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TENDER DOCUMENT

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

Tender for Design, Engineering, Supply, installation,

testing and commissioning of DUST SUPPRESSIONPACKAGE AND ASSOCIATED WORKS for the project ofAugmentation of Raw Material Handling Receipt andHandling facilities with new OHP Part B (Package- 061)of Bhilai Steel Plant, (SAIL).

VOLUME 2B

TECHNICAL SPECIFICATION

ENGINEERING PROJECTS (INDIA) LIMITED

(A GOVT. OF INDIA ENTERPRISE)Core-3, Scope Complex, 7, Institutional Area,

Lodhi Road, New Delhi-110003TEL NO: 011-24361666 FAX NO. 011- 24363426

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VOLUME - 2B

CONTENTS

Sl. No. DESCRIPTION

1. Documents/information to be furnished alongwith offer

2. Scope of Supply

3. Brief System Description

4. Technical Specifications Dust Suppression Package

5. Spares

6. Technical data sheet (to be filled by the vendor)

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GENERAL

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

SAIL and General Specification, the provisions in this Technical Specification shalltake precedence.

1.0 DOCUMENTS/ INFORMATION TO BE FURNISHED

ALONGWITH OFFER.

(i) Clear Scope of supply.

(ii) Type and quantity of oil, lubricants & consumables for initial fill till successfulcommissioning of equipment.

(iii) List of Commissioning spares and start-up spares with unit rates.

(iv) List with unit rates of special tools and tackles, if any required.

(v) Price Schedule for supply & erection work as per the format enclosed.

(vi) List of recommended spare parts for 3 years trouble free operation andmaintenance alongwith unit rates as per the format enclosed in price schedule.

(vii) Technical Data sheets duly filled by the vendor (blank data sheets enclosed).

(viii) Weight of the equipment in Kgs.

(ix) Catalogues/ Leaflets and O&M Manuals.

(x) Reference list of your Customers for the similar supply of items.

(xi) Unpriced Copy

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2.0 SCOPE OF SUPPLY

The scope of the supply includes Design, engineering, manufacture, shopfabrication. assembly, testing and inspection at manufacturers works, packing ,dispatch, transportation, delivery to site, receipt, required fabrication at site,installation, testing & commissioning completion of facilities, performance

guarantee testing, final painting at site and handing over to Bhilai Steel Plant,SAIL / EPI of COMPLETEDUST SUPPRESSION PACKAGE and ASSOCIATEDWORKS as per specifications and scope defined in tender documents completewith all accessories and drive, which are not mentioned specifically but arerequired for the efficient and trouble free operation of the equipment/system.

2.1 Following items are also included in bidders scope.

(i) Complete items as per the details given in the specifications.

(ii) Consumables like first fill of lubricating oils etc. for the initial operation ofthe equipment till handing over.

(iii) Commissioning spares and start-up spare parts.

(iv) Special tools & tackles, if any required.

(v) Recommended spare parts for (3) three years trouble free operation andmaintenance.

(vi) Painting of complete equipment (including final painting before handingover to the Employer).

(vii) Installation, testing & commissioning at site.

(viii) All drawings/documents along with operation and maintenance manuals asper requirement mentioned elsewhere in the tender document.

(ix) Getting approval of design/drawings and any other design calculation

related to the equipment from BSP/MECON/EPI.(x) 3 Ph, 415V +10% & -15%, 50Hz +4% & -6% power supply shall be

provided at Power cum Control Panel of Ventilation at one point onlythrough power cables. Other voltage levels, if required shall be arrangedby the bidder itself. Installation, testing & commissioning of panel shall bein Bidders scope.

(xi) Carrying out any modifications/deletions/additions/alteration indesign/drawings/documents as required by client & Clients consultant andEPI for proper execution of works at site till completion and handing overof the project to the client.

(xii) Drinking Water & Construction Power shall be provided free of cost to thebidder at one point. However, further distribution shall be in the biddersscope. Bidder has to ensure the optimum and effective utilization ofConstruction Water & Construction Power.

(xiii)Construction Water shall be arranged by the bidder themselves.

Exclusions:

(i) Civil works including grouting.

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2.2 Bidder to note the following:

1) BSP approved preferred make list shall be followed for Hydraulics & Pneumatics.

2) All HT and LT AC/DC motors, actuators, brakes etc. as per technological and

process requirement.

3) Generally Squirrel Cage Induction Motor with DOL starter / Soft Starter will beprovided. Use of Slip ring motor in general will be avoided. Suitable Rotorcontactor panels and SS-grid Resistance Boxes will be provided for slip ringmotors if inevitable.

4) Soft starter will be provided for LT motors of rating more than 75kW.

5) All LT motors for conveyors will be S6 duty and will have class F insulation withtemperature rise limited to class B.

6) Equipment selection and dating will generally be based on ambient temperatureof+50 Deg.C. For specific areas and shops, the ambient temperature conditions

indicated above will be taken into consideration and equipment suitably deratedwherever necessary.

7) The equipment should be suitable for smooth, efficient and trouble free servicein the tropical humid climate prevailing at plant site and under the ambienttemperature conditions indicated above for the different shops and areas. Inhot areas of higher temperature conditions, the equipment will be adequatelyprotected against damage from radiant heat and hot air.

8) Roller bearings will be provided at DE end for motor of rating 30KW and above.

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3.0 BRIEF SYSTEM DESCRIPTION

The turnkey package of this Contract Document comprises of the following sub-systems:

1) New Ore Handling Plant (OHP-II) including receiving, unloading, Stacking &Reclaiming and finally transporting of Raw Material required for Blast Furnace#8, Sinter Plant-III.

2) New conveyor line for New Lime Dolomite plant RMP3 and for proposed SMS-III.

3) Modifications/ up-gradations of existing equipment, including:

An additional series of conveyor from OHP I to JH-20 and JH-42(Exstg) parallel to existing route.

Up gradation of capacity of existing shuttle conveyors J9BRSC1.

3.1 New Ore Handling Plant (OHP-II)

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

(i) Design Considerations

The Ore Handling Plant (OHP-II) has been planned based on the followingassumption:

A. Size of Raw Material

1. Lump Iron Ore : -40 mm

2. Iron ore fines : - 8 mm

3. Lime Stone (BF/SP grade) : -60 mm

4. Dolomite (BF/SP grade) : -60 mm

5. Quartzite : -50 mm

6. Lime Stone (SMS grade) : -25 mm

7. Dolomite (SMS grade) : -25 mm

8. Pellets : -18 mm

9. Manganese Ore : -25 mm

10. Coke Breeze : -25 mm

B. No of Days of Working per year: 330 days

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C. Maximum material carrying capacity of each wagon shall be as per IS: 10095-1982 reaffirmed 2001. Iron-ore-lump will be received in Track-Hopper & all othermaterial in Wagon Tipplers. Two Track Hoppers have been considered formaterials received in BOBS/ BOBRN wagons (mainly iron-ore), whereas wagontippler with side arm charger has been considered for unloading the materialsreceived in BOXN/BOST/ BOXNHA/BOY/BOBS, BOXNEL, BOYL wagons.

(II) UNLOADING, STORAGE, BLENDING AND RECLAIMING IN OHP-II

One number Wagon tippler WT no.B1 along with a Track Hopper TH-B1 with twoparallel tracks on it have been envisaged for unloading Iron ore (lump and fines),Limestone & Dolomite (both BF grade and Sinter Plant grade), Mn-ore, Quartzite etc.

The Wagon Tippler shall be of Rota-side type capable of unloading BOXN andproposed BOXNHA ,BOXNHS, BOBS, BOY wagons as per IS:10095-1982, reaffirmed2001. The rated unloading capacity shall be rated 20 Tips/hour. Adequate system ofhandling sticky rakes such as vibrator/ air blaster shall be provided.

25t wagon axle load and 110t gross weight of wagons (BOX, BOXN, BOXN HA, BOXNHS, BOXN EL, BOYEL) to be considered for design of Wagon Tippler and trackhopper. 2 nos. Weighbridges included in contractor's scope. The location of WeighBridge shall presently be considered at entry of pre hopper yard. However as thetotal railway track is being engineered by RITES, the location of Weigh Bridge mayundergo change in detailed engineering stage. The drawings of wagon tippler/trackhopper shall be subjected to approval by RITES /SECR/RDSO as applicable.

The placement of rakes shall be done by Side arm chargers capable of handling a fullrake BOXN, BOXNHA, BOBS, BOY, BOXN EL, BOYEL wagons.

Two nos. of track hopper each of length 210 m excluding maintenance bay andholding capacity of 6000 t each considering material of bulk density of 1.6 t/ cu.m.

shall be included in contractor's scope. The side angle of hopper with vertical shall beminimum 60 deg. Each hopper shall have four compartments. Track hopperenvisaged to accommodate minimum 18 BOBS wagons. Contractor to maintainsufficient height of the track hopper superstructure to take care of OHE.

Total 4 nos. Electric hoist of 5 t capacity shall be provided for maintenance of PaddleFeeder at both ends of Track Hopper building. Two nos. double door pressurizedcabin shall be provided for paddle feeder inside the track hopper tunnel. Anti-derailment device/ check rail shall be provided in the track hopper subject toapproval of RITES. Supply / Laying of 60 kg/ m rail with continuous MS insert platewithin track hopper building only are in scope of contractor.

In addition to the above, one dedicated compressor station at track hopper TH-B1forunloading of BOBRN wagons is to be provided. Compressed air connection to BOBRN

wagons to be provided at 15 mts interval. The details of requirement of compressedair, the pressure and type shall be obtained from RDSO. Other points as applicablefor compressed air station shall be considered as per CS for compressed air facilitiesindicated elsewhere.

Provision of adequate illumination should be there on both pre & post tippler as wellas on Merry Go Round circuit.

Two belt feeders below Wagon Tippler shall discharge the raw material on either oftwo conveyors i.e. Z1-C1 or Z1-C2 which, in turn will discharge the material at Jn

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House JH-Z1. From Jn House JH-Z1, conveyors Z3-C1 & Z3-C2 will carry the materialand discharge at JH-Z3. There will be three incoming conveyors in Junction HouseJH-Z3. The tail end of two conveyors Z3-C1 & Z3-C2 will start from JH-Z1 and Beltconveyor Z3-C3 from JH-Z2. Junction house JH-Z2 shall be located in between theJH-Z1 & JH-Z3.

The track hopper with four nos. paddle feeders of 1500 tph each, two on conveyorsZ2-C1 and two on conv Z2-C2 has been envisaged. From Jn. House JH- Z2, either ofthree conveyors Z3-C1, Z3-C2 (coming from JH-Z1) & Z3-C3 (begin from JH-Z2)shall carry the material upto Jn house JH -Z3. Reversible shuttle conveyorsZ2RSC1/2 at JH-Z2 will facilitate to discharge the material on either of any threeconveyors. Therefore, JH-Z2 shall be designed suitably so as to receive material fromany of the conveyors coming from Track Hoppers. Non sticky liners/ polymer linersare to be fixed in the track hoppers to improve flowability.

Suitable interchangeability shall be provided below Wagon Tipplers and TrackHoppers for the conveyors by providing Diverter gates.

In Jn House Z3, three nos. Reversible Shuttle conveyors no. Z3-RSC1,2&3 can feedany one of conveyor no. Z6C1, Z6C2 and Z6C3. Contractor to provide jumbo gallery

suitable for three nos. mobile trippers up to JH-Z5 from JH Z4 over conveyors Z6C1,Z6C2 and Z6C3. Out of three trippers, two nos. (Over conv. Z6C2 and Z6C3) shallextend upto JH-Z6 and one no. shall have provision of extension up to junction housecoming in future. Maintenance hoist of minimum 5t cap shall be provided for thetrippers. Each of the three conveyors Z6C1, Z6C2 and Z6C3 shall be capable offeeding the stacking conv. Z4BC1 as well as itself in JH Z4 and stacking conv. Z5BC1as well as itself in JH Z5. Each of the two conveyors Z6C2 and Z6C3 shall be capableof feeding the stacking conv. Z6BC1 as well as future conveyor in Junction House JH-Z6.

The raw material can be either transported via. Jn House Z4, Z5 or Z6 to therespective stacking conveyors Z4B-C1, Z5B-C1 & Z6B-C1 for stockpiling or can befed directly to the reclaiming conveyors Z7-C1/ Z7-C2 which means convey material

directly from the WT/ Track Hopper to:(a) To the Blast Furnace#8 Stock House

(b) To the Fuel & Flux crushing circuit of Sinter Plant-III.

Suitable interchangeability shall be provided at Junction house JH-Z4, 5 & 6 for theconveyors by providing 2-way chutes in mobile tripper. 5T Electric hoist each shall beprovided at JH-Z5 & JH-Z6. Whereas, JH-Z4 shall be designed only as a transferpoint.

The Stacking conveyors Z4B-C1, Z5B-C1 & Z6B-C1 can form a stockpile 30m wide,350m long and 10.5 m (maximum) high with the help of Twin boom stackers.

Suitable number of electrically operated Under-Slung Cranes, Hoists etc. shall be

provided in all floors of Junction Houses and building for maintenance of equipment.Electro-Magnetic Separators, In-Line Magnetic Separators, Metal Detectors, Belt-Weigh-Scales, Air-Blasters/ Bin Vibrators shall be provided to make the systemcomplete and the operation/ maintenance smooth.

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(iii) STORAGE AND RECLAMATION OF ORE

From the Wagon Tipplers WT-B1 and the Track Hopper TH-B1, the raw material maysometimes be fed directly to the consuming plant in case of emergency. However,this shall not happen under normal circumstances, when the three Twin-boomstackers over conveyors Z4B-C1, Z5B-C1 & Z6B-C1 store the raw material in thedesignated place of the yard in bed nos. 1 to 6. Flexibility shall be in built in the JnHouses Z4, Z5, & Z6 to ensure stacking is trouble free.

Bed blending system shall be possible with the stacker running to and fro on thelength of the pile -or- on a length between two defined position in case more thanone material is stored in a bed marked by travel limit switches, which through a relaysequencing circuit, with time control-reverses the traveling gear after the travel ineach direction covering the desired length of the pile. After a layer of some pre -determined amount is deposited in one traveling direction of the stacker, probesfitted on the stacker boom gives it a raise signal as soon as a net height of materialis formed. The next layer is then formed.

Iron ore may require stockpile formation as described above for blending anduniformity. However, the emphasis on blending shall be for iron ore fines which shall

be blended while stacking.Four nos Bucket-wheel reclaimers have been envisaged for bed no. 1 to 6.

All stacking line conveyors feeders and stackers etc. shall have a rated capacity of1500 tph & a designed capacity of 1800 tph.

All reclaim line equipment shall have a rated capacity of 1500 tph and a designedcapacity of 1800 tph in the ore handling area.

Reclamation takes place by the conveyors Z7-C3 (Bed no. 1), Z4A-C1 (Bed 2or 3),Z5A-C1 (Bed no.4 or 5) and Z6A-C1 (Bed no. 6) and the reclaimed material via JnHouse Z4A, B, Z5A, B, Z6A and Z6B shall reach Jn House Z7. Two reclaim conveyorsZ7-C1 and Z7-C2 between Z6A to Z7 will receive all the materials from yard forfurther transportation.

Reclamation from OHP takes place for the following circumstances:-

Feeding of iron ore lump, dolomite, limestone, manganese, quartzite, pelletetc. to BF#8 stock house.

Transporting Limestone/ Dolomite (SP grade) and iron-ore fines to fuel & fluxcrushing area for Sinter Plant-III.

Two streams of belt conveyors shall reclaim the material from new OHP-B yard toabove places. Belt conveyor Z7-C1 & C2 shall carry the material and transport thruZ8-C1, C2, Z9-C1, C2, Z10-C1, C2 to Z11-C1& C2 to Junction house JH-Z11.Junction House-Z11 can discharge the material either to existing conveyors R103/R104 of Sinter Plant-III or proposed conveyor Z12-C1/ C2 of BF#8, with the help of

reversible conveyors. To receive the material from Z11-C1 & C2, suitablemodification in existing gallery of R103 & R104 is required. Also a junction house JH-Z11 with two reversible conveyors & tail end of belt conveyors Z12-C1 & C2 shall beerected above these conveyors. Further, conveyor Z12-C1 & C2 and then Z13-C1 &C2 shall move towards stock house of BF#8 and discharge at JH-Z15 onto reversibleshuttle conveyors J15RSC1/2. The gallery from JH-Z14 to JH-Z15 shall haveprovision for installation of three identical conveyors i.e. Z15-C1, Z15-C2 and futureconveyor Z15-C3. Suitable insert plate/ foundation bolts shall be provided for futureconveyor Z15-C3. However, future conveyor Z15-C3 is not in scope of contractor.

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Specification of future conveyor:

Length - ~ 35 m: Lift 0.0 m: Capacity 1200 tph: Belt width 1400mm

Centre to centre distance from Z15C2 3010 mm

A junction house JH-Z14 shall be provided in between the junction houses JH-Z13 &JH-Z15. Two series of belt conveyors shall discharge the Sinter at the Junction HouseZ14 over belt conveyor Z15-C1 & C2. Junction House JH-Z14 and conveyors Z14-C1/C2 shall be in the scope of Employer i.e. BSP.

Suitable Junction houses with RCC floors, diverter gates & galleries shall be providedto transfer the material from one conveyor to another. The scope of contractor shallfinish at JH-Z15 with complete drive and discharge (including reversible shuttleconveyor) facilities. The receiving belt conveyor below Z15-C1 & C2 shall be in thescope of Employer i.e. BSP. However, JH-Z15 shall have a provision (inserts/foundation bolts) to erect outgoing conveyors to Stock House.

3.2 OTHER ADDITIONS/ MODIFICATIONS AND UPGRADATION IN EXISTINGOHP (REF. DRG. NO. MEC/S/9101/11/17/0/00/00/061.B01)

(i) An Additional series of conveyor from OHP to J-20 and JH-42(Exstg)

Another proposed conveyor No J9-C1 parallel to J9-C3/J9-C4, besides conveyors R-102, shall start from Jn. House JH-9B and shall discharge the material in a proposedconveyor J9H-C1 in existing JH-9, which in turn feeds to conveyor J10-C2 in newJunction house JH-9H . Conv J10-C2 can feed proposed conveyor J11-C3, J11-RC2,J14-C2/J12-C2 (Exstg) , J15-C2. Conv J15-C2 shall feed new reversible conv. J15-RC1 in junction house JH-15, which in turn can feed either existing SMS-II feedingconv. J15A-C1 or new conv. J15B-C1. Conv. J15B-C1 or another new conv. J15B-C2which shall receive sinter from existing conv. SS-10 shall feed new conveyor J16-C3in new junction house JH-15B which in turn shall discharge onto new conv. J16-C3A

in new junction house JH-16A. Conv. J16-C3A shall discharge onto new conv. J17-C3in JH-16A which shall convey material to conveyor J17A-C1 in JH-17(exstg).Conveyor J17A C1 (Capacity 1500tph) shall discharge to either of the two conveyorsJ20C3 or J17B-C1 through a adjustable flap gate in junction house J17A. furtherJ17B-C1 shall discharge the material over J42-C2 in JH-17B. The capacity of theoutgoing conveyors J20C3 and J17B-C1/J42C2 shall be 500tph and 1000tphrespectively. Conveyor J20-C3 shall be provided with one no. belt weigh scale andhave provision of discharging onto existing sinter carrying conveyor J27-C5 (Exstg)in junction house JH-20 (Exstg). Conveyor J42-C2 shall have provision of dischargingonto existing conveyor J44-C5 in junction house J42 (Exstg). Necessarymodification/strengthening shall be carried out in junction house J42 to take care ofadditional loads by new conveyor. Suitable electrical interlock shall be provided

between the conveyors J27-C5 & J20-C3 in junction house JH-20 to trip all theincoming conveyors in case feed rate exceeds capacity (500tph) of the correspondingdownstream conveyor J27-C5. Similar interlock shall also be provided between J44-C5 & J44-C2 in junction house JH-42 to avoid any spillage/chute blockage.

These additional conveyors with gate will facilitate a new additional route for BF #7.

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

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be new Junction houses. For conveyor no. J11-C3, J11-RC2,J14-C2, J15-C2, J15-RC1, J15B-C1, J15B-C2 , J17-C3, J17A-C1, J20-C3 & J42-C2, the existing junctionhouses (JH-10, JH-11, JH-14, JH-15, JH- 17, JH-20 and JH-42) shall be suitablymodified to suit proposed conveyor transfer points/crossing over.

(ii) Up gradation of Reclaiming conveyors

The capacity up-gradation and utilization of reclaim conveyors are of utmostimportance to ensure smooth operation in the OHP.

The list of conveyors in the reclaiming circuit that shall be upgraded to 1500 tphare given in table 03.01.

Table 03.01

EXISTING PROPOSEDSLNo

CONVEYORNO

BELT WIDTH

mmCAP

BELT WIDTH

mmCAP tph

1 J9B-RSC1 1400 500m3/hr

1400 1500

The capacity of all Belt conveyors shall be 1500tph for all raw materials viz. iron ore,limestone, dolomite with 1400mm belt width and belt speed shall be 2.0 m/s with atroughing angle of 35o. (Bulk density of raw material shall be considered as 2.2 t/m3for power calculation/load data of structures and 1.6 t/m3 for volumetric capacitycalculation of conveyor)

3.3 NEW LIME DOLO PLANT (RMP III) AND SMS III CIRCUIT

Existing conveyor R-101/R-102 shall be utilized to convey raw material required forLime/Dolo Calcination plant RMP III and of SMS-III by tapping the conveyor from Jnhouse JH-N102 (With suitable modification in the Jn House) and taking a new routeto the proposed Lime/Dolo calcination plant/SMSIII. Any civil work related toinstallation of new conveyors in existing junction house JN#102 shall be contractorsscope.

The SMS grade limestone, dolomite and iron ore in existing OHP-I shall be reclaimedvia. Jn House N101, N102. Existing Belt Conveyors R101/102 coming from OHP-Ishall now mostly carry Lime stone and dolomite. In JH-N102, two existing reversibleconveyor R103A & R104A are having a provision for taking material to Sinter plantIII as well as proposed Lime Plant. A discharge chute below R103A & R104A to feedat the tail end of proposed belt conveyor L1C1 shall be provided at Junction house J-N102. Belt conveyor L1C1 shall discharge the material on L2C1 in junction house JH-L2. Conv L2C1 discharges onto conveyor L3C1 which discharges onto L4C1 in JHL3.Conv L3C1 in turn discharge material at Junction House JH-L4 to any of the twoconveyors i.e. L5C1 & L7C1 with the help of diverter Gate.

Thereafter, conveyor L7C1 will carry the material and transfer onto conveyor L9C1.Conveyor L9C1 will carry the material up to Surge Bin building JHL9 throughreversible shuttle conv. JL9RSC1. Surge bin building JHL9 shall have 3 nos. bunkersof minimum geometric capacity 190 cub m each for storing iron ore lump/limestone/bauxite. Suitable rod gate and motorized rack and pinion gates shall be fitted at thebottom of bunkers. Three (3) nos. VVF controlled vibro feeders of 420 tph capacityeach shall withdraw material from bunker and discharge it onto conveyor L10C1

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which shall convey up to Junction house JH L10 for onward transportation to SurgeBin Building for SMS-III (Surge bins with Vibro-feeder as shown in flow diagram atJH-L9 are in contractors scope.) through SMS feeding conveyor. Conveyor L10C1complete with discharge facilities and junction house JH L10 shall be in the scope ofcontractor and SMS feeding conveyor shall be in the scope of employer.

The other conveyor L5C1 shall receive material from conveyor L4C1 and discharge atJH-L5 on to conv. L6C1 which shall convey up to junction house JH-L6 and dischargeonto lime plant feeding conveyor for onward transport to Lime & Dolomite calcinationplant RMP III. Conveyor L6C1 complete with discharge facilities and junction houseJH L6 shall be in the scope of contractor .However lime plant feeding conveyor shallbe in the scope of employer i.e. BSP.

Calcined lime/dolomite is received from the day bins of lime/dolo product storagebuilding of RMP III onto conveyor L8C1.Conv. L8C1 discharges onto conv. L9C2 in JHL8 which in turn discharges onto conveyor L10C1 in Surge Bin building JH L9. Thisfinished product of RMP III is transported to the junction house JH L10 by conveyorsL10C1 which shall also carry limestone, bauxite, iron ore received directly from OHP Iyard to SMS III. The scope of contractor starts from tail end on conveyor L8C1including skirt boards.

A fixed hopper of 8 cub m capacity on conveyor L10C1 near JH L9 with VVFcontrolled vibro feeder of 420 tph capacity shall also be used to transport coke finesas and when required in the storage bins of the bulk material charging system ofSMS III. Any other material e.g limestone/ DRI can also be transported underemergency conditions through fixed hopper. Suitable ramp shall be provided tounload the material over hopper.

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4.0 Technical Specifications of DUST SUPPRESSION PACKAGE

The scope of work of Dust Suppression package includes;

4.1 Dust Suppression System

4.2 Compressed Air System

4.3 Water Supply System

4.1.0 Dust Suppression System

4.1.1 Scope of work of Dust Suppression System

The scope of work of dust suppression system include

(i) Plain water dust suppression (DS) system of track hopper & stock piles.

(ii) Plain water dust suppression system for paddle feeders of track hoppers. Thedust suppression system will be integral part of the paddle feeders and willbe captive unit of these mobile equipment.

Separate set pump (1W+1S) & water tank will be provided for dustsuppression system of each plough feeder.

(As dust suppression system will be integral part of the paddle

feeders, dust suppression system for paddle feeders shall not be inthe scope of bidder. However, the bidder has to provide Ring Header

for DS of Paddle Feeders of the Track Hopper. The water requirementof paddle feeders shall be met out by the water pumps installed for

dust suppression of Track Hopper Periphery)

(iii) Dry fog dust suppression system (DFDS) at material transfer points indifferent junction houses, hoppers/bunker/ bin buildings and other dustgenerating areas.

New OHP area:

DFDS systems will be provided at wagon tippler bottom belt feeders &conveyors, JH-Z1, JH-Z2 (including the conveyors coming from existing trackhoppers), JH-Z3, JH-Z4, JH-Z5, JH-Z6, JH-Z4A, JH-Z5A, JH-Z6A, JH-Z4B, JH-Z5B, JH-Z6B, JH-Z7, JH-Z8, JH-Z9, JH-Z10, JH-Z11, JH-Z12, JH-Z13, JH-Z14,

JH-Z15.

Existing OHP area

DFDS systems will be provided at all the new and upgraded conveyors atjunction houses JH-9B, JH-9, JH-9H, JH-10A, JH-11, JH-14, JH-15, JH-15B,JH-16A, JH-17, JH-17A, JH-17B, JH-20, JH-42, JH-N102, JH-L1,JH-L2, JH-L3, JH-L4, JH-L5, JH-L6, JH-L7, JH-L8, JH-L9, JH-L10

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

4.1.2 APPLICABLE CODES AND STANDARDS

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

latest Indian Standards specification where the same are available or the reputed

standards acceptable to the owner / consultant. In case such specifications are not

available, the work will be according to good engineering practice and norms

acceptable to owner / consultant.

4.1.3 DESIGN CRITERIA

(1) DS/DFDS system will be provided in all the new and upgraded areas(1a) Work zone dust concentration will be less than 5 mg/Nm3 (at 5m to 7 m

distance from source) above ambient level.

(2) Water line velocity will be maintained less than 1.5 m/sec. Water pipe line

will be supported at regular interval. Make-up water, quick fill, drains and

overflow connection will be included at each pump station tank. Duplex

strainer will be included at inlet to dust suppression system pumps. IS-1239

heavy class, ERW, G.I pipe line (for size up to 150 NB) will be used in the

water line. The pipes above 150 NB will be MS, spirally welded, 6 mm thick &

conforming to IS: 3589. Water pipe line will be preferably be laid over

ground along conveyor gallery. In case of non-availability of same suitable

supporting scheme will be provided to suit site. Underground pipeline

(wherever provided) will have wrapping and coating as per IS 10221

(preferably wrapping coating will be coal tar based). Hume pipe protection

will be laid at road crossing area.

(3) IS-1239 heavy class, ERW, G.I pipe line will be used in the compressed air

line. Compressed air pipeline network over ground laying will 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 will 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.

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(4) Dust suppression system for stockpiles are to suppress the generated dust due

to wind blowing. Sprinkler post of approx. 2m height will be installed on the

spray header along both sides of the stockpile. Before each sprinkler ball

valve & solenoid valve will be provided for manual control and automatic

control respectively. The sprinklers should be swiveling type. Water sprayquantity will be minimum 1.6 litre/hr/m2 of area. Sprinklers will be sized and

spaced to ensure complete coverage of stock pile. Sequence timer will control

solenoid valve open/ close operation & water spray. Sprinkler will be

operated for a predefined time period at different location of stockpile.

A bypass line (with pressure relief valve) from pump discharge line to water

tank will be provided. In addition to above a bypass line with ball valve will

also be provided.

There will be three water pumps (two working and one reserve).

(5) Spray Nozzles/Spray bar for DFDS systems at transfer points will be selected

so as to ensure complete coverage. Solenoid valves will be mounted on each

spray nozzle header at material transfer points. Solenoid valves will be

interlocked with under belt switch and conveyor drives so that spray of water

& compressed air take place when conveyor running with material. At

reversible shuttle conveyor spray nozzles will be provided at both side.

The DFDS system nozzles will have air driven acoustic oscillator capable of

producing super fine atomization of water droplets of size as that of dust

particles & blanket of extremely fine fog. The approximate water addition will

not be more than 0.2% of the weight of material being handled.

In DFDS pumping station, 2 nos. pumps (1w+1s) will be provided.

(7) Compressed air receiver and water tank at different pumping station will be

provided with connecting valve, pipe fitting, and instruments for quality

checking.

(8) In track hopper, spray nozzles will be arranged in a no. of groups to cover the

entire track hopper. Water spray in each group of nozzles will be throughsolenoid valve. The operation (open/ close) of solenoid valves may be by local

push buttons. There will be two water pumps (one working and one

reserve).

(9) In wagon tippler, spray nozzles will be arranged in three rows, at both side of

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

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group of nozzles will be through solenoid valve. The operation (open/ close)

of solenoid valves will be linked with the wagon tippler rotation, i.e wagon

tippler position switches and timers rotation.

There will be two water pumps (one working and one reserve).

(10) Compressed air station will be provided for DFDS systems. Standbycompressor will be provided.

(11) At each pump station air receiver capacity will be considered @ 16% of the

compressed air consumption in m3/min or 2 m3 capacity, whichever is higher.

(12) Adjacent to pump station of stock piles & track hopper, RCC water tank will

be provided with minimum 30 minutes water storage capacity. For all other

pump stations of DFDS system & wagon tippler dust suppression system, MS

tank of 5 mm thick with stiffener for 1-hour storage capacity will be provided

by the Contractor. The inside surface of MS tank will be epoxy painted.

(13) The Contractor will provide platform, walkway, stair case adequate for the

necessary approach to the equipment for operation & maintenance point of

view.

(14) Duplex strainer with SS filter element will be provided at inlet to dust

suppression system pumps to remove all suspended particles exceeding 100

micron

(15) Monorail with chain pulley block will be provided for handling of equipment of

weight more than 300 Kg

(16) The Contractor will 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 will be provided :

-- Independent pressure gauge & control valve (Ball valves) will be provided

for pressure regulation .This unit will housed in a steel cabinet of IP-55

construction.

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-- For flow activation, solenoid operated valves will be provided in water and

airline.

-- Belt conveyor load monitoring switch will be provided for sensing conveyor

running with material.

-- Pressure switch in compressed air line to prevent spray operation at lowpressure.

-- Indication lamp in FAS to show ON/OFF operation of spray.

-- Individual valve will have selection mode to run in Auto/Manual mode.

-- Sprinkler operation will be regulating by sequence timer.

4.1.4 EQUIPMENT SPECIFICATIONS

The equipment for "DFDS" dust control system is grouped into two main categories.

Main Equipment

The main equipment will include spray bar assemblies fitted with dual-fluid air driven

acoustic oscillator atomizing nozzles, pressure regulating units, and flow activation

stations for ON-OFF control of the system and instrumentation for auto operation.

Auxiliary Equipment

The auxiliary equipment will include water storage and pumping unit with duplex

water filter and associate electrical works, air and water piping, enclosures,

necessary hoods and skirt boards on belt conveyors / equipment to suit spray nozzle

operation.

Starter cum control panel will be provided at pumping station and local control panel

will be provided at different application points.

Brief Specifications of various components of the system are given below

Main Equipment

Spray bar assembliesThe spray bar assemblies will be manufactured from stainless steel tubing drilled

and tapped for connection of nozzle adapters. A specially designed and selected dual

fluid atomizing nozzle will 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 will be

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of stainless steel while the adaptors will be of brass. Each spray bar will 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 will

be provided in the system. The pressure regulating unit will consist of diaphragm

type pressure regulator with pressure gauge and ball valve for isolation of air and

water line. The operator can adjust both the air and water pressures independently

to change the fog characteristics to obtain optimum dust suppression results vis-a-

vis the site requirements. The pressure regulators will be installed in a metallic

enclosure with inspection door with rubber sealing arrangement. Flexible hose will

be provided for connection of PRU to the air & water pipeline.

The number of pressure regulating units will depend upon the position / elevation of

spray bars. Generally independent pressure regulating units will 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 will consist of solenoid valves in air & water line,

pressure switch in the airline, selector switch, and indication lamps. Isolation ball

valves will be provided in the air & water line. All the equipment will be installed ina metallic enclosure with inspection door with rubber sealing arrangement. Flexible

hoses will be provided with each FAS for connection to air and water pipeline.

The "ON - OFF" control of the fogging system will be through the flow activation

stations with facility for both manual and auto mode. A three-position selector switch

will be provided to select the mode of operation. The switch when energized will

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open the electric solenoid valves, which will permit compressed air and water to

enter into the pressure regulating units and spray bars.

In addition, a pressure switch will be installed in the airline to ensure that air and

water solenoid valves are energized only when sufficient air pressure is available inthe line. This will ensure that the system cannot operate without sufficient air

pressure to the nozzles and reduces the chance of un-atomized water to pour into

the dust source. Flow activation will have indication for: -

- System ON

- System OFF due to lower air pressure

Auto operation

The flow activation stations will have provision for both manual and automatic

operation. For manual operation, the system will 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 will be provided with requisite number of

spray bar assemblies with DFDS atomizing nozzles. Pressure regulating units will be

provided at each location to regulate the pressure of compressed air and water.

The dust suppression system will be divided into independent circuits taking into

account the flow diagram, operational requirements, distances between dust

suppression locations etc. Flow activation stations with instruments for auto

operation are provided for each circuit for ON/OFF control of the dust suppression

system.

Centrifugal Pump :

Horizontal back pull out pump will be provided. Pump casing will be vertically

split type. Impeller rpm will generally not exceed 1450. However, for pumps with

low capacity & high head may be provided with 2900 rpm. Pump will be coupled to

motor with flexible coupling. Spacer type coupling will be provided. Pump will

conform to IS : 1520.

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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 andwith 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 be non overloading type. Impeller will

be made in one piece & keyed to the shaft.

Material of construction

Casing - C.I

Impeller - Bronze

Bearing Bracket - C.I

Shaft protection sleeve - Bronze

Wearing ring - Bronze

Shaft - EN-8

Common base frame for pump & motor - M.S

Common base plate for pump & motor will be in one piece & made of welded steel

construction. 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.

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 be beveled. Pipe fittings will be as per

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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 be provided.

Pipes will be of welded joints. Welding (manual metal arc welding) will be as per

relevant IS code and only certified welders will be employed.

All piping systems will be hydro tested at 1.5 times the design pressure.

Auto air venting valves will be provided at highest point of the pipe lines & drain

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

Pipe supports comprising pipe shoes, saddles, base plate, clamps & structural

members like channels, angles etc. will be provided

Valves

Butterfly Valves will be provided in water line of size 65 NB and above and ball

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

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

Butterfly valve

Type : Wafer design, flange less

Body : SG iron with nitrile rubber/ EPDM lining

Disc : SG Iron with teflon (PTFE) coating

Stem : High tensile stainless steel

The valves will 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 conform to BS : 5155 / IS : 13095.

Extended valve shaft will be provided so that the lever can be operated without any

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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

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4.2.0 Compressed Air System

4.2.1 Instruction to Contractor

Dedusting system of RMH plant (Part-B) will require substantial quantity of

compressed air. Also, compressed air will be required for track hopper poking. Tomeet these air requirements, one common compressed air station along withinterconnecting inter-shop and in-shop piping facilities upto the individual consumerswill be provided in the RMH area on turnkey basis. The compressed air station will belocated suitably to ensure proper distribution of air to all the consumer points.

The Compressed Air shall be supplied to the following Areas;

A) Track Hopper BuildingB) Wagon Tippler BuildingC) Area Repair ShopD) All Water Pump Houses (5 Nos., PH-1 to PH-5)E) All Material Transfer Points where DFDS (Dry Fog Dust Suppression) system is to

be installed in various buildings, Junction Houses, Trippers etc.

Dry fog dust suppression system (DFDS) at material transfer points in differentjunction houses, hoppers/bunker/ bin buildings and other dust generating areas.

New OHP area:

DFDS systems will be provided at wagon tippler bottom belt feeders &conveyors, JH-Z1, JH-Z2 (including the conveyors coming from existing trackhoppers), JH-Z3, JH-Z4, JH-Z5, JH-Z6, JH-Z4A, JH-Z5A, JH-Z6A, JH-Z4B, JH-Z5B, JH-Z6B, JH-Z7, JH-Z8, JH-Z9, JH-Z10, JH-Z11, JH-Z12, JH-Z13, JH-Z14,JH-Z15.

Existing OHP area

DFDS systems will be provided at all the new and upgraded conveyors at junctionhouses JH-9B, JH-9, JH-9H, JH-10A, JH-11, JH-14, JH-15, JH-15B, JH-16A, JH-17, JH-17A, JH-17B, JH-20, JH-42, JH-N102, JH-L1,JH-L2, JH-L3, JH-L4, JH-L5, JH-L6, JH-L7, JH-L8, JH-L9, JH-L10

All Compressor Cooling Water Pumps, Cooling Towers, Make-up WaterPumps, Piping, Valves & Fittings, Instrumentation, Controls etc. are in the

scope of Bidder.

4.2.2 The Contractor will furnish all the drawings, documents, data like fault diagnosis,operation and maintenance manuals, general details and layout drawings, design

calculations and equipment specification of plant and equipment, together with `asbuilt' 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 andequipment. Site conditions will be assumed to be as follows:

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Temperature : 500C (Max)

50C (Min)Humidity

Maximum : 100%Minimum : 25%

Altitude above MSL : 307m

4.2.4 Selection Criteria

a) Compressors will be designed at 500C temperature and 60% RH, 350C coolingwater temp., 50 Hz frequency.

b) Performance guarantee tests will be demonstrated at 350C temperature and60% RH, 330C cooling water temp., 50 Hz frequency.

c) Motor will be selected at 50C temperature and 100% RH, 50 Hz frequency.d) Design ambient temperature for Electrics will be considered as 500 C.

e) Compressors will safely run in the frequency range of 50 Hz +3% to -6%.

4.2.5 Delivery Schedule

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

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

4.2.7 Scope of Work

The Scope of work will include design, engineering, manufacture, assembly, shoptesting at manufacturers works, painting, supply, transportation and delivery F.O.R.site of all the plant & equipment and connected utilities of compressed air facility,handling and storage at site, erection, testing, commissioning, demonstration ofperformance guarantee tests and final handing over of all plant and equipment withconnected accessories along with the following facilities.

The compressors will be housed inside a building (compressed air station). The Airreceivers will be installed outside but adjacent to the building. The building andequipment foundations including grouting and chipping works, structural works, etc.are also covered under the scope of this specification. The routing of inter-shop and

in-shop compressed air piping system will be overhead.

The compressed air station will comprise of the following main equipment :

i) Five (5) sets (3W + 1S + 1MS) each of 36 Nm3/min (@ 8 kgf/cm2(g)discharge pressure after aftercooler) oil free, water cooled rotary screwpackaged type air compressors with electric motor and all its accessories &auxiliaries including the following:

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a) Intercooler, after cooler, moisture separator with trap station,

b) Suction air filter cum silencer,

c) Lube oil system.

d) Cooling water system including duplex type filters in supply line.

e) Acoustic enclosure along with exhaust fan and necessary illumination.

Each Compressor will have dual type control system, which will permitoperation of each compressor in either of the following way:

(a) Continuous Variable Load /unload regulation(b) Automatic Start-Stop Regulation.

ii) 2 no. of Air Receivers of 12 m3 water holding capacity at 8 kgf/cm2(g)operating pressure, complete with all fittings such as safety valves, drain

connection with auto condensate trap and bypass valve, vent connections andall inlet and outlet connections with companion flanges, supportingarrangement, access platforms, instruments etc. The material of constructionwill be as per IS 2002 Gr. 2A . The air receiver will be designed,manufactured and tested according to IS 7938, 1976 (RA 1991).

iii) All necessary interconnecting pipes (from compressors outlet upto theconsumer points including dedusting system and track hopper poking),valves, fittings including supports and supporting structures.

iv) Drain pipelines from compressed air station to nearest drain/drain pit.

v) Miscellaneous structures, access platforms for operation and maintenance ofequipment parts, valves, instruments, etc. forming part of the equipment.

vi) A complete new and unused set of all special tools & tackles required foroperation and maintenance.

vii) Complete Electrics and C&I as required for the successful operation of theplant.

viii) Contractor has furnished list of itemwise spares for 2 years O&M along withunit rate. The item rates will be valid upto 12 months from last consignmentat site

ix) All anchor bolts & nuts, washers, foundation bolts, shear lugs, counter flangesfor inlet and outlet of each compressor, receivers and connected piping & baseframe for equipment. Miscellaneous materials and services, if not otherwisespecifically mentioned will be included, but not limited to nuts, bolts, washers,gaskets, necessary connections for hook up with employers pipe network andequipment.

x) List of spare parts for 2 years operation & maintenance.

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xi) Supply of first fill of lube oil & consumables and also for testing,commissioning and performance guarantee. Specification of all consumableswill be indicated.

xii) Commissioning spares (All spares used until the plant is handed over to theemployer).

xiii) Training of O&M staff of Employer for 10 mandays.

xiv) Complete civil & structural works.

xv) Contractor will provide a separate compressor for track hopper poking andwagon tippler if required.

4.2.8 PLANT ELECTRICS

The Contractor will supply complete electrical equipment for compressors.All the technical specifications of the electrical equipment/system including LT

switchgear, MCC, Metering and protection, cables, etc., shall be as per GTS/TS.

The scope of supply for electrics shall include the following:

i. Drive motors for compressors & lubrication system as well as for motoroperated valves.

ii. Control Cabinet/ Console: one for each compressor.

iii. Double compression brass cable glands and cable lugs for all electricalequipment supplied by the Contractor.

iv. For compressor motor bearing and winding temperature detection,monitoring, interlocking, signalling & annunciation, micro processor basedtemperature controller shall be provided for each motor by the Contractor.The scanner will be housed in an independent control panel.

v. Contractor shall note that the HT Power for the Compressed Air Station shallbe fed from the nearby HT sub-station through 5 nos. 6.6kV feeders. Supply,laying & termination of the incoming cables from the HT substation to thecompressed Air station along with terminations at both ends shall be done bythe Contractor. The cables shall be routed through underground trench.Further distribution of HT and LT power shall be done by the Contractor.

vi. All erection/installation accessories, cable trenches, cable support

structures/cable gallery, cable termination at ends, cable fixing, and supportmaterials etc. for all equipment within the scope of supply of Contractor withinthe plant area including cables from OHP HT switch board are in the scope ofContractor. Employer shall only provide the HT switch board at Ore handlingplant substation. Further distribution of HT and LT power shall be done by theContractor.

vii. Power and control cables from the control cabinets, for interlocking & interconnection to all motors, instruments, consumers etc.

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viii. Junction boxes with required number of terminals including 20% spare

terminals.

ix. All other equipment, accessories, field devices, safety switch etc required forsafety interlocks, process control & interlocking etc.

x. The contractor shall include all power and control cables in adequatequantities in turnkey/lot basis as per actual requirement at site.

xi. Contractor shall include commissioning spares in their scope. They are alsofurnish the list of commissioning spares.

xii. Make of all the equipment shall be restricted to the list of preferred makesgiven in the TS.

xiii. HT compressor motor shall be provided with Flux compensated magneticamplifier (FCMA) type soft starter enclosed herewith. The HT soft starter to be

designed considering the incoming feeder line distance from the supply feederend. Motor soft starter to be connected in line side of motor.

xiv. LT Power to the compressed air station shall be fed from a dedicated MCCcum PDB which shall have 2 incomers with bus-coupler arrangement.

xv. Local push button stations

xvi. UPS as per requirement shall be provided with 60 minutes backup forcompressed air station.

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 singlecore cables, cable markers, cable identification tags, and all other hardwarematerial 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 includingsource feeders, pumps/motors, cable laying, etc.

xxiv. Fire protection system including Fire Detection and Alarm System for thecomplete plant, etc.

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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 startsystem limiting motor current to 2 to 2.5 times shall be provided to ensure voltagedrop at motor terminals limited to 15% with a provision of DOL starting . Contractorto submit the voltage drop calculation, considering adequate fault level at 6.6 kVboard.

The soft start system shall be based on principle of flux compensated non-saturatedmagnetic amplifiers for control of motor starting current. Also, the starter should notintroduce any harmonics into the system.

The flux compensated magnetic amplifiers shall work on principle of flux oppositionand operate in the linear non saturable zone of magnetic circuit. The system willwork on constant mode in the starting zone so as to result in smooth start.

The enclosure class shall be IP54.

The Sheet steel thickness shall be 1.6 mm.

The control circuit will utilize auxiliary contacts and timers for starting function.

Lamp indication shall be provided using LED type lamps.

Ammeter shall be provided on front door.

The cubicle will have cable entry and exit from bottom through gland plate.

Bypass device used shall be 6.6kV contactor.

4.2.9 CONTROL & INSTRUMENTATION

General

Electronic type instruments generally working on 4- 20 mA DC signal system will beused. The instrument panel will be suitably installed in the compressor room. Allinstrumentation items will be selected to function satisfactorily in shop floorenvironment.

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List of measurements & controls

For each compressor, the list of measurements & controls will include, but not limitedto, the following:

i) Equipment/ local panel mounted measurements

i. Indication of differential pressure across suction air filter for each compressor.

ii. Indication of pressure of compressed air after after-cooler and aftercompressor.

iii. Indication of temperature of compressed air after after-cooler and aircompressor.

iv. Indication of pressure of compressed air in air receiver.

v. Indication of pressure of lube oil before & after oil cooler.

vi. Indication of temperature of lube oil before & after oil cooler.

vii. Indication of differential pressure across lube oil filter.

viii. Indication of temperature at the inlet & outlet of common header ofcompressor cooling water circuit.

ix. Indication of pressure at the outlet of common header of compressor coolingwater circuit.

x. Indication of flow of compressed air.

ii) Alarms and interlocks

01Following 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 - Alarm only.

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.

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9) Temperature of lube oil to compressor high- 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

4.2.10 COMPRESSED AIR PIPES, FITTINGS & VALVES

1. Pipe sizing will be done considering a velocity of 10 -12 m/s. The pipes will be hydrotested at shop as well as at site.

2. All pipes and valves will be as per the following tables.

Specification of Pipes & Fittings

Sl. Service Size Pipes Fittings Flanges Gaskets EndType

1.0 CompressedAir System

65NB A53 GR.Bor

IS 1239,Heavy

Grade

ASTM A234Gr.WPB

ASTMA105

Teflon Welded/Flanged

Specification of valves

Sl. Service Size Body/Bonnet

Disc Stem HandWheel

Valveends

1.0 >65NB

>25 &

< 50NB

ASTM A216 Gr.WCB

ASTM A

105

ASTM A216 Gr.WCB

ASTM A

479,Type410-2

ASTM A479Type 410-2

ASTM A

479,Type410-2

ASTM A47Gr. 32510

ASTM A47

Gr 32510

FlangedRaisedFace

Flanged

Flat Face

CompressedAir System

< 25NB

ASTM A105

ASTM A479,Type410-2

ASTM A479,Type410-2

ASTM A47Gr. 32510

SocketWelded

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

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4.2.11 TESTING

Unless otherwise stated, main equipment, valves and other ancillary units will betested to various stipulations stated in Indian Standards of BIS or any other reputedinternational standard listed.

Recommended tests on Air Compressors are listed hereunder. Compressors may betested using a suitable shop motor.

i) Volumetric and overall efficiency (type test)

ii) Capacity (Routine test)

iii) Specific power consumption from no load to full load (Routine test)

iv) Speed (Routine Test)

v) Testing of unloader (Routine test)

vi) Safety valve test (Routine test)

All other tests will be performed in accordance with IS: 5456.

4.2.12 STANDARDS AND CODES

The complete system as a whole and individual equipment will be in accordance withthe Indian Standards, British Standards, DIN or American Standards like ASME, ANSIor any other internationally accepted codes.

4.2.13 GUARANTEE AND PENALTIES

The Contractor will guarantee individual as well as integrated performance of all theequipment supplied by them for period as stipulated in the GCC prior to the date ofissue of taking over certificate by the Employer. The final acceptance certificate will beissued by the Employer after successful commissioning of the Plant by the Contractorshowing all the performance test at specified parameters.

The following parameters will be guaranteed at 350 C, 60% RH, 330 C cooling watertemp., 50Hz frequency.

Air Compressor:

* Rated Capacity at lowest : 36 Nm3/ min (each)frequency

* Rated discharge pressure : 8 kgf/cm2 (g)at the outlet of after cooler

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* Discharge temperature after :

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4.2.14 LIST OF PREFERRED MAKES

- Compressor

M/s Atlas Copco, M/s ELGI, M/s Ingersoll Rand, M/s KirloskarPneumatics.

- Electrics

1. Motors

Alstom Ltd. , Asea Brown Boveri Ltd. , BHEL, CGL, NGEF, KirloskarElectric Co.

2. Cables

Cables Corporation of India,Fort Gloster Industries Ltd.

Industrial Cable (I) Ltd.Nicco Corporation Ltd.Universal Cables Ltd.Torrent Cables Ltd.

3. Control Stations Weather Proof

Baliga Lighting equipment Ltd., Bhartia Industries Ltd.Electrical Equipment Corporation, Ex-Protecta,Shrenik & Company.

4. Light fittings & Accessories

CGL, Philips, Bajaj.

5. Actuators - MOV

Auma India Ltd.,Flow tork Inc. USA,Continental Profiles Ltd.,Rotork Control Ltd.

- Instrumentation

TRANSMITTERS (PRESSURE, FLOW & LEVEL) :

FUJI, YOKOGAWA BLUESTAR LTD., EMERSON, TATA HONEYWELLLTD, ABB.

BARGRAPH INDICATORS :FUJI, YOKOGAWA BLUESTAR LTD., MASIBUS ELECTRONICS.

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DIGITAL INDICATORS :YOKOGAWA BLUESTAR LTD., MASIBUS ELECTRONICS, RANUTROLLTD.MICROPROCESSOR BASED RECORDERS :YOKOGAWA BLUESTAR LTD., LAXSONS ENGG. & ELECTRONICS PVT.LTD.(CHINO), FUJI, ABB.

PRESSURE/TEMPERATURE GAUGES :A.N. INSTRUMENTS PVT. LTD., GENERAL INSTRUMENTS, MANOMETER(INDIA) LTD.

RTDs & THERMOCOUPLES :GENERAL INSTRUMENTS, INDUSTRIAL INSTRUMENTATION,INSTRUMENTATION LTD, NAGMAN SENSORS, TOSHNIWAL BROTHERS.

TEMPERATURE TRANSMITTER :YOKOGAWA BLUESTAR LTD, EMERSON, TATA HONEYWELL LTD, ABB.

DIGITAL SCANNER:JYOTI, LECTROTEK, PROCON, MASIBUS.

PRESSURE SWITCH :INDFOSS (INDIA) LTD., SWITZER INSTRUMENTATION PVT LTD.

FLOW TOTALISER:YOKOGAWA BLUE STAR LTD., FUJI, SIEMENS.

LEVEL SWITCH / SENSORS:

LEVEL GAUGE :

J. N. MARSHALL & SONS, LEVCON INSTRUMENTS PVT. LTD.,SIGMA.

SOLID STATE ALARM ANNUNCIATOR :APPLIED ELECTRONICS LTD. (APLAB), PROCON INSTRUMENTATIONPVT. LTD., PIRI SYSTEMS PVT LTD., IIC, MINILEC, MASIBUS.

POWER CABLES :CABLE CORPORATION OF INDIA LTD., UNIVERSAL CABLES LTD., FORTGLOSTER INDUSTRIES LTD., ASIAN CABLES LTD, FINOLEX CABLESLTD., KEI.

INSTRUMENTATION SCREENED CABLES :

CABLE CORPORATION OF INDIA LTD., FINOLEX CABLES LTD.,TOSHNIWAL CABLES, DELTON CABLES, KEI, ASIAN CABLES,UNIVERSAL CABLES.

COMPENSATING CABLES :TOSHNIWAL CABLES, GENERAL INSTRUMENTS, UDAY RAJ, KEI.

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4.2.15 Water System Facilities for Air Compressor Unit

a) Cooling Water System

i) The cooling water system will generally comprise the following main

units:-

Open Indirect Industrial water (clean) cycle:

a. Pumpsets

b. Cooling tower

c. Strainers (simplex with manual backwash through valves

operation)

d. Interconnecting piping

e. Chemical conditioning system

f. Electrics, instrumentation & control system.

ii) For cooling of plant and equipment of the air-compressor unit there shall

be a separate cooling water re-circulation system for each unit / 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.

iii) The cooling water system shall be supplied in line with the GTS with

regard to design norms (including no. of standby pumps, type of pumps,

valves and piping design) and subject to Purchasers approval.

iv)The total cooling water to the units shall be filtered through simplex

strainers. For this simplex strainers (1W+1S) of 500 microns filtration

grade shall be installed on each of the two supply headers complete with

isolation valves. Strainers shall be backwash type.

v) The cooling water circuits shall be provided with chemical conditioning

system to control corrosion and scaling and prevent bio-fouling. To reduce

blow-down higher cycle of concentration shall be targeted.

vi)Pump houses shall be provided with air-washer based air-conditioning and

ventilation system.

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vii)With a view to conserve and save upon fresh water requirement the

Contractor will plan to utilize/ reuse/ recycle the reject/blow-down from

the cooling water systems in the plant with necessary treatment etc. as

specified by the Purchaser.

viii) Make-up water for cooling water re-circulation system for thecompressor will be tapped from the Purchasers existing industrial water

network as mentioned under the clause for Battery Limits and will be

conveyed to the various consumers through a pipe network.

b) Make- up Water System

i) The water loss in the various processes in evaporation, process/ system,

minor leakages including service water requirement, etc. shall bereplenished by a separate common make-up water system to be provided

by the Contractor.

ii) Make up water system will include extension of pipelines from the battery

limit with isolation valve to the recirculation cooling water system for

equipment cooling, water circulation system for ACVS facilities as well as

service and process needs.

iii) Make-up water will be tapped from the Purchasers existing industrial

water network as mentioned above under the clause for Battery Limits and

will be conveyed to the various consumers through a pipe network.

iv)Tapping of industrial make-up water shall be based on two points feeding

and shall conform to provisions of TS/GTS. Contractor shall extend the

industrial water line with an isolation valve alongwith flow meter to his

proposed systems for service/make-up water requirement for the entire

plant area.

v) Quality of industrial make-up water is furnished in the GTS. This water will

be supplied as make-up water to Package 061 for process & cooling needs

at only one point for the entire needs of the Package 061 at battery limit

as specified. The Contractor shall provide necessary treatment facility,

wherever required, to make the water suitable for cooling and other

purposes.

vi)Drinking water & Feed water for DM Plant-Maroda-II water quality as per

GTS shall be followed,

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vii)Industrial make-up water Maroda-I water quality as per GTS shall be

followed.

viii) All make up tapings should have flow meters with by-pass arrangement

with isolation facility.

ix)Online boosting of the make-up water is not permitted. A makeup watersump with pumps and piping (pump house and sump are to be provided

by the Contractor), if required, shall be provided.

c) Water Conditioning System

i) To protect the circulation water system from corrosion and scale formation

and to bring the make up water to the condition suitable for the cooling

water requirement of air-compressor unit there shall be a waterconditioning facility as per system requirement and inline with the details

given in GTS.

ii) It shall consist of dosing tanks, pumps, valves, pipes, fitting, pipe supports

and associated civil, structural, technological structures, electrical,

instrumentation, material handling, air-conditioning & ventilation etc. The

scope of work for all these remains the same as specified for cooling water

system.

iii) These pumps may also be housed in the same pump-house for cooling

water system or separately.

iv)The Contractor shall furnish the details of chemical dosing proposed for

the system.

v) The Contractor shall include in the scope of supply three months chemicals

requirement for the chemical conditioning system from the date of

commissioning.

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4.2.16 COOLING TOWER

Type : Induced draft counter flow

Casing/ Basin : FRPFrame 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

(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

4.2.17 WATERPUMPS

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.

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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. Pump casing will be

vertically split type. Impeller rpm will generally not exceed 1450. However,

for pumps with low capacity & high head may be provided with 2900 rpm.

Pump will be coupled to motor with flexible coupling. Spacer type coupling

will 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 be non

overloading type. Impeller will be made in one piece & keyed to the shaft.

Material of construction

Casing - C.I

Impeller - Bronze

Bearing Bracket - C.I

Shaft protection sleeve - Bronze

Wearing ring - Bronze

Shaft - EN-8

Common base frame for pump & motor - M.S

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Common base plate for pump & motor will be in one piece & made of

welded steel construction. 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.

4.2.18 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 be beveled.

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

Fabricated fittings manufactured from the pipes may be provided for pipes of

sizes 200 NB & above.

Plate type pipe flanges (as per IS 6392) will be provided.

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

as per relevant IS code and only certified welders will be employed.

All piping systems will be hydro tested at 1.5 times the design pressure.

Auto air venting valves will be provided at highest point of the pipe lines &

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

segments.

Pipe supports comprising pipe shoes, saddles, base plate, clamps & structural

members like channels, angles etc. will be provided

Valves

Butterfly Valves will be provided in water line of size 65 NB and above and

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

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

required.

Butterfly valve

Type : Wafer design, flange lessBody : SG iron with nitrile rubber/ EPDM lining

Disc : SG Iron with teflon (PTFE) coating

Stem : High tensile stainless steel

The valves will be provided with integrally moulded & bonded body liner to

provide perfect seating and complete isolation of body material from fluid. The

body liner will provide the seating to valve disc, primary seal to the stem &

gasket joint with mating pipe flanges. Valves will be provided with self

locking lever operation from open to fully closed position with intermediate

positions marked on the indicator plate mounted on the top flange. The valves

will conform to BS : 5155 / IS : 13095. Extended valve shaft will be

provided so that the lever can be operated without any obstruction on the

insulated pipes. Gear operated valves will 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 valveType : 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

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Pressure Gauge

Manufacturing Standard : IS 3624

Range : 0 6 Kg/ cm2 or 0-10 Kg/ cm2

Range (at pump suction) : (-)2 to (+) 2 Kg/ cm2

Dial Diameter : 100 mm

Accuracy : + 1% of FSD

Degree of protection : IP 65

Sensing element : Bourdon tube

Bourdon tube material : AISI SS316

Connection : Screwed

Connection size : BSP (M)

Mounting : Direct with bottom entry

Case : Die cast Al stove enamelled black finish

Bezel (screwed) : Die cast Al stove enamelled black finish

Dial window : Shatter proof glass

Pointer : Al anodised black

Dial : Al white with black letters

Movement assembly : AISI 304SS

Shank : AISI 3166SS

Adjustable pulsation damper : Yes

Pressure gauges will be provided with isolation valves (Ball valves)

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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 (Track Hopper building, WagonTippler building & Junction House JH-Z1) and Drainage system for PumpHouses (6 Nos.),

4.3.2 Battery Limit

All water tappings shall be made by the Contractor through two points (~10-15m

apart) from the Purchasers network through isolation valves; make-up water

tappings shall be through flow meter with requisite isolation valves on either side and

by-pass arrangement.

a) Industrial water / Service Water

Industrial quality make-up water (quality as indicated in GTS) will be made

available to the Contractor at one point within 100 m from the proposed Package

061 area at a pressure of approximately 1.0 kgf/ cm2.

b) Drinking water

Drinking water will be made available to the Contractor at one point within 100 m

from the proposed Package 061 area at a pressure of 1.5-2.0 kgf/ cm2.

4.3.3 Specification and Description of Work

Water System Facilities:

Water system shall in general include the following facilities:-

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a) Drinking Water System

i) The drinking water shall be made available at one point near Package 061within battery limit as specified. The Contractor shall extend the pipeline

from battery limit with an isolation valve in a valve pit up to various

drinking water consumers under the subject package.

ii) Tapping of drinking water shall be based on two points feeding and shall

conform to provisions of TS/GTS. Contractor shall extend the drinking

water line with an isolation valve in a valve-pit to his proposed units for

drinking water requirement for the entire plant area.

iii) On-line boosting of the drinking water is not permitted. If the pressure,

as indicated in battery limit parameters, is felt inadequate for the area

under the scope of the Contractor, Contractor shall provide separate sump

and drinking water pumps along with piping and electrics etc. to meet the

requirement.

iv)The details and specification of pumps, valves, pipes, fitting, pipe supports

and associated civil, structural, electrical, instrumentation, material

handling, air-conditioning & ventilation etc. for cooling water system is

applicable for this system also.

v) Drinking water to be supplied to the entire junction houses, Control

Rooms, Area Repair Shop, Stores (sub-store), Welfare Buildings; except

for the Welfare Buildings the drinking water tappings shall be one for each

no. and type of premise. Drinking water shall be supplied through

continuous pumping.

b) Service Water System

For Service Water, pipeline network shall start from common pump house

to all the transfer points of each floor and conveyor gallery. In each floor,

1 no. tapping point will be provided and for the conveyor gallery the

tapping point shall be provided at every 50metre interval. For each

tapping point 1 no. gate valve, hose (DN25) and quick fix connection shall

be provided.

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For service water line each tapping point discharge rate will be 2m/hr.

and maximum 6 Nos. points can be operated at a time. Pumping system

shall be conforming to GTS for design norms including no. of standby

units, pump rpm, piping etc.

c) Dewatering system for underground premises and Drainage system for

Pump Houses

Dewatering system for underground sumps (Track Hopper building,

Wagon Tippler building & Junction House JH-Z1) and Drainage system for

Pump Houses (5 Nos.) shall be provided as required. The water from the

sumps will be pumped to the nearest surface drainage system through

pumping arrangement to be provided as per GTS and subject to

Purchasers approval.

The details of Sump Pumps are given below;

1.Track Hopper building - 4 Nos. (2W+2S), (2 Nos. each side).

2.Wagon Tippler building - 2 Nos.(1W+1S)

3.Junction House JH-Z1 - 2 Nos.(1W+1S)

All Sump Pumps shall have Cap. 50 CBM /Hr. & Head - 15 Mtr.

The details of Drainage Pumps are given below;

1.Pump House (5 Nos.) - 10 Nos. (5W+5S)

All Drainage Pumps shall have Cap. 25 CBM /Hr. & Head - 15 Mtr.

All Piping, Valves, Fittings, Instrumentation, Controls etc. are in the scope

of Bidder.

All the water lines including Drinking water, Service Water, DustSuppression Water, Dewatering, Make-up water lines will generally be laid

over-ground.

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d) Water Pollution Control and Conservation

Extensive recycling will be adopted in the design of plant water systems.

Quality of circulating water will be maintained through dosing of conditioning

chemicals for controlling corrosion, scale deposit and microbial growth.

Through cascaded reuse of blow down, the water scheme will ensure

minimization of waste water discharge from the industrial water circuits. Any

discharge/reject into the Purchasers system shall conform to the local

pollution control norms.

Design Criteria

Efficiency, reliability and flexibility of operation and maintenance will be the

guiding criteria of the design of the water system for the proposed plant.

Water system shall be designed as per TS/GTS and subject to Purchasers

approval.

The followings are the guiding factors for designing the water system:

i. The water system shall be designed & supplied generally as per the

contract document, GTS and subject to Purchasers approval.

ii. Design norms including no. of standby units, pump rpm, piping shall

conform to GTS as applicable for this package.

iii. Following MOC to be considered:

Gate valve:

Body & Cover: CS ASTM A216 Gr WCB, Disc: ASTM A216 Gr WCB Face

ring 13% Cr steel, Body seat ring: 13% Cr. Steel, Stem: SS 410, Gaskets:

Neoprene rubber, Gland packing: Rubber, End connections: Flanged to be

drilled as per IS: 6392-1971 (RA 1998) T-17.

Butterfly valve:Body: ASTM A216 Gr WCB, Disc: CF8, Seat: EPDM (integral with the

body), shaft: AISI 410 self-lubricated PTFE lined bearings for both drive

end and non-drive end, hand lever /hand wheel: pressed/forged steel, end

connection: Flanged to IS6392, T-17.

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iv. Pipe thickness shall be as per GTS (numerical values indicated for each of

the pipe sizes).

v. Tapping of Industrial water / Service water, Make up water & Drinking

water will be based on two points feeding and will conform to provisions of

TS & GTS.vi. Isolation gate valves shall be provided in suction and delivery side of

pumps as per GTS.

vii. The drainage pumps shall be split casing; self priming and horizontal

centrifugal pumps type with common base frame with drive motors, there

will be one reserve pump for one wo