TS-Compressed Air System

8/22/2019 TS-Compressed Air System

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BRAMHANI INDUSTRIES LTD.,JAMMALAMADUGU,

KADAPA DISTRICT.

MECON

LIMITED

2.5 MT CAPACITY INTEGRATED STEEL PLANT

BAR MILL AND WIRE ROD MILL

CHAPTER NO. 05.14

MEC/S/Q6L2/01/PJ/T06-001, Rev. 0 PAGE No. 05.14 - 1 of 32

2008, MECON Limited. All rights reserved.

05.14 COMPRESSED AIR FACILITIES

05.14.01 Intent of Specification

This specification is intended to cover the supply and installation of 3 nos. of 75

Nm3/min (approx.) centrifugal air compressors and auxiliary equipment in the rolling mill

area. The compressors are intended to supply oil free compressed air required to

various units of Bar mill and Wire rod mill. The air compressors and auxiliaries are to bedesigned, engineered and installed in accordance with this technical specification.

05.14.02 Instructions to Tenderer

05.14.02.01 Scope of work

The scope of work covers design, engineering, manufacture, procurement, shipping,

testing, shop painting, transportation including transit insurance, unloading at site,

storage at site, erection, testing and commissioning of the complete Compressor

System along with all related mechanical items, motors & other electrical items, piping,

instruments, cables and other accessories, its auxiliary facilities and final painting, on

turnkey basis as per the applicable standards & suitable to the site conditions.

The tenderer shall include in his scope all equipment, material, all accessories and

auxiliaries, measuring and control equipment, all necessary interconnecting pipes and

pipe fittings, wiring in conduits for instrument sensors upto terminal box mounted on

equipment and upto the control panel, electrics, earthing, which are not specially

mentioned but are required to complete the equipment offered in every respect for

satisfactory operation

01 Stage wise inspection of the equipment during manufacturing/procurement as per

approved QAP/Documents/drawings and performance test of the equipment before


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dispatch will be conducted by the contractor in the presence of owner/consultant at the

manufacturers work are also included in scope of work.

02 The location of compressors in the mill area should be furnished by tenderer and it

should be located in the area nearby maximum load center.

03 The tenderer shall comply with the equipment parameters as specified in datasheets.

04 Scope of work also includes supply of spares for 2 years for normal operation &

maintenance.

05.14.02.02 Material and Workmanship:

The materials used for manufacturing of items shall be new and best of i ts kind and shall

comply with relevant Indian / international standards. All materials used for fabrication /

assembly shall ascertain for the quality of material as per relevant standard with all

documentary support, testing and inspection, wherever required.

Qualified and certified welders shall be employed for carrying out the fabrication work.

Welder qualification as well as welding procedure qualification shall be carried out as

per applicable standards / codes in presence of Owner / Consultant as required.

The workmanship covering welding, casting, fabrication / manufacture, assembly, etc.

shall be of best quality as per relevant standards.

The material of construction of all items shall be as indicated in the datasheet/approved

drawings. Deviation, if any, from agreed material of construction shall be only with prior

approval of Owner / Consultant.


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01 Foundation Bolts, Lifting Lugs

The scope includes supply of foundation bolts, nuts, washers, base plates for the

equipment. Any special fixing / installation arrangement, if required shall have to be

spelt out and shall also be included in scope.

Equipment to be supplied shall have suitable lifting lugs, eyebolts, etc, to facilitate

erection & maintenance.

02 Inspection

Inspection will be carried out as per procedure laid down and details stipulated

elsewhere in this specification. For all items, QAP as per enclosed format shall be

submitted for approval to Owner / Consultant. Inspection shall be done based on

approved QAP. Apart from such inspection by Owner/Consultant, the Contractor shall

comply with all other inspection requirements of the applicable/specified codes or by

statuary authorities having jurisdiction over the installation.

03 Name Plate

Each equipment will be fitted with an SS nameplate containing approved details.

04 Cleaning, Protection and Painting

Internal/external surfaces of equipment must be free from oil, grease, dirt, protective

coatings (on materials as received from factory) and other foreign matter. Descaling,

pickling and passivation shall be done for all stainless steel parts. Cleaning solution

should be chloride free (especially for stainless steels). Painting shall be done as per

enclosed painting specification.

05 Spares

All spares are to be supplied as indicated in the specification and BOQ will be as per

Price Schedule.


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06 Consumables

All consumables are to be supplied in line with stipulations indicated in the

specification.

07 Special Tools and Tackles

Special tools and tackles, if any, shall be supplied in line with specification.

05.14.03 BATTERY LIMITS AND SITE CONDITIONS

05.14.03.01 BATTERY LIMITS

a) Suction of air compressor at suction filter.

b) Delivery of air pipelines - upto the user points of the mills.

c) Cooling water supply and return from cooling tower to equipment & back to coolingtower.

d) Anti-surge valve at 1 m above the building roof.

e) E lectrics : from the main electrical panel upto the equipment.

05.14.03.02 Design Conditions

1) Approx. +225 m above MS L

2) Ambient temperature : 460C

3) Relative humidity : 100% (max.)

4) P ower supply frequency : 47.5 Hz

For capacity calculations in Nm3/Hr. both 460 C and 100% RH s hall be considered

occurring simultaneously.


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Codes And Standards

05.14.04.01 System

Metric system of units shall be followed in design and manufacture of all equipment as

well as drawing /document. Name plate of equipment as well as operating /

maintenance instructions shall be in English language

05.14.04.02 Applicable Codes and Standards

The material used and the equipment supplied shall be new and the best of their

respective kinds and shall comply with the latest revision of relevant Indian Standards

specification /relevant International Standards. The equipment shall also comply with

the statutory requirements of Government of India, Govt. of Andhra Pradesh, and the

latest revision of Indian Electricity rules. Where the equipment is not according to Indian

Standard, the regulations to which the equipment conforms shall be submitted along

with the tender.

05.14.05 Techn ical Specification

The following air compressors are envisaged for Bar mill and Wire rod mills. Broad

technical parameters are given below.


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05.14.05.01 TECHNICAL PARAMETERS

11.Surge margin at 50 Hz. 75

Nm3/min, 8.0 Kg/cm2 (g)25%

12.Surge margin at 47.5 Hz. 75

Nm3/min, 8.0 Kg/cm2 (g)Not less than 10%

13.Operation at 47.5 Hz. 75

Nm3/min, 8.0 Kg/cm2 (g)Stable

14.Turndown at 47.5 Hz., 8.0

Kg/cm2 (g)25 % minimum

SL.

NO.PARAMETER DESCRIPTION

1. No. of air compressors 3 nos.(2W+1S)

2. Capacity

75 Nm3/min. (dry moisture free) with

zero negative tolerance. The volume is

net output measur ed at the after cooler

outlet3. Type of air compressor Centrifugal

4.Delivery pressure at the out let of

after cooler8.00 Kg/Cm2(g)

5.Delivery temperature at the out

let of after cooler100C above inlet cooling water temp.

6. Lubricated/non lubricated Non lubricated

7. Cooling Water cooled

8. Design power supply frequency 47.5Hz

9. No. of stages 3

10. Cooling water inlet temperature Approx. 320C



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05.14.05.02 General Requirement of Air Compressors

01 The air compressor shall be a 3 stage, integral gear design air compressor and shall be

designed generally as perAPI 672. The compressors shall be axial/ radial, mixed flow

design. The compressors shall have high efficiency over the required wide range of

operation and shall be suitable for continuous operation under the specified conditions

and shall meet the most severe and fluctuating process requirements without operating

anti-surge valve. A liberal factor of safety shall be allowed as regards to duty and

mechanical design of air compressor, so that machine shall be capable of delivering the

specific process air requirement at duty conditions indicated in the specification. The

critical speed of the air compressor shall be sufficiently away from the normal working

range.

02 The air compressor shall be of integral gear design, with suitable split casing for the

integral gear. The machine shall be of heavy duty construction, with cast-in short air

passages to reduce internal pressure drop and noise.

03 The machine parts shall be designed to balance the machine loads due to fluid flow by

suitably engineering the components to reduce, the axial thrust by canceling.

04 The inter cooler and after cooler shall be designed in such a way that, the tubes bundles

can easily be accessible for cleaning. The location of the inter cooler shall be such that

water carry over to the next stage shall be minimum (preferably least or zero). The inter

coolers and after coolers shall be external type.

05 The impeller blades shall be optionally designed in radial /mixed configuration to give

optimum size for the impellers. The diffuser and impeller combination shall be designed

to give best efficiency over wide range of capacity of the impeller. The size of the

impellers shall be chosen to deliver flows in excess of 100 % with only a slight reduction

in pressure. The design shall have low operating stress levels giving high mechanical


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integrity. The material of blades and diffusers shall be selected in such a way that the

affect of erosion and corrosion on the life of the machine is negligible.

06 Separate and horizontally split air and oil seals shall be provided to keep the air totally

oil free.

07 An acoustic enclosure for gear box & compressor shall be provided to limit the noise

level at 85 dBA at 1 meter from the compressor.

08 The capacity of the air compressor shall be controlled with the inlet guide vane control.

09 Anti Surge Control Device

An anti-surge control device shall be provided to protect the compressor against

mechanical damage for process disturbance. The device shall automatically open a

blow-off valve, when the load fluctuates below the surge line. Blow off valve (or surge

control valve) shall be actuated automatically by electric-pneumatic actuators. The anti

surge pipe shall be provided with silencer & shall be terminated 1 meter above thebuilding roof with suitable supports & cowl. The anti-surge control loop shall be

controlled from local panel. The impeller combination shall be such that the volume turn

down and efficiency of the compressor shall be optimum for the size of the air

compressor specified.

10 Turn down

The compressors will be used for supply of process air. The air demand on the air

compressors vary very widely. The compressors having high turn down will be

advantage for operation.

11 Suction Air filter


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Heavy duty dry type air filter shall be supplied. Pressure drop across the filter at full

load should not exceed the limit normally allowed for the type of filter offered. Filters

supplied shall have sufficient reserve capacity and it shall be indicated in the tender.

12 Silencer

Adequate provision of appropriate type of silencers shall be supplied for suction and

discharge sides. The expected noise level from the compressor with silencer and also

without silencer shall be indicated. The compressor casing including suction pipeline be

acoustic insulated in addition to thermal insulation so as to contain the noise level in the

limits 85 dBA at 1 meter from the compressor. The sound level from the antisurge valve

silencer shall also be less than 85 dba at 1 meter fr om the silencer.

13 Cooling system

The compressors shall be provided with inter and after coolers for the air and lubricating

oil cooler. The cooler shall be high efficiency type. These shall be water cooled. Intercoolers and after coolers shall be provided with moisture separator.

i) Inter coolers : Water cooled inter coolers shall be provided as per the compressor

manufactur es standard.

ii) After coolers: Water cooled inter coolers shall be provided as per the compressor

manufactures standard.

The cooling water requirements for 3 compressors (2W+1S), shall be included while

designing the cooling tower for the mill. Tenderer shall offer 4 cooling water pumps

each shall have capacity of cooling water required for one compressor working at full

load. Out of 4, 3 pumps will be working for 3 compressors & one will be standby. The

pumps shall be provided in the common circulating cooling water pump house of the

mill. The tenderer shall include the interconnecting waterlines to cater for 3

compressors working. Scope of suppliers shall also include the suction & delivery


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isolating valves. Each pump shall have one non-return valve, suction strainer &

pressure gauge on delivery side.

14 Lubrication & Governing oil system

A self contained oil system for lubrication of motor & Compressor and reduction gear

bearings shall be provided. The system shall comprise of a main shaft driven oil pump

& A.C motor driven auxiliary oil pump of full capacity. A D.C motor driven emergency oil

to supply only bearing lubrication and flushing oil when main and auxiliary pumps are

out of operation (if required) shall be provided. An automatic interlocking system shall

be provided to operate the various oil pumps in a sequential manner as desired for the

protection of the compressor. An oil tank of adequate capacity (5 meters retention time)

with duplex filter including changeover and all other necessary fittings and motor driven

vent blower shall be provided. Adequate arrangement shall be made for proper filtration

and cleaning of the oil as it circulates through the system. The straining elements shall

be replaceable when the machine is under operation. Not less than 2 oil coolers of

adequate size shall be provided. Each cooler shall be capable of meeting 115 %maximum requirement of the machi ne, thus providing one of the cool er as standby.

Lubricating oil line from oil filter to the machine shall be of SS 304 material. Oil filter

body also shall be of SS 304

15 Bearings

The bearings of the motor, reduction gear and compressor shall be lined with white

metal and arranged for forced lubrication. A combined journal and thrust bearing shall

be provided with adequate cooling. The bearing type selected shall be such that

vibrations are minimum. Impellers shall be provided with segmented tilting pad bearings.

16 Piping, Valves and Fittings


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Supply of air compressor and auxiliaries shall include all interconnecting compressed

air, cooling water, Antisurge and drain piping complete with valves, fittings, supports as

required for the system within the terminating points defined elsewhere in the

specification and generally as indicated below:

a) Suction air pipeline from suction filter to inlet of compressor (Stainless steel material),

and air discharge pipeline including discharge silencer, Non return valve, shut off valve

pipe, pipe fittings and supports. Expansion joints shall be provided on both inlet and

outlet pipelines.

b) Drains, vents and other miscellaneous pipelines for all the units of the

system.

c) Exhaust pipelines from all equipment. The pipelines shall be complete with blow off

valves, silencers, etc. The exhaust line leading to atmosphere shall be suitably

terminated and left such as not to cause any damage to bui lding structures.

d) Oil pipeline interconnecting various sub systems with necessary valves and pipefittings shall be provided to complete lubricating system.

17 Non-return valve

Each compressor after the after cooler shall be provided with a non-return valve of plate

type. The valve body shall be of cast steel and the nominal diameter shall be 150 mm.

18 Shut off valve

Each compressor shall be provided with a shut off valve after the non-return valve. The

body of valve shall be of cast steel and having a nominal diameter of 150 mm. The valve

shall be a butterfly with soft seating and SS 304 disc.

19 Air Receiver


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The Air receiver of capacity 15 m3 volume to be provided and arranged properly.The

inter connecting piping should be as per the scheme.

20 Filters

Each compressed air system shall be provided with the following filters

1. Materi al of construction

a) Body : Carbon steel

b) F iltering element : S intered stainless steel

2. Capacity : 75 Nm3/min.

3. Pressure : 8.00 Kg/cm2

4. Size : 5 microns

21 Electrics

All motors and other electrical equipment necessary for operation and control ofthe air compressor, shall be provided. Chapter 05.07 of the specification shall be

referred for the details. .

22 Instrumentation

1. All controls and instrumentation necessary for operation and control of the air

compressor, shall be provided. Chapter 05.07 of the specification shall be referred

for the details. The following are minimum instruments & controls required for each

compressor, over & above any other instruments & controls required shall also be

included.

A. MEASURING INSTRUMENTS.


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1. Indication & integration of air flow through the compressor, with

Pressure & temperature correction in NM/min

2. Indication & control of air pressure at the compressor discharge.

3. Instruments on the oi l cooler- on common line

a) Oil side - Inlet temperature Local gauge

- Outlet temperature Local gauge

- Inlet pressure Local gauge

- Outlet pressure Local gauge

b) Cooling water

Side

- Inlet water pr. Local gauge

- Outlet water pr. Local gauge

- Inlet water temp. Local gauge

- Outlet water temp. Local gauge

4. Indication of air temperature

- Local gauge at the inlet of compressor

- Local gauge at each inter stage

- Local gauge on delivery side of thecompressor

5. Indication of air pressure

- Local gauge at the inlet of compressor

- Local gauge at each inter stage of compressors

- Indication of differential pressure gauge on suction filter

- Indicating of each bearing temperature local panel

6. Vibration measuring system one set of X, Y probes on eachimpeller, axial vibration on each probe

7. Two displacement probes on shaft.

8. Inlet guide vane - % opening for indication on local panel

B. ALARM AND TRIPS


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1. Thrust bearing temperature High - Alarm

Very high - Trip

2. Vibration High - Alarm

Very high - Trip

3. Axial displacement of impeller High - Alarm

Very high - Trip

4. Differential pressure across the suction

filter

High - Alarm

5. Temperature of lube oil High - Alarm

6. Position of blow off valve Open - Alarm

7. Lubricating oil supply pressure Low

Very low

- Alarm

- Trip

8. Oil tank level Low - Alarm

Very low - Trip

9. Impeller Bearing temperature High - Alarm

Very high - Trip10. Suction air temperature High - Alarm

C. INTER LOCKS

1. Compressor cannot be started unless the oil level in the oil tank is above the minimum

level and so water flow is present.

2. Compressor cannot be started unless the lubricating oil pressure is within the limits.

All the bearing temperature alarms and trip level signals to be taken to DCS installed

by the owner. All analog signals and digital signals shall be wired to the local J B in

compressor room for connecting to DCS . A mod bus connection shall also be provided

05.14.05.03 Desiccant Type Air Dryer


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a) No. of desiccant air dryer : 3 nos. (2W+1S)

b) Type : Split flow no loss

c) Capacity : 75 Nm3/min..

d) Cycle time : 8+8 hours drying cycle

e) Pressure before the air dryer : 8 kg/cm2 maximum

f) Temperature before the air dryer : 43 deg. C maximum

g) Source of air : From the outlet of air compressor

h) Air pressure drop across the air dryer : Not more than 0.2 kg/cm2i) Automatic/Manual : Automatic

j) Pre filter : 25 microns sintered stainless steel

k) After filter : 25 microns after filter Sintered SS

l) Dew point after the dryer : (-) 40 deg. C atmospher ic dew point

m) Desiccant : Silica gel/activated alumina

Each air dryer shall be complete with the following:

i ) Base frame mounting all the components of the dryer

ii) Twin desiccant towers:- The towers shall be designed as per ASME

Section VIII Div-1. Materials of construction shall be as per IS :2062 Gr.

II.

iii) Instrumentation

- Air pressure gauge before and after the dr yer

- A ir temperature gauge before and after the dry er and heater

iv) Dew point apparatus

v) Timer - Mechanical


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vi) Silencers on each exhaust air lines

vii) By pass valve (ball valve) on dryer

05.14.06 Inspectio n and Testing

06.01 Inspection and Testing at Manufacturers Premises

06.01.01 GENERAL

06.01.01.01 The owner/ consultant shall be allowed to use all the inspection/testing facilities

available with the manufacturers for the purpose of inspection/testing and

tenderer shall offer all necessary facilities for the same free of cost.

06.01.02 INSPECTION

06.01.02.01 The owner or his representative will be entitled to inspect the manufacturer's andhis contractors facilities as well as review non-proprietary drawings and

calculations, quality plans, fabrication schedules, materials, workmanship and

equipment any time during the design and fabrication period. The inspections

may not disturb the normal work proceedings, unless an item being fabricated

does not comply with the specifications.

06.01.02.02 The i nspection at manufacturer's works shall be carried out by the owner/

consultant in order to ensure follow up and implementation of the approved Q C

and QA .

06.01.02.03 Inspection shall be carried based on approved drawings and specifications and

as per relevant standards.


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06.01.02.04 A copy of the order on the sub-contractors, comprising of all the detailed

specification and the qualities of the materials, bill of materials shall be sent to

the owner/ consultant sufficiently prior to the start of inspection.

06.01.02.05 The manufacture shall control his production by sample tests in his laboratory to

make sure that the materials are in accordance with the data given in the

specification of the order. The results of such tests done at the place of

manufacture shall be made available to the owner.

06.01.02.06 The tenderer shall inspect the material before offering to the owner/ consultant

for inspection and satisfy himself with regard to the quality and quantity and

issue an internal inspection certificate along with manufacturer's test certificate

duly signed by competent authority to the owner for the review. Inspection shall

be done at the place of manufacturer's premises as well as on arrival at the site

unless otherwise mentioned.

06.01.02.07 The tenderer shall intimate for inspection along with his internal inspectioncertificate at atleast three weeks prior to start of inspection. While sending the

information, the tenderer shall ensure that reasonable quantity is offered for

inspection.

06.01.02.08 During the inspection, the owner/ consultant in the presence of manufacturer

shall draw samples for testing of various properties. The supplier shall render all

the help during drawing samples, checking for physical appearance, size

tolerance and testing at their laboratory. The testing shall be conducted as per

relevant IS and / or mutually agreeable standards.

06.01.02.09 The final acceptance certificate will be issued by the owner/ consultant within a

week after completion of inspection and testing.


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06.01.02.10 In case of any dispute, the samples shall be sent to a national laboratory for

necessary testing at the full expenses of the manufacture/ tenderer.

06.01.02.11 The owner/ consultant shall have the full right to accept or reject the materials, if

during inspection and testing, the materials are found not conforming to

specification.

06.01.02.12 Inspection by the owner/ consultant or his representatives shall not relieve the

successful tender of his liability for rectifying any defects, which may

subsequently appear or be detected during or after erection. After rectification,

the testing of the plant and equipment/ pipe joints etc. shall be repeated to the

satisfaction of the owner.

06.01.02.13 All the items of work and supply as covered under this specification shall be

subject to inspection by owner/ consultant. Primer paint shall not be applied

before inspection.

06.01.03 Testing

06.01.03.01 All the necessary testing shall be carried out at the manufacturer's premises in

the presence of the owners/consultant and the test results shall be signed by

both the manufacture and the owner/ consultant.

06.01.03.02 Manufacturer shall provide all the test tools, material and test parts. If any part is

found defective the same shall be replaced by the manufacturer at his own cost.

06.01.03.03 Suitable test rigs as per relevant international approved codes and standards

shall be installed at the test premises to carry the following tests

Tes ts for air compressors

Capacity test.


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Specific power consumption test.

Speed test.

Overall efficiency

Functioning of constant pressure controls

Functioning of Anti-surge control system

Any offer test relevant to air compressor to be carried out mutually decided by

owner/consultant and the manufacturer s premises

Tests for air dryer.

a) Dew point test

b) Functional test

Tests for valves

a) Body test

b) Seat test

06.02 SITE TESTING

The following tests shall be carried out at site

06.02.01 Hydrostatic test for all pipelines, etc.

06.02.02 Supplier shall perform dew point test at the site along with the centrifugal

compressors at full load

06.02.03 Run test of compressors and its accessories

05.14.07 PREPARATION, PACKING & FORWARDING


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07.01 GENERAL

07.01.01 The successful tender on receipt of acceptance certificate shall ensure the

dispatch of the accepted material only.

07.01.02 The supplier shall in no case dispatch the materials from his works unless it has

been inspected, tested and accepted by the owner / consultant.

07.01.03. Material shall be dispatched only after receipt of dispatch clearance from the

owner.

07.02 PREPARATION

07.02.01 All openings in the equipment shall be sealed to prevent entry of foreign matter

during shipment. Couplings shall be provided with pipe lugs or tight metal caps

to protect the threads and flanges shall be provided with wooden covers bolted

in place to protect the flange face.

07.02.02 All unprotected parts liable to rust shall be given a protective coating. All moving

parts shall triple coated with a rust preventive heavy lubricant and then wrapped

in plastic suitable for prolonged periods of outside storage.

07.02.03 All items shall be provided with adequate lifting lugs to facilitate unloading and

handling before and during erection and shall be properly braced and supported

during handling and shipment.

07.02.04 All items are to be permanently marked with the respective equipment, part and

order numbers.

07.02.05 All components shall be aligned and mating parts marked before disassembly for

shipment.


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07.02.06 All machined surfaces shall be protected against corrosion and physical damage

during shipping.

07.03 PACKING & FORWARDING

07.03.01 All equipment shall be suitably packed to prevent any damage or deterioration

during transit.

07.03.02 Packing must also be suitable for inland transport, railway or truck, and strong

enough for several reloading and long term storage under the climatic conditions

specified under "Site Conditions .

07.03.03 Packing must be suitably for crane, fork lift or hand loading operations.

07.03.04 All connections/protrusions shall be suitably protected. Flanges, if any, shall be

provided with suitable wooden disc protection fastened to equipment as bolts.

Threaded connections shall be closed with plugs.

07.03.05 Fragile components shall be specially protected during handling and storage.

07.03.06 All items are to be permanently marked with the respective equipment, part and

order number s.

07.04 ERECTION AND COMMISSIONING

07.04.01 General

a) The erection of all plant and equipment shall be carried out according to the

latest engineering practices and according to the working drawings,

specifications, instructions etc. duly approved by the owner/ consultant. The

tenderer shall carry out the works in the presence and/ or as per the


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instructions of site engineers /supervisory personnel deputed by the Owner.

The erection shall be carried out by highly skilled workmen.

b) The Tenderer shall take care of positioning, leveling and plumbing of all

pipelines and equipment as well as supporting structures within the

required accuracy and tolerance limits. It shall be a contractual obligation

that the pipes are not thrown out of alignment or lifted off curing

commissioning and subsequent operation.

c) There may be more than one contractor working in the area at the same

time. As such the work has to be carried out in proper co-ordination and

consultation with the Owner and all other parties concerned with the work.

The Tenderer shall take due notice of the working conditions, practices and

agreements prevalent in the area of the plant site and satisfy himself before

quoting.

d) The Tenderer shall be responsible for paying strict attention to statutoryregulations for prevention of accidents and to other safety rules. The

regulations for prevention of accidents shall be displayed at appropriate

places and should be distinctly visible to all personnel working in the area.

e) The Tenderer shall submit with the tender, a list of similar works executed

by him, indicating the column of erection work in each of them.

f) The Tenderer shall supply all required consumables, construction and

erection materials, petrol, diesel, oil, kerosene, solvents, sealing

compounds, tapes, brazing and soldering materials, welding sets, pipe

bending matches, cable clamping tools, gauges, erection bolts, nuts and

packing sheets/ compounds, temporary supports, wooden blocks, spacers,

templates, jute and cotton wastes, sand and emery paper etc. as required

for satisfactory completion of erection work.


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g) The Tenderer shall make his own arrangement for handling the equipment

and pipelines at the stores and transporting it to the site of installation.

h) In addition to the above, the Tenderer shall follow all the relevant erection

clauses/ conditions stated under various chapters of this specification.

07.04.02 Equipment (Compressors, Air dryers, etc)

a) The equipment shall be erected on prepared foundation and leveled with

shims and wedges with the help of precision levels and other instruments.

b) The drive and coupling shall then be coupled and aligned. The method of

alignment and tolerance for alignment shall be maintained as specified in the

manufacturer's instruction manual.

c) During manual rotation, it shall be ensured that the shaft assembly movesfreely and no noise develops from bearings.

d) Before coupling the motor to the equipment it shall be ensured that the

direction of rotation of the motor corresponds to that of the equipment

indicated by the manufacturer /supplier.

07.04.03 Valves

Before erection of valves, it shall be ensured that

a) All grit and foreign matter are removed from the inside of the valves before

connecting the pipes.


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b) All the faces are thoroughly cleaned and coated with a thin layer of mineral

grease.

c) Valves shall normally be installed with the spindle vertical except on vertical

pipes where the spindle shall be horizontal.

The valves shall be tightly closed when being installed, to prevent any foreign

matter from getting on between the working parts of valves.

07.04.04 Piping

Laying and joining of pipelines

a) Compressed air pipes shall not be connected by screwed joints. They

shall be butt welded by electric arc welding.

b) Pipes shall be laid to lines and levels as shown in the approved drawings.Laying and joining of welded pipes shall be as per IS :5822-1994. For

making welded joints, the welding shall be performed by the manual

shielded metallic arc process. All welding including the proposed

procedure and the qualification of welders and welding operations shall be

done according to power piping code ANSI B 31.1 and ASME Section IX

or approved equivalent. Pipes for butt welded run shall be supplied with

ends levelled by machining or grinding. The ends of the pipe -to-pipe, pipe-

to-fitting and fitting-to-fitting joints shall be aligned as accurately as is

practical within the existing commercial tolerance on pipe diameters, wall

thickness and out- of -roundness. Alignment shall provide the most

favourable conditions for weld deposition of the root bead. Welds shall be

full penetration, continuous without defects.


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c) As a rule, butt welding shall be carried out without interruption until the

entire joint is welded. In any case, however, welding of butt joints must not

be interrupted till atleast 50% to 60% of welding thickness is completed.

d) If there is an unscheduled interruption in such work, it is necessary to

ensure slow and uniform cooling of metal by covering it with asbestos or by

other means to eliminate the possibility of sharp zonal cooling of metal.

Before starting the welding again, it is necessary to heat the butt upto the

required temperature and maintain this temperature till the butt welding is

completed.

e) Besides systematic inter-operational control, the quality of welded joints

shall be controlled by visual inspection and mechanical tests in conformity

with the provisions of applicable standard codes.

f) The Contractor shall supply/fabricate and install pipes and fittings in strict

compliance with the detailed engineering drawings. Deviations ifconsidered necessary to suit site conditions could however, be permitted in

consultation with and with prior approval of the Owner/ Consultant.

g) All openings in the piping shall be kept effectively closed until assembled

in the system to avoid foreign matter entering into the system.

h) All piping shall follow the general arrangement drawings, shall be cut

accurately to measurements established for the work by the Contractor

and shall be installed without springing.

i) All piping shall be installed with adequate clearance for lighting, bracing,

doors, windows and other openings.


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j) Piping shall be arranged in the straightest possible runs with minimum

amount of fittings. Flanges of the pipelines, fittings, etc., must be so

mounted that top bolt holes are symmetrical about the vertical axis of the

flange.

k) J oints should be as far as possible located at one third span from supports

and must be avoided in the middle of the span.

l) Openings provided in the walls for pipelines must be closed with bricks or

mortar with 10 to 20 mm clearance between the brick work and pipe. The

clear space must be stuffed with felt or asbestos.

m) The Contractor shall supply/fabricate and install pipe supports and all that

is necessary to completely support all the piping and piping components

including but not limited to beam clamps, pipe clamps, fabricated structural

supports, guides and anchors, brackets, saddles, U-bolts, etc. Only

approved type of anchor fasteners shall be used for RCC ceiling and walls.Also supporting members required in addition to building structure shall be

furnished and installed. Concrete pedestals for supporting the pipes as

well as valves are also included in the Contractor s scope of work.

n) Screwed joint (wherever applicable)

Pipe sealant shall be used to makeup screwed joints and shall be applied

to male threads only. Threaded parts shall be wiped clean of oil or grease

using appropriate solvent if necessary and allowing proper time for drying

before applying the sealant. Pipe shall be free from fins and burs. Pipe

ends shall be reamed or filled out to size of bore and all chips shall be

removed.

Mating surfaces shall be coated with white lead. All the joints shall be


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ensured for water tightness.

o) Flanged joint

Flanged joint shall be used for connections to vessels, equipment, flanged

valves, and road crossings and also on suitable straight lengths of pipelines

of strategic points to facilitate erection and subsequent maintenance work.

05.14.08 PERFORMANCE GUARANTEE

1. The performance of the individual equipment of the system shall be guaranteed

by the contractor as per the requirements of individual equipment specification.

2. For compressors & air dryers, power consumption at the motor/ dryer terminal

shall be guaranteed. The additional power consumption for each compressor /

dryer shall be penalized at the rate of Rs . 3,00,000/- per extra kW, drawn from

the mains.

3. Input Power to Motor of Compres sor indicated is guaranteed value without any

positive tolerance.

4. Party shall carryout the test for establishing guaranteed input power to motor at

the works during inspection, prior to dispatch. All test facilities & measuring

instruments of required accuracy shall be provided at the works, with no extra

cost to owner.

5. The guaranteed motor input power shall be indicated as per enclosed format

along with the price bid and blanked format shaft power shall be submitted along

with the technical bid.

05.14.09 LIST OF APPROVED MAKES


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1. Centrifugal Air compressors Atlas Copco, Ingersoll Rand, Chicago

Pneumatics, Elgi Equipment, CICB

Siemens, Industrial systems & equipment

BHEL, Bharat pumps & compressors ltd.,

Industrial systems & equipment, Cooper

turbo compressors, Buffalo, USA

2. Air dryers Refrigeration type Del Air

Gem equipment

Lloyds Steel Industries

Sanpar Air dryers

3. Air receivers Gem equipment

L&T

Lloyds Steel Industries

Artson Engineering Ltd.,

Patel Air Temp (India)

Cethar VesselsEagle Engineers

4. Intercoolers / After coolers. BHPV

Excel Engineering & Design organization.

Reliance Heat Transfer Pvt. Ltd.,

Kaveri Engineering

As per manufacturers standard


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5. Seamless P ipes TATA

J indal

Lloyds Metals & Engineers

BHEL

Steel Tube Company

Maharastra Seam less Ltd.,

The Indian Seam less

Metal Tubes Company Ltd.,

6. Centrifugal Pumps Best and Crompton

KSB Pumps

Mather & Platt

Beacon Weir Ltd.,

Kirloskar Brothers

7. Ball Valves Audco India Ltd.

KSB Pumps

Virgo Engineers.

Micro finish

8. Non Return Valves Audco India Ltd.

KSB Pumps

9. Cooling Towers

Paharpur

Thermopack

Gem

10. Fine Filter Ultra Filters

Dominic Hunter

11 Motors SIEMENS / Bharat Biglee / ABB / Kirloskar

/ Alstom / Crompton Greaves

12 Switchgear & Control gear : SFU,

ACB, MCCB, Load break switches,

Fuses, Contractors, Overload Relays

with SPP,

SIEMENS / L & T / GEPC / CGL/ ABB


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13 Control voltage Transformer Southern Electric / KAPPA / Automatic

Electric / Kalpa

14 Control Circuit Breakers SIEMENS / MDS / STD / GEPC / Havell /

Indo Kopp / North West Switchgear / S &

S Power Swtich gear

15 Meters : Ammeter, Voltmeter AE / IMP / MECO

16 Push buttons Vaishno / Siemens / L & T / BCH / GEPC

17 CTs/PTs Pragati/Kappa/P recise/AE

18 Control/Selector switches Kaycee / Salzer

19 LT Power Cables & LT Control

Cables.

Asian / CCI / Finolex / Fort Gloster / KEI

/Nicco / Polycab / Universal

Yokogawa Blue star Ltd

Tata Honey Well Ltd

20

Transmitters SMART type

(Pressure, flow, level and DP)

Rosemount (India) Pvt Ltd

Engineering Specialties Pvt. Ltd.Micro Precisions

Instrumentation Ltd

Hydro pneumatic

21 Flow Measurements(Orifice plate)

Baliga

22 Pressure Switches Switzer / Indfoss / Varmatrafag

23 Local pressure gauges / temperature

gauge

H Guru / Waree instruments / WI /

General instruments

SB Electro Mechanical

Nivo Controls / Placka instruments

24 Level Measurement

Sigma / Chemtrols / KROHNE-

MARSHALL


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General instruments

Pyro Electric

Toshbro Pvt Ltd

25 Temperature Measurement

Instrumentation Ltd

ASCO / Rotex / Schrader26 Solenoid valves

Duncan Ltd

Samson / ARCA / FOURESS

Instrumentation LtdFisher xomox

27 Control Valves

MIL Controls Ltd.

28 Control Panel Megatech, Chemin control,

Instrumentation Ltd

29 Digital Indicators /

Controllers / Recorders.

Yokogawa Bluestar / Leetrotek Systems /

MASIBUS / SIEMENS / ABB

30 Programmable logic controller SIEMENS/ABB/Allen Bradely/GE/Fanuc

31. Micro processor based meters Enercon/Swift/Neptune/ABB/Siemens

32. Indicating meters AE/IMP/MECO/Rishabh

33. LT MCCs & PDB Schneider/L & T / Siemens

34. ACBs Schneider/Siemens/L & T

35. MCCBs Merlin Gerin/L & T/Siemens/ABB

36. MPCBs Siemens / Telemechanique / Sprecher

and Schuh

37. Contactors, O / L relays with SPP Telemecanique/L & T / Siemens

38. SFU, Load break switches, Fuses, , SIEMENS / L & T / GEPC / Schnieder/

ABB

39. Control voltage Transformer Southern E lectric / KAPPA / Automatic

Electric / Kalpa / Pragathi Electrics

40. MCB / ELCB MDS/Hager/Siemens

41. Motor protection relays L & T (MM-30) / Schneider


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(SEPAM)/Multilin (239)

42.Variable Frequency Drives

ABB / Siemens / L & T/ Schneider / Allen

Bradley

43. Cables NICCO/Polycab)/Fort

Gloster/Universal/RPG (LT power &

control)/Delton (control)

44. Push buttons Vaishno / Siemens / L & T / BCH / GEPC

45. Indicating lamps (LED type) Siemens / Raas Controls / L&T46.

Industrial P lugs & SocketsBest & Crompton/Schneider Electrics/

Bharatia Industries

47. Local push button station BLEP/Flexpro/Flameproof

Equipment/Pushtron

48. GRP cable Trays ERCON/General composites/Densons


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BAR MILL & WIRE ROD MILL

CHAPTER NO.05.15 SECTION I

MEC/S/Q6L2/01/PJ/T06-001, Rev. 0 PAGE No.05.15 - 1 of 1


SECTION I : CONTENTS & GENERAL SCOPE

1.00 The Technical specification for civil works is covered under the following

chapters :

SECTION DESCRIPTION NO.OF

PAGES

SECTION - I CONTENTS & GENERAL SCOPE 1 - 5

SECTION - II ACHITECTURAL AND DESIGN

REQUIREMENTS6-29

SECTION IIII TECHINICAL SPECIFICATIONS 30- 211

SECTION IV DIMENSIONAL TOLERANCES 212-218

SECTION - V METHOD OF MEASUREMENT 219

SECTION VI SAFETY REQUIREMENTS FOR

CONSTRUCTION WORKS220-224

SECTION VII LIST OF RECOMMENDED MAKES &

MANUFACTURERS225-228

2.00.00 GENERAL SCOPE OF WORK

2.01.00 The work to be performed under this specification consists of providing all

labour, materials (For owner supplied materials refer clause 2.11.00),

construction equipment, tools and plant, batching plant, scaffolding,

supplies, transportation, all incidental items not shown or specified, but

reasonably implied or necessary for successful completion of the work

including Contractors supervision and in strict accordance with the


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drawings and specifications.

2.02.00 The nature of work shall generally involve earthwork in excavation

including hard rock/ soft rock, dewatering, shoring and strutting,

backfilling around completed structures and plinth filling, disposal of

surplus excavated materials, piling if required, formwork, placement of

reinforcement, inserts, steel gratings, checkered plates, anchor bolts,

concreting, brick work, architectural finishes etc., construction of RCC

foundations, structures, trenches, laying of GI/ PVC conduits and other

ancillary items.

2.03.00 The layout and levels of all structures, etc. shall be made by the

Contractor at his own cost from the general grid of the plot and bench

mark given by the Consultant. He shall provide all instrument, materials

and men to the Consultants for checking the layout and levels. However,

the Contractor shall be fully responsible for correctness of layout and

levels

2.04.00 The contractor will be required to set up site laboratory at his own cost

and maintain all the equipment in proper condition with all calibration and

certificates of the equipment. The site laboratory will be manned by

independent qualified engineer. The cost of setting up site laboratory and

performance of all the tests shall be borne by the Contractor. In case any

specific test such as testing of reinforcement, testing of specific materials

requiring specialist equipment and conditions, shall be done in approved

laboratories. The cost of such tests and the arrangements for witnessing

such tests shall be borne by the Contractor.


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2.05.00 The contractor shall be required to make all arrangements for storage of

materials like cement, steel, and other construction materials. In case the

materials are issued by the owner, the cost of transportation, weighment,

loading & unloading shall be to contractors account.

2.06.00 The scope of work also includes clearance of site of any vegetation,

bushes, scrap, debris, etc. before starting the work and recording spot

levels at the site of work as well as storage areas. The cost of such

clearance shall be included in the quoted rates. The Contractor shall also

clear the construction site of all debris and construction materials before

handing over.

2.07.00 The construction site is in arid area, water table is expected to be very

low. However, the Contractor shall adopt dewatering methods as

approved by Consultant. The period for which the de-watering should be

in effect shall be as directed by the Consultant.

2.08.00 For underground structures like cable cellars, hydraulic room, tunnels,

scale pit requiring open excavation with dewatering, completely dry

working conditions during excavation, shuttering, placement of

reinforcement, concreting, water proofing of structures, backfilling and

any other operation shall be maintained by suitable dewatering method as

approved by Consultant.

2.09.00 All costs towards construction of temporary roads, covered and open

storages, site office, fencing watch & ward/ security, receiving,

transportation, loading & unloading of owner supplied materials shall be


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deemed to have been included in the quoted rates.

2.10.00 Cost towards inspection, testing of materials, workmanship, etc is

deemed to have been included in the quoted rates unless specified

otherwise in the specifications and schedule of items.

2.11.00 Client intends to supply cement, reinforcement steel, steel for light

structural and embedded conduits. The general requirement of these

materials, size-wise shall be brought to the notice of the client well in

advance so that work does not get hampered due to lack of availability of

materials.

3.00.00 DRAWINGS

3.01.00 The work shall be executed in accordance with the specification and the

drawings issued for construction. Drawings will be issued by the turnkey

supplier of the plant facilities in stages in close coordination with the

availability of data and sequence of construction. Drawings for such

facilities which are outside the scope of the turnkey supplier will be

furnished by the consultant. Only latest revisions of the drawings shall be

followed. All old revisions shall be clearly marked SUPERCEEDED and

kept separately or destroyed as directed by Consultant.

4.00.00 SITE RECORDS

4.01.00 All works shall be recorded in appropriate proformas to be firmed up by

the contractor in consultation with the Consultant. Where ever required


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reference to drawings and clauses of specification shall be recorded in

the correspondence.

4.02.00 Records of cement and steel receipts, issue, and consumption shall be

scrutinized from time to time by consultants and Owner. Statement of

cement and steel receipts, statement of theoretical consumption and

reconciliation accompany every bill. Records of spot levels jointly

recorded before the start of the work shall form the basis of all

measurements.

5.00.00 APPROVAL AND TESTS

5.01.00 A high standard of quality is required for all materials and workmanship in

construction work. They shall be best of the kind obtainable indigenously

in each case and shall be procured from manufacturers of repute in order

to ensure uniformity of quality and timely supply.

5.02.00 All materials shall be subjected to inspection and testing. The Contractor

shall submit samples for testing as may be required by the Consultant.

Sampling and testing shall be carried out in accordance with relevant IS

Standards.

5.03.00 Where ever IS codes are referred, they shall be latest edition/ publication

as on date irrespective of the date of finalisation of the work.

6.00.00 REJECTION OF MATERIALS


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6.01.00 Any material brought to site which, in the opinion of the Consultant is

damaged, contaminated, deteriorated or does not comply with the

requirement of this specification shall be rejected.

6.02.00 If the routine tests or random site tests show that any of the materials,

brought to site, do not comply in any way with the requirements of this

specification or of IS codes as applicable, then that material shall be

rejected.

6.03.00 The Contractor at his own cost shall remove from site any and all such

rejected material within the time specified by the Consultant.

7.00.00 SITE MOBILISATION

7.01.00 Tenderers shall clearly indicate their present job commitments and their

proposed deployment for the present work. Tenderers shall also indicate

the capacity of their construction equipment and their availability in

respect of the following:

a) Batching plant

b) Weigh batchers

c) Concrete pumps

d) Tuffets

e) Transit mixers

f) Shuttering material

g) Barbending equipment

h) Vibrators


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i) Pumps and curing methods

7.02.01 Tenderers shall also indicate their proposed deployment of site personnel

and their responsibilities.

7.03.00 Tenderers shall indicate their internal quality assurance plan


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CHAPTER NO.05.15 SECTION II

SECTION II : ARCHITECTURAL AND DESIGN PARAMETERS

1.0 GENERAL

1.1 This part of the specification defines the Architectural requirements and

design parameters for analysis and design of the civil buildings, civil

Structures and facilities.

2.0 ARCHITECTURAL DESIGN REQUIREMENTS

2.1 Architectural design shall be in accordance with the following referenced

publications:

a) National Building code of India,

b) State Government Factories Act.

c) Local Municipality or any other authoritys Bye-laws as applicable.

2.2 Spatial requirements:

2.2.1 Spatial requirements inside a building shall be based on the activities to be

performed in the building, equipment layout, etc.

2.2.2 The objective of spatial arrangement is to satisfy functional requirements

and physical comfort and safety regulations as well as aesthetics which has

significant role in creating a favourable working and living conditions.

2.2.3 However the following are the limiting sizes, dimensions for various

purposes, which are to be adhered to:

TS-Compressed Air System

Documents

Transcript of TS-Compressed Air System