ASTM A105 Or IS 1239, Part-II ASTM A234 Gr.WPB

Flanges ASTM A105

Gaskets Teflon

End Type Plain End

>65NB

ASTM A105

Teflon

Welded/ Flanged

Sl. 1.0

Service Compressed Air System

Size >65NB

Specification of valves Body/ Disc Bonnet ASTM A 216 Gr. WCB ASTM 105 ASTM 105 A A ASTM A 216 Gr. WCB ASTM A 479,Type 410-2 ASTM A 479,Type 410-2

Stem ASTM A479 Type 410-2 ASTM A 479,Type 410-2 ASTM 479,Type 410-2

Hand Wheel ASTM A47 Gr. 32510 ASTM A47 Gr 32510 A ASTM A47 Gr. 32510

Valve ends Flanged Raised Face Flanged Flat Face Socket Welded

>25 & < 50 NB < 25 NB

(*)

Testing of valve body, seat and back seat will be as per ANSI B16.34.

4.2.11 TESTING Unless otherwise stated, main equipment, valves and other ancillary units will be tested to various stipulations stated in Indian Standards of BIS or any other reputed international standard listed. Recommended tests on Air Compressors are listed hereunder. Compressors may be tested using a suitable shop motor. i) ii) iii) iv) v) vi) Volumetric and overall efficiency (type test) Capacity (Routine test) Specific power consumption from no load to full load (Routine test) Speed (Routine Test) Testing of unloader (Routine test) Safety valve test (Routine test)

All other tests will be performed in accordance with IS: 5456. 4.2.12 STANDARDS AND CODES The complete system as a whole and individual equipment will be in accordance with the Indian Standards, British Standards, DIN or American Standards like ASME, ANSI or any other internationally accepted codes. 4.2.13 GUARANTEE AND PENALTIES The Contractor will guarantee individual as well as integrated performance of all the equipment supplied by them for period as stipulated in the GCC prior to the date of issue of taking over certificate by the Employer. The final acceptance certificate will be issued by the Employer after successful commissioning of the Plant by the Contractor showing all the performance test at specified parameters. The following parameters will be guaranteed at 350 C, 60% RH, 330 C cooling water temp., 50Hz frequency. Air Compressor: * Rated Capacity at lowest frequency * Rated discharge pressure at the outlet of after cooler : : 36 Nm3/ min (each) 8 kgf/cm2 (g)

* Discharge temperature after after cooler at rated capacity and pressure * Oil content in the air at the outlet of air compressor

<390 C

Oil free

* Specific Power consumption of the compressor at the rated condition mentioned above (kwh/Nm3) (at motor input) * Noise Level * Volumetric efficiency of each the compressor * Inter cooler/ After cooler pressure drop

6.17

: :

80 dB(A) 87.4 %

0.2 kgf/cm2 (max)

4.2.14

LIST OF PREFERRED MAKES Compressor M/s Atlas Copco, Pneumatics. 1. Electrics Motors Alstom Ltd. , Asea Brown Boveri Ltd. , BHEL, CGL, Electric Co. 2. Cables Cables Corporation of India, Fort Gloster Industries Ltd. Industrial Cable (I) Ltd. Nicco Corporation Ltd. Universal Cables Ltd. Torrent Cables Ltd. 3. Control Stations Weather Proof Baliga Lighting equipment Ltd., Bhartia Industries Ltd. Electrical Equipment Corporation, Ex-Protecta, Shrenik & Company. 4. Light fittings & Accessories CGL, Philips, Bajaj. 5. Actuators - MOV Auma India Ltd., Flow tork Inc. USA, Continental Profiles Ltd., Rotork Control Ltd. Instrumentation TRANSMITTERS (PRESSURE, FLOW & LEVEL) : FUJI, YOKOGAWA BLUESTAR LTD., EMERSON, TATA HONEYWELL LTD, ABB. BARGRAPH INDICATORS : FUJI, YOKOGAWA BLUESTAR LTD., MASIBUS ELECTRONICS. NGEF, Kirloskar M/s ELGI, M/s Ingersoll Rand, M/s Kirloskar

DIGITAL INDICATORS : YOKOGAWA BLUESTAR LTD., MASIBUS ELECTRONICS, RANUTROL LTD. MICROPROCESSOR BASED RECORDERS : YOKOGAWA BLUESTAR LTD., LAXSONS ENGG. & ELECTRONICS PVT. LTD.(CHINO), FUJI, ABB. PRESSURE/TEMPERATURE GAUGES : A.N. INSTRUMENTS PVT. LTD., GENERAL INSTRUMENTS, MANOMETER (INDIA) LTD. RTDs & THERMOCOUPLES : GENERAL INSTRUMENTS, INDUSTRIAL INSTRUMENTATION, INSTRUMENTATION LTD, NAGMAN SENSORS, TOSHNIWAL BROTHERS. TEMPERATURE TRANSMITTER : YOKOGAWA BLUESTAR LTD, EMERSON, TATA HONEYWELL LTD, ABB. DIGITAL SCANNER: JYOTI, LECTROTEK, PROCON, MASIBUS. PRESSURE SWITCH : INDFOSS (INDIA) LTD., SWITZER INSTRUMENTATION PVT LTD. FLOW TOTALISER: YOKOGAWA BLUE STAR LTD., FUJI, SIEMENS. LEVEL SWITCH / SENSORS: LEVEL GAUGE : J. N. MARSHALL SIGMA. & SONS, LEVCON INSTRUMENTS PVT. LTD.,

SOLID STATE ALARM ANNUNCIATOR : APPLIED ELECTRONICS LTD. (APLAB), PROCON INSTRUMENTATION PVT. LTD., PIRI SYSTEMS PVT LTD., IIC, MINILEC, MASIBUS. POWER CABLES : CABLE CORPORATION OF INDIA LTD., UNIVERSAL CABLES LTD., FORT GLOSTER INDUSTRIES LTD., ASIAN CABLES LTD, FINOLEX CABLES LTD., KEI. INSTRUMENTATION SCREENED CABLES : CABLE CORPORATION OF INDIA LTD., FINOLEX CABLES LTD., TOSHNIWAL CABLES, DELTON CABLES, KEI, ASIAN CABLES, UNIVERSAL CABLES. COMPENSATING CABLES : TOSHNIWAL CABLES, GENERAL INSTRUMENTS, UDAY RAJ, KEI.

4.2.15

Water System Facilities for Air Compressor Unit

a)

Cooling Water System

i)

The cooling water system will generally comprise the following main units:Open Indirect Industrial water (clean) cycle: a. Pumpsets b. Cooling tower c. Strainers (simplex with manual backwash through valves operation) d. Interconnecting piping e. Chemical conditioning system f. Electrics, instrumentation & control system.

ii) For cooling of plant and equipment of the air-compressor unit there shall be a separate cooling water re-circulation system for each unit / subsystem with pumps, cooling towers and piping network. Contractor shall provide a separate pump house to house compatible group of pumps. Separate group of pumps and separate piping shall be provided for each sub-system to enable flexibility in operation. iii) The cooling water system shall be supplied in line with the GTS with regard to design norms (including no. of standby pumps, type of pumps, valves and piping design) and subject to Purchasers approval. iv) The total cooling water to the units shall be filtered through simplex strainers. For this simplex strainers (1W+1S) of 500 microns filtration grade shall be installed on each of the two supply headers complete with isolation valves. Strainers shall be backwash type. v) The cooling water circuits shall be provided with chemical conditioning system to control corrosion and scaling and prevent bio-fouling. To reduce blow-down higher cycle of concentration shall be targeted. vi) Pump houses shall be provided with air-washer based air-conditioning and ventilation system.

vii) With a view to conserve and save upon fresh water requirement the Contractor will plan to utilize/ reuse/ recycle the reject/blow-down from the cooling water systems in the plant with necessary treatment etc. as specified by the Purchaser. viii) Make-up water for cooling water re-circulation system for the compressor will be tapped from the Purchasers existing industrial water network as mentioned under the clause for Battery Limits and will be conveyed to the various consumers through a pipe network.

b)

Make- up Water System

i)

The water loss in the various processes in evaporation, process/ system, minor leakages including service water requirement, etc. shall be replenished by a separate common make-up water system to be provided by the Contractor.

ii)

Make up water system will include extension of pipelines from the battery limit with isolation valve to the recirculation cooling water system for equipment cooling, water circulation system for ACVS facilities as well as service and process needs.

iii) Make-up water will be tapped from the Purchasers existing industrial water network as mentioned above under the clause for Battery Limits and will be conveyed to the various consumers through a pipe network. iv) Tapping of industrial make-up water shall be based on two points feeding and shall conform to provisions of TS/GTS. Contractor shall extend the industrial water line with an isolation valve alongwith flow meter to his proposed systems for service/make-up water requirement for the entire plant area. v) Quality of industrial make-up water is furnished in the GTS. This water will be supplied as make-up water to Package 061 for process & cooling needs at only one point for the entire needs of the Package 061 at battery limit as specified. The Contractor shall provide necessary treatment facility, wherever required, to make the water suitable for cooling and other purposes. vi) Drinking water & Feed water for DM Plant-Maroda-II water quality as per GTS shall be followed,

vii) Industrial make-up water Maroda-I water quality as per GTS shall be followed. viii) All make up tapings should have flow meters with by-pass arrangement with isolation facility. ix) Online boosting of the make-up water is not permitted. A makeup water sump with pumps and piping (pump house and sump are to be provided by the Contractor), if required, shall be provided.

c)

Water Conditioning System

i)

To protect the circulation water system from corrosion and scale formation and to bring the make up water to the condition suitable for the cooling water requirement of air-compressor unit there shall be a water conditioning facility as per system requirement and inline with the details given in GTS.

ii) It shall consist of dosing tanks, pumps, valves, pipes, fitting, pipe supports and associated civil, structural, technological structures, electrical, instrumentation, material handling, air-conditioning & ventilation etc. The scope of work for all these remains the same as specified for cooling water system. iii) These pumps may also be housed in the same pump-house for cooling water system or separately. iv) The Contractor shall furnish the details of chemical dosing proposed for the system. v) The Contractor shall include in the scope of supply three months chemicals requirement for the chemical conditioning system from the date of commissioning.

4.2.16

COOLING TOWER Type : Induced draft counter flow Casing/ Basin : FRP Frame Work : MS hot dip galvanized Fills : PVC Nozzles : Brass Bolts, nuts, miscellaneous hardware : MS electro galvanized Fan hub & blades : Cast Aluminium Fan type : Axial flow, direct drive Fan speed : 720 rpm Degree of protection of motor : IP 55 (temperature rise limited to class B) Ladder : Galvanised steel ladder with safety cage & hand railing up to the top of tower. Inclined to 300 to the vertical Eliminators : No. of deflector to be arranged to reduce drift loss < 0.2% water circulation. Cooling Tower Accessories: (i) (ii) (iii) (iv) (v) (vi) (vii) Level switch at cooling tower basin (to be interlocked with pump) Make up connection with float valve (float made of copper) & back up ball valve Quick fill connection with ball valve Overflow connection Drain connection with ball valve GI wire mesh 18 gauge strainer Equalizing line of cooling towers with isolation valves of

4.2.17

WATER PUMPS be provided for capacity 15 m3/hr & less. Pump will

Mono block pump will bronze & will

conform to IS: 9079-1989. Pump casing will be of C.I & impeller will be of have stuffing box arrangement for gland packing. IP-55 be provided. protection motor will

Horizontal back pull out pump will m3/hr. Centrifugal Pump : Horizontal back pull out pump will vertically split type. Impeller rpm will Pump will will

be provided for capacity more than 15

be provided.

Pump casing will

be

generally not exceed 1450. However,

for pumps with low capacity & high head may be provided with 2900 rpm. be coupled to motor with flexible coupling. Spacer type coupling conform to IS : 1520. be provided. Pump will

Pump will give satisfactory performance at any point on the H-Q curve over a range of 40% of rated flow to 120% of the rated flow. The maximum efficiency will preferably be within 10% of the rated design flow. The total be continuous rising towards the shut off without head -capacity curve will the design head. Pumps will have shaft seal by gland packing. Pump will be fitted with double wearing rings, one is fitted in the front of the impeller on the casing and the other is fitted in the back of the impeller on the impeller itself. Impeller will vibration will be dynamically balanced. The magnitude of peak to peak be limited to 75 micron. Pump impeller will be non be made in one piece & keyed to the shaft.

any zone of instability and with a minimum shut-off head of 15% more than

overloading type. Impeller will

Material of construction Casing Impeller Bearing Bracket Shaft protection sleeve Wearing ring Shaft - C.I - Bronze - C.I - Bronze - Bronze - EN-8

Common base frame for pump & motor - M.S

Common base plate for pump & motor will welded steel construction. piping. Pumps will

be in one piece & made of be provided between pump

Adequate space will

drain connection and base plate for installation of minimum 15 mm drain be supplied with suitable drain pans or drain rim type base plates with tapped drain connections. Critical speed of the shaft will speed. 4.2.18 Water Piping and Fittings Water piping up to 150 mm NB size will be GI, ERW, heavy class and be MS, spirally be beveled. be at least 30 percent above the operating

conforming to IS-1239 Part- 1. The pipes above 150 NB will Pipe fittings will

welded , 6 mm thick and conforming to IS:3589. Pipe ends will

be as per IS 1239, Part -2 for pipes of size up to 150 NB.

Fabricated fittings manufactured from the pipes may be provided for pipes of sizes 200 NB & above. Plate type pipe flanges (as per IS 6392) will Pipes will be provided. be

be of welded joints. Welding (manual metal arc welding) will be employed.

as per relevant IS code and only certified welders will All piping systems will

be hydro tested at 1.5 times the design pressure. be provided at highest point of the pipe lines &

Auto air venting valves will segments.

drain valves will be provided at lowest points of the pipelines in different

Pipe supports comprising pipe shoes, saddles, base plate, clamps & structural members like channels, angles etc. will Valves Butterfly Valves will ball valve will be provided in water line of size 65 NB and above and be provided

be provided for pipe size below 65 NB. However, ball valve

will

be provided in the pipe line (irrespective of sizes) when flow control is

required. Butterfly valve Type : Wafer design, flange less Body : SG iron with nitrile rubber/ EPDM lining Disc : SG Iron with teflon (PTFE) coating Stem : High tensile stainless steel The valves will body liner will be provided with integrally moulded & bonded body liner to provide the seating to valve disc, primary seal to the stem & pipe flanges. Valves will be provided with self provide perfect seating and complete isolation of body material from fluid. The gasket joint with mating

locking lever operation from open to fully closed position with intermediate positions marked on the indicator plate mounted on the top flange. The valves will conform to BS : 5155 / IS : 13095. Extended valve shaft will be provided so that the lever can be operated without any obstruction on the insulated pipes. Gear operated valves will 250 NB. Ball Valve Body : Cast steel Body liner : Nitrile rubber/ EPDM Ball : ASTM A351 Gr CF8 3 piece design Socket welded type Ball valves will be with 200 mm length welded joint pipes from manufacturer works. Check valve Type : Dual plate check valve with two springs hinged on a central hinge rod Body : SG iron Body liner : Nitrile rubber/ EPDM Disc : ASTM A351 Gr CF8 Wafer design be provided for sizes more than

Pressure Gauge Manufacturing Standard : IS 3624 Range : 0 6 Kg/ cm2 or 0-10 Kg/ cm2 Range (at pump suction) : (-)2 to (+) 2 Kg/ cm2 Dial Diameter : 100 mm Accuracy : + 1% of FSD Degree of protection : IP 65 Sensing element : Bourdon tube Bourdon tube material : AISI SS316 Connection : Screwed Connection size :

BSP (M)

Mounting : Direct with bottom entry Case : Die cast Al stove enamelled black finish Bezel (screwed) : Die cast Al stove enamelled black finish Dial window : Shatter proof glass Pointer : Al anodised black Dial : Al white with black letters Movement assembly : AISI 304SS Shank : AISI 3166SS Adjustable pulsation damper : Yes Pressure gauges will be provided with isolation valves (Ball valves)

4.3.0 Water Supply System

4.3.1 Scope of work of Water Supply System The scope of work of water supply system include (i) (ii) (iii) Drinking water system, Service water system, Dewatering system for underground premises (Track Hopper building, Wagon Tippler building & Junction House JH-Z1) and Drainage system for Pump Houses (6 Nos.),

4.3.2 Battery Limit All water tappings shall be made by the Contractor through two points (~10-15m apart) from the Purchasers network through isolation valves; make-up water tappings shall be through flow meter with requisite isolation valves on either side and by-pass arrangement.

a)

Industrial water / Service Water Industrial quality make-up water (quality as indicated in GTS) will be made available to the Contractor at one point within 100 m from the proposed Package 061 area at a pressure of approximately 1.0 kgf/ cm2.

b)

Drinking water Drinking water will be made available to the Contractor at one point within 100 m from the proposed Package 061 area at a pressure of 1.5-2.0 kgf/ cm2.

4.3.3 Specification and Description of Work Water System Facilities: Water system shall in general include the following facilities:-

a)

Drinking Water System i) The drinking water shall be made available at one point near Package 061 within battery limit as specified. The Contractor shall extend the pipeline from battery limit with an isolation valve in a valve pit up to various drinking water consumers under the subject package. ii) Tapping of drinking water shall be based on two points feeding and shall conform to provisions of TS/GTS. Contractor shall extend the drinking water line with an isolation valve in a valve-pit to his proposed units for drinking water requirement for the entire plant area. iii) On-line boosting of the drinking water is not permitted. If the pressure, as indicated in battery limit parameters, is felt inadequate for the area under the scope of the Contractor, Contractor shall provide separate sump and drinking water pumps along with piping and electrics etc. to meet the requirement. iv) The details and specification of pumps, valves, pipes, fitting, pipe supports and associated civil, structural, electrical, instrumentation, material handling, air-conditioning & ventilation etc. for cooling water system is applicable for this system also. v) Drinking water to be supplied to the entire junction houses, Control Rooms, Area Repair Shop, Stores (sub-store), Welfare Buildings; except for the Welfare Buildings the drinking water tappings shall be one for each no. and type of premise. Drinking water shall be supplied through continuous pumping.

b)

Service Water System

For Service Water, pipeline network shall start from common pump house to all the transfer points of each floor and conveyor gallery. In each floor, 1 no. tapping point will be provided and for the conveyor gallery the tapping point shall be provided at every 50metre interval. For each tapping point 1 no. gate valve, hose (DN25) and quick fix connection shall be provided.

For service water line each tapping point discharge rate will be 2m/hr. and maximum 6 Nos. points can be operated at a time. Pumping system shall be conforming to GTS for design norms including no. of standby units, pump rpm, piping etc. c) Dewatering system for underground premises and Drainage system for Pump Houses Dewatering system for underground sumps (Track Hopper building, Wagon Tippler building & Junction House JH-Z1) and Drainage system for Pump Houses (5 Nos.) shall be provided as required. The water from the sumps will be pumped to the nearest surface drainage system through pumping arrangement to be provided as per GTS and subject to Purchasers approval. The details of Sump Pumps are given below; 1. Track Hopper building 3. Junction House JH-Z1 - 4 Nos. (2W+2S), (2 Nos. each side). - 2 Nos.(1W+1S) 2. Wagon Tippler building - 2 Nos.(1W+1S) All Sump Pumps shall have Cap. 50 CBM /Hr. & Head - 15 Mtr. The details of Drainage Pumps are given below; 1. Pump House (5 Nos.) - 10 Nos. (5W+5S) All Drainage Pumps shall have Cap. 25 CBM /Hr. & Head - 15 Mtr.

All Piping, Valves, Fittings, Instrumentation, Controls etc. are in the scope of Bidder. All the water lines including Drinking water, Service Water, Dust Suppression Water, Dewatering, Make-up water lines will generally be laid over-ground.

d)

Water Pollution Control and Conservation Extensive recycling will be adopted in the design of plant water systems. Quality of circulating water will be maintained through dosing of conditioning chemicals for controlling corrosion, scale deposit and microbial growth. Through cascaded reuse of blow down, the water scheme will ensure minimization of waste water discharge from the industrial water circuits. Any discharge/reject into the Purchasers system shall conform to the local pollution control norms. Design Criteria Efficiency, reliability and flexibility of operation and maintenance will be the guiding criteria of the design of the water system for the proposed plant. Water system shall be designed as per TS/GTS and subject to Purchasers approval. The followings are the guiding factors for designing the water system: i. ii. iii. The water system shall be designed & supplied generally as per the contract document, GTS and subject to Purchasers approval. Design norms including no. of standby units, pump rpm, piping shall conform to GTS as applicable for this package. Following MOC to be considered: Gate valve: Body & Cover: CS ASTM A216 Gr WCB, Disc: ASTM A216 Gr WCB Face ring 13% Cr steel, Body seat ring: 13% Cr. Steel, Stem: SS 410, Gaskets: Neoprene rubber, Gland packing: Rubber, End connections: Flanged to be drilled as per IS: 6392-1971 (RA 1998) T-17. Butterfly valve: Body: ASTM A216 Gr WCB, Disc: CF8, Seat: EPDM (integral with the body), shaft: AISI 410 self-lubricated PTFE lined bearings for both drive end and non-drive end, hand lever /hand wheel: pressed/forged steel, end connection: Flanged to IS6392, T-17.

iv. v.

Pipe thickness shall be as per GTS (numerical values indicated for each of the pipe sizes). Tapping of Industrial water / Service water, Make up water & Drinking water will be based on two points feeding and will conform to provisions of TS & GTS.

vi. vii.

Isolation gate valves shall be provided in suction and delivery side of pumps as per GTS. The drainage pumps shall be split casing; self priming and horizontal centrifugal pumps type with common base frame with drive motors, there will be one reserve pump for one working pump. The pumps shall not be of mono-block design.

viii.

Each pump shall have independent suction. The delivery line of each pump shall be connected to the main header with isolating header gate valves for isolating delivery valves.

ix.

Suitable number of header valves shall be such that delivery valve of pump can be isolated for maintenance without affecting other stand-by pumps availability.

x. xi.

Motorized gate valves shall be provided in automated pumping system for pumps suction & delivery. Commissioning spares & consumables as required for the successful commissioning are included in the scope of the Contractor.

4.3.4 Erection, Testing and Commissioning 1. The erection of all plant and equipment shall be carried out according to the latest engineering practices and according to the drawings, specifications, Instructions etc. duly approved by the Purchaser. 2. 3. The welding work should be carried out as per the approved WPS and PQR. The successful Contractor shall supply all required manpower, tools and related equipment, all hoisting equipment, all necessary scaffoldings, all necessary transporting equipment, consumables. Construction and erection materials, petrol, diesel oil, kerosene, solvents, sealing compound, tapes, brazing and soldering materials, welding and brazing gases, erection bolts, nuts and packing sheets/compounds, temporary supports, wooden blocks,

spacers, templates, jute and cotton wastes, sand/emery paper etc. as required for the satisfactory completion of work. 4. After erection, all equipment having moving part, subject to pressures or voltages shall be given trial operation. The trial operation shall consist of 72 hours of continuous operation. All modifications and rectifications required during the trial operation or required for proper operation shall be done at his own cost by the Contractor as accepted by the Purchaser. 5. Rotating equipment shall be checked for proper direction of rotation and shaft alignment. Equipment subject to pressures shall be carefully examined for leakage. All equipment, such as pressure taps, temperature measurement connections, flow measurement devices etc. shall be provided by the Contractor. 6. On completion of the work, the Contractor shall remove and dispose off all rubbish and other unsightly materials caused by his working to a distance of five kilometer from the Package 061 7. or as directed by the Purchaser and thereby leaving the premises in good, clean, safe and operable condition. Before giving call for final inspection, all the documents shall be furnished to the Purchaser. The record of manufacturing details, inspection and tests carried out by the Contractor shall be made available to the final inspecting authority. However, approval and final inspection at the manufacturing works shall not relieve the Contractor of responsibility of replacing at his cost any defective part/material which may be detected by the purchaser during erection and commissioning or guarantee period. 8. All materials required for fabrication, construction, testing and inspection shall be supplied by the successful Contractor. No material shall be free issue to the Contractor. 9. 10. 11. No equipment or part item shall be dispatched without final inspection and issuance of inspection certificate. All equipment, assemblies, sub-assemblies shall be shop tested as per relevant standards and the test certificates shall be submitted by the supplier. Erection, testing & commissioning of various equipments and piping etc shall be done also inline with details given in various chapters of GTS. 4.3.5 Painting The Contractor shall follow the painting procedure as mentioned in GTS.

4.3.6 Preferred Makes The Contractor shall follow the list of preferred makes indicated hereinafter. 4.3.7 Drawings/documents to be furnished by the Contractor for approval: 1. 2. 3. Scheme of the complete water supply system with descriptive and illustrative literature. Process flow diagram indicating the water consumption figures complete with temperature, pressure and quality requirements. P&IDs of each circuit of the complete water supply system showing all the consumers, flow rate, pipe diameters, broad parameters of each equipment, instruments, interlocks, water losses etc. 4. 5. 6. 7. 8. Write -up detailing the control logic for the entire water system. All equipment and piping sizing calculations, Data sheets for various pumps, strainers, filters, valves and other equipment as applicable in line with in the GTS. Pipeline materials and specifications considered for various systems. Layout drawing showing the battery limits of service water, make up water, drinking water and the pipeline route to various consumers including requirement of service water, make-up water and drinking water at battery limits. 9. 10. 11. 12. 13. 14. 15. 16. General arrangement drawings of pump houses showing tentative dispositions of various equipment and piping. Layout of piping system indicating pipe routing, location of supports, valves and other fittings as required. Data sheets and technical details of all the equipments, valves and piping. Catalogues, literatures and GA drawings of all equipments and valves. List of special tools and tackles. Test procedures for preliminary and final acceptance tests. Quality Assurance Plan. Test certificates for the following: Material test certificate for all major equipment and their components. Hydraulic test of equipment, pipe fittings & valves. Static and dynamic balancing of all rotary parts/ equipments

17. 18. 19. 20. 21. 22.

List of commissioning spares. List of spares for two years of normal operation and maintenance with item wise prices. Specification and capacity of all equipment, valves etc. offered by the Contractor. Details of various drives, instruments, handling & hoisting facilities, air conditioning & ventilation facilities, etc. Bill of Quantities covering all equipments, valves, strainers, pipelines, etc. Any other drawing/ documents as required by the Purchaser.

4.3.8 Drawings / Documents to be furnished by the Contractor for reference and record 1. The Contractor shall submit required sets of all the approved / received for reference drawings, documents and manuals for Purchasers record and use. Further, after erection of plant and equipment, the Contractor shall submit one set of linen tracings/ reproducible in required number of prints along with soft copies in CD (in AutoCAD format) of each As built drawings. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Operating and maintenance manual. Spare parts recommendation and price list. Instruction for erection, testing and commissioning. Manufacturers test certificates. Various equipment assembly drawings and bill of material. Welding procedure. Hydraulic test logs. Equipment GA drawings and bill of materials. Operation and maintenance manuals for all equipments, valves and complete water system along with soft copies. Test and calibration certificates. Warranty/ guarantee certificates. Technical literature, catalogues and manufacturers drawings for all brought out equipment, valves and other items. All inspection/ test report/ certificates. Any other drawing/ documents as required by the Purchaser/Consultant.

4.3.9 Preferred makes List of vendors for Water System Sl No. 1. Horizontal centrifugal Pumps 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Submersible pumps Dosing Pump Cooling Towers Sluice Gates Basket Strainers Rubber expansion joints CS Valves (gate, NRV) Plug Valves Ball Valves Butterfly Valves (manually & electrically operated) 12. 13. 14. 15. 16. 17. 18. Float Valve Control Valve Solenoid Valve Air Release Valve Check Valve (Zip type) Electric Actuators Pneumatic Actuators : : : : : : Leader, IVPL, Levcon. Audco, Fouress, IL, Xomox, Fluid Line. Rotex, INDFOS, AVCON. IVPL, L&T, Leader, BDK, Fouress, Chemtech Beacon Rotork, Auma, Limitorque, IL, Palghat, EI-O-Matic AL Saunders, Xomox, EL-O-Matic, AUMA : : : : Audco, Fouress, BHEL, KSB, BDK, Kirloskar, Leader, KSB. Audco, Xomox, BDK, KSB. AUDCO, Fouress, Intervalves. Chemtech. Audco, Xomox, BDK, Tufiln, Chemtrol Samit, : : : : : : : Kirloskar Brothers, KSB, Beacon Weir, Voltas, Mather & Platt, Jyoti, WPIL (Worthington). KSB, SU Motors, Kirloskar Brothers. Shapo Tools, Asia LMI (Madras), Toshniwal, Milton Roy India. Paharpur, Jash, IVPL. Filteration Engineers, Superflo. BDK, CORI Engineers. Shriram Tower Tech, Gammon, Southern Cooling Tower. Item Description : Manufactures

Sl No. 19. 20. 21. 22.

Item Description Hoses Pipe a) MS/GI MS/GI Pipe Fittings Chemical Dosing System

: : : : :

Manufactures Senior Flexonics, Hydrocrimp SAIL, TATA, Jindal, MAN, SAW, Welspun, Prakash, PSL, MSL, Tube bends, Stewards & Lloyds, BST, Jindal. GE India Industrial Private Limited, Ion Exchange, Chembond Drewtreat.

4.4

LEVEL OF VARIOUS BUILDINGS AND JUNCTION HOUSES

(A) Z-LINE Sr. No. Name of Building / Junction House Wagon Tippler Building Pump House-2 LTSS-1 JH-Z1 JH-Z2 Track Hopper Building JH-Z3 JH-Z4A JH-Z5A JH-Z6A JH-Z7A JH-Z4 JH-Z4B JH-Z5B JH-Z6B JH-Z7 Main Pump House-1 Compressor House LTSS-2 JH-Z8 FTH-1 JH-Z9 JH-Z10 JH-Z11 Pump House-3 LTSS-3 JH-Z12 JH-Z13 JH-Z15 Ground Level (Mtr.) 307.250 307.250 307.250 306.000 307.000 308.358 306.000 303.000 303.000 303.000 303.000 303.000 303.000 303.000 303.000 303.000 303.000 303.000 303.000 303.000 311.000 308.000 310.500 310.000 310.000 310.000 310.000 310.000 308.500 No. of Floors Floor Levels (Mtr.) I 307.250 ----303.750 309.000 308.358 306.000 303.000 303.000 303.000 303.000 309.000 303.000 303.000 303.000 303.000 ------316.600 318.000 313.900 317.000 320.000 ----316.500 322.900 343.800 II 304.982 ----300.050 313.000 299.158 310.100 307.100 307.100 307.100 307.100 312.600 309.000 309.000 308.700 308.300 ------321.600 322.500 317.500 320.600 323.700 ----320.000 328.000 347.400 III 298.500 ----296.050 316.900 --314.100 310.600 310.600 310.600 310.600 ----------------------324.100 327.300 --------350.400 IV 295.000 ------------315.800 ------------------------------------------V 291.100 -------------------------------------------------------

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

5 ----3 3 2 3 4 3 3 3 2 2 2 2 2 ------2 2 2 3 3 ----2 2 3

(B) L-LINE Sr. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 Name of Building / Junction House JH-J102 JH-L1 JH-L2 JH-L3 JH-L4 LTSS-4 JH-L5 JH-L6 JH-L7 Pump House-4 JH-L8 JH-L9 JH-L10 Ground Level (Mtr.) 310.000 310.900 310.100 310.500 310.000 310.000 310.000 308.500 306.000 306.000 304.000 312.000 307.000 No. of Floors 1 2 2 2 3 --2 2 2 --2 3 1 Floor Levels (Mtr.) II III IV --318.525 328.225 324.325 320.400 --320.150 327.670 316.500 --309.300 328.000 ----------324.000 ------------332.000 -----------------------------

I 317.100 314.525 325.625 317.800 316.800 --315.332 322.670 312.900 --304.000 312.000 352.600

V ---------------------------

(C) J -LINE Sr. No. 1 2 3 4 5 6 7 8 9 10 11 Name of Building / Junction House JH-J9B JH-J9H JH-J10A JH-11 Pump House-5 JH-J14A JH-J15B LTSS-5 JH-J17A JH-J17B JH-J20 Ground Level (Mtr.) 308.500 309.200 310.000 310.000 310.000 310.000 309.500 309.500 307.300 307.300 307.300 No. of Floors 1 3 2 3 --2 4 --2 3 1 Floor Levels (Mtr.) II III IV --316.000 327.800 319.600 --321.100 318.650 --317.700 327.100 ----320.000 --323.800 ----322.150 ----330.800 --------------325.650 ---------

I 308.500 312.120 324.000 312.400 --317.578 314.650 --313.700 323.300 330.850

V -----------------------

5.0 SPARES
(A) Commissioning Spares and Insurance Spares Supply of commissioning spares and insurance spares as required shall be in scope of supply of the Bidder alongwith the equipment. The list of commissioning spares and the insurance spares as per the format as given in SBD shall be furnished alongwith the tender. It shall cover requirements of erection, cold tests, startup and initial operation of the plant till integrated testing & successful commissioning and commencement of commercial production up to a period of six months. Any leftover commissioning spares shall be the property of the Purchaser. Any commissioning spares required over and above the list given by the Bidder shall have to be provided by the Bidder free of cost up to the successful commissioning & commencement of commercial production of the plant and equipment. The Bidder shall supply adequate insurance spares to ensure smooth operation and maintenance of the plant. (B) Consumables The Bidder shall supply all consumables such as initial fill of lubricants, oils, grease, chemicals, refractories, resins etc. as required to complete the plant till commissioning and shall have a shelf life of minimum one year. The scope of consumables shall include electrodes, shims, packings, bolts, nuts, gaskets, rivets, washers etc. The Bidder shall fulfill the requirement given in SBD. The Bidder shall also furnish Indian equivalent of oils, lubricants, refractories and other consumables along with necessary specifications, drawings, catalogues etc. to enable the Purchaser to procure them from indigenous sources. The Bidder shall indicate the annual requirement of all such consumables. (C) Operating, Maintenance and Two Years Spares: (1) The Bidder shall ensure the interchangeability of the parts wherever possible. The Bidder shall furnish an itemized list of interchangeable spares as given in SBD. (2) The list of spares as necessary and recommended by the respective manufacturer for two years of reliable and trouble free operation and maintenance of all equipment under this package shall be in the scope of the Bidder. The same shall be quoted separately. In the event of order the successful Bidder shall furnish complete specification of the same. (3) Spares list giving complete list of the replaceable parts, fully illustrated, shall be supplied. The list shall include the following information. Item designation Reference drawings Quantity installed

Quantity recommended for two years normal operation including the insurance spares Weight of each spare part Supplier or sub-suppliers catalogue number Recommended minimum stock Expected replacement time Installation instruction in detail shall be supplied both for original installation and future, for replacement of major electrical equipment, circuit wiring diagram shall be provided.

(D)

Special Erection / Maintenance Tools and Tackles: (1) The Bidder shall supply a complete and unused wet of all the special tools and tackles including required number of tool boxes as required for erection, maintenance, overhaul or complete replacement of the equipment and components required for the plant. The Bidder shall submit a list of such special erection and maintenance tools and tackles. (2) All the tools shall be supplied in separate containers clearly marked with the name of the equipment for which they are intended. (3) The Successful Bidder shall indicate list of construction machineries, handling equipment and other facilities including tower crane or equivalent for erection at high elevation required for the execution of work based on their previous experience, considering site conditions and other considerations of work and furnish resource deployment plan. The successful Bidder shall mobilize these equipment at site for the execution of work and this is an important requirement of the project. The availability of required facilities shall be ensured for completeness of the project in time. (4) For any fabrication / control assembly (necessary for erection) work to be done in the plant premises the plan shall be indicated by the Bidder. The necessary equipment such as plate bending machines, special purpose welding machines, fixtures, tools & tackles and other equipment required for fabrication shall be arranged by the successful Bidder. (5) The successful Bidder shall carry out the testing of welded joints by radiographic and ultrasonic methods. They must have only qualified / certified welders with them for completing all the welding jobs. (6) All the measuring instruments shall be calibrated having reference to NPL (National Physics Laboratory).

(7) All tools and tackles, apparatus, special instruments required for erection, testing, commissioning and establishment of the Performance Guarantee Test, measurements required for establishing the pollution control norms and such other instruments, as required, shall be arranged by the successful Bidder. After

commissioning, the successful Bidder shall handover all the special tools & tackles to the Purchaser as per the requirement given in SBD. (8) The successful Bidder shall supply all required consumables, initial fill, oil, lubricants, construction and erection materials including but not limited to shims, packing plates, joining compounds, kerosene, solvents, sealing compounds, tapes, connectors, brazing and soldering materials, welding and brazing gases and rods, electrodes and wires, erection bolts, nuts, rivets, piano wire, packing sheet and packing compounds, temporary supports, spacer templates, jute and cotton waste cloth, sand and emery paper etc. for the commissioning of the plant. (9) For load testing of handling equipment, loads shall have to be arranged by the successful Bidder. Electrical/ operation tests, as per standard practice, shall also be arranged and completed by them.

(10) All materials, equipment, tools, tackles etc. brought at site by the successful Bidder within the plant area shall not be removed without the written permission of the Purchaser. Similarly, all enabling works built/erected and/or acquired by them within the plant premises shall not be dismantled and removed without the written permission of the Purchaser.

(E)

Information/ Data on Spares and Consumables The list of Spares & consumables shall be furnished by the successful Bidder as required in SBD. However, the successful Bidder shall furnish various information regarding spares, consumables, tools & tackles etc. as per the schedules indicated in chapter 12 of this Technical Specification.

DATA SHEETS

6.0 6.1

TECHNICAL DATA SHEET (To be filled by the vendor) DUST SUPPRESSION SYSTEM (To be furnished separately for all the systems)

1. 2. 3. 4. 5. 6. 7. 8. 9.

Type of dust suppression system

Total capacity of dust suppression system : Make of equipment Design water flow quantity Work zone dust concentration Total power requirement Total water requirement Any specific design consideration Noise level at 1m distance from the dust suppression equipment : : : : : :

10. 11. 12. 13. 14. 15. 16. 17. 18. 19.

Space requirement (L x B x H) Support / Structure / Weathering shed DS system List of drive Spray nozzle make rating, quantity Spray nozzle material of construction Sprinkler make, rating, quantity Sprinkler material of construction Load monitoring switch type, quantity and rating

: : : : :

Sequence timer type, quantity and rating : Solenoid valve type, quantity and rating :

6.2

Technical Information of Dry Fluid Dust Suppression System (DFDS) The Bidder shall also fill up the following questionnaire and submit with his offer. This data shall form a part of the contract with Successful Bidder. a) Sl. No 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. b) Sl. No 1. 2. 3. 4. 5. 6. Characteristics Make and model no. Type of pump Capacity. Total head. Quantity Material of construction m3/hr m WC Unit Characteristics Make of equipment Design water flow quantity Design compressed flow requirement Work zone dust concentration Total power requirement Total water requirement Any specific design consideration Noise level at 1m distance from the dust suppression equipment Support / Structure / Weathering shed DS List of drive Spray nozzle make rating, quantity Spray nozzle material of construction Load monitoring switch type, quantity and rating Sequence timer type, quantity and Solenoid valve type, quantity and PUMPS FOR DFDS dB(A) Unit GENERAL

Value

Value

Sl. No i) Shaft ii) 7. 8. 9. Impeller rpm iii) Casing Pump speed Shaft power Drive details i) Motor make ii) Motor KW iii)Insulation class iv) Frame size 10. 11. 12. 13. c) Bearing type & make Type of coupling Vibration level Noise level at 1 m distance for pump set PIPES FOR DFDS dB(A) Characteristics Unit

Value

Sl No 1. 2. 3. 4. 5. 6. 7. 8. 9. Material Standard Class

Characteristics

Unit

Value

Thickness of pipe material Pipe size, length and weight Make Maximum Maximum recommended operating temperature recommended 0C

operating pressure Type of protective coating

d) Sl. No 1. 2.

PIPE FITTINGS FOR DFDS

Characteristics Type of fittings Size (O.D x Thickness)

Unit

Value

Sl. No 3. 4. 5. 6. 7. 8. e) Standard Lengths Maximum recommended operating temperature Maximum recommended operating pressure Type of protective coating Weight of fittings kg Characteristics Unit

Value

VALVES (GATE, GLOBE, CHECK, BUTTERFLY, FLOAT, PRESSURE RELIEF) FOR DFDS Value

Sl. No 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. f)

Characteristics Type: Body / Bonnet / Cover: Spindle: Disc: Body seat ring & Disc seat ring End connections: Pressure rating: Flange facing: Manufacturing std.: Hand wheel: Packing: Companion Flanges Hydrostatic testing: Test certificates: SOLENOID VALVES FOR DFDS

Unit

Sl. Characteristics No 1. Make and Model 2. Type 3. Power Supply 4. Quantity 5. Solenoid Valve Box size

Unit

Value

Enquiry Specification for Dust Suppression, Compressed Air & Water Supply Package

g)

LOAD SENSOR UNIT FOR DFDS Value

Sl. Characteristics No 1. Make and Model 2. Type 3. Quantity h) MATERIAL SENSOR UNIT FOR DFDS

Unit

Sl. Characteristics No 1. Make and Model 2. Type 3. Quantity i) Sl. No 1. 2. 3. j) Sl. No 1. 2. 3. k) Sl. No 1. 2. 3. Type Quantity SEQUENCE TIMER FOR DFDS Characteristics Make and Model Power Supply Quantity Characteristics Make and Model Type Quantity PRESSURE GAUGES FOR DFDS Characteristics Make and Model PRESSURE SWITCH FOR DFDS

Unit

Value

Unit

Value

Unit

Value

Unit

Value

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6.3 A. 01.

TECHNICAL DATA SHEET (To be filled by the vendor) AIR COMPRESSORS Manufacturer's Name & address Model No. Type No. provided Rated capacity Nm3/min Rated discharge pressure kgf/cm2g kW input at motor terminal Motor rating Air temp. at delivery after after-cooler at rated capacity and pressure, deg.C. : : : : : : : : :

Screw Speed, rpm 1st stage (male & female) : 2nd stage (male & female) : Oil content in the air at outlet of air compressor, ppm. Noise level at source when the compressor running at rated capacity, dB (A). Cooling water requirement Pressure drop across compressor Temp. rise 02. Inter cooler & after cooler No. per compressor Design standard/code Make Max. working pressure, kgf/cm2g i) Water side : : : : : : :

: : : Inter cooler Aftercooler

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Enquiry Specification for Dust Suppression, Compressed Air & Water Supply Package

ii)

Air side

: : : : :

Tube material, size and thickness Shell material and thickness, mm Moisture content in air after aftercooler, ppm Space required for pulling out tube assembly of intercooler : & aftercooler 03. Moisture separator Make Type Model Number Design standard/code for pressure vessel Shell material and thickness Design pressure,kgf/cm2 (g) Moisture content after separator B. Motor Type Make Rated kW at 50 deg.C Rated kW at 40 deg.C Rated voltage & system condition Frame size Class of insulation Rated speed & direction of rotation Starting system

: : : : : : : :

: : : : : : : : :

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C.

AIR RECEIVER Number Design Standard/ Code Capacity Overall dimensions Wall plate thickness Plate material Design Pressure Working Pressure : : : : : : : :

D.

COOLING TOWER for Water Line Make & Model Type Quantity Overall size of cooling tower Capacity of cooling in TR. Water flow m3/h Air flow Design water inlet temperature, outlet temperature Material of construction and its thickness Speed in rpm Drive details Shaft Power consumption Wheel diameter Efficiency Size of fan Static & Dynamic weight of fan & motor assembly : : : : : : : : :

: : : : : : :

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Bare weight and operating weight of cooling tower

Noise level at 1m distance in dB(A) : Fixing details Vibration level Water spray nozzle type : : :

6.4

CENTRIFUGAL PUMP for Water Supply System (To be furnished separately for all the systems) 1. 2. 3. 4. 5. 6. Make and model no. Type of pump Capacity in m3/hr. Total head in m WC Quantity Material of Construction of 7. 8. 9. Shaft Impeller Casing : : : : : : : : : :

Pump speed (rpm) Shaft power Drive details Motor make Motor kW Class of insulation Frame size

: : : : : : :

10. 11. 12.

Bearing type & make Type of coupling Vibration level

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13. 14. 15. 16. 17. 6.5

Noise level at 1 m distance Duty

: :

Weight of pump & motor separately: Characteristic curves for pumps Type of liquid to be handled : :

WATER LINE VALVES for Water Supply System

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 6.6

Make & Model Type Quantity Size Pressure rating Material of construction Operating system Drive details Gland packing End connections Service Test pressure

: : : : : : : : : : : :

WATER LINE PIPES for Water Supply System

1. 2. 3 4. 5. 6.

Material Standard Class Thickness of pipe material Pipe size, length and weight Make

: : : : : :

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7.

Maximum recommended 0C operating temperature

: : : : :

8.

Maximum recommended operating pressure

9.

Type of protective coating

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