contract agreement for - Engineering Projects India Ltd.

contract agreement for - Engineering Projects India Ltd.
TENDER DOCUMENT
NIT No.: DLI/C&E/WI-675/271
FOR
Tender for „Design, Engineering, Supply, installation,
testing and commissioning of DFDS SYSTEM PACKAGE
AND
ASSOCIATED
WORKS‟
for
the
project
of
“Augmentation of Fuel and Flux crushing facilities
(Package- 064) 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
Enquiry Specification for Dust Suppression & Water Supply System
(A)
1
2
Bidder's Scope of Work :Design and Engineering of total "DFDS PACKAGE AND ASSOCIATED WORKS"
as mentioned in NIT & Tender Documents.
Supply of all materials / items except covered under (B) mentioned below i.e.
Items/Materials excluded from Bidder's Scope of Work, from Sr. no. 1 to 8.
3
Supply of Commissioning Spares as mentioned in NIT & Tender Documents.
4
Erection (i.e. Installation, Testing and Commissioning) of all Equipment / Items
covered under "DFDS PACKAGE AND ASSOCIATED WORKS" as mentioned in NIT
& Tender Documents except cable laying and Termination.
(B)
Sr.
no.
1
Materials / Items excluded from Bidder's Scope of Work :Item Description
Power & Control Cable including of HT cable for Air Compressor, Earthing,
Hardware and Cable tray.
2
Main Electrical Equipment comprising of Local Starter Panel, Local Push Button
Station, Push Button Station, Controller and Power Distribution Box
3
Instrumentation comprising of Flow Meter, Level Transmitter, Level switch,
Temperature Transmitter/Gauge and Pressure Transmitter/ Gauge
4
Compressed Air System comprising of Air Compressors, Main Air Receivers
(outside Compressor house) and Cooling Towers.
Soft Starter Panel for Air Compressors
5
6
Air & Water Pipe Line complete with necessary fittings (fittings mean bends, Tee,
Flanges, and Reducers)
7
Isolation valves at Tapping points (from Client‟s network) and Flow Transmitters
8
Mechanical Hose reel with drum, Quick release coupling etc. for service water
EPI – New Delhi
Volume-2B, Rev.0
Page 1 of 26
Enquiry Specification for Dust Suppression & Water Supply System
1.0
Technical Specifications of DUST SUPPRESSION SYSTEM
DUST SUPPRESSION SYSTEM
Dry fog dust suppression (DFDS) system shall be provided at different
material transfer points as given below
Re-routing of existing sinter fines conveyors and transportation of coke
breeze from CSP No. 4 to conveyor 102 & transportation of fines from
B.F to JH 127
Sl No.
Location
Description of DFDS application points
1
JH-2
Conveyor discharge
Receipt on conveyor C3A-C1
2
JH-3CA
conveyor C3A-C1
Receipt on conveyor C3-C2 or C3-C1 from C3A-C1
Conveyor C3A-C2 discharge
Receipt on conveyor C3-C2 from C3A-C2
3
JH-C3
Conveyor
Conveyor
Conveyor
Conveyor
C3-C2
C4-C2
C3-C1
C4-C1
discharge
receipt from C3-C2
discharge
receipt from C3-C1
4
JH-C4
Conveyor
Conveyor
Conveyor
Conveyor
C4-C2
C5-C2
C4-C1
C5-C1
discharge
receipt from C4-C2
discharge
receipt from C4-C1
5
JH-C5
Conveyor
Conveyor
Conveyor
Conveyor
C5-C2
C7-C1
C5-C1
C6-C1
discharge
receipt from C5-C2
discharge
receipt from C5-C1
6
JH-C6
Conveyor C6-C1 discharge
Conveyor J127-C1 receipt from C6-C1
7.
JH-127
Conveyor J127-C1 discharge
Conveyor F101 receipt from J127-C1
8
JH-C7
Conveyor C7-C1 discharge
Conveyor C102A receipt from C7-C1
9.
EPI – New Delhi
Transfer stations of conveyor C1, C2 & C7
Volume-2B, Rev.0
Page 2 of 26
Enquiry Specification for Dust Suppression & Water Supply System
Coke crushing and screening and grinding facilities
Sl No.
Location
Description of DFDS application points
1
JH-CK1
Conveyor RC-106 discharge
Receipt on conveyor C106A from RC-106
2
JH-CK2
Conveyor C-106A discharge
Bunker
Receipt on conveyor RC-CK2
Receipt on conveyor C107A from roll crusher or RCCK2
3
JH-CK3
Conveyor RC-107A discharge
Receipt on conveyor C107B
4
Screening
building
Discharge of conveyor 107B
Screen
Receipt on conveyor C111A
Bunker
Receipt on conveyor C110A
5
Coke Grinding
Bldg.
Conveyor C111A discharge
Receipt on conveyor C112A
Bunker
Belt feeder receipt
Belt feeder discharge
Receipt on conveyor C114 from rod mill
Bunker
Belt feeder receipt
Belt feeder discharge
Receipt on conveyor C114 from rod mill
Receipt on conveyor C114 from C113A
CONVEYOR STREAM FEEDING TO COAL TOWER-7
Sl No.
Location
1
JH-4
Description of DFDS application points
Discharge point of conveyor Y-14
Reciving point on conveyor Y11-131 or Y-15
EPI – New Delhi
2
JH-11A
Discharge point of conveyor Y11-131
Reciving point on conveyor Y11-132
3
JH-11B
Discharge point of conveyor Y11-132
Reciving point on conveyor Y11-133
Volume-2B, Rev.0
Page 3 of 26
Enquiry Specification for Dust Suppression & Water Supply System
4
Coal
tower
no. 7
Discharge point of conveyor Y11-133
Receiving point on conveyor Y11-134
Discharge point of conveyor Y11-134
Receiving point on reversible shuttle conveyor
Y11-135 or Y11-136
Additional silos, junction houses & final crushing station
Sl No.
Location
Description of DFDS application points
(i)
JH-2C
Discharge point of conveyor Y7-49
Reciving point on conveyor Y11-125 or
Y7-50
(ii)
JH-11C
Discharge point of conveyor Y11-125
Reciving point on conveyor Y11-126
(iii)
5
nos.
new
mixing
bin
Discharge point of belt feeder (5 point)
Reciving point on conveyor
point)
Y11-127 (5
(iv)
JH-11D
Discharge point of conveyor Y11-127
Reciving point on conveyor Y11-128
(vi)
JH-11E
Discharge point of conveyor Y11-128
Reciving point on conveyor Y7- 35
(vi)
JH-3C
Discharge point of conveyor Y7-35
Reciving point on conveyor Y7- 36
Discharge point of conveyor Y7-36
Reciving point on conveyor Y11-129 or
Y7-51
(vii)
JH-11F
Discharge point of conveyor Y11-129
Reciving point on conveyor Y11-130
(viii)
Crushing
station
Discharge point of conveyor Y11-130
Receiving point on conveyor Y7-12
Discharge point of conveyor Y7-12
Sl No.
Location
(ix)
Mixing
station
Description of DFDS application points
Receiving point of conveyor Y7-13
Discharge point of conveyor Y7-13
Receiving point on conveyor Y-18 or Y-14
EPI – New Delhi
Volume-2B, Rev.0
Page 4 of 26
Enquiry Specification for Dust Suppression & Water Supply System
There shall be minimum 2 nos. DFDS system, one for re-routing of existing sinter
fines conveyors, coke crushing, coke screen facilities and the other for conveyor
streams feeding to coal tower-7 and additional silos, junction houses and final
crushing station. In each DFDS pumping station 2 nos. pumps (1W + 1S) shall be
provided. DFDS system will also be provided at transfer stations of conveyor C1, C2
& C7.
1.2
INSTRUCTIONS TO CONTRACTOR
The dust suppression system vendor shall have experience of execution of at least 2
installation of DFDS system, already commissioned and under operation successfully
from last one year. DFDS system vendor shall be from M/s. F Harley/ TPS/
Spraying System
1.3
APPLICABLE CODES AND STANDARDS
The execution of the work covered under this specification shall 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 shall be according to good engineering practice and norms acceptable to
owner / consultant.
1.4
(1)
DESIGN CRITERIA
Work zone dust concentration (at 5-7m distance from source) shall not be more than
5 mg/Nm3 above ambient condition.
(2)
Water line velocity shall be maintained less than 1.5 m/sec. Water pipe line shall be
supported at regular interval. Make-up water, quick fill, drains and overflow
connection shall be included at each pump station tank. Duplex strainer shall be
included at inlet to dust suppression system pumps. IS-1239 heavy class, ERW, G.I
pipe line shall be used in the water line. Water pipe line shall be preferably be laid
over ground along conveyor gallery . In case of non-availability of same suitable
supporting scheme shall be provided to suit site. Underground pipeline (wherever
provided) shall have wrapping and coating as per IS – 10221 (preferably wrapping
coating shall be coal tar based). Hume pipe protection shall be laid at road crossing
area.
(3)
IS-1239 heavy class, ERW, G.I pipe line shall be used in the compressed air line.
Compressed air pipeline network over ground laying shall be preferred 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 shall be 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.
In DFDS pumping station, 2 nos. pumps (1w+1s) shall be provided.
A pressure relief valve shall be provided to by pass water to storage tank in case the
pressure increases above the set value.
Spray Nozzles/ Spray bar for DFDS systems at transfer points (at both conveyor
discharge & receiving points) shall be selected so as to ensure complete coverage.
Solenoid valves shall be mounted on each spray nozzle header at material transfer
points. Solenoid valves shall be interlocked with the operation of conveyor running
with material. For this necessary load sensor units shall be designed, installed and
(4)
(5)
EPI – New Delhi
Volume-2B, Rev.0
Page 5 of 26
Enquiry Specification for Dust Suppression & Water Supply System
(6)
(7)
(8)
(9)
(10)
(11)
(12)

hook up with conveyor drives/ panel. At reversible shuttle conveyor spray nozzles
shall be provided at both sides.
The DFDS system nozzles shall 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 shall not be more than
0.2% of the weight of material being handled.
Compressed air receiver and water tank at different pumping station shall be provided
with connecting valve, pipe fitting, and instruments for quality checking.
At each pump station air receiver capacity shall be considered @ 16% of the
compressed air consumption in m3/min or 2 m3 capacity, whichever is higher.
MS tank of 6 mm thick with stiffener for 1-hour storage capacity shall be provided at
pump stations of DFDS system by the contractor. The inside surface of MS tank shall
be epoxy painted .
The contractor shall provide plat form, walkway, stair case adequate for the necessary
approach to the equipment for operation & maintenance point of view.
Duplex strainer with SS filter element shall be provided at inlet to dust suppression
system pumps to remove all suspended particles exceeding 100 micron
The contractor shall provide the following minimum instruments
High level and low level switch in water tank. Low level switch interlocked with 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 shall be provided :
-
Independent pressure gauge & control valve (Ball valves) shall be provided for
pressure regulation .This unit shall housed in a steel cabinet of IP-55 construction.
For flow activation, solenoid operated valves shall be provided in water and airline.
Belt conveyor load monitoring switch shall be provided for sensing conveyor running
with material.
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 shall have selection mode to run in Auto/Manual mode.
-
1.5
EQUIPMENT SPECIFICATIONS
The equipment for "DFDS" dust control system is grouped into two main categories.
Main Equipment
The main equipment shall 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 shall include water storage and pumping unit with duplex
water filter and associate electrical works, air and water piping, enclosures,
EPI – New Delhi
Volume-2B, Rev.0
Page 6 of 26
Enquiry Specification for Dust Suppression & Water Supply System
necessary hoods and skirt boards on belt conveyors / equipment to suit spray nozzle
operation.
Starter cum control panel shall be provided at pumping station and local control
panel shall 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 shall be manufactured from stainless steel tubing drilled
and tapped for connection of nozzle adapters. A specially designed and selected dual
fluid atomizing nozzle shall be fitted into each of the adapters. These nozzles are
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 shall be
of stainless steel while the adaptors shall be of brass. Each spray bar shall be
provided with mounting brackets and flexible hoses for connection to the air & water
pipeline.
Pressure regulating units (PRU)
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 shall
be provided in the system. The pressure regulating unit shall 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 shall be installed in a metallic
enclosure with inspection door with rubber sealing arrangement. Flexible hose shall
be provided for connection of PRU to the air & water pipeline.
The number of pressure regulating units shall depend upon the position / elevation of
spray bars. Generally independent pressure regulating units shall be provided when
the elevation of spray bars exceeds 3 m. Further the number of nozzles operating
from one PRU should not exceed 6 ~ 8.
Flow activation stations (FAS)
The flow activation station shall consist of solenoid valves in air & water line,
pressure switch in the airline, selector switch, and indication lamps. Isolation ball
valves shall be provided in the air & water line. All the equipment shall be installed in
a metallic enclosure with inspection door with rubber sealing arrangement. Flexible
hoses shall be provided with each FAS for connection to air and water pipeline.
The "ON - OFF" control of the fogging system shall be through the flow activation
stations with facility for both manual and auto mode. A three-position selector switch
shall be provided to select the mode of operation. The switch when energized shall
EPI – New Delhi
Volume-2B, Rev.0
Page 7 of 26
Enquiry Specification for Dust Suppression & Water Supply System
open the electric solenoid valves, which shall permit compressed air and water to
enter into the pressure regulating units and spray bars.
In addition, a pressure switch shall 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 shall have indication for: -
System ON
System OFF due to lower air pressure
Auto operation
The flow activation stations shall have provision for both manual and automatic
operation. For manual operation, the system shall become operational with selector
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 shall be provided with requisite number of
spray bar assemblies with DFDS atomizing nozzles. Pressure regulating units shall be
provided at each location to regulate the pressure of compressed air and water.
The dust suppression system shall 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 shall be provided . Pump
split type. Impeller rpm shall generally not exceed 1450 .
low capacity & high head may be provided with 2900 rpm.
motor with flexible coupling. Spacer type coupling shall
conform to IS : 1520.
casing shall be vertically
However, for pumps with
Pump shall be coupled to
be provided. Pump shall
Pump shall 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 shall
preferably be within ± 10% of the rated design flow. The total head -capacity curve
shall 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 shall have shaft seal by gland packing. Pump shall 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 shall be dynamically balanced. The magnitude of peak to peak vibration
shall be limited to 75 micron. Pump impeller shall be non overloading type. Impeller
shall be made in one piece & keyed to the shaft.
EPI – New Delhi
Volume-2B, Rev.0
Page 8 of 26
Enquiry Specification for Dust Suppression & Water Supply System
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 shall be in one piece & made of welded steel
construction.
Adequate space shall be provided between pump drain connection
and base plate for installation of minimum 15 mm drain piping. Pumps shall be
supplied with suitable drain pans or drain rim type base plates with tapped drain
connections.
Critical speed of the shaft shall be at least 30 percent above the operating speed.
Water Piping and Fittings
Water piping up to 150 mm NB size shall be GI, ERW, heavy class and conforming to
IS-1239 Part- 1. Pipe ends shall be beveled. Pipe fittings shall be as per IS 1239,
Part -2 for pipes of size up to 150 NB.
Plate type pipe flanges (as per IS 6392) shall be provided.
Pipes shall be of welded joints. Welding (manual metal arc welding) shall be as per
relevant IS code and only certified welders shall be employed.
All piping systems shall be hydro tested at 1.5 times the design pressure.
Auto air venting valves shall be provided at highest point of the pipe lines & drain
valves shall 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. shall be provided
Valves
Butterfly Valves shall be provided in water line of size 65 NB and above and ball
valve shall be provided for pipe size below 65 NB. However, ball valve shall be
provided in the pipe line (irrespective of sizes) when flow control is required.
Specification of butterfly valve, ball valve & check valve shall conform to
GS-08 of “General Technical Specification”.
ES24 of
Air Receiver (1no. for each pump station)
Vertical self supporting in cylindrical design with dished end at both ends having
minimum capacity of 2 m3 volume. The air receiver shall be designed for a working
pressure of 8 kg/cm2 g. Design , manufacture, inspection and testing of air receiver
EPI – New Delhi
Volume-2B, Rev.0
Page 9 of 26
Enquiry Specification for Dust Suppression & Water Supply System
shall be in accordance with IS:7938 and IS: 2825 – 1969 (RA 1984), Class-2, Dished
ends IS: 4049 Part-1, 1979 (RA 1991). Material of construction shall be as follows:
Shell and dished ends
: IS: 2002 Gr2 or equivalent
Supports pad, leg, skirt, base
: IS: 2062-1992
Plate, nozzles
: A 105 (below 300 mm NB)
A 106 Gr B (above 300mm NB)
Flanges & matching flanges
: A 105
The air receiver shall be supplied with following accessories:
- Circular skirt welded to the bottom portion of the shell.
- Circular base plate welded to the skirt with holes for foundation bolts.
- Foundation bolts/studs, nuts, washers.
- Nozzles for inlet and outlet with weld neck flanges.
- Manhole nozzles at an accessible height with weld neck flange and cover having
devit arrangement.
- Safety valve of sufficient blowing capacity mounted at a suitable height connected
through a flanged joint to nozzle welded on the receiver shell.
- Safety valve shall be provided with test lever and gagging arrangement.
- Vent valve at the point of the dished end for releasing the air during hydro test.
- Water drain nozzle at the lowest point with drain isolation valve, trap station and
pass valve.
- Companion flanges with bolts, nuts and gaskets for inlet and outlet nozzles and
other valves.
- Studs for pressure indigator for local measurement of pressure.
Pressure Gauge
Manufacturing Standard
Range
Range (at pump suction)
Dial Diameter
Accuracy
Degree of protection
Sensing element
Bourdon tube material
Connection
Connection size
Mounting
Case
Bezel (screwed)
Dial window
Pointer
Dial
Movement assembly
Shank
Adjustable pulsation damper
Pressure gauges shall be provided
EPI – New Delhi
: IS 3624
: 0 – 6 Kg/ cm2 or 0-10 Kg/ cm2
: (-)2 to (+) 2 Kg/ cm2
: 100 mm
: + 1% of FSD
: IP 65
: Bourdon tube
: AISI SS316
: Screwed
: ½ “ BSP (M)
: Direct with bottom entry
: Die cast Al stove enamelled black finish
: Die cast Al stove enamelled black finish
: Shatter proof glass
: Al anodised black
: Al white with black letters
: AISI 304SS
: AISI 3166SS
: Yes
with isolation valves (Ball valves)
Volume-2B, Rev.0
Page 10 of 26
Enquiry Specification for Dust Suppression & Water Supply System
Levels of Various Buildings & Junction Houses of Coke Sorting Plant (CSP)
S.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Name of Building/
Junction House
JH-8
JH-10
JH-9
JH-11
JH-12
JH-5
JH-6
Coke Dedusting Unit (CDU)
JH-3
JH-1
Coke Crushing Station (CCS)
Surge Bunker Building (SBB)
JH-7
JH-4
Coke Screening Station (CSS)
JH-13
Coke Breeze Bunker (CBB)
JH-2
JH-C3A
JH-Z17
Ground
Level
(Mtr.)
No. of
Floors
308.500
308.500
308.500
308.500
308.500
308.500
308.500
308.500
308.500
308.500
308.500
308.500
308.500
308.500
308.500
308.500
308.500
308.500
309.030
308.500
2
3
3
3
3
2
2
6
3
3
3
4
3
3
4
3
4
3
3
3
Floor Levels (Mtr.)
I
2
3
4
5
6
309.000
309.000
309.000
309.000
309.000
309.000
309.000
309.000
309.000
309.000
309.000
309.000
309.000
302.835
309.000
309.000
309.000
309.000
309.530
309.000
314.500
313.625
314.000
318.708
318.200
312.550
315.600
311.500
316.000
318.614
316.500
314.500
334.074
309.000
315.750
331.800
315.250
321.390
315.530
340.800
317.625
317.600
322.308
321.800
315.809
319.600
326.500
320.000
332.029
337.674
315.700
322.500
335.500
333.300
325.890
319.530
344.400
319.755
336.529
328.500
338.500
-
326.155
-
329.755
-
Levels of Various Buildings & Junction Houses of Coal Handling Plant (CHP)
S.
No.
1
2
3
4
5
6
7
8
9
Name of Building/
Junction House
JH-4 (Mod.)
JH-11A
JH-11B
Coal Tower No.7
JH-11D
JH-11E
Final Crushing Station
JH-2C (Existing)
JH-11F
EPI – New Delhi
Ground
Level
(Mtr.)
No. of
Floors
308.500
308.500
308.500
308.500
308.500
308.500
308.500
308.500
308.500
1
3
3
3
2
2
4
1
3
Floor Levels (Mtr.)
I
2
3
4
5
6
329.00
309.00
309.00
348.50
309.00
309.00
308.70
332.39
309.00
324.450
351.350
354.500
312.100
310.532
320.296
329.896
328.700
355.250
358.100
324.796
333.796
331.996
-
-
-
Volume-2B, Rev.0
Page 11 of 26
Enquiry Specification for Dust Suppression & Water Supply System
Levels of Various Buildings & Junction Houses of C-Line (C-Line)
S.
No.
1
2
3
4
5
6
7
8
Name of Building/
Junction House
JH-C2 (Existing)
JH-C3A
JH-C3
JH-C4
JH-C5
JH-C6
JH-C7
Pent House (Exisitng)
Ground
Level
(Mtr.)
No. of
Floors
309.030
309.030
308.030
308.030
308.230
308.230
308.230
310.900
1
3
3
3
3
2
3
1
Floor Levels (Mtr.)
I
2
3
4
5
6
309.530
309.530
308.530
308.530
308.730
308.730
308.730
315.386
315.530
324.450
314.400
316.086
316.086
315.686
-
319.530
328.425
324.450
319.986
319.386
-
-
-
-
Levels of Various Buildings & Junction Houses of Fuel Crushing & Screening Facility (FCSF)
S.
No.
1
2
3
4
5
Name of Building/
Junction House
JH-CK2
JH-CK3
JH-CK-1
Coke Breeze Screening Building
Coke Grinfing Building
Ground
Level
(Mtr.)
No. of
Floors
310
310
310
310
310
3
3
3
7
4
Floor Levels (Mtr.)
I
2
3
310.5
310.5
305.15
310.5
310
318.7
323
308.75
312.3
315.5
331.296
327
311
316.5
325.35
4
5
322.3
328.55
326.27
-
-
6
-
329.27
-
-
Levels of Various Buildings & Junction Houses of Flux Crushing & Screening Facility (FCSF)
S.
No.
1
2
Name of Building/
Junction House
Flux Crushing Building
Flux Screening Building
EPI – New Delhi
Ground
Level
(Mtr.)
309.65
310
No. of
Floors
Floor Levels (Mtr.)
I
2
3
4
310
306.4
316.55
310
330.53
314.6
330.34
325.5
Volume-2B, Rev.0
Page 12 of 26
5
326.44
-
6
-
-
Enquiry Specification for Dust Suppression & Water Supply System
02
WATER SYSTEM
2.1
Scope of work
The scope of work shall include design, engineering, fabrication,
manufacturing,
assembly
&
supply,
erection/construction/laying,
commissioning, testing & performance guarantee tests etc of plant &
equipment and piping etc of complete water supply facilities including pump
house buildings, civil & structural work & technological structures, electrics,
instrumentation,
automation,
telecommunication,
air-conditioning
&
ventilation, material handling & hoisting equipment etc as specified and
required for complete water systems technological structures, pipe-support
structures, etc as specified and required for the complete water system for
proposed plant as specified in this chapter as well as various chapters of this
contract specification in line with General Technical Specification (GTS) and
subject to Employer‟s approval, complete in all respect on turnkey basis.
The scope of work shall include the following activities.
i)
Design, engineering, manufacture /fabrication, assembly, shop testing,
painting, packing sequential delivery FOR site, unloading, unpacking, storage
at site, preparation & submission of all drawings for civil, mechanical,
structural, piping, construction & erection drawings, construction & erection as
per approved drawings, site-testing, painting, commissioning and fulfillment
of guarantee performance of all plant & equipment of water supply facilities
for the proposed plant including drinking water system, industrial
service/make-up water system and water based fire-fighting system, in
accordance with the water system requirements of the proposed plant.
ii)
Supply of pipeline supports, thrust blocks/ anchor blocks, R.C.C. pedestals
etc. for over head / on-ground /underground pipelines.
iii)
Supply of all technical literature, drawings & documents, general arrangement
drawings, assembly & sub-assembly drawings of all the plant & equipment,
construction & erection drawings,
as-built drawings, operation &
maintenance manuals, manufacturing drawings, etc.
iv)
Submission of all drawings at (iii) above, design calculations, data sheets for
various equipments, pipeline sizing calculation and for approval of Employer/
Consultant and finalizing the same as per approval of Employer/ Consultant.
The approval of the same however does not absolve the contractor from his
responsibilities.
v)
Supply of commissioning spares & consumables; a list there of shall be
submitted by the Contractor.
vi)
Contractor shall submit an itemized price-list of two years operation and
maintenance spares.
vii)
Supply of special tools, tackles for construction, erection operation and repair
& maintenance of the plant & equipment.
viii)
Supply of special tools and tackles, spares as mentioned in GTS shall be in the
scope of Contractor.
EPI – New Delhi
Volume-2B, Rev.0
Page 13 of 26
Enquiry Specification for Dust Suppression & Water Supply System
ix)
All necessary connections for hook-up with Employer‟s system at battery
limits.
x)
Supply of erection, testing & commissioning equipment and material.
xi)
Piping network flushing fluids, chemicals & consumables.
xii)
First fill of oils, lubricants, filter media, resins, chemicals reagents and other
consumables.
xiii)
Inspection and performance testing of individual equipment and system as a
whole.
xiv)
Participation in design conference with the Employer & Consultant as and
when called for.
xv)
Contractor shall provide two nos drainage pumps for each underground
premises, one working, one standby, of suitable capacity and head to drain
out the seepage water and rain water from the underground premises. The
pumps shall be capable of handling slurry water. The exact numbers, capacity
and type of pump shall be finalised during engineering stage.
The Contractor‟s scope also covers extension of fire-fighting line, drinking
water line and industrial water line from the battery limits to various
consumer points of the proposed plant in line with the present Contract
technical specification and GTS.
Water supply system/ sub-systems shall be complete in all respects and any
equipment or material not specifically mentioned in this specification, but
required for safe, efficient & smooth operation and guaranteed performance of
the plant shall be deemed to be included under the scope of work of the
Contractor. Diversion of existing overhead / underground water pipelines
(including those identified during package execution) required for installation
of the proposed units covered under this package is included in the scope of
work of the Contractor. However, the price & other terms and conditions shall
be mutually discussed and agreed during the execution of job by the
Contractor.
2.2
Battery Limit
a)
Industrial water
Industrial quality make-up water (quality as indicated in GTS, Maroda-I) will
be made available to the Contractor at only one point within 100m from the
proposed plant at a pressure of approx 1.5 to 2.0 kgf/ cm2 (g). The top of
the pipeline (carbon steel) shall be approximately 1.2 m below the area
ground level. Tapping of industrial make-up water shall be based on two
points feeding and shall conform to provisions of GTS. Contractor shall extend
the same through isolation gate valves in valve-pit alongwith flow meter
(complete with isolation valves and by-pass arrangement) to his proposed
systems for service/make-up water requirement for the entire plant area.
Contractor shall indicate the make-up water quantity requirement, pipe size,
end connection, MOC of pipeline, etc. at the battery limit.
EPI – New Delhi
Volume-2B, Rev.0
Page 14 of 26
Enquiry Specification for Dust Suppression & Water Supply System
b)
Drinking water
Drinking water will be made available to the Contractor at only one point
within 100m from the proposed plant at a pressure of approx 1.0 kgf/ cm2
(g). The top of the pipeline (carbon steel) shall be approximately 1.2 m below
the area ground level. Tapping of drinking water shall be based on two points
feeding and shall conform to provisions of GTS. Contractor shall extend the
same from the battery limit through isolation gate valves in valve-pit to his
proposed systems/ shops, offices, toilets, drinking water platforms, water
coolers, etc. for the entire plant area.
The Contractor shall indicate the drinking water quantity requirement, pipe
size, end connection, MOC of pipeline, etc. at the battery limit.
c)
Construction Water
Construction water arrangement shall be in the scope of contractor. The
location of borewells, if planned by the Contractor for construction water
requirement would require clearance / approval from BSP/MECON.
2.3
Specification and Description of Work
Water System Facilities:
Water system shall in general include the following facilities:a)
b)
c)
d)
e)
f)
g)
a)
Cooling water system,
Make-up water system,
Water conditioning system,
Water supply system for air conditioning & ventilation system,
Drinking water system,
Service Water System,
Dewatering system for underground premises
Cooling Water System
1.
For cooling of plant and equipment of the air-compressor unit there
shall be a separate cooling water re-circulation system for each unit /
sub-system 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.
2.
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 Employer‟s approval.
3.
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.
4.
Pump houses shall be provided with air-washer based air-conditioning
and ventilation system.
EPI – New Delhi
Volume-2B, Rev.0
Page 15 of 26
Enquiry Specification for Dust Suppression & Water Supply System
5.
b)
c)
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 Employer.
Make- up Water System
1.
Make-up water for various usage including cold sump of cooling water
circuit for air-compressor, air-conditioning and ventilation systems etc.
and for supply of industrial service water will be tapped from the
existing industrial water network and will be conveyed to the various
consumers through a pipe network, preferably over-ground.
2.
Quality of industrial make-up water is furnished in the GTS. This water
will be supplied as make-up water to proposed plant unit for process &
cooling needs at only one point for the entire needs of the proposed
plant unit at battery limit as specified. The Contractor shall provide
necessary treatment facility, wherever required, to make the water
suitable for cooling and other purposes.
3.
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.
4.
The Contractor shall indicate make-up
corroborated by back-up calculation.
5.
Make up water system will include extension of pipelines from the
battery limit with isolation gate valves in valve pit, along with pumps
(if required), valves, valve pits, sumps etc., to the cooling water
recirculation system, ACVS, service water requirement as well as
process needs.
6.
Online booster shall not be accepted. A makeup water sump with
pumps and piping (pump house and sump are to be provided by the
Contractor), if required, shall be provided.
water
requirement
duly
Water Conditioning System
1.
To prevent 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 in the proposed plant there shall be a
water conditioning facility as per system requirement and inline with
the details given in GTS.
2.
It shall consist of dosing tanks, pumps, valves, pipes, fitting, pipe
supports and associated civil, structural, electrical, instrumentation,
material handling, air-conditioning & ventilation etc. The scope of work
for all these remains the same as specified for cooling water system.
EPI – New Delhi
Volume-2B, Rev.0
Page 16 of 26
Enquiry Specification for Dust Suppression & Water Supply System
d)
e)
3.
These pumps may also be housed in the same pump-house for cooling
water system or separately.
4.
The Contractor shall furnish the details of chemical dosing proposed for
the system.
5.
The Contractor shall include in the scope of supply three months
chemicals requirement for the chemical conditioning system.
Water Supply System for air-conditioning & ventilation
1.
The entire piping network for water supply for air-conditioning and
ventilation and other Systems/ Sub-systems is in the scope of the
Contractor.
2.
It shall consist of pumps, valves, pipes, fitting, pipe supports and
associated civil, structural, electrical, instrumentation, material
handling, air-conditioning & ventilation etc.
3.
The details and specification of pumps, valves, pipes, fitting, pipe
supports and associated civil, structural, electrical, instrumentation,
material handling, air-conditioning & ventilation etc. as specified for
cooling water system is applicable for this system also.
4.
Makeup water for the system shall be provided by the Contractor from
the make-up water network provided for the main plant. No separate
connection at battery limit will be provided for this purpose.
5.
Pumphouses shall be provided with air-washer based air-conditioning
and ventilation system.
Drinking Water System
1.
The drinking water shall be made available at one point near proposed
plant within battery limit as specified. The Contractor shall extend the
pipeline from battery limit with isolation gate valves in valve-pit upto
various drinking water consumers.
2.
The Contractor shall indicate drinking
corroborated by back-up calculation.
3.
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. Online booster shall
not be accepted.
4.
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.
EPI – New Delhi
Volume-2B, Rev.0
water
requirement
Page 17 of 26
duly
Enquiry Specification for Dust Suppression & Water Supply System
f)
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 and quick fix connection shall be provided.
For service water line each tapping point discharge rate will be 2m³/hr. and
maximum 6 Nos. points can be operated at a time.
Service 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 Employer‟s approval.
g)
Dewatering system for underground premises
Dewatering system for underground sumps shall be provided for underground
portion of the proposed plant. 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 Employer‟s approval.
The details of Sump Pumps are given below;
1. Junction House JH-4
- 2 Nos. (1W+1S)
2. Flux Crushing Building - 2 Nos.(1W+1S)
All Sump Pumps shall have Cap. – 50 CBM /Hr. & Head - 15 Mtr.
The cooling water systems will generally comprise the following main
units:
a)
Open Indirect Industrial Water Cycle:

Cooling tower,

Pumpsets,

Strainers,

Interconnecting piping,

Chemical conditioning System,

Electrics, instrumentation & control system.
b)
EPI – New Delhi
Miscellaneous and Common Facilities:

Make-up water system,

Drinking Water System.
Volume-2B, Rev.0
Page 18 of 26
Enquiry Specification for Dust Suppression & Water Supply System
2.4
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.
Following design criteria in addition to GTS provisions shall be followed:
1.
Water System will be designed as per the provisions of GTS in respect
of various design aspects including type of pumps, no. of standby
pumps, piping, pipe specification, type of valves, cooling tower, sidestream filtration, handling & hoisting facilities, air-conditioning and
ventilation facilities etc.
2.
Each circulation system shall be connected with two nos. of delivery
headers from the pumphouse and two nos hot return water headers
from the consumers to the cooling tower/ pumphouse / treatment unit.
The water carrying capacity of each header shall be such that incase
one of the headers is under maintenance the other header should be in
a position to carry the required quantity of water to the consumers,
i.e., 100% of designed flow so that normal production of unit is not
affected with only one delivery / return header in operation. There
shall be proper isolating facilities in these headers so that supply of
water in any circuit or to any area of the Complex is not affected due
to leakage in one of header line.
3.
All sumps shall be compartmentalised as per GTS and each pump shall
have independent suction.
4.
Each pump shall have independent suction. Each pump shall be
provided with a gate valve on the suction side and a non-return valve
and gate valve on delivery side. The delivery line of each pump shall
be connected to the main header with isolating header gate valves for
isolating pumps‟ delivery valves. Motorised gate valves shall be
provided in automated pumping system for pumps‟ suction & delivery.
5.
Suitable number of header valves shall be provided such that delivery
valve of a pump can be isolated for maintenance without affecting
other stand-by pump‟s availability.
6.
All the valves of diameter 450 mm and above and the valves requiring
remote control operation shall be electrically / pneumatically operated.
Electrically operated valves shall be provided with limit switches as a
safety measure. Electrically operated valves shall have provision for
manual operation also. All manual valves of sizes DN 350 and above
shall be gear operated. Frequently operated delivery valves and header
valves below diameter 450 mm shall also be electrically operated.
7.
Total no. of pumps in a pumping circuit shall be as per GTS. Pump type
shall be as per the provisions of the GTS. Pump rpm shall be governed
by the kW rating in line with the provisions of the GTS.
8.
Drainage pumps (split casing, self priming and horizontal centrifugal
pumps) will be one reserve pump for one working pump. The pumps
shall not be of mono-block design.
EPI – New Delhi
Volume-2B, Rev.0
Page 19 of 26
Enquiry Specification for Dust Suppression & Water Supply System
9.
All gate valves shall be cast steel with SS internals, NRVs shall have SS
internals, rest of the design features shall be as per GTS.
10.
Following MOC to be considered for valves:
a)
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.
b)
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.
11.
Pipe materials shall be as per CRLA,RSP,SAIL.
12.
Sluice gates will have SS internals.
13.
Butterfly valves usage shall be accepted for non-critical applications for
flow modulation purpose at the express approval of the Employer.
14.
Contractor will consider provision of strainers in each header as
follows:

open industrial water circuit : for 100% flow, simplex strainers,
1W+1S,
15.
Material handling facility for the units of the Water System shall be as
per GTS.
16.
Pump houses shall be provided with air-washer based air-conditioning
and ventilation system.
17.
Design criteria of the cooling tower shall be as per GTS.
18.
Special maintenance tools and spares as mentioned in cl. no. 01.05 in
„Design Criteria for Cooling Towers‟, list of spares & tools & tackles as
listed in cl. no. 8.18, list of tools and tackles as listed in cl. no. 8.18.02
of GTS for Water System shall be supplied by the Contractor.
19.
Tapping of industrial make up water, drinking water & fire-fighting
water shall be based on two points feeding as explained elsewhere in
this chapter and shall conform to provisions of GTS.
20.
Pipe thicknesses shall be as per GTS provisions.
EPI – New Delhi
Volume-2B, Rev.0
Page 20 of 26
Enquiry Specification for Dust Suppression & Water Supply System
21.
2.5
As for as possible pipelines shall be laid above ground or in concrete
trenches / tunnels. Wherever, it is not possible then only pipelines
shall be laid underground.
Description of Cooling Water System
Open Industrial Water Cycle
Open industrial water circuits with filtered industrial water as the cooling
medium shall be provided for indirect cooling of compressor unit.
Hot industrial cooling water after cooling compressor unit will reach the
cooling towers under residual pressure for cooling. Cold water from the
cooling tower basin will flow into the cold well of the pump house. From the
cold well separate group of pumps shall pump water to the various
consumers.
Make-up water shall be added in the cold well to make-up the losses in the
system.
2.6
Erection, Testing and Commissioning
i.
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 Employer/Consultant.
ii.
The welding work should be carried out as per the approved WPS and PQR.
iii.
The 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.
iv.
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 Employer/ Consultant.
v.
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.
vi.
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 proposed plant area or as directed by the Employer
and thereby leaving the premises in good, clean, safe and operable condition.
EPI – New Delhi
Volume-2B, Rev.0
Page 21 of 26
Enquiry Specification for Dust Suppression & Water Supply System
2.7
vii.
Before giving call for final inspection, all the documents shall be furnished to
the Employer. 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 employer during
erection and commissioning or guarantee period.
viii.
All materials required for fabrication, construction, testing and inspection shall
be supplied by the Contractor. No material shall be free issue to the
Contractor.
ix.
No equipment or part item shall be dispatched without final inspection and
issuance of inspection certificate.
x.
All equipment, assemblies, sub-assemblies shall be shop tested as per
relevant standards and the test certificates shall be submitted by the supplier.
xi.
Erection, testing & commissioning of various equipments and piping etc shall
be done also inline with details given in various chapters of GTS.
Painting
The Contractor shall follow the painting procedure as mentioned in GTS.
2.8
Drawings & documents
2.9
Drawings/documents to be furnished by the Contractor for approval
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
EPI – New Delhi
Process flow diagram indicating the water consumption figures
complete with temperature, pressure and quality requirements.
Process & instrumentation diagrams for the water systems indicating
location of all instruments alarms and interlocks functions using ISA
symbols.
General arrangement and cross-sectional drawings, characteristics
curves and technical details of all the equipments (pumps, diesel
engine, , cooling tower, , sluice gates, , fire hydrants, etc.) , valves
and piping including GA drawings showing plan, elevation and sectional
views of the water system.
List of instruments comprising bill of materials and instrumentation
data sheets.
Layout of piping system indicating pipe routing, location of supports,
valves and other fittings as required.
General arrangement drawings of pump houses and sump / tank
(including civil, structural and other facilities) showing dispositions of
various equipment and piping.
Data sheets, characteristic curves and technical details of all the
equipments, valves and piping.
List of safety interlocks.
Test procedures for preliminary and final acceptance tests.
Quality Assurance Plan.
All equipment and piping sizing calculations.
GA drawings and details of air conditioning & ventilation facilities.
Volume-2B, Rev.0
Page 22 of 26
Enquiry Specification for Dust Suppression & Water Supply System
13.
14.
15.
16.
17.
3.0
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
Any other drawing/ documents as required by the Employer.
Drawings / documents to be furnished by the Contractor for reference
and record
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
3.1
The Contractor shall submit required sets of all the approved drawings,
documents and manuals for Employer‟s record and use. After erection
of 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”.
Operating and maintenance manual.
Spare parts recommendation and price list.
Instruction for erection, testing and commissioning.
Manufacturer‟s test certificates.
Lubrication schedule and quantity and quality of lubricant for one
year‟s normal operation.
Various equipment assembly drawings and bill of material.
Welding procedure.
Hydraulic test logs.
Equipment GA drawings and bill of materials.
Characteristics curves of the pumps, motors and other equipments.
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 manufacturer‟s drawings for all
brought out equipment, valves and other items.
All inspection/ test report/ certificates.
Any
other
drawing/
documents
as
required
by
the
Employer/Consultant.
Preferred Makes
The Contractor shall follow the list of proffered makes as per the following:
Sl
No.
1.
EPI – New Delhi
Item Description
Manufactures
Horizontal centrifugal
Pumps
Kirloskar Brothers, KSB, Beacon Weir, Voltas,
Mather & Platt, Jyoti, WPIL (Worthington).
2.
Submersible pumps
KSB, SU Motors, Kirloskar Brothers.
3.
Dosing Pump
Shapo Tools, Asia LMI (Madras), Toshniwal,
Milton Roy India.
Volume-2B, Rev.0
Page 23 of 26
Enquiry Specification for Dust Suppression & Water Supply System
Sl
No.
4.
Item Description
Manufactures
Cooling Towers
Paharpur, Shriram Tower
Southern Cooling Tower.
Tech,
5.
6.
7.
Sluice Gates
Basket Strainers
Rubber expansion joints
Jash, IVPL.
Filteration Engineers, Superflo.
BDK, CORI Engineers.
8.
9.
Hoses
Pipe a) MS/GI
10.
11.
b) DI
MS/GI Pipe Fittings
Chemical Dosing System
12.
Fire hydrants
Senior Flexonics, Hydrocrimp
SAIL, TATA, Jindal, MAN, SAW, Welspun,
Prakash, PSL, MSL.
Electro Steel Casting
Tube bends, Stewards & Lloyds, BST, Jindal.
GE India Industrial Private Limited, Ion
Exchange, Chembond Drewtreat.
New Age Industries, Steelage Industires,
ASCO, Strumech, Vijay Fire, Zenith
Valves
1.
C.S. Gate /Globe Valve
A. (Non-IBR- for all Sizes and Ratings) :







M/s.
M/s.
M/s.
M/s.
M/s.
M/s.
M/s.
B.D.K. Engg. Industries Ltd.,
BHEL,
Fouress Engg. (India) Ltd,
K.S.B. Pumps Ltd,
Larsen & Toubro Ltd., (Audco).
Leader Valves Ltd.,
Oswal Industries Ltd.,
Hubli.
Tiruchirapalli.
Aurangabad.
Kolkata.
Chennai.
Jalandhar.
Ahmedabad.
2. Butterfly Valve:
 M/s. Advance Valves Pvt. Ltd,
 M/s. Avcon Control Pvt. Ltd.,
(For Actuator operated Valves)
 M/s. B.D.K. Engg. Industries Ltd.,
 M/s. Crane Process Flow Tech. (India) Ltd.,
 M/s. Fisher Xomox Sanmar,
 M/s. Fouress Engg. (India) Ltd,
 M/s. Inter Valves (Pvt.) Ltd.,
 M/s. Larsen & Toubro Ltd., (Audco).
 M/s. Tyco Valves,
 M/s. Virgo Engineers Ltd.,
Noida.
Mumbai
Hubli.
Pune.
Trichinapalli.
Aurangabad.
Pune.
Chennai.
Baroda.
Pune.
3. Ball Valve:







EPI – New Delhi
M/s.
M/s.
M/s.
M/s.
M/s.
M/s.
M/s.
B.D.K. Engg. Industries Ltd.,
Delval Flow Control Pvt. Ltd.,
Fisher Xomox Sanmar.,
Flowchem Ind.,
Fouress Engg. (India) Ltd,
Habonim Vaas Automation Pvt. Ltd.,
Inter Valves,
Volume-2B, Rev.0
Hubli.
Pune.
Trichinapalli.
Ahmedabad.
Aurangabad.
Chennai.
Pune.
Page 24 of 26
Gammon,
Enquiry Specification for Dust Suppression & Water Supply System
 M/s. Larsen & Toubro Ltd., (Audco).
 M/s. Oswal Industries Ltd.,
 M/s. Virgo Engineers Ltd.,
Chennai.
Ahmedabad.
Pune.
4. CI/Sluice Gate Valves
A.
M/s.
M/s.
M/s.
M/s.
M/s.
M/s.
M/s.
M/s.
M/s.









For all Sizes and Ratings:
B.D.K. Engg. Industries Ltd.,
Calsens Private Ltd.,
G.M.Dalui & Sons,
H. Sarker & Co.,
Hawa Engineers Ltd.,
Kirloskar Brothers,
Leader Valves Ltd.,
Venus Pump & Engg. Works.,
Neta Valves Pvt. Ltd.,
Hubli.
Kolkata.
Howrah.
Kolkata.
Ahmedabad.
Nagpur.
Jalandhar.
Howrah.
Jalandhar
B. For Sizes upto NB 100 mm & PN 10 Rating:
M/s. Ronex Engg. Company,
Kolkata
M/s. Upadhyaya Valve Manuf. Pvt. Ltd.,
Kolkata
M/s. Steam & Mining Industries,
Kolkata.
(Vendors appearing under „A‟ shall be eligible for „B‟ also)



5.
Plug Valve:
M/s.
M/s.
M/s.
M/s.




B.D.K. Engg. Industries Ltd. ,
Hubli.
Fisher Xomox Sanmar Ltd. ,
Chennai .
Habonim Vaas Automation Pvt. Ltd., Chennai.
Larsen & Toubro Ltd., (Audco).
Chennai.
6. Cock Valve for Gas applications:
M/s. Larsen & Toubro Ltd., (Audco).

Chennai.
7. Check Valve/Non Return Valve:








M/s.
M/s.
M/s.
M/s.
M/s.
M/s.
M/s.
M/s.
Advance Valves Pvt. Ltd,
B.D.K. Engg. Industries Ltd.,
Fouress Engg. (India) Ltd.,
Inter Valves (Pvt.) Ltd.,
K.S.B. Pumps Ltd,
Larsen & Toubro Ltd., (Audco)
Leader Valves Pvt. Ltd.,
Oswal Industries Ltd.,
Noida.
Hubli.
Aurangabad.
Pune.
Kolkata.
Chennai.
Jalandhar.
Ahmedabad.
8. Fabricated Gate Valve.



9.
Aurangabad.
Chennai.
Germany.
Piston Valve:


EPI – New Delhi
M/s. Fouress Engg. (India) Ltd,
M/s. Larsen & Toubro Ltd., (Audco)
M/s. Zimmermann & Janseen, Duren,
M/s. Spirax Marshall Ltd.,
M/s. Uni -Klinger Ltd.,
Volume-2B, Rev.0
Nagpur.
Pune.
Page 25 of 26
Enquiry Specification for Dust Suppression & Water Supply System
10. Knife Edge Gate Valve:




M/s.
M/s.
M/s.
M/s.
Energo Engg.,
Fouress Engg. (India) Ltd,
Orbinox India Pvt. Ltd.,
Vass Ind. Pvt. Ltd.,
Delhi.
Aurangabad.
Coimbatore.
Chennai.
11. Non-Ferrous Valve:




EPI – New Delhi
M/s.
M/s.
M/s.
M/s.
Leader Valves Ltd.,
Neta Valves Pvt. Ltd.,
Sant Valves Pvt. Ltd,
Zoloto Ind.,
Volume-2B, Rev.0
Jalandhar.
Jalandhar.
Jalandhar.
Jalandhar.
Page 26 of 26
03.00
BRIEF SYSTEM DESCRIPTION
03.01
DESCRIPTION OF EXISTING COAL HANDLING PLANT
03.01.01
Coal Preparation Plant No.1
i)
Rotary wagon tippler unloads incoming coal from WT#1 and 2 each
having capacity of 800 tph and receives in two conveyor stream Y9-68 &
Y9-69. Both the wagon tipplers are provided with electric pusher car on
the inhaul side. The empty wagons are released over a gradient.
ii)
Coal from both the streams is fed, through a series of belt conveyors to
the CPP-1 coal yard. One stream has toothed roller crusher while other
stream has no crusher. Each of the streams has a capacity of 800 tph.
iii)
CPP-1 storage yard No. 1 has a storage capacity of 180,000 t.
iv)
Out of the three Nos. of gantry cranes in coal storage yard No.1 (i.e.
CPP-1) only two nos. are existing at present which are planned to be
phased out in future.
v)
Reclaimed coal from the storage yard is fed to storage cum blending
bunker (15nos) in two rows via. Conveyor series of Y5-Y6. Coal is
withdrawn from silos and conveyed to coal tower No. 1, 2 and 4 via
junction house J3, J4, J5 and J6. (Presently battery no 5&6 are under
rebuilding. After replacement of coal gallery Y6-38, CHP will feed coal to
CT-3 also).
vi)
CHP has 4 nos. of hammer crusher of capacity 250 tph and two nos. of
200 tph.
03.01.02
Coal preparation Plant No.2
i)
Incoming coal is unloaded by rotary wagon tippler No. WT# 3 on
conveyor no. Y9-87, Y9-88, Y9-90, Y9-91(and finally stacked through
stacker-cum-reclaimer I & II through yard conveyors Y9-94 & 95).
Wagon tippler is provided with Electric Pusher Car on the inhaul side.
The empty wagons are released over a gradient. Under rail hoppers are
provided for manual unloading of coal from sick wagon.
ii)
Coal from the conveyor stream like Y9-87, Y9-88, Y9-90, Y9-91 etc. are
fed to the series of belt conveyor by passing the preliminary crusher to
the coal storage yard No.2 (CPP-2). The single line conveyor capacity is
800 tph upto the storage yard.
iii)
Coal storage yard No.2 (CPP-2 existing) have storage capacity of
120,000 t.
iv)
Provision of direct despatch of coal to the storage cum blending bunkers
by passing the storage yard has been kept. The conveyor stream
CHAP-03 BRIEF SYSTEM DESCRIPTION.doc
Page 1 of 20
capacity from the storage yard to the top of the storage cum blending
bunkers is 800 tph.
v)
Coal is withdrawn from 14 nos silos in two rows- 7 nos in each row
according to predetermined blend ratio in two streams and fed to the
final crushing station No.2.
vi)
Four reversible hammer crushers of 300T/h have been provided for final
crushing in crushing station No.2.
vii)
From final crushing station No.2, crushed coal blend is dispatched to
junction No. 3F and finally to coal towers No. 5 and 6 and coal tower no
4 in case of constraint in coal supply of CHP.
viii)
Also new conveyors Y9-99A and Y9-99B have been commissioned in
the year 2002 to have the provision for taking coal from CPP-2 coal yard
to conveyor Y9-80 and Y9-81, so that coal can be fed to silos of
batteries 1 to 8.
ix)
Blending is done through 14 nos of Belt weigh feeders/ Automatic
Proportioning Device (APDs).
DESCRIPTION OF PROPOSED COAL HANDLING PLANT FOR
COAL TOWER NO.- 7 OF COB#11 COMPLEX
03.02
1.
General
In order to meet the enhanced required of coal for coke making,
following additions, augmentation & modification to the existing coal
handling plant is proposed:

Addition of 5 nos. of RCC mixing bins (Silos), each of 500t storage in 3rd
row of silos parallel to existing two rows of silos.

Installation of 2 nos. additional reversible hammer mills (designated as
hammer mill 7&8), each of capacity 300t/h in existing row of hammer
mills after extending the existing final crushing station suitably.

Replacement of existing hammer mills no. 5 & 6 by new hammer mills of
300 t/h capacity each, along with 630 KW slip ring reversible electric
motors. Room for resistance banks & control panels for hammer mill no.
5, 6, 7 & 8 shall be provided in the new portion of the final crushing
station.

Upgrading & modification of existing collecting conveyors Y7-12 & Y7-13
to 1000 t/hr. rated capacity in the existing location with minimum
shutdown.

Connecting conveyor stream, connecting new coal tower no.-7 with
existing coal handling plant.
CHAP-03 BRIEF SYSTEM DESCRIPTION.doc
Page 2 of 20

Connecting conveyor for new silos & new crushers to the existing Coal
Handling Plant.

4 nos. split gates for coal handling plant on conveyors Y7-36, Y11-130,
Y7-13 and Y11-134.
Flow diagram drawing no. MEC/S/9101/11/17/55/01/064.12/R0 (Sheet 1
of
2
&
Sheet
2
of
2)
and
layout
drawing
no.
MEC/S/9101/11/17/55/01/064.13/R0 showing the tentative location of
proposed unit are enclosed for reference.
New conveyor Y11-125 will take feed from existing conveyor Y7-49 in
the existing junction house 2C and feed conveyor Y11-126 with a
traveling tripper to feed the individual silos (5 nos. new). Each silo will be
of 500 tonne effective storage capacity. The vertical portion at a height
of 1m and conical portion (slope 60°) shall be lined with 409M 8mm thick
SS liner plate.
Each silo will be provided with identical Belt Weigh Feeder with PLC
being provided in existing SILOS.
Silos shall be provided with pneumatic blow down facility. Bunker
discharge mouth level shall be +10.2m and shall have floor at +6.2m
level for laying conveyor Y11-127.
Belt weigh feeders will feed the coal to proposed conveyor Y11-127 and
through conveyor Y11-128, the coal will be fed to existing conveyor Y735, which also carries coal from existing 2nd row of similar bunkers. The
rated capacity of conveyor Y7-35 shall be 600t/hr. Conveyor Y7-35 will
feed to modified conveyor Y7-36. The modification & strengthening of
these conveyors are in the scope of contractor. Apart from replacing
existing one way chute with split gate, conveyor Y7-36 shall be modified
for accommodating split gate and upgraded to 600 tph.
Modified conveyor Y7-36 will feed the coal to existing conveyor Y7-51 &
new conveyor Y11-129 through a bifurcated chute & split gate. Coal
from conveyor Y11-129 will be fed to the new hammer mill nos. 7 & 8
through conveyors Y11-130 & bifurcated chute with split gate.
The existing final crushing building shall be extended suitably to
accommodate new hammer mills (No. 7 & 8) and related items &
electrics. The building shall be of RCC upto top floor with structural
roofing. Each hammer mill shall have independent foundation.
In order to collect crushed product from the new hammer mills, the
existing conveyor Y7-12 will be extended at the tail end adequately & it’s
capacity shall be upgraded to 1000 t/h rated capacity. The existing
conveyor Y7-13 will also be upgraded to 1000 t/h rated capacity and will
be provided with a bifurcated chute with split gate to enable feeding of
CHAP-03 BRIEF SYSTEM DESCRIPTION.doc
Page 3 of 20
existing conveyors Y14 & Y18. These two conveyors shall have stand-by
drives. The upgraded conveyor shall be provided with new drive
(1W+1S), belt, 35 degree carrying and 10 degree return idlers. The
drives of upgraded conveyor Y7-12 and Y7-13 shall be of 1 step higher
rating. The belting shall be 1400mm wide and N/N grade of 1250 kN/m
rating minimum.
The proposed stream connecting the new Coal Tower No - 7, comprises
of new belt conveyor nos. Y11-131, Y11-132, Y11-133, Y11-134 &
reversible shuttle conveyors Y11-135 & Y11-136. The existing chute
feeding to the existing Conveyor No. Y-15 will be replaced by a
bifurcated chute fitted with a 2 position motorised diverter gate to feed
the new conveyor no. Y11-131. The coal will be conveyed to the new
coal tower no.-7 via new conveyors Y11-131, Y11-132 & Y11-133
through new junction house no. 11A & 11B. The stream rated capacity
shall be 600t/h.
Reversible shuttle conveyors Y11-135 & 136 shall be provided at the top
of the coal tower no.-7. These shuttle conveyors shall be fed by
conveyor Y11-134 through a split diverter gate. Each of the shuttle
conveyors will be of 400 t/h capacity and shall be mounted on parallel
tracks and can be placed on different compartments of the coal tower to
uniformly distribute the coal charge in the coal tower. For this purpose
suitable nos. of limit switches shall be provided.
Additionally, the coal tower shall be provided with 18 nos. of level
monitors for giving continuous measurement of level of coal in the coal
tower.
A belt weigh scale shall be provided on the new conveyor no. Y11-132
to indicate the flow rate & total quantity of coal fed to the coal tower.
The new equipment & conveyors shall be interlocked & controlled with
the existing coal handling plant from the existing control room.
The existing system of LSTB shall be extended to all the new units up to
the top of new Coal Tower no.-7 for communication.
Facilities for dust suppression, fire fighting facilities and proper
illumination of galleries and junction house is included in the scope of
work.
The conveyor drives of 30 KW and above shall be provided with fluid
coupling. All coupling bolts shall be replaceable without shifting of drive
components. Chutes shall be lined with 8mm thick 409M SS liners. Each
discharge legs of the chutes shall be provided with chute jam indicators.
Flap/ Diverter gates shall be lined with 8mm thick SS 409M liner plates.
CHAP-03 BRIEF SYSTEM DESCRIPTION.doc
Page 4 of 20
Each junction house shall be provided with Electric hoist. The Capacities
of EOT Cranes / Electric Hoists for maintenance shall be at least 1.2
times the heaviest load – or – the Capacity & approximate height of
some Junction houses are indicated as below:
Silo top
Jn. House 11E
Final crushing station
New JH No.11A
New JH No.11B
Top of coal tower no.7
-
3t cap
2t cap
10t cap
2t cap
3t cap
3t cap
-
37m lift
24m lift
10m lift
30m lift
45m lift
50m lift
- 1no.
- 1no.
- 2nos.
- 1no.
- 1no.
- 1no.
03.03
DESCRIPTION OF PROPOSED COKE SORTING PLANT FOR
COB#11
03.03.01
Design Limits
Following design limits are to be considered for the proposed Coke
Sorting Plant (CSP-4)
a)
b)
c)
d)
e)
f)
03.03.02
From & including surge hopper in the junction house no.1. Junction
house no.1 is included in the scope of the contractor.
Upto & including junction house no. Z17 and upto & including discharge
chutes of conveyors K11-21 & K11-22.
Including upgradation of existing conveyor no. KD-1, modification of
gallery of KD-1 is included in the scope of the Contractor.
For coke breeze from the proposed conveyor KA-3 to the coke breeze
bunkers & C3A-C2 with two way Diverter gate at Junction house JHC3A. Nut coke from CSP coke breeze bunkers shall be disposed off by
wagons and conveyor C3A-C2, for any exigency 100% disposal facilities
by wagon will be provided.
The discharge chute with pneumatically operated sector gate for coke
car track from surge hopper in JH – 1 is in the scope of contractor.
3 nos. bin vibrators shall be considered for each bunker; hence, total no.
of vibrators for coke sorting plant shall be 6.
Brief Description
A coke sorting plant of 300t/h capacity has been envisaged for the plant.
The coke sorting plant will sort out the coke into three fractions i.e. 30-60
mm, 60-80mm & (-) 30mm. The coke will pass through a series of
screens and coke cutters for this purpose. Flow diagram, layout,
sections etc. are shown in drgs. MEC/S/9101/11/17/55/01/064.01 to
064.08.
The (-) 30mm fraction will be sent and stored in the 150t capacity RCC
bunkers, after screening at 15mm. The other coke fractions will be sent
through conveyors to Blast furnace stock house. In addition to the
above, an open mechanized emergency coke storage yard of about
2500t capacity will be provided. Required conveyor streams, traveling
CHAP-03 BRIEF SYSTEM DESCRIPTION.doc
Page 5 of 20
trippers will be provided for storage of coke. Coke will be reclaimed by
an underground reclaiming conveyor as shown in the drawings.
Additionally a 1400mm wide 200 t/h conveyor streams shall be provided
to carry BF coke from existing CSP-1 and feed to two numbers of 100t
capacity RCC surge hoppers provided over conveyors K11-13 & K11-14.
Each surge hopper shall be provided with level meters & belt weigh
feeders to properly proportion the coke coming from CSP-1 & the new
CDCP plant.
To take tapping from existing conveyor KD-1 a fixed tripper with a
bifurcated gate shall be provided. One leg of the chute will feed coke to
the new conveyor KA-1 of 1400mm wide & the other leg will feed the
conveyor KD-1. A split gate shall be provided to enable feeding of coke
to both the conveyors simultaneously. The walkway of conveyor KD-1
shall be suitably modified in the vicinity of the fixed tripper to facilitate
movement of plant personnel.
All the buildings, junction houses, conveyor galleries will have adequate
facilities like ventilation, illumination, hoisting and handling equipment,
dust suppression facilities, etc. wherever necessary. All buildings shall
be provided with LSTB system for communication.
Further, a dust extraction system shall be provided in the proposed Coke
Dedusting Unit (CDU). A brief description of the same is given below:
03.03.03
Dust Extraction System with Air Blasting Unit
03.03.03.01 Brief Description
A dust extraction system with an air-blasting unit is to be provided in the
coke-dedusting unit (CDU).
The system shall comprise dust extraction unit and air blasting unit. The
dust extraction unit shall comprise suction hoods on the coke dedusting
chute, ducting network, electrically operated dampers, bag filter unit,
centrifugal fans, stack, electrics & control.
Bag filter unit shall consist of distribution chamber, filtering chamber with
filter bags & fitting for the bags, outlet chamber, dust collection hopper
with rotary air lock valves & screw conveyor, dust storage cum disposal
hopper with rack & pinion gate and disposal chute, structural stair case
and platform, timers etc. and one multiclone and one spark arrestor in
the ducting network at the inlet side of distribution chamber of bag filter
unit. (these two equipment are required to collect the hot/ glowing coke
particles thereby preventing them to enter into bag filter). Two suction
ducts of the ducting network shall be provided with electrically operated
dampers & flanges for connecting them with the coke dedusting unit
(CDU) chambers (2 nos.) separately.
CHAP-03 BRIEF SYSTEM DESCRIPTION.doc
Page 6 of 20
The air blasting unit shall consist of air intake louver, transition piece,
centrifugal blasting fan, main duct and two numbers of branch ducts with
electrically operated dampers & flanges.
03.03.03.02 Arrangements and the Components:
The air intake louver of air blasting unit shall be installed in the opening
of wall exposed to ambient. This shall be connected to suction side of
blasting fan through transition piece. The delivery side of this fan shall
be connected to ducting network. The branch ducts (2 nos.) shall be
connected to both the coke deducting unit (CDU) chambers through the
flanges separately. There shall be two air stream/ paths, one working &
one standby, from air blasting unit to dust extraction unit, through CDU
chamber. The material flow in the CDU chambers conceptually shall be
perpendicular to the airflow of air stream from blasting unit to dust
extraction unit. Electrically operated dampers provided in the air stream
at the both sides of CDU chamber shall be interlocked with the operation
of CDU chambers; this is required to isolate the stand by CDU from air
stream and to take the working CDU into air stream of our above
system.
03.03.03.03 Functional Description
While running the CDU, air blasting unit fan shall suck ambient air
though air intake louver & transition piece and blast/ supply the air into
the CDU through the ducting network.
The working of the dust extraction unit shall suck the air dust laden air
including blasting air shall be sucked from CDU and hot/unburnt glowing
coke particles shall be collected in multiclone and spark arrestor placed
in the ducting network at the suction side of bag filter. The dust disposal
from bag filter, multiclone & spark arrestor shall be through discharge
into a central pneumatic system (through dust storage hopper).
However, central pneumatic system shall not be in the scope of
Contractor.
03.03.04
Major Facilities
03.03.04.01 The major scope of work of Coke Sorting Plant comprising of Coke
crushing station, coke screening station, coke breeze bunkers,
emergency coke storage yard, coke dedusting units, junction houses,
traveling tripper bridge, galleries and associated mechanical, civil,
structural, electrical works of COBP # 11 is given below: -
2 nos. grizzly screens (80mm), capacity 300 t/h.
-
Grizzly shall be of Manganese steel casting DISC and the underpass
chute liners should be cast Basalt 110mm thick
-
2 nos. coke cutters (+80mm) capacity 180 tph.
CHAP-03 BRIEF SYSTEM DESCRIPTION.doc
Page 7 of 20
-
2 nos. vibrating screens, (30 mm) capacity 300 t/h. Screen wires should
be 5 mm dia SS.
-
2 nos. grizzly screens (60 mm), capacity 200 t/h. Grizzley specifications
and chute liners shall be same as mentioned above.
-
Conveyor stream capacity 300/150 t/h.
-
2 nos. variable speed belt weigh feeders 20t/h to 100 t/h.
-
Chain samplers – 2 nos., one each for different BF coke fractions.
-
Belt conveyors as per conveyor data sheets.
-
Belt weighers shall be provided on Coke Conveyors K11-11, K11-12,
K11-15, K11-16 & conveyor K11-18.
-
Capacity up gradation of existing conveyor KD-1 to 400tph from 300tph.
-
Capacity of conveyor staying from conveyor KD-1 to the CSP-4 shall be
300t/h.
-
All chutes should be box design to avoid direct fall of Coke on Chute
liners.
-
Only Cast Basalt/ Ceramic liners of 110 mm thk are to be used in Coke
Transfer Chutes.
-
DE system shall be provided for dust extraction at all transfer points.
-
Control room & maintenance room shall be provided in coke screening
station.
-
Automation & control facilities shall be interfaced with coke oven battery
operation.
-
The extension of existing conveyor stream comprising conveyors KA2/KA-3 to the new breeze bunkers of CSP-4 for onward conveyance to
SP-3.
-
Wagon loading shall be provided for BF coke in the coke screening
station of CSP-4.
-
Shift in-charge & supervisor room shall be air condition.
-
Maintenance post with Air Conditioned Supervisors room along with shift
in changes room and toilet block is to be provided in the Coke Screening
Station.
-
Handling & Hoisting facilities: All Junction houses shall be equipped with
suitable handling & hoisting facilities. Junction houses below 6m height
shall have suitable capacity (2t min.) manual hoist and more than 6m
CHAP-03 BRIEF SYSTEM DESCRIPTION.doc
Page 8 of 20
height shall have electric hoists. Under slung & EOT cranes as required
in CS and other handling facilities as specified in system description
shall be provided.
1 no. mobile belt coiler / decoiler type belt changing device and 2 nos.
hot vulcanizing unit suitable for 1600 mm belt width. Contractor shall
also to provide guide rollers at required locations for coiling / decoiling of
belt near each junction house / take up unit.
-
03.03.05
Other Features
In addition to the above, following is to be provided in this package by
the Contractor.
1.
The capacity of the belt weighers shall be 1.2 times the rated capacity of
the respective conveyors.
2.
The two way diverter gates shall be of robust design and of wear
resistant material for longer life.
3.
Flap/ Diverter gate drives shall be of adequate rating to take care of dirty
conditions of the chute’s interior.
4.
Flap/ Diverter/ split gate, surge hoppers etc shall be lined with 10 mm
thick ‘Hardox 500’ material with CSK bolting.
5.
RCC bunkers/ under-ground hoppers shall be lined with 8mm thick SS409M Stainless Steel.
6.
Scrapper/ breeze chutes should have a minimum inclination of 70
degree and should be made up 409M SS.
7.
In case of bifurcated chutes, where steep angle scrapper chute is not
possible, the scrapper shall be provided in the main chute with proper
design to ensure easy accessibility for removal of scrapper for
maintenance purpose.
8.
Suitable windows shall be provided in chutes & scrapper chutes to
enable proper cleaning of the chute’s interior.
9.
The yard surface slope shall be such that drainage is outward.
10. Side sheeting & roofing shall be of suitable material and shall be
properly fixed to ensure longer life in corrosive atmosphere.
11. Fiber glass roofing & sheeting shall be provided at suitable intervals for
proper illumination in the galleries.
12. Each underground hopper in the stockyard shall be provided with
manually operated sector gates.
CHAP-03 BRIEF SYSTEM DESCRIPTION.doc
Page 9 of 20
13. Yard reclaim conveyor K11-10D shall be 1600mm wide with 35°
troughing angle and without skirt board.
14. Discharge chutes shall be lined with 110mm thk. liners/ cast basalt
liners.
15. Anti-corrosion painting shall be provided on all structures.
16. Silos shall be lined with 8mm thick SS-409M with SS steel coping at 1m
high in vertical & complete in slope portion.
17. DE system shall be provided for dust extraction at all transfer points.
18. Grizzly screens discs shall be of high manganese cast steel.
19. All types of gear boxes shall be supplied with input shaft with matching
gear wheel assly.
20. Control room & maintenance room shall be provided in coke screening
station.
21. Automation & control facilities shall be interfaced with coke oven battery
operation.
22. The control room shall be provided with package type AC.
23. Existing conveyor KD-1 shall be renovated with following features.
i)
Capacity
:
400t/h
ii)
Belt width
:
1400m
iii)
Troughing Angle
:
35°
iv)
To be provided with fixed tripper
v)
Drive to be changed accordingly.
i)
For disposal of coke breeze from CSP-1, the existing conveyor
stream comprising conveyors KA-2/KA-3 shall be extended to the
new breeze bunkers of CSP-4 for onward conveyance to SP-3.
Nut coke from CSP coke breeze bunkers shall be disposed off by
wagons and conveyor C3A-C2. For any exigency 100% disposal
facility by wagon will be provided.
ii)
Nut coke from CSP-1 shall disposed off by wagons as per present
practice.
iii)
Nut coke from CSP-4 bunkers shall also be disposed off by
wagons/ road. Facility for the same shall be provided.
CHAP-03 BRIEF SYSTEM DESCRIPTION.doc
Page 10 of 20
24. Wagon loading shall be provided for BF coke in the coke screening
station of CSP-4.
25. Maintenance post with Air Conditioned Supervisors room along with shift
in changes room and toilet block is to be provided in the Coke Screening
Station.
Conveyor belt width, troughing angle and belt width will be properly
selected to prevent coke spillage. Conveyor galleries, buildings will
follow IPSS norms and will be provided with adequate maintenance
facilities and space.
Coke crushing station, coke screening station, coke bunkers and
junction house no. 1 & coke dedusting unit shall be of civil construction
upto the top floor, above which it shall be of steel structure.
Other Junction Houses & travelling Tripper Bridge shall be of steel
structure with RCC flooring.
Electric hoists/ manual hoist of suitable capacity & lift shall be provided
in each junction house & buildings to cater to the maintenance needs.
Electric hoists shall be provided wherever height of lift is more than 6
meters.
CHAP-03 BRIEF SYSTEM DESCRIPTION.doc
Page 11 of 20
Brief System Description of Augmentation in Flux - Fuel
Preparation and Plant return fines handling for SP III
03.04
The turnkey package of this CS also comprises of the following subsystems:

Up gradation / Addition of coke crushing and screening and
grinding facilities

Up gradation/ addition of Flux crushing & screening facilities in an
integrated manner.

Transportation of Fines from Blast Furnace nos.1 to 7 & BF # 8 to
Existing Junction house JH-127

Transportation of Coke Breeze from CSP#4 to Conveyor C102 in an
integrated manner.
Brief descriptions of the various sub-systems are given below and are
also reflected in the drawings enclosed. However the Contractor shall
consider the contract drawings only as indicative and any changes for
completeness and improvement shall be finalized during submission of
basic engineering document for approval by the Contractor.
03.04.01
RECEIPT OF RAW MATERIAL
Presently iron ore fines and fluxes are being conveyed to SP-III from
existing Ore Handling Plant (OHP) through two series of belt conveyors
and coke from existing Coke Sorting Plant (CSP) by dump-cars unloaded in
an underground hopper & through a series of belt conveyors. All the three
conveyors pass through JH-111A. This system is adequate to feed both
strands (existing & proposed) of Sinter Plant-III.
Sieve analysis of raw material input to fuel & flux crushing & Screening
circuit
CHAP-03 BRIEF SYSTEM DESCRIPTION.doc
Page 12 of 20
1. Lime Stone (received from Koteswar)
Max
+ 75 mm
- 75 mm
- 60 mm
- 50 mm
- 30 mm
Min
to
to
to
to
+ 60 mm
+ 50 mm
+ 30 mm
+ 25 mm
- 25 mm
-
%
2.0%
15.0%
16.6%
40.2%
9.2%
17.0%
-
%
1.3%
7.3%
44.9%
16.7%
14.3%
15.5%
Moisture- 15%
2. Raw Dolomite
Max
+ 60 mm
- 60 mm
- 50 mm
- 20 mm
- 10 mm
Min
to
to
to
to
+ 50 mm
+ 20 mm
+ 10 mm
+ 6 mm
- 6 mm
Moisture- 15%
3. Coke Breeze
Max
+ 25 mm
- 25 mm
- 15 mm
- 10 mm
- 5 mm
Min
%
4.3%
to
+ 15 mm
12%
to
+ 10 mm
- 11.5%
to
+ 5 mm
- 15.3%
to
+ 3 mm
- 16.5%
- 3 mm
- 40.4%
Moisture- 10% (normally), 15% (in rainy season)
Tentative size distributions of raw material (sizes as required in this CS)
are shown in Table: 05.01 below. Further, the product/ output of crushed
fuel & flux shall be in accordance with the sizes is also given below:
Table: 05.01
Sl no
Material
Size Distribution (mm)
Percentage
1
Iron ore fines
- 8 mm
+8mm (5% max.)
2
Lime stone/
- 5mm
100%
Dolomite (Crushed)
- 3 mm
95% (Minimum)
- 1 mm
70%(Minimum)
3
Coke breeze (Crushed)
- 5mm
100%
-3 mm
90% or above
-1.0mm
Not to exceed 50%
-0.5mm
Not to exceed 30%
4
Mill scale
- 8 mm
+8mm (5% max.)
CHAP-03 BRIEF SYSTEM DESCRIPTION.doc
Page 13 of 20
5
6
03.04.02
BF sinter return fines
Flue dust
- 8 mm
- 1 mm
+8mm (5% max.)
+1mm (5% max.)
ADDITIONS/ MODIFICATIONS AND UPGRADATION IN EXISTING
RAW MATERIAL PREPARATION SYSTEM
03.04.02.01 EXISTING FUEL crushing and screening facility
There is a provision of covered storage for coke breeze received from
blast furnace adjacent to coke crushing and screening building. The
coke breeze is reclaimed by front end loaders and conveyed to coke
crushing and screening building through series of conveyors C101,
C102, C103, C104, C105 and finally C106. The coke breeze gets
crushed by 2 roll crusher to -10 mm from -25mm size and subsequently
screened by Mogensen
sizer.
+3mm
output
from
the
sizer
is
conveyed to coke grinding building by conveyor C111and discharged
onto reversible conveyor C112. Conveyor C112 discharges into 2 nos.
surge bins from where belt feeders extracts material and feeds to rod
mill (2 nos.) where it gets crushed to -3mm. (-)3 mm size from crushing
and screening building is directly conveyed and discharged onto
conveyor C114 through conveyors C110 and C113 ,which in turn
discharges to conveyor C 115.
03.04.02.02 Existing FLUX crushing and screening facility
Limestone and dolomite required for the existing machine of Sinter Plant
III is drawn from bunkers of flux proportioning building and conveyed by
conveyor 105 to surge bin of existing flux crushing building. The material
is discharged onto reversible shuttle conveyor L106 from where it is
discharged onto bins. The material is withdrawn by vibratory feeder and
fed to primary hammer mill (3 nos.) of 250tph capacity. From the
hammer mills the crushed flux is conveyed by conveyors L109, L110 and
L111 onto secondary hammer mills (3 nos.) These three conveyors carry
crushed flux to flux screening building and discharge into surge bins(3
nos.). Material is withdrawn from each of the two openings by traveling
CHAP-03 BRIEF SYSTEM DESCRIPTION.doc
Page 14 of 20
vibro feeder (6nos.) and fed to flux screens (6 nos.) for screening -3mm
size fraction. The under size (-3 mm) from each of the six screens is fed
to a common conveyor L120 which conveys the material onward to
storage and proportioning bin building. The oversize (+3mm) is fed to a
common conveyor L115 and recycled back to flux crushing building for
further crushing.
03.04.02.03 PROPOSED Fuel and Flux Crushing and Screening Facility
In order to cater to increased requirement of fuel and flux for the new
sinter machine, following three facilities have been envisaged under this
package which shall form part of scope of this Contract:

Up gradation / Addition of coke crushing and screening facilities.

Up gradation / Addition of Coke Grinding facilities

Up gradation/Addition of Flux crushing & screening facilities.
The existing facilities also need to be modified/ extended so as to
integrate the existing with proposed facilities.
03.04.02.03.A
UP gradation / Addition of coke crushing and screening and
grinding facilities
A similar facility for coke breeze crushing, screening & grinding with
related facilities shall be added adjacent to the existing one.
As described earlier that the coke breeze is being received from the
existing track hopper via belt conveyors C101, C102, C103, C104 to the
coke storage yard. It is now proposed that Coke breeze & BF return
fines shall also be received by conveyor C-102 for further transportation
to coke storage yard. Belt conveyor C-104 shall be suitably modified &
extended and discharge onto new reversible conveyor RC 106. RC 106
shall be able to discharge either onto existing conveyor C106 or onto
new conveyor C106A in a new Junction house CK-1. Conveyor C-106A
shall carry the material to feed over a hopper of capacity 200m3
(effective volume) with suitable gate at proposed New Coke crushing
house CK-2. A reversible belt conveyor RC-CK2 will receive the material
CHAP-03 BRIEF SYSTEM DESCRIPTION.doc
Page 15 of 20
from bunker and feed either to the two roll crusher or bypass the crusher
and feed to conveyor C107A as shown in the flow diagram. The two roll
crusher shall be of capacity 50 tph and shall receive -25mm (10-15%
moisture) coke breeze, crush and discharge over conveyor C-107A.
Conveyor C-107A shall further transfer Crushed/ bypassed uncrushed
material to Junction house CK-3 and discharge over a Mogensen Sizer
of capacity 50 tph for product size of (-3) mm. The oversize (+ 3 mm)
from sizer shall be discharged onto conveyor C-111A which shall convey
and discharge the material onto new conveyor C- 112A in new coke
grinding building. Conveyor C-112A shall discharge into either of two
nos. surge bins of effective capacity ~100 m3 each from where material
shall be withdrawn by Belt feeder and fed to rod mill. Sized material (3mm) from rod mill shall be discharged onto existing conveyor C-114,
which shall further convey the material to existing storage and
proportioning bin building through existing conveyors C115, C115A and
C115B.
It may be noted that input material of size -25mm and product material of
size -3mm is the basic system requirement of the integrated fuel
crushing and screening system. The facilities envisaged between input
stage to output stage have been given in the CS. Crushing of coke at
two roll crusher, screening at coke sizer and grinding at rod mill shall be
decided by the contractor in an integrated manner to given the plant
output of –3mm.
03.04.02.03.B
Up gradation/Addition of Flux crushing & screening facilities
An additional stream similar to the existing one consists of Primary &
Secondary Hammer Mill with surge bin & vibro-feeders and related
facilities shall be provided by extending flux crushing building. Further
screens with surge bin & vibro feeders in screen building with feeding
conveyor from crushing building to screen building shall be provided.
Limestone and dolomite required for the existing machine of Sinter Plant
III is drawn from bunkers of flux proportioning building and conveyed by
CHAP-03 BRIEF SYSTEM DESCRIPTION.doc
Page 16 of 20
the conveyor L105 to surge bin of existing flux crushing building. It is
proposed to extend the existing conveyor L 105 by nearly 7.3 m to new
proposed extension of flux crushing building.
The existing reversible shuttle conveyor L-106 shall be replaced by new
one of larger length so that it can feed existing three crushing series
surge bins as well as a new crushing series surge bin (200 m 3 effective
volume each). New series having a Primary hammer Mill shall receive
the material from respective surge bin through vibro-feeder and after
crushing it will discharge onto a new conveyor L111A. Conveyor L111A
shall further feed the crushed material to secondary Hammer Mill. After
crushing in secondary crusher, the material shall be conveyed to new
surge bin in the screen building (100m3 Effective volume) with the help
of a new belt conveyor L114A. The surge bin of this screen building shall
have two discharge points so as to feed the new two nos. screens.
The undersized material (-3mm) shall be received by the existing
conveyor L120. The tail end, horizontal gravity take up arrangement,
electrics, control, etc. of belt conveyors L120 shall be suitably extended
backward to receive the above material from Screens.
The over sized material (+3 mm) shall be recycled through existing
conveyors L115, L116 & L117 to the Crushing building. The tail end,
horizontal gravity take-up arrangement, electrics, control, etc. of belt
conveyors L115 shall be suitably extended backward to receive the
above material from Screens. Belt conveyor L117 shall further discharge
the material onto the new reversible shuttle conveyor L118. The existing
reversible shuttle conveyor L118 shall be replaced by new one of larger
length so that it can feed existing three surge bins as well as a new
surge bin (75m3 EV). The surge bins will then discharge the material
over the same (as referred above) new secondary Hammer Mill with the
help of Vibro-Feeder. The material shall be further crushed and fed to
the screens as described above.
CHAP-03 BRIEF SYSTEM DESCRIPTION.doc
Page 17 of 20
Flow diagram and Layout drawing for Proposed Fuel and Flux
Crushing and Screening Facility of Sinter Plant-III is enclosed as Drg.
No:
MEC/S/9101/11/17/01/55/064.18/R0
and
MEC/S/9101/11/14/0/A/00/064.2522/R2 for reference.
03.04.02.04 RE-ROUTING OF EXISTING SINTER FINES CONVEYORS (C-LINES).
The existing series C-line conveyor is feeding BF return fines from
existing Blast furnaces to the sinter return fines (IPRF) conveyor F101 of
SP-III at JH-127. It is now proposed to dispatch these return fines
straight to the same conveyor with strengthening & modification of
gallery. The same shall be executed by dismantling & re-routing of the
existing C-line conveyors so as to install new CDCP unit in place of Cline Belt conveyor no. C3, and hence the existing C3, C4, C5 & C6 belt
conveyors require relocation.
Dismantling of the existing belt conveyors C3, C4, C5 & C6, related
galleries & junction houses no.-3, 4, 5 & 6 is included in the scope of the
contractor. Junction house - C2 shall be suitably modified to re-install the
tail end of new conveyor-C3 from perpendicular direction as shown in
General layout drg. No. MEC/S/9101/11/14/0/00/00/064.03/R0.
Belt Conveyor No. C3 shall be re-routed and re-installed (two conveyors
C3A-C1 & C3-C1) along the existing gallery of JH124 & 123A/B adjacent
to railway tracks so as to feed the fines at relocated junction house -C3.
Belt Conveyor C3A-C1 shall receive BF return fines at JH-C2 and
discharge onto conveyor C3-C1 as well as conveyor C3A-C2 shall
receive coke breeze from CSP#4 and discharge onto conveyor C3-C2 at
Junction house JH-C3A. These two belt conveyors i.e. C3-C1 & C3-C2
together carry the material through common gallery and discharge onto
belt conveyor C4-C1 & C4-C2 respectively. Belt conveyor C5-C1 (Sinter/
ore fines) and C5-C2 (Coke fines) shall receive the material from BF#8
Stock house and discharge over C6-C1 and C7-C1 respectively at JHC5. Also Conveyor C4-C1 and C4-C2 shall discharge the material over
CHAP-03 BRIEF SYSTEM DESCRIPTION.doc
Page 18 of 20
conveyor C5-C1 & C5-C2 respectively at JH-C4. Conveyor gallery C5C1 & C5-C2 shall cross over the existing gallery of conveyors between
JH-120 & Emergency Sinter Storage Building.
Belt conveyor C6-C1 shall carry the Iron bearing fines (BF return) and
discharge over conveyor J127-C1 at JH-C6 and in turn to F101 existing
Belt conveyor at JH-127. Junction house JH-127 shall be suitably
modified so as to accommodate drive and discharge end of belt
conveyor J127-C1. Existing drive and discharge of belt conveyor C6
shall be dismantled before installation of new conveyor J127-C1. Belt
conveyor C7-C1 shall discharge the material over belt conveyor C102A
at Junction house JH-C7 and in turn feed to existing belt conveyor C102
at pent house. As a storage capacity of 12 hrs has been envisaged in
BF#8 return coke bunker in BF#8 itself, no separate storage/ surge bin
has been considered in C102A to C102 conveyor transfer points.
Suitable gallery structure to place drive/ discharge end of conveyor belt
C102A, de-dusting system, skirt board & impact idlers on existing
conveyor C-102 shall be provided to receive coke breeze. The pent
house roof shall be locally dismantled to enable erection of transfer
house and discharge onto conveyor C-102. However, after installation of
new Junction house over pent house, the roof & structure of pent house
may again be utilized to cover remaining part of pent house.
Two dedicated routes shall be provided to transport Iron bearing material
(BF return fines) till existing belt conveyor F101 of SP-III and coke fines
from coke sorting plant & BF#8 stock house till existing belt conveyor
C102 of SP-III. A common gallery may be considered for all parallel
conveyors.
Floors of Conveyor galleries of all return line conveyors from junction
house C2 to new junction house J127 & pent house of C102 shall be of
chequered plate construction (Minimum 8mm O/P) with semi circular
hood over conveyor.
CHAP-03 BRIEF SYSTEM DESCRIPTION.doc
Page 19 of 20
Rerouting of these conveyor series shall be so meticulously planned that
minimum shut down is required in the existing plant. Design, supply,
erection, commissioning and performance guarantee test of the Rerouted conveyors are under the scope of the Contractor. Existing
equipments/
components
of
dismantled
(by
the
Contractor)
conveyor/gallery/ junction houses shall not be re-used.
All Proposed junction houses shall have Electric hoist. The capacity & lift
may be followed as per CS. Junction houses (where these facilities are
not considered) of below 6m height shall have suitable capacity ( 2t min.)
manual hoist and more than 6m height shall have at least 5t cap electric
hoists. Under slung & EOT cranes as specified in CS and other handling
facilities as specified in system description shall be provided.
CHAP-03 BRIEF SYSTEM DESCRIPTION.doc
Page 20 of 20
4.2.0
COMPRESSED AIR FACILITY
4.2.1
INSTRUCTION TO CONTRACTOR
Dedusting system of Coal Handling & Coke Sorting plant for COB #11 plant
will require substantial quantity of compressed air. To meet the air
requirement, a compressed air station along with interconnecting inter-shop
and in-shop piping system upto the individual consumers will be provided in
the Coal Handling & Coke Sorting plant area on turnkey basis.
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.
4.2.3
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.
:
480C
90C
Maximum
Minimum
:
:
100%
25%
Altitude above MSL
:
307m
Temperature
(Max)
(Min)
Humidity
Design ambient condition for the compressors will be taken as 450C
temperature and 60% RH. Design ambient temperature for Electrics
will be considered as 500 C.
4.2.4
Delivery Schedule
Delivery schedule will be matched with schedule of the overall package.
4.2.5
SCOPE OF WORK
The Scope of work will include design, engineering, manufacture, assembly,
shop testing at manufacturer‟s 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 facility will comprise of following main equipment :
i)
Three (3) sets (2 W + 1SB) 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, aftercooler, 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.
f)
Each Compressor will have dual type control system, which will permit
operation of each compressor in either of the following way:
(a)
(b)
Continuous Variable Load /unload regulation
Automatic Start-Stop Regulation.
ii)
2 no. Refrigerant type of Air Dryer‟s of Capacity 4 Nm3/min each will be
provided.
iii)
1 no. of Air Receiver of 4 m3 capacity for instrument air and 1 no. Air
Receiver of capacity 12 m3 for plant air 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).
iv)
All necessary interconnecting pipes (from compressors outlet upto the
consumer points), valves, fittings including supports and supporting
structures.
v)
Drain pipelines from compressed air station to nearest drain/drain pit.
vi)
Miscellaneous structures, access platforms for operation and maintenance
of equipment parts, valves, instruments, etc. forming part of the
equipment.
vii)
A complete new and unused set of all special tools & tackles required for
operation and maintenance.
viii)
Electrics and C&I .
ix)
Contractor will furnish 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
x)
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
employer‟s pipe network and equipments.
xi)
Special tools & tackles (along with list), Nil - as per Annexure-B.
xii)
Supply of first fill of lube oil & consumables and also for testing,
commissioning and performance guarantee. Specification of all consumables
will be indicated.
xiii)
Commissioning spares (All spares used until the plant is handed over to the
employer), Nil, as per Annexure-B.
xiv)
Training of O&M staff of Employer for 10 mandays.
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., will be as per
GTS/TS.
The scope of supply for electrics will include the following:
i.
Drive motors for compressors & lubrication system as well as for motor
operated valves.
ii.
Control Cabinet/ Console: one for each compressor.
iii.
Double compression brass cable glands and cable lugs for all electrical
equipment supplied by the Contractor.
iv.
For compressor motor bearing and winding temperature detection,
monitoring, interlocking, signaling & annunciation, micro processor based
temperature controller will be provided for each motor by the Contractor.
The scanner will be housed in an independent control panel.
v.
Contactor will note that the HT Power for the Compressed Air Station will be
fed from the near by HT sub-station SS-45 through 3 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 will be
done by the Contactor. The cables will be routed through under ground
trench. Further distribution of HT and LT power will be done by the
contactor.
vi.
All erection/installation accessories, cable trenches, cable support
structures/cable gallery, cable termination at both ends, cable fixing,
support materials etc. for all equipment within the scope of supply of
Contractor within the plant area including cables from HT switch board at
HTSS-45.
vii.
Power and control cables from the control cabinets, for interlocking & inter
connection to all motors, instruments, consumers etc.
viii.
Junction boxes with required number of terminals including 20% spare
terminals.
ix.
All other equipment, accessories, field devices, safety switch etc required
for safety interlocks, process control & interlocking etc.
x.
The contractor will include all power and control cables in adequate
quantities in turnkey/lot basis as per actual requirement at site.
xi.
Contractor will include commissioning spares in their scope. They are also
furnish the list of commissioning spares.
xii.
Make of all the equipment will be restricted to the list of preferred makes
given in the TS.
xiii.
HT compressor motor will 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.
xiv.
LT Power to the compressed air station will be fed from a dedicated MCC
cum PDB which will have 2 incomers with bus-coupler arrangement.
xv.
Local push button stations
xvi.
UPS as per requirement will be provided.
xvii.
LDBs / Junction Boxes, etc. (as per the requirement).
xviii.
Earthing for all equipment within the scope of supply.
xix.
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.
xx.
Fire sealing materials for laying termination and sealing of cables.
xxi.
Complete electrics of material handling equipment like cranes, lifts, hoists,
etc (if any).
xxii.
Complete electrics of ventilation systems for area under battery limit.
xxiii.
Water drainage pumps in required numbers with complete electrics
including source feeders, pumps/motors, cable laying, etc.
xxiv.
Fire protection system including Fire Detection and Alarm System for the
complete plant, etc.
xxv.
Welding sockets, 240 V power sockets and 24 volts AC sockets with
transformers.
xxvi.
Illumination for the entire plant and boundaries.
xxvii.
Installation, erection accessories.
xxviii.
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 will 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 will be based on principle of flux compensated nonsaturated magnetic amplifiers for control of motor starting current. Also, the
starter should not introduce any harmonics into the system.
The flux compensated magnetic amplifiers will 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 will be IP52.
The Sheet steel thickness will be 1.6 mm.
The control circuit will utilize auxiliary contacts and timers for starting
function.
Lamp indication will be provided using LED type lamps.
Ammeter will be provided on front door.
The cubicle will have cable entry and exit from bottom through gland plate.
Bypass device used will be 6.6kV contactor.
4.2.6
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
1.
Indication of differential pressure across suction air filter for each
compressor.
2.
Indication of pressure of compressed air after after-cooler and after
compressor.
3.
Indication of temperature of compressed air after after-cooler and air
compressor.
4.
Indication of pressure of compressed air in air receiver.
5.
Indication of pressure of lube oil before & after oil cooler.
6.
Indication of temperature of lube oil before & after
7.
Indication of differential pressure across lube oil filter.
8.
Indication of temperature at the inlet & outlet of common header of
compressor cooling water circuit.
9.
Indication of pressure at the outlet of common header of compressor
cooling water circuit.
oil cooler.
10. Indication of flow of compressed air.
ii)
Alarms and interlocks
Following audiovisual alarms and interlocks will be provided for each
compressor:
1.
Differential pressure of air across suction air filter high
- alarm only.
2.
Temperature of air after air compressor high - alarm only.
3.
Temperature of air after air compressor too high - alarm and trip.
4.
Pressure of air after after-cooler high
5.
Pressure of air after after- cooler too high
- alarm & trip.
6.
Differential pressure across lube oil filter high
- alarm only.
7.
Pressure of lube oil to compressor low
- alarm only.
8.
Pressure of lube oil to compressor too low
- alarm & trip.
9.
Temperature of lube oil to compressor high
- alarm only.
- alarm only.
10. Cooling water supply pressure low
- alarm only.
11. Cooling water supply pressure too low
- alarm & trip.
12. Motor over load
- alarm & trip.
13. Manual tripping
- alarm only
4.2.7
PIPES, FITTINGS & VALVES
1. 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.
2. All pipes and valves will be as per the following tables.
Specification of Pipes & Fittings
Sl.
1.0
Service
Compressed
Air System
Size
<50NB
>65NB
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
ASTM A105
Teflon
Welded/
Flanged
Specification of valves
Sl.
Service
Size
Body/
Bonnet
Disc
1.0
Compressed
Air System
>65NB
ASTM A
216 Gr.
WCB
ASTM
216
WCB
>25 &
< 50
NB
< 25
NB
ASTM
105
A
ASTM
105
A
ASTM
A
479,Type
410-2
ASTM
A
479,Type
410-2
(*)
A
Gr.
Stem
Hand Wheel
Valve
ends
ASTM A479
Type 410-2
ASTM A47 Gr.
32510
Flanged
Raised
Face
ASTM
479,Type
410-2
ASTM
479,Type
410-2
A
ASTM A47
Gr 32510
Flanged
Flat Face
A
ASTM A47
Gr. 32510
Socket
Welded
Testing of valve body, seat and back seat will be as per ANSI B16.34.
4.2.8
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.
4.2.9
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.
4.2.10
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 as regards to Air compressor at
the design ambient conditions : Temp. 450 C, 60% RH, cooling water temp.
340 C.
Air Compressor :
* Rated Capacity at lowest
frequency
:
36 Nm3/ min (each)
* Rated discharge pressure
at the outlet of after cooler
:
8 kgf/cm2 (g)
* Discharge temperature after
after cooler at rated capacity
and pressure
:
450 C
* Oil content in the air at the
outlet of air compressor,
:
Oil free
* Specific Power consumption
:
of the compressor at the rated
condition mentioned above (kwh/Nm3)
To be indicated by the
Contractor
* Noise Level
:
80 dB(A)
* Volumetric efficiency of each
compressor
:
To be indicated by the
Contractor
* Inter cooler/ After cooler
pressure drop
:
0.2 kgf/cm2 (max)
Tolerance on guarantee values of energy consumption, volumetric
efficiency, intercooler & after cooler pressure drop is ± 0.00%
4.2.11
LIST OF PREFERRED MAKES
-
Compressor
M/s Atlas Copco, M/s ELGI, M/s Ingersoll Rand, M/s Kirloskar
Pneumatics.
Water System Facilities for Air Compressor Unit
4.2.12
a)
Cooling Water System
1.
For cooling of plant and equipment of the air-compressor unit there
shall be a separate cooling water re-circulation system for each unit
/ sub-system 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.
2.
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 Employer‟s
approval.
3.
The cooling water circuits shall be provided with chemical
conditioning system to control corrosion and scaling and prevent biofouling. To reduce blow-down higher cycle of concentration shall be
targeted.
4.
Pump houses shall be provided
conditioning and ventilation system.
5.
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 Employer.
6.
The cooling water systems will generally comprise the
following main units:
a)
Open Indirect Industrial Water Cycle:

Cooling tower,

Pumpsets,

Strainers,
with
air-washer
based
air-
b)
c)

Interconnecting piping,

Chemical conditioning System,

Electrics, instrumentation & control system.
Make- up Water System
1.
Make-up water for various usage including cold sump of cooling
water circuit for air-compressor, air-conditioning and ventilation
systems etc. and for supply of industrial service water will be tapped
from the existing industrial water network and will be conveyed to
the various consumers through a pipe network, preferably overground.
2.
Quality of industrial make-up water is furnished in the GTS. This
water will be supplied as make-up water to proposed plant unit for
process & cooling needs at only one point for the entire needs of the
proposed plant unit at battery limit as specified. The Contractor shall
provide necessary treatment facility, wherever required, to make the
water suitable for cooling and other purposes.
3.
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.
4.
The Contractor shall indicate make-up water requirement duly
corroborated by back-up calculation.
5.
Make up water system will include extension of pipelines from the
battery limit with isolation gate valves in valve pit, along with pumps
(if required), valves, valve pits, sumps etc., to the cooling water
recirculation system, ACVS, service water requirement as well as
process needs.
6.
Online booster shall not be accepted. A makeup water sump with
pumps and piping (pump house and sump are to be provided by the
Contractor), if required, shall be provided.
Water Conditioning System
1.
To prevent 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 in the proposed plant there shall
be a water conditioning facility as per system requirement and inline
with the details given in GTS.
2.
It shall consist of dosing tanks, pumps, valves, pipes, fitting, pipe
supports and associated civil, structural, electrical, instrumentation,
material handling, air-conditioning & ventilation etc. The scope of
work for all these remains the same as specified for cooling water
system.
3.
These pumps may also be housed in the same pump-house for
cooling water system or separately.
4.2.13
4.
The Contractor shall furnish the details of chemical dosing proposed
for the system.
5.
The Contractor shall include in the scope of supply three months
chemicals requirement for the chemical conditioning system.
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%
of water circulation.
Cooling Tower Accessories:
(i)
Level switch at cooling tower basin (to be interlocked with pump)
(ii)
Make up connection with float valve (float made of copper) & back
up ball valve
4.2.14
(iii)
Quick fill connection with ball valve
(iv)
Overflow connection
(v)
Drain connection with ball valve
(vi)
GI wire mesh 18 gauge strainer
(vii)
Equalizing line of cooling towers with isolation valves
WATER PUMPS
Mono block pump will
be provided for capacity 15 m3/hr & less. Pump will
conform to IS: 9079-1989. Pump casing will be of C.I & impeller will be of
bronze & will
have stuffing box arrangement for gland packing. IP-55
protection motor will
be provided.
Horizontal back pull out pump will
be provided for capacity more than 15
m3/hr.
Centrifugal Pump :
Horizontal back pull out pump will
be provided.
vertically split type. Impeller rpm will
Pump casing will
be
generally not exceed 1450.
However, for pumps with low capacity & high head may be provided with
2900 rpm. Pump will
type coupling will
be coupled to motor with flexible coupling. Spacer
be provided. Pump 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 limited to 75 micron. Pump impeller will
overloading type. Impeller will
be non
be made in one piece & keyed to the shaft.
Material of construction
Casing
- C.I
Impeller
- Bronze
Bearing Bracket
- C.I
Shaft protection sleeve
Wearing ring
- Bronze
- Bronze
Shaft
- EN-8
Common base frame for pump & motor - M.S
Common base plate for pump & motor will
welded steel construction.
be in one piece & made of
Adequate space will
be provided between
pump drain connection and base plate for installation of minimum 15 mm
drain piping. Pumps will
be supplied with suitable drain pans or drain rim
type base plates with tapped drain connections.
Critical speed of the shaft will
be at least 30 percent above the operating
speed.
4.2.15
Water Piping and Fittings
Water piping up to 150 mm NB size will
be GI, ERW, heavy class and
conforming to IS-1239 Part- 1. The pipes above 150 NB will
be MS,
spirally welded , 6 mm thick and conforming to IS:3589. Pipe ends will
beveled. Pipe fittings will
be
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 of welded joints. Welding (manual metal arc welding) will
as per relevant IS code and only certified welders will
All piping systems will
be
be employed.
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
and ball valve will
valve will
be provided in water line of size 65 NB and above
be provided for pipe size below 65 NB. However, ball
be provided in the pipe line (irrespective of sizes)
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
when flow
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 fully closed position
with
intermediate positions marked on the indicator plate mounted on the top
flange. The valves will
shaft will
conform to BS : 5155 / IS : 13095. Extended valve
be provided so that the lever can be operated without any
obstruction on the insulated pipes. Gear operated valves will
be provided
for sizes more than 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
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 : ½
“
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)
Drinking water system,
(ii)
Service water system,
(iii)
Dewatering system for underground premises (Emergency Coke Yard,
Junction House CK-1 etc.),
(iv)
Interplant pipeline for Make-up water system
4.3.2
Battery Limit
a)
Industrial water / Service Water
Industrial quality make-up water (quality as indicated in GTS, Maroda-I) will
be made available to the Contractor at only one point within 100m from the
proposed plant at a pressure of approx 1.5 to 2.0 kgf/ cm2 (g). The top of
the pipeline (carbon steel) shall be approximately 1.2 m below the area
ground level. Tapping of industrial make-up water shall be based on two
points feeding and shall conform to provisions of GTS. Contractor shall
extend the same through isolation gate valves in valve-pit alongwith flow
meter (complete with isolation valves and by-pass arrangement) to his
proposed systems for service/make-up water requirement for the entire
plant area.
Contractor shall indicate the make-up water quantity requirement, pipe
size, end connection, MOC of pipeline, etc. at the battery limit.
b)
Drinking water
Drinking water will be made available to the Contractor at only one point
within 100m from the proposed plant at a pressure of approx 1.0 kgf/ cm2
(g). The top of the pipeline (carbon steel) shall be approximately 1.2 m
below the area ground level. Tapping of drinking water shall be based on
two points feeding and shall conform to provisions of GTS. Contractor shall
extend the same from the battery limit through isolation gate valves in
valve-pit to his proposed systems/ shops, offices, toilets, drinking water
platforms, water coolers, etc. for the entire plant area.
The Contractor shall indicate the drinking water quantity requirement, pipe
size, end connection, MOC of pipeline, etc. at the battery limit.
c)
Construction Water
Construction water arrangement shall be in the scope of contractor. The
location of borewells, if planned by the Contractor for construction water
requirement would require clearance / approval from BSP/MECON.
4.3.3 Specification and Description of Work
a) Drinking Water System
1.
The drinking water shall be made available at one point near
proposed plant within battery limit as specified. The Contractor shall
extend the pipeline from battery limit with isolation gate valves in
valve-pit upto various drinking water consumers.
2.
The Contractor shall indicate drinking water requirement duly
corroborated by back-up calculation.
3.
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. Online
booster shall not be accepted.
4.
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.
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 and quick fix connection
shall be provided.
For service water line each tapping point discharge rate will be 2m³/hr.
and maximum 6 Nos. points can be operated at a time.
Service 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 Employer‟s approval.
c) Dewatering system for underground premises
Dewatering system for underground sumps shall be provided for
underground portion of the proposed plant. 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 Employer‟s
approval.
d) Interplant Pipelines
Interplant pipeline for Make-up water shall be tapped from Purchaser‟s
network through flow meter with requisite isolation valves on either side
and by-pass arrangement and shall be brought to common Make-up
water tank near Pump House. Supply of make-up water required for Air
Washer Units shall be in the scope of other bidders
All the water lines including make-up water, fire water and drinking
water lines, process and cooling water lines will generally be laid overground preferably on structural trestles.
e) Water Pollution Control and Conservation
Extensive recycling shall 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 being made into the Employer‟s existing network shall
conform to the local pollution control norms fulfilling the statutory
requirements.
4.3.4
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. Following design criteria in addition to GTS
provisions shall be followed:
1.
Water System will be designed as per the provisions of GTS in
respect of various design aspects including type of pumps, no. of
standby pumps, piping, pipe specification, type of valves, cooling
tower, side-stream filtration, handling & hoisting facilities, airconditioning and ventilation facilities etc.
2.
Each circulation system shall be connected with two nos. of delivery
headers from the pumphouse and two nos hot return water headers
from the consumers to the cooling tower/ pumphouse / treatment
unit. The water carrying capacity of each header shall be such that
incase one of the headers is under maintenance the other header
should be in a position to carry the required quantity of water to the
consumers, i.e., 100% of designed flow so that normal production of
unit is not affected with only one delivery / return header in
operation. There shall be proper isolating facilities in these headers
so that supply of water in any circuit or to any area of the Complex
is not affected due to leakage in one of header line.
3.
All sumps shall be compartmentalised as per GTS and each pump
shall have independent suction.
4.
Each pump shall have independent suction. Each pump shall be
provided with a gate valve on the suction side and a non-return
valve and gate valve on delivery side. The delivery line of each pump
shall be connected to the main header with isolating header gate
valves for isolating pumps‟ delivery valves. Motorised gate valves
shall be provided in automated pumping system for pumps‟ suction &
delivery.
5.
Suitable number of header valves shall be provided such that
delivery valve of a pump can be isolated for maintenance without
affecting other stand-by pump‟s availability.
6.
All the valves of diameter 450 mm and above and the valves
requiring remote control operation shall be electrically /
pneumatically operated. Electrically operated valves shall be
provided with limit switches as a safety measure. Electrically
operated valves shall have provision for manual operation also. All
manual valves of sizes DN 350 and above shall be gear operated.
Frequently operated delivery valves and header valves below
diameter 450 mm shall also be electrically operated.
7.
Total no. of pumps in a pumping circuit shall be as per GTS. Pump
type shall be as per the provisions of the GTS. Pump rpm shall be
governed by the kW rating in line with the provisions of the GTS.
8.
Drainage pumps (split casing, self priming and horizontal centrifugal
pumps) will be one reserve pump for one working pump. The pumps
shall not be of mono-block design.
9.
All gate valves shall be cast steel with SS internals, NRVs shall have
SS internals, rest of the design features shall be as per GTS.
10.
Following MOC to be considered for valves:
a)
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.
b)
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.
11.
Pipe materials shall be as per CRLA,RSP,SAIL.
12.
Sluice gates will have SS internals.
13.
Butterfly valves usage shall be accepted for non-critical applications
for flow modulation purpose at the express approval of the
Employer.
14.
Contractor will consider provision of strainers in each header as
follows:

15.
open industrial water circuit :
strainers, 1W+1S,
for 100% flow, simplex
Material handling facility for the units of the Water System shall be
as per GTS.
4.3.5
16.
Pump houses shall be provided
conditioning and ventilation system.
with
air-washer
based
air-
17.
Design criteria of the cooling tower shall be as per GTS.
18.
Special maintenance tools and spares as mentioned in cl. no. 01.05
in „Design Criteria for Cooling Towers‟, list of spares & tools & tackles
as listed in cl. no. 8.18, list of tools and tackles as listed in cl. no.
8.18.02 of GTS for Water System shall be supplied by the
Contractor.
19.
Tapping of industrial make up water, drinking water & fire-fighting
water shall be based on two points feeding as explained elsewhere in
this chapter and shall conform to provisions of GTS.
20.
Pipe thicknesses shall be as per GTS provisions.
21.
As for as possible pipelines shall be laid above ground or in concrete
trenches / tunnels. Wherever, it is not possible then only pipelines
shall be laid underground.
Description of Cooling Water System
Open Industrial Water Cycle
Open industrial water circuits with filtered industrial water as the cooling
medium shall be provided for indirect cooling of compressor unit.
Hot industrial cooling water after cooling compressor unit will reach the
cooling towers under residual pressure for cooling. Cold water from the
cooling tower basin will flow into the cold well of the pump house. From the
cold well separate group of pumps shall pump water to the various
consumers.
Make-up water shall be added in the cold well to make-up the losses in the
system.
4.3.6
Erection, Testing and Commissioning
i.
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 Employer/Consultant.
ii.
The welding work should be carried out as per the approved WPS and PQR.
iii.
The 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.
iv.
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 Employer/ Consultant.
4.3.7
v.
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.
vi.
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 proposed plant area or as directed by the Employer
and thereby leaving the premises in good, clean, safe and operable
condition.
vii.
Before giving call for final inspection, all the documents shall be furnished to
the Employer. 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 employer
during erection and commissioning or guarantee period.
viii.
All materials required for fabrication, construction, testing and inspection
shall be supplied by the Contractor. No material shall be free issue to the
Contractor.
ix.
No equipment or part item shall be dispatched without final inspection and
issuance of inspection certificate.
x.
All equipment, assemblies, sub-assemblies shall be shop tested as per
relevant standards and the test certificates shall be submitted by the
supplier.
xi.
Erection, testing & commissioning of various equipments and piping etc
shall be done also inline with details given in various chapters of GTS.
Painting
The Contractor shall follow the painting procedure as mentioned in GTS.
4.3.8
Drawings & documents
Drawings/documents to be furnished by the Contractor for approval
1.
Process flow diagram indicating the water consumption figures
complete with temperature, pressure and quality requirements.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Process & instrumentation diagrams for the water systems indicating
location of all instruments, alarms and interlocks functions using ISA
symbols.
General arrangement and cross-sectional drawings, characteristics
curves and technical details of all the equipments (pumps, diesel
engine, , cooling tower, , sluice gates, , fire hydrants, etc.) , valves
and piping including GA drawings showing plan, elevation and
sectional views of the water system.
List of instruments comprising bill of materials and instrumentation
data sheets.
Layout of piping system indicating pipe routing, location of supports,
valves and other fittings as required.
General arrangement drawings of pump houses and sump / tank
(including civil, structural and other facilities) showing dispositions of
various equipment and piping.
Data sheets, characteristic curves and technical details of all the
equipments, valves and piping.
List of safety interlocks.
Test procedures for preliminary and final acceptance tests.
Quality Assurance Plan.
All equipment and piping sizing calculations.
GA drawings and details of air conditioning & ventilation facilities.
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
Any other drawing/ documents as required by the Employer.
Drawings / documents to be furnished by the Contractor for
reference and record
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
The
Contractor shall submit required sets of all the approved
drawings, documents and manuals for Employer‟s record and use.
After erection of 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”.
Operating and maintenance manual.
Spare parts recommendation and price list.
Instruction for erection, testing and commissioning.
Manufacturer‟s test certificates.
Lubrication schedule and quantity and quality of lubricant for one
year‟s normal operation.
Various equipment assembly drawings and bill of material.
Welding procedure.
Hydraulic test logs.
Equipment GA drawings and bill of materials.
Characteristics curves of the pumps, motors and other equipments.
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 manufacturer‟s drawings for all
brought out equipment, valves and other items.
All inspection/ test report/ certificates.
Any
other
drawing/
documents
as
required
by
the
Employer/Consultant.
4.3.9
Preferred Makes
The Contractor shall follow the list of proffered makes as per the following:
Sl
No.
1.
Item Description
Manufactures
Horizontal centrifugal
Pumps
Kirloskar Brothers, KSB, Beacon Weir, Voltas,
Mather & Platt, Jyoti, WPIL (Worthington).
2.
Submersible pumps
KSB, SU Motors, Kirloskar Brothers.
3.
Dosing Pump
Shapo Tools, Asia LMI (Madras), Toshniwal,
Milton Roy India.
4.
Cooling Towers
Paharpur, Shriram Tower
Southern Cooling Tower.
5.
6.
7.
Sluice Gates
Basket Strainers
Rubber expansion joints
Jash, IVPL.
Filteration Engineers, Superflo.
BDK, CORI Engineers.
8.
9.
Hoses
Pipe a) MS/GI
10.
11.
b) DI
MS/GI Pipe Fittings
Chemical Dosing System
12.
Fire hydrants
Senior Flexonics, Hydrocrimp
SAIL, TATA, Jindal, MAN, SAW,
Welspun,
Prakash, PSL, MSL.
Electro Steel Casting
Tube bends, Stewards & Lloyds, BST, Jindal.
GE India Industrial Private Limited, Ion
Exchange, Chembond Drewtreat.
New Age Industries, Steelage Industires,
ASCO, Strumech, Vijay Fire, Zenith
Tech,
Valves
1.
C.S. Gate /Globe Valve
A. (Non-IBR- for all Sizes and Ratings) :







M/s.
M/s.
M/s.
M/s.
M/s.
M/s.
M/s.
B.D.K. Engg. Industries Ltd.,
BHEL,
Fouress Engg. (India) Ltd,
K.S.B. Pumps Ltd,
Larsen & Toubro Ltd., (Audco).
Leader Valves Ltd.,
Oswal Industries Ltd.,
2. Butterfly Valve:
 M/s. Advance Valves Pvt. Ltd,
 M/s. Avcon Control Pvt. Ltd.,
(For Actuator operated Valves)
 M/s. B.D.K. Engg. Industries Ltd.,
 M/s. Crane Process Flow Tech. (India) Ltd.,
 M/s. Fisher Xomox Sanmar,
 M/s. Fouress Engg. (India) Ltd,
 M/s. Inter Valves (Pvt.) Ltd.,
 M/s. Larsen & Toubro Ltd., (Audco).
Hubli.
Tiruchirapalli.
Aurangabad.
Kolkata.
Chennai.
Jalandhar.
Ahmedabad.
Noida.
Mumbai
Hubli.
Pune.
Trichinapalli.
Aurangabad.
Pune.
Chennai.
Gammon,
 M/s. Tyco Valves,
 M/s. Virgo Engineers Ltd.,
Baroda.
Pune.
3. Ball Valve:










M/s.
M/s.
M/s.
M/s.
M/s.
M/s.
M/s.
M/s.
M/s.
M/s.
B.D.K. Engg. Industries Ltd.,
Delval Flow Control Pvt. Ltd.,
Fisher Xomox Sanmar.,
Flowchem Ind.,
Fouress Engg. (India) Ltd,
Habonim Vaas Automation Pvt. Ltd.,
Inter Valves,
Larsen & Toubro Ltd., (Audco).
Oswal Industries Ltd.,
Virgo Engineers Ltd.,
Hubli.
Pune.
Trichinapalli.
Ahmedabad.
Aurangabad.
Chennai.
Pune.
Chennai.
Ahmedabad.
Pune.
4. CI/Sluice Gate Valves
A.









M/s.
M/s.
M/s.
M/s.
M/s.
M/s.
M/s.
M/s.
M/s.
For all Sizes and Ratings:
B.D.K. Engg. Industries Ltd.,
Calsens Private Ltd.,
G.M.Dalui & Sons,
H. Sarker & Co.,
Hawa Engineers Ltd.,
Kirloskar Brothers,
Leader Valves Ltd.,
Venus Pump & Engg. Works.,
Neta Valves Pvt. Ltd.,
Hubli.
Kolkata.
Howrah.
Kolkata.
Ahmedabad.
Nagpur.
Jalandhar.
Howrah.
Jalandhar
B. For Sizes upto NB 100 mm & PN 10 Rating:
 M/s. Ronex Engg. Company,
Kolkata
 M/s. Upadhyaya Valve Manuf. Pvt. Ltd.,
Kolkata
 M/s. Steam & Mining Industries,
Kolkata.
(Vendors appearing under „A‟ shall be eligible for „B‟ also)
5.
Plug Valve:




M/s.
M/s.
M/s.
M/s.
B.D.K. Engg. Industries Ltd. ,
Fisher Xomox Sanmar Ltd. ,
Habonim Vaas Automation Pvt. Ltd.,
Larsen & Toubro Ltd., (Audco).
Hubli.
Chennai .
Chennai.
Chennai.
6. Cock Valve for Gas applications:
 M/s. Larsen & Toubro Ltd., (Audco).
Chennai.
7. Check Valve/Non Return Valve:








M/s.
M/s.
M/s.
M/s.
M/s.
M/s.
M/s.
M/s.
Advance Valves Pvt. Ltd,
B.D.K. Engg. Industries Ltd.,
Fouress Engg. (India) Ltd.,
Inter Valves (Pvt.) Ltd.,
K.S.B. Pumps Ltd,
Larsen & Toubro Ltd., (Audco)
Leader Valves Pvt. Ltd.,
Oswal Industries Ltd.,
Noida.
Hubli.
Aurangabad.
Pune.
Kolkata.
Chennai.
Jalandhar.
Ahmedabad.
8. Fabricated Gate Valve.
 M/s. Fouress Engg. (India) Ltd,
 M/s. Larsen & Toubro Ltd., (Audco)
 M/s. Zimmermann & Janseen, Duren,
9.
Aurangabad.
Chennai.
Germany.
Piston Valve:
 M/s. Spirax Marshall Ltd.,
 M/s. Uni -Klinger Ltd.,
Nagpur.
Pune.
10. Knife Edge Gate Valve:




M/s.
M/s.
M/s.
M/s.
Energo Engg.,
Fouress Engg. (India) Ltd,
Orbinox India Pvt. Ltd.,
Vass Ind. Pvt. Ltd.,
Delhi.
Aurangabad.
Coimbatore.
Chennai.
11. Non-Ferrous Valve:




M/s.
M/s.
M/s.
M/s.
Leader Valves Ltd.,
Neta Valves Pvt. Ltd.,
Sant Valves Pvt. Ltd,
Zoloto Ind.,
Jalandhar.
Jalandhar.
Jalandhar.
Jalandhar.
10.00
A.
01.
Technical Particulars furnished by the Contractor
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)
02.
:
:
:
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
:
Inter cooler & after cooler
Inter cooler
No. per compressor
03.
Design standard/code
Make
Max. working pressure, kgf/cm2g
:
:
i)
Water side
:
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
:
Moisture separator
Make
:
Type
:
Model
:
Number
:
Design standard/code for
pressure vessel
:
Shell material and thickness
:
Aftercooler
B.
C.
Design pressure,kgf/cm2 (g)
:
Moisture content after separator
:
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
:
Air Receiver
Number
:
Design Standard/ Code
:
Capacity
:
Overall dimensions
:
Wall plate thickness
:
Plate material
:
Design Pressure
:
Working Pressure
:
STEEL AUTHORITY OF INDIA LIMITED
BHILAI STEEL PLANT (BSP)
CONTRACT AGREEMENT FOR
“Augmentation OF Fuel & FLUX CRUSHING FACILITIES”
(PKG NO. 064)
04.08
WATER SYSTEM
04.08.00
Scope of work
The scope of work shall include design, engineering, fabrication,
manufacturing, assembly & supply, erection/construction/laying,
commissioning, testing & performance guarantee tests etc of plant &
equipment and piping etc of complete water supply facilities including
pump house buildings, civil & structural work & technological structures,
electrics,
instrumentation, automation, telecommunication, airconditioning & ventilation, material handling & hoisting equipment etc as
specified and required for complete water systems technological
structures, pipe-support structures, etc as specified and required for the
complete water system for proposed plant as specified in this chapter as
well as various chapters of this contract specification in line with General
Technical Specification (GTS) and subject to Employer‟s approval,
complete in all respect on turnkey basis.
The scope of work shall include the following activities.
i)
Design, engineering, manufacture /fabrication, assembly, shop testing,
painting, packing sequential delivery FOR site, unloading, unpacking,
storage at site, preparation & submission of all drawings for civil,
mechanical, structural, piping, construction & erection drawings,
construction & erection as per approved drawings, site-testing, painting,
commissioning and fulfillment of guarantee performance of all plant &
equipment of water supply facilities for the proposed plant including
drinking water system, industrial service/make-up water system and
water based fire-fighting system, in accordance with the water system
requirements of the proposed plant.
ii)
Supply of pipeline supports, thrust blocks/ anchor blocks, R.C.C.
pedestals etc. for over head / on-ground /underground pipelines.
iii)
Supply of all technical literature, drawings & documents, general
arrangement drawings, assembly & sub-assembly drawings of all the
plant & equipment, construction & erection drawings, as-built drawings,
operation & maintenance manuals, manufacturing drawings, etc.
iv)
Submission of all drawings at (iii) above, design calculations, data
sheets for various equipments, pipeline sizing calculation and for
approval of Employer/ Consultant and finalizing the same as per
approval of Employer/ Consultant. The approval of the same however
does not absolve the contractor from his responsibilities.
CHAP-04.08 WATER SYSTEM.doc
Page 1 of 19
STEEL AUTHORITY OF INDIA LIMITED
BHILAI STEEL PLANT (BSP)
CONTRACT AGREEMENT FOR
“Augmentation OF Fuel & FLUX CRUSHING FACILITIES”
(PKG NO. 064)
v)
Supply of commissioning spares & consumables; a list there of shall be
submitted by the Contractor.
vi)
Contractor shall submit an itemized price-list of two years operation and
maintenance spares.
vii)
Supply of special tools, tackles for construction, erection operation and
repair & maintenance of the plant & equipment.
viii)
Supply of special tools and tackles, spares as mentioned in GTS shall
be in the scope of Contractor.
ix)
All necessary connections for hook-up with Employer‟s system at battery
limits.
x)
Supply of erection, testing & commissioning equipment and material.
xi)
Piping network flushing fluids, chemicals & consumables.
xii)
First fill of oils, lubricants, filter media, resins, chemicals reagents and
other consumables.
xiii)
Inspection and performance testing of individual equipment and system
as a whole.
xiv)
Participation in design conference with the Employer & Consultant as
and when called for.
xv)
Contractor shall provide two nos drainage pumps for each underground
premises, one working, one standby, of suitable capacity and head to
drain out the seepage water and rain water from the underground
premises. The pumps shall be capable of handling slurry water. The
exact numbers, capacity and type of pump shall be finalised during
engineering stage.
The Contractor‟s scope also covers extension of fire-fighting line,
drinking water line and industrial water line from the battery limits to
various consumer points of the proposed plant in line with the present
Contract technical specification and GTS.
Water supply system/ sub-systems shall be complete in all respects and
any equipment or material not specifically mentioned in this
specification, but required for safe, efficient & smooth operation and
guaranteed performance of the plant shall be deemed to be included
under the scope of work of the Contractor. Diversion of existing
overhead / underground water pipelines (including those identified
CHAP-04.08 WATER SYSTEM.doc
Page 2 of 19
STEEL AUTHORITY OF INDIA LIMITED
BHILAI STEEL PLANT (BSP)
CONTRACT AGREEMENT FOR
“Augmentation OF Fuel & FLUX CRUSHING FACILITIES”
(PKG NO. 064)
during package execution) required for installation of the proposed units
covered under this package is included in the scope of work of the
Contractor. However, the price & other terms and conditions shall be
mutually discussed and agreed during the execution of job by the
Contractor.
04.08.01
a)
Battery Limit
Industrial water
Industrial quality make-up water (quality as indicated in GTS, Maroda-I)
will be made available to the Contractor at only one point within 100m
from the proposed plant at a pressure of approx 1.5 to 2.0 kgf/ cm2 (g).
The top of the pipeline (carbon steel) shall be approximately 1.2 m below
the area ground level. Tapping of industrial make-up water shall be
based on two points feeding and shall conform to provisions of GTS.
Contractor shall extend the same through isolation gate valves in valvepit alongwith flow meter (complete with isolation valves and by-pass
arrangement) to his proposed systems for service/make-up water
requirement for the entire plant area.
Contractor shall indicate the make-up water quantity requirement, pipe
size, end connection, MOC of pipeline, etc. at the battery limit.
b)
Drinking water
Drinking water will be made available to the Contractor at only one point
within 100m from the proposed plant at a pressure of approx 1.0 kgf/
cm2 (g). The top of the pipeline (carbon steel) shall be approximately 1.2
m below the area ground level. Tapping of drinking water shall be based
on two points feeding and shall conform to provisions of GTS. Contractor
shall extend the same from the battery limit through isolation gate valves
in valve-pit to his proposed systems/ shops, offices, toilets, drinking
water platforms, water coolers, etc. for the entire plant area.
The Contractor shall indicate the drinking water quantity requirement,
pipe size, end connection, MOC of pipeline, etc. at the battery limit.
c)
Fire-fighting water
Industrial quality water (quality as indicated in GTS) will be made
available to the Contractor at one point within 100m from the proposed
plant at requisite pressure. The top of the pipeline (carbon steel) shall be
approximately 1.2 m below the area ground level. Tapping of industrial
make-up water shall be based on two points feeding and shall conform
CHAP-04.08 WATER SYSTEM.doc
Page 3 of 19
STEEL AUTHORITY OF INDIA LIMITED
BHILAI STEEL PLANT (BSP)
CONTRACT AGREEMENT FOR
“Augmentation OF Fuel & FLUX CRUSHING FACILITIES”
(PKG NO. 064)
to provisions of GTS. Contractor shall extend the same from battery limit
through isolation gate valves in valve-pit to the entire plant area.
d)
Construction Water
Construction water arrangement shall be in the scope of contractor. The
location of borewells, if planned by the Contractor for construction water
requirement would require clearance / approval from BSP/MECON.
04.08.02
Specification and Description of Work
Water System Facilities:
Water system shall in general include the following facilities:a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
a)
Cooling water system,
Make-up water system,
Water conditioning system,
Water supply system for air conditioning & ventilation system,
Drinking water system,
Water based fire-fighting system,
Service Water System,
Dewatering system for underground premises
Interplant pipelines,
Water pollution control & conservation.
Cooling Water System
1.
For cooling of plant and equipment of the air-compressor unit
there shall be a separate cooling water re-circulation system for
each unit / sub-system 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.
2.
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 Employer‟s
approval.
3.
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.
CHAP-04.08 WATER SYSTEM.doc
Page 4 of 19
STEEL AUTHORITY OF INDIA LIMITED
BHILAI STEEL PLANT (BSP)
CONTRACT AGREEMENT FOR
“Augmentation OF Fuel & FLUX CRUSHING FACILITIES”
(PKG NO. 064)
b)
4.
Pump houses shall be provided with air-washer based airconditioning and ventilation system.
5.
With a view to conserve and save upon fresh water requirement,
the Contractor will plan to utilize/ reuse/ recycle the reject/blowdown from the cooling water systems in the plant with necessary
treatment etc. as specified by the Employer.
Make- up Water System
1.
Make-up water for various usage including cold sump of cooling
water circuit for air-compressor, air-conditioning and ventilation
systems etc. and for supply of industrial service water will be
tapped from the existing industrial water network and will be
conveyed to the various consumers through a pipe network,
preferably over-ground.
2.
Quality of industrial make-up water is furnished in the GTS. This
water will be supplied as make-up water to proposed plant unit for
process & cooling needs at only one point for the entire needs of
the proposed plant unit at battery limit as specified. The
Contractor shall provide necessary treatment facility, wherever
required, to make the water suitable for cooling and other
purposes.
3.
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.
4.
The Contractor shall indicate make-up water requirement duly
corroborated by back-up calculation.
5.
Make up water system will include extension of pipelines from
the battery limit with isolation gate valves in valve pit, along with
pumps (if required), valves, valve pits, sumps etc., to the cooling
water recirculation system, ACVS, service water requirement as
well as process needs.
6.
Online booster shall not be accepted. A makeup water sump with
pumps and piping (pump house and sump are to be provided by
the Contractor), if required, shall be provided.
CHAP-04.08 WATER SYSTEM.doc
Page 5 of 19
STEEL AUTHORITY OF INDIA LIMITED
BHILAI STEEL PLANT (BSP)
CONTRACT AGREEMENT FOR
“Augmentation OF Fuel & FLUX CRUSHING FACILITIES”
(PKG NO. 064)
c)
d)
Water Conditioning System
1.
To prevent 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 in the proposed plant there shall
be a water conditioning facility as per system requirement and
inline with the details given in GTS.
2.
It shall consist of dosing tanks, pumps, valves, pipes, fitting, pipe
supports
and
associated
civil,
structural,
electrical,
instrumentation, material handling, air-conditioning & ventilation
etc. The scope of work for all these remains the same as
specified for cooling water system.
3.
These pumps may also be housed in the same pump-house for
cooling water system or separately.
4.
The Contractor shall furnish the details of chemical dosing
proposed for the system.
5.
The Contractor shall include in the scope of supply three months
chemicals requirement for the chemical conditioning system.
Water Supply System for air-conditioning & ventilation
1.
The entire piping network for water supply for air-conditioning and
ventilation and other Systems/ Sub-systems is in the scope of the
Contractor.
2.
It shall consist of pumps, valves, pipes, fitting, pipe supports and
associated civil, structural, electrical, instrumentation, material
handling, air-conditioning & ventilation etc.
3.
The details and specification of pumps, valves, pipes, fitting, pipe
supports
and
associated
civil,
structural,
electrical,
instrumentation, material handling, air-conditioning & ventilation
etc. as specified for cooling water system is applicable for this
system also.
4.
Makeup water for the system shall be provided by the Contractor
from the make-up water network provided for the main plant. No
separate connection at battery limit will be provided for this
purpose.
CHAP-04.08 WATER SYSTEM.doc
Page 6 of 19
STEEL AUTHORITY OF INDIA LIMITED
BHILAI STEEL PLANT (BSP)
CONTRACT AGREEMENT FOR
“Augmentation OF Fuel & FLUX CRUSHING FACILITIES”
(PKG NO. 064)
5.
e)
f)
Pumphouses shall be provided with air-washer based airconditioning and ventilation system.
Drinking Water System
1.
The drinking water shall be made available at one point near
proposed plant within battery limit as specified. The Contractor
shall extend the pipeline from battery limit with isolation gate
valves in valve-pit upto various drinking water consumers.
2.
The Contractor shall indicate drinking water requirement duly
corroborated by back-up calculation.
3.
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.
Online booster shall not be accepted.
4.
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.
Water based Fire-Fighting System
To cater to the needs of water based fire-fighting system, a fire water
piping network shall be planned with provision of yard hydrants and
internal hydrants at regular intervals. The proposed network shall be
connected with the existing network at the battery limits with isolation
gate valves in valve-pit.
The following specification of work shall be considered:i)
ii)
iii)
iv)
Category of hazard
Yard hydrants
Internal hydrants
Min. pressure at remotest hydrant -
ordinary (as par TAC)
at 45 m intervals
at 30 m intervals
3.5 kg/cm2
Two nos. of 15 m long hose shall be provided alongwith fittings for each
yard hydrant and 2 nos. of 15 m long hose shall be provided along with
fittings for each internal hydrant.
The water based fire fighting system shall be designed, supplied &
erected in line with the stipulations under various clauses of GTS-02 and
CHAP-04.08 WATER SYSTEM.doc
Page 7 of 19
STEEL AUTHORITY OF INDIA LIMITED
BHILAI STEEL PLANT (BSP)
CONTRACT AGREEMENT FOR
“Augmentation OF Fuel & FLUX CRUSHING FACILITIES”
(PKG NO. 064)
subject to Employer‟s / Consultant‟s approval. The details of the MVWS
system have been dealt with separately.
The Contractor shall indicate fire fighting water requirement duly
corroborated by back-up calculation.
g)
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 and quick fix connection shall
be provided.
For service water line each tapping point discharge rate will be 2m³/hr.
and maximum 6 Nos. points can be operated at a time.
Service 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 Employer‟s approval.
h)
Dewatering system for underground premises
Dewatering system for underground sumps shall be provided for
underground portion of the proposed plant. 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 Employer‟s
approval.
i)
Interplant Pipelines
Industrial water for make-up water supply and general plant usage will
be met through the proposed pipeline to be laid from the tapping point to
these units.
Drinking water network and fire water network will be provided to various
consumption points in the proposed industrial premises.
All the water lines including make-up water, fire water and drinking water
lines, process and cooling water lines will generally be laid over-ground
preferably on structural trestles.
CHAP-04.08 WATER SYSTEM.doc
Page 8 of 19
STEEL AUTHORITY OF INDIA LIMITED
BHILAI STEEL PLANT (BSP)
CONTRACT AGREEMENT FOR
“Augmentation OF Fuel & FLUX CRUSHING FACILITIES”
(PKG NO. 064)
j)
Water Pollution Control and Conservation
Extensive recycling shall 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 being made into the Employer‟s existing network shall
conform to the local pollution control norms fulfilling the statutory
requirements.
The cooling water systems will generally comprise the following
main units:
a)
Open Indirect Industrial Water Cycle:

Cooling tower,

Pumpsets,

Strainers,

Interconnecting piping,

Chemical conditioning System,

Electrics, instrumentation & control system.
b)
04.08.03
Miscellaneous and Common Facilities:

Make-up water system,

Interplant pipelines,

Water based Fire Fighting system,

Drinking Water System.
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. Following design criteria in addition to GTS provisions shall be
followed:
1.
Water System will be designed as per the provisions of GTS in
respect of various design aspects including type of pumps, no. of
standby pumps, piping, pipe specification, type of valves, cooling
CHAP-04.08 WATER SYSTEM.doc
Page 9 of 19
STEEL AUTHORITY OF INDIA LIMITED
BHILAI STEEL PLANT (BSP)
CONTRACT AGREEMENT FOR
“Augmentation OF Fuel & FLUX CRUSHING FACILITIES”
(PKG NO. 064)
tower, side-stream filtration, handling & hoisting facilities, airconditioning and ventilation facilities etc.
2.
Each circulation system shall be connected with two nos. of
delivery headers from the pumphouse and two nos hot return
water headers from the consumers to the cooling tower/
pumphouse / treatment unit. The water carrying capacity of each
header shall be such that incase one of the headers is under
maintenance the other header should be in a position to carry the
required quantity of water to the consumers, i.e., 100% of
designed flow so that normal production of unit is not affected
with only one delivery / return header in operation. There shall be
proper isolating facilities in these headers so that supply of water
in any circuit or to any area of the Complex is not affected due to
leakage in one of header line.
3.
All sumps shall be compartmentalised as per GTS and each
pump shall have independent suction.
4.
Each pump shall have independent suction. Each pump shall be
provided with a gate valve on the suction side and a non-return
valve and gate valve on delivery side. The delivery line of each
pump shall be connected to the main header with isolating header
gate valves for isolating pumps‟ delivery valves. Motorised gate
valves shall be provided in automated pumping system for
pumps‟ suction & delivery.
5.
Suitable number of header valves shall be provided such that
delivery valve of a pump can be isolated for maintenance without
affecting other stand-by pump‟s availability.
6.
All the valves of diameter 450 mm and above and the valves
requiring remote control operation shall be electrically /
pneumatically operated. Electrically operated valves shall be
provided with limit switches as a safety measure. Electrically
operated valves shall have provision for manual operation also.
All manual valves of sizes DN 350 and above shall be gear
operated. Frequently operated delivery valves and header valves
below diameter 450 mm shall also be electrically operated.
7.
Total no. of pumps in a pumping circuit shall be as per GTS.
Pump type shall be as per the provisions of the GTS. Pump rpm
shall be governed by the kW rating in line with the provisions of
the GTS.
CHAP-04.08 WATER SYSTEM.doc
Page 10 of 19
STEEL AUTHORITY OF INDIA LIMITED
BHILAI STEEL PLANT (BSP)
CONTRACT AGREEMENT FOR
“Augmentation OF Fuel & FLUX CRUSHING FACILITIES”
(PKG NO. 064)
8.
Drainage pumps (split casing, self priming and horizontal
centrifugal pumps) will be one reserve pump for one working
pump. The pumps shall not be of mono-block design.
9.
All gate valves shall be cast steel with SS internals, NRVs shall
have SS internals, rest of the design features shall be as per
GTS.
10.
Following MOC to be considered for valves:
a) 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.
b) 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.
11.
Pipe materials shall be as per CRLA,RSP,SAIL.
12.
Sluice gates will have SS internals.
13.
Butterfly valves usage shall be accepted for non-critical
applications for flow modulation purpose at the express approval
of the Employer.
14.
Contractor will consider provision of strainers in each header as
follows:

15.
open industrial water circuit :
strainers, 1W+1S,
for 100% flow, simplex
Material handling facility for the units of the Water System shall
be as per GTS.
CHAP-04.08 WATER SYSTEM.doc
Page 11 of 19
STEEL AUTHORITY OF INDIA LIMITED
BHILAI STEEL PLANT (BSP)
CONTRACT AGREEMENT FOR
“Augmentation OF Fuel & FLUX CRUSHING FACILITIES”
(PKG NO. 064)
04.08.04
16.
Pump houses shall be provided with air-washer based airconditioning and ventilation system.
17.
Design criteria of the cooling tower shall be as per GTS.
18.
Special maintenance tools and spares as mentioned in cl. no.
01.05 in „Design Criteria for Cooling Towers‟, list of spares & tools
& tackles as listed in cl. no. 8.18, list of tools and tackles as listed
in cl. no. 8.18.02 of GTS for Water System shall be supplied by
the Contractor.
19.
Tapping of industrial make up water, drinking water & fire-fighting
water shall be based on two points feeding as explained
elsewhere in this chapter and shall conform to provisions of GTS.
20.
Pipe thicknesses shall be as per GTS provisions.
21.
As for as possible pipelines shall be laid above ground or in
concrete trenches / tunnels. Wherever, it is not possible then only
pipelines shall be laid underground.
Description of Cooling Water System
Open Industrial Water Cycle
Open industrial water circuits with filtered industrial water as the cooling
medium shall be provided for indirect cooling of compressor unit.
Hot industrial cooling water after cooling compressor unit will reach the
cooling towers under residual pressure for cooling. Cold water from the
cooling tower basin will flow into the cold well of the pump house. From
the cold well separate group of pumps shall pump water to the various
consumers.
Make-up water shall be added in the cold well to make-up the losses in
the system.
04.08.05
i.
Erection, Testing and Commissioning
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
Employer/Consultant.
CHAP-04.08 WATER SYSTEM.doc
Page 12 of 19
STEEL AUTHORITY OF INDIA LIMITED
BHILAI STEEL PLANT (BSP)
CONTRACT AGREEMENT FOR
“Augmentation OF Fuel & FLUX CRUSHING FACILITIES”
(PKG NO. 064)
ii.
The welding work should be carried out as per the approved WPS and
PQR.
iii.
The 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.
iv.
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 Employer/
Consultant.
v.
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.
vi.
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 proposed plant area or as directed by
the Employer and thereby leaving the premises in good, clean, safe and
operable condition.
vii.
Before giving call for final inspection, all the documents shall be
furnished to the Employer. 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 employer during erection and commissioning or
guarantee period.
viii.
All materials required for fabrication, construction, testing and inspection
shall be supplied by the Contractor. No material shall be free issue to the
Contractor.
CHAP-04.08 WATER SYSTEM.doc
Page 13 of 19
STEEL AUTHORITY OF INDIA LIMITED
BHILAI STEEL PLANT (BSP)
CONTRACT AGREEMENT FOR
“Augmentation OF Fuel & FLUX CRUSHING FACILITIES”
(PKG NO. 064)
ix.
No equipment or part item shall be dispatched without final inspection
and issuance of inspection certificate.
x.
All equipment, assemblies, sub-assemblies shall be shop tested as per
relevant standards and the test certificates shall be submitted by the
supplier.
xi.
Erection, testing & commissioning of various equipments and piping etc
shall be done also inline with details given in various chapters of GTS.
04.08.06
Painting
The Contractor shall follow the painting procedure as mentioned in GTS.
04.08.07
Drawings & documents
04.08.08
Drawings/documents to be furnished by the Contractor for
approval
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Process flow diagram indicating the water consumption figures
complete with temperature, pressure and quality requirements.
Process & instrumentation diagrams for the water systems
indicating location of all instruments, alarms and interlocks
functions using ISA symbols.
General
arrangement
and
cross-sectional
drawings,
characteristics curves and technical details of all the equipments
(pumps, diesel engine, , cooling tower, , sluice gates, , fire
hydrants, etc.) , valves and piping including GA drawings showing
plan, elevation and sectional views of the water system.
List of instruments comprising bill of materials and
instrumentation data sheets.
Layout of piping system indicating pipe routing, location of
supports, valves and other fittings as required.
General arrangement drawings of pump houses and sump / tank
(including civil, structural and other facilities) showing dispositions
of various equipment and piping.
Data sheets, characteristic curves and technical details of all the
equipments, valves and piping.
List of safety interlocks.
Test procedures for preliminary and final acceptance tests.
Quality Assurance Plan.
CHAP-04.08 WATER SYSTEM.doc
Page 14 of 19
STEEL AUTHORITY OF INDIA LIMITED
BHILAI STEEL PLANT (BSP)
CONTRACT AGREEMENT FOR
“Augmentation OF Fuel & FLUX CRUSHING FACILITIES”
(PKG NO. 064)
11.
12.
13.
14.
15.
16.
17.
04.08.09
All equipment and piping sizing calculations.
GA drawings and details of air conditioning & ventilation facilities.
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
Any other drawing/ documents as required by the Employer.
Drawings / documents to be furnished by the Contractor for
reference and record
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
04.08.10
The Contractor shall submit required sets of all the approved
drawings, documents and manuals for Employer‟s record and
use. After erection of 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”.
Operating and maintenance manual.
Spare parts recommendation and price list.
Instruction for erection, testing and commissioning.
Manufacturer‟s test certificates.
Lubrication schedule and quantity and quality of lubricant for one
year‟s normal operation.
Various equipment assembly drawings and bill of material.
Welding procedure.
Hydraulic test logs.
Equipment GA drawings and bill of materials.
Characteristics curves of the pumps, motors and other
equipments.
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 manufacturer‟s drawings for
all brought out equipment, valves and other items.
All inspection/ test report/ certificates.
Any other drawing/ documents as required by the
Employer/Consultant.
Preferred Makes
CHAP-04.08 WATER SYSTEM.doc
Page 15 of 19
STEEL AUTHORITY OF INDIA LIMITED
BHILAI STEEL PLANT (BSP)
CONTRACT AGREEMENT FOR
“Augmentation OF Fuel & FLUX CRUSHING FACILITIES”
(PKG NO. 064)
The Contractor shall follow the list of proffered makes as per the
following:
Sl
No.
1.
Item Description
Manufactures
Horizontal centrifugal
Pumps
Kirloskar Brothers, KSB, Beacon Weir,
Voltas, Mather & Platt, Jyoti,
WPIL
(Worthington).
2.
Submersible pumps
KSB, SU Motors, Kirloskar Brothers.
3.
Dosing Pump
Shapo Tools, Asia LMI (Madras), Toshniwal,
Milton Roy India.
4.
Cooling Towers
Paharpur, Shriram Tower Tech, Gammon,
Southern Cooling Tower.
5.
6.
7.
Sluice Gates
Basket Strainers
Rubber expansion
joints
Hoses
Pipe a) MS/GI
Jash, IVPL.
Filteration Engineers, Superflo.
BDK, CORI Engineers.
8.
9.
b) DI
10. MS/GI Pipe Fittings
11. Chemical Dosing
System
12. Fire hydrants
CHAP-04.08 WATER SYSTEM.doc
Senior Flexonics, Hydrocrimp
SAIL, TATA, Jindal, MAN, SAW, Welspun,
Prakash, PSL, MSL.
Electro Steel Casting
Tube bends, Stewards & Lloyds, BST,
Jindal.
GE India Industrial Private Limited, Ion
Exchange, Chembond Drewtreat.
New Age Industries, Steelage Industires,
ASCO, Strumech, Vijay Fire, Zenith
Page 16 of 19
STEEL AUTHORITY OF INDIA LIMITED
BHILAI STEEL PLANT (BSP)
CONTRACT AGREEMENT FOR
“Augmentation OF Fuel & FLUX CRUSHING FACILITIES”
(PKG NO. 064)
Valves
1. C.S. Gate /Globe Valve
A. (Non-IBR- for all Sizes and Ratings) :
 M/s. B.D.K. Engg. Industries Ltd.,
 M/s. BHEL,
 M/s. Fouress Engg. (India) Ltd,
 M/s. K.S.B. Pumps Ltd,
 M/s. Larsen & Toubro Ltd., (Audco).
 M/s. Leader Valves Ltd.,
 M/s. Oswal Industries Ltd.,
2. Butterfly Valve:
 M/s. Advance Valves Pvt. Ltd,
 M/s. Avcon Control Pvt. Ltd.,
(For Actuator operated Valves)
 M/s. B.D.K. Engg. Industries Ltd.,
 M/s. Crane Process Flow Tech. (India) Ltd.,
 M/s. Fisher Xomox Sanmar,
 M/s. Fouress Engg. (India) Ltd,
 M/s. Inter Valves (Pvt.) Ltd.,
 M/s. Larsen & Toubro Ltd., (Audco).
 M/s. Tyco Valves,
 M/s. Virgo Engineers Ltd.,
Hubli.
Tiruchirapalli.
Aurangabad.
Kolkata.
Chennai.
Jalandhar.
Ahmedabad.
Noida.
Mumbai
Hubli.
Pune.
Trichinapalli.
Aurangabad.
Pune.
Chennai.
Baroda.
Pune.
3. Ball Valve:
 M/s. B.D.K. Engg. Industries Ltd.,
 M/s. Delval Flow Control Pvt. Ltd.,
 M/s. Fisher Xomox Sanmar.,
 M/s. Flowchem Ind.,
 M/s. Fouress Engg. (India) Ltd,
 M/s. Habonim Vaas Automation Pvt. Ltd.,
 M/s. Inter Valves,
 M/s. Larsen & Toubro Ltd., (Audco).
 M/s. Oswal Industries Ltd.,
 M/s. Virgo Engineers Ltd.,
Hubli.
Pune.
Trichinapalli.
Ahmedabad.
Aurangabad.
Chennai.
Pune.
Chennai.
Ahmedabad.
Pune.
4. CI/Sluice Gate Valves
A. For all Sizes and Ratings:



M/s. B.D.K. Engg. Industries Ltd.,
M/s. Calsens Private Ltd.,
M/s. G.M.Dalui & Sons,
CHAP-04.08 WATER SYSTEM.doc
Hubli.
Kolkata.
Howrah.
Page 17 of 19
STEEL AUTHORITY OF INDIA LIMITED
BHILAI STEEL PLANT (BSP)
CONTRACT AGREEMENT FOR
“Augmentation OF Fuel & FLUX CRUSHING FACILITIES”
(PKG NO. 064)






M/s. H. Sarker & Co.,
M/s. Hawa Engineers Ltd.,
M/s. Kirloskar Brothers,
M/s. Leader Valves Ltd.,
M/s. Venus Pump & Engg. Works.,
M/s. Neta Valves Pvt. Ltd.,
Kolkata.
Ahmedabad.
Nagpur.
Jalandhar.
Howrah.
Jalandhar
B. For Sizes upto NB 100 mm & PN 10 Rating:



M/s. Ronex Engg. Company,
Kolkata
M/s. Upadhyaya Valve Manuf. Pvt. Ltd.,
Kolkata
M/s. Steam & Mining Industries,
Kolkata.
(Vendors appearing under „A‟ shall be eligible for „B‟ also)
5. Plug Valve:




M/s. B.D.K. Engg. Industries Ltd. ,
M/s. Fisher Xomox Sanmar Ltd. ,
M/s. Habonim Vaas Automation Pvt. Ltd.,
M/s. Larsen & Toubro Ltd., (Audco).
Hubli.
Chennai .
Chennai.
Chennai.
6. Cock Valve for Gas applications:

M/s. Larsen & Toubro Ltd., (Audco).
Chennai.
7. Check Valve/Non Return Valve:
 M/s. Advance Valves Pvt. Ltd,
 M/s. B.D.K. Engg. Industries Ltd.,
 M/s. Fouress Engg. (India) Ltd.,
 M/s. Inter Valves (Pvt.) Ltd.,
 M/s. K.S.B. Pumps Ltd,
 M/s. Larsen & Toubro Ltd., (Audco)
 M/s. Leader Valves Pvt. Ltd.,
 M/s. Oswal Industries Ltd.,
Noida.
Hubli.
Aurangabad.
Pune.
Kolkata.
Chennai.
Jalandhar.
Ahmedabad.
8. Fabricated Gate Valve.



M/s. Fouress Engg. (India) Ltd,
M/s. Larsen & Toubro Ltd., (Audco)
M/s. Zimmermann & Janseen, Duren,
Aurangabad.
Chennai.
Germany.
9. Piston Valve:


M/s. Spirax Marshall Ltd.,
M/s. Uni -Klinger Ltd.,
CHAP-04.08 WATER SYSTEM.doc
Nagpur.
Pune.
Page 18 of 19
STEEL AUTHORITY OF INDIA LIMITED
BHILAI STEEL PLANT (BSP)
CONTRACT AGREEMENT FOR
“Augmentation OF Fuel & FLUX CRUSHING FACILITIES”
(PKG NO. 064)
10. Knife Edge Gate Valve:




M/s. Energo Engg.,
M/s. Fouress Engg. (India) Ltd,
M/s. Orbinox India Pvt. Ltd.,
M/s. Vass Ind. Pvt. Ltd.,
Delhi.
Aurangabad.
Coimbatore.
Chennai.
11. Non-Ferrous Valve:




M/s. Leader Valves Ltd.,
M/s. Neta Valves Pvt. Ltd.,
M/s. Sant Valves Pvt. Ltd,
M/s. Zoloto Ind.,
CHAP-04.08 WATER SYSTEM.doc
Jalandhar.
Jalandhar.
Jalandhar.
Jalandhar.
Page 19 of 19
04.09
INSTRUMENTATION & CONTROL
04.09.01
GENERAL
01. This document is intended to define the basic requirements for
instrumentation system for Coal Handling Plant & Coke Sorting Plant for
COB #11 and Flux & Fuel Preparation and Plant Return Fines Handling for
SP-III coming under the 7.0 MTPA expansion of Bhilai Steel Plant (BSP)
with a view to achieve smooth, efficient, safe and reliable operation of the
process.
02. This document, read together with the Instrumentation & Automation part of
the General Technical Document (No.GS-03), General Conditions of
Contract (GCC) and other commercial terms & conditions, will form the
Contract document pertaining to Instrumentation & Control System of Coal
Handling Plant & Coke Sorting Plant for COB #11 and Flux & Fuel
Preparation and Plant Return Fines Handling which will be complied by the
Contractor while executing the package.
03. Measurement and control equipment supplied for the process will be
complete in all respect in line with this document. Any equipment /
accessories not explicitly indicated in this document, but considered
essential for proper functioning of technological equipment and process are
included in Contractor‘s scope of work and supply.
04. Monitoring, sequential operation, alarm & interlock functions for the process
& equipment of the Coal Handling Plant & Coke Sorting Plant for COB #11
and Flux & Fuel Preparation and Plant Return Fines Handling for SP-III will
be achieved through automation system. All instrumentation facilities will be
interfaced with automation system accordingly. The requirement regarding
automation system has been separately described under ‗Automation
system (level-1)‘ chapter of this Document.
05. Instrumentation system of the plant will be in general, Field Bus compatible
and will be interfaced with the automation system having Field Bus interface
modules. However, in cases, where some instruments are not available with
Field Bus compatible features, conventional instrumentation equipment
(SMART & 4-20 mA DC signal output) will be supplied. Signals from these
instruments will be interfaced through hardware input/ output modules of the
automation system.
06. All field-mounted level transmitters will be radar type. Suitable enclosures
will be provided at field for the controller/ electronic unit of the level
transmitters. Other features of the instrumentation facilities will be as
indicated in the Instrumentation part of General Technical Document
(No.GS-03). Level transmitters will measure accurately & reliably the level
of bulk solids and powders during fill cycle regardless of the dust or material
variation in density or moisture.
CHAP-04.09 INSTRUMENTATION & CONTROL.doc
Page 1 of 15
For high level interlock, suitable contact type level switches to be
considered.
07. If required, air purging of level sensor (radar type) will be provided. All
necessary tubes/pipes, valves, pipe fittings etc. for the same will be
provided by Contractor.
08. The field signals which are to be interfaced with the I/O system or Field Bus
interface modules of automation system, will be connected to the nearest
Remote I/O stations of the automation system considered for that area/ unit.
Suitable junction boxes will be considered as per the finalized requirement.
The cabling activities will be carried out as per the finalised cable schedule
and wiring & termination drawings of the Contractor.
09. All the instrumentation equipment will be brand new & supplied from the
latest product ranges of reputed manufacturers as per the List of Preferred
Makes, indicated at clause no. 04.09.06. Employer/ Consultant reserve the
right of selecting particular make and model of instrumentation equipment
with a view of standardisation of the whole plant. Contractor will comply with
such requirements. In case, certain instruments to be supplied by
Contractor as per his standard design and system requirement whose make
has not been indicated in the document, Contractor will propose make of
such items with credentials and catalogues for Employer/ Consultant‘s
consideration.
10. Contractor will execute complete instrumentation package on turnkey basis
to the satisfaction of Employer/ Consultant. Contractor will comply with all
the requirements indicated under General; Scope of Work and Supply; List
of measurement, control, alarm & interlock; Submission of drawings &
documents and other related clauses/ annexure included in this document.
11. Temperature measurement under package units & motors will be connected
directly to respective automation system‘s temperature input card.
12. All correspondences / documents will be in English language and for all the
data, drawings & documentation metric or SI units will be followed.
04.09.02 SCOPE OF WORK AND SUPPLY
Contractor‘s scope of work and supply will include design; engineering;
manufacture/ procurement; assembly; calibration; shop testing; inspection
at works & at site; painting; packing; transportation to site including loading,
unloading, storage & handling of all instrumentation equipment including
electrical accessories, cables, pipes, erection accessories, panels/ cabinets
and all associated hardware, as required for completeness of
CHAP-04.09 INSTRUMENTATION & CONTROL.doc
Page 2 of 15
instrumentation system in all respect along with site fabrication, erection,
testing, commissioning of
the complete instrumentation system for
completeness & satisfactory stable operation of Coal Handling Plant, Coke
Sorting Plant for COB #11, Flux & Fuel Preparation and BF Return Fines
Handling for SP-III. The scope of work will also include liquidation of defect
points, participation in tests for establishment of plant performance
guarantee (PG) and post commissioning activities till issue of final
acceptance certificate (FAC) by BSP.
The scope of work and supply will also include, but not limited to, the
following:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Instrumentation equipment as per the measurement list covered under
clause number 04.09.03 of this document.
Field bus devices, Field bus interface modules, Field bus cables,
terminators, couplers, connectors, power supply modules, power
conditioners, surge suppressors, repeaters, Field bus junction boxes, T
devices, pull boxes, etc., required for completeness of implementation of
Field Bus based system.
All maintenance, diagnostic tools & devices required for implementation,
maintenance & trouble-shooting of Field Bus system.
For air purging of instruments to remove/avoid dust accumulation (if
required), all required with piping, pipe, fittings valves etc.
Supply of testing equipment, tools & tackles as per clause no. 04.09.05.
All electrical accessories for instrumentation system including UPS and
other instrument power supply equipment as applicable.
All types of control, signal, LT power & special cables, as required for this
package.
Fully wired cabinets/ panels, junction boxes, pull boxes, transmitter
cabinets, etc. Suitable panels for electronics units of the level transmitters
and transmitter cabinets/ junctions boxes for the transmitters & connectors
for the field bus based instruments, etc., will be provided and properly
located at the field/ rooms.
Galvanized trays, conduits, protection pipes, fittings, steel structures &
frames, erection hardware & accessories, as required for this package.
Submission of drawings and documents as defined in this document.
Erection, testing, calibration and commissioning of the total equipment
included in this document. Contractor will arrange tools, tackles and
consumables as may be required for erection, testing, calibration and
commissioning activities.
One no. hand held universal type calibrator (Lap top based) having
sufficient memory capacity and with battery & battery charger as required
for calibration of all level transmitters. All the necessary software will be
loaded in the calibrator.
Preparation of earthing pit, supply of earthing materials including cables and
installation of separate earthing system for case earthing, power and
instrument signal earthing.
CHAP-04.09 INSTRUMENTATION & CONTROL.doc
Page 3 of 15
14. Arrangement of and participation in inspection of Instrumentation equipment
by Employer/ Consultant. Inspection and Testing will be carried out in
compliance with the Quality Assurance Plans, to be approved during
detailed engineering stage.
15. Scope includes arranging visits by respective instrumentation equipment
manufacturer‘s representatives at site, as & when required, during erection
& commissioning.
16. Providing training to Client‘s personnel on special instrumentation
equipment, at manufacturer‘s works and also at site.
17. Two years maintenance spares, if the order is separately placed by
Employer.
18. Commissioning spares and three months consumables.
19. Supply of all instrumentation items from ―list of preferred makes‖ as
indicated at clause no. 04.09.06. From the list, for any particular type of
instrument, only those vendors will be selected which are field bus
compatible. However, for a particular type of instrument, if no vendor can
provide field bus compatible instrument, then conventional type can be
supplied.
20. Compliance with Instrumentation part of ‗General Technical Document‘ .
04.09.03. LIST OF MEASUREMENTS
An indicative list of measurements, alarms & interlocks for Coal Handling
Plant, Coke Sorting Plant for COB #11, Flux & Fuel Preparation and Plant
Return Fines Handling for SP-III is given below. However, Contractor will
supply all the measurements, alarms & interlocks as may be required for
efficient & satisfactory operation of the system. Unless specifically
mentioned, all monitoring of the process parameters will be achieved in
level-1 automation system and displayed in HMI stations and field
instrumentation equipment will be supplied accordingly
A) Coal Handling Plant:
The measurements for Coal Handling Plant will include, but not limited
to, the following:
i. Level measurement of coal towers (18 nos.): For each tower minimum
one no. of level transmitter (radar type) and one no. of high level switch
will be provided. These signals will be hooked up with the automation
system for alarms and necessary interlocks. The required no. of level
transmitters will be provided as per the bunker design. For interlocks,
separate high level switches for each bunker will be provided as per the
process requirement, no. of feeding points etc.
ii. Level measurement of new silos (5 nos.): For each silo, 2 numbers of
radar type level transmitters and 4 numbers of level switches per silo will
CHAP-04.09 INSTRUMENTATION & CONTROL.doc
Page 4 of 15
be provided. These signals will also be hooked up with the automation
system for alarms and necessary interlocks.
B) Coke Sorting Plant:
The measurements for Coke Sorting Plant will include, but not limited to,
the following:
i. Level measurement of bunkers (4 nos.): For each bunker one no. of
level transmitter (radar type) and one no. of high level switch will be
provided. These signals will also be hooked up with the automation
system for alarms and necessary interlocks.
C) Fuel & Flux Crushing & Screening system:
The measurements for Fuel & Flux Crushing & Screening system will
include, but not limited to, the following:
i. Level measurement of bunkers (6 nos.): For each bunker one no. of
level transmitter (radar type) and one no. of high level switch will be
provided. These signals will also be hooked up with the automation
system for alarms and necessary interlocks.
ii. Level measurement of bunkers (1 no.): For this bunker two nos. of level
transmitters (radar type) and two nos. of high level switches will be
provided. These signals will also be hooked up with the automation
system for alarms and necessary interlocks.
04.09. 04. LIST OF DRAWINGS & DOCUMENTS
Following drawings and documents will be submitted by the Contractor for
Instrumentation system:
I)
For Approval :
01. Finalised process and instrumentation (P & I) diagram indicating all local &
remote measurements, alarms and interlock functions, using ISA symbols
and using suitable tag numbers against each instrumentation equipment.
02. Finalised list of measurements, alarms & interlocks, along with BOQ and
document of each instrumentation item indicating make, model number,
scale range, quantity, application and tag number (as per P&I diagram).
03. Detailed specification datasheet for each instrumentation item, filled in as
per the format finalized for this plant.
04. Overall general arrangement drawings & sectional views of various
cabinets, panels, consoles, etc., showing internal disposition of all
components/ units, with dimensional details and bill of materials.
CHAP-04.09 INSTRUMENTATION & CONTROL.doc
Page 5 of 15
05. Single line power supply diagram with document and bill of quantities of
electrical accessories along with that of UPS.
06. Quality assurance plan for each instrument & control system.
II)
FOR SCRUTINY AND RECORDS
01. Detailed technical literature/ catalogue for each instrumentation item.
02. Instrument Installation/ Hook up diagrams with bill of materials.
03. Instrumentation layout drawings showing location of instruments and route
of cables from these upto control room.
04. Wiring and termination diagrams with details of termination of field signals to
local JBs/ panels and from JBs to panels/ marshalling racks/ cabinets
including internal wiring drawings.
05. Cable schedule.
06. Manufacturer‘s test, calibration and guarantee certificates for all
instruments.
07. Operation and maintenance manuals for instruments.
08. ‗As-built‘ documentation.
09. Soft copy of all the above drawings & documents in CD-ROMs/ DVDs.
04.09. 05 LIST OF TESTING EQUIPMENT
Following testing equipment pertaining to Instrumentation will be supplied
by the Contractor:
1.
4-1/2 Digit Digital Portable Multimeter
Make
Quantity
Type
Display
Range:
Fluke/ Yokogawa/Philips
2 Nos.
Portable & handheld type
4-1/2 digit, LCD
DC Voltage -DC Current –
Selectable upto 1000 V min.
Selectable upto 10 A min, and will be capable to
measure mA signals for instrument use
Selectable upto 1000 V min.
Selectable upto 10 A min
Selectable upto 50 M Ohm min.
Selectable upto 10 mF min.
10.00 KHz to 199.99 KHz.
The multimeter will have the facilities like Diode
testing, Continuity testing, Data hold facility, Auto hold
facility, Auto power off facility, and with alligrator clips,
holster, temperature probe, battery, user manual &
operator‘s guide. Multimeter will be suitable for true
AC Voltage –
AC Current –
Resistance—
Capacitance—
Frequency-Other facilities
CHAP-04.09 INSTRUMENTATION & CONTROL.doc
Page 6 of 15
RMS measurement of AC voltage and current.
2.
Laptop based programmer for level transmitters: 1 no.
3.
Tools & Tackles
Make
Tester
Allen key set, Size: 1.5 mm to 10 mm
(one set consisting of 8 pieces)
D Spanner set, Size: 6 mm to 20 mm
(one set consisting of min. 8 pieces)
Ring Spanner set, Size: 6 mm to 20 mm
(one set consisting of min. 8 pieces)
Screw drivers (champion set)
Combination Pliers, Size: 6‖ & 8‖
Nose Pliers Size: 6‖
Hammers
Files,Size:12‖ flat, 12‖ half round, 12‖
round
Slide (adjustable) wrench, Size: 8‖, 12‖,
18‖
Pipe wrench, Size: 8‖, 12‖, 18‖
Wire stripper
Cutting plier Size: 6‖
Taparia/ Everest
5 nos.
1 set
1 set
1 set
1 set
1 set
1 no.
1 no.
1 set
2 sets
1 set
1 no.
2 nos.
04.09. 06 LIST OF PREFERRED MAKES
PREFERRED VENDOR LIST OF INSTRUMENTATION EQUIPMENT
SL.
No.
1.
1.1
ITEM DESCRIPTION
PREFERRED MAKES
PRESSURE INSTRUMENTS
Pressure / Differential
Pressure Gauge
1.
2.
3.
4.
5.
6.
CHAP-04.09 INSTRUMENTATION & CONTROL.doc
WIKA,
Ashcroft,
Forbes Marshall
Budenberg
Waaree instruments,
Hirlekar (DP gauge)
Page 7 of 15
1.2
A). Pressure / Differential
Pressure
switches.
(Mech. Type)
1.
2.
3.
4.
5.
B). Pressure / Differential
Pressure
switches.
(Electronic Type)
1.3
Switzer,
Ashcroft,
Solon
Budenberg,
Forbes Marshall
1. Ifm.
2. WIKA,
3. Kobold
Pressure / Differential
Pressure Transmitters
2.
1. Emerson (Rosemount),
2. Honeywell,
3. Yokogawa,
4. Siemens,
5. ABB
6. Endress & Hauser.
TEMPERATURE NSTRUMENTS/SENSORS
2.1
Temperature gauges
1.
2.
3.
4.
WIKA,
Ashcroft,
Budenberg
Waaree instruments
2.2
Thermocouple & RTD /
thermo well
1.
2.
3.
4.
Tempsens,
Toshniwal Industries,
Detriv.
Temptech,
2.3
Temperature Switch
1. WIKA,
2. Switzer
3. Ifm.
2.4
Temperature transmitter
1.
2.
3.
4.
5.
6.
2.5
Infrared radiation
pyrometer/portable
1. Land,
2. Ircon,
3. Raytek,
CHAP-04.09 INSTRUMENTATION & CONTROL.doc
Emerson (Rosemount),
Yokogawa,
Honeywell,
MTL
Phoenix.
Siemens
Page 8 of 15
4. Impac,
5. Keller HCW
3
FLOW INSTRUMENTS
3.1
Rotameters
1.
2.
3.
4.
5.
Forbes-Marshall,
Chemtrols,
Rota Instruments.
Eureka instruments
SMC
3.2
Orifice Plate & flanges
Assembly/ Venturi, Flow
nozzle
1.
2.
3.
4.
Engineering Specialties,
Micro-precision,
Instrumentation ltd,
Uni-control
3.3
DP type Flow / Level
Transmitters
1.
2.
3.
4.
5.
6.
Emerson (Rosemount),
Honeywell,
Yokogawa,
Siemens,
ABB
E&H,
3.4
Flow Switch
1.
2.
3.
4.
Ifm.
Kobold,
Mobrey
Sitron
3.5
Electromagnetic flow meter
1.
2.
3.
4.
Yokogawa,
Emerson (Rosemount),
Forbes -Marshall,
Endress & Hauser.
3.6
Vortex Flow meter
1.
2.
3.
4.
Emerson (Rosemount)
Forbes –Marshall
Yokogawa
Endress & Hauser
3.7
Mass (coriolis) flow meter
1.
2.
3.
4.
Emerson (Rosemount
Yokogawa
Forbes –Marshall
Endress & Hauser,
4
LEVEL INSTRUMENTS
CHAP-04.09 INSTRUMENTATION & CONTROL.doc
Page 9 of 15
4.1
Level gauge (magnetic &
reflex type)
1.
2.
3.
4.
4.2
Level Switch (Conductivity
type)
1. Vega
2. Endress & Hauser
3. Pepperl &Fuchs
4.3
Level Switch
(Capacitance/RF type)
1.
2.
3.
4.
4.4
Level Switch (Tuning fork/
Rod type)
1. Chemtrol (Vega)
2. Endress & Hauser
3. Pepperal &Fuchs
4.5
Level Switch (Float type)
1.
2.
3.
4.
Emerson
Forbes Marshall
V-Automat
Mobrey
4.6
Level Switch/ Transmitter
(Displacer type)
1.
2.
3.
4.
Emerson
Chemtrols (Eckard)
Mobrey
Masoneilan
4.7
Level Switch/ Transmitter
(Ultrasonic type)
1.
2.
3.
4.
5.
Endress & Hauser
Forbes –Marshall
Siemens (Miltronics)
Sick
Pepperal &Fuchs
4.8
Level Switch/ Transmitter
(Radar type)
1.
2.
3.
4.
5.
Emerson (Rosemount)
Endress & Hauser
Forbes- Marshall
Sick
Mobrey
4.9
Level Switch/ Transmitter
(Nucleonic type)
1. Concord International (Dr.
Berthold)
2. Emerson (Kay Ray)
3. E&H
5
CONTROL VALVES AND ACCESSORIES
CHAP-04.09 INSTRUMENTATION & CONTROL.doc
Chemtrol
Forbes Marshall
Mobrey
Hi-Tech (levelstat)
Vega
Endress & Hauser
EIP Bulk
Sapcon
Page 10 of 15
5.1
Control valve
1.
2.
3.
4.
5.
6.
Fisher-Xomox
Instrumentation Ltd
Masoneilan
Valflo
Samson Controls
Forbes Marshall (Arca),
5.2
Electrical Actuator
1.
2.
3.
4.
Auma
Limitorque
Instrumentation Ltd(Bernard)
Beck
5.3
Pneumatic Actuator
1.
2.
3.
4.
5.
6.
Fisher-Xomox
Instrumentation Ltd
Masoneilan,
Valflo
Samson Controls
Forbes Marshall (Arca)
5.5
Self- regulating pressure
control valve
1.
2.
3.
4.
5.
Samson Controls
Forbes Marshall
Instrumentation Ltd.
Nirmal Industries
Fisher-Xomox
5.6
I/P converters
1. Forbes
Marshall
products)
2. ABB
3. Emerson
4. Honeywell
5.7
Pneumatic Positioner,
1.
2.
3.
4.
5.
6.
Instrumentation Ltd
Dresser Industries (Masoneilan)
Samson Controls
Forbes Marshall (Arca)
SMC
Fisher Xomox
5.8
Electro- pneumatic
positioner
1.
2.
3.
4.
5.
Fisher-Xomox
Siemens
Masoneilan
Samson Controls
Instrumentation Ltd.
CHAP-04.09 INSTRUMENTATION & CONTROL.doc
(Moore
Page 11 of 15
6. Forbes Marshall (Arca)
7. ABB
5.9
Solenoid Valve
1.
2.
3.
4.
5.
6.
Herion,
Rotex
Schrader-Schovill
Asco
Mac
Burkert
5.10
Air filter regulator
1.
2.
3.
4.
Shavo-Norgren
Marsh-Bellofram
Placka
Schrader-Schovill.
6
CABLES
6.1
Instrumentation Cable
1.
2.
3.
4.
5.
6.
7.
Universal Cables
Delton
Lapp cables
Brooks Cables
Asian cables
Belden
MEM
6.2
Thermocouple
Compensating Cable
1.
2.
3.
4.
5.
Toshniwal Cables
Paramount Cables
Udey pyro-cables
Brooks
MEM
B.
CONTROL ROOM INSTRUMENTATION
7.1
Distributed Control System
(DCS)
7.2
Programmable Logic
Controllers.
7.3
Digital Indicator
1. Yokogawa (CS 3000)
2. Honeywell ((Experion +C 300)
3. Emerson (Delta-V)
Refer Electrical
1.
2.
3.
4.
5.
CHAP-04.09 INSTRUMENTATION & CONTROL.doc
PEPL
Masibus
Lectrotek
Honeywell.
Yokogawa
Page 12 of 15
6. ABB
7. Micro controls
8. Radix
7.4
Bar graph Indicator
1.
2.
3.
4.
Masibus Instruments
Lectrotek
ABB.
Yokogawa
7.5
Recorders (Chart less)
1.
2.
3.
4.
Eurotherm
Yokogawa
Honeywell
ABB.
7.6
Microprocessor based
controller
1.
2.
3.
4.
5.
6.
Yokogawa
Siemens
Honeywell
Eurotherm
Forbes Marshall
Toshiba
7.7
Digital scanners
1.
2.
3.
4.
5.
Masibus Instruments
Lectrotek
Radix
Micro Controls
PEPL
7.8
DC Power Supply Unit
1.
2.
3.
4.
5.
Aplab
Phoenix
Schneider
P&F
Siemens
7.9
IS Interface/Zenner Barrier
1. Pepperl & Fuchs
2. MTL
3. Stahl
7.10
Signal isolators
1.
2.
3.
4.
5.
CHAP-04.09 INSTRUMENTATION & CONTROL.doc
Pepperl & Fuchs
MTL
Yokogawa
Forbes Marshall (Protech)
Phoenix
Page 13 of 15
7.11
Annunciation system
1.
2.
3.
4.
5.
6.
IIC
Minilec
Procon
Digicont
MTL
BETA instruments
7.12
Instrument Panels/ Control
Desk
1. Rittal
2. Pyrotech
3. Instrumentation Ltd.
7.13
Manual loaders
1. Masibus
2. PEPL
3. Lectrotek
7.14
Totalizer
1.
2.
3.
4.
C.
ANALYTICAL / SPECIAL INSTRUMENTS
Masibus
PEPL
Lectrotek
Bivak
8.2
Gas Detectors
1.
2.
3.
4.
5.
6.
8.4
Moisture Analyzers
(Nucleonic)
1. Concord
International
Berthold)
2. Emerson (Analytical).
3. Sick
4. Thermo Electron
8.6
IR type Moisture analyzer
1. Moistech
2. NDC(EMC)
CHAP-04.09 INSTRUMENTATION & CONTROL.doc
Dragger
Crowcon
MSA
BW Technologies
Reiken-Keiki Japan
Bieler & Lang
(Dr.
Page 14 of 15
8.8
Vibration sensors & monitors
A. For turbines and other
high speed critical
machines
B. For other applications
8.9
Opacity/Dust concentration
meter
8.11
SPM analyzer
1. Bentley Nevada
2. Shinkawa (Forbes –Marshall)
1.
2.
3.
4.
SPM
Rockwell
Vibro-meter
Shinkawa (Forbes –Marshall)
1.
2.
3.
4.
5.
6.
Codel (Forbes- Marshall)
Durag
Emerson
Land
GESensing
Chemtrol
1.
2.
3.
4.
5.
6.
Emerson
Yokogawa
Durag
ABB
Honeywell
Forbes Marshall (Codel).
Emerson
Yokogawa
ABB
Siemens
Honeywell
Forbes Marshall (Codel).
8.12
SOx- NOx analyzer
1.
2.
3.
4.
5.
6.
8.13
Moisture Sensor &
Transmitter
1. Invensys (Foxboro)
2. Bartec
3. GE-Panametrics
CHAP-04.09 INSTRUMENTATION & CONTROL.doc
Page 15 of 15
04.10
ELECTRICAL POWER
ILLUMINATION
04.10.01.
General
DISTRIBUTION,
DRIVES,
CONTROL
&
This section covers major features of Power distribution System, ShopElectrics, Drives, Control, Automation and Illumination System to be
supplied by Contractor for the Coal Handling Plant (CHP) & Coke
Sorting Plant (CSP), Augmentation in Flux - Fuel Preparation and Plant
Return Fines Handling for SP III (FFP).
The Contractor will refer to General Technical Specification for Electrics
(GS-03) for detailed specification of equipment/components. This
Contract Specification (CS), General Technical Specification (GTS)
including Preferred Makes for Equipment and supplies (GS-13) and
other attached documents/ Annexure E-01(Tools & Tackles), E02(Commissioning Spares), E03, E-04, E-05 considered, as a whole will
comprise the complete Contract Specification. These are
complementary and anything laid down in one and not in other will be
deemed as binding, as though laid down in the Contract specification as
a whole. In case of conflict between the Contract specification and GTS,
the Contract specification (CS) will prevail.
04.10.02.
HT Power Supply System & Battery Limit
Power supply for the Coke Sorting Plant and Coal Handling Plant will be
made available from the 11/6.6 kV switchboards proposed to be installed
at HT substations (HTSS) near COB#11(HTSS-48), under a separate
package by EMPLOYER (package no. 071).
Power supply for the Augmentation in Flux - Fuel Preparation And Plant
Return Fines Handling for SP III of SP-3 Complex will be made available
from the 11/6.6 kV HTSS for SP-III -HTSS-43 and HTSS-45 (beside
HTSS-42) Complex
under a separate package by EMPLOYER
(package no. 071).
Refer typical power distribution drawing no.MEC/S/9101/11/E1/06/00/00/
064.01/R1 for HTSS
The scope of work of the Contractor will commence from the outgoing
terminals of 11/6.6 kV switchboard located at HTSS-48, HTSS-45 and
HTSS-43 Complex for the respective facilities.
This 11/6.6 kV Switchboards at HTSS will be used to supply power to all
LT substations (LTSS) and all 6.6 KV HT Motors under the scope of this
package. Supply, laying and termination (at both ends) of all HT &
Control Cables from HT switchboard to LTSS & HT motors will be in the
CHAP-04.10 ELECTRICAL POWER DISTRIBUTION, DRIVES, CONTROL &
ILLUMINATION.doc ELECTRICAL
Page 1 of 50
scope of Contractor. Power to all the HT motors will be supplied from the
6.6kV HT Switchboards.
Adequate number of LT Substations (LTSS), (at suitable locations to be
decided by the Contractor) each comprising of LT switchboard along
with two transformers will be included by the Contractor in his scope of
work. The transformer rating will be worked out on the basis of
guidelines given in General Technical Specification. However, the rating
of transformers will be 2000/ 1000 kVA depending upon the load. The
interconnection between transformer secondary and LT switchboard will
be through bus ducts.
The Contractor will indicate the numbers of 11KV and 6.6 kV feeders
required by them from HTSS during Basic Engineering to provide HT
feeders by Employer. The Contractor will indicate the details of
connected load (KW) & Maximum Demand in 15 min. duration for each
feeder and also the overall expected maximum demand in 15 min
duration for the entire plant under normal operating conditions.
The following are to be considered in addition to the equipment
specification spelt out in GTS.
a)
The vector group for all distribution transformers (LT S/S) will be
of Dyn11 only to take care of circulation of harmonic currents.
However, care should be taken not to envisage mixing of supply
with the existing LT power sources of 2.5 MT area as the existing
distribution transformers are of Yy0 vector group.
b)
Separate analogue voltmeters for line voltage & bus voltage and
ammeter in each of the three phases will be provided.
c)
All out going ACBs will be 800A, 1000A or 1600 A as per
requirement with protection settings selectable at site.
d)
Check-synchronising relay will be provided wherever
sectionalizing is envisaged between two different sources of
power supplies.
e)
Care should be taken to avoid location of LT Substations under
Conveyor galleries/ dust prone areas.
f)
LT Bus-duct insulators will be of porcelain.
g)
The CT mounting arrangement inside the cable chambers of all
feeders will be such that CTs and secondary connections will be
CHAP-04.10 ELECTRICAL POWER DISTRIBUTION, DRIVES, CONTROL &
ILLUMINATION.doc ELECTRICAL
Page 2 of 50
easily accessible for maintenance, replacement, etc.
Each of the LT substations will have the following facilities:
a)
b)
c)
d)
e)
f)
g)
h)
04.10.03.
The substation design will be dust proof and all entry points will
be provided with double door arrangements.
Sufficient quantity of fire extinguishers at various locations will be
provided as part of safety equipment inside sub-station.
Air cooling facility will be provided in all LT substations with air
washing.
Lighting circuits of different rows will be controlled by different
MCBs for better energy saving.
Breaker handling facilities will be provided.
Tools & tackles along with store room facilities will be provided.
Two nos of 4 legged wooden stools of height 1m and 4m each
will be provided.
Chain pulley block or telpher arrangement will be provided.
Scope of Work
The scope of work of Contractor will cover design, basic and detailed
engineering, submission of drawings for approval, manufacture, testing,
inspection by EMPLOYER/Consultant, packing, loading, forwarding,
delivery at Plant site, loading/unloading, storage, handling of
material/equipment for erection, erection, no-load and load testing,
commissioning, PG test, PAT/FAT and liquidating the defects and
handing overall electrics related to Power Distribution, drives & control,
illumination for complete & satisfactory operation of Coal Handling
Plant(CHP) & Coke Sorting Plant(CSP), Augmentation in Flux - Fuel
Preparation and Plant Return Fines Handling for SP III (FFP) on Turnkey
basis.
Any item or equipment not specifically mentioned but essential for
proper installation, operation, maintenance and safety of plant,
equipment and personnel will be included by the Contractor in his scope
of work
The scope of work for this package will include but not limited to the
following:
I)
Power Distribution Equipment
1.
Adequate numbers of Double ended 11/0.433 kV or 6.6/0.433 kV LT
substations(LTSS )
2.
Each double ended substation will comprise of 11/0.433 kV or 6.6/0.433
kV Distribution transformers, 415 V PCC, 415 V Bus-duct, ACDB ,
MLDB , LDB, HT/ LT power & control cables and other necessary items
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as required for completion and successful operation of the power
distribution network, in an integrated manner.
3.
Vacuum circuit breaker (VCB) without protections in the transformer
room if transformer is fed from remote HT switchboard for tripping of
upstream breakers
-
Push Button stations with trip PBs (press to lock and turn to release)
in the transformer room if transformer is fed from HT switchboard
located in the same building for tripping of upstream breakers.
4.
Power and control cables, Cable termination kits, laying and termination
(at both ends) of all associated power and control cables from the
EMPLOYER’s 11/6.6 kV switchboard. Only 11kV (UE) grade cable will
be used for 6.6kV (UE) applications.
5.
AC distribution boards (PDB) - Single front, non draw-out type, sheet
steel enclosed, modular construction with IP54 enclosure, having two
incomer with a bus coupler will be provided for auxiliary equipment of
LTSS.
6.
Contractor to provide 2 feeders of 400A each in the CSP LTSS for
EMPLOYER’s use.
Construction Power Supply:
The facilities for distribution of construction power supply will be in the
scope
of
the
Contractor.
For construction power supply, one no. outgoing feeder of 415V AC,
3ph, 50 Hz will be made available at the nearest construction power substation by the EMPLOYER for each Coal Handling Plant, Coke Sorting
Plant and additional Flux & Fuel crushing & Fines handling system
respectively.
.
Supply, erection, testing and termination at both ends of incoming power
cable to Contractor’s construction power distribution board, further
distribution and regular maintenance of the construction power supply
network will be under the scope of Contractor
II)
DRIVES, CONTROLS AND ILLUMINATION SYSTEM
1. All HT and LT AC/DC motors, actuators, brakes etc. as per technological
and process requirement.
 HT motor winding and bearings, temperature sensors, vibration
sensors will be hooked up with PLC for monitoring.
 For HT motor, surge suppressor to be installed near the motor.
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




Generally Squirrel Cage Induction Motor with DOL starter / VFD /
Soft Starter will be provided.
Suitable Rotor contactor panels and SS-grid Resistance Boxes
will be provided for starting and speed control of slip ring motors
wherever required as per Technological requirement.
All HT conveyor motors will be S1 duty.
All LT motors for conveyors will be S6 duty and will have class F
insulation with temperature rise limited to class B.
Inverter duty motors (used for VFD application) will have class H
insulation with temperature rise limited to class F.
2. Indoor 415 V LT MCC and Control panel with CT, PT, metering and
Protection etc. as required.
 Motor Control Centres for Coal Handling Plant and Coke Sorting
Plant area will be Intelligent, draw out type with two incomers and
bus coupler for control of drives of rating up to 90kW, of various
technological units having communication with Plant Automation
System.

Motor Control Centres for Augmentation in Flux - Fuel Preparation
and Plant Return Fines Handling for SP III will be Conventional,
drawout type with two incomers and bus coupler for control of drives
of rating up to 90kW, of various technological units.

For control of drives of rating from 110kW to 200kW of various
technological units, Intelligent type Motor control panels (MCPs) for
CHP, CSP and FFP area having communication with Plant
Automation System.

Control panel for Tripper car, crane, hoist, small machines and
Auxiliaries will be conventional type, non draw-out control panel. All
control panels on the mobile machines will be mounted on anti
vibration pad.
Electronic over load relay for motors upto 90kW and Motor Protection
Relays for motors above 90 kW will be used in conventional type
(non-intelligent) MCC / Control panel. The electronic overload relay
will be of Manual Reset type.
Local/Remote selector switch will be mounted on MCC & Control
Panel.
Motor feeders up to 45 kW rating will have MPCB and MCCB beyond
45 KW rating.
Current monitoring for all drives of rating above 30kW
Conveyors feeding to Augmentation in Flux - Fuel Preparation and
Plant Return Fines Handling for SP III (FFP) C7-3.5KW, C1-30KW &
C2-45KW will be fed from new MCC under the scope of package.
Contractor will consider Power cable for feeding the same. These
Conveyors will be connected and controlled by new PLC envisaged





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in this package of FFP. Suitable control cable and other accessories
will be considered.
3.
VVVF converters :
 VVVF converters for 415 V motor drives having requirement of
speed control where process requirement calls for variable speed
application. All drives will have communication capability with
Plant Automation System.
 VVVF Converter having communication capability as above at
medium voltage (like 690 V) complete with 3 winding Converter
transformer (for 12 pulse configuration) & incoming ACBs for
higher rated motors.
 VFD will have following features:

Minimum rating of AC drives and reactors will be 150% of
the full load current of the motor.

Automatic disconnection of individual Motor in case of
failure of AC drive.

Use of isolation transformer for more than 90 KW drive and
use of series reactor for less than 90 KW drive for VFD
application.
4.
Soft Starter :
 All HT Motors for conveyor drives will be provided with Flux
Compensated Magnetic Amplifier (FCMA) Soft starter for low
starting current. FCMA soft starter will have suitable By-pass
contactors and controls to ensure running of the motor at full
speed. FCMA soft starter will be indoor duty, rugged in
construction, user friendly and maintenance free.
 FCMA Soft starter for HT conveyor motors will be connected to
motor at neutral end with suitable enclosure to prevent the dust
entry.
 Soft starter will be provided for LT motors of rating more than
75kW.
5.
Dual parallel redundant UPS system consisting of SMF battery bank
for 30 minute back up incase of power failure, Battery charger, UPS
Power distribution boards & sub-distribution boards for distribution of
UPS power supply to control & Automation equipments,
Instrumentation system equipment, FDA system, Weighing system &
any other equipment as per requirements.
6.
Local control stations housing push buttons, indication lamps etc. for
all drive. LCS for HT motor will have Ammeter also. All Local control
stations will have double doors. LCS for conveyors will have belt sway
switch bypass. Local/Remote selector switch will be mounted on MCC
& Control Panel and not on LCS.
7.
Power distribution boards (PDB) with two incomers and one bus
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coupler for repair network like welding sockets, maintenance cranes
and hoists. All PDBs to be mounted in Technological/Auxiliary/Service
buildings (Other than Electrical room) will have double doors.
Enclosure Class will be IP54.
8.
Main Lighting Distribution Boards (MLDB) with two incomers and one
bus coupler for Power supply to various Lighting distribution Boards
(LDB). Enclosure Class of MLDB & LDB will be IP54.
Adequate nos. of LDBs and Sub Lighting distribution boards for
providing power to light fittings.
9.
Emergency lighting distribution boards (ELDBs) with two incomers and
one bus coupler for Power supply to various Emergency Sub Lighting
distribution Boards (ESLDBs) and feeding arrangement will be as per
GTS.
Adequate nos. of Emergency Sub Lighting Distribution Boards
(ESLDBs) for providing power to emergency light as given below :
 20% Emergency lighting in all Junction houses, Process /
technological buildings, pump houses, compressor houses,
conveyor tunnels, underground premises, LTSS, Despatcher /
Control rooms, staircases, entry / exit of building, office rooms,
attendant / operators rooms, shift in charge rooms, canteen / rest
rooms etc.
 10% Emergency lighting in conveyor galleries.
10. Exit light from UPS distribution board for the following areas :
 LTSSs / Electrical premises.
 Dispatcher / Control rooms.
11. Portable Emergency lights will also be provided in strategic areas like
LTSSs, Electrical premises, control rooms, staircases, entrance of
cable tunnels / basements, escape routes, attendant / operators room
in the technological buildings etc.
12. DCEM Brakes with economizing resistance will be used for Conveyors
and brake panels will be housed in MCC room.
A Brake panel will not feed power to more than 2 nos. of brakes.
13. Surge protection device will be provided at the incoming side of MCCs,
VFDs, Soft starters, PLCs/Remote I/O stations etc. to protect the
system/equipment as required.
14. All field devices, valves, safety switches like Pull chord switches and
belt sway switches, zero speed switch, chute jamming switches and
Proximity switches, Warning hooters, level sensors, relays, limit
switches, isolators, speed sensors etc. as necessary for the process
and control of the material handling equipment / system and its all
associated / auxiliary equipment / systems.
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





Addressable type PCS, Addressable type BSS, ZSS and Belt
rupture protection switches will be provided for all new and
existing conveyors being upgraded.
Proximity type Limit switches will be used for shuttle conveyors,
tripper car etc.
Sensing distance of proximity in the Zero Speed Switch will be 60
mm.
RF admittance type chute clogging switches flush with chute body
will be provided.
Infrared type Belt rupture protection switches will be provided in
all conveyors. The minimum set of belt rapture switches will be
provided as given below :

1 set for conveyors of length up to 50m.

2 sets for conveyors of length above 50m and below 100m.

3 sets for conveyors of length above 100m.
Chute Jamming switches in all chute including chute in Tripper
Car.
15. All HT/LT Power, control, signal, communication cables (fiber optic /
electrical), special cables, rubber insulated flexible cables, illumination
cables etc. as required.
 All HT and LT Power cables will be XLPE insulated.
 All HT Power cables will be 11kV UE grade and FRLS sheathed.
 LT Control cables will be PVC insulated.
 Minimum size of Control cables will be 2.5 sq. mm.
 Copper cable will be used for imported motors, crane and moving
equipment.
16. 415V, 100A interlocked switch socket outlets for repair network,
welding sockets at different floor, premises, buildings and other areas.
Maximum 3 nos. Welding sockets will be connected to one feeder with
100Amp MCCB rating & minimum size of cable will be 3.5 x 70sqmm.
17. 240V, 15A and 24V, 5A receptacles from Lighting Distribution Board /
Sub Lighting Distribution Board.
18. Load break isolators for maintenance crane, hoists, tripper car etc. to
be located near the equipment.
19. Power and control junction boxes will be made up of SS sheet with
weatherproof enclosure for termination of field cables.
20. Power trolley line conductor (DSL) / Festoon Cable trolley system /
Plastic Cable Carriage system including rails / angles, supporting
brackets, insulator assembly, junction box etc. will be provided as
follows :
 Festoon Cable trolley system for hoists etc.
 Plastic Cable Carriage system for power and control trailing
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cables for shuttle conveyors, EOT cranes etc.
21. Cable Reeling Drum with stall torque induction motor will be provided
for Tripper Car.
Tripper car will have interlocking of chute clogging switch with
conveyor through wireless radio communication. Interlocking with the
CRD control cable will be given as back-up.
22. Illumination of the plant covering new storage yard, outdoor area
lighting, peripheral lighting, coal tower top, shuttle conveyor floor, Road
in and around the proposed units, Sub- stations, MCC rooms, Control
rooms, Ventilation rooms, conveyors, Junction houses, various
technological / auxiliary buildings and other installations of the plant by
providing Lighting Transformer, Main Lighting Distribution Board,
Lighting Distribution Boards, Sub-lighting Distribution Boards, Feeder
pillars, Light Fittings, Lighting towers, high mast, low voltage switch
sockets, conduits, Ceiling fans, Exhaust Fans, all lighting cables etc.
New plant lighting system will comprise of the following categories
lighting system.
 Normal /240V AC lighting system.
 24V AC maintenance lighting system.
 Emergency lighting system.
of
23. Illumination, AC, Ventilation, 240V, 5A/ 15A sockets, Exhaust fan for
toilet etc. for office building etc.
24. Complete electrics including motors, control panel, LCS, Brakes with
panel, field devices, cables etc. for Conveyors, Screens, Actuators,
valves, gates, vibro feeders, belt feeders etc. as required.
25. Complete electrics including motors, control panel, LCS, Brakes with
panel, field devices, cables etc. for Shuttle conveyors, Tripper cars,
Cranes, Hoists etc.
26. Complete electrics and load cell for Weigh feeders, Weigh hoppers,
Belt scales etc. as required.
27. Complete electrics required for Suspended magnets, In Line Magnetic
Separators, Metal presence detectors etc.
28. Complete electrics, controls, instruments, level controllers, solenoid
valves, Bag filters, Timer controls etc. for the Dust suppression system,
Dust extraction system, Ventilation, Air Conditioning system as
required.
29. Completes electrics including motors, control panel, LCS, level
sensors, cables etc. for sump pumps, slurry and dewatering pumps will
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be provided in underground floor of technological building/ Junction
houses, Tunnels, cellar etc.
415V, 100A Sockets will also be provided near sumps.
30. Completes electrics including motors, control panel, LCS, level
sensors, cables etc. for all pump houses, fire fighting system etc.
31. Complete electrics for Bin vibrators with rectifier panels and Air Blaster
with solenoids, control panels, cables etc. for Bunkers as required.
32. Complete electrics for sampling systems covering motors, control
panels, cables LCS etc.
33. Complete electrics for all Crushers including the followings :
 Motors for main and auxiliary drives with necessary accessories
and brakes as required.
 Rotor contactor panels, Resistance boxes for Slip ring motors /
VFD or DOL or Soft starter for Squirrel Cage motors as required.
 Control Panel, Local control stations, field devices, safety
devices, Limit switches, speed relays, solenoids, Power & Control
Junction Boxes etc. as required.
 Power and control panel for roll grinding attachment including
drive motors for roll crusher.
 Control panel for hydraulic and lubrication system including drive
motors as required.
 All power, control and special / instrument cables etc.
 Earthing.
 Hammer crusher will have local control station in which necessary
Push buttons, Ammeter, Temperature Monitoring facility,
indication lamp, hooter etc. will be provided to operate locally as
well as from control desk.
 Hammer crusher will be operated from Local Control Post. Apart
from LCS, Local Control Post will be provided which will be kept
in same crusher building. AC for Local Control Post will be
provided. Extensive monitoring of HT drive will be done from
Local Control Post and the information will be sent to Dispatcher
for monitoring.
34. All LCS for outdoor application will be made of SS sheet. All control
Push Button will be covered with Silicon Rubber Boot to prevent dust
ingress.
35. Scope of work and Battery limit for Electrics and Automation for up
gradation, modification, integration of existing drives / mechanism is
defined in the Clause No. 04.10.11.
36. Automation system:
a)
PLC based Automation system of proposed Coal Handling Plant
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Pkg-064, will be interfaced with Automation system of Coal
Transportation Plant (Pkg-062) being arranged by the EMPLOYER
through a separate package (as indicated in Automation
Configuration Drawing enclosed) so that entire coal transportation
from silos to all coal towers can be operated in an integrated way
from a common despatcher / control room D2 (under
EMPLOYER’s scope). The PLC based Level-1 automation system
of CHP will be provided as mentioned in the automation chapter.
b)
PLC based Level-1 automation system of proposed Coke Sorting
Plant will be provided as mentioned in the automation chapter for
running the new Coke Sorting Plant from a new control room/
despatcher under the scope of Contract.
c)
PLC based Level-1 automation system of Augmentation in Flux Fuel Preparation and Plant Return Fines Handling for SP III which
will be connected to existing PLC through suitable gateway. The
new PLC & HMIs will be housed in existing Control Room 1(CR1).The existing HMIs will suitably be upgraded to match the new
HMIs for operation of the entire existing and new FFCS plant.
37. Contractor to provide following feeders for EMPLOYER’s use in
Electrical Premises near Coke Dedusting unit of Coke Sorting Plant:
 2 no. feeders of 100A each in MLDB/LDB.
 2 nos. of power supply feeder of 100A each in PDB.
38. CCTV camera with cleaning facility will be provided in the following
tentative locations with monitors at Despatcher / Control room for
extensive monitoring of given below areas:
a) Coke Sorting Plant.
 2 Nos. for Coke storage area.
 2 Nos. at Coke Screening Station.
 2 Nos. at Coke Crushing Station
b) Coal Handling Plant
 2 nos. for new silos
 2 nos. at New Coal Tower no.-7
Final location will be decided during detailed engineering.
39. Electrical equipment will be supplied as per the Make list given in GTS
(GS-13). However, in case of non-availability or delay in delivery, the
Contractor will take prior approval of BSP/MECON for additional make
before ordering. Make of Plastic Cable Carrier system will be IGUS /
Kable Schlepp.
III)
Control Rooms, Electrical Premises, Ventilation, Air-Conditioning
& FDA System
1. All civil construction work for cable basement/cellar, cable tunnel and
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concrete cable trenches, MCC Rooms, Despatchers/Control rooms,
Electrical premises etc. including their associated utility areas like
Ventilation rooms, Stairs, Toilet etc.
2. Control for the proposed Coal Handling Plant will be from Despatcher
(D2) building being arranged by EMPLOYER under separate
package (62). The Contractor will furnish space requirement and
assignment to the EMPLOYER for making the provision in the
Despatcher-D2.
3. Control of Augmentation in Flux - Fuel Preparation and Plant Return
Fines Handling for SP III will be done from existing Control Room
1(CR-1). Necessary modification, if required for laying of cables and
mounting equipment in the existing control room, the same will be
provided by the Contactor.
4. Control of Coke Sorting Plant will be done from a new control room/
despatcher under the scope of Contract.
5. Cable Tunnels / Structures for overhead cable bridge as required.
6. Intelligent, microprocessor based, addressable type automatic fire
detection and alarm system for all MCC rooms, Electrical Premises,
Cable cellar, Despatcher cum Control room using smoke detectors,
heat detectors with cross zoning.
7. Air conditioning system for Control rooms cum Despatchers (housing
Operator control/HMIs, Servers, Engg. stations, Instrument panels,
UPS etc).
8. Air conditioning system at (35 deg C max.) for premises housing
Intelligent MCCs, MCPs & VVVF panel rooms and other local control
rooms complete with instruments, electrics, controls etc.
9. Ventilation system for substation building, Cable tunnels, Cable
basement / cellar consisting of suitable capacity fan, Pumps, GI
ducting etc.
10. Exhaust ventilation system for toilets, storerooms, Battery rooms etc.
11. Excavation, back filling, and leveling of cable trenches within battery
limits.
12. Cable cellar for all Electrical premises/ LTSS/ MCC room etc.
13. MCC room and LTSS can be combined building with a separation
wall and with a door for interconnection .
14. Cable supporting structures in the Electrical Premises, Despatchers /
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control rooms, cable cellars, cable tunnel, cable channel or overhead
cable bridge for interplant cabling.
15. The tentative location of LTSS: CHP –LTSS opposite 5 silos, CSPLTSS near JH-11 and Coke Screening station and FFP-LTSS near
JH-117 and Coke breeze storage yard. If the nos. of LTSSs
increases during Basic Engineering to suit the technological
requirement in line with GTS, the same will be proposed by
Contractor during Basic Engineering.
IV)
Earthing and Lightning Protection
1. Measurement of soil resistivity test at site for designing earthing
system.
2. Lightning protection system for entire plant including Air termination,
separate dedicated earthing stations, conductors, testing links,
interconnections and accessories as per IS.
3. Supply and installation of complete earthing system including earth
pits, earth grid with GI strips for the substations, neutral earthing of
transformers, earthing of all electrical equipments in electrical
premises, Junction houses, process / technological building etc.
4. Special earthing system (including earth pits, earth grid with GI strips,
Copper Cables as required) for earthing of PLC, RIO panels, VFD,
other Electronics equipment & automation system as per their
manufacturer’s recommendation. It will be distinct and separate from
the power and lightning equipment earthing system.
V)
Erection accessories, spares, safety items, documentation &
other miscellaneous items
1.
Supply of all erection accessories and materials, all steel members
(angle, channel, plate, steel sheet, etc.) for installation of electrical
equipment, GI pipes, GI conduits, bends, clamps, nut, bolts, ladder and
perforated type cable trays, tray installation materials & accessories,
cable supporting structures, heat protection materials, flexible metallic
hoses, sealing materials for openings/conduits, double compression
cable glands, cable lugs, cable tags, cable fasteners, insulating tapes,
ferrules, RCC slabs, sand, bricks for under ground cable laying, GI
pipes for protection of cables at road crossings and other places, cable
markers, cable jointing & termination kits and materials, earthing strips
of different sizes, junction boxes, pull boxes, heat resistance paints
and all consumable materials for complete laying & termination of
cables, erection of electrical equipment and earthing system etc.
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2.
Arranging construction power supply including PDB, power (both
incoming and outgoing) and control cables, cable trays, cable laying
etc.
3.
Submission of basic and detailed engineering drawings, design
calculations etc.
4.
Supply of As-built drawings, operation and maintenance manuals. CD
in duplicate and reproducible of all As built drawings.
5.
Supply of all commissioning spares as required till the plant is
commissioned and handed over to BSP. List of minimum
commissioning spares will be supplied as per attached Annexure E-02.
6.
List of two years Maintenance / operational spares will be finalized
during detailed engineering stage.
7.
Supply of Special tools & tackles, measuring instruments etc. as per
Annexure - E-01.
8.
Canopy of all outdoor electrical equipment, if any.
9.
First fill of all consumables, printers, papers, cartridges, floppy, CDs
etc.
10. Safety items like hand gloves, shock treatment charts, discharge rods,
rubber mats (of required voltage classes) in front and rear of all panels,
danger/caution boards, fire extinguishers, fire sand buckets, nicely
framed As built Single Line Diagram of LTPCCs, MCCs, PDBs,
MLDBs, LDBs, SLDBs keys and key boxes etc.
11. Supply and installation of GI pipes for protection of cables at road
crossings and other places where cables may be subjected to
mechanical stress and damage.
12. Supply and installation of cable supporting structures in the LT
substation building, cable cellars, cable tunnel, cable channel or
overhead cable bridge for interplant cable routing.
13. Walkable Cable Bridge between EMPLOYERs’s HT Substations to
Contractor’s LTSSs and further for routing outgoing cables to different
consumers / buildings etc. as required.
14. Intershop outdoor cable route will be through only walkable Overhead
Cable Bridge/ conveyor gallery/ cable tunnel. No underground buried
cable will be provided. Concrete cable trench covered with pre cast
slab is accepted only in covered shed or indoor area.
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15. Cables of one area/conveying route will not cross and will not be laid
through conveyor of other area/conveying route.
16. Minimum 1 No. electrical area repair shop (Min. size –18M X9M X 6M)
in Coke Sorting Plant will be considered with a facility of rest room,
repair area, store, provision to keep tools and tackles, measuring
instruments/testing instrument including megger, clamp tester, hand
held tachometer, CRO, multimeter, vibrometer etc.
17. Furniture for the monitor, control rooms etc.
18. Training of EMPLOYER’s engineers at manufacturer's works/training
centers for Automation system, UPS system, AC drives, Weighing
system etc.
19. Any additional items/equipment which is necessary for achieving
specified performance and completeness of the system will be
provided by the Contractor within the time schedule unless it has been
excluded from the scope of the Contractor.
04.10.04.
Approval of Statutory Authorities
The Contractor will obtain necessary approval of statutory authority as
per rules of State Government and Central Electricity Authority for the
work under his scope, before energizing/charging the equipment.
However, EMPLOYER will extend all assistance in this regard, like
submission of application, relevant documents and payment of statutory
fees etc.
04.10.05.
Installation
For installation work at site, the contractor will be fully responsible for
arranging the required tools and tackles, welding sets, pipe bending
machine, cable crimping tools, gauges, scaffoldings, ladders, temporary
water and power connections.
On completion of the installation but before energisation of the system,
all installation will be physically checked and properly tested. These
checks and tests will be conducted by the contractor under the
supervision of BSP / MECON. The contractor will furnish the final status
and test results. Any defect observed during such check and tests will be
rectified by the contractor free of cost within contract completion period.
All clamps brackets, bolts, nuts, screws, markers, ferrules, lugs and
glands and other hardware necessary for erection work, will be included
in the scope of work and will be arranged by the contractor. Equipment
will be painted to withstand the heavily polluted and saline environment
prevailing in at site.
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04.10.06.
Design basis for equipments & installations
Ambient conditions of shop units
Generally following ambient temperature will be considered in Electrical /
Control Rooms.
S.N.
Area
Ambient Temp
A.
Electrical Rooms
1.
LT Sub-station/ switchgear room + 45 Deg. C
(Pressurized ventilation)
2.
MCC rooms (housing intelligent + 35 Deg. C
MCCs,
VFD
panels,
TR
controllers, RI/Os etc.)
3.
Cable basements / tunnels
B.
Control Rooms
1.
Control rooms – Air conditioned
+ 50 Deg. C
+ 24 Deg. C
-
Equipment selection and derating 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.
-
Equipment installed in MCC rooms/Control rooms will be designed
for + 50 deg C so that in case of failure of Air-conditioning/ventilation
facilities also the equipment should not be affected.
-
The equipment offered 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.
-
The equipment will be designed to give efficient and reliable
performance under heavy steel mill conditions and will be such that
the risks of accidental short-circuit due to animals, rodents and
vermin are obviated.
-
The quantities of equipment, cables, cable terminations, straight
through joints, cable supporting structures, earthing / lightning and
erection materials, will be as per actual requirement in accordance
with the approved detail engineering drawings.
CHAP-04.10 ELECTRICAL POWER DISTRIBUTION, DRIVES, CONTROL &
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Page 16 of 50
04.10.07.
-
All equipment will strictly conform to the General Specification,
except where any deviations have been explicitly spelt out,
specifically discussed and mutually agreed upon between the
Contractor and the EMPLOYER.
-
The detailed specification and schedule of quantities will be worked
out based on the detailed engineering to be carried out by the
Contractor, for complete and proper execution of the specified tasks.
-
The final ratings of the circuit breakers, CTs, busbars will be
adequate for the actual loads and considering the derating factors as
substantiated by temperature rise test on the 415 V switchboards. All
CT ratios / VA burdens, ranges of meters and instruments, types of
relays and relay setting ranges will be submitted for EMPLOYER’s
approval during detail engineering.
-
All HT cables will be 11 kV (UE) grade of size 3x185 sq mm (min).
Design basis for electrical premises for the proposed units
GTS is to be referred for designing of electrical premises & layouts,
selection of equipment and installation. In addition to this, following
points will be considered.
-
-
-
04.10.08.
Motor Control Centre (MCC), RIO stations, PDB, MLDB etc. to be
installed in various MCC rooms, will be provided near various
shop/technological units.
Wherever required, MCC rooms and LT substation rooms (including
rooms for distribution transformers) can be combined with separation
wall and independent entry for both LTSS and MCC rooms
considering the location of Substation and shop unit. Each LTSS
building will have store facility.
No under ground cable basement to be provided below MCC
buildings.
-
PLC, CPU panels, Operator panel / HMIs, Engg stations, UPS, UPS
battery will be located in the air-conditioned room in the control room
floor.
-
For high rise buildings structural walkway will be provided for
maintenance of light fittings.
Design Basis for Illumination System
GTS is to be referred for designing of Illumination System, selection of
equipment and installation. In addition to this, following points will be
considered.
CHAP-04.10 ELECTRICAL POWER DISTRIBUTION, DRIVES, CONTROL &
ILLUMINATION.doc ELECTRICAL
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-
Illumination levels of all units will be as indicated elsewhere in this
specification.
-
The maintenance factor for design of illumination level will be
considered as 0.6 for all areas.
-
For arriving at utilization factor, manufacturer's recommendation will
be followed.
-
All rooms with false ceilings will be provided with recessed type
decorative mirror optics fittings.
-
All MCC Rooms will have lighting switches near doors.
-
All decorative type fittings will be mirror optics type.
-
All buildings will be provided with peripheral lighting.
-
The power factor of lighting system will be improved to 0.9 by
providing in built capacitors with individual light fittings.
-
Area, outdoor and peripheral lighting will be fed from separate
LDB/SLDBs having two modes of control - AUTO and Manual. Under
AUTO mode lights will be automatically switched ON/OFF through
24Hrs Timer & Contactor where as in Manual mode, lights will be
switched ON/OFF through local control station located in
Despatcher/Control room. Selector switch for mode of control will be
located on local control station.
-
Lighting in conveyor gallery and junction houses (floors above
ground) will be connected to separate lighting circuit and the same
will be switched ON/OFF by PLC based control from HMI at
Despatcher.
-
Area lighting, wherever applicable, will be provided through 400W,
HPSV flood light fittings mounted on lighting towers.
-
Road lighting will be provided with 250W HPSV street light fittings.
-
All the offices will be provided with ceiling fans.
-
For indoor lighting, outgoing feeders in MCB DBs will be 20A SPN
MCBs. Each feeder will not be loaded more than 2 kW. Incomer to
MCB DB will be suitably rated heavy-duty switch and ELCB for
detection of leakage current.
-
For area and road lighting, 3 phase & neutral feeders may be used
and accordingly suitably rated 4 core cables may be provided.
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-
HPSV lamp fittings will be provided with external electronic igniters
and a built in sensor to sense failure of lamp and switch off igniters.
-
Single phase/three phase circuits are connected to RYB phase such
that total connected load to each phase equal and phase balancing is
achieved.
-
Stroboscopic effect will be corrected by providing power factor
improvement capacitor and power phase distribution.
Point wiring will be done through PVC insulated PVC sheathed
Copper cable.
-
-
Single phase 3 pin 230V, 15A and 5A, switch-socket outlets will be
provided with interlocked switches (male and female units) at the
following locations:
o
o
04.10.09.
At each floor of building at every 30 m intervals or minimum one
for each row/side.
Two numbers each in switch gear room, cable basement, control
room and MCC room.
-
Group control and sectorial control will be envisaged through MCBs
provided in the respective LDBS. Separate control switches will be
envisaged for light points and fan points.
-
Near every chute in Junction houses and other technological
buildings sufficient no. of 24V, 5A sockets will be provided for
maintenance lighting by hand lamp.
Cable Routes, Cables
Contractor will note the following requirements.
Sl.
Requirement
No.
1. EMPLOYERs’s
HT
Substations
to
Contractor’s LTSSs
2. Inter
shop
cable
routing
Remarks
Walkable Cable Bridge
Through walkable overhead cable
bridge/ structure/Cable Tunnel/ Conveyor
gallery. No underground buried cable will
be provided. Concrete cable trench
covered with pre cast slab is accepted
only in covered shed or indoor area.
3. Bottom most level of Above ground level
cable trench in MCC
room
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04.10.10.
Control and Operational Requirement:
1. All the necessary controls, interlocks and annunciation as required
for smooth, efficient and safe operation of the plant will be provided.
2. Contractor will provide suitable PLC based automation system
including all hardwares and softwares to run the existing and new
material handling plant in an integrated manner.
a) PLC based Automation system of proposed Coal Handling Plant
Pkg-064, will be interfaced with Automation system of Coal
Transportation Plant being arranged by the EMPLOYER through a
separate package (Pkg-062) (as indicated in Automation
Configuration Drawing enclosed) so that coal transportation from
silos to coal tower can be operated in an integrated way from a
common despatcher / control room. The PLC based Level-1
automation system of CHP will be provided as mentioned in the
automation chapter.
b) PLC based Level-1 automation system will be provided as
mentioned in the automation chapter for running the new Coke
Sorting Plant from a new control room/ despatcher which is to be
provided by the Contractor.
c)
PLC based Level-1 automation system will be provided as
mentioned in the automation chapter for running the Flux - Fuel
Preparation and Plant Return Fines Handling for SP III from a
existing Control room CR-1 as indicated in the automation
configuration diagram.
3. All HT drives will be provided with extensive monitoring facilities for
fault detection and alarm annunciation. Alarm annunciation will be
provided for over winding temperature, over bearing temperature,
overload etc.
4. Alarm annunciation system will cover all the equipment of the
electrical system.
5. Mode of control :
i)
Plant will have four modes of control.

Local de-interlock mode for control of individual drive motor
from local push button station (LCS).

Local interlock mode for running the drive motor in sequence
interlock mode from LCS.

REMOTE interlocked individual drive control from the HMI at
Dispatcher/ Control room.
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
REMOTE interlocked route wise control of conveying system
from the HMI at Dispatcher/ Control room.
ii)
Mechanism selector switch for selection of above modes of operation
of each drive motor will be provided in the MCC / Control Panel /
MCP. A selector switch box will be provided near respective Remote
I/O station for HT motors. Local selection of any drive will be shown
on the HMI screen with some sort of caution.
iii)
The local de-interlock mode is meant for testing and maintenance
purpose only. However, all safety interlocks (Pull Chord Switches,
motor Over Load & emergency stop etc.) will be connected in LOCAL
de-interlock mode of operation. In local de-interlock mode the
mechanism is not interlocked with other drive and after receive of
permission from operator / PLC drive/equipment can be started from
LCS independently.
The stop P.B. of local control station will be able to stop the drive
mechanism selected for any mode of control. Hooter PB will be
provided in LCS for pre start warning.
iv)
In Local interlock mode the drive / equipment can be run in sequence
interlock from LCS. Selector switch will be put in local interlocked
position and permission from operator / PLC will be a condition for
operation in this mode. Start, stop, motor Over Load, emergency
stop, Pull Chord and Belt Sway Switches, Zero Speed Switch, chute
jamming switches will be connected in the circuit in addition to
sequence interlock with successive drives. All the above will be
connected through hardwire.
v)
In Remote interlocked individual mode of control the drives/
mechanisms in the material flow path will be started in succession
sequentially opposite to direction of material movement from
operating station / HMI. On tripping of any conveyor/drive/
mechanism, all the mechanisms feeding to the affected (tripped)
mechanisms will stop according to material flow diagram. All the
mechanism selector switches of the selected material flow path will
be set to REMOTE position in this case. Programmable Logic
controller will be used for the control, interlocking, operation, and
monitoring of the equipment.
vi)
In Remote interlocked Route-wise control, following operations is to
be carried out from HMI by the operator before starting of a
conveying route:
a) Selection of material flow path including source and destination
as per requirement.
b) Selection of mechanisms within the selected material flow path.
c) Selection of switching devices, flap gate etc. in a conveying route
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d) Selection of control mode in REMOTE of master selector switch
for each material flow path block chain.
On receiving start permissive signal from HMI, the operator will give
ON command to start the desired conveying route.
vii) Normal stop and Emergency stop of mechanism for each material
flow path, P.B, switches for pre-start warning signal for each material
flow path, start & stop P.B. switches of drives with independent
operation etc. will also be mounted on desk/ HMI.
viii) A pre-start audio warning signal through hooters will be given in the
premises where the mechanisms are to be started before start of the
mechanism. The duration of the pre-start audio signal will be as per
requirement. Sequential start of the mechanism will be possible only
after the pre-start audio signal is over.
ix) The conveying system will be integrated with the associated auxiliary
/ other system for interlocking, sequencing and monitoring.
x) Stopping of mechanisms:
a) For regular stop, the feeding equipment will be stopped first to
stop the material flow in the conveying path and then after some
time delay the equipment in the route will be stopped in sequence
from feeding end ensuring no material is in the conveying path.
b) Emergency stop push button will be provided on the Control desk
for emergency stop of material flow path.
c) In case of tripping due to fault of any drive, the part of the
conveying route before the faulty drive will stop. There will have
signaling of the stopped mechanisms by changing color in the
graphic. This will give an indication of the fault.
6. Signaling:
A) Status of ON, OFF, Trip/Fault, Route selection etc. for all
mechanisms of conveying system, dedusting system, dust
suppression system, weigh feeder etc. will be available in the
operator work station.
B) When a drive in a conveying route is shifted to local controls,
indication will be available in the HMI.
C) The annunciation will be provided on HMI for each drive fault and
actuation of safety and limit switches.
a) Annunciation for O/L & fault of each drive motor.
b) Individual annunciation for all HT motors trip due to high
CHAP-04.10 ELECTRICAL POWER DISTRIBUTION, DRIVES, CONTROL &
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bearings and winding temperature.
c) Combined fault HT switch gear for Each HT motor including
power supply to MPR failure separately.
e) Switching devices, flaps etc failed to close or open.
f) Individual annunciation for HT motors bearings and winding
temperature high alarm.
g) Individual annunciation for following conditions of electrical
system:
- 11KV and 6.6 kV switchgear trouble
- 415 switchgear trouble
- Transformer trouble alarm.
- Combined fault/trouble in bag filter system of D.E
- Unhealthiness of various machines
- Any other failures
h) Every unplanned stoppage or abnormal condition will be
brought to the notice of operator.
7. Current readings of all HT and LT motors connected to Intelligent
MCC will be available in HMI at Dispatcher. Current monitoring for
drives of rating above 30KW.
8. Drainage/sump/slurry pump will be provided with Auto/Local mode of
operation. Under automatic mode of operation any one of the pump
motors will start automatically at set level and if the level rises further
the second/ reserve pump will start automatically at second set level
and both the pumps will stop at set low level. If the first pump trips,
second pump will start automatically. Emergency high level
annunciation will be available in the control room.
Under local mode of operation, the pump motors will start/stop locally
through local control boxes depending on level.
9 For fire fighting system, suitable control system will be provided for
main fire water pump, jockey pump, hydro pneumatic tank etc. with
line pressure switch.
04.10.11.
ELECTRICS AND AUTOMATION FOR EXISTING DRIVES
Scope of work for Electrics and Automation for up gradation,
modification and integration of existing conveyors to be upgraded as per
technological requirements and will consist of Complete new MCC, PLC,
field switches, LCS, Power and control cables and New Brake panel and
associated cables.
Gallery lighting of existing conveyors under up-gradation will be in the
scope of Contractor. Dismantling of the existing light fittings, cables etc.
will also be under the scope of the Contractor.
Contractor will provide new PLC based automation system for new and
CHAP-04.10 ELECTRICAL POWER DISTRIBUTION, DRIVES, CONTROL &
ILLUMINATION.doc ELECTRICAL
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existing drives (to be upgraded as per technological requirements) for
integrated operation of the overall CHP, CSP, and FFP with respective
existing/new units as shown in configuration diagram and elsewhere.
The approval / clearance of BSP / their representative will be taken
before carrying out new installation for up gradation for existing
conveyors / equipment.
For the EMPLOYER’s approval / clearance, Contractor will submit
detailed shut down plan of the existing drives indicating temporary
arrangement to be made by the Contractor for running suitable
alternative conveying routes so that plant can maintain production level.
In the temporary arrangement in case any electrics is required, the same
will be provided by the Contractor without any price implication.
Scope of work:
04.10.12.

Except MCC, Contractor will dismantle existing motor, LCS, safety
and limit switches, associated power and control cables, Jn. Boxes,
earth wire, GI strip etc. related to the particular drives. The same will
be removed from site to facilitate new installation as per requirement
of TS and GTS and for running the equipment.

Contractor will provide complete new electrics including motor,
suitable intelligent type motor feeder in MCCs/MCPs, brake panels,
all safety and limit switches, local control station (LCS), Junction
boxes, necessary hardware and software for PLC based automation
(including power supply, input, output and communication cards etc.)
all power, control and signal cables, earthing.
ELECTRICS AND AUTOMATION FOR ADDITIONAL FLUX AND FUEL
CRUSHING AND FINES HANDLING SYSTEM
All the equipments for this facility will be new.
04.10.13.
04.10.13.01.
TECHNICAL SPECIFICATION
General
GTS will be referred for technical specification of various electrical
equipment. However for specific application following TS will be
considered.
04.10.13.02.
Non intelligent type Control Panel
01. Control panel for Tripper car, crane, hoist and small machine will
have conventional non draw-out type and mounted on anti vibration
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ILLUMINATION.doc ELECTRICAL
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pad. Weatherproof enclosures will be used for outdoor control
panels.
02.
Constructional Features
 Non-Draw out type.
 All other features will be similar to Intelligent type indicated in
GTS
03
Incoming Feeder
The incoming feeder will have:
 MCCB
 Ammeter and voltmeter with selector switch.
 3 nos. current transformers
 3 nos. indicating LED type lamps (R, Y, B)
 3 nos. indicating LED type lamps (ON, OFF, TRIP)
04
Outgoing Feeders
Each outgoing motor feeder will have following:
 MCCB (above 45 kW motor) / Motor Protection Circuit Breaker
(up to 45 kW motor)
 Three pole contactor
 Ammeter with CT & Selector switch.
 Stop & Test Push Buttons
 ON/ OFF/ Trip indication LEDs
 Digital microprocessor based overload relay with SPP & manual
reset facility
 Motor Protection Relays for motors above 90 kW rating.
Each outgoing non motor feeders will have following:
 MCCB.
 ON/OFF indication LEDs.
05
All motors will be operable from Control desk, pendant or LCS.
Only the facilities for testing the control circuit by-passing the power
circuit will be provided.
06
Two number of DC power pack feeders complete in all respects
with change over scheme will be provided for DC power supply to
solenoid valves etc as required.
07. Ammeters for essential drive motors will be provided.
08. Major components will conform to General Technical Specification
(GTS).
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ILLUMINATION.doc ELECTRICAL
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04.10.13.03.
Motorized Damper, Switching Device, Slide Valve, Diverter Gate,
Flap Gate Etc.
01
The motor will be 3 phase squirrel cage TEFC class F insulated
(temperature rise limited to 70 deg. C. over an ambient of 50 deg. C), IP55 enclosure both for motor switches & its terminal box, and with high
starting torque and high stalling torque. The duty cycle will be S2-10 min
or S4/ S5-1200 cycles per hour or S4/ S5-600 cycles per hour depending
upon the rating and application of the actuator.
02
Each actuator will be provided with 'Open' and 'Close' torque and position
limit switches. Once the torque switch has tripped in either direction, it
can only be reset by operation of the actuator in the opposite direction.
Each switch will have 2 NO + 2 NC potential free double break contacts.
Switch contact ratings on inductive circuits will be 5A AC at 230 V AC.
Actuator will be provided with motor over-riding feature like hand wheel
for emergency manual operation and a limit switch will be provided which
contacts will be used in the motor control circuit to forbid the motorised
operation during manual operation by hand wheel. Also when the motor is
switched 'ON' the hand wheel connection will be disengaged
automatically. Motor operation will always have priority over manual
operation.
Internal wiring will be tropical grade PVC insulated, stranded copper
conductor cable of 10A rating for control circuits and required ratings for
motor. All wires will be clearly numbered at both the terminal block and
component ends. Cable ferrules will be robust and numbers will be
indelible in nature.
The voltage grade of cables/ wires will be 1100V. Power terminals will be
separated from the control terminals by means of an insulating cover.
Separate terminal block fitted to switching unit will be provided. The
terminal box will be designed for the protection class or IP-65. A durable
terminal identification card showing plan or terminals will be provided
attached to the inside of the terminal box cover indicating serial number,
external voltage values, wiring diagram number and terminal layout.
The actuator will be suitable for operation at specified ambient
temperature. All actuators will be neoprene O-ring sealed water tight and
dust proof to IP-67 protection and will at the same time have an inner
watertight neoprene O-ring seal between the terminal box and the internal
electrical elements of the actuator, fully protecting the switch mechanism,
motor and all other internal electrical elements of the actuator from
ingress of moisture and dust when the terminal box cover is removed on
site for cabling/ maintenance.
The actuators will be operated from the Remote Control Station and Local
control station (LCS) will be provided separately for local operation of the
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actuator for testing and maintenance purpose. Isolator along with starter
for the actuator motor will be located in the Contractor's MCC. Separate
power cable will be used for motor wiring.
04.10.13.04.
Belt Weigh Feeders
General Technical Specification (GTS) will be referred for detailed
specification of Belt Weigh Feeders.
04.10.13.05.
Belt Weigh Scales
General Technical Specification (GTS) will be referred for detailed
specification of Belt Weigh Scale.
04.10.13.06.
Suspended Electromagnet/ ILMS
The magnet will be of high permeability cast steel as per IS : 4491 with
an integral terminal box of adequate size. Leads will be brought to the
terminal box through a water tight sealed gland. An earthing terminal will
be provided inside the terminal box. The coil of the magnet will be
designed for continuous duty for full supply voltage. The magnet will be
fed from 220V DC obtained through rectifier panels.
The magnet coil will be Fiber glass wound copper wire and class H
insulation will be used.
Control panel will be free standing, floor mounted, front attended, made
of CRCA sheet steel of thickness not less than 2mm with IP54 enclosure
class. In-comer feeder will have load break switch interlocked with the
door.
Panel will have air cooled control transformer, full wave, silicon diode
rectifier bridge having 220V DC output and complete with RC circuit
across each diode, PIV of diode will not be less than 1560V.
Complete safety and protection equipment against surge voltages,
discharge resistance in DC load side will be provided. Electronic
temperature sensing circuits for protection against excessive
temperature in the magnet coil will also be provided.
For In Line Magnetic Separator necessary electrics will be included.
04.10.13.07.
Dust Suppression System
Control Panel for DS system will have necessary starter for Pump
motors and 24V DC power supply arrangement for Solenoid valves.
Valves will be energised either by Local Push button station or by under
CHAP-04.10 ELECTRICAL POWER DISTRIBUTION, DRIVES, CONTROL &
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belt switch depend upon selection of control mode. Necessary electrics
will be provided for desired operation of pumps, compressors, valves etc.
for DS system. DS system will be interlocked with corresponding
conveyors / technological equipment. DS system will have local manual
and remote auto mode control. Compressor may be connected to
nearest MCC considering location of Compressor house.
Control panel for outdoor application will have weatherproof enclosure.
04.10.13.08.
DUST EXTRACTION SYSTEM
The Dust Extraction System will be started first and will be suitably
interlocked with corresponding conveyors / technological equipment.
The equipment of D.E. system will be operated in sequence as per
requirement in the REMOTE mode from the HMI. Power supply to bag
filter panel will be interlocked with the DE fan. Bypass arrangement will
be provided such that technological equipment may be operated without
operation of DE system in case need arises.
Electrics for Bag Filter System of DE System.
The bag filters of D.E. system will consist of pressure switches cum
indicator in the compressed air line, differential pressure switches,
solenoid valves, control panel and all other associated equipment. The
brief specification of the major components will be as given below:
01
Control panel for Bag filter
The control panel will be free standing floor mounting fabricated from 2.5
mm thick CRCA sheet steel on a base channel or 250 mm height
provided with cable gland plates, having synthetic rubber gasketting
provided with double door & canopy and enclosure conforming to IP-55.
The control panel will be factory assembled, wired with 1.1 kV grade
PVC flexible wire of copper conductor (minimum size 2.5 sq.mm),
factory painted. The control panel will be provided with following major
equipment :
a)
Incoming switch (minimum 30A, AC23 duty) with operating handle
inter-locked with the door, HRC fuses, contactors, MPCBs in the
various circuits.
b)
Control transformer or required VA rating having +/-5 percent and
+/- 2.5 percent tapings in the primary side of the control
transformer with Isolating switches/ MCBs in the primary &
secondary sides.
c)
24V DC power pack complete with fitter and protective elements
and also isolation cum short circuit protection both at AC and DC
CHAP-04.10 ELECTRICAL POWER DISTRIBUTION, DRIVES, CONTROL &
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sides for power supply to solenoid valves.
d)
Auxiliary contactor for control
interlocking, and controls etc.
e)
Auto-manual selector switches, push button switches, indication
lamps, various monitoring devices, terminals (with 20 percent
spare terminals) and other circuit elements required for control
and monitoring
Solid State Bag filter timers.
f)
power
supply
monitoring
02
The bag filter timer will be solid state device suitable for dusty,
tropical and specified aggressive environment. The bag filter- timer
will be provided with internal semi-conductor fuse protection and will
have provision for pulse frequency setting and pulse duration setting
through independent operating knobs. The number of contacts in the
timer will be equal to number of solenoid operated valves so that the
timer will energise only one solenoid valve at a time.
03
The Bag Filter Timer will provide timed sequential energisation of
24V DC operated solenoid valves of bag filters LEDs for each
solenoid energisation. Power ON in PCB feed back relay will be
provided with potential free contacts which will close under following
conditions:
i) Fault in the PCB.
ii) Open contact in the output side connected to individual solenoid
valves. The contact will not close in the event of power failure to
the controller.
iii) The sequential control (i.e. process) will start when the Differential
Pressure (DP) switch is actuated at the first set point for normal
operation. The process will continue till the pressure differential
drops below the set value. When again the DP switch is actuated
the process will continue from the previous position (i.e. next
solenoid valve). However, when the power supply to sequential
controller trips, the process will stop and sequential controller is
reset to first load position enabling the process to start from the
beginning.
iv) Sufficient space will be provided for installation of bag filter panel
with required front clearances for operation and maintenance
including side and back clearances as required.
04
Differential Pressure Switch
i) The differential pressure switch will have two sets of independent
micro switches. The first set will be used for normal sequential
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cleaning operation of the bag filters as per lower set value of
differential pressure. This set point will be independently
adjustable.
ii) The second set of N.O. contact will close at upper set value of
differential pressure representing clogging condition of bag filter
and will be used for signaling and monitoring. This set point will
also be independently adjustable. The contacts will be rated for 5
Amp, 240V AC.
iii) The DP switch will be suitable for outdoor installation. The DP
switch casing will be made of pressure die cast Aluminium with
enclosure conforming to IP-65.
iv) One number differential pressure switch with two set points will be
provided for each module of the Bag filter. Alternatively, two
numbers of DP switches may be provided for each module one
for initiation of bag cleaning operation and other for signaling and
monitoring of clogging condition.
05
Solenoids
The solenoid coil will have encapsulated coil (class 'F' insulated with a
water proof (IP-65) plug-on connector. The coil will be suitable for 24V
DC. The coil will be made of copper conductor.
06
Air Pressure Switch cum indicator
One number compressed air pressure switch cum indicator will be
provided for each DE system in the incoming compressed air pipe line of
the bag filter. The pressure range will match with the operating pressure.
The switches will be snap action type with 1 NO + 1 NC contacts of SA,
230 V AC. These contacts will be wired up to terminals in the bag filter
control panel. The enclosure of the air pressure switch will be pressure
die cast aluminium conforming to IP-55.
04.10.13.09.
Type of Light Fittings and Illumination Levels
Illumination level and light fittings will be provided for different units as
indicated below :
SL.
NO.
UNITS
ILLUMINATION
LEVEL (LUX)
TYPE OF LIGHT
FITTINGS
1.
Electrical
substations,
Rooms etc.
rooms,
MCC
200
Trough
type,
2x40W,
fluorescent
tube
light
fittings with reflectors.
2
Junction Houses and
Conveyor Galleries /
100
70W/150W, HPSV, well
glass fittings and 250W
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SL.
NO.
UNITS
ILLUMINATION
LEVEL (LUX)
tunnels
TYPE OF LIGHT
FITTINGS
High bay as required.
3
Crusher house, other
process
and
Technological Building
150
70W/150W, HPSV, well
glass fittings and 250W
High bay fitting as required
4.
Office rooms
300
Trough
type/Decorative
recessed type, 2x40W,
fluorescent
tube
light
fittings.
5.
Corridors,
staircase
walkways,
100
Trough
type,
2x40W
fluorescent
tube
light
fittings with reflectors.
6.
Control
room,
laboratories,
instrumentation rooms.
300
Decorative type, 2x40W
fluorescent
tube
light
fittings with mirror optics.
7.
Battery room
100
Corrosion/Vapour
proof,
2x40W fluorescent tube
light fittings.
8.
Battery Charger/ UPS
room
200
Decorative type, 2x40W
fluorescent
tube
light
fittings with mirror optics.
9.
Periphery of buildings
and cooling towers
50
70W, well glass fittings
with HPSV lamps.
10.
Pump Houses
200
70W/150W, well glass
fittings with HPSV lamps.
11.
Area lighting through
flood light towers
20
400W, flood light fittings
with HPSV lamps.
12.
Area and road lighting
20
250/400W,
flood
light
fittings with HPSV lamps
and 250W, street light
fittings with HPSV lamps.
Number of light fittings will be decided on the basis of specified lux level,
maintenance factor 0.6 and appropriate co-efficient of utilization as per
manufacturer's recommendation.
04.10.14.
DRAWINGS AND DOCUMENTS
Contractor’s scope of work for all design drawings and documents will
be as given below.
The Contractor will submit a list of all drawings and documents he
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ILLUMINATION.doc ELECTRICAL
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proposes to submit within 2 weeks of LOI. The list will be approved by
Client / MECON and may be modified if necessary. Each
drawing/documents in the list will be identified with a serial number,
description and scheduled date of submission. All the drawings will have
complete forward & backward reference.
Contractor will also furnish soft copies of all the drawings indicated
below and drawings of technological layout/units.
All design, engineering and manufacturing drawings will be required to
be approved by EMPLOYER/Consultant.
Work will be carried out exactly as indicated on the approved drawings
and specification. No alterations will be made without prior written
approval by EMPLOYER / his consultant.
The Contractor will check all the drawings prepared by them and/or
received from their vendors/supplier/sub-supplier and satisfy themselves
about
the
correctness
of
drawings
before
issuing
to
EMPLOYER/Consultant. After checking, properly stamped drawings will
be sent to EMPLOYER/Consultant for approval / clearance.
Comments on all drawings will be forwarded to the Contractor for
incorporation and resubmission.
The approval of drawings by EMPLOYER or their authorised
representative does not absolve or relieve the supplier from any of his
obligations under this contract and he will be wholly and solely
responsible for the satisfactory operation and guaranteed performance
of equipment / system / plant.
A. Basic Engineering drawings (To be Submitted For Approval )
1.
List of drawings (Basic Engg /Detailed Engg/ Reference) and
drawing numbering system along with schedule of submission.
2.
Single line diagrams of HT/LT switchgear equipment, PCCs, MCCs
/Control Panels, PDBs, MLDBs, LDBs, SLDBs, Main fire detection
and alarm panel etc. with rating of components, cable sizes and
details of protection and metering etc.
3.
HT & LT Motor and component list including field mounted electrics
4.
HT and LT Motor data sheets as per enclosed format.
5.
Type-II Co-ordination chart as per IS: 13947-1993 for MPCB/
MCCB, Contactor and Overload relay.
6.
Schematic drawing of different feeders, control, alarm, indications,
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ILLUMINATION.doc ELECTRICAL
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interlocking and other schematics.
7.
Shop/Unit wise Maximum Demand calculations
8.
Relay settings with calculations for total network to ensure proper
co-ordination.
9.
Busbars sizing calculation with respect to temperature rise & short
circuit withstand capacity.
10. Design Calculations for selection of main equipment such as
transformers drive motors, AC drives, bus bars, cables, batteries
etc.
11. Typical schemes of DOL, RDOL feeders indicating inputs & outputs
applicable to the various feeders indicated in SLDs.
12. Power and regulation schemes of AC drives.
13. Calculation for temperature rise of busbars.
14. Layout of substations, electrical rooms and control rooms including
ventilation and air-conditioning rooms, handling facilities. The layout
drawings indicating cable trench, wall openings, conduit inserts,
plate inserts, Minimum clearances from electrical panels for
installation of panels, cable trays, conduits for concealed wiring etc.
15. Electrical Equipment Layout of all electrical rooms, control rooms
indicating panel dimensions, space available for future expansion
with building dimensions.
16. General arrangement of equipment with plan, front view and
sectional views, comprehensive bill of materials with description,
quantity, make and type.
17. Cable layout drawings in cable tunnel, cable channels, overhead
cable structures/bridge and incoming cable route etc.
18. Interplant cable route drawings.
19. Type tests certificates of all major equipment like transformers,
switchgear etc.
20. Level-1 automation system configuration & I/O lists, Belt Scale, Belt
Weigh feeder, UPS & VVVF single line diagrams.
21. Functional description, control philosophy for the plant indicating
start up, shut down, control locations, interlocking and annunciation
system, mimic pages, report/data formats (for reference).
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22. Scheme for Illumination system & emergency lighting system
indicating sizes, ratings & locations of various LDBs & SLDBs.
23. Tentative Dimensions of panels.
24. Earthing and lightning protection scheme and layout of earthing and
lightning protection network with calculations.
25. Basic interconnection scheme for FDA, Telecommunication & PA
system.
26. Quality assurance plan for various electrical equipment.
B. Detailed engineering drawings. (To be Submitted For Approval )
1. Civil/Structural engineering design drawings of Electrical buildings,
Electrical rooms, Control rooms, Motor foundations, Cable tunnels,
Overhead cable structures/Bridge etc.
2. General arrangement of all electrical equipment/electronic
panels/controllers with plan, front view and sectional views,
comprehensive bill of material with description, quantity, make and
type.
3.
Equipment and cable layout drawings in LT Substation, Electrical
premises, Control rooms etc.
4. Schematic drawing of different feeders, control, alarm, indications,
interlocking, inputs/outputs to PLC and other schematics.
5. Single line diagrams of all ACDBs, PCCs, MCCs/ Control Panels,
PDBs, MLDBs, LDBs, SLDBs, UPS, other equipment Control panel
for sump pump, magnet and other auxiliary system etc. Module
wiring diagrams indicating all interlocks, terminal numbers. Wiring
terminal plan drawings with cable connections.
6. Single line diagram of VVVF Drives, Soft Starter etc.
7. GA, BOQ, Layout drawings, dimensional details for LT switchgear
equipment, MCCs/Control Panel, PDBs, MLDB, LDBs, SLDBs,
Main fire detection and alarm panel etc. with rating of components,
cable sizes and details of protection and metering etc.
8. Level-1 automation system software and graphic displays.
9. I/O listing in specified format to be finalised during engineering.
10. Sizing calculation of the UPS and the backup battery. UPS panel
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ILLUMINATION.doc ELECTRICAL
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wiring diagram and circuit diagrams.
11. Wiring terminal plan drawings with cable connections.
12. Technical data sheets for Motor, Brake, Proximity switches & all
field mounted electrics, GA drawings.
13. Interplant cable route drawings.
14. Layout of cable trays in cable cellars inside the substation & other
electrical premises, cable channels, cable tunnel, overhead cable
structures, cable shafts etc.
15. Cable layout drawings in cable tunnel, cable channels, overhead
cable structure (as applicable), and incoming cable route etc.
16. Power & control cable schedules
17. GA drawing for erection accessories like cable trays, supporting
structures etc.
18. Installation drawings of all equipment with layout of equipment,
cables.
19. Illumination layout of all the indoor & outdoor premises. Layouts at
each floor of Electrical/Technological building with details and
numbers & locations of light fittings, Lighting distribution boards etc.
SLDs of Lighting distribution board.
20. Detail scheme of FDA system, List of annunciation/alarm points
(location wise) & wiring scheme
21. Earthing and lightning protection scheme and layout of earthing and
lightning protection network with calculations including special
electronics earthing.
22. Relay settings with calculations for total network to ensure proper
co-ordination.
23. Communication cable (Field bus) routing and procedure for laying
of communication cable.
24. QAP for all items covered in this specification
C. For Reference/Erection purposes
1.
Schedule of electrics, and their location.
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2.
HT/LT feeder requirement with individual maximum demand.
3.
Control circuit diagrams. The control circuit diagram should be
available on / inside of respective panel / LCS.
4.
Static and dynamic loading of all major equipment
5.
External connection diagram (panel wise and scheme wise).
6.
Composite drawings showing circuitry of switch-gear remote
panels, and other items pertaining to complete circuit for its
proper functioning.
7.
Power & regulation schemes for AC drive, UPS, soft starter
including FCMA type.
8.
Motors & field devices.
9.
Speed-torque, current vs. time, thermal withstands characteristics
for motors.
10. List of interfaces between
EMPLOYER’s equipment.
Contractor’s
equipment
and
11. Cable termination plans with terminal block arrangement and
markings.
12. Interconnection diagrams.
13. Internal wiring diagrams of equipment.
14. Fire detection systems: layout & cable list.
15. Motor and electric consumer list.
16. Consolidated Bill of materials and volume of work for erection.
17. Procedure for testing and commissioning of the entire plant,
electrical & automation equipment. This will also be furnished in
soft copy.
18. Erection specification with bill of materials of erection materials,
earthing materials, junction box, GI conduits etc. This will also be
furnished in soft copy.
19. Spare part list and drawings.
20. Instruction for storage /erection, testing & commissioning.
21. Operation and maintenance manual.
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22. Detailed technical literature / catalogue of manufacturers.
23. Graphic display sheets, report/data generation, fault listing etc.
24. Terminal plan drawings
25. System grounding/ earthing scheme
26. Application
software
documentation.
program
listings
with
detailed
27. Ladder Logic diagram /Statement Lists and software details.
28. Formats and work sheets for generation and display of overview,
groups, loops, graphics, alarms, operator’s guide messages, real
time and historical trends Log and shift formats.
29. List of drawings & spare parts.
30. Final test & calibration certificates and guarantee certificate /
warrantee certificate.
31. As built Control description with Operational instruction use of
various commands, instruction for control of plant and equipment
from Operator workstation.
32. Drawings/documents for inspection of equipment:
a)
b)
c)
d)
e)
f)
Type test certificate for identical equipment.
Sub-supplier’s/vendor’s catalogue/technical literature.
Test reports for internal inspection.
Test certificate of components.
Technical specification & data sheets of equipment.
All “Approved” drgs./ “Commented” drgs as applicable.
33. Automation systems.
a)
b)
c)
d)
e)
f)
g)
Software including media and documentation.
Description of all components of the user system with
functional description, overview flow diagram, interface
listing, mathematical models, and fault message lists,
operator commands, simulation facilities, etc.
Source code of the user system.
Object code of the user system.
I/O listing
Ladder/block diagrams, etc.
Factory Acceptance Tests & procedures for PLC/DCS
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34. Other Drawings/documents :
a)
b)
c)
d)
e)
f)
g)
Operation & maintenance manual.
Catalogues and manuals.
All ”As-built” drawings.
Soft copies of all drawings.
Technical specification/data sheet of equipment.
Instructions for storage/erection/testing/commissioning
Commissioning report.
The Contractor will submit all the drawings in Si-graph or equivalent
format along with the multi user system software.
D. As built drawings
Upon installation and commissioning supplier will incorporate revisions/
modifications if any in the reproducible and submit 'as built' drawings for
EMPLOYER's record as per general condition of contract.
Complete and comprehensive instruction manuals for operation and
maintenance of the equipment with drawings. This will include the
following:
1.
Log sheets indicating daily/hourly recordings of power system
parameters to be noted down by customers operating personnel.
The parameters will indicate loading of various electrical equipment
quality of power supply, energy consumption of various units,
energy consumption and maximum demand of the plant.
2.
Preventive maintenance schedule for equipment.
3.
Procedure for shut down and energisation.
4.
Safety procedures for safe operation of equipment and complete
system.
5.
Specification of equipment installed.
6.
Test procedure for site tests.
7.
All as built drawings.
8.
Spares list for each equipment for 2 year operation and
maintenance.
9.
At least two sets of clearly legible site corrected drawings will be
submitted after commissioning
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04.10.15.
10. As built drawings will be first Copy / Clear photo copy and will be
properly arranged in suitable folders. The folders will have a list of
all the drawings it contains on the front inside cover. Different
folders will be used for different major categories like 11 kV
switchgears, MCC / PDB, Drives etc.
FORMAT FOR MOTOR DATA SHEET
1.
PROJECT
:
2.
MAKE
:
3.
DRIVEN EQUIPMENT
:
4.
MOTOR TAG NO.
:
5.
QUANTITY
:
6.
VOLTAGE WITH VARIATION
:
7.
NO. OF PHASES/CONNECTION/
:
NO OF TERMINALS
8.
FREQUENCY WITH VARIATION :
9.
FAULT LEVEL (MVA) & DURATION
:
10.
MOTOR TYPE AND DUTY
:
11.
kW RATING/POLE
:

AT 40 DEG. C.

AT SPECIFIED AMBIENT TEMP. :

WITH DERATING.

BHP/BKW OF DRIVEN EQPT.
:
:
AT RATED LOAD
12.
FRAME SIZE/MOUNTING
:
13.
INSULATION CLASS WITH TEMP RISE:
14.
ENCLOSURE TYPE
:
15.
FULL LOAD SPEED
:
16.
FULL LOAD TORQUE (FLT)
:
17.
STARTING TORQUE AS % OF FLT
:
18.
PULLOUT TORQUE AS % OF FLT
:
19.
FULL LOAD CURRENT (FLC)
20.
STARTING CURRENT AS % OF FLC
21.
STARTING TIME ON RATED LOAD AT :
:
:
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22.

RATED VOLTAGE
:

85 % OF RATED VOLTAGE
:
LOCKED ROTOR WITHSTAND TIME

COLD
:

HOT
:
23.
ROTATION VIEWED FROM DRIVING END
24.
GD SQUARE OF MOTOR
25.
GD SQUARE OF DRIVEN EQUIPMENT :
26.
WEIGHT OF MOTOR
27.
POWER FACTOR AT
28.
:
:

50 % LOAD
:

75 % LOAD
:

100 % LOAD
:
EFFICIENCY AT

50 % LOAD
:

75 % LOAD
:

100 % LOAD
:
29.
SPACE HEATER WATTS/VOLTS
:
30.
TERMINAL BOX TYPE &
:
NO. OF TERMINALS
31.
NO. OF STARTS PER HOUR
:
32.
NOISE LEVEL AT A DISTANCE OF 1M :
FROM THE MOTOR
33.
THERMAL WITHSTAND TIME
:
34.
COOLING
:
35.
APPLICABLE STANDARD
:
36.
LOCATION
:
37.
HAZARDOUS AREA CLASSIFICATION :
38.
BEARING DETAILS

TYPE OF DE/NDE
:

SIZE OF DE/NDE
:

MAKE
:
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39.
LOCATION OF TERMINAL BOX
:
POSITION FROM DE SIDE
40.
LUBRICATION TYPE
:
41
CABLE SIZE
:
42.
PAINT SHADE
:
43.
G.A., DIMENSIONS & MOUNTING
: YES/NO
DETAIL DRAWINGS ENCLOSED
44.
DETAILS DRAWINGS FOR T.B.
: YES/NO
45.
PERFORMANCE CHARACTERISTICS : YES/NO
CURVES VIZ. SPEED V/S CURRENT &
SPEED V/S TORQUE ENCLOSED
TOOLS & TACKLES (ANNEXURE-E01)
Sl,
No.
Item
Quantity
(Nos.)
1.
True RMS Digital Multimeter (hand held)
8
2.
Digital tong tester (hand held)
8
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3.
Testing Jig for PLC (OEM supplied)
3
4.
Low range ohm meter
4
5.
Megger (0– 500V)
8
6.
Megger (0-1000V)
5
7.
Megger ( 0-2500V)
6
8.
Earth Meggar
4
9.
Milli ohm meter
2
10.
Combination pliers
4
11.
Nose pliers
6
12.
Hand drills (pistol)
8
13.
Allen key
6 Sets.
14.
Ratcher Spanner Set
6 Sets
15.
Ring Spanners of different sizes
7 Sets
16.
DE Spanners of different sizes
8 Sets
17.
Vibration monitor (hand held)
6
18.
Soldering / de-soldering station
3
19.
Testing table / bench for installation of testing / repair
1
equipment complete with single phase / three phase
power supply points and separate electronic earthing
20.
Blower cum vacuum cleaner (portable)
5
21.
Tool kit (screw driver set, spanner set etc.)
22.
Component storage steel rack (pigeon hole)
3
23.
Steel Almirah for storage of test equipment
10
24.
Bench vice
6
25.
Power saw suitable for bakelite / hilem board cutting
1
26.
Cable Preparation & Termination Toolkit (for special
cables), including Crimping Tool
27.
HT Line Tester
28.
Steel chairs
12
29.
Steel tables
4
30.
Radio communication Equipment testing Jig
1 Set
31.
F.O Cable Testing Kit including OTDR
1 Set
32.
Field bus Analyzer
1 Set
33.
Radio communication Analyzer
1 Set
34.
Tools for backup & storage
 DVD-RW
8 sets
1 set
5 Nos.
50 Nos
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



Thumb drives
Backup Tape for Servers
Cleaning Tape
Disk Imaging S/W for Server &clients
10 Nos
20 Nos
2 Nos
1 Set
35.
Ethernet Analyzer
1 Set
36.
Portable Oscilloscope
1 Set
37.
Hydraulic fan puller
1 Set
38.
Box Spanner Set
1 Set
39.
Hydraulic Coupling Puller
1 Set
40.
Hydraulic Bearing Puller
1 Set
41.
Cable Fault Locator Machine
1 Set
42.
Motorized torque range
1 Set
43.
PCB Cutter
1 Set
44.
Motor Checker
1 Set
45.
Current Recording meter
1 Set
46.
1.5 mm/ 2.5 sq.mm Crimping Tool
1 Set
47.
AC/DC Digital tongue testor
1 Set
48.
Welding Transformer
1
49.
Power Hack Saw
2
50.
Grinding machines
2
ANNEXURE – E-02
SCHEDULE OF MINIMUM COMMISSIONING SPARES FOR ELECTRICAL
EQUIPMENT FOR PKG.-064
The Contractor will supply following minimum commissioning spares along with the
main equipment. However, during testing and commissioning of the plant, in case of
requirement of any additional commissioning spares, same will be supplied by
Contractor without any extra cost to the Employer. The Contractor will hand-over /
deliver these spares directly at the Employer's stores. During testing and
commissioning in case of requirement of any commissioning spares, same will be
brought by the Contractor from Employer's stores. All unused commissioning spares
will remain with the Employer.
SL.
NO.
I.
DESCRIPTION
QUANTITY
Transformer
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1
2
3
II.
1
2
3
4
5.
6.
7.
8.
III.
1.
a)
b)
c)
d)
e)
f)
g)
h)
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
HT Bushing
1 No.
Winding temperature indicator with alarm &trip 1 No.
contacts
Gasket
1 No.
LT Switch Gear
Auxiliary Contact Set
5% of each type & rating.
(minimum 1 set/No. of each
type & rating)
Closing Coils
Tripping Coils
- DO Ammeters
- DO Voltmeters
- DO Coils for the Contactors & Aux. Contactors
- DO Control Isolating & Selector Switch
- DO Push Button of Various Colours
- DO MCCs, PDBs, MLDB/LDBs
Air Circuit Breakers
Fixed arcing contact
- DO Moving arcing contacts
- DO Arc chute
-DOCluster contacts
-DOArc barriers
- DO Trip coil assembly
- DO MWS complete kit
-DOClosing coil assembly
-DOMPCB of different ratings
- DO MCCB of different ratings
- DO Handles of MCCB of different ratings
-DOPower contactors of different ratings
-DOMoving contacts of Power contactors of - DO different ratings
Fixed contacts of Power contactors of different - DO ratings
Coil for Power contactors of different ratings
-DOAuxiliary contacts for Power contactors
-DOMPR Overload relays of different ranges
-DOMicropressor based Over load relay for - DO Convential type MCC
Intelligent module/cards for intelligent MCC / - DO MCP
Auxiliary contactor (2NO+2NC)
- DO Coils for auxiliary contactors
-DOAdd on block for auxiliary contactors
-DOCTs
- DO PTs
- DO Voltmeters
-DO-
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19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
IV.
1.
Ammeters
Ammeter selector switch
Voltmeter selector switch
Control switches
Control MCBs
Indicating lamps (LED) with holder
Busbar support insulators
Push buttons switches (start & stop)
Contact block (2NO+2NC) for start & stop PB
Actuator head for start & stop PB
Local-off-Remote selector switch
Control switch spring return type
LOCAL CONTROL STATIONS
Push buttons (start)
2.
3.
4.
5.
Push buttons (stop)
Contact block (2NO+2NC) for start & stop PB
Actuator head for start & stop PB
Ammeters
V.
1.
MOTORS (OF EACH TYPE & RATING)
Bearing (DE)
2.
3.
4.
5.
VI.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
-DO- DO - DO -DO-DO- DO - DO -DO- DO -DO- DO - DO 5% of each type & rating.
(minimum 1 set/No. of each
type & rating)
- DO - DO -DO-DO-
5% of each type & rating.
(minimum 1 set/No. of each
type & rating)
Bearing (NDE)
-DOCooling Fan
-DOTerminal Block
-DOGrease Nipple & Plug, Grease pump with -DOmotorised.
PLC/automation
Digital input module with connection unit if 10% of each type & rating.
applicable.
(minimum 1 set/ No. of each
type & rating)
Digital output module with connection unit if - DO applicable.
Analog input module with connection if - DO applicable.
Analog output module with connection if -DOapplicable.
Processor card
-DOPower supply unit for PLC
- DO Memory board (Part of CPU Board)
- DO Communication modules
- DO Control modules of any other type
-DOControl fuse set consisting of 3 nos.
- DO Fan unit
-DO-
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12.
13.
14.
15.
16.
17.
18.
19.
20.
VII.
Fused terminals with LED
Special connectors/cables/ TERMINATORS
Racks / Chassis
Interposing relays / Relay Boards
Ethernet switches
Media converter
Radio comm. Equipment including antena
Load power supply
Special cards in PC / servers/ clients / PG
UPS
1.
Thyristors
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
VIII.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
IX.
1.
cell
-DO-DO-DO-DO-DO-DO-DO-DO-DO-
(Complete
assembly) 5% of each type & rating.
(minimum 1 set/No. of each
type & rating)
Semiconductor fuses set consisting of 3 Nos. - DO Diodes
- DO Regulation & pulse generation modules
-DOStatic bypass control module
-DOCapacitors
- DO Resistors, varistors
- DO CTs
- DO Surge suppression unit
5% of each type & rating.
(minimum 1 set/No. of each
type & rating)
Power transistors/IGBT
-DODC MCCB
-DOIndication LED
- DO Pulse transformer unit
- DO Trigger pulse generator
- DO VVVF DRIVES / SOFT STARTER
IGBT of each type
5% of each type & rating.
(minimum 1 set/No. of each
type & rating)
Diode of each type
-DOFuses of each type
- DO Regulation Cards of VVVF, each type
- DO Pulse transformer unit
-DOTrigger Pulse Generator
-DORC Snubber Unit
-DOHRC Fuse Link
-DO Push Button actuator with contact element
-DO(Red & Green)
Mushroom head push button actuator
-DOLED indication lamp (Red, Green, Yellow)
-DOBELT SCALES
Load Cell
5% of each type & rating.
(minimum 1 set/No. of each
CHAP-04.10 ELECTRICAL POWER DISTRIBUTION, DRIVES, CONTROL &
ILLUMINATION.doc ELECTRICAL
Page 46 of 50
2.
3.
X.
1.
Electronic cards
Display Units
SAFETY AND LIMIT SWITCHES
All Types of Limit Switches
2.
3.
4.
5.
6.
7.
8.
9.
10.
XI.
1.
Level Sensor / Switches
Photo Electric Sensor
Transducers
Flow Switches
Temprature Switches
Proximity Switches
Encoders
Magnetic Switches
Code Reader for Oven identification
HYDRAULIC UNIT
Solenoid Valves
2.
3.
XII.
1.
Oil Seals
O-rings
ILLUMINATION
MCBs
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
type & rating)
-DO-DO 5% of each type & rating.
(minimum 1 set/No. of each
type & rating)
-DO-DO-DO-DO -DO-DO-DO-DO-DO5% of each type & rating.
(minimum 1 set/No. of each
type & rating)
-DO-DO -
5% of each type & rating.
(minimum 1 set/No. of each
type & rating)
Ballast for High bay, well glass, street light - DO fittings etc.
Chokes, starter, holder for fluorescent tubular - DO fittings
Igniter for Flood light, High bay, well glass, -DOstreet light fittings etc.
Capacitor, holder, control gear for Flood light, -DOHigh bay, well glass, street light fittings etc.
Fluorescent fixture
- DO Well glass HPSV lamp fittings
- DO Flood light, High bay, Street light fittings etc.
- DO 40W fluorescent lamps
- DO 70W, 150W, 250W, 400W HPSV lamps
-DOTerminal blocks
- DO -
CHAP-04.10 ELECTRICAL POWER DISTRIBUTION, DRIVES, CONTROL &
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Page 47 of 50
ANNEXURE – E-03
ADDITIONAL POINTS FOR AUTOMATION WITH RESPECT TO GTS
Sl.
No.
GS Clause
Additional Points for Automation
1. Ch-1, 06.03.01
Drawings of all listed categories (except fabrication drawings)
will be submitted to EMPLOYER in minimum 6 sets.
2. Ch-1, 06.03.03
Original hardcopy documentation and manuals are to be
supplied, for all relevant hardware, software, network,
technology, etc.
3. Ch-3(Elect),
For all equipment with redundant power supply, supply from two
1.02.15.01.A.2.0 separate sources will be drawn.
4. Ch-3
(Elect), No mode selection at LCS.
1.01.15.02.A
5. Ch-3
(Elect), Conduits carrying special cables will be painted, coded, marked
1.02.21.02 (10)
as per plant norms.
6. Ch-3(Elect),
Provisions to be made for off-line testing of Level-I systems prior
1.02.15.01.B.16. to actual deployment.
0
7.
Max CAT-6 length of 30m for shop floor installations.
8.
Necessary facility/software will be supplied
management and monitoring of the entire network.
9.
Network teams from multiple switches to be employed for all the
important machines (computers).
CHAP-04.10 ELECTRICAL POWER DISTRIBUTION, DRIVES, CONTROL &
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for
remote
Page 48 of 50
ANNEXURE-E04
SL.
NO.
DESCRIPTION
1.
The HT and control cable from HTSS to the respective technological
package will be routed through covered structural overhead cable gallery
only.
2.
All circuit breakers used for 6.6 KV and 11 KV unearthed system should be
1. VCB’s
2. They will be horizontal isolation type, trolley mounted and ground
operated (non cassette type)
3. The jaw contacts (female) will be mounted on the breaker and will be
drawout along with the breaker.
4. The male contact will be of flat type with mounting on bus side
5. Type tests pertaining to BIL requirements (7.2/28/60KV for 6.6 KV and
12/35/75 KV for 11 KV) will be witnessed by EMPLOYER.
6. Minimum panel width will be 800 mm.
3.
Continuous current of Variable speed AC drives will be 150% of motor full
load rated current at continuous duty operation.
4.
Insulation level for MCC & MCP: One minute power frequencies withstand
voltage will be 1500V for control circuit.
5.
Contact rating for Push Button will be
AC15, 6A at 230V
DC13 ,4A at 230 V
6.
MCB short circuit rating capacity will not be less than 10 KA at 0.8 power
factor
7.
LT Switchboard Incomer & Bus-coupler Circuit Breaker ratings will be 2000A
for 1000KVA transformer
8.
Control terminal block will be ELMEX type suitable for terminating 2 cores of
2.5 sq mm wire.
9.
Terminal type
Power terminal: Stud type- with maximum 2 connections on one terminal.
Control terminal for CT: Disconnecting type
ANNEXURE-E05
SL.
DESCRIPTION
CHAP-04.10 ELECTRICAL POWER DISTRIBUTION, DRIVES, CONTROL &
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Page 49 of 50
NO.
1.
All HT motor will have FCMA based soft starter.
2.
For HT motor surge suppressors to be installed near the motor.
3.
All HT motors will have fluid coupling.
4.
HT motors less than 2.0 MW, condition monitoring equipment
(temperature monitoring, vibration monitoring etc.) to be envisaged. For more
than 2.0 MW, condition monitoring equipment (temperature monitoring,
vibration monitoring and partial discharge monitoring etc.) to be envisaged.
5.
Isolated transformer will be provided for VVVF drive of more then 90 KW,
and series rector will be provided for VVVF drive less than 90 KW.
6.
Copper cable will be used for imported motors, crane and moving equipment.
7.
For all LT motors for more than 75KW soft starter will be provided.
8.
All HT cable will be of FRLS type.
CHAP-04.10 ELECTRICAL POWER DISTRIBUTION, DRIVES, CONTROL &
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04.11
AUTOMATION SYSTEM (LEVEL-1)
04.11.01
GENERAL
01. This specification is intended to define the basic requirements for
Automation (Level-1) system of the Coal Handling Plant (CHP) and
Coke Sorting Plant (CSP) and Augmentation in Flux - Fuel Preparation
and Plant Return Fines Handling for SP III (FFP) coming under the 7.0
MTPA Expansion of BHILAI Steel Plant (BSP) with a view to achieve
smooth, efficient, safe, integrated and reliable operation of the process.
02. Monitoring, Control, Interlocking and Sequential functions for the entire
Coal Handling Plant and Coke Sorting Plant and Augmentation in Flux Fuel Preparation and Plant Return Fines Handling for SP III will be
achieved through PLC based Level-1 automation system.
03. Coal Handling Plant

A common dispatcher cum control room (D-2) under package no. 062, is being arranged by the employer for operating the entire coal
blending, crushing and transportation from existing & new silos to
existing batteries (10 nos.) and new battery (1 no.) with a provision to
install the automation equipment of proposed CHP package-064 as
shown in the attached Automation Configuration Drg. No. MEC/S/9101/11/E9/55/01/064.01/R1). Contactor will provide PLC-4
with all hardware and software and integrate the offered system with
that of Pkg 062(New Coal Handling Plant).

To understand the interfacing points, enclosed Material flow diagram
(Drg No-MEC/S/9101/11/17/55/01/064.12, Sheet 1&2) and a
schematic drg (Drg. No.-MEC/S/9101/11/E9/0/00/00/064.03) may be
referred.

The Contactor will furnish assignment drawing and space requirement
to the employer to keep the provision in the Despatcher-D2.
04. Coke Sorting Plant

Control, Monitoring, Interlocking and Sequential functions of new
drives and equipment proposed for Coke sorting plant covered under
this specification as per technological layout and material flow
diagram with new automation. Proposed CSP will receive material
from CDCP (for COB#11), Existing Coke Sorting Plants CSP-1
through Conveyor KA1 and KA2 which in turn after crushing &
screening material will transport to Stock House of BF#8 and SP-III
through C-line conveyor (Pkg064) in line with technological material
flow diagram.
For operation of Coke sorting plant, a separate new Dispatcher will be
provided by the Contactor with dedicated PLC based automation
CHAP-04.11 AUTOMATION.doc
Page 1 of 15

system
as
per
Automation
Configuration
Diagram
(MEC/S/9101/11/E9/55/01/064.02/R1).
In the new Automation system, provision will be kept for interfacing
employer’s PLC and /or Remote I/O stations for all source and
destination conveyors.
05. Augmentation in Flux - Fuel Preparation and Plant Return Fines
Handling for SP III- Control, Monitoring, Interlocking and Sequential
functions of new drives and equipment proposed for Augmentation of
Flux and Fuel crushing and screening circuit as described below in line
with material flow diagram:
i. Feeding of coke breeze from coke breeze bunker of coke sorting
plant(CSP4) to existing conveyor C102
ii. BF fines from existing BFs through conveyor C7, new conveyor
C3A-C1 to existing Conveyor F101 in junction house JH 127.
iii. Feeding of sinter /ore fines from BF8 fines storage bins to existing
conveyor F101 in junction house JH 127
iv. Feeding of coke fines from BF8 fines storage bins to existing
conveyor C102.
v. New Fuel & Flux Crushing and Screening system
vi. New Conveyor route starting from C104 through Rod Mill feeding
to existing Proportioning building.
vii. New Conveyor route starting from L105 through Hammer Crusher
feeding to existing Proportioning building.
The above will be achieved by providing new hot redundant PLC
with suitable remote I/O station. New PLC will be integrated to the
existing PLC based Automation system by providing suitable
gateway as shown in the enclosed Automation Configuration
Diagram. For interfacing with New Sinter machine suitable gateway
also will be provided for establishing interlocking, signal, monitoring
etc.
 The Automation system facilities will be generally offered inline with
the basic ‘Automation System Configuration’ diagram (Drg. No:
MEC/S/9101/11/E9/55/01/064.04/R3) enclosed with this specification for
Augmentation in Flux - Fuel Preparation and Plant Return Fines
Handling for SP III.
 Contractor will provide gateways, all hardware and software required for
integrated operation of the new drives defined above along with the
existing equipments for flux and fuel crushing & screening facility and
the associated conveyors in existing Rockwell make 5-60/5-80 series
PLC based Automation system.
CHAP-04.11 AUTOMATION.doc
Page 2 of 15
 Conveyors feeding to Augmentation in Flux - Fuel Preparation and Plant
Return Fines Handling for SP III i.e. C7-3.5KW, C1-30KW & C2-45KW
will be fed from new MCC under the scope of package. These
Conveyors will be connected from new PLC of Augmentation in Flux Fuel Preparation and Plant Return Fines Handling for SP III. Suitable
control cable and other accessories will be considered.
 Necessary modification, if required for laying of cables and mounting
equipment in the existing control room CR1, the same will be provided
by the Contractor.
06. This specification should be read together with the General Technical
Specification (No. GS-03) separately attached with this specification,
General Conditions of Contract (GCC) and other commercial terms &
conditions.
07. Automation equipment considered for the process will be complete in all
respect in line with this specification. Any equipment / accessories, not
explicitly indicated in this specification, but considered essential for
proper functioning of technological equipment and process (including
utilities) will be included by Contactor in their scope of work and supply.
08. All the automation equipment will be supplied brand new & from the
latest product ranges of reputed manufacturers as per the List of
Preferred Makes, furnished in this Contract document. Employer/
Consultant reserve the right of selecting particular make and model of
Automation equipment with a view of integration with employer’s
Automation system and standardization of the whole plant. Contactor will
comply with such requirements.
09. Contactor will execute the entire automation work as part of turnkey
package of the CHP and CSP, Augmentation in Flux - Fuel Preparation
and Plant Return Fines Handling for SP III to the satisfaction of
Employer/ Consultant. Contactor will comply with all the requirements
indicated under General; Salient Features of Automation system, Scope
of Work and Supply; Submission of Drawings & Documents and other
related clauses/ annexure stipulated in this specification. Design aspects
and selection criteria of PLC systems and also other hardware/
peripheral units have been elaborated in GTS. The GTS (GS-03) is
being issued as a separate document along with this Contract, which will
also be complied with.
10. Interfacing:
 Coal Handling Plant: -Automation systems of CHP (Pkg-062), new
Coke Oven Battery-11, etc. will be separately arranged by Employer
along with its technological package. The proposed PLC based
automation system of Coal Handling Plant (Pkg-064) will be interfaced
CHAP-04.11 AUTOMATION.doc
Page 3 of 15
with CHP (Pkg-062), new Coke Oven Battery-11 & existing plants /
shops as per Technological Material Flow Diagram for information
exchange, interlocking and monitoring of the plant. Contactor will provide
required hardware & software for interfacing of the offered automation
system with the automation system of the above plants. The required
communication bus from the PLC of the above plants to respective
Despatcher / Control Room of the Contactor’s offered Coal Handling
Plant will be included under this package. Details of interfacing
requirement will be finalised during detailed engineering stage.
 Coke Sorting Plant: Automation systems of CDCP (for Coke Oven
Battery-11), Stock House of Blast Furnace # 8, etc. will be separately
arranged by Employer along with its technological package. The PLC
based automation system of CSP (Pkg-064) will be interfaced with
CDCP (for Coke Oven Battery-11), Stock House of Blast Furnace # 8,
Augmentation in Flux - Fuel Preparation and Plant Return Fines
Handling for SP III (Pkg-64) & existing CSP 1 plant as per Technological
Material Flow Diagram for information exchange, interlocking and
monitoring of the plant. Contactor will provide required hardware &
software for interfacing of the offered automation system with the
automation system of the above plants. The required communication
bus from the PLC of the above plants to respective Despatcher / Control
Room of the Contactor’s offered Coke Sorting Plant will be included
under this package. Details of interfacing requirement will be finalised
during detailed engineering stage.
 Augmentation in Flux - Fuel Preparation and Plant Return Fines
Handling for SP III: Automation systems of Blast Furnace #8, Sinter
Plant#3 etc. will be separately arranged by Employer along with its
technological package. The PLC based automation system of
Augmentation in Flux - Fuel Preparation and Plant Return Fines
Handling for SP III (Pkg-064) will be interfaced with stockhouse of Blast
Furnace #8, Sinter Plant #3, CSP (Pkg-64) , Existing Coke handling,
crushing and screening facility, Existing Flux crushing and screening
facility, etc. as per Technological Material Flow Diagram for information
exchange, interlocking and monitoring of the plant. Contactor will provide
required hardware & software for interfacing of the offered automation
system with the automation system of the above plants. The required
communication bus from the PLC of the above plants to respective
Despatcher / Control Room of the Contactor’s offered Augmentation in
Flux - Fuel Preparation and Plant Return Fines Handling for SP III will be
included under this package. Details of interfacing requirement will be
finalised during detailed engineering stage.
11. The Automation system facilities for CHP, CSP and Augmentation in
Flux - Fuel Preparation and Plant Return Fines Handling for SP III of this
package (064) will be generally offered inline with the basic ‘Automation
System
Configuration’
diagram
(Drg.
No:
MEC/S/9101/11/E9/55/01/064.01/R1)
for
CHP
&
Drg.
No:
CHAP-04.11 AUTOMATION.doc
Page 4 of 15
(MEC/S/9101/11/E9/55/01/064.02/R1)for
CSP
and
(Drg.
No:
MEC/S/9101/11/E9/55/01/064.04/R3)MEC/S/9101/
11/E9/0/00/00/
064.04/R3 for Augmentation in Flux - Fuel Preparation and Plant Return
Fines Handling for SP III) enclosed with this specification. Client-server
based architecture will be considered for automation. Contactor will
submit configuration diagram of the automation system provided by
them accordingly. Requirements of Controllers & their division, Workstations/Servers, Engineering stations, Printers etc. will be indicated in
the configuration drawing.
12. Automation system of proposed plants will have three level Ring
Architecture type communication buses as follows :
a) HMI-level Ethernet for HMI Stations, MIS Servers, MIS Clients,
Higher-level systems etc. Contactor to provide for CSP in line with
Automation Configuration drawing.
b) Control-level Ethernet for connecting PLCs, Servers, Emergency
Work Stations, Engineering Stations etc. Contactor to provide for
CSP in line with Automation Configuration drawing.
c) I/O level communication bus. Contactor to provide for CHP & CSP
in line with Automation Configuration drawing.
13. 1 No. field programming unit for CHP, 2 Nos. field programming units for
CSP and 2 Nos. field programming units for Augmentation in Flux - Fuel
Preparation and Plant Return Fines Handling For SP III will be in the
scope of Contactor. Apart from standard features, these field
programming units will be capable of connection from every Remote I/O
station for engineering and troubleshooting purposes.
14. 2 Nos. MIS servers each will be included in the Automation system of
CSP and Augmentation in Flux - Fuel Preparation and Plant Return
Fines Handling for SP III.
15. All printers provided with PCs will be laser jet type.
16. The design will be done in such a manner that involvement of cabling
and wiring is minimum.
17. All the automation equipment will be configurable to a user configurable
fail-safe state to avoid dangerous situations in case of any failures due
to power failure, communication failure etc.
18. Different levels of networks will be inter-connected through intelligent
devices which are capable of high speed switching at least at Layers 3 &
4 with access control. For all important systems firewall will be provided,
taking care at Layers 3 to 7.
19. Temperature monitoring of all remote I/O stations will be provided
through respective PLC.
CHAP-04.11 AUTOMATION.doc
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20. Power & Control Supply monitoring of all mechanisms will be provided
through PLC.
21. Status of UPS to be monitored through PLC / HMI.
22. All new PLCs supplied in this package, will be interfaced to Main PLC on
Ethernet. Apart from main PLC as described in automation configuration
drg., other PLCs (if) coming under this package shall interface with main
PLC of CHP/CSP/FFP
23. The communication networks will be dully tested & certified by
authorized agency.
24. For better co-ordination, the complete automation system will be ordered
on one sub-vendor i.e. the OEM of PLC system.
25. Ethernet network (FO and UTP)




04.11.02
GTS GS-12 shall be referred for specifications related to ethernet
network
FO link from CSP IV control room to main control room of
COB#11(Battery and CDCP) and from existing SP3 CR1 to main
control room of SP 3 machine 2 for exchange of needed information.
FO link to be used (Not UTP) if link taken outside building or shop
floor.
All FOC/UTP carrying conduits/pipes to be paint marked as per
standard color code specified by employer
SCOPE OF WORK AND SUPPLY
Contactor’s scope of work and supply will include design, engineering,
manufacture/ procurement, assembly, calibration, shop testing,
inspection at works & at site, painting, packing, transportation to site
including loading, unloading, storage & handling of all Automation
equipment including electrical accessories, cables, GI pipes, erection
accessories, panels/ cabinets and all associated hardware, as required
for completeness of Automation system in all respect along with site
fabrication, erection, testing, commissioning of the complete automation
system and interfacing with different PLCs as described else where in
the contract for completeness & satisfactory operation of the entire Coal
Handling Plant, Coke Sorting Plant and Augmentation in Flux - Fuel
Preparation and Plant Return Fines Handling for SP III as per
technological layout and material flow diagram. The scope of work will
also include liquidation of defect points, participation in tests for
establishment of plant performance guarantee (PG) and post
commissioning activities till issue of final acceptance certificate (FAC) by
BSP.
CHAP-04.11 AUTOMATION.doc
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The scope of work and supply will include but not limited to the following:
1.
Automation system as per the facilities indicated in the Automation
System Configuration diagram (Drg. No: MEC/S/9101/11/E9/55/01/
064.01/R1) for CHP & Drg. No: (MEC/S/9101/11/E9/55/01/064.02/R1)for CSP
and (Drg. No: MEC/S/9101/11/E9/55/01/064.04/R3)MEC/S/9101/ 11/E9/0/00/00/
064.04/R3 for Augmentation in Flux - Fuel Preparation and Plant
Return Fines Handling for SP III and as described in ‘General’ and
‘Salient Features of CHP, CSP and Augmentation in Flux - Fuel
Preparation and Plant Return Fines Handling for SP III’.
a. For CSP this will mainly include independent PLC systems with
redundancy in: - processors, power supply modules,
communication modules, network interface modules, MIS servers
etc. for plants/units. Number of operator’s station and engineering
work station shall be as automation configuration diagram.
Communication bus will be ring architecture type. The automation
system will be client-server based configuration. All the required
facilities & features for interfacing of PLC systems will be
considered and provided accordingly.
b. For CHP, the Contactor will provide PLC based automation
system, with redundancy in:- processors, power supply modules,
communication modules etc in line with GTS. Number of
operator’s station and engineering work station shall be as
automation configuration diagram. Remote I/O stations, I/O Level
communication Bus, necessary gateway (associated hardware
and software) for interfacing with employer Automation network,
Engineering station, HMI shall be as shown in Automation
Configuration drawing.
c. For Augmentation in Flux - Fuel Preparation and Plant Return
Fines Handling for SP III, the Contactor will mainly provide PLC
based automation system, with redundancy in :- processors,
power supply modules, communication modules, network
interface modules as per GTS. Number of operator’s station and
engineering work station shall be as automation configuration
diagram. 0perator’s and engineering workstations, Remote I/O
stations, I/O Level communication Bus, Control-level bus,
necessary gateway (associated hardware and software) for
interfacing with employer Automation network, Engineering
station, HMI shall be as shown in Automation Configuration
drawing.
2.
Required nos. of local/remote I/O panels with adequate quantity of
various types of I/Os cards, i.e. Digital, Analogue, RTD,
Thermocouples, Pulse, power supply cards, communication cards,
Relays with NO contacts for outputs etc. at different locations.
CHAP-04.11 AUTOMATION.doc
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Contactor will also consider input interposing relays for field mounted
proximity switches in the I/O chassis.
3.
Preferred Makes of individual equipment i.e. PLC systems,
Workstations, Servers, Engineering stations, printers etc., will be in
line with GS-13. All the Hardware in Individual Systems will be from
the same product series.
4.
All required software i.e. System software, HMI software, Application
programmes etc. for PLC, Workstations, Servers, communication
interface amongst various automation systems etc. Required number
of software licenses will also be provided.
5.
All maintenance, diagnostic tools & devices
implementation, maintenance & trouble shooting.
6.
1 No. field programming unit for CHP, 2 Nos. field programming units
for CSP and 2 Nos. field programming units for Augmentation in Flux
- Fuel Preparation and Plant Return Fines Handling for SP III will be
in the scope of Contactor. Apart from standard features, these field
programming units will be capable of connection from every Remote
I/O station for engineering and troubleshooting purposes.
7.
All Network components like Gateways / interfacing modules, cables,
multi-port switches (if applicable) etc., as required for interfacing.
8.
Optical Link Modules, Light Interface Unit, Redundant link modules,
Power supply Cards, Converters, Terminators etc. as per
requirements.
9.
Other than the PLC systems specified in the configuration diagram, if
any separate PLC systems are required for operation of the auxiliary
units of the proposed CHP, CSP and Augmentation in Flux - Fuel
Preparation and Plant Return Fines Handling for SP III the same will
also be offered and suitably interfaced with the main automation
system.
10.
All types of system cables, communication cables, LT power cables,
special cables, etc., as required. This will also include the required
communication interface and cable for interfacing with the PLCs of
conveying system of COB#11, Blast Furnace Stock House, Sinter
Plant, CDCP etc. (as described in ‘Interfacing’ in CTS), located at
respective control rooms.
11.
Necessary co-ordination with employer / Mecon for establishing
interfacing and integration requirement by providing new PLC,
multiplying relays as required, interconnecting cabling between
employer’s MCC/ other panels and Contactor’s PLC/ Remote I/o
stations etc.
CHAP-04.11 AUTOMATION.doc
required
for
Page 8 of 15
12.
Fully wired cabinets/ panels, etc with MCBs, Fuses, CFL Lamps,
Universal type service sockets, Earth strips, etc.
13.
Control room furniture for CSP dispatcher
14.
In existing Control Room/Dispatcher –CR1 of Augmentation in Flux Fuel Preparation and Plant Return Fines Handling for SP III, existing
4 monitors will be replaced by new TFT monitor of size 22”, identical
to new monitors for aesthetic looks.
15.
Submission of drawings and documents as per mentioned at clause
no. 06.11.05 of this CS.
16.
a) In the automation system for CHP, few facilities from Pkg-062 are
proposed to be used. These facilities include Fault-tolerant HMI
server, Fault-tolerant history and process support server, Faulttolerant MIS server, Network at Despatcher-D2, etc. Contactor will be
responsible for all necessary activities, including coordination, with
the supplier of Pkg-062 towards licensing requirements, development
of application for Pkg-064, deployment of clients, network etc.
b) Erection, testing, calibration and commissioning of the total
Automation equipment / system of CHP, CSP and FFP included in
this specification. Required interfacing with employer’s PLCs by
providing necessary hardware and software and interconnecting
cables. This will also include laying and termination of system bus
cables as required.
17.
Contactor will arrange tools, tackles and consumables as may be
required for erection, testing, calibration and commissioning
activities.
18.
Contactor will arrange inspection of Automation equipment by
Employer/ Consultant. Inspection and Testing will be carried out in
compliance with the Quality Assurance Plans and FAT document, to
be approved during detailed engineering stage.
19.
Contactor will arrange visit by respective Automation manufacturer’s
representatives at site, as & when required, during erection &
commissioning.
20.
Testing tools & equipment for automation system
21.
Special tools will be provided in sufficient number for tracing, location,
testing, jointing, fault location & rectification, termination etc. for all
cables including special cables.
CHAP-04.11 AUTOMATION.doc
Page 9 of 15
22.
Contactor will involve Employer / Mecon in control philosophy
development, design of application software and hardware, drawing
up of software specifications, software development, off-line testing
etc.
23.
All tests on software, hardware, network, communication etc. will be
carried on the basis of a pre-agreed protocol clearly listing out steps
involved in testing with its responsibility and minimum expected
results as per specifications, engineering and other documents.
24.
Troubleshooting manual for all application software, system software,
configuration, hardware, network etc. will be provided clearly spelling
out possible causes, checks and measures for corrective action.
25.
Contactor will arrange training for Employer’s personnel on the
automation system at manufacturer’s works and also at site.
26.
Two years maintenance spares, if the order is separately placed by
Employer.
27.
Commissioning spares and three months consumables.
04.11.03
SALIENT FEATURES OF CONTROL & AUTOMATION SYSTEM FOR
COAL HANDLING PLANT, COKE SORTING PLANT AND
AUGMENTATION IN FLUX - FUEL PREPARATION AND PLANT
RETURN FINES HANDLING FOR SP III
01.
For monitoring, control, interlocking and sequential operation of CHP,
CSP and FFP, PLC based automation systems will be provided.
Considering information exchange & operational requirement all the
systems will be suitably interfaced. All the printers will be provided
with network connectivity.
02.
In Client server based Automation system, hot redundant servers will
be considered. This architecture will have 3 level ring type bus
system. The PLC systems will communicate with each other and the
servers through a common ring tropology bus. All the HMI stations
will be interfaced with the servers through a separate higher level
bus. Respective PLCs will have independent engineering station.
Suitable communication cards will be provided in respective I/O
panels for interfacing with HT switch-boards; Intelligent MCCs,
Remote I/O station, Weighing Controllers, TR controllers etc.
03.
Each Operator Workstations will have 22” Flat dual TFT Monitor as
shown in Configuration drawings.
04.
The automation system will be powered from UPS of suitable rating.
Details of UPS have been separately indicated in this TS and GTS.
CHAP-04.11 AUTOMATION.doc
Page 10 of 15
05.
All the new MCCs of CHP and CSP and MCPs of CHP, CSP and
FFP will be of Intelligent Type. i.e. every controller (DOL/RDOL
feeder) will have an intelligent relay having capability to communicate
directly with PLC Controller. Power supply feeders in MCC need not
to communicate with PLC except of those feeders which feed to
other Process MCCs & ACB/MCCB incomers.
06.
All the HT breakers & LT breakers in PCC will also have
communication ability to Automation system.
07.
All the weighing controller/Indicator panels,
communicate directly with PLC Controller.
08.
Optical link module will be used for converting Electrical bus to
Optical bus.
09.
Contactor will consider Remote I/O panels at each electrical
premises with all kinds of Remote I/Os.
10.
Additional Engineering spare Remote I/Os will be carefully planned at
each location in such a way that they can be used in the unlikely
event of non-establishment of communication with field devices
having bus communication.
11.
One Remote I/O panel (with required numbers interface
modules/types of I/Os) will be planned in each electrical premises,
each electrical floor (in case of multi-story rooms) & junction houses /
Technological Buildings for interfacing of field switches.
12.
All the communication cables will be laid in GI pipes. Separate pipes
with separate routes (to the extent possible) will be used for ring
tropology type communication bus.
VFD
etc.
will
GENERAL CONTROL REQUIREMENT
13.
All the drives will generally be provided with following modes of
operation and control:
 Local De-interlock
 Local interlock
 Remote
Mode of selection will be carried out for all drives with the help of
selector switch provided on the MCCs / MCPs and required nos. of
wall mounted boards / boxes for HT motors.
14.
For local operation of drives, permission from Operator at
Despatcher Control room will be obtained which will be named as
CHAP-04.11 AUTOMATION.doc
Page 11 of 15
automation permission. For this purpose, specific menu will be
provided with operator workstation for such drives.
15.
Local De-interlock mode of operation will be used only for
adjustment, maintenance and testing purpose. After the selector
switch at MCC / MCP is selected to Local De-interlock mode and
Operator/PLC permission is obtained from Control room, the
drives/valves can be started/opened/closed from Local control
stations using start/open/close push buttons. Under this mode of
operation, all safety interlocks (Pull Chord Switches, motor over load,
Emergency switch etc.) will be provided through hardwire in the
circuit.
The stop push button provided in Local Control station will stop the
drive under all mode of operation. In case of emergency Stop, alarm
will be provided at the Operator workstation at control room to warn
the operator. Hooter PB will be provided in LCS for pre start warning.
16.
Local interlock mode for running the drive in sequence interlocked
mode from LCS. Selector switch will be put in local interlocked
position and permission from operator / PLC will be pre requisite
condition. In this mode start, stop, motor over load, emergency stop,
Pull Chord & Belt Sway Switches, Zero Speed Switch, chute jamming
switches will be in the circuit through hardwire in addition to interlock
with successive conveyor / equipment.
17.
Under remote mode of operation, following control modes for all
drives will be provided through Operator workstation.
i.
Remote Manual
ii. Automatic
Selection of remote manual or automatic mode of operation will be
carried out using command menus through Operator workstations.
Remote Manual mode
Under remote manual mode of operation, individual drives will be
started/stopped from Operator workstation. However, necessary safety
interlocks will be provided by automation system. This mode can be
used for testing of individual drives from Control room.
Automatic mode
Under Automatic mode, the plant/equipment will be controlled,
started/stopped automatically in sequence by automation system using
various command menus from any of the Operator workstations.
04.11.04
CONTROL ROOM / DESPATCHER ROOMS
A. COAL HANDLING PLANT:-
CHAP-04.11 AUTOMATION.doc
Page 12 of 15
Route wise operation of offered CHP (under Pkg-064) of the Contactor
and Coal transportation system (under Pkg-062) of the employer will be
operated from a common dispatcher D2. The Despatcher D2 building is
located near COB#11 and is in Employer’s scope covered under
Package 062. The Contactor will supply PLC, Engineering Station, Work
Station, Emergency Work Station etc. as per Automation Configuration
Drawing (No.- MEC/S/9101/11/E9/0/00/00/064.01/R1) of CHP. The
Contactor will furnish assignment drawing and space requirement to the
employer to keep the provision in the Despatcher-D2.
B. COKE SORTING PLANT:One no. Despatcher will be provided by the Contactor for control of
transportation of coke from JH-1 to various destination as per Material
Flow Diagram & Technological layout. Despatcher will be a new building
near Coke Screening Station under Contactor’s scope. Civil, Structural,
floor & Ceiling requirements for the Despatcher / Control Building are
described elsewhere in the TS.
C. New PLC with RIO’s will be provided for Augmentation in Flux - Fuel
Preparation and Plant Return Fines Handling for SP III which will be
connected to existing PLC through suitable gateway. The new PLC &
HMIs will be housed in existing Control Room 1(CR-1). The existing
HMIs will suitably be upgraded to match the new HMIs for operation of
the entire existing and new Flux & Fuel Crushing & Screening plant.
D. COMMON POINTS:01. The Despatcher / Control Buildings will be air-conditioned and
provided with false ceiling & false flooring. The respective rooms will
have following suitable aluminum framed glass partitions as listed
below:
a. At one partition called as operator room will house the operator
workstations, printers and other peripherals of the automation
system along with Control desk (for work stations/printers) &
operator chairs.
b. A separate partition in the control room / Despatchers will be used
for installation of Engineering Stations, Servers (if applicable) &
Software/Hard-ware related documentation.
c. A separate partition will be used for installation of PLC Panels, I/O
panels, Instrumentation panels, Weighing panels, & all other
electronic panels as per the detail engineering.
02. All the above partitions will be accessible directly from a common
walkway.
CHAP-04.11 AUTOMATION.doc
Page 13 of 15
03. Control room and Despatcher will also have facility of Toilet block.
Central control room will have one conference room (with Table &
Chairs for 12 persons) & Pantry. However Contactor may
accommodate some of these facilities on floor below Control room
also, during detail engineering.
04. Control desk (for installation of HMIs & Engineering Stations etc) will
be of most modern & aesthetic design with Cable Management
system.
04.11.05
LIST OF DRAWINGS & DOCUMENTS
Following drawings and documents will be submitted by the Contactor:
A.
TO BE SUBMITTED BY THE CONTACTOR DURING DETAILED
ENGINEERING
I)
FOR APPROVAL:
01. Finalised system configuration diagram for the automation system
along with its peripherals with list of hardware and write-up on the
system.
02. Bill of Materials & Data Sheets of all the hardwares i.e. Processors,
Communication modules, Power supply cards, RLM, OLM, Operator
stations, Eng Stations, Servers, Bus cables etc.
03. Overall General arrangement drawings & sectional views of various
cabinets, panels, consoles, etc., showing internal disposition of all
components/ units, with dimensional details and bill of materials.
04. Interconnecting diagram between existing MCCs & other panels of
employer and PLC / Remote I/O stations of the Contactor.
05. Single line power supply diagram with specification and bill of
quantities of electrical accessories.
06. Quality assurance plan & Factory Acceptance Test procedures for
Automation system.
07. Control room layout drawing showing disposition of panels, consoles,
desks, etc with dimensional details.
II) FOR SCRUTINY AND REFERENCE
01.
Detailed technical literature/ catalogue for Automation system with
peripherals, highlighting the model number.
CHAP-04.11 AUTOMATION.doc
Page 14 of 15
02.
Input/ Output list.
03.
Terminal diagram of all the RI/O & Marshalling panels.
04.
Cable schedule and specification.
05.
System grounding scheme.
06.
Formats and work sheets for generation and display of overview,
groups, loops, graphics, alarms, operator’s guide messages, real
time & historical trends, log & shift formats.
07.
Detailed listing of application software, system software, HMI
software, etc and the number of licenses.
08.
Application software formats and details in documentation and CDs.
09.
Manufacturer’s test, calibration and guarantee certificates for all
instruments and automation system.
10.
Operation and maintenance manuals for Automation system.
III
As-built drawings and documents.
1.
Drawings and documents of complete automation systems
2.
Soft copy of all the above drawings & documents in CDs/DVDs.
CHAP-04.11 AUTOMATION.doc
Page 15 of 15
Enquiry Specification for DFDS System Package
DATA SHEETS
EPI – New Delhi
Volume-2B, Rev.0
Page 1 of 4
Enquiry Specification for DFDS System Package
TECHNICAL DATA SHEET (To be filled by the vendor)
1.0
CENTRIFUGAL PUMP for Water Supply System (To be furnished separately for
all the systems)
1.
Make and model no.
:
2.
Type of pump
:
3.
Capacity in m3/hr.
:
4.
Total head in m WC
:
5.
Quantity
:
6.
Material of Construction of
•
Shaft
:
•
Impeller
:
•
Casing
:
7.
Pump speed (rpm)
:
8.
Shaft power
:
9.
Drive details
•
Motor make
:
•
Motor kW
:
•
Class of insulation
:
•
Frame size
:
10.
Bearing type & make
:
11.
Type of coupling
:
12.
Vibration level
:
13.
Noise level at 1 m distance
:
14.
Duty
:
15.
Weight of pump & motor separately:
16.
Characteristic curves for pumps
:
17.
Type of liquid to be handled
:
EPI – New Delhi
Volume-2B, Rev.0
Page 2 of 4
Enquiry Specification for DFDS System Package
1.1
1.2
WATER LINE VALVES for Water Supply System
1.
Make & Model
:
2.
Type
:
3.
Quantity
:
4.
Size
:
5.
Pressure rating
:
6.
Material of construction
:
7.
Operating system
:
8.
Drive details
:
9.
Gland packing
:
10.
End connections
:
11.
Service
:
12.
Test pressure
:
AIR LINE VALVES for Air Supply System
1.
Make & Model
:
2.
Type
:
3.
Quantity
:
4.
Size
:
5.
Pressure rating
:
6.
Material of construction
:
7.
Operating system
:
8.
Drive details
:
9.
Gland packing
:
10.
End connections
:
11.
Service
:
12.
Test pressure
:
EPI – New Delhi
Volume-2B, Rev.0
Page 3 of 4
Enquiry Specification for DFDS System Package
1.3
AIR RECEIVER
Number
:
Design Standard/ Code
:
Capacity
:
Overall dimensions
:
Wall plate thickness
:
Plate material
:
Design Pressure
:
Working Pressure
:
EPI – New Delhi
Volume-2B, Rev.0
Page 4 of 4
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