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Tender Document
Main Oven with motorized trolley drive system and internal Mandrel Water circulation system & Agni Oven
and
Electrical, Instrumentation & Control Systems
Satish Dhawan Space Centre SHAR
Indian Space Research Organization
Sriharikota
October 2017
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Table of Contents
1. Scope of the Tender .................................................................. 8
1.1. Introduction ............................................................................ 8
2. General Terms and Conditions .................................................. 8
2.1. Instruction to Bidders .............................................................. 8
2.2. Schedule Price ....................................................................... 12
2.3. Customs Duty ....................................................................... 13
2.4. Publicity Related to Tenders ................................................... 14
2.5. Site Visit ................................................................................ 14
2.6. Validity of Offer: ..................................................................... 14
2.7. Cost of Bidding ...................................................................... 14
2.8. Applicable Language .............................................................. 14
2.9. Project Monitoring ................................................................. 15
2.10. Arbitration ............................................................................. 15
2.11. Applicable Law & Jurisdiction ................................................ 16
2.12. Acceptance and Rejection ...................................................... 17
2.13. Suspension ............................................................................ 17
2.14. Performance Bank Guarantee ................................................ 17
2.15. Foreign Exchange Outgo and Variation .................................. 18
2.16. Liquidated Damage ................................................................ 18
2.17. Security Deposit .................................................................... 18
2.18. Earnest Money Deposit .......................................................... 18
2.19. Force Majeure ........................................................................ 19
2.20. Extension of Time .................................................................. 20
2.21. Warranty ............................................................................... 20
2.22. Payment Terms ...................................................................... 21
2.23. Delivery ................................................................................. 22
2.24. Packing & Forwarding ............................................................ 23
2.25. Exclusion of Tenders ............................................................. 23
2.26. Drawings ............................................................................... 23
2.27. Arrangement of Bid ................................................................ 24
3. Documents Comprising the Bid ............................................... 25
3.1. Part – I Technical and Unpriced Commercial .......................... 25
3.2. Part – II Priced Commercial Bid .............................................. 26
3.3. Bid Submission ..................................................................... 26
3.4. Bid Evaluation ....................................................................... 27
3.5. Determination of Responsiveness ........................................... 28
4. Scope of Works: ....................................................................... 31
4.1. Main Oven with motorized trolley & Internal Mandrel water circulation system ................................................................. 31
4.2. Agni Oven .............................................................................. 31
4.3. Instrumentation and Control Systems.................................... 31
4.4. Electrical Systems ................................................................. 31
4.5. Inspection & Testing .............................................................. 32
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4.6. General Description ............................................................... 32
4.7. Equipment & Services to be provided by the Supplier............. 34
4.8. Instructions during Fabrication ............................................. 39
4.9. Codes and Standards ............................................................. 40
4.10. Safety .................................................................................... 40
4.11. Painting ................................................................................. 41
4.12. Summary of Data to be furnished by Party ............................. 41
5. Main Oven with Motorized trolley and internal water circulation system 44
5.1. Basis of Design & System Description .................................... 44
5.2. Outside Atmospheric Conditions ............................................ 46
5.3. Oven Parameters ................................................................... 46
5.4. Oven Construction ................................................................. 47
5.5. Air Distribution System ......................................................... 48
5.6. Heating System...................................................................... 50
5.7. Power Supply ......................................................................... 52
5.8. Temperature Uniformity ......................................................... 52
5.9. Interlocks .............................................................................. 53
5.10. Motorized Trolley ................................................................... 53
5.11. Wiring ................................................................................... 59
5.12. Internal Mandrel Water Circulation System............................ 59
6. AGNI Oven .............................................................................. 69
6.1. Basis of Design & System Description .................................... 69
6.2. Specification of AGNI Oven .................................................... 71
6.3. Interlocks .............................................................................. 71
6.4. Atmospheric Conditions ......................................................... 72
6.5. Oven Parameters ................................................................... 73
6.6. Oven Construction ................................................................. 73
6.7. Air Distribution System ......................................................... 74
6.8. Heaters & Heater Battery ....................................................... 75
6.9. Electrical Requirements ......................................................... 76
7. Electrical Systems................................................................... 79
7.1. Scope of Work – Electrical Systems ........................................ 79
7.2. General Terms ....................................................................... 79
7.3. Intelligent Motor Control Centre (i-MCC) ................................ 80
7.4. Feeders for Intelligent Motor Control Centre (i-MCC) .............. 87
7.5. Motor Management System (MMS) ......................................... 93
7.6. Measuring & Monitoring Requirements .................................. 95
7.7. Operation Modes ................................................................... 97
7.8. i-MCC Configuration for Operating Modes .............................. 98
7.9. Terminal Blocks and Labels ................................................... 99
7.10. Power & Control Cables ....................................................... 100
7.11. Cable Termination ............................................................... 101
7.12. Control Wiring ..................................................................... 102
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7.13. Cable Trays ......................................................................... 102
7.14. List of Cables ....................................................................... 102
7.15. Inspection – FAT & SAT ....................................................... 103
7.16. Erection & Commissioning ................................................... 104
7.17. Training ............................................................................... 105
7.18. Standards ............................................................................ 105
7.19. Spares ................................................................................. 106
7.20. Technical Specifications (Data Sheets) ................................. 107
8. Instrumentation & Control Systems ...................................... 120
8.1. Scope of Work ...................................................................... 120
8.2. Equipment & Services to be supplied by the Party................ 120
8.3. General Instructions to the Party ......................................... 121
8.4. Design & Reviews ................................................................ 124
8.5. Inspection – FAT & SAT ....................................................... 124
8.6. Training ............................................................................... 125
8.7. The PLC system ................................................................... 126
8.8. The SCADA system .............................................................. 132
8.9. Data Acquisition & Control System (DACS) programming ..... 136
8.10. Power Supply Systems ......................................................... 138
8.11. Safety Systems .................................................................... 139
8.12. Cables ................................................................................. 140
8.13. Earthing .............................................................................. 140
8.14. Equipment or Services not in the scope of the contract ........ 141
8.15. IO Details – Main Oven ........................................................ 141
8.16. IO Details – AGNI Oven ........................................................ 151
8.17. IO Details – Control Room .................................................... 160
8.18. IO Channel / Module Summary ........................................... 162
8.19. Instrumentation Items ......................................................... 164
8.20. Technical Specifications (Data sheets) .................................. 170
9. Suggested Vendors ................................................................ 202
9.1. Main Oven, AGNI Oven & Sub Systems – Mechanical ........... 202
9.2. Electrical Systems ............................................................... 203
9.3. Instrumentation & Control Systems ..................................... 204
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List of Figures
Fig. 1. Motorized Trolley ........................................................................ 55
Fig. 2. Control Consoles ...................................................................... 196
List of Tables
Table 1. Specifications of the Ovens ..................................................... 32
Table 2. Codes and Standards............................................................. 40
Table 3. Ovens Parameters .................................................................. 46
Table 4. Drive System Specifications.................................................... 55
Table 5. Pump Specifications ................................................................ 62
Table 6. List of Items for Water Circulation System ............................. 63
Table 7. Specification of AGNI Oven ..................................................... 71
Table 8. Interlocks of AGNI Oven .......................................................... 71
Table 9. Feeders for i-MCC – Main Oven .............................................. 87
Table 10. Feeders for i-MCC – AGNI Oven .............................................. 89
Table 11. Parameters – Digital & Analog................................................ 95
Table 12. Power Cables – Quantity – Main Oven ................................. 102
Table 13. Power Cables – Quantity – AGNI Oven ................................. 103
Table 14. List of Standards .................................................................. 105
Table 15. List of Spares – Main Oven ................................................... 106
Table 16. List of Spares – AGNI Oven................................................... 106
Table 17. Specifications of Switch Gear - ACB ..................................... 107
Table 18. Specifications of Switch Gear - MCCB .................................. 108
Table 19. Specifications of Switch Gear - MPCB .................................. 108
Table 20. Specifications of Switch Gear - MCB .................................... 109
Table 21. Specifications of Switch Gear - Contactor ............................. 109
Table 22. Specifications of Switch Gear – Aux Contactor ..................... 110
Table 23. Specifications of Switch Gear - OLR ..................................... 110
Table 24. Specifications of Earth Leakage Relay ................................. 110
Table 25. Specifications of Power & Control Cables ............................. 110
Table 26. Specifications of Soft Starter ................................................. 111
Table 27. Specifications of VFD for BOGIE MOTOR .............................. 112
Table 28. Specifications of Electric Motors – Blowers & Pumps ........... 112
Table 29. Specifications of Electric Motors – Bogie Motor ..................... 113
Table 30. Specifications of Thyristor Controller .................................... 114
Table 31. Specifications of Heater Banks – Hot Water Tank ................ 115
Table 32. Specifications of Heater Banks – Main Curing Hot Air ......... 116
Table 33. Specifications of Heater Banks – AGNI Curing Hot Air ......... 117
Table 34. Analog Inputs – RTD Inputs .................................................. 141
Table 35. Analog Inputs – RTD Inputs for Hardwire ............................ 142
Table 36. Analog Inputs – IO Panel ...................................................... 142
Table 37. Digital Inputs ........................................................................ 144
Table 38. Digital Outputs...................................................................... 150
Table 39. Analog Outputs ..................................................................... 151
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Table 40. Analog Inputs – RTD Inputs .................................................. 151
Table 41. Analog Inputs – RTD Inputs for Hardwire ............................ 152
Table 42. Analog Inputs – IO Panel ...................................................... 152
Table 43. Digital Inputs ........................................................................ 154
Table 44. Digital Outputs...................................................................... 159
Table 45. Analog Outputs ..................................................................... 160
Table 46. Analog Inputs – Control Room .............................................. 160
Table 47. Digital Inputs – Control Room ............................................... 161
Table 48. Digital Outputs – Control Room............................................. 162
Table 49. Instrumentation Items – List ................................................. 164
Table 50. RTD Sensors ......................................................................... 170
Table 51. Temperature Transmitter ...................................................... 171
Table 52. Pressure Transmitter ............................................................ 171
Table 53. Single Loop Controllers (SLC) ................................................ 172
Table 54. Level Switch.......................................................................... 173
Table 55. Level Transmitter .................................................................. 173
Table 56. Proximity Sensors ................................................................. 174
Table 57. Isolators & IS Relays ............................................................ 174
Table 58. Low Air Pressure Switch ....................................................... 175
Table 59. Water Flow Switch................................................................ 175
Table 60. DC Voltage Transducer ......................................................... 176
Table 61. DC Current Transducer ........................................................ 176
Table 62. UPS Voltage Transducer ....................................................... 177
Table 63. UPS Current Transducer ....................................................... 177
Table 64. 24 V DC Power Supply ......................................................... 178
Table 65. IO Rack ................................................................................. 178
Table 66. Programmable Logic Controller ............................................. 180
Table 67. DI Modules ............................................................................ 181
Table 68. DO Modules .......................................................................... 181
Table 69. Temperature Input Modules .................................................. 182
Table 70. Analog Input Modules ........................................................... 182
Table 71. Analog Output Modules ........................................................ 183
Table 72. Supervisory Control and Data Acquisition system ............... 183
Table 73. Server for SCADA / Historian ............................................... 185
Table 74. Operator Workstation ........................................................... 186
Table 75. Thin Client Unit ..................................................................... 188
Table 76. Programming Station (Laptop) .............................................. 189
Table 77. Ethernet Switch – L2 (Field) .................................................. 190
Table 78. Ethernet Switch – L2 (Control Room) .................................... 190
Table 79. Ethernet Switch – L3 (Control Room) .................................... 191
Table 80. Surge Suppressor ................................................................. 194
Table 81. Control Consoles ................................................................... 194
Table 82. Server Rack .......................................................................... 196
Table 83. 43 Inch LED TV ..................................................................... 197
Table 84. 16 Pair Signal Cables ........................................................... 198
Table 85. 1 Pair / 3 Pair Signal Cables ................................................ 199
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Table 86. Heat Resistant Cables .......................................................... 201
Table 87. Optic Fiber Cables ................................................................ 202
Table 88. Suggested Vendors - Mechanical .......................................... 202
Table 89. Suggested Vendors – Electrical Systems .............................. 203
Table 90. Suggested Vendors – Instrumentation & Control Systems ... 204
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1. Scope of the Tender
1.1. Introduction
1.1.1. SDSC SHAR invites tenders from reputed firms with proven ability in Design of ovens, preparation of drawings, fabrication, inspection and testing of sub systems at vendor/sub vendor works, site fabrication, erection, commissioning, inspection, testing and carrying out trial runs of following ovens and associated systems as per the technical specifications enclosed to the tender document for SDSC SHAR, Sriharikota as per the scope and specifications.
1.1.2. Scope of work includes
Realization of Hot Air recirculation type curing oven with
motorized trolley including internal mandrel water
circulation system for segment curing operation. – 1 No
Realization of Hot Air recirculation type curing oven
complete with double leaf manual door and thermally
insulated bottom structure for Agni Grain & Carton curing
operations. – 1 No
Supply, Erection and commissioning of Electrical Systems
and interfacing with various sub-systems at Curing
Facilities.
Supply, Erection and commissioning of Instrumentation
and Control System (ICS) and related accessories at
Curing Facilities.
1.1.3. Arrangements shall be made by the supplier for the inspection and testing during different stages of manufacture starting from the raw materials till the completion of all works by the SDSC SHAR, at supplier’s site and at out site, as per the approved Quality Assurance Plan (QAP).
2. General Terms and Conditions
2.1. Instruction to Bidders
2.1.1. One set of proposal document along with the drawings is issued. Bidder shall sign and stamp each page of proposal as a token of his acceptance & submit along with his offer. Document shall be scanned and uploaded in e-procurement portal.
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2.1.2. Proposal documents shall remain the property of Department and if obtained by one intending Bidder shall not be utilized by another without the consent of the Department.
2.1.3. The proposal shall be completely filled in all respects and shall be submitted together with requisite information. Any offer incomplete in any particulars is liable for rejection.
2.1.4. Bidders shall set their quotations in firm figures and without qualifications or variations or additions in the terms of the Proposal documents. Proposal containing qualifying expressions such as "subject to minimum acceptance" or "subject to prior sale" or any other qualifying expressions or incorporating terms and conditions at variance with the terms and conditions incorporated in the Proposal documents are liable for rejection.
2.1.5. Annual turnover of the tenderer during the last three years should be at least 9 crore.
2.1.6. Price shall include all costs for complete execution of the entire scope of work of the party, as envisaged in the document. Price quoted shall be firm and fixed.
2.1.7. Price shall be quoted in Indian National Rupee only.
2.1.8. Tenderer should have at least 5 years of experience in the field of design, fabrication, erection, testing and commissioning of hot air recirculation type of ovens.
2.1.9. Successful Bidder shall identify a project team, submit project execution plan and work break down chart, detailing the methodology of execution (process plan) within 15 days from the date of issue of purchase order.
2.1.10. Bidder Should have configured, designed, manufactured, erected and commissioned at least 1 no. of hot air recirculation type of oven of size 4.6m ×4.6m ×7m or with an oven chamber volume of 175 m3 during the last 5 years. Documentary evidence in the form of PO.
2.1.11. Vendor should have executed single order value of worth minimum 3 crore for the last 10 years
2.1.12. Bidder Should have experience in design, fabrication, erection and commissioning of trolley of 60 t capacity with inbuilt drive mechanism for loading and un loading of job / articles from the oven.
2.1.13. Bidder should award any part of the work under the scope of this tender to any sub vendor only after obtaining necessary approval from the department. Bidder shall submit relevant
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information as required by the department to evaluate the capabilities of sub vendor. Department has every right to accept or reject the proposal submitted. Approval of the department is no way relieves the bidder from his responsibility and the bidder is wholly responsible for execution of work as per the specifications, terms, and conditions mentioned in this document.
2.1.14. Bidder Should have in-house team for fabrication, erection of ovens.
2.1.15. If the party has only engineering staff and planned to outsource, details and credentials of sub contract vendors shall be provided in the bid.
2.1.16. If bidder is planning to subcontract any part of this tender document, then the bidder shall indicate clearly such of those works planned to offload to his sub-vendor in their offer.
2.1.17. The Sub-Vendor shall meet following conditions specified.
2.1.18. Sub-Vendor should have minimum 5 Years of experience in the field of Control systems and minimum 2 years of experience in the field of Electrical systems proposed make along with proof.
2.1.19. Sub-Vendor should have executed at least 1 project of worth more than 1 crore for similar Instrumentation & control system and electrical system proposed. Proof shall be submitted to consider the offer.
2.1.20. Annual turnover of the sub-vendor executing Electrical, instrumentation and control systems during the last three years should be at least 1 crore.
2.1.21. The conditions of the sub-contracts if any, shall be framed by the bidder such that interest of the Department and its rights are protected in accordance with the original contract terms and conditions.
2.1.22. The erection works at this facility requires that, the party (successful bidder) shall adhere to good daily housekeeping practices. During erection, the party shall keep all work and storage areas used by them free from accumulation of waste materials. Scrap shall be removed from the site to the satisfaction of the purchaser.
2.1.23. Satish Dhawan Space Centre – SHAR (SDSC-SHAR), Sriharikota is declared as prohibited place under official secrets act 1923. Hence during execution of site works necessary security requirements enforced by the department from time to time shall be followed strictly.
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2.1.24. SDSC SHAR shall have the right of inspection and supervision of the manufacturing process adopted by the Supplier for the manufacture of equipment at various stages through their authorized representatives. In case the manufacturing process adopted is not found suitable and commensurate with the desired quality of the equipment, the Supplier will be advised to adopt the correct manufacturing process which will be binding on the Supplier. SDSC SHAR’s decision regarding the quality of work and its acceptability shall be final and binding on the Supplier.
2.1.25. Defects in the steel raw materials like fractures, cracks, blow holes, laminations, pitting, etc., are not acceptable.
2.1.26. During the erection, testing and commissioning of equipment at site in Sriharikota, the supplier has to make his own arrangements for boarding, lodging and transportation of his men and materials. However, subjected to availability, hostel accommodation may be provided by the Purchaser (SDSC SHAR) on chargeable basis.
2.1.27. Free electricity and water will be provided by the Purchaser at one location close to the site (SDSC SHAR) for the erection, testing and commissioning works. Bidder shall take this into account while quoting the price. Distribution of water and electricity from site to the required location shall be taken care by the party.
2.1.28. Before starting the site work (at SDSC SHAR), the party shall provide insurance as per workman compensation act to all his personnel working at site in Sriharikota against accidents. Insurance for the same shall be borne by the party.
2.1.29. While performing the contractual work, the contractor must ensure compliance with all the existing statutory labour enactment/ regulations under Contract Labour (R & A) Act, 1970 & rules framed thereunder. The Contractor is to comply with all the provisions of the Act including the following important requirements under the Act.
2.1.30. Till commissioning of equipment, the safe storing and handling of all equipment is in the scope of supplier.
2.1.31. The transfer of title to the Purchaser (SDSC SHAR) will take place only after satisfactory erection, testing and commissioning of the all the equipment by the supplier and full acceptance by the Purchaser (SDSC SHAR).
2.1.32. Transportation & Transit Insurance are fully in the scope of supplier and the same shall be borne by the party.
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2.1.33. GST: Supplier has to clearly indicate the percentage of GST applicable along with applicable HSN & SAC. Documentary proof for the same shall be submitted along with invoice for final payment.
2.1.34. Necessary care shall be taken during erection and commissioning of equipment at our site. Any damage to the property of Department shall be adequately compensated by the Party.
2.1.35. The BIDDER shall confirm the size / rating of all equipment / components based on the requirements and meet all system guarantees during testing & operation of oven.
2.1.36. The clear dimensions indicated in the GA drawing no. MEC/10JN/11/11/35D/0016 for the oven are minimum dimensions. The SS 304 sheet cladding shall not get encroached the clear oven space indicated.
2.1.37. Upon completion of work at site, Bidder shall remove all his equipment and material from the site within one month or time mutually agreed. Bidder at all times shall keep site in clean condition and remove all unwanted material at regular intervals. In case bidder fails to remove all his equipment and material within the mutually agreed time it is deemed that Department will arrange to remove the same at the bidder’s cost besides imposing penalty for failure.
2.1.38. Should there be any ambiguity or doubt as to the meaning of any of the tender clause/condition or if any further information is required, the matter shall be immediately brought to the notice of Head, Purchase & Stores, SDSC SHAR in writing for necessary clarifications prior to the opening of the tenders.
2.2. Schedule Price
2.2.1. CONTRACT price shall include all costs of “Design of ovens, preparation of drawings, fabrication, inspection and testing at vendor/sub vendor works, site fabrication, supply, erection, commissioning, inspection, testing and carrying out trial runs of main oven, Agni curing oven & associated system” as per the technical specifications enclosed to the tender document, Shop floor testing, packing, forwarding, transport to site, unloading, storage, all risk coverage, erection, installation, supply of spares required, training, testing & evaluation and commissioning of equipment including associated minor civil work and any other cost for proper and complete execution of the CONTRACT.
2.2.2. CONTRACT prices shall also include all travelling expenses,
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living expenses, salaries, overtime, benefit and any other compensation for engineers, supervisors, skilled, semiskilled workmen, watch and ward staff, labourer and other staff employed by the Bidder, cost of tools and tackles required for erection and other consumable material required, and all taxes, duties, and levies as applicable on the date of submission of bid.
2.2.3. Price quoted shall be firm & fixed. The price shall be filled in the format available in e-procurement portal. The bidder shall also fill up the format enclosed (Annexure 5)without price figures and shall confirm by filling the appropriate fields as “QUOTED”.
2.2.4. Quote shall be based on DAP (Delivery at Place) Sriharikota.
2.2.5. All rates of taxes/duties/levies applicable with details of percentage and applicable portion of the price should be spelt out clearly in the offer.
2.2.6. The taxes applicable for supply, erection & commissioning shall be indicated separately in terms of percentage in the price bid. If
the offers submitted by the bidders are silent on taxes, it will be presumed that quoted rates are inclusive of taxes & duties and no claim in this regard will be entertained later.
2.3. Customs Duty
2.3.1. SDSC-SHAR is eligible for Customs Duty exemption. This may be taken into account while considering the pricing of the imported items.
2.3.2. To avail of customs duty exemptions, the Bidders are required to produce “Custom Duty exemption” certificate and “Not Manufactured in India” certificate at the appropriate time.
2.3.3. Bidder should indicate the list of items with quantities that are identified for import to be indicated clearly along with bid. Customs Duty exemption will be provided for the items listed only.
2.3.4. Party shall enclose the list of items in the format given below.
S. No. Item / Description Qty Remarks
1
2
3
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2.4. Publicity Related to Tenders
2.4.1. Advertisements, press release or other specialized publicity documents, which are related to or reveal the existence of a tender and are intended by the Bidder for public distribution and/or the press, broadcasting, or television, shall be cleared/approved by the Department.
2.4.2. The Department may direct the Bidder to withhold such publicity or to require modifications to the publicity material. The Bidder shall comply with such direction.
2.5. Site Visit
2.5.1. Bidders may visit and examine the site and its surrounding to familiarize themselves of the existing facilities and environment and may collect all other information which may be required for preparing and submitting the Bid. Bidders shall visit within 10 days from the date of tender enquiry.
2.5.2. Claims and objections due to ignorance of existing conditions or inadequacy of information will not be considered after submission of the Bid and during implementation.
2.6. Validity of Offer:
2.6.1. Bid shall remain valid for acceptance for a period of six months from the due date of submission of the Bid.
2.6.2. The Bidder shall not be entitled during the said period to revoke or cancel his Bid or to vary the Bid except and to the extent required by Department in writing.
2.6.3. Bid shall be revalidated for extended period as required by Department in writing.
2.6.4. In such cases, unless otherwise specified, it is understood that validity is sought and provided without varying either the quoted price or any other terms and conditions of Bid finalized till that time.
2.7. Cost of Bidding
2.7.1. All direct and indirect costs associated with the preparation and submission of Bid (including clarification meetings and site visit, if any), shall be to Bidder's account and the Department (SDSC SHAR) will in no case be responsible or liable for those costs, regardless of the conduct or outcome of the Bid process.
2.8. Applicable Language
2.8.1. The Bid and all correspondence incidentals to and concerning
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the Bid shall be in the English Language. For supporting document and printing literature submitted in any other language, an accurate English Translation shall also be submitted. Responsibility for correctness in translation shall lie with the Bidder.
2.9. Project Monitoring
2.9.1. Bidder shall provide details of project team within 10 days from the date of placement of order.
2.9.2. Party shall submit the project status report every 15 days mentioning the status of various activities w.r.t. planned schedule for realization.
2.9.3. Party shall depute their Project team/ engineers for Monthly meeting to review the status and discuss/ resolve minor issues related to project execution at SDSC SHAR/ party’s site based on mutually agreeable dates.
2.10. Arbitration
2.10.1. In the event of any question, dispute of difference arising under these conditions or any conditions contained in the Purchase Order, (except as to any matters the decision of which is specially provided for by these conditions) the same shall be referred to the sole arbitration of the Director SDSC SHAR Office or some other person appointed by him, it will be no objection that the arbitrator is a Government Servant that he had to deal with matter to which the contract relates or that in the course of his duties as Government Servant he had expressed views on all or any of the matters in disputes or difference. The award of the arbitrator shall be final and binding on the parties of this contract.
2.10.2. If the arbitrator be the head of the purchase office.
(a) In the event of his being transferred or vacating his office by resignation or otherwise, it shall be lawful for his successor-in office either to proceed with the reference himself, or to appoint another person as arbitrator, or.
(b) In the event of his being unwilling or unable to act for any reason, it shall be lawful for the Head of the Purchase Office to appoint another person as arbitrator: or
2.10.3. If the arbitrator be a person appointed by the Head of the Purchase Office in the event of his dying, neglecting or refusing to act, or resigning or being unable to act, for any reason, it
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shall be lawful for the Head of the Purchase Office either to proceed with the reference himself or to appoint another personas arbitrator in place of the outgoing arbitrator.
2.10.4. Subject as aforesaid, the Indian Arbitration and Conciliation Act, 1996 and the rules there under and any statutory modifications thereof for the time being in force shall be deemed to apply to the arbitration proceedings under this Clause. The arbitrator shall have the power to the extent with the consent of the Purchaser and the Contractor the time making and publishing the award.
2.10.5. The venue of arbitration shall be place as the purchaser in his absolute discretion may determine. Work under the purchase order shall, if reasonably possible, continue during arbitration Proceedings.
2.10.6. In case order is concluded on the public Sector Undertakings, the following Arbitration Clause will be applicable.
(a) In the event of any dispute or differences relating to the interpretation and application of the provisions of contracts, such dispute or difference shall be referred by either party to the Arbitration of one of the Arbitrator in the Department of Public Enterprises to be nominated by the Secretary to the Government of India in-charge of the Bureau of Public Enterprises.
(b) The Indian Arbitration and Conciliation Act, 1996 shall not be applicable to the Arbitration under this clause.
(c) The award of the arbitrator shall be binding upon the parties to the dispute provided; however, any party aggrieved by such award may make a further reference for setting aside or revision of the award to the Law Secretary, Department of Legal Affairs, Ministry of Law & Justice, Government of India. Upon such Additional Secretary when so authorized by the Law Secretary whose decision shall bind the parties finally and conclusively.
(d) The parties to the dispute will share equally the cost of arbitration as intimated by the arbitrator.
2.11. Applicable Law & Jurisdiction
2.11.1. The contracts shall be interpreted in accordance with the laws of the Union of India. Any legal issue or dispute arising out of the contract are within the jurisdiction of Courts of Andhra Pradesh, India only.
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2.12. Acceptance and Rejection
2.12.1. On completion of the work or part of the work as specified in the contract by the bidder, bidder shall inform the same to the department as soon as possible. The department / its representative shall inspect as per mutually agreeable schedule.
2.12.2. If the ordered systems, sub-systems etc., do not meet the prescribed specifications or are damaged at the time of delivery or fail during inspection/testing, they shall be rejected and the Bidder / manufacturer shall replace them at their own cost.
2.12.3. Purchaser has the right to reject the goods on receipt at site during final inspection though the goods have already been inspected and cleared at pre-dispatch stage by the purchaser’s inspector, if they found not meeting the overall performance requirements.
2.12.4. Goods accepted by the purchaser at initial inspection and in final inspection in terms of the contract shall in no way dilute purchaser’s right to reject the same later, if found deficient in terms of the warranty clause of the contract.
2.13. Suspension
2.13.1. Department may notify the Bidder to suspend performance of any or all of his obligations under the Contract. Such notice will specify the reasons for suspension and the effective date of suspension. Bidder there upon shall suspend the performance of such obligations until ordered in writing to resume performance of Contract by Department.
2.13.2. If Bidder’s performance or his obligations remain suspended or the rate of progress is reduced, then, the time of completion will be suitably extended and all costs incurred by Bidder as a result of suspension or reduction in rate of progress will be paid to Bidder provided that the suspension or reduction in the rate of progress is not by reasons of Bidder’s default or breach of Contract.
2.14. Performance Bank Guarantee
2.14.1. PBG at 10% of the value of the Purchase Order shall be submitted through bank guarantee from any of the Scheduled Banks executed on non-judicial stamp paper of appropriate value, and shall be valid for a period of sixty days beyond the date for completion of warranty period.
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2.15. Foreign Exchange Outgo and Variation
2.15.1. The foreign exchange component shall be included in the lump-sum price quoted /unit rates quoted. Foreign exchange variation if any shall be borne by the party and will not be compensated.
2.16. Liquidated Damage
2.16.1. Time is the essence of this order. If the supplier's defined scope of work is not made by the end of delivery period, liquidated damage will be levied @ 0.5 % per week or part thereof subject to a maximum of 10% of value of undelivered stores.
2.17. Security Deposit
2.17.1. Party shall submit security deposit, within 10 days of Order Acknowledgement, for 10% of the total order value. Security Deposit shall be obtained through Bank Guarantee or fixed deposit receipt from any of the Scheduled Banks executed on non-judicial stamp paper of appropriate value, and shall be valid for a period of sixty days beyond the date for completion of the Purchase Order.
2.17.2. In case the vendor fails to furnish the security deposit within the specified date or extended due date, the Purchase Order/Contract shall be cancelled, and the EMD, if any, made earlier shall be forfeited, and, in addition, appropriate penal action will be taken.
2.17.3. Central PSUs/PSEs/Autonomous Bodies shall be exempted from the payment of Security Deposit, and instead, an Indemnity Bond shall be submitted by them in lieu of the Security Deposit.
2.18. Earnest Money Deposit
2.18.1. Party shall submit EMD of Rs.5.0 Lakh. EMD shall be submitted in a single instalment through Demand Draft / Banker’s Cheque / Fixed Deposit Receipts or Bank Guarantee from any of the Scheduled Banks executed on non-judicial stamp paper of appropriate value.
2.18.2. Central PSUs/PSEs/Autonomous Bodies, Micro and Small Enterprises, KVIC, National Small Industries Corporation etc. are exempted from the payment of EMD.
2.18.3. Parties who are registered (registered and empaneled) at Satish Dhawan Space Centre e-procurement portal are also exempted from the payment of EMD.
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2.18.4. In case of bank guarantee, it shall be valid for a period of 45 days beyond the final tender validity date.
2.18.5. Any tender not accompanied with EMD shall be treated as invalid tender and rejected. Vendors seeking exemption from payment of EMD shall submit necessary proof like registration number, etc.
2.18.6. EMD of a vendor shall be forfeited if the tenderer /Contractor withdraws or amends his tender or deviates from the tender in any respect within the period of validity of the tender.
2.18.7. Failure to furnish security deposit by a successful vendor within the specified period shall also result in forfeiture of EMD.
2.18.8. EMD shall be refunded to all the unsuccessful vendors within thirty days after placement of the Purchase Order.
2.18.9. EMD shall be refunded to the successful tenderer/Contractor after payment of the Security Deposit or may be adjusted against the Security Deposit.
2.18.10. EMD shall be refunded to all the participants in cases where the tender is cancelled or withdrawn by the Centre/Unit, within thirty days from the date of such cancellation or withdrawal.
2.19. Force Majeure
2.19.1. Force Majeure is an event beyond the control of the supplier and not involving the supplier’s fault or negligence and which is not foreseeable. Such events may include, but are not restricted to, acts of the purchaser either in its sovereign or contractual capacity, wars or revolutions, hostility, acts of public enemy, civil commotion, sabotage, fires, floods, explosions, epidemics, quarantine restrictions, strikes, lockouts, and freight embargoes.
2.19.2. If there is delay in performance or other failures by the supplier to perform its obligation under its contract due to event of a Force Majeure, if a Force Majeure situation arises, the supplier shall promptly notify the purchaser in writing of such conditions and the cause thereof within twenty-one (21) days of occurrence of such event.
2.19.3. Unless otherwise directed by the purchaser in writing, the supplier shall continue to perform its obligations under the contract as far as reasonably practical, and shall seek all reasonable alternative means for performance not prevented by the Force Majeure event.
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2.19.4. There may be a Force Majeure situation affecting the purchase organization only. In such a situation the purchase organization is to take up with the supplier on similar lines as above for further necessary action.
2.20. Extension of Time
2.20.1. If the completion of deliveries of equipment and / or work is delayed due to reason of Force Majeure the Bidder shall without delay give notice to the Department in writing of their claim for an extension of time. The Department on receipt of such notice may agree to extend the Contract period or delivery date as may be reasonable but without prejudice to other terms and conditions of the Contract.
2.20.2. Both parties shall keep a record of the circumstances referred to above which are responsible for causing delays in the execution of the services and shall give notice to the other bidder of any such cause as soon as it occurs. An event of Force Majeure, where so ever it occurs, provided it affects either bidder in fulfilling its obligations under this contract, shall justify the affected bidder’s claim of Force Majeure.
2.20.3. Should one or both the parties be prevented from fulfilling their contractual obligations by a state of Force Majeure lasting continuously for more than a month, the parties shall consult with each other regarding the future execution of the contract.
2.21. Warranty
2.21.1. The Equipment and related accessories shall be warrantied against any manufacturing defects for a period of 12 months from the date of commissioning. For defects noticed during the guarantee period, replacement rectification should be arranged at free of cost within a reasonable period of such notification.
2.21.2. Party shall carryout mandatory checks as mutual agreed. During this period, party shall replace/ rectify them of defective/ failed parts at free of cost.
2.21.3. Party has to attend unlimited breakdown calls.
2.21.4. Upon oral or written notification of defects or malfunctioning of the goods during the warranty period which require corrective action, bidder shall send the necessary personnel to job site to supervise and assume responsibility for repairs and/or replacement, if necessary, of the defective goods or material at his own cost.
2.21.5. If Party does not respond, within seven (7) days after receipt of
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notification, the department has got every right to resolve reported problem and Department may do so at the cost and expense of the Party. Party shall reimburse to the Department all expenses incurred by Department to repair or replace malfunctioning or non-conforming goods and Forfeit the performance security.
2.21.6. Department has no obligation to discover defects, patent or otherwise, and this shall be sole responsibility of Bidder. Inspection and clearance for shipment by Department’s inspectors or Inspection agency appointed by Department shall not relieve Bidder of any of his obligation and duties under the terms and conditions herein.
2.21.7. Where defects in items are remedied under warranty, the period for which the warranty operates shall be extended by such period, as the items were not available to the Department. Where defective items are replaced by new ones, the full warranty period stipulated in the contract shall apply to such replacement items as from the date of their delivery.
2.21.8. Party shall obtain similar warranty from each of his sub-vendors. However, the overall responsibility shall lie with the Bidder.
2.22. Payment Terms
2.22.1. Our standard payment term is 80% of supply cost including taxes and transportation cost within 30 days after receipt and acceptance of sub-systems in finished form at SDSC SHAR. 20% of supply portion and 100 % of erection and commissioning charges along with taxes will be paid after successful commissioning and handing over of the ovens at SDSC SHAR on submission of Performance Bank Guarantee.
2.22.2. Wherever advance payment is requested, maximum of 30% will be provided upon furnishing Bank Guarantee from any Nationalized Bank/Scheduled Bank. In case of advance payments, if the party is not supplying the material within the delivery schedule, interest will be levied as per the Bank Lending Rate plus 2% penal interest. This is in addition to LD clause.
2.22.3. Interest will be loaded for advance payments/stage payments as per the lending rate of Bank and will be added to the landed cost for comparison purpose. In case of different milestone payments submitted by the parties, a standard and transparent methodology like Net Present Value (NPV) will be adopted for evaluating the offers.
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2.23. Delivery
2.23.1. Party shall follow the following schedule for executing the contract
S. No Mile Stone
Expected
date of
completion
1 Purchase order date T
2
Submission of GA drawing of oven, hot air
circulation system, water circulation
system, iMCC, PLC and SCADA
configuration.
T + 3 weeks
3
Submission of detailed design calculations
of major Systems and subsystems with
respect to mechanical, structural, Electrical
and Electronics.
T + 4 Weeks
4
Submission of Design and fabrication
drawings, P&I diagrams including
specifications and details of all bought out
components.
T + 6 weeks
5 Final drawings. T + 8 weeks
6 Order placement for all bought out
components. T + 10 weeks
7
Pre-delivery inspection of sub systems and
receipt of all items in finished / semi-
finished/brought out items at SDSC SHAR.
T + 8 months
8 Oven Erection & Commissioning T + 12 months
NOTE: Micro schedule shall be submitted by the party after
placement of order
2.23.2. Party shall inform the Department within 30 days of any occurrence that is likely to cause delay in delivery. The Department shall determine, in the light of circumstances reported, whether or not any respite or modification of the delivery requirements of the contract can be permitted on this account.
2.23.3. An extension of the time limit for execution or postponement of delivery shall be granted only in the respect of delay, which is not attributable to the fault or the negligence of the Bidder. An extension of the time limit for execution shall be granted to the
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bidder to the extent that he establishes force majeure events.
2.24. Packing & Forwarding
2.24.1. The tenderer will be held responsible for the stores being sufficiently and properly packed for transport by rail, road, sea or air, to withstand transit hazards and ensure safe arrival at the destination. The packing and marking of packages shall be done by and at the expenses of the Contractor.
2.25. Exclusion of Tenders
The following tenders shall be summarily rejected from the procurement process
2.25.1. Tenders of vendors who have been removed from the vendor list or banned/debarred from having business dealings.
2.25.2. The tenders which materially depart from the requirements specified in the tender document or which contain false information.
2.25.3. The tenders which are not accompanied by the prescribed Earnest Money Deposit.
2.26. Drawings
2.26.1. Each drawing submitted by the Bidder shall be clearly marked with the following details.
a) Name of the Owner: Satish Dhawan Space Centre, ISRO
b) Project Title:
Main & Agni Ovens, ICS, i-MCC & Accessories
c) Purchase Order No:
d) Title of the Drawing clearly identifying the system, equipment or part.
e) Drawing, Revision Number and Date.
f) Name of the Bidder: In case of Sub-Vendor or Manufacturer's drawing, name of the Bidder and Sub-Vendor or Manufacturer shall be incorporated.
g) Drawings duly signed in "checked" and “approved" columns.
h) Scale to which the drawing is drawn.
i) Cross references to all relevant drawings.
j) All relevant notes to the drawing: All notes necessary for understanding and execution of work shown on a drawing shall be presented on the same drawing.
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k) All legends to all notations.
l) Details of revisions carried out
m) Bill of materials shall be tabulated, wherever required.
n) All titles, noting’s, markings and writings on the drawing shall be in English
o) All the dimensions shall be in metric units.
2.26.2. If standard catalogues are submitted, the applicable items shall be highlighted therein.
2.26.3. The drawings shall indicate all dimensions and details of equipment, materials of construction etc.
2.26.4. For all revisions of the drawing, Bidder shall ensure that all revisions are clearly encircled with revision numbers marked on the drawing.
2.26.5. Bidder shall also ensure that general details of revisions are indicated for each revision in the revision block of the drawing along with the date and signed by the approving authority.
2.27. Arrangement of Bid
2.27.1. The Bid shall be neatly presented and shall not contain any terms and conditions which are not applicable to the Bid.
2.27.2. The Bid and all details submitted by the Bidder shall be signed and stamped on each page as token of acceptance by a person, legally authorized to enter into agreement on behalf of the Bidder. Corrections/ alteration, if any, shall also be signed by the same person. Bidder shall submit Power of Attorney in favour of the person who signs the Bid and subsequent submissions on behalf of the Bidder.
2.27.3. Department will not be bound by any Power of Attorney granted by the Bidder or changes in the constitution of the firm made subsequent to submission of the Bid or after the award of the contract. Bidder may however, recognize such Power of Attorney and changes after obtaining proper legal advice, the cost of which will be borne by the Bidder.
2.27.4. The cancellation of any document such as Power of Attorney, partnership Deed etc should be communicated by the Bidder to the Department in writing well in time, failing which Department shall have no responsibility or liability for any action taken by Bidder on the strength of the said documents. All the relevant papers shall be scanned and uploaded along with bid
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3. Documents Comprising the Bid
This is e-procurement tender. All the documents need to be
scanned and attached to the bid under “documents solicited from
Vendor” form.
Offers shall be sent online only using standard digital signature
certificate of class III with encryption / decryption. The tenders
authorized on or before the open authorization date only will be
considered as valid tenders even though the bids are submitted online.
The tenderer must authorize bid opening within the time stipulated in the schedule by SDSC SHAR. Otherwise the online bid submitted will not be considered for evaluation.
On-line bids shall consist of the following: -
3.1. Part – I Technical and Unpriced Commercial
Technical and un-priced commercial part shall comprise the following documents/information. All the documents shall be scanned and uploaded in the SDSC SHAR e-procurement portal.
3.1.1. Submission of bid letter along with one set of proposal document duly signed and stamped as token of acceptance. Scanned copy shall be uploaded in the ISRO e-procurement portal.
3.1.2. Power of attorney in favour of authorized signatory of the bid/ proposal documents.
3.1.3. Registration Number certificate of the Company.
3.1.4. Latest income tax clearance certificate (Last three FY).
3.1.5. Latest solvency certificate from a scheduled bank as detailed in bid qualification criteria. (Current FY)
3.1.6. List of projects in hand & completed during last five financial year indicating the name of client with contact details.
3.1.7. List and make of the bought-out components as well as imported items considered by bidder for this tender.
3.1.8. Organization chart for the proposed work with bio data of key personnel
3.1.9. Schedule Bar charts for realization of ovens.
3.1.10. Execution Plan. Any part of the work is planned to outsource, details of the same shall be provided along with bid documents.
3.1.11. Any other relevant document, bidder desires to submit.
3.1.12. Confirmation w.r.t bid qualification criteria as per Annexure-1.
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3.1.13. Compliance statement as per Annexure-2.
3.1.14. Quality Assurance Plan shall be as per Annexure-3. Detailed QAP shall be submitted by the party after placement of order based on the finalized manufacturing process plan.
3.1.15. Deviations, if any, w.r.t technical and commercial terms & conditions shall be clearly brought out under deviation list Annexure-4. If deviations are not listed separately, it will be presumed that party is adhering to all the specification and terms & conditions given in this document.
3.1.16. Party shall submit unpriced price bid format as per Annexure-5. Party shall only enter required tax percentages. In place of price columns, party shall mention “QUOTED”.
Note: All the above documents shall be uploaded in the ISRO e-procurement portal.
3.2. Part – II Priced Commercial Bid
Priced commercial bid shall contain schedule of prices and shall
be filled in ISRO e-procurement portal. No deviations, terms and
conditions, assumptions, discounts etc. shall be stipulated in price
bid. Department will not take cognizance of any such statement
and may at their discretion reject such bids.
3.3. Bid Submission
3.3.1. Bid shall be submitted in two parts
• Part -1 Techno-Commercial Part of the Bid
• Part-2 Price Part of the Bid
3.3.2. Offers should be submitted On-line using standard digital signature of class-3 with encryption/decryption options.
3.3.3. Prices shall be mentioned in the space/column provided for such purpose in the ISRO e-procurement portal.
3.3.4. Prices quoted should be on the basis of Delivery at Place (DAP), Sriharikota.
3.3.5. The purchaser will not pay separately for transit insurance and same shall be included in the cost quoted by the Bidder.
3.3.6. All risks in transit shall be exclusively borne by the contractor and the purchaser shall pay only for such items as are actually received in good condition in accordance with the purchase order.
3.3.7. Bids duly filled in by the Bidder should invariably be submitted as stipulated in the e-procurement portal.
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3.3.8. Department may open Part – I of the bid on the due date of opening at convenience. Price Bid (Part-II) of the bid of the technically and commercially acceptable bids will be opened at a later date.
3.3.9. Department reserves the right to reject any or all the Bids without assigning any reasons thereof.
3.4. Bid Evaluation
3.4.1. The bidder shall provide all the relevant data / details required for evaluating the bid technically and commercially in the specific formats enclosed with the tender. Apart from this, Bidder is free to add any other relevant information.
3.4.2. During evaluation, Department may request Bidder for any clarification on the bid/ additional documents/ information required. Bidder shall submit all clarifications/ additional documents/ information requested in original. If not submitted within the stipulated time department has right to reject such bids.
3.4.3. Techno-commercial discussion shall be arranged with Bidder, if needed. Bidder shall depute his authorized representatives for attending discussions.
3.4.4. The complete scope of work is defined in the Proposal document. Bidders, who undertake total responsibility for the complete scope of work as defined in the Proposal document will only be considered. As the items are interdependent, combined lowest cost shall only be considered to arrive at Lowest Offer.
3.4.5. In case Bid does not fully comply with the requirement of Proposal document and the bidder stipulates deviations to the clauses of the proposal, which are unacceptable to the Department, the Bid will be rejected.
3.4.6. Performance of Bidder on similar nature of works executed/ under execution shall be taken into consideration before selecting the Bidder for opening his price bid.
3.4.7. The time schedule for completion is given in the Proposal document. Bidder is required to confirm the completion period unconditionally.
3.4.8. Department shall not be obliged to furnish any information / clarification to unsuccessful bidder as regard non-acceptance of their Bids.
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S. No Annexure Reference
1. Bid Qualification Criteria Annexure-1
2. Compliance Statement Annexure-2
3. QAP Annexure-3
4. Deviations Annexure-4
5. Unpriced Price Bid Format Annexure-5
6. Main Oven & AGNI Oven - Drawings Annexure-6A
7. Water Circulation System Annexure-6B
8. Instrumentation & Control System -
Details Annexure-6C
9. Electrical System - Details Annexure-6D
10. Layout & Location – Drawings Annexure-7A
11. Above Ground Curing Facility –
Civil Drawings Annexure-7B
12. Agni Curing facility – Civil Drawings Annexure-7C
3.5. Determination of Responsiveness
3.5.1. SDSC SHAR will scrutinize bids to determine whether the bid is substantially responsive to the requirements of the tender documents. For the purpose of this clause, a substantially
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responsive bid is one which inter-alia conforms to all the terms and conditions of the entire Tender document without any deviations and reservations. The decision of Department shall be final in this regard.
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Main Oven with Motorized trolley & Internal Mandrel Water Circulation System
Agni Oven
Electrical Systems
Instrumentation & Control System
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4. Scope of Works:
4.1. Main Oven with motorized trolley & Internal Mandrel water
circulation system
4.1.1 The scope of work under this purchase order covers design of
oven with Motorized trolley, Internal Mandrel water circulation system, preparation of drawings, supply, manufacture, fabrication, inspection and testing at vendor’s / sub-vendor’s works, packing, transportation to site, unloading (Material handling equipment’s for erection will be provided by us on chargeable basis subject to availability) and storage at site, transportation to place of erection, site fabrication, erection inside the building, testing, cleaning and commissioning including trial run necessary to qualify all the systems.
4.2. Agni Oven
4.2.1 The scope of work under this purchase order covers design of
Agni oven preparation of drawings, supply, manufacture, fabrication, inspection and testing at vendor’s / sub-vendor’s works, packing transportation to site, unloading (Material handling equipment’s for erection will be provided by us on chargeable basis subject to availability) and storage at site, transportation to place of erection, site fabrication, erection inside the building, testing, cleaning and commissioning including trail run necessary to qualify all the systems.
4.3. Instrumentation and Control Systems
4.3.1. The scope of work covers Design, Supply, Erection and Commissioning of Instrumentation and Control System (ICS) for Main Oven, Internal Mandrel water circulation system and Agni Oven including support for trial run towards qualification of all the systems. The details of work are covered in ICS Chapter.
4.4. Electrical Systems
4.4.1. The scope of work covers Design, Supply, Erection and
Commissioning of two nos. of Intelligent Motor Control Centers
(i-MCC) one i-MCC for Main Oven & Internal mandrel water
circulation system and one for Agni Oven including necessary
interfacing with Blower, Heater battery, trolley, Fire damper
motor, control panel and SCADA system with support for trial
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run as per details covered in electrical systems chapter.
4.5. Inspection & Testing
4.5.1. For Scope of Work defined above, arrangements shall be made
by the supplier for the inspection and testing during different
stages of its manufacture starting from the raw materials till
the completion of works, as declared by SDSC SHAR.
4.6. General Description
4.6.1. SDSC SHAR is planning to realize Ovens Systems along with
Sub systems.
4.6.2. As the ovens are used for heating rocket propellants, indirect
heating shall be employed using air as medium. The blower and
heaters shall be placed in service room and the oven shall be
located in oven bay. The oven and blower –heater system shall
be connected through ducts. The abstract specifications of the
Ovens are below
Table 1. Specifications of the Ovens
Description Main Oven Agni Oven
Clear internal dimensions
(L x W x H)- meters 4.6 x 4.6 x 6.75 7.0 x 5.5 x 3
Mass of heating (excluding of oven structures+ ducts)
30 tons structural steel + 35 tons propellant.
12 tons structural steel +
3 tons Propellant.
No. of blowers Required
1 working + 1 standby (2nos.)
1 working + 1 standby (2nos.)
No. of heater banks 03
On/Off - One bank Thyristor controlled – 02 Banks
03 On/Off - One bank
Thyristor controlled – 02 Banks
Operating temp. 50 to 600C 50 to 600C
Ramp up time from ambient
temperature 30 min for 600C 30 min for 600C
Oven performance Set temp +/-20C Set temp +/-20C
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Description Main Oven Agni Oven
Spatial variation 1.5 0C or better 1.5 0C or better
Doors/base structures
Shall have double leaf manually operated steel doors and motorized trolley
Shall have manually operated double leaf swing doors.
No. of RTDs
Oven Data logging and monitoring-600mm Length:12nos.
On/Off & Thyristor control for Three Banks-600mm Length: 03 nos.
Hot Water Circulation System-800 mm Length: 03nos.
Oven heater box compartment (400 mm length)- 2nos
Fire dampers(400 mm length)- 2nos
Room temparature (400 mm length)- 1no
Blower duct Inlet & outlet(400 mm length)- 2no
Hot water Line Inlet & outlet(300 mm length)- 2no
(Total: 27) Ref: ICS Section
Data logging and monitoring-600mm Length :8nos
On/Off & Thyristor control for Three Banks-600mm Length: 02 nos.
Oven heater box compartment (400 mm length)- 2nos
Fire dampers(400 mm length)- 3nos
Room temparature (400 mm length)- 1no
(Total: 14) Ref: ICS Section
Controllers 03 nos. 03 nos.
4.6.3. The operator console consisting of SCADA Station and PLC as
detailed in I&C section shall be common for both the new ovens
and shall be located in a remote control room at a distance of
250 m from the main oven and 300 meters from the Agni oven.
4.6.4. The Intelligent Motor Control Centre (IMCC) shall be two nos.
For the Main Oven & Mandrel Jacket water circulation
For the AGNI Oven.
4.6.5. All the necessary cables between the control room and the
ovens are to be laid below (trench) the ground with few road
crossings in an approved manner with cable markers, cable
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trenches and Hume pipes will be provided by the department at
road crossings. Push button station, indication lamps,
annunciation panel temperature controller (only space) to
indicate alarms like blower off, air fail, over temperature, door
open etc., are already provided in common control and console
located in control room. These elements in common control and
console to be interfaced with iMCC systems. The details are
furnished in I & C chapter. Control console consisting of MMI
for SCADA based control and monitoring for all ovens and
water circulation systems shall be provided as I&C chapter.
4.7. Equipment & Services to be provided by the Supplier
4.7.1. Design, Supply, erection and commissioning of the following systems
Main Oven with motorized trolley & Internal Mandrel water circulation system.
Agni Oven.
Electrical Systems.
Instrumentation & Control Systems.
4.7.2. Hot air oven structures for Main and AGNI oven including doors
4.7.3. AGNI oven bottom structure
4.7.4. Hot air re-circulation Blowers 2no.s (one working & one stand by) for Main oven & 2nos (one working & one stand by) for AGNI oven, complete with base frame and anti-vibration pads, heater banks for Main & AGNI, hot air distribution system, thermal insulation of Blowers & ducts.
4.7.5. Internal Mandrel water circulation system complete with hot water tank with heaters, water re-circulation pumps 2nos. (one working & one standby) interconnection piping complete with valves and specialties and their thermal insulation, spray pond piping ring header with nozzles as shown in the schematic diagrams. The civil works related to spray pond is not in the scope of the contractor.
4.7.6. Motorized trolley for main oven.
4.7.7. Electrical works and Instrumentation works required for the successful operation of hot air ovens.
4.7.8. The details / designs and drawings given in the tender for various systems / equipment are of minimum requirement and are for guidance only. Contractor is free to modify / improve /
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redress the design if required to meet the guaranteed performance of the systems / equipment being supplied. However, any modification / improvement shall be carried out after approval from the Department.
4.7.9. Quality assurance plan for manufacturing, fabrication and testing w.r.t sub-systems as well as complete system
4.7.10. Quality records, history dockets, as built drawings and all documentation related to manufacturing, inspection, testing and erection.
4.7.11. Painting of oven structures, all piping, equipment, doors & approach platform-ladders.
4.7.12. All anchor /foundation bolts, nuts, washers and inserts to be embedded in concrete for the equipment, piping and ducting.
4.7.13. First fill of oil, grease, lubricants as required during start-up and commissioning,
4.7.14. Temporary equipment’s like piping with fittings, flanges, strainers, supports, tanks, pumps, compressors and any other necessary equipment required for testing, cleaning and flushing of the system.
4.7.15. Auxiliary steel/ structural steel supports for supporting the equipment, ducting, piping and cabling.
4.7.16. Engineering and construction of foundation for equipment.
4.7.17. Drawings for review and approval.
4.7.18. Shop inspection and tests as per specifications shall be arranged by the contractor / sub vendor to enable Department to inspect. Wherever not specified, the shop inspection tests shall be as per recent codes applicable.
4.7.19. Operation and maintenance manuals of all components and systems. Hard Copy: 02 nos., and soft copy – 01 no.
4.7.20. Training of persons for the operation and maintenance in the Electrical (soft starter, VFD, Thyristor controllers & MMS) and instrumentation system (PLC/SCADA) from M/s Siemens /Schneider/AEI /Allen Bradley to be provided as specified in Electrical & I&C chapter.
4.7.21. The ovens and their instrumentation systems shall be
calibrated by a Govt. approved testing centre / agency to meet
the technical specifications and requirements.
4.7.22. Delivery period is essence of the contract. Bidder shall comply
with the delivery schedule of 12 months.
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4.7.23. The CONTRACTOR shall perform tests on the total system at
the end of commissioning. All the subsystems shall be offered
for stage inspection prior to delivery.
4.7.24. Testing and Evaluation of equipment shall be carried out by the
CONTRACTOR to meet the functional requirements of each
individual equipment and systems.
4.7.25. After ensuring that the testing and evaluation of all individual
sub systems are completed in the facility, each equipment /
system shall be operated for endurance trial of min.15 days to
ensure that design specifications are met by the CONTRACTOR.
4.7.26. The party shall depute its team of competent personnel to
assist the Department staff in carrying out the process trials
during a specified period (for a min. of 15 days), after
completion of commissioning and endurance trials.
4.7.27. It is not the intent to specify completely herein all details of
design, supply, manufacture and construction of ‘equipment /
work’. However, the equipment, materials and services shall
conform in all respects to approved standards of engineering
design, workmanship and be capable of performing in
continuous commercial operation in a manner acceptable to the
DEPARTMENT who will interpret the meaning of drawings and
specifications and shall have the power to reject any
‘work/equipment’ or material which in its judgment is not in
full accordance therewith.
4.7.28. All the structural and door drawings are to indicate the
minimum requirement that the party shall meet. The party may
be asked to modify the systems if required to meet the actual
site conditions. The party shall carefully study all the interface
and dimensional details of the systems with the building
dimensions and shall ensure that the fabricated items meet the
functional requirements and to suit site conditions. The party
shall study the adequacy of all item from functional as well as
fabrication point of view and may come out with better
alternatives also if any which may be implemented after
obtaining approval from us.
4.7.29. The party shall carefully go through the civil drawings of the
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buildings where the ovens will be installed and design the
ovens and its ducts accordingly. The ovens shall be fabricated
in parts and shall be assembled at our site.
4.7.30. Steel shim plates required to level the Equipment during installation.
4.7.31. All hardware e.g. Fasteners, flanges, O-rings, gaskets etc. is in the Party’s scope. No separate claim shall be entertained, in this respect. At least 10% extra hardware shall be provided for any installation/fixing work to ensure ready availability of hardware in case of damage of some hardware during installation. Party shall also arrange the necessary hardware required to carry-out hydro test and functional test.
4.7.32. Slings, ropes, D-shackles etc., required for handling of equipment at SDSC SHAR shall be provided by the party.
4.7.33. The details shown in the drawing shall be verified with actual site conditions and minor changes if any required shall be incorporated. It is advised to visit the site to understand the interfaces and take essential dimensions wherever equipment is having interface with civil structure/equipment realized by others.
4.7.34. Minor changes, if any required to meet the functional requirement shall be incorporated at no extra cost.
4.7.35. Drawings for review and approval as mentioned in this proposal
4.7.36. For standard bought out components whose details were furnished in the tender either in the form of catalogue/data sheet, the contractor shall strictly adhere to the respective makes only.
4.7.37. In case Bidder suggests any changes in the Make/vendor, same shall be supported with complete technical details including need for such changes proposed. Alternate make suggested by the Party shall be better than the make suggested in this tender document. Department has the right to accept or reject the changes in the suggested make/vendors list.
4.7.38. Any changes envisaged by the party shall be mentioned in the deviation sheet along with the bid.
4.7.39. The Party’s scope of work shall also include erection, testing, start up, commissioning, operational trials covered in this specification.
4.7.40. Supplier is wholly responsible for getting necessary approvals from the concerned departments/ authorities to transport the
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Equipment from party’s site to SDSC SHAR.
4.7.41. All bolts/studs shall be of class 8.8 or higher and shall be of Unbrako/DFL/TVS make only. Each fastener shall be supplied with two flat washers.
4.7.42. Bidder shall mobilize following minimum equipment of adequate quantity for carrying out fabrication work at our site. These items can be taken back by the party after completion of work.
• Welding equipment & TIG welding
• Gas cutting machine
• Drilling machine with magnetic base
• Grinding machine, Cutting machine & Buffing machine
• Grouting machines for drilling in concrete.
• Consumables, cleaning agents.
• Manila ropes
• Ladders, stools, to approach different heights etc.
• Other equipment/tools required for erection
4.7.43. Any other system not indicated herein, but required to make the system complete shall be included and provided by the bidder at no extra cost unless otherwise specifically excluded as indicated. Such of these items considered by the supplier shall be identified and listed separately.
4.7.44. All equipment supplied shall have capacities not less than those specified in the offer and necessary test certificates shall be furnished in this regard.
4.7.45. The motor rating indicated in the bid shall be minimum and bidder is free to select higher capacity if found essential to meet the requirements specified in the tender.
4.7.46. Structures of ovens need to be fabricated in modules in such a way that the modules can be brought inside the room/building and assembled. Bidder shall note the clear dimensions of the openings provided in the building for handling each module and accordingly the oven shall be split into minimum number of modules.
4.7.47. Party shall offer for stage and final inspection prior to dispatch at the party / sub vendor’s premises of the following items. Blowers, Heater battery, Pumps, Hot water tanks, structural modules, doors, Motor control centres, Control panel, Instrumentation & Data Acquisition system and other items if any decided during execution.
4.7.48. Party shall submit physical & chemical properties with respect
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to materials used in construction of ovens & sub systems.
4.7.49. Party shall submit material and performance test certificates for all items.
4.7.50. Party shall submit the programming code of SCADA and iMCC software programming code which can be edited to convert or augment the features at a later date.
4.7.51. A detailed manufacturing / fabrication drawing is to be submitted and the fabrication is to be started only after Department’s approval.
4.7.52. Users shall have access for stage inspection during the various stages of fabrication. Any minor modifications that become necessary during the manufacturing period or during erection shall be done free of cost.
4.7.53. The supply of cables and termination is also in the scope of the party.
4.7.54. All the structural steels used for oven fabrication shall be of reputed make like TATA steel, SAIL, RINL and Jindal
4.7.55. All pre-polished SS sheets and plates shall be Salem Steel / Jindal/SAIL steel only. SS sheets shall be polished / buffed to have mirror finish.
4.7.56. Non-standard make / re-rolled steels/ old stock etc., are not acceptable
4.8. Instructions during Fabrication
The following instructions shall be followed during /after carrying out the fabrications of equipment by the Party
4.8.1. Mill certified plates only shall be used for fabrication.
4.8.2. 100% DP test for root and final weld pass.
4.8.3. 100% Ultra sonic test for plates of 20 mm thick or above
4.8.4. 100% Radiography test for all butt welds of plates of 20 mm thick or above
4.8.5. All welds shall be ground and free of burrs and undulations.
4.8.6. The entire fabrication activity shall be performed in a planned/sequential manner to achieve desired dimensional/geometrical tolerance specified in the drawing or functional requirement mentioned in this document.
4.8.7. Dimensions shown in the drawing are final acceptance dimensions. Allowances for machining and thinning due to fabrication process shall be added to arrive at material sizes.
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4.8.8. Dimensional tolerance wherever not specified shall follow the standard open dimension tolerances provided in the drawing.
4.8.9. The effective throat thickness of a fillet weld shall be shortest distance from the root to face of the diagrammatic weld.
4.8.10. Wherever welded attachments are used to facilitate fabrication, same shall be removed carefully by cutting or chipping and surface of material shall be finished smooth by grinding. As far as possible, hammering shall be avoided.
4.8.11. Edge preparation shall be carried out for all joints as mentioned in the drawing or as per standard fabrication procedure.
4.9. Codes and Standards
4.9.1. All equipment, systems and works covered under this specification shall comply with all currently applicable statutes, regulations, standards and safety codes in the locality where the equipment will be installed.
4.9.2. In particular, the latest editions of the following standards are applicable.
Table 2. Codes and Standards
(i) Steel for general structural purposes
IS 2062
(ii) Rolled sections and special sections IS:808, IS:1161, IS:1173, IS:1252, IS:1730, IS:1731, IS:1732, IS:1863, IS:1864, IS:2314,
4.9.3. Other national standards established to be equivalent or superior to the codes and standards specified are also acceptable.
4.9.4. In the event of any conflict between the codes and standards referred to in the specification and the requirements of this specification, the more stringent of these requirements shall govern.
4.9.5. Unless indicated otherwise, all codes and standards referred to in this enquiry specification shall be understood to be the latest version on the date of offer made by the bidder.
4.10. Safety
4.10.1. It is the Party’s responsibility to see the safety of workmen and protection of surrounding equipment at the work zone.
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4.10.2. All the safety equipment required for carrying out the work such as face shields, welding goggles, helmets, safety belts etc. shall be supplied by the Party at his own cost.
4.10.3. Party shall give an under taking to observe all safety norms put forth by department from time to time, until completion of the work.
4.11. Painting
4.11.1. Spray Painting of Agni oven, main oven, water circulation system,supporting structures of oven, ducts, supports, platforms and equipment’s shall be as follows:
4.11.2. Surface Preparation: Cleaning by wire brush or power tools to remove any loose dirt or mill scales from the surface.
4.11.3. Primer: One coat of zinc rich primer with red oxide and zinc phosphate pigments to achieve total DFT of 70 to 75 micron.
4.11.4. Final Coat: Two coats of Aluminium heat resistant paint of total 100-micron DFT.
4.11.5. Total DFT shall be 175 microns (min.)
4.11.6. Oven shall be painted with Al heat resistant paint and all other items shall be painted with PU paint of 2 coats of ASIAN/BERGER/NEROLAC make of approved shade.
4.11.7. The grade of paint (heat resistant paint) shall be chosen such that it will withstand the maximum temperatures to which the painted components will be subjected. Epoxy paint selected shall meet this requirement.
4.11.8. Any intermediate cleaning required between successive coats of paint shall also be carried out as per paint manufacturer’s standard.
4.12. Summary of Data to be furnished by Party
4.12.1. Bar chart for supply & erection schedule indicating the date of
completion of various activities so as to complete the execution
of the tender within the time frame stipulated in the tender
specification.
4.12.2. Quality Assurance Plan based on the proposed manufacturing
process.
4.12.3. Proposed Project execution plan and fabrication process plan.
4.12.4. P&ID & Layout for Service Equipment
4.12.5. Party shall submit all fabrication drawings.
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4.12.6. Party shall send copies of instruction manuals along with the
dispatch of equipment. Instruction manual shall contain full
details, as-build drawings of all equipment, erection procedure,
testing procedure, operation & maintenance procedure of the
equipment. If after commissioning and initial operation of the
equipment, the instruction manuals require any modifications
/ additions the same shall be incorporated and the updated
instruction manuals shall be submitted by the Party to
Purchaser.
4.12.7. Unpriced Purchase orders for bought out components
4.12.8. Test Certificates (physical and chemical) for all raw materials.
4.12.9. Procedures for Welding, Qualifications of Welders, Painting and
Finishing
4.12.10. Transportation Plan
4.12.11. Erection and Commissioning Plan
4.12.12. Inspection and Testing Plan
4.12.13. Dimensional inspection reports generated during entire
fabrication process, erection and commissioning.
4.12.14. All the reports generated during fabrication including material
test certificates and other NDT tests.
4.12.15. Final as built drawings, 2 sets hard copy and one set soft copy
in *.dwg format.
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General Specifications & Mechanical Systems
for Main Oven with Motorized trolley and
Internal Mandrel water circulation system.
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5. Main Oven with Motorized trolley and internal water circulation system
5.1. Basis of Design & System Description
5.1.1. Curing is carried out after the propellant casting of segments (Head end, Middle and Nozzle end segments) in the casting facility. The assembled segment with propellant is transported from casting facility in vertical position by means of trailer. The segment shall be lifted by EOT crane and positioned on the motorized trolley. This trolley shall be bottom portion of the oven and shall be movable from the motor receiving bay to the oven. The oven shall be provided with double leaf swing doors. The segment placed inside the hot air oven is subjected to curing operation to achieve required mechanical properties for the case bonded propellant grain.
5.1.2. The oven shall be provided with suitable spring loaded pressure relief arrangement. This pressure relief arrangement shall be operated at 1 Ksc of pressure and size of vent/ disc shall be of 300mm diameter.
5.1.3. Curing operation is carried out over a period of 200 hours continuously, of which, the first 85 hours shall be heating phase and remaining 115 hours shall be cooling phase.
5.1.4. The oven shall be operated between 500C to 600C based on the process requirement. The design temp of the oven shall be 750C. The oven operating temp shall reach 600C within 30 minutes.
5.1.5. The oven internals are cooled to ambient conditions during the cooling phase. No temperature control is required during the cooling phase of curing cycle.
5.1.6. The hot air re-circulation system for oven comprises of the following:
2 Nos. (1 Working +1 Standby) hot air re-circulation
blowers
Supply & return air ducting with dampers
Supply and return air grills.
5.1.7. The dampers for blower selection shall be operated manually and shall be provided with end limit switches (proximity type).
5.1.8. Black heat type (Each heater element shall not become red hot when in operation with the blower running) electric heater for heating of air. Heater watt density to be designed accordingly.
5.1.9. The entire heater battery shall be divided in to three banks.
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Two of the heater banks shall be controlled by PID controller with Thyristor power controller and the remaining one heater bank shall be controlled by On / Off mode with power contactors. The oven shall be capable of maintaining the operating temp., either with one on / off bank or one heater bank with Thyristor power controller INDEPENDENTLY. Heater elements pertaining to each heater banks shall be uniformly distributed along the cross section heater battery to have uniform heating.
5.1.10. Blower and heater battery shall be located in the service room.
5.1.11. Insulated oven chamber, complete with concealed supply & return GI ducts, SS grills for uniform air distribution in X & Y axes, sheet metal cladding and its support structure.
5.1.12. The oven shall be maintained at a positive pressure, so that outside cool air does not enter the ovens.
5.1.13. The oven shall be airtight and thermally leak proof such that the fall of oven temp., by 50C from an operating temperature of 600C shall not occur earlier than 20 minutes.
5.1.14. Hot air shall be supplied from both sides of the oven. Return air shall be collected at the bottom, close to the oven floor refer the drawing no. MCO/SD & DD/01
5.1.15. The total live mass of steel to be considered inside the oven shall be 30 tons which includes mass of support stool, end rings, segment case, and mandrel. Party shall consider the actual mass of oven structural that may get heated up when the oven is under operation for finalizing the heater banks, blower capacities to maintain temp. within specified limits and to attain the operating temperature with in stipulated time
5.1.16. The mass of propellant need not be considered in sizing the heater and the blower since the thermal conductivity of propellant is very low.
5.1.17. Spatial variation when measured inside the oven shall not exceed 1.5 0C.
5.1.18. Total No. of RTDs required including spare– 54 nos.
5.1.19. The heater shall have minimum 20% margin over design values.
5.1.20. The Blowers shall be sized for additional 20% capacity over the design capacity.
5.1.21. Blowers capacity shall be arrived by considering the following
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The discharge pressure drop across ducts, dampers,
heater banks, grills etc.
Attaining the operating temp within stipulated period.
No. of air changes required to maintain uniform
temperature (spatial variation: 1.50 C or better)
To maintain a positive pressure inside the oven so that
the cool air from outside shall not enter the oven. The
blowers shall develop minimum static pressure of 120
mm WC.
Blowers’ frame size shall be selected considering the
space available in the service room and the door entry
dimensions.
5.2. Outside Atmospheric Conditions
Parameter Summer Monsoon Winter
Dry bulb temperature 0C 42.2 28.3 18.3
Wet bulb temperature 0C 28.3 26.7 13.9
Relative humidity % 35.0 >90 60.0
5.3. Oven Parameters
Table 3. Ovens Parameters
Description Specifications
Operating principle Hot air re-circulation
Hot air oven dimensions
(Clear internal dimensions.)
4600mm(L) x 4600mm(W) x
6750mm(H)
Blower capacity Min 40000 cfm
Static pressure Min 120 mm of water column
Heater bank capacity Min 300 kW
No of heater banks
03nos each 100KW
01nos. On/Off
02 nos. Thyristor power controlled
Operating temperature for
hot air oven 50 - 60 0C
Design temperature 750C
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Description Specifications
Outer skin temperature of
oven
Not to exceed 5 0C over the ambient
for 600C
Time to reach operating
temp., from ambient
temperature of 30 0-C
30 minutes for 600C operating temp.
RH controls Not required
5.4. Oven Construction
5.4.1. The oven structure shall be of free standing type.
5.4.2. Oven shall be fabricated in double wall construction. The outer wall shall be of 5 mm thick carbon steel plate. The inner side of the oven shall be covered with 2mm thick SS 304 pre-polished sheet/panels, suitably stiffened. Material certificate shall be produced for SS sheets/panels.
5.4.3. TIG welding shall only be used for welding of all SS fabrication works.
5.4.4. The annular gap between the outer wall and inner wall shall be filled with Rock wool mattress which shall be used for insulating the oven walls so that outer skin temperature is limited as specified. Studs shall be provided to retain the mattress in the position without collapsing.
5.4.5. Insulation mattress shall be sandwiched between SS sheet (oven side) and MS sheet on the rear side (Oven outer wall side). 10 mm dia. studs shall be welded on MS sheets to retain the insulation mattress in position.
5.4.6. All internal SS sheets used for door and grills shall be buffed at welded regions and polished to have mirror like finish. Enough care shall be taken to purchase only plastic cover protected pre-polished SS sheets and the plastic cover shall be removed after erection at site.
5.4.7. The oven outer walls shall be provided with ladders and working platforms as decided at site for accessing the individual sensors for repair / other maintenance works and also to reach top of oven roof.
5.4.8. The oven shall be provided with a bogie/trolley with double flanged wheels’ movable on rails.
5.4.9. The oven shall be provided with two front openable doors operating on heavy hinges with a provision for locking. The
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doors shall have hinges with antifriction bearings. Special care shall be taken that the door bearings can be replaced without dismantling the entire door. The doors shall have manual locking arrangement.
5.4.10. Intrinsic safe proximity sensors shall be provided for doors to meet fully closed, fully opened and for door locked conditions
5.4.11. Sealing between the doors, trolley and oven walls shall be ensured so that no leak of air is present.
5.4.12. Oven structural design shall be approved by the Department before fabrication.
5.4.13. Oven structures shall support water & air lines of fire-fighting deluge system (not in the scope of the party). However necessary support brackets for installing these lines inside the oven are in the scope of this contract.
5.5. Air Distribution System
5.5.1. Blowers: Oven shall be provided with 2 Nos of centrifugal blowers of same capacity for hot air circulation out of which one blower shall be a standby blower connected in parallel to the heater battery with suitable isolation dampers. Dampers shall be provided to select the blowers.
5.5.2. The blowers shall be suitably interlocked such that the blowers can be switched on only when the concerned dampers are kept open and dampers of other blower are kept in closed condition and oven door shall be kept in closed condition. Hence dampers shall be provided with limit switches to sense whether they are in open or in closed condition and this status shall be available in the data acquisition system. The blower shall also be interlocked with fire damper motor.
5.5.3. The blowers shall be of approved make and blowing sufficient capacity of air at 750C and static pressure of 120mm of water gauge. The blowers and drive system shall be rated for continuous operation. The motor shall be of S1 duty and energy efficiency IE2 or better. The motor current shall not Exceed 80% of rated current of motor. Each blower shall be connected by V- belts to a separate electrical motor of sufficient capacity for continuous running.
5.5.4. Blowers shall be located in the service room adjacent to the hot air oven bay. The blowers are sized to provide sufficient number of air changes inside the oven to limit the spatial variation inside the oven to 1.50 C.
5.5.5. Two nos., of blowers (1 working & 1 standby) shall be provided.
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The blowers shall be mirror image of each other. The area available in the service room and the door entry at the service room shall be taken into account while selecting the blowers.
5.5.6. The blowers shall be sized to suit the requirement such that the operating temperature is reached within 30 min for 600C.
5.5.7. Blowers shall be thermally insulated and designed to handle hot air at 750C. Blowers shall have butterfly dampers, vibration isolators, inlet and outlet with duct interfacing arrangements.
5.5.8. Blower performance shall be inspected before dispatch at party site.
5.5.9. Blower pedestal requirement as blower mounting frame size, load condition (static & dynamic) shall be provided prior to dispatch.
5.5.10. Each independent blower performance & run test shall be performed in our presence. However, the material test certificates for the critical components and ultrasonic testing for shaft, DP test for all weld joints shall be submitted. Dynamic balance report for impeller shall be submitted.
5.5.11. Blower motor shall be selected such that blower should draw a maximum current of 80% of rated current at a rated delivery and static head.
5.5.12. Blower motor shall be provided with space heater to avoid low IR values during prolonged idle period.
5.5.13. Blower and all other brought out component details drawings shall be submitted for approval before procurement.
5.5.14. The location of the blowers w.r.t. ovens is indicated in building and equipment lay out dwg. no. MEC/10JN/11/11/35D/0016
5.5.15. Supply and return air to / from the oven shall be through rectangular galvanized iron (GI) ducts.
5.5.16. Ducts shall be of double wall construction made of 2 mm thick GI sheets. Rockwool insulation (min 150mm) shall be chicken mesh sandwiched between the walls. The rock wool insulation shall be kept in position by chicken mesh.
5.5.17. Ducts shall be made in segments with flanged joints. Joints shall be provided with asbestos /millboard gaskets of thickness not less than 5 mm.
5.5.18. Ducts shall be air tight & smoke test for ducts and duct assemblies where ever possible for ensuring the air tightness.
5.5.19. Ducts shall be suitably reinforced with stiffeners. Overhanging ducts shall be supported with ISMC members.
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5.5.20. The heater battery shall be of same size of oven ducts to avoid convergent and divergent arrangement of ducts.
5.5.21. Heater battery shall be mounted inside the discharge ducts.
5.5.22. The Heater battery compartment shall be provided with air-tight doors for accessing heating coils for maintenance.
5.5.23. SS grills with volume control dampers shall be provided to ensure uniform air distribution in the oven.
5.5.24. Motorized Fire dampers shall be provided both for suction and discharge ducts of the ovens. Each fire dampers shall have a RTD (2nos one for Temperature Controller and one for PLC logic) for and dedicated Temp controller with motorised damper closing provision. The damper motor to be interlocked with temp controller to operate and close the damper when the temperature of Hot air is equal /above the set value. In case damper closes blower also shall be switched off. The RTD details are mentioned in ICS chapter
5.5.25. Provision shall be made available in the ducts to install air flow switch. The air flow switch shall be interlocked with blower. The supply and installation of Air flow switch minimum two nos (one for Hardwired logic and one for PLC logic) also in the scope of the party.
5.5.26. All ducts shall be fully insulating and covered with GI sheets.
5.5.27. The ducts discharge and suction grills inside the oven shall be of SS material.
5.5.28. Duct end flanges shall be 5mm thick MS and duct joints shall be at intermediate locations as decided during detailed engineering, for easy dismantling in case of any repair. All bolts shall be galvanized and of 8.8 class. All ducts shall be rectangular cross section & only blower interface/ connecting duct shall be matching with blower duct / delivery ports.
5.5.29. The blower manufacturer shall specify bearings greasing quality and requirements.
5.5.30. Bearings shall be easily dismantling type whenever required.
5.5.31. Rotating parts shall be provided with guard like belts, extended shafts etc.
5.5.32. The party shall supply 5 sets of V belts as spare for main oven and Agni oven.
5.6. Heating System
5.6.1. The heater shall be fitted with withdrawal type, sheathed,
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tubular heating element. The entire heater battery should be mounted inside a double walled mild Steel casing having rock wool insulation of not less than 150 mm thickness between walls in order to prevent heat losses. The heater terminals must be brought to one side so as to facilitate connection and replacement easily. They shall be terminated in a terminal box.
5.6.2. The heater shall be suitable for mounting on air duct. Heaters battery shall have flanges for connecting the heater and ducts. Heater battery shall be sized same as that of the duct size preferably.
5.6.3. Heaters shall be encased in tubes to avoid ingress of hot air and to enable replacement of heating elements during operation suitable provision is to be made.
5.6.4. Heaters shall be black heat type. The heaters shall not become red hot when air flow exists.
5.6.5. Heating elements shall be of nickel-chrome resistance wire. The elements shall be packed with magnesium oxide powder and compressed by swaging to ensure rapid heat transfer.
5.6.6. The heating coil shall be supported at sufficient intervals, but not more than 600mm.
5.6.7. All the electrical terminations shall be airtight. The termination shall be carried out using heat resistant Teflon wire or better arrangement. The heater body shall be air tight to prevent any leakage of hot air / gases.
5.6.8. The heater assembly shall be complete with all accessories (Mechanical, Electrical & Instrumentation connection accessories, controllers, control panels, sensors, and wiring accessories).
5.6.9. The design & arrangement shall be suitable for standard cabling into the terminal enclosure without the need for an intermediate junction box and high temperature cables. If this requirement is not met by the product, then necessary high temperature cables & junction box shall be provided by the contractor / party.
5.6.10. Elements/banks shall be arranged/ connected in such a way, that failure of few elements does not affect the uniformity of heat drastically.
5.6.11. Heaters shall be protected against over temperature and shall be provided with auto power cut-off.
5.6.12. It shall be possible to dismantle & replace / repair components & heating elements at site.
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5.6.13. Silicone seal shall be applied to the lead exit and between lid and terminal box to improve ingress protection. This shall be supplied in adequate quantity along with the equipment.
5.6.14. Watt densities of heating elements shall be limited to a suitable value to prevent red hot (black heat operation).
5.6.15. Heater battery shall be painted with heat resistant paint.
5.6.16. Heater element specifications shall be:
Tube: INCOLOY
Sheath: SA240 Gr. 304
Heating element: Nichrome wire (Nickel- chrome
resistance wire)
Replaceable.
Individual heater capacity: Limited to prevent red hot.
(black heat operation)
Heater body: Carbon steel.
Mounting arrangement: Suitable for mounting on duct.
5.6.17. Heater battery design and construction.
Maximum pressure drop across the battery should be:
15mm WC.
Heater battery shall have flanges for connecting the
heater and ducts.
All the electrical terminations shall be airtight.
Heater battery shall be painted with heat resistant
paint.
Each heater shall be with 1.1kW rating.
5.7. Power Supply
5.7.1. The oven shall be designed for operating on 415V, 3ph, 50Hz AC, 4 wire systems. All motors shall be operated with 415V, 3ph, and 50Hz supply. Power supply will be available at the Power control centre of the facility. The supply and laying of incoming cables for MCC (supplied by the party) from PCC and from IMCC to all systems and to control room are in the scope of the party.
5.8. Temperature Uniformity
5.8.1. The maximum temperature difference between any two points inside the oven should be maintained within 1.5 0C of the set temperature. The oven should be sufficiently insulated so as to limit the oven skin temp within 5.00C above the ambient
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temperature when the oven is working at maximum design temperature.
5.9. Interlocks
5.9.1. Blower shall not be switched ON unless the doors are closed, their respective suction and delivery dampers and fire dampers are in open condition
5.9.2. When one blower is ON, the other blower shall not get on.
5.9.3. Heater banks shall get ON only when blower is ON and availability of air flow.
5.9.4. Fire dampers and oven heater banks shall be interlocked with temperature sensors provided at fire damper inlet & outlet and heater battery duct through dedicated temperature controller fixed at iMCC panel and these temperature controllers in turn is to be interlocked with PLC PID controller for oven temperature control purpose.
5.9.5. All the heater banks shall get off if the Temp Controller installed in the ducts operate in addition to the control from the temperature controllers installed in the Control panel.
5.9.6. Alarm shall be provided for following conditions: Main Oven: Blower 1 off, Blower 2 off, Air fail, Air low temp., Air over temp., Water pump 1 off, water pump 2 off, water level low, water flow not ok, water temp high etc. AGNI Oven: Blower 1 off, Blower 2 off, Air fail, Air low temp., Air over temp, Fire damper motor operated.
5.10. Motorized Trolley
5.10.1. The movement of the trolley shall be achieved by means of flameproof electrical motor of suitable capacity through reduction gear box. The bogie design shall be such that the motor, gear box drive shaft, Plummer blocks etc are not in the hot zone. The bogie with drive system shall be designed to a safe working load of 60 tons.
5.10.2. An electro mechanically operated trolley of 60 tons shall be provided.
5.10.3. The top and sides of the bogie platform shall be covered with 20mm thick MS sheet cladded with 2mm thick SS 304 pre-polished sheets. Trolley shall be designed such that the load can be positioned anywhere with an offset of 200 mm on both X and Y axis.
5.10.4. This trolley shall move in and out through a set of guide rails. Rails shall be laid above ground. Supply and erection of
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suitable rails are also in the scope of the party. The length of travel of this trolley shall be approximately 20m.
5.10.5. Anti-friction bearings shall be provided at wheels. Wheel stoppers shall be provided to limit over travel of the trolley in addition to the limit switches.
5.10.6. Drive motor shall be flame proof suitable for Gas group IIA, IIB and temp class T4 (1350C) with ‘F’ insulation class but temp rise limited to class B (Flame proof receptacle shall be provided for connecting the power cable). Thermistor shall be provided for winding protection. The motor shall be compatible for operation with VFD. Motor shall be inverter duty compatible for VFD and certificate indicating suitability shall be furnished.
5.10.7. The trolley shall be designed with suitable gear mounted motor. The geared motor shall be located on the outer side of the wheel module. The trolley can have motor, gear box and chain drive system.
5.10.8. The power cables to the trolley drive system shall be through cable drag chains.
5.10.9. The department shall approve the drive mechanism before fabrication.
5.10.10. It shall be possible to dismantle the wheel module for easy maintenance.
5.10.11. Party shall demonstrate trolley movement at their site. Load testing of the trolley shall be carried out at our site.
5.10.12. The trolley shall be moved at two levels of speed I. 2.5 m/min II. 0.50 m/min using local push button station with suitable intrinsically safe barrier interfacing. The control & power wiring shall be interfaced with VFD in iMCC. The trolley shall be interlocked with proxy sensors for bogie in and bogie out positions. Shall also interlocked with door open/close status.
5.10.13. The power & control cable to the trolley shall be through cable drag chain. The party shall submit control drawing for approval. The operation for Bogie shall be from Pendent with for/rev/stop push buttons and indication lamps. The pendent push buttons/ indication lamps shall be intrinsically safe and be interfaced with Intrinsic safe barriers of P & F make and barriers shall be placed in i-MCC.
5.10.14. The drive system specifications given below are indicative. The party shall design and submit the design details for approval.
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Fig. 1. Motorized Trolley
Table 4. Drive System Specifications
Sl.
No Item Description Qty
1. Gear box
Make: M/s Shanthi / PBL
Parallel shaft double helical gear box
HQN-320
Gear ratio 630:1
Type: Bi- direction
Foot mounted
Double extended output shaft
01
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2. Motor
Make: Crompton/ PBL/ Bharat Bijilee
/CEMP/ SEW Kirloskar
FLP brake motor 5.5kW
No. of poles: 6, Ex-d
Gas group: IIA/ IIB Temp. Class T4
Electrical motor frame size: 132 M
IP 55
415 ± 10 %, 50 Hz ± 5 %
Duty S4
Speed: 960 rpm
Insulation Class F or better with
temp. rise limited to Class B.
“Or”
The flame proof motor shall be provided
with integrated flameproof Disc brake of
M/s PETHE make or Brake with
Department Approval with necessary
shaft extension arrangement.
Motor shall be compatible for inverter
duty addressing bearing currents/better
insulation requirements/ voltage rise
time.
Motor shall be provided with Thermistor
in the winding with tripping arrangement
using external Thermistor trip relay.
It shall be suitable for VFD.
01
3. Plummer
block Heavy duty 8
4. Couplings Flanged couplings 4
5. Circlips 4 mm thick dia matching
6. Bogie wheel Ø500mm Dia single flanged wheel, 100
thk forged steel C-55 (EN9) 4
7. Rail 120 Lbs – STD 50m
8. Shaft
Material: EN-24U
Diameter: 125 mm
Length:2800 mm
02
9. Top plate 20 mm
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10. Cladding
plate 3 mm thick
11. Chain 1.25 “pitch, Duplex chain
Length: 5000 mm (approximate) 03
12. Driven chain
wheel
(sprocket)
Pitch 1.25”
Teeth 27
Suitable for 1.25”, Duplex chain
04
13. Idler
sprocket
Pitch 1.25”
Suitable for 1.25”, Duplex chain 02
14. Cable drag
chain
Make: IGUS
Length: 25 m
Plastic closed type
Width: 50mm (appx.)
With guide brackets.
01
15. Power Cable
Make: IGUS
1C X 4 sq.m, Copper
(Suitable for IGUS cable drag chain
trailing application)
Length: 30m.
With suitable flame proof glands -
2Nos for end termination.
01
16. Cable glands
12 pair, 0.5 sq.mm control cable.
Suitable gland 2 Nos. for end
termination.
01
17.
Push button
station
Panel: 2 mm thick pre-polished
SS sheet, Power coated with the
following components.
Emergency: Key operated, lockable,
Make: Siemens, Qty: 1 No.
Indication lamps: Intrinsically safe,
Type: BA 390 Make: BEKA, Qty: 4Nos.
Push buttons: Make: Siemens, Qty:
2Nos.
01
18. Cable tray
with covers
Perforated, GI, Size: 100 mm, Each
2.5 m length.
With supporting brackets, clamps and
grounding bolts.
100
mtrs.
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19. Keys
20 x 20 -155 long coupling end – 8 nos
80 long wheels - 8nos 75 long sprockets -06 nos
22
20. Fasteners Make: Unbrako /TVS
21. Power Cable
Make: Finolex / RR Kabel / National /
Lapp / CCI / Universal /Asian/
Polycab / Incab / Havell / Torrent
Armoured, 4 C X 4 sq.mm, Copper,
XLPE insulation, 1.1 kV, confirming
to IS:7098.
Length: 100 m.
With suitable flame proof gland-1 No.
and Non-flame proof- 1 No. for end
termination.
01
22. Cable
control
Make: Finolex / RR Kabel / National /
Lapp/ CCI / NICCO / Universal /
Asian / Polycab / Incab / Havell /
Torrent
Armoured, 16 C X 1.5 sq.mm, Copper
XLPE insulation, 1.1 kV.
Length: 200 m
With suitable flame proof gland- 1No.
and Non-flame proof -1No. for end
termination.
01
23. Power
supply unit
Make: Semens
24VDC, 5A 01
24. 2- Channel
isolated
barrier
KFD2-SR2- Ex.2 for Proximity
sensors. 04
25. 2- Channel
Solenoid /
LED driver
KFD2-SL2- Ex.2 for indication lamps. 04
26. Switch gears Make: Siemens
MCCB (63 A, 50KA, Qty: 1No) 01
27. VFD Make: Siemens / ABB
28. Thermal
relay Make: Siemens / Any reputed make
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5.11. Wiring
5.11.1. The oven shall be wired through an intelligent motor control centre (i-MCC) located in the service room as marked in the drawing and a common control and monitoring console is located in the control room from service room. All data cables, RTD sensors, power cables, control cables are to be supplied, laid and terminated by the party. The details of Motor control centre are given in electrical system chapter.
5.12. Internal Mandrel Water Circulation System
5.12.1. This system provides water circulation in the mandrel jacket of the segment during curing cycle. During heating phase, hot water is circulated in the mandrel jacket.
5.12.2. During cooling phase cold water is circulated in the mandrel jacket.
5.12.3. The system comprises of the following:
Hot water circulation system comprising of a hot water
tank with heating elements, hot water circulation
pumps, piping, valves, controllers (at CCMC), Flow
switch, pressure gauge, level switch, RTDs, etc.
Cold water circulation system comprising of
interconnecting piping for circulating the mandrel
jacket water during cooling phase.
5.12.4. Hot Water Tank
Clear Internal dimensions:1130mm (L) x 1130mm (W) x
1200mm (H)
Material of Construction: SS 304L
Bottom plate shall be of 10mm thick SS 304L material
Inner wall shall be of 5 mm thick SS 304L material
Outer wall shall be of 3 mm thick SS304L material
Tank shall be suitably reinforced by structural steel.
Rock wool insulation mattress shall be provided
between the walls so that the tank outside wall
temperature is same as the ambient temperature.
Thickness of insulation shall be 75 mm minimum.
Suitable provisions shall be made to mount the RTDs,
level switch etc.
The tank shall have visual level indicators; inspection
covers as per standard industrial practice.
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The tank shall have arrangement to know the water
level without opening the cover.
The hot water tank shall be fitted with electrical heating
elements to raise the water temperature to a maximum
of 800C within 1 hour.
5.12.5. Hot Water Heaters
Total no. of heaters shall be divided into two banks.
Bank 1 shall be controlled in on/off mode and Bank 2
controlled by an analog input. Bank 2 shall be powered
through a Thyristor power controller whereas Bank 1
shall be powered through power contactor. In both
modes PLC PID controllers will control contactor &
Thyristor controller.
1. Supply of immersion type water heaters as per the specifications given below.
2. Capacity of each heater is 6.0KW (Each heater shall be consisting of three elements of 2.0KW each suitable to connect in Star 4 wire refer Electrical chapter).
Temperature controllers (2 nos.) shall be provided at
CCMC control room for controlling the water
temperature in hardwired control mode.
Each heater shall be provided with MCB
Each bank feeder shall be provided with ELMCB
The heater shall be fitted withdraw type, sheathed,
immersion type tubular heating elements. The heater
shall be fitted to the body of the hot water tank by
flanged connections with PTFE gasket to enable easy
installation.
Heating elements shall be of nickel- chrome resistance
wire. The element shall be covered by magnesium oxide
powder and compressed by swaging to ensure rapid
heat transfer. All the electrical terminations shall be
water tight.
Individual heater capacity shall not exceed 6 kW. 230 V
AC. All the heaters shall be equally distributed among
the phases.
Heater sheath shall be out of SS 316 L, suitable for raw
water quality
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The tubular heating elements shall be supported if
required.
All the electrical terminations shall be watertight.
The Distribution box consisting of ELMCB and MCB for
two heater banks shall be mounted on Tank with
suitable Gland plate for terminating Incomer cables
from i-MCC. The outgoing wires shall be taken to
individual heaters.
Elements/banks shall be arranged/ connected in such
a way that failure of few elements does not affect the
uniformity of heat drastically.
Heaters shall be protected against dry run and over
temperature and shall be provided with auto cut-off for
the dry/exposed bank.
Heaters shall get ON only when sufficient water is
available in the tank. One no of level transmitter to
display the water level in the tank to the operator at
control room.
There shall be one level transmitter and level switch to
be provided and interlocked with water pump as
detailed in Electrical and I & C sections.
The unheated length of elements shall be sufficient to
allow only the heated section to be immersed in water.
All the heaters shall be of equal rating & capacity.
Silicone seal shall be applied to the lead exit and
between lid and terminal box to improve ingress
protection.
Heater terminals and cable entries shall be protected
from dripping, condensation and spill over. Heater
terminal box shall be dust and vermin proof with
hinged doors having locking arrangement.
Teflon insulated wires shall be used near the heaters.
The capacity of the heaters shall be 20% more than the
actual heaters’ capacity required
Schematic sketch shown is only indicative.
Location of ports shall be finalized based on the piping
layout.
5.12.6. Circulating Pumps & Circulation System
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Two (2) nos. (1w+1s) centrifugal pumps, with flooded
suction shall be provided for hot / cold water re-
circulation.
The pump shall be capable of circulating the water at a
pressure of 3.0 kg/cm2; the other details are as follows
Table 5. Pump Specifications
Total Head 35 m Flow rate 3lps
Suction/ Delivery 50 / 32 mm Motor : 3phase induction
Motor & pump
make Kirloskar Duty S1
Pump model DB32/16
Orientation Suction inside,
,Delivery at top
Motor &
pump
Coupled through
love joy flexible
coupling
Electric motor
power rating
Pumps shall have mechanical seal with SS body.
Suitable three phase electrical motor shall be provided
for the above pump.
The hot water lines shall be thermally insulated with
pre-formed insulation material of suitable thickness.
Aluminium cladding shall be provided over the
insulation.
All the valves shall be L & T make, 3-piece construction,
flanged end ball valves except at the pump delivery
where it shall be a globe valve.
A bypass line shall be provided for flow control.
Piping shall be common for both hot and cold-water
circulation systems and hot water circulation lines shall
be thermally insulated.
Connections between the mandrel and water lines
provided on the wall of the oven shall be established
manually by a flexible hose prior to commencement of
curing operation. Supply of flexible hose of 5 m length
(2no.) with flanges at both ends is also in the scope of
party.
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Hot/cold water circulation lines are to be terminated
inside the oven at a convenient height and location
shall be provided with valves as shown in the
Schematic diagram.
Pipe lines shall have flanged joints at intermediate
locations as decided during detailed engineering for
easy dismantling of piping in case of any repair.
The piping shall be suitable for the pump, flow
requirement, pressure requirement etc.
Suction filter shall be of 300-micron rating.
All piping (piping and fittings) shall be of SS304 L
Seamless pipes. All flanges used shall be of SORF
flanges. All pipe fittings shall be butt welded except
SORF flanges.
The entire hot water system shall be located in the
service room of the curing facility.
The party shall weld the pipe joints using TIG welding.
The party shall provide pipe supports for every 2.0 m
either from the wall or from the floor as per the
requirement. The party shall use SS clamps, Structural
steel of Jindal / SAIL/ TATA and Hilti make anchor
fasteners for providing supports.
Entire piping system shall be hydro pressure tested at 5
ksc.
Die penetration (DP) test shall be carried out before and
after hydro test and test certificate shall be provided by
the party.
The following list of materials is required for water
circulation system. The listed material /quantity shall
be supplied.
Table 6. List of Items for Water Circulation System
S No Item Qty
1. 1 ½” SS304 L seamless pipe Sch 40 in m 90
2. 2” SS304 L seamless pipe Sch 40 in m 45
3. 2” 900 elbow ASTM A 403 WP 304L ANSI B 16.9 BW
OF Sch40 OF butt weld type 25
4. 1 1/2” 900 elbow ASTM A 403 WP 304L ANSI B 16.9
BW OF Sch40 OF butt weld type 10
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S No Item Qty
5. 2” Equal TEE ASTM A 403 WP 304L ANSI B 16.9
BW OF Sch40 OF butt weld type 10
6. 1 1/2” Equal TEE ASTM A 403 WP 304L ANSI B
16.9 BW OF Sch40 OF butt weld type 15
7. 1 ½” – 1” Unequal TEE ASTM A 403 WP 304L ANSI
B 16.9 BW OF Sch40 OF butt weld type 6
8. 1 ½” – 1/2” Unequal TEE ASTM A 403 WP 304L
ANSI B 16.9 BW OF Sch40 OF butt weld type 15
9. 2” SORF forged flange of ASTM A 182 F304L ANSI
B16.5 of 150lb standard OF SS304L 26
10. 1” SORF forged flange of ASTM A 182 F304L ANSI
B16.5 of 150lb standard OF SS304L 16
11. 1 1/2” SORF forged flange of ASTM A 182 F304L
ANSI B16.5 of 150lb standard OFSS304L standard 60
12. 2” SORF blind forged flange of ASTM A 182 F304L
ANSI B16.5 of 150lb standard OF SS304L 10
13. 1 1/2” SORF blind forged flange of ASTM A 182
F304L ANSI B16.5 of 150lb standard OF SS304L 10
14. 1” SORF blind forged flange of ASTM A 182 F304L
ANSI B16.5 of 150lb standard OF SS304L 6
15. 1½” Barrel nipple of BSPT 100mm long of ASTM A
403 WP 304L ANSI B 16.9 of Sch40 20
16. 2” Barrel nipple of BSPT 100mm long of ASTM A
403 WP 304L ANSI B 16.9 of Sch40 12
17. ½” Barrel nipple of BSPT 100mm long of ASTM A
403 WP 304L ANSI B 16.9 of Sch40 20
18. 2” –1 ½” concentric reducer of ASTM A 403 WP
304L ANSI B 16.9 BW OF Sch40 OF butt weld type 5
19.
1½” 2 piece carbon steel ball valve with flanged
ends of L &T make, Body: ASTM A 216 Gr. WCB
Ball & stem: SS304, Seat: Glass filled PTFE (with
backup metal seat), Bolts: ASTM A 193 Gr. B7/
ASTM A 194 Gr. 2H, Operation: 4-inch lever
25
20. 2” 2 piece carbon steel ball valve with flanged ends
of L &T make 8
21. ½” 2 piece carbon steel ball valve with BSP threaded
ends 15
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S No Item Qty
22.
½” port pressure gauge with a dial size of 100mm,
range: 0-7 ksc with resolution of 0.1 ksc of H Guru/
Wika / Atlas make
10
23.
2” Y type strainer
• Body & cover: Carbon steel fabricated IS 2062 Gr A
• Screen basket: CAF, IS 2712 GR.0/2
• SS mesh of 300 microns
• Ends; Flanged ends, SORF, B16.5, 150#
4
24.
1 ½” non-return valve
• Dual plate, spring loaded
• Ends: wafer to suit 150#
• Valves shall be suitable for mounting between
• Slip on flanges of 150 # as per ANSI B16.
• Body; ASTM A216 GR. WCB
• Plate: 13% Cr steel
• Seal: EPDM
• Hinge pin & stop pin: SS304
• Spring: Spring steel.
5
25. Foot valve with strainer 2
26. 1" Rubber braided steam hose of 5m length of 10
bar rating 6
27. 6 kW immersion heater 25
28. Kirloskar water pumps 3
29. Mechanical seals for water pumps - spare 6
30. Neoprene gaskets of 3 mm thk for 1 1/2" size
flange 100
31. 2" Neoprene gaskets of 3 mm thk for 2" size flange 75
32. 1"Neoprene gasket of 3 mm thk for 1” size flange 50
33. M12 X 60 long with 2 washers of UNBRAKO/TVS
make of 8.8 class as required 500
34. M12 X 75 long with 2 washers UNBRAKO/TVS
make of 8.8 class 500
35. M16 X 60 long with 2 washers UNBRAKO/TVS
make of 8.8 class 500
36. M16 X 75 long with 2 washers UNBRAKO/TVS
make of 8.8 class 500
37. Al cladding of water line in m 100
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5.12.7. Cold Water Circulation System
The cooling phase shall be for a period of 115 hours.
During this phase water from the cold water circulation
system is to be circulated through the mandrel jacket.
10000 litters sump shall be provided by the
department.
After completion of heating cycle water from the
mandrel at 60 0C with a flow rate of 3 lps will come to
the cold water circulation system.
Pumps which are used for hot water circulation will
also be used for cold water circulation. Piping shall be
planned such that the pumps can used for both the Hot
and cold water. Refer P &ID
Electrical Instrumentation and Control System for
Water Circulation System (Details are covered in
Electrical & ICS Chapters)
The pumps shall have provisions to start /stop locally
from i-MCC and also from control room from SCADA
console/CCMC.
All interlocks for pumps and heaters shall be provided
in the PLC system in the control room. All alarms shall
also be provided in the SCADA console.
Temperature sensors shall be provided at the inlet and
outlet lines and tank.
Flow switch ( two nos.) shall be provided in the return
line.
Hot water temperature in the hot water tank, inlet and
outlet of mandrel shall be monitored continuously and
heater banks shall be controlled based on the same.
The water temperature shall be maintained by
monitoring the tank temperatures 6 nos including
spare. (01 for monitoring & 02 for controlling). RTD
(800 mm length) shall be provided in the tank and 2
nos of RTD (300 mm length) in inlet and outlet.
Heaters shall get on only when sufficient water is
available in the tank. One no of Level transmitter to be
provided to display the water level in the tank to the
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operator at control room. Alarm and Status shall be
provided in SCADA
Pressure transmitter shall be provided in water line
8nos of valves to be provided with Limit switch /
proximity sensors for valve open / close interlocking /
proximity requirements. These valves are to be
interlocked with pumps. The pumps status, valve
status & alarm shall be provided at SCADA.
5.12.8. Tests and Certificates
Party shall submit hydro & pneumatic test certificates
for ball valves.
Party shall submit pump performance test certificates.
Party shall carry out DP test for all weld joints before
and after hydro test.
Party shall carry out hydro test to a pressure of 5.0 ksc
and provide test certificate.
Party shall provide pump guarantee certificate.
Pressure transmitter, RTDs, pressure gauge calibration
certificates shall be submitted.
Rock wool insulation & pre formed insulation material
& test certificates shall be submitted.
Routine test certificate for blower motor, pump motor
and bogie motor.
Flameproof test certificate for bogie motor shall be
submitted.
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General Specifications and Mechanical
systems for AGNI Oven
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6. AGNI Oven
6.1. Basis of Design & System Description
6.1.1. Curing is carried out after the casting of AGNI grains & cartons samples in the Agni casting/SPF facilities. The samples /AGNI grains will be transported in explosive van/forklift / tractor & trolley with proper latching arrangement from the Agni casting/SPF facilities. The oven shall be provided with double leaf steel swing door in the front. The samples /AGNI grains placed inside the hot air oven are subjected to curing operation to achieve required mechanical properties.
6.1.2. The oven shall be provided with suitable spring loaded pressure relief arrangement. This pressure relief arrangement shall be operated at 1 ksc pressure and shall be of size 300 mm.
6.1.3. Curing operation is carried out over a period of 120 hours continuously.
6.1.4. The oven will be operated from 500C to 600C. The design temp shall be 750C. The oven temperature shall be raised to 600C within the first 30 minutes. The temperature of the oven shall be maintained thereon until curing operation is completed.
6.1.5. The hot air re-circulation system for oven comprises of the following:
Two Nos. (1W+1S) hot air re-circulation fans,
supply & return air ducting with dampers,
supply and return air grills.
6.1.6. The dampers for blower selection shall be operated manually and shall be provided with proximity sensors.
6.1.7. The entire heater battery shall be divided in to three banks and controlled using PLC PID controllers. Two of the heater banks shall be controlled using analog command to Thyristor power controller and the remaining one heater bank shall be controlled in On/Off mode (digital) commanding heater bank power contactor. The oven shall be capable of maintaining the operating temp., either with the on / off controller or with the PID controllers independently.
6.1.8. Blower and heater battery shall be located in the service room.
6.1.9. Insulated oven chamber, complete with concealed supply & return GI ducts, SS grills for uniform air distribution in X & Y axes, sheet metal cladding and its support structure.
6.1.10. The oven shall be maintained at a positive pressure so that the
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outside cool air does not enter the oven.
6.1.11. The oven shall be airtight and leakage through the oven doors, SS sheet cladding shall be avoided. The oven shall be airtight and thermally leakage proof such that the fall of oven temp. by 50C from an operating temperature of 600C shall not occur earlier than 20 minutes.
6.1.12. Hot air shall be supplied from the roof of the oven. Return air shall be collected at the bottom sides, close to the oven floor refer the drawing.
6.1.13. The total mass of steel to be considered inside the oven shall be 12 tons, which includes mass of AGNI &Carton crates, AGNI &Carton moulds. Party shall consider the mass of oven structures that may get heated up to finalize the heater banks, blower capacities to maintain temp. within specified limits and to attain the operating temperature with in stipulated time.
6.1.14. The mass of propellant need not be considered in sizing the heater and the blower since the thermal conductivity of propellant is very low.
6.1.15. Spatial variation when measured inside the oven shall not exceed 1.50C.
6.1.16. Heater elements shall be of black heat operation type – i.e., the heaters shall not become red hot during normal operation (when air flow exists) of the oven.
6.1.17. The heater shall have minimum 20% margin over design values.
6.1.18. The Blowers shall be sized for additional 20 % capacity over the design capacity.
6.1.19. Blowers capacity shall be arrived by considering
The discharge pressure drop across ducts, dampers, heater banks, grills etc.
Attaining the operating temp within stipulated period.
No. of air changes required to maintain uniform temperature (Spatial variation: 1.5o C or better)
To maintain a positive pressure inside the oven so that the cool air from outside shall not enter the oven
The blowers shall develop a static pressure of 120 mm WC
Blowers’ frame size shall be selected considering the space available in the service room and the door entry dimensions
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6.2. Specification of AGNI Oven
Table 7. Specification of AGNI Oven
DESCRIPTION Specification
Oven clear internal
dimensions
(LXWXH)- meters
7.0X5.5X3.0
Base structures
Bottom base structure of size -
5.5mX7.0mDept will provide fire brick & MS
grid (1.0 x 1.0 mt) arrangement for oven
area of 5.5m X 7.0m to withstand oven
temp of 75 Deg Cel.
Oven doors Manually operated double leaf swing doors
No. of blowers
1 working + 1 standby
(Total: 2nos.)
Fan capacity Minimum 40,000 CMH (23543 CFM)
Fan static pressure Minimum 120mm WC
No. of heater banks Total: 3 Nos. (distributed in equal capacity)
Heater bank capacity Minimum 150 kW
ON/OFF controlled
banks 1 Nos.
Thyristor controlled
bank 02 No.
Operating temp. 50 0C to 60 0C
Design temperature 75 0C
Ramp up time from
ambient temperature
30 min for 60 0C
30 min for 60 0C
∆T – Outer skin
temperature of the
oven & amb.
Temperature
5 for 60 0C
Spatial variation 1.5 0C or better
Oven performance –
controllability Set temp. ± 20C
6.3. Interlocks
Table 8. Interlocks of AGNI Oven
Sl. No Activity Interlocks
1. Blower on 1. Stand by blower should be in off mode
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2. Oven doors are closed
3. Blower dampers open.
4. CCMC emergency released
5. Fire damper.
2. Air heater
on
1. Blower is on
2. Air flow switch is on
3. Duct based RTD should be normal.
4. fire damper open
5. Blower RPM- 80%
6. Not in Local mode
7. Temperature inside oven is below set point
6.3.1. Blower shall not be switched on unless the doors are closed, their respective suction and delivery dampers and fire dampers are in open condition
6.3.2. When one blower is ON the other blower shall not get ON.
6.3.3. Heater banks shall get ON only when blower is ON and availability of air flow.
6.3.4. Fire dampers and oven heater banks shall be interlocked with temperature sensors provided at fire damper inlet & outlet and heater battery duct through dedicated temperature controller fixed at iMCC panel and these temperature controllers in turn is to be interlocked with PLC PID controller for oven temperature control purpose.
6.3.5. All the heater banks shall get off if the Temp Controller installed in the ducts operate in addition to the control from the temperature controllers installed in the Control panel.
6.3.6. Alarm shall be provided for following conditions: AGNI Oven: Blower 1 off, Blower 2 off, Air fail, Air low temp., Air over temp, Fire damper motor operated.
6.4. Atmospheric Conditions
Parameter Summer Monsoon Winter
Dry bulb temperature 0C
42.2 28.3 18.3
Wet bulb temperature 0C
28.3 26.7 13.9
Relative humidity % 35.0 >90 60.0
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6.5. Oven Parameters
Description Specification
Operating principle Hot air re-circulation
Hot air oven dimensions
(Clear internal
dimensions.)
7000mm(L) x 5500mm(W) x
3000mm(H)
Operating temperature
for hot air 50 - 60 0C
Design temperature 750C
Outer skin temperature
of oven
Not to exceed 50C from the ambient for
600C
Time to reach operating
temp., from ambient of
30 0-C
30 minutes for 600C operating temp.
Rh controls Not required
No. of temperature
sensors required 32 nos (Including spare)
6.6. Oven Construction
6.6.1. The oven structure shall be of free standing type. Refer drawing in this regard.
6.6.2. Oven shall be fabricated in double wall construction. The outer wall shall be of 5 mm thick carbon steel plate. The inner side of the oven shall cover with 2mm thick SS 304 sheets/panels, suitably stiffened. Material certificate shall be produced for SS sheets/panels. The oven base structure area 7000mm X 5500mm shall be provided with fire bricks with MS grid of 1.0 m X 1.0 m size to withstand oven temp of 75 degree C. SS cladding (3.0 mm thk) shall be done by the oven supplier. Fire brick and MS grid work is in the scope of department.
6.6.3. The drawing is only indicative and the supplier may work on 6 mm thk MS plate out any other alternate method but shall be implemented with the approval of the Department.
6.6.4. TIG welding shall be used for welding of all SS fabrication works.
6.6.5. Rock wool mattress of at least 150 mm thickness shall be used for insulating the oven walls such that the outer skin temperature is limited as mentioned earlier. Spikes shall be provided to retain the mattress in the position without
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collapsing.
6.6.6. Insulation mattress is sandwiched between SS304 sheet (oven side) and MS sheet on the rear side (Oven outer wall side).10 mm dia. studs shall be welded in MS sheets to retain the insulation mattress in position.
6.6.7. All internal SS304 pre-polished sheets, shall be buffed after welding and merge it properly. Doors and grills shall be buffed and polished to have mirror like finish. Enough care shall be taken to purchase only plastic coated SS304 sheets and the plastic cover shall be removed after erection at site.
6.6.8. The oven outer walls shall be provided with ladders for accessing the individual sensors for repair / other maintenance works and also to reach top of oven roof.
6.6.9. Manually operated double leaf swing door at the front shall be provided.
6.6.10. Intrinsic safe proximity switches shall be provided for Doors locked condition.
6.6.11. Use only silicon gaskets for sealing between the doors and oven walls so that no leakage of air exists.
6.7. Air Distribution System
6.7.1. The blowers shall be located in the service room adjacent to the hot air oven. The blowers are sized to provide sufficient number of air changes inside the oven to limit the spatial variation inside the oven to 1.50 C.
6.7.2. Two nos., of blowers (1 working & 1 standby) shall be provided. The blowers shall be mirror image of each other. The area available in the service room and the door entry at the service room shall be taken into account while selecting the blowers.
6.7.3. The blowers shall be sized to suit the requirement such that the operating temperature is reached within 30 minutes.
6.7.4. Blowers shall be thermally insulated. Impellers shall be designed to handle hot air at 75oC. Blowers shall have butterfly dampers, vibration isolators, inlet and outlet with flexible bellows with flame retardant material.
6.7.5. The blower location w.r.t. ovens are indicated in building and equipment lay out drawing.
6.7.6. Ducting requirements for the hot air distribution system shall be as follows:
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Supply and return air to / from the oven shall be
through rectangular galvanized iron (GI) ducts.
Ducts shall be of double wall construction made of 2 mm
thick GI sheets. Rockwool insulation (150mm) shall be
sandwiched between the walls. The rock wool insulation
shall be kept in position by chicken mesh.
Ducts shall be made in parts with flanged joints. The
joints shall be provided with asbestos /millboard gaskets
and ensure leak tight.
Ducts shall be air tight and shall be tested as per
standard procedure.
Ducts shall be reinforced with suitable stiffeners.
6.7.7. The heater battery shall be of same size as that of oven ducts or proper divergent & convergent portions are to be provided.
6.7.8. Heating coils shall be mounted inside the discharge ducts.
6.7.9. The Heater battery compartment shall be provided with air-tight doors for accessing the heating coils during maintenance.
6.7.10. SS grills with volume control dampers shall be provided to ensure uniform air distribution in the oven.
6.7.11. All ducts shall be fully insulated, and covered with GI sheet.
6.7.12. Motorized Fire dampers shall be provided both at the suction and discharge ducts of the ovens. The fire dampers shall be controlled through Temp Controller which closes the damper if the temperatures of Hot air are equal/above the set value.
6.7.13. Hot air supply shall be from both sides of the oven and return air duct shall be routed from top/roof to the oven.
6.7.14. Provision shall be made available in the ducts to install air flow switch.
6.7.15. Oven structures shall support fire hydrant lines and air lines of deluge system. Necessary support brackets shall be made available for installing these lines inside the oven.
6.8. Heaters & Heater Battery
6.8.1. The heater shall be fitted with withdraw type, sheathed, tubular heating element. The entire heater battery should be mounted inside a double walled mild Steel casing having rock wool insulation of not less than 150 mm thickness in between in order to prevent heat losses. The inside sheets of heater
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battery should be with G.I. The heater terminals must be brought to one side so as to facilitate connection and replacement easily. They shall be terminated in a terminal box.
6.8.2. The heater shall be suitable for mounting on air duct. Heater battery shall have flanges for connecting the heater and ducts. Heater battery shall be sized based on the duct size preferably.
6.8.3. Heaters shall be encased in tubes to avoid egress of hot air and to enable replacement of heating elements during operation suitable provision is to be made.
6.8.4. Heaters shall be black heat type. The heaters shall not become red hot with air flow.
6.8.5. Heating elements shall be with of nickel-chrome resistance wire. The elements shall be covered by magnesium oxide powder and compressed by swaging to ensure rapid heat transfer.
6.8.6. The heaters shall be encapsulated in hollow tubes.
6.8.7. The heating elements shall be supported at sufficient intervals, but not more than 600 mm.
6.8.8. All the electrical terminations shall be airtight.
6.8.9. The heater body shall be air tight to prevent any leakage of hot air / gases.
6.8.10. Elements/banks shall be arranged/ connected in such a way that failure of few elements does not affect the uniformity of heat drastically.
6.8.11. Heaters shall be protected against over temperature and shall be provided with auto cut-off.
6.8.12. It shall be possible to dismantle & replace/repair heating elements at site.
6.8.13. Silicone seal shall be applied to the lead exit and between lid and terminal box to improve ingress protection.
6.8.14. Watt densities of heating elements shall be selected properly to prevent carbonisation.
6.8.15. Heater battery shall be painted with Aluminium heat resistant paint.
6.9. Electrical Requirements
6.9.1. The enclosure shall be provided with removable gland plates for cable entries
6.9.2. All elements shall be of equal wattage & voltage.
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6.9.3. The heater capacity shall have a margin of +20 % (i.e. more by 20 % than the design value)
6.9.4. The heater battery terminal box shall have hinged doors with a standard cupboard like locking arrangement.
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Electrical Systems
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7. Electrical Systems
7.1. Scope of Work – Electrical Systems
7.1.1. Design, Fabrication and supply of intelligent Motor Control Centres (i-MCC) – 2 No’s.
i-MCC 1 for Hot Air Recirculated type Main oven and Mandrel Jacket water circulation system.
i-MCC 2 for Hot Air Recirculated type Agni Oven.
7.1.2. Testing and commissioning of above intelligent Motor Control Centres (i-MCC – 1 & 2))
7.1.3. Erection of the intelligent Motor Control Centres (i-MCC – 1 & 2) and interconnecting of field equipment’s along with Power & Control wiring etc. to the above panels.
7.1.4. Supply of Electric motors, Heater Banks, VFD drive, Thyrister controllers and other items and their erection and testing as per detailed specification. (Some of the items are part of iMCC itself)
7.1.5. Supply and laying of power and control cables, earth strips etc as per related specification mentioned in the following tender document.
7.2. General Terms
7.2.1. Party shall realize Intelligent Motor Control Centre (iMCC) as per detailed specifications furnished below.
7.2.2. The iMCC shall be fabricated and Integrated by an Authorized panel manufacturer.
7.2.3. Party shall engage panel manufacturer, obtain and submit GA Drawing, power and control circuit drawings, including selection of switch gear ratings, control drawing, Motor management scheme, Bill of material for Dept. Approval prior to start of fabrication.
7.2.4. The panel shall undergo functional checks, HV test, Dielectric strength checks, Dimensional checks and other qualification tests as per standards at panel manufacturer works in the presence of the Department.
7.2.5. The i-MCC panel shall be designed for operation in high
ambient temperature up to 50°C, high relative humidity up to 95 % and tropical atmospheric condition.
7.2.6. Instruction, Operation and maintenance manuals of items like MMS, Thyristor controller, VFD, switch gears etc. shall be
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submitted along with dispatch document.
7.2.7. Rubber mats of 2mx1m, 33 kV grade shall be provided for the complete length of all the panels (the panels which are in the scope of supplier) both in front and back side such that persons stand on rubber mats during maintenance.
7.2.8. The vendor shall supply documents consisting of as built drawings (iMCC power & control drawings, cable schedule), catalogue of all bought out electrical items, VFD parameterization Details & motor management system manual, Motor management coding.
7.2.9. The supplier shall provide three complete sets of all the drawings, operation and maintenance manuals and test certificates for the operation and maintenance purpose of the department.
7.2.10. i-MCC Panel cubical keys, Handles, interlock keys, are to be
handed over to department during supply.
7.2.11. Party shall submit the following for approval before fabrication
7.2.12. Detailed Schematics of the i-MCC Panel
7.2.13. General arrangement drawings with complete bill of materials, Bus bar layout, installation details etc.
7.2.14. Control wiring drawings.
7.2.15. Switchgear/Cable Ratings
7.2.16. The party should incorporate all changes / modifications / rectifications suggested by Department after verifying Drawings and bill of materials.
7.2.17. Any specification deviations required on technical grounds or non-availability of specified items have to be brought to the department notice in the deviation table in the Annexure and changes in these regards shall only be acceptable with the approval of the department.
7.2.18. Any item not specified but required for satisfactory functioning and integration of the total system to be considered and included by the party and demonstrating the total functionality of the system as specified is the responsibility of the party.
7.2.19. Trouble shooting and Maintenance documents to be prepared and submitted for electrical systems.
7.3. Intelligent Motor Control Centre (i-MCC)
7.3.1. Party shall carryout supply, Testing & Commissioning of front operated indoor cubicle type free standing and Compartment
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arrangement intelligent Motor Control Centre suitable for operation on 3-Phase, 4 wire 415V ± 10%, 50Hz ± 3% AC supply.
7.3.2. The panel should be designed, manufactured and tested in accordance with IS 8623(Pt1), IS 13947(Pt4/Sec1) and as per the specifications issued by us.
7.3.3. Enclosure symmetrical frame construction (16-fold profile) of rolled hollow sections made up from 1.5mm Thickness sheet with holes on a 25mm DIN pitch pattern.
7.3.4. Static load bearing capacity of the enclosure shall be around 1400 kg.
7.3.5. It shall have Horizontal sections, Vertical sections with fixing levels for space saving interiors installation.
7.3.6. Doors shall be fitted with concealed hinge to ensure 130 deg opening.
7.3.7. Lock shall be of 7 mm Triangular Bit Lock insert with key.
7.3.8. Panel lighting shall be provided in the cable chamber and it shall be LED lamps only. The same needs to be controlled with panel door open / close limit switch.
7.3.9. Removable Type Rear, side panel and Roof plate made of 1.5mm sheet steel, with foamed in seal (PU Foam gasket mixture of polyol and isocyanate).
7.3.10. Ingress protection: Should comply to IP54. Partial doors, Covers are PU Foamed (mixture of polyol and isocyanate) integrated to ensure I54 of Ingress Protection.
7.3.11. The panels shall be of modular design with a horizontal bus bar compartment running at the top and the cable entry shall be from the bottom for MCC unless it is specified.
7.3.12. The outgoing feeders shall be arranged in multi – tier mode. The panel front shall contain individually enclosed switchgear modules. All of the electrical accessories shall be mounted on the front side of the panels with facility to remove /refit form the front side.
7.3.13. Completely enclosed vertical bus bars shall be provided for feeding to the feeder modules.
7.3.14. The corners shall be rounded and no rough or sharp edges shall be left.
7.3.15. The dimensions of the panel shall be designed liberally allowing suitable access for using the maintenance tools in all cubicles / alleys.
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7.3.16. The panel can be limited to maximum height of 2100 mm excluding ISMC base of 100 mm, Overall height of the panel is 2200 mm.
7.3.17. Liberal clearances shall be maintained in all panel cubicles, bus bar chambers and cable alleys by considering the maintenance point of view.
7.3.18. All contacts / terminals of the switchgear components shall be wired to the terminal block.
7.3.19. MCCB add-on blocks, intelligent modules terminals are to be wired with single wire only. No multiplication is allowed in the above said terminals.
7.3.20. The structure shall be mounted on a rigid base frame of ISMC 100 channel. The design shall ensure that the weight of the components is adequately supported without deformation or loss of alignment during transit or during operation.
7.3.21. The ISMC channel shall be provided with adequate no. of holes at bottom in order to ensure installation convenience at site.
7.3.22. i-MCC panel shall have provision to access from the back side of the panel and also all the feeders shall have provision for entry of cable from the back side bottom of the panel except marshalling chamber.
7.3.23. Marshalling chamber shall be provided for both front side bottom as well as back side bottom.
7.3.24. Detachable, split gland plates of 3mm thick sheet steel shall be provided for panels both in the top and bottom.
7.3.25. Multiplication if any can be done only in the terminal blocks using shorting link between the terminals.
7.3.26. Complete metallic partition sheets shall be provided between any two adjacent vertical panels or horizontal feeders.
7.3.27. For the bus bar chamber, the doors shall be of bolted type. Suitable cable core clamping arrangement shall be provided in the cable alley/chamber.
7.3.28. Cable alley/chamber should have a minimum width of 400mm.
7.3.29. Cable alley /chamber should be provided with removable bottom plate to have cut outs for cable entry.
7.3.30. Each feeder compartment shall be provided with suitable nameplate showing feeder name with rating as given in the bill of quantities table. Name plates should be made of aluminum black enamel painted and names should be engraved and screw fixing type. Inscription shall also be provided for indication
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lamps, meters, operating handles and panel opening lock.
7.3.31. All live parts shall be shrouded with non – deteriorating insulating barrier to prevent against accidental contact.
7.3.32. All the feeders shall be properly extended up to the rear side of the panel for cable termination with suitable connecters and insulating barriers.
7.3.33. Suitable cable chamber housing the cable end connections, power and control cable terminations shall be provided in the backside of the individual compartment.
7.3.34. Marshalling chamber can be planned preferably in the middle of the i-MCC. All the feeders control terminals shall be brought
to this chamber. Control cables and communication cables from the field are to be entering through this chamber only.
7.3.35. Suitable provision can be made for routing the control cable and communication cable separately inside the entire length of i-MCC panel. Nowhere, it shall get linked.
7.3.36. Mounting of the switchgear components inside the i-MCC panel also to be arranged in such a way that the control and communication cables shall not get crossed anywhere.
7.3.37. The design shall ensure generous availability of space for ease of installation and maintenance of cabling and adequate safety for working in one vertical section without coming into accidental contact with live parts in the adjacent section.
7.3.38. The i-MCC should have necessary compartment cubicles of electrical switch gear as mentioned in the document below.
7.3.39. Provision shall be made for lifting and handling of panel by eyebolts.
7.3.40. Fire retardant DMC / SMC fillings for openings around bus bars near the sectional barriers shall be provided. Also adequate fire barriers are to be provided appropriate locations in all feeder compartments in such a way that products of combustion if any shall not spread to other compartments of the panel.
7.3.41. The panel shall have high mechanical and dielectric strength.
7.3.42. The panel shall be suitable for horizontal expansion in future on both sides. Hence necessary provisions like providing full length bus bars in the main bus chamber, providing holes in the main bus bar ends for connecting fish plates and providing separate end covers in the bus bar ends for chamber shall be made.
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7.3.43. Bus bar support conductors shall be FRP type firmly fitted to the frame work of the panel.
7.3.44. Safety
• All electrical panels shall have finger touch protection, for human safety viz. working on one component shall not cause shock to the personnel due to any other live component in the panel. Also, the terminal live parts shall not be accessible by fingers (finger cannot come in contact with live parts of the terminals).
• The apparatus and circuits in the i-MCC panel shall be so arranged as to facilitate their operation and maintenance and at the same time to ensure the necessary degree of safety.
• Apparatus forming part of i-MCC panel shall have the following minimum clearances as per the standards
a. Between Phases
b. Between Phase and Neutral
c. Between Phase and Earth
d. Between Neutral and Earth
• All the live parts to be covered properly (no live parts to be visible after opening the door) in order to avoid the possibility of in advent touching of the same during operation and maintenance.
• Mounting of both measuring as well as protection CBCTs should be taken care properly.
• Routing of all the control cables planned such a way that it should not cross any live parts.
• Routing of all the communication cables planned such a way that it should not cross any live parts.
• All the insulated materials used in the construction of the panel shall be non-hygroscopic, duly treated to withstand the effect of high humidity, high temperature and tropical ambient service conditions.
• Door interlocking facility and defeat interlock facility is to be provided for all MCCB handle mechanisms on the front door of the cubicle.
• All the feeders shall be provided with double Earthing.
• All the feeders shall be provided with LOTO (Lock out Tag out) devices. Necessary locks are to be supplied from the standard manufacturer of LOTO products. The same will be approved by department during drawing approval.
7.3.45. Bus bars
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• The bus bar arrangement shall confirm to IS 11353:1985
• Copper bus bars made of high conductivity electrolytic grade
copper confirming to IS 613:1984 of suitable capacity shall
be provided.
• The bus bars shall be sleeved (heat shrinkable sleeve) air
insulated and made of high conductivity, high strength
Electrolytic copper complying with the requirements of IS
5082.
• The bus bar shall be suitably braced with non-hygroscopic
supports to provide a through fault withstand capacity as
specified earlier.
• MS Bolt / nuts are to be used for Busbar coupling and
Stainless steel bolts / nuts to be used for busbar chamber
covers, Panel coupling bolts and for Earth busbar
connections.
• Suitable Bus bar support to be planned.
• The neutral as well as the earth bus shall be capable of
withstanding the fault level as mentioned above. However,
earth bus shall not be less than 50 x 6 mm CU.
• Fire retardant SMC/DMC fillings for openings around the
bus bar in the feeder compartments near the sectional
barriers shall be provided.
• Large clearance and creepage distances shall be provided on
the bus bar system to minimize the possibility of a fault.
• High tensile bolts, nuts and spring washers shall be
provided at all bus bar joints. Additional lock nut (i.e. double
nut) has to be provided in all the bus bar tappings.
• The short circuit strength of bus bars shall be 50kA rms
(minimum), one second and 105 kA peaks.
• They shall be of uniform cross section thought out the panel
with a current density of 80Amps per square centimetre or
better.
• Suitable colour – coded heat shrinking sleeves shall be
provided for the bus bar conductors with colour – coding.
• Cadmium plated high – tension bolts and nuts shall be used
for the joints. Spring washers will be used for sustaining the
contact pressure.
• All joints / tapping points of the buses shall be suitably
shrouded to prevent accidental contact.
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• Panels shall have bus bars with respective phase colour
coded heat shrinkable PVC sleeve. All joints shall be
shrouded. No live terminal shall be directly accessible, but
shall be properly shrouded.
• Proper shrouding arrangement shall be provided between
the auxiliary bus bars and the main bus bars.
• Minimum clearances shall be maintained as per the latest IS
code.
• All the live bus bars shall be covered with transparent
acrylic sheets / FRP, Sheet.
• Main bus-bar shall be rated for minimum of 120% more
than the selected switchgear rating of main incomer.
7.3.46. Earthing
• Earth copper bus bars of minimum 300 Sq. mm size shall be provided throughout the length of the panel.
• Within the panel board all the switch gear bodies shall be duty connected to the earth bus bars.
• Provision for connection to the plant earth grid shall be provided at both the ends of the panel.
• All hinged doors with electrical accessories shall be provided with flexible copper earth connections.
7.3.47. Power Wiring
• Power wiring shall be carried out with minimum 4.0 Sq. mm size of 660/1100V grade multi strand single core copper flexible wires. While selecting individual feeder cable size, current rating one step above the feeder rating is to be considered.
• Panel Control wiring shall be carried out with minimum 1.5 Sq. mm sizes of 660/ 1100V grade multi strand single core copper flexible wires.
• Transducer outputs and control/signal wires from all cubicles should be wired with shielded cables and terminated in terminal blocks housed in control compartment.
• Inter connections in the DOL starter and MCCB feeders shall be carried out with suitable rated wires.
• All the power wires shall be wired up to the clip on type terminals mounted on the edge of the feeder base sheet in the cable alley for facilitating easy cable termination.
• All the control wires shall be wired up to the Control terminals of Nylon Unbreakable type “PHONIX” or any other
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reputed make mounted on the edge of the feeder base sheet in the cable alley for facilitating easy cable termination.
• Tube Insulated copper lugs shall be used for terminating the control wires.
• All the wires at the terminal block shall be identified properly by providing suitable number / letter ferrules.
• All Switchgear shall be of AC 23 Duty.
7.4. Feeders for Intelligent Motor Control Centre (i-MCC)
7.4.1. The i-MCC should be provided with following feeders with compartmentalized cubicles separated from each other, with bus bars on top and bottom cable entry
Table 9. Feeders for i-MCC – Main Oven
Feeder Description
Capacity (KW)
Specification
Incomer To be
arrived by Vendor
ACB with adjustable short circuit, earth fault and overload. Electrically operated.
Multi-Function meter with Profinet/ Ethernet connectivity for local display and remote data logging.
Shall have RYB indication lamps, on, off, trip status and Suitable Current CTs to be provided for current measurement and display at Multi-Function meter.
Outgoing Feeders
ON/OFF Heater Bank – 1
(Air) 100
Switchgear: MCCB, Contactor
(There shall be two contactors connected in series to avoid heater getting on in case of contact welding.)
Earth Leakage protection with MMS
Measurement & Monitoring with MMS
Thyristor Heater Bank – 2
(Air) 100
Switchgear: MCCB, Contactor
Thyristor controller (Detailed specification for Thyristor Controller is given in data sheets)
Conventional Earth Leakage Relay
Measurement & Monitoring with Thyristor Controller
Thyristor Heater Bank – 3
(Air) 100
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Blower - 1 55
Semiconductor Fuse as incomer to soft starter
Soft Starter – 2 no’s (Main & Redundant for Blower-1)
Soft Starter- 1 no’s (For Blower-2)
Conventional Earth Leakage Relay
Measurement & Monitoring with Soft Starter
Local Push Buttons
Note for Blower-1 Soft starter:
a. Provide interlocking between Soft starter (Main & Redundant) such that only one Soft starter shall be ON at a time.
b. This feeder is with Main & Redundant Soft starter and changeover shall be possible from both starters.
c. The selection between Main & Redundant Soft starter to be effected by operation of a key operated selector switch and the power & control connection changes to be effected by operation of Power & Auxiliary contactors.
Blower - 2 55
Fire Damper Motor - 1 2 Switchgear: MPCB, Contactor
Earth Leakage protection with MMS
Measurement & Monitoring with MMS
Fire Damper Motor – 2 2
Hot Water Pump - 1 3.7
Switchgear: MPCB, Contactor Earth Leakage protection with MMS Measurement & Monitoring with
MMS Local Push Buttons
Hot Water Pump – 2 3.7
ON/OFF Bank – 1 (Water) 18
Switchgear: MCCB, Contactor
(There shall be two contactors connected in series to avoid heater getting on in case of contact welding.)
Earth Leakage protection with MMS
Measurement & Monitoring with MMS
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Thyristor Controlled Bank –
2 (Water) 18
Switchgear: MCCB, Contactor
Thyristor controller (Detailed specification for Thyristor Controller is given in data sheets)
Conventional Earth Leakage Relay
Measurement & Monitoring with thyristor Controller
Bogie Motor 5.5
MCCB/Semiconductor fuse
VFD Refer Data Sheets
Conventional Earth Leakage Relay
Note:
a. AOP (Advanced operator panel) of drive should be mounted on cubicle door of panel. The ON /OFF, forward, reverse & emergency OFF are to be provided in a push button station located in Bay.
b. VFD shall be interfaced from PBS for forward &reverse operations of Bogie.
c. VFD need not to be interfaced with PLC/SCADA.
Table 10. Feeders for i-MCC – AGNI Oven
Feeder Description
Capacity (KW)
Specification
Incomer To be
arrived by Vendor
MCCB with adjustable short circuit, earth fault and overload. Electrically operated.
Multi-Function meter with Profinet/ Ethernet connectivity for local display and remote data logging.
Shall have RYB indication lamps, on, off, trip status and Suitable Current CTs to be provided for current measurement and display at Multi-Function meter.
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Outgoing Feeders
ON/OFF Heater Bank – 1
(Air) 50
Switchgear: MCCB, Contactor
(There shall be two contactors connected in series to avoid heater getting on in case of contact welding.)
Earth Leakage protection with MMS
Measurement & Monitoring with MMS
Thyristor Heater Bank – 2
(Air) 50
Switchgear: MCCB, Contactor
Thyristor controller (Detailed specification for Thyristor Controller is given in data sheets)
Conventional Earth Leakage Relay
Measurement & Monitoring with Thyristor Controller
Thyristor Heater Bank – 3
(Air) 50
Blower - 1 30
Switchgear: MPCB, Star Delta Starter
Earth Leakage protection with MMS
Measurement & Monitoring with MMS
Local Push Buttons
Blower - 2 55
Fire Damper Motor - 1 2
Switchgear: MPCB, Contactor
Earth Leakage protection with MMS
Measurement & Monitoring with MMS
Fire Damper Motor – 2 2
7.4.2. Feeders shall have the following features as per the above specifications
Switch Gear • MCCB: MCCB with adjustable short circuit, earth fault
and overload protection with necessary arrangements. Electrically operated. Specifications as per the Data sheets
• MPCB: MPCB with adjustable short circuit, and earth
fault with necessary arrangements. Electrically operated. Specifications as per the Data sheets
• Contactor: DOL starter with contactors of suitable
rating. 4 NO + 4 NC contacts shall be provided in contactor for on/off status etc. Specifications as per the Data sheets
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Earth Leakage protection • Earth Leakage protection shall be provided through MMS
with External CBCT. In case the selected MMS brand is not offering an integrated/add on Earth leakage module (documentary proof from OEM to be submitted) microprocessor based ELR of PROK DVS can be used and interfaced through MMS digital input.
Conventional Earth Leakage protection • Earth Leakage protection shall be provided with
microprocessor based Earth leakage relay with adjustable current/time and display of earth leakage current. ELR of Prok DVS make shall be provided.
Measurement & Monitoring with MMS
• Motor Management System
Measurement & Monitoring with Soft Starter • Soft starter shall be interfaced with SCADA/PLC System
meeting communication Interfacing/Protocol Requirements.
Measurement & Monitoring with Thyristor Controller • Thyristor Unit shall have Communication Compatibility
with PLC/SCADA to display Current / Voltage / Power / Healthy Status etc.,
Local Push Buttons: • Illuminated Push buttons for ON / OFF & Indications
Lamps shall be provided on Feeder compartment hinged Door for local mode operation.
7.4.3. Ethernet switches required quantity shall be arrived by vendor (Refer Instrumentation and control section for details) and shall be located in the i-MCC itself as a separate compartment.
7.4.4. Necessary power supply unit, power supply online monitoring systems needs to be introduced and located in the same compartment.
7.4.5. Network switch compartment shall have a glass door for easy monitoring.
7.4.6. All the feeders shall have sufficient no. of aux. contacts (NO & NC) in power contactor apart from the power contactors to use with Digital inputs of PLC and SCADA depending on the requirement (No add-on block for the contact multiplication is acceptable).
7.4.7. For all design purposes, ambient temperature shall be considered as 50°C. Temperature rise shall be as per IS-8623
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7.4.8. All the feeders shall be compartmentalized.
7.4.9. The Control and data acquisition is through PLC & SCADA. The PLC envisaged for this automation is dual redundant with criss-cross configuration. The i-MCC should use PROFINET/MODBUS TCP/ETHERNET communication Protocol and all feeder elements should be configured suitable to this dual redundant configuration. All feeder currents, VFD currents,on/off/trip status, On/Off commands status, run status, feeder protection (EL, SC, OC, winding temp) should be communicated through communication cable.
7.4.10. i-MCC communication cable (main & redundant -2 runs) should be laid from i-MCC to control room with sufficient extra length.
7.4.11. The HMI/operator panels MMS (door display unit) are to be mounted on the front door of each compartment.
7.4.12. All the above listed feeders should have iMCC/MMS modules for remote ON/OFF status, current monitoring etc
7.4.13. The Intelligent motor management system shall consist of necessary modules and add-ons for control and status monitoring, current/voltage measurement, operator panel with display unit for each motor feeder, ground fault monitoring, winding temp. monitoring etc.
7.4.14. Panel shall have the 3-phase indication lamps in the metering cubicle controlled by 3-pole MCB.
7.4.15. Voltage input to the Multifunction meter shall be routed through 3-pole MCB.
7.4.16. Resin cast Current transformer shall be planned and secondary to be routed through terminal dis-connector.
7.4.17. The incomer panel shall consist of MCCB with safety lock and key with suitable rating, which will be used to switch off power supply during EMERGENCY OFF.
7.4.18. Control transformer can be planned for the control supply. Incoming and Outgoing MCBs shall also be planned for the same.
7.4.19. Control transformer can be mounted on the front side / backside of the panel in any of the compartment with suitable ventilating arrangement.
7.4.20. Sizing of the control transformer to be submitted for review and clearance before proceeding for the fabrication.
7.4.21. All the feeders control supply to be routed through the suitable
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/adequate rating MCB having the provision of acquiring ON, OFF and TRIP Status.
7.4.22. All the MCBs shall have the provision for ON, OFF and Alarm contact provisions. The same shall be wired for the control logics and SCADA information as per the requirement.
7.4.23. Local/Remote Selection Switch: Blowers and water pumps be provided with Local/Remote Selector Switch to facilitate Local/Remote Operation Selection. The status of Local / Remote Switch shall be taken as one of the input to respective Remote DI Module. The Push Button also shall be taken as DI to PLC input module. The PLC DO shall issue command after fulfilling all interlocking requirements.
7.5. Motor Management System (MMS)
7.5.1. Motor Management System means Electronic Modules capable of Monitoring, protecting, controlling motor feeders and as the nomenclature of the system is different among different makes term “MMS” will be used to represent the system. MMS shall provide protection, metering, control, monitoring, and historical logging for 3ɸ AC induction motors and Heater Bank currents up to 200A (min) using integral current transformers (CTs) or external CTs as applicable.
7.5.2. The make of the motor management system should be of Siemens/ Schneider/Allen Bradley make MMS and the make shall be same as that of PLC selected.
7.5.3. Protections: MMS shall provide all current and voltage based
protections mentioned below:
Thermal overload
Current phase imbalance
Current phase loss
Current phase reversal
Long start
Jam (locked rotor during run)
Undercurrent
Over current
Ground Fault protection (internal)
Motor temperature sensor
Voltage phase imbalance
Voltage phase loss
Voltage phase reversal
Under / Over voltage
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Any other additional protection feature as applicable.
7.5.4. Monitoring:
It shall provide monitoring of all 3ph currents, ground
current, avg. current, voltages, power, PF, active and
reactive and energy, it shall have fault recording with all the
current, voltage values for the last minimum 5 faults.
Ground fault protection & leakage protection shall be
possible & it shall also have the provision to connect the
(external) CBCT to MMS.
MMS shall have provision to directly connect to the
temperature sensor, with or without expansion module
MMS shall monitor, display and communicate the
temperature value (when connected with PT100 sensor)
7.5.5. Communication
Device should have integrated communication port for the
communicating through Modbus TCP, Ethernet IP, Profinet,
communication suitable for SCADA/PLC system with media
redundancy
7.5.6. Control Voltage: 24VDC or 100-240V AC, 50 Hz
7.5.7. The MMS Module shall have integral or through add on/Expansion modules
Digital inputs
Programmable relay outputs
Temperature sensor input
CBCT input terminal.
7.5.8. Configuration / Programming:
MMS shall be programmable from HMI / PC.
MMS shall have prebuilt configuration modes for motor
starters (DOL / star-delta)
MMS shall be configurable to operate as an overload relay
Custom logic for programming DI/DO shall be possible and
the software shall have the provision for programming on
structured text / Function block.
Digital outputs shall be potential free. Each output shall be
capable to be connectable to different field voltages
7.5.9. User Interface:
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HMI or Memory plug shall have the capability to upload /
download parameters to MMS
The address & other communication parameters shall be
configurable from HMI or through address module.
HMI shall have the simple text display in English
7.5.10. Earthing of intelligent modules to be connected to the
Instrumentation earth (Earth strip available within 25 mtrs). Insulated copper of 2R x 1C x 10 sq.mm at both the ends of the i-MCC panel.
7.5.11. Minimum 20% spare with respect to NO & NC terminals shall be provided in all compartments.
7.6. Measuring & Monitoring Requirements
7.6.1. Panel shall be provided with Multifunction meter with Add-on DI / DO modules and PROFINET/ETHERNET module as applicable to motor management system selected.
7.6.2. Motor management system modules, Thyristor Controller, PAC Meter etc., in all feeders shall be suitable for communication protocol and dual redundant criss-cross configuration used in PLC & SCADA system.
7.6.3. Parameters from iMCC both digital and analog are listed in following table. The list is indicative and exact list is to be finalized along with iMCC GA drawing and BOM approval.
Table 11. Parameters – Digital & Analog
Feeder type Digital data Analog data
Incomer feeder
MCCB ON/OFF
Aux Contactor
Control Trfr off (supply to
control Trfr cut off)
MCCB ON status
ELR trip status
MCB (Primary of Control
transformer) ON/OFF Status
MCB (secondary of Control
transformer) ON/OFF Status
Emergency OFF Status
-
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Feeder type Digital data Analog data
Outgoing feeder with MPCB
Permanent local mode MCB ON status (shunt trip
coil supply) MCB ON status (Control
supply) MPCB ON status MPCB trip status MCB trip status (control
supply) Panel start (P/B) stop(P/B) Power contactor ON/OFF
status
Three phase currents
Voltage(average) Time for tripping
OL Last trip current Restarting time
after trip Motor / feeder
operating hours (In addition to above for Thyristor Heater bank, Power)
Outgoing feeder with MCCB
MCB ON status (Shunt coil supply)
MCB ON status (Tr supply) MCB ON status 24V DC
supply MCCB ON status ELR trip status.
Outgoing feeder with Thyristor Controller
MCCB ON status MCB ON status (Shunt coil
supply) Load circuit (Overcurrent,
under current) Mains voltage Thyristor unit health
Multi-function Meter Incomer Feeder
-
Voltage L-L, L-N, Current Per phase, Neutral conductor
current Active power Per
phase and total Power factor Per
phase and total Frequency THD voltage Per
phase THD current Per
phase
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7.7. Operation Modes
Operating modes shall be provided as per the following.
7.7.1. MODE - 1:
SCADA PLC iMCC CONTACTOR MOTOR/HEATER BANK
(iMCC only for Monitoring & Data logging purpose)
In this mode, operations are carried out from operator console at control room using SCADA Station, The SCADA Station is interfaced with PLC configured in Main & redundant mode in criss-cross configuration.
Remote I/O’s are provided both in control room and service room are to be linked by communication cable running from control room to service room.
The PLC DO in service room will be driving Soft Starter to switch on blower and DOL starter for water pumps fire damper Motor using PLC. Contactors are provided in iMCC for powering heater bank in ON/OFF mode PID control.
Thyristor controlled heater banks shall be commanded (Analog) from PLC. Motor management system (MMS) consists of Current/Voltage measurement module, Basic module etc., are to be provided in iMCC and to be interfaced with PLC for monitoring of voltage, current, protection features, ON/OFF status. MMS shall not be used for control purpose. All control shall be through PLC remote DI/DO’s.
7.7.2. MODE - 2: Console Push Button Station
CCMC Panel PB’s CONTACTOR MOTOR/HEATER BANK
MODE 2: Redundant mode using CCMC Push Button Station @ control room (Remote)
This mode will be chosen in case of failure in SCADA/PLC.
In this mode push button from CCMC at control room are hardwired with soft starter, water pump DOL starter and Fire damper motor contactor etc., using control cable to be laid between control room and service room.
ON/OFF command for heater banks to be hardwired from temperature controller provided at control room panel and Analog voltage from PID controller provided at control room panel.
The push buttons and indication lamps are already provided
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in a control cum monitoring console and mounting place for temperature controller. Similar provision is there for Agni Grain Ovens also. Please refer to I & CS section for further information.
7.7.3. MODE - 3: Maintenance Mode
LOCAL PBS IN SERVICE ROOM PLC CONTACTOR BLOWER /
WATER PUMPS
MODE-3: Control from iMCC in Local mode.
This mode is only for switching on Blowers, Water pumps for maintenance purpose from service room.
Illuminated pushbutton for Blower/Water pumps are provided in respective compartments at iMCC for interfacing Soft starter /contactor (DOL). This PBs shall be taken as Digital Inputs to PLC.
Local/Remote switching modes are enabled through PLC selection.
7.8. i-MCC Configuration for Operating Modes
7.8.1. Power Wiring:
i-MCC shall accommodate all the conventional Switchgears like MCCB/MPCB, Power Contactor, ELRs, Soft Starters, Thyristor Banks etc.,of each individual feeder Motors/Heater banks.
For Selecting norms of Switchgears vendor shall refer Switchgear Selection Chapter. In addition to this MMS shall be introduced in the panel for the purpose of monitoring and Data Acquisition (through current & voltage module) only not for Controlling. Please refer Drawings
7.8.2. Control Scheme:
iMCC panel shall be realized in such a way serving for the both operation modes Main Mode & PLC/SCADA fail safe Mode.
7.8.3. Scheme Illustration:
iMCC shall be interfaced with:
a. PLC/SCADA: Control Station for Mode-1 (Through Soft linking)
b. CCMC Panel: Control Station for Mode-2 (Through Hardwiring)
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All Functional Interlocks like Proxy sensors of Bogie In/Out, Oven Doors Open/Close, Dampers Open/Close, Air Flow switch etc.,are to be interfaced with Intrinsic safe single input dual output isolators, the two Outputs obtained shall be utilized for following purpose:
a. As input to Another Intrinsic safe single input dual output isolator (PLC mode purpose – Mode-I)
b. As Input to Aux. Contactor(4NO/4NC as per Hard wired Interlocking requirements – Mode – II purpose).
Further the two Outputs of Intrinsic safe single input dual output isolator shall be utilized for Following Purposes:
a. Output-1: As input to PLC Main b. Output-2: As input to PLC Redundant.
The Aux. Contactor Outputs can be utilized for achieving the conventional Hardwired interlocks and status monitoring.
These Intrinsic safe single input dual output isolators along with Auxiliary contactors, power Supply etc., for Hardwiring and interlocking to be accommodated in a cubicle.
Control panel shall be envisaged with PID controllers for Hot Air, Hot Water (On & OFF banks) & Fire damper. These PID controllers are dedicated for hard wire control interlocks in case of PLC/SCADA failure. The specs are defined in instrumentation Chapter.
7.9. Terminal Blocks and Labels
7.9.1. Terminal blocks shall be of 500 Volts grade of the stud type and shrouded.
7.9.2. Insulating barriers shall be provided between adjacent terminals.
7.9.3. Provisions shall be made for label inscriptions for the easy identification of terminal blocks (by means of numbering)
7.9.4. Group TBs can be planned with respect to the cleared control scheme. Group TBs are to be named clearly.
7.9.5. All the power terminals are to be selected for connecting the ring type lugs (in both panel and FLP junction boxes if required)
7.9.6. All the power terminals and live parts are to be covered with proper terminal covers.
7.9.7. Group terminal markers to be used for the clear identification.
7.9.8. All the power and control terminals are to be provided with suitable terminal numbers.
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7.9.9. Power terminal blocks shall be separated from each by means of replaceable insulated spacers.
7.9.10. The nomenclature shall mention the feeder rating in Amps and details of feeder.
7.9.11. The nomenclature feeder details for the label plates shall be furnished by Department during detailed engineering.
7.9.12. Equipment tag plate inside the i-MCC panel and compartment
nameplates shall be of acrylic engraved sheets only and same to be fixed by screws/rivets and shall not be pasted.
7.9.13. All the compartment needs to be provided with ON / OFF / TRIP indication lamps. The self-illuminated push button planned for ON / OFF operation may be used for ON / OFF indication lamps. However, a separate TRIP indication lamps needs to be considered.
7.9.14. ON/OFF/TRIP inscriptions shall be clearly marked over the individual compartment with clear marking of direction of the operation of handle apart from the standard marking provided by the switchgear manufacturer.
7.9.15. ON/OFF inscriptions shall be clearly marked over the individual feeder cubicles with clear marking of direction of the operation of handle apart from the standard marking provided by the switchgear manufacturer.
7.9.16. Enamel Danger plates of size and descriptions as recommended in the relevant IS, shall be provided on the MV Panel inscribed in Telugu, Hindi and English languages mainly. The same to be indicated the G.A after getting the order and before proceeding for fabrication.
7.10. Power & Control Cables
7.10.1. Party shall supply Power cables, control cables, cable trays as per the specifications in the data sheets and shall also carryout cable laying on wall /trench /cable tray as applicable. All the miscellaneous items like cable glands, lugs, ties, fixers shall also be supplied by the party.
7.10.2. Power wiring with suitable rated armoured cables as per load requirements shall be provided. The cable make shall be as per specifications (datasheets).
7.10.3. The power wiring shall be carried out for the following
PCC to Both iMCCs (Incomer)
I-MCCs to other loads (Motors, Hot water Pumps, Blowers,
heater Banks etc.)
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7.10.4. The cables shall comply with LT voltage level 1100V, Armoured with XLPE insulation as per IS:7098. The minimum size of cable shall be 4 sq. mm copper conductor for all power wiring. All feeders shall be with copper conductor cables. The power wiring shall be carried out with necessary saddles, clamps, cable tags, glands, etc.
7.10.5. In case of FLP Bay, FLP Items shall be used.
7.10.6. Necessary cable glands and suitable lugs with respect to the feeder requirement and field equipment’s are in the scope of supplier.
7.10.7. All the power and control cables which are routed from i-MCC
panel are to be routed through SS cable tray with proper cover inside the cable trench as per the direction given by the department.
7.10.8. Wiring shall be neatly bunched, adequately supported and properly routed through cable alley (duct) to allow easy access and maintenance.
7.10.9. The ferrules shall be of the ring type and of non-deteriorating material.
7.10.10. They shall be firmly located on each wires so as to prevent free movement.
7.11. Cable Termination
7.11.1. Wherever copper to aluminum Interconnections are made, necessary bimetallic washers shall be used.
7.11.2. In case of control cables all cores shall be identified at both ends by their terminal numbers by means of PVC ferrules for core size. Wire numbers shall be as per schematic wiring/inter-connection diagram. All unused spare cores of control cables shall be nearly bunched and ferruled with cable tag at both ends, for future use.
7.11.3. Contractor shall drill holes for fixing glands wherever necessary. Gland plate shall be wherever more number of cables are terminated. All unused cable entries on equipment/panels shall be plugged or sealed.
7.11.4. The cable shall be terminated at electrical equipment/switchboard through glands of proper size.
7.11.5. Before energizing, the insulation resistance of every circuit shall be measured from phase to phase, phase to neutral and from phase/neutral to earth. The approximate cable length requirements are listed in below mentioned table.
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7.12. Control Wiring
7.12.1. The control wiring shall be armoured with minimum copper conductor size of 2.5 sq. mm of XLPE/PVC insulation, voltage grade 660V/1100V as per IS: 1554/7098. The control wiring shall consist of following:
7.12.2. Master Emergency OFF at Control room shall be hardwired with i-MCC panel incomer MCCB trip circuit.
7.12.3. i-MCC panel to Control room
7.13. Cable Trays
7.13.1. Cable trays shall be provided for cables that are laid both inside and outside the facility. Power cables, control cables and communication cables shall be laid separately in different cable trays.
7.13.2. The cable tray shall be wire mesh cable tray of CABLOFIL (LEGRAND) or suitable cable tray/make with Dept approval.
7.13.3. Supply and installation of Cable tray is in the scope of the party. Civil cable trenches shall be provided by the department.
7.14. List of Cables
7.14.1. The quantity of Power & control cables required to meet various interfacing field elements is specified below. The details are indicative and party shall meet extra cable requirements in case of requirement.
7.14.2. The size of the cable should be decided based on the expected highest load in the cable adding 50% cushion. Calculations arriving the cable sizing should be submitted for approval. Any other cable not listed below but required for completion of the system/proper working of the system shall be provided by the party without any additional cost.
Table 12. Power Cables – Quantity – Main Oven
Cable Description Capacity (tentative)
Length (metre)
Cable from i-MCC Three Air Heater banks-100KW-
Aluminium 150Sq.mm X 4C 100
Cable from i-MCC to Blower motors-Cu
35 Sq.mm X 3C 50
Cable from i-MCC Air damper Motors-Cu
4 Sq.mm X 3C 60
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Cable Description Capacity
(tentative)
Length
(metre)
Cable from i-MCC to Hot water Pumps-Cu
4 sqmm X 3C 60
Cable from i-MCC to Water Heater Banks-Cu
6 sq.mm X 4C 90
Cable from i-MCC to Bogie Motor-Cu
6 sq.mm X 3C 75
Cable from PCC to i-MCC - Aluminium
400 Sqmm X 4C 30
Control Cable From iMCC to CMCC Panel
37 Core X 2.5 sqmm 350
Control Cable From iMCC to CMCC Panel
30 Core X 2.5 sqmm 350
Table 13. Power Cables – Quantity – AGNI Oven
Cable Description Capacity (tentative)
Length (metre)
Cable from i-MCC Air Heater bank - 50KW - Cu
25Sq.mm X 4C 90
Cable from i-MCC to Blower motors- Cu
16 Sq.mm X 3C 60
Cable from i-MCC Air damper Motors - Cu
4 Sq.mm X 3C 60
Control Cable from i-MCC 2.5 Sq.mm X 24C 600
Power cable PCC to i-MCC 95 Sq.mm X 4C 30
7.15. Inspection – FAT & SAT
7.15.1. FAT:
The i-MCC panels shall be completely assembled, wired, and
tested for operation under stimulated conditions to ensure correctness of wiring and interlocking and proper functioning of all components.
HV & IR checks as per standard procedure shall be conducted.
The above tests shall be successfully carried out at factory with the presence of Department Engineers and necessary
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test certificates shall be enclosed along with dispatch of panels in triplicate.
Any modification and rectification suggested by inspection team should be incorporated /attended before dispatch.
Subject to the clearance from Department after the satisfactory completion of tests at factory / works panel can be dispatched.
Any transit damage should be rectified at site
Routine test certificates shall be provided for all motors. FLP test certificates shall be provided for all FLP motors
Test certificates, data sheets and manuals of Switchgears, CTs, ELRs, Transducers, Motor management system and Power electronic controller shall be produced.
7.15.2. SAT
During commissioning / energisation of the MV panel, the supplier shall depute their supervisor and perform the following tests on the feeders at site prior to commissioning.
Insulation resistance between the phases and individual phases and earth.
Earth continuity checks.
All the protective relays and tripping mechanism shall be checked for their proper operation and setting / grading shall be done as per the directions by department.
All metering functions shall be checked to ensure proper operation / indication.
Operation and functionality tests of the switch gear and interlocks
All i-MCC functionality to be demonstrated at site.
7.16. Erection & Commissioning
7.16.1. The party has to erect i-MCC over the designated trench, with channels L angles and fasters as required.
7.16.2. Power connection to the i-MCC including incomer connections from PCC to be completed.
7.16.3. Erection of all electrical systems is in the scope of party and shall be under the supervision of an engineer deputed by the party.
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7.16.4. All control interfaces & control wiring from i-MCC to PLC and other elements to be carried out.
7.16.5. Soft copy of drive parameters in CD/DVD shall be provided.
7.16.6. The Integration of i-MCC with PLC & SCADA shall be carried out at SDSC, SHAR. A team of Authorized Engineers (M/S Schneider / Siemens / Allen Bradley) who has expertise in MMS shall be deployed @ SDSC, SHAR for integration, commissioning and testing of i-MCC with PLC/SCADA and shall be made available till completion of first live trial. They should demonstrate all functional and protective features.
7.16.7. Party shall employ (BS Techno LTD Chennai or AE) authorised person for commissioning of Thyristor Controller.
7.16.8. All cable laying and suitable termination, loop checking, interfacing and trial runs is in scope of supplier. Necessary works like clamping, crimping, ferruling etc. is in party’s scope.
7.17. Training
7.17.1. Training shall be provided from the Original Equipment
Manufacturer at their training centre for 2 persons deputed by
Department on the following
• Maintenance, configuration & troubleshooting of Motor Management system by Siemens / Schneider / Allen Bradley
• Maintenance, configuration & troubleshooting of Thyristor Controller by AEG
• Maintenance, configuration & troubleshooting of VFD by Siemens / ABB
• Training is to be arranged before the start of erection by the supplier at our site.
7.17.2. The quoted price shall be inclusive of the cost of training
7.18. Standards
7.18.1. The Electrical systems shall conform to respective IS/IEC
specification with latest amendments.
7.18.2. An indicative list is given below
Table 14. List of Standards
S No Description of the Item Standard
1 FLP/INTRINIC SAFE ITEMS IEC60079 / IS 2148
IS 5571 / 5572
2 Motors IEC 60034 / IS 325
3 PVC Cables IS 1554
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S No Description of the Item Standard
4 XLPE Cables IS 7098
5 LV switch gear and control gear IEC 13947
6 General requirements for switch gear and control gear for voltages not exceeding 1000 V
IS 4237
7 Current Transformers IS 2705
8
MV Panel – Factory built assemblies of switch gear and control gear for voltages up to and including 1000 V AC and 1200 V DC.
IS 8623
7.19. Spares
7.19.1. Party shall supply the following spares as per the specifications
(data sheets)
Table 15. List of Spares – Main Oven
S No Item Description Rating Qty
1. Thyristor(Hot Water Heater) 1
2. VFD Drive for Bogie Motor 1
3. MCCB for Hot air Heater ON/Off &
Thyristor Bank 250 A 2
4. MCCB for Hot Water Heater Thyristor
Bank 63 A 2
5. MPCB for Hot Water Heater Pumps 8A 1
6. Contactor Kit & Coils for Hot air
Heater Bank ON/OFF & Thyristor Bank
205 A 2
7. Contactor Kit & Coils for Hot air
Heater ON/OFF & Thyristor Bank 205A 2
8. Contactor for Hot Water Heater Bank
ON&OFF 32A 1
9. Contactor Kit & Coils for Hot Water
Heater Bank ON&OFF 32A 2
10. Contactor Spare for Hot Water Pump 9A 2
Table 16. List of Spares – AGNI Oven
S No Item Description Rating Qty
1. MCCB for Hot air Heater Bank ON &
OFF 160A 1
2. MPCB for Blowers 63 A 1
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3. Contact for Hot Air Heater Banks 75A 1
4. Contact Kit & Coil Spares for Hot Air
Heater Banks 75 A 1
5. Contact Kit & Coil Spares for Blowers 63A 1
7.20. Technical Specifications (Data Sheets)
Party shall supply the items as per the following specifications.
Table 17. Specifications of Switch Gear - ACB
Description Essential Specification
Maximum rated current (In max)
Standard Rating higher than 150% of the calculated maximum current
Rated short circuit breaking capacity Ics(=Icu)
85kA or higher
Rated insulation voltage Ui 1000V
Rated operational voltage Ue 690V
Rated Impulse withstand voltage Uimp
12kV
Standard IEC 60947-2
Over current release features
Overload protection (L-tripping), Short time delay short circuit protection(S-tripping), Instantaneous short-circuit protection (i-tripping), Neutral conductor protection (N-tripping), Earth fault tripping.
Load monitoring, short circuit protection and overload protection switchable to I2t. Changeable parameter set. Graphical display.
Communication via Ethernet / Profibus, parameterization by communication
Motor operating mechanism Working on 208 - 240 V AC
Auxiliary releases Shunt trip, closing coil, Signaling switch, Capacitor energy storage unit for shunt releases
Indicators and operating elements
Locking set, Make-break operation counter, Electrical on pushbutton, Emergency off pushbutton
Model Latest series meeting the above specification
Make M/s Siemens / L&T / Schneider
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Table 18. Specifications of Switch Gear - MCCB
Description Essential Specification
Maximum rated current (In max)
Standard Rating
• Incomer Feeder- 150% Rated Current
• Motor Loads-150% Rated Current
• Other loads-125% Rated Current
Rated short circuit breaking capacity Ics(=Icu)
55kA for incomers and main feeder switches,35kA for sub feeders
Rated insulation voltage Ui 1000V
Rated operational voltage Ue 690V
Standard
Circuit breakers shall comply with the following standards:
• IEC 60947-2
• IEC 60947-1
• Isolating features in accordance
with IEC 60947-3
Over current release features
Overload protection (L-tripping), Short time delay short circuit protection(S-tripping), Instantaneous short-circuit protection (i-tripping), Neutral conductor protection (N-tripping), Earth fault tripping.
Load monitoring, short circuit protection and overload protection switchable to I2t.
Communication via Ethernet / Profibus, parameterization by communication
Auxiliary releases Shunt trip, closing coil, Signaling switch
Model Latest series meeting the above specification
Make M/s Siemens / L&T / Schneider
Table 19. Specifications of Switch Gear - MPCB
Description Essential Specification
Maximum rated current (In max)
Standard rating higher than 120% of the motor name plate current.
Rated short circuit breaking capacity Ics(=Icu)
35kA or higher
Standard IEC60947-2, IEC60947-4-1
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Description Essential Specification
Releases Relay Function
Aux Contacts 1NO + 1NC
Add ons Additional 1NO+1NC, short circuit
signaler with 1NO+1NC (Preferable)
Model Latest series meeting the above
Make M/s Siemens / L&T / Schneider
Table 20. Specifications of Switch Gear - MCB
Description Essential Specification
Maximum rated current (In max)
Standard rating higher than 120% of the calculated maximum current.
Rated short circuit breaking capacity Ics(=Icu)
10kA or better
Rated operational voltage Ue 415V
Standard IEC 60898-1 or IS 8828
Curve C Curve for highly inductive loads
Model Latest series meeting the above specification
Make M/s Siemens / L&T / Schneider / Legrand
Table 21. Specifications of Switch Gear - Contactor
Description Essential Specification
Maximum rated current (In max)
Standard rating higher than 200% of the calculated maximum current.
AC3 current rating at 415V to be considered.
AC4 for inching operatonal requirements
AC1 for resistive loads
Rated short circuit breaking capacity Ics(=Icu)
50Ka or better
Rated operational voltage Ue 415V
Control Coil Voltage 230V AC
Standard IEC 60947, IS13947
Aux Contacts Required 2NO + 2NC (minimum)
Model Latest series meeting the above specification
Make M/s Siemens
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Table 22. Specifications of Switch Gear – Aux Contactor
Description Essential Specification
Control Coil Voltage 230V AC
Standard IEC 60947, IS13947
Aux Contacts Required 4NO + 4NC
Model Latest series meeting the above specification
Make M/s Siemens
Table 23. Specifications of Switch Gear - OLR
Description Essential Specification
Trip Class 10
Standard IEC 60947, IS13947
Aux Contacts Required 1NO + 1NC (minimum)
Model Latest series meeting the above specification
Make M/s Siemens
Table 24. Specifications of Earth Leakage Relay
Description Essential Specification
Detail Microprocessor based Earth Leakage
Relay with CBCT of Resin Cast
Model MPEL-02
Current Range 30 mA – 3000 mA
Current Range Setting 18 steps
Tripping time 0 – 5 sec
Auxiliary Voltage 85 – 275 V AC
CBCT Type and Size Resincast Circular
Contact rating 8A, 250V AC / 8A 30V DC 2 C/O
Contacts
Mounting Flush
Dimensions 96 mm x 96 m x 70 mm (W x H x D)
Make Prok DVs
Table 25. Specifications of Power & Control Cables
Description Essential Specification
Type Armoured Copper Conductor
Size Power cable – 4 sq mm. (minimum) Control cable – 1.5 sq. mm. (minimum) Profinet/Ethernet cable-As per standard
Make – 1.1 KV LT Power Cable
CCI / Universal / Finolex / Polycab / IGUS / Gloster / Lapp / KEI / Havells
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Description Essential Specification
Make – 1.1 KV LT PVC Control Cable
Finolex / RR Kabel / Gloster / Lapp / KEI / Havells / Polycab / IGUS
1.1 KV Panel Wire
Finolex / RR Kabel / Lapp / Havells
Table 26. Specifications of Soft Starter
Description Essential Specification
Quantity 2 +1
Make Siemens
Rated operating voltage
200-460 V , 3 Phase
Duty Heavy duty
Output rating One size higher in standard Soft starter rating of selected motor full load rating
Features required
Soft start, Soft stop, Adjustable current limit. Ramp up minimum up to 120 Sec
Bypass contactor
Integrated
Programmable inputs
4 Nos (minimum)
Programmable outputs
3 Nos (minimum)
Protection Integrated microprocessor based relay with adjustable trip class 5/10/15/20/30 (Overload relay should remain active when drive is in bypass mode also)
Motor winding temp protection
Thermistor protection through PTC
Communication Profibus/Profinet/Modbus/Ethernet TP communication module to be provided.
Parameterisation Through PC interface(Necessary software and connector and cable for PC interface to be provided)
Operator panel External display and operating module to be provided
Control voltage 230V AC
Fault/Error signals required
Missing voltage, Wrong direction of rotation, wrong starting condition, phase failure, missing load, current unbalance, thermal overloading of thyristors, undercurrent and over current limit exceeded, ground fault, Maximum number of starts exceeded.
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Table 27. Specifications of VFD for BOGIE MOTOR
Description Essential Specification
Quantity 1 Nos
Make Siemens / ABB
Main voltage 380-480 V , 3 Phase
Input Frequency
48-63 Hz
Output rating One size higher standard Drive rating of selected motor full load rating
Control requirement
The drive should start & stop in slow speed and in between higher than start speed .The start, stop and acceleration should not cause any considerable jerk.
Overload capacity
150 % for 60 sec
Digital inputs 6 Nos programmable (minimum)
Analog inputs 2 Nos programmable (0-10 V, 0-20 mA, and -10 to +10 V) (minimum)
Relay outputs 3 Nos programmable (minimum)
Analog outputs 2 Nos programmable (0-20 mA) (minimum)
Safety guidelines
IEC 61800
Ambient Temperature
50 Deg C
Choke or filter Choke/Filter of suitable rating to limit THD as per IEEE519
Operator panel Advanced Operator panel (AOP)mounted on panel cubicle door
Table 28. Specifications of Electric Motors – Blowers & Pumps
BLOWER - MAIN OVEN BLOWER - AGNI OVEN HOT WATER PUMPS
Description Essential Specification
Make Make: Kirloskar /Crompton Greaves/Bharat Bijili /CEMP /Marathon / Siemens
RPM 1500RPM (SYN)
Motor capacity
The motor capacity should be selected such that motor shall draw only 80% of rated current at full load. Design calculations to be submitted towards arrival of motor power rating and approval to be obtained.
Motor type Induction motor
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Operating Voltage
415 V ± 10 %, 3 Phase
Operating Frequency
50 Hz ± 3 %
Duty class Continuous
Protection IP 54 or better
Insulation class
F and temperature rise limited to class B
Efficiency IE 2 or Better
Thermistor Embedded in windings to monitor winding temperature and trip system upon high winding temperature.
Standard Motors shall comply IS:325 or Equivalent IEC standard
Table 29. Specifications of Electric Motors – Bogie Motor
Description Essential Specification
Make Kirloskar / Crompton Greaves / Bharat Bijili / CEMP / Marathon / SEW / PBL
RPM 1000RPM(SYN)
Motor capacity
The motor capacity should be selected such that motor shall draw only 80% of rated current at full load. Design calculations to be submitted towards arrival of motor power rating and approval to be obtained.
Motor type Flameproof induction motor Ex-d
Operating Voltage
415 V ± 10 %, 3 Phase
Operating Frequency
50 Hz ± 3 %
Hazardous zone operation
Zone I, Group IIA, Group IIB compatible
Duty class Inverter Duty
Protection IP 55 or better
Winding Protection
Minimum Two no’s of Thermistor to be provided for winding protection and interfaced with thermistor relay.
Temperature classification
T4 (135) or better
Insulation class
F and Temperature rise limited to class B
Connector Armoured copper conductor cable terminated using double compression flameproof gland
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Hazardous zone certification
Flame proof certificate to be issued by CMRI, Dhanbad, ERDL or any other approved body shall provide along with motor.
Standard Motors shall comply IS: 325 or Equivalent IEC standard and provided with Anti Friction Bearings. Motor shall be compatible for operating with VFD addressing issues like Voltage Rise time, Better Insulation Class, bearing currents & documentary proof towards this should be furnished.
Table 30. Specifications of Thyristor Controller
Description Essential Specification
Quantity
Heater Bank - Hot Air (Main Oven – 100kW)- 2No’s Heater Bank - Hot Air (Agni oven – 50kW) )-2No’s Heater Bank - Hot Water (18kW) - 2No’s
Make AE
Model ThyroPX-
Main voltage 380-480 V, 3 Phase
Input Frequency
47-63 Hz
Load type 3phase resistive connected in star configuration
Controller type 3Legged, Digital Processor, 32 Bit or Higher
Firing mode TAKT (Burst Firing), VAR (Phase Angle) and SSSD (Soft Start & Soft Down )
LED Indication LED indications 4 Green, 3 Red LEDs (Freely Configurable Type)
Control mode option required
Vrms, V2, Irms, I2, P or OPEN LOOP selectable with Highest accuracy of 0.5% in V & I Control & 1.0% in P Control
Display Unit Local Display and Monitoring unit for Configuration and Parameterisation with COPY & SAVE function
Removable type display: The Local Display shall be equipped with a graphic touch display and SD card. Process data recorder feature shall be available as standard. Display shall also have following option
Line chart (6 values Min) Operation display (6 values, Min) Bar chart (4 values, Min) Data logger Multi-colour Line / Bar chart
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Communication Features: Communication Feature – Required for digital data transfer with Motor Management System (MMS)
ProfiNET-V3 / Ethernet IP Communication shall be a Plug & play card type (Communication to be selected based on PLC/MMS Communication Protocol selected) with following key features: - Minimum of 3 free digital Inputs (Configurable for Local / Remote Setpoint change, etc.) - The ProfiNET / Ethernet plug-in card shall have two RJ45 ports which are equipped with a switch functionality which allows a line topology to be constructed - Bumpless Setpoint Transfer shall be a key feature
Digital Load synchronisation
Automatic Synchronisation of Multiple power controller for load optimisation shall be available as standard
Digital inputs 6 No’s programmable (minimum)
Analog inputs 3 No’s programmable (0-10 V, 0-20 mA, and -10 to +10 V) (minimum)
Relay outputs 3 No’s programmable (minimum)
Analog outputs 3 No’s programmable (0-10V / 0-20 mA) (minimum) Configurable
Ambient Temperature
45Deg C
Choke or filter Choke/Filter of suitable rating to limit THD as per IEEE519, if required
Configuration method
PC software or Through Local Display
Short circuit test Compliance
Shall have 100KA Short circuit test certificate from any International Test Lab
Table 31. Specifications of Heater Banks – Hot Water Tank
Description Essential Specification
Bank Capacity No of heating elements
ON/Off Heater Bank –I : 18 kw and Thyristor Controller Heater Bank II :18 Kw No of elements : Bank I-Three No’s Bank-II Three Nos, Each element 6kW (standard immersion heater working on 240V AC)
Heater control ON/OFF control for Bank 1, and Thyristor control for bank 2
Water level Automatic water level controller using level
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control sensor
Connection
There shall be a local power distribution board mounted on Tank outer wall consisting of six numbers of MCB (one for each heater) & two ELCB one for each bank with Bus bar arrangement in star 4 wire configurations for both heater banks. There will be one heater in each phase and Neutral in each bank.
Teflon wires or suitable heat resistance wires shall be used for terminating heaters from Bus bar in local DB Size of the wire is 200% with respect to the heater drawing current.
Teflon wires or suitable heat resistance wires shall be used for terminating heaters from Bus bar in local DB.
Size of the wire is 200% with respect to the heater drawing current.
Capacity 36 Kw
No of Banks 2Nos
Supply Voltage 415V+/-10% 3phase, 4 wire
Connection 3Phase Star Configuration
Individual Heating Element Voltage
1 Phase, 240V AC
Heater tube material
INCONEL
Heater Material Nichrome 80/20
Insulation Material
Magnesium oxide
Table 32. Specifications of Heater Banks – Main Curing Hot Air
Description Essential Specification
Capacity ON/Off Control Heater Bank 100Kw- 1No Thyristor Controller Heater Bank 100 Kw – 2Nos Total Capacity: 300 KW
Supply Voltage
3phase, 4 Wire, 415V+/-10%
Individual Heating Element Voltage
1 Phase, 240V AC
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Connection 3Phase Star Configuration
Heater tube material
INCONEL
Heater Material
Nichrome 80/20
Insulation Material
Magnesium oxide
Heater box housing
The entire heater battery should be mounted inside a double walled mild Steel casing having rock wool insulation of not less than 100 mm thickness between walls in order to prevent heat losses. The heater terminals must be brought to one side so as to facilitate connection and replacement easily. They shall be terminated in a terminal box. The heater shall be fitted with withdrawal type, sheathed, tubular heating element Heaters battery shall have flanges for
connecting the heater and ducts. Heater battery
shall be sized same as that of the duct size
preferably.
The design & arrangement shall be suitable for
standard cabling into the terminal enclosure
without the need for an intermediate junction
box and high temperature cables. If this
requirement is not met by the product, then
necessary high temperature cables & junction
box shall be provided by the contractor / party.
Silicone seal shall be applied to the lead exit
and between lid and terminal box to improve
ingress protection. This shall be supplied in
adequate quantity along with the equipment.
Black heat operations
Heaters shall be black heat type. The heaters shall not become red hot with air flow. Watt densities of heating elements shall be limited to a suitable value to prevent red hot.
Table 33. Specifications of Heater Banks – AGNI Curing Hot Air
Description Essential Specification
Capacity ON/Off Control Heater Bank 50 KW- 1No Thyristor Controller Heater Bank 50 KW – 2Nos Total Capacity: 150 KW
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No of Banks 3 Nos
Supply Voltage 3phase, 4 Wire, 415V+/-10%
Individual Heating Element Voltage
1 Phase, 240V AC
Connection 3Phase Star Configuration
Heater tube material
INCONEL
Heater Material Nichrome 80/20
Insulation Material
Magnesium oxide
Heater box housing
The entire heater battery should be mounted inside a double walled mild Steel casing having rock wool insulation of not less than 100 mm thickness between walls in order to prevent heat losses. The heater terminals must be brought to one side so as to facilitate connection and replacement easily. They shall be terminated in a terminal box. The heater shall be fitted with withdrawal type, sheathed, tubular heating element Heaters battery shall have flanges for connecting the heater and ducts. Heater battery shall be sized same as that of the duct size preferably.
The design & arrangement shall be suitable for standard cabling into the terminal enclosure without the need for an intermediate junction box and high temperature cables. If this requirement is not met by the product, then necessary high temperature cables & junction box shall be provided by the contractor / party.
Silicone seal shall be applied to the lead exit and between lid and terminal box to improve ingress protection. This shall be supplied in adequate quantity along with the equipment.
Black heat operations
Heaters shall be black heat type. The heaters
shall not become red hot with air flow. Watt
densities of heating elements shall be limited
to a suitable value to prevent red hot.
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Instrumentation & Control Systems
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8. Instrumentation & Control Systems
8.1. Scope of Work
8.1.1. Design, procurement, integration, factory testing, supply, packing, forwarding, unloading at site, erection, testing & commissioning of total instrumentation & control system for the operation of Segment & AGNI Curing Oven
8.2. Equipment & Services to be supplied by the Party
Party shall carryout Supply, installation and commissioning of Instrumentation and Control System (ICS) and related accessories for Curing Facilities as detailed in this document.
8.2.1. The details of the systems, equipment & services from the party
are listed below
S. No Description Details
1. The PLC System
As per enclosed specifications &
Annexures 6C-1 to 6C-8
2. The SCADA System
3. Data Acquisition & Control System
(DACS)
4. Power Supply Systems
5. Panels & Field Instruments
6. Cables
7. Miscellaneous Items
8.2.2. Preparation of P&ID and detailed engineering drawings.
8.2.3. Design of data acquisition and control system for curing
process as per technical specification, Procurement of items as
per technical specifications.
8.2.4. Panel wiring, assembly, factory acceptance testing, packing
forwarding and delivery at site.
8.2.5. PLC & SCADA environment and application programme
development.
8.2.6. Installation, interfacing PLC & SCADA with associated sub-
systems with field instruments, electrical systems (i-MCC) etc.,
8.2.7. Ferruling, wiring terminations at junction boxes and laying of
cables to the PLC panel
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8.2.8. PLC logic implementation as per User Requirement Documents,
which will be given after the award of contract.
8.2.9. All software development works shall be carried out at
purchaser’s site.
8.2.10. Site acceptance test, commissioning & handing over of systems
for automated operations.
8.2.11. Factory Acceptance Test (FAT) procedures (verification of BOM,
functional checks, compliance to specifications, load test of
power supplies, environment software testing, diagnostics data,
alarms and report generation check etc.,) shall be submitted to
department for approval.
8.2.12. Quality Audit Plan (QAP) assurance plan containing the
detailed test and evaluation plan for instrumentation and
control system with identified stages shall be submitted.
8.3. General Instructions to the Party
Party shall comply with the following general instructions to realise the Instrumentation and Control System (ICS) and related accessories as detailed in this document.
8.3.1. The party should select the control system components with the preferred makes mentioned in the technical specification section.
8.3.2. The details of the control system configuration, PLC and
SCADA systems, I/O’s and sensor specifications are mentioned
in the below sections.
8.3.3. Party shall inform to purchaser at identified stages to carry out
inspection and the copies of such reports after inspection shall
be forwarded to Purchaser.
8.3.4. The original copies of test certificates shall be submitted along
with other documents at the time of site acceptance testing.
8.3.5. The commissioned instrumentation, control system and its
subsystems are to be subjected to Test and Evaluation by the
Purchaser Committee. This is to ensure that the integrated
system is meeting all its intended requirements as per the given
specifications. Any deviations observed shall be resolved by the
supplier at no extra cost
8.3.6. In addition to Instrumentation & Control System, the supply
and interfacing of auxiliary systems like Operator consoles,
Panels / Junction Boxes, UPS Distribution Panels along with
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SPDs, Cables etc. are also in the scope of the supplier
8.3.7. The Oven manufacturer shall employ an authorized system
integrator of M/s Schneider / M/s Siemens/ M/s Allen Bradley
to execute the Instrumentation and SCADA Systems.
Authorization certificate shall be produced along with tender
document
8.3.8. IMCC shall be similar make of PLC/PAC only
8.3.9. The quantity mentioned in the specifications/ data sheets is
the minimum quantity to be supplied.
8.3.10. Party shall submit P&ID, detailed panel engineering and I/O
wiring schemes to obtain clearance (from SHAR) prior to the
commencement of erection and commissioning activities.
8.3.11. Party shall obtain clearance for panel engineering drawings,
P&ID Diagrams, I/O wiring schemes, Marshalling chamber
termination schemes and Technical specifications of all the
items from Department prior to the supply, erection and
commissioning activities. Any other make/Model/ Dimensions
require prior approval from department
8.3.12. Party shall be OEM or employ an authorized & reputed system
integrator of OEM (Siemens/ Schneider/Allen Bradley), in case
of outsourcing DACS works. This system integrator shall be
approved by department & shall have minimum 5 Years of
experience in the field of Control systems proposed make along
with proof.
8.3.13. Much care has been taken in arriving the list of equipment and
quantities, however if any equipment or components which is
not mentioned explicitly but essentially required for the
completion of system is in the scope of the Party.
8.3.14. The configuration of major bought out items like PLC, SCADA
etc., shall be reviewed and wetted by original equipment
manufacturer (OEM). If any of the item supplied as part of this
contract is not meeting the system requirement or any
compatibility/ interface issues with other systems are found at
any stage of the project, same shall be replaced with suitable
items without any additional cost.
8.3.15. The party should interface the control system with all field
elements which are brought to the instrumentation junction
box. The supply of isolators / signal conditioners / signal
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converters required to interface the field elements are in the
scope of the party. Specifications of the isolators are as per the
datasheet
8.3.16. The party should interface Drives and iMCC through suitable
interfaces as mentioned in the technical specification section
and also data to SCADA from existing PACs also.
8.3.17. The User Requirement Document for PLC/SCADA program
development will be handed over to the party after the award of
contract.
8.3.18. Detailed schedule of execution is mentioned in earlier part of
this document
8.3.19. The party shall necessarily fill the compliance statement and
may visit site before bidding for discussion.
8.3.20. For the warranty period, Party shall deploy team to carry out the updations, if any required in SCADA or PLC program after commissioning. They shall also carry out fine tuning/ carry out modifications in DACS and train the operators. The team should have thorough knowledge on PLC & SCADA systems and worked for this project.
8.3.21. During the warrantee period, party has to arrange for periodical maintenance once in every three months and unlimited breakdown calls and replacement of failed/ malfunctioning components without any additional cost.
8.3.22. Party shall provide PLC/SCADA Project backup.
8.3.23. The configuration of major bought out items like PLC, SCADA
etc., shall be reviewed and vetted by original equipment
manufacturer (OEM)
8.3.24. List of documents to be submitted (one set of soft & 2 set of printed copy);
• Full set of as built drawings (system configuration, GA, as built wiring, cable layout, instrument layout etc.).
• Software design documents – SRS, SDD, PLC/SCADA – Configuration & Program, test case documents, contingency procedures and operational check lists. PLC program shall be provided as hard copy also.
• Final BOM with make & model number.
• All technical catalogues and datasheets of all items.
• All test results (Internal tests by vendor, FAT, software test results, SAT etc.).
• Warranty certificates.
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• Passwords/ Licenses/ Operating keys etc.,
• Any other relevant document not listed above.
8.4. Design & Reviews
Party shall carryout the design of the systems and submit the documents as a part of design review of the systems.
8.4.1. Proposed control room layout indicating of operator consoles,
SCADA Server, SCADA Historian/ Ethernet Accessories/ UPS
Distribution panel etc.
8.4.2. GA drawing of the I/O panel in field and PLC panel in the
Control room.
8.4.3. Cable routing schemes indicating the cable trenches, junction
boxes and terminations etc.
8.4.4. PLC and SCADA configuration indicating the Field elements,
I/O modules, network switches, Ethernet to fibre converters,
Operator work stations, SCADA Servers, SCADA Historian,
SCADA Clients, etc.
8.4.5. Wiring diagram for DI, DO, AI and AO.
8.4.6. Tentative I/O list
8.4.7. Details of interfacing with Drives, i-MCCs, Pumps,
Compressors, weighing scales, CCTV systems etc.
8.4.8. Final BOM of all the systems.
8.5. Inspection – FAT & SAT
8.5.1. Purchaser reserves the right to inspect all phases of Supplier’s
operations. Therefore, it is the responsibility of the supplier to
provide the necessary support for the inspection agency and
get the works inspected at all stages of work as identified in
Quality Assurance Plan. The Supplier shall carry out required
supervision and inspection as per Quality Assurance Plan and
furnish all assistance required by the Purchaser in carrying
out inspection work during this phase.
8.5.2. Supplier shall inform the Department the readiness for
Instrumentation & Control Systems pre-delivery inspection at
least 10 days in advance. All necessary test results /
inspection reports / certificates as per the QAP and any other
test results mutually agreed by Department and supplier shall
be made available to the Purchaser after conducting tests as
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mentioned above in pre-dispatch inspection for obtaining the
dispatch clearance.
8.5.3. The following items will be inspected by department at factory
before dispatch (FAT), necessary test set up and test
equipment shall be arranged by supplier,
• Field Elements
• 24V DC power supply modules.
• PLC & SCADA systems assembled as per system configuration with environment software.
• Simulation of Digital and Analog Signals
• All IO panels, control consoles and UPS Distribution Panel.
• All types of cables
8.5.4. After delivery of items to site, the installation works shall be taken up after obtaining clearance from department.
8.5.5. Site Acceptance Test (SAT) procedures for the following tests shall be submitted for approval prior to inspection.
• BOM verification.
• Functional checks, compliance to specifications, load test and burn-in test of all items.
• I/O loop End to End checks, line calibration and environment software validation.
• Application software testing including failure modes, validation of diagnostics data, event & alarms log view, data logging, report generation etc.
• Trial runs with nominal & off-nominal cases.
8.5.6. After completion of installations, testing and commissioning, Site Acceptance Test at SDSC SHAR will be carried out.
8.6. Training
8.6.1. Training shall be provided from the Original Equipment
Manufacturer at their training centre for 2 persons deputed by
Department on the following
• Hot Standby PLC configuration and programming
• SCADA configuration, programming, trend and alarm generation and data backup
8.6.2. The training shall be for a minimum duration of 1 week on each
topic. Training is to be arranged before the start of PLC
program development by the supplier.
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8.7. The PLC system
8.7.1. Supply, installation, testing and commissioning of PLC/PAC components like CPU, communication modules, power supply modules, I/O modules, 3rd party interface devices, I-MCC interface modules and associated PLC accessories as per the enclosed technical datasheets. IMCC for curing operation is only for monitoring.
8.7.2. PLC/PAC shall be provided with suitable communication ports to interface with intelligent motor control center (I-MCC) of similar make as PLC for monitoring of their electrical health parameters as described in Electrical section of this tender document.
8.7.3. A common hot standby PLC shall be planned for both Ovens and shall be located in control room Control console and Remote IOs shall be located in respective oven service room IO Panel.
8.7.4. Hot standby PLC/PACs with Ethernet IP Port & with Criss-Cross configuration & with communication ring shall be provided. Service rooms are away from the control room. The distance between Main oven service room and AGNI oven service room from the CCMC located at control room are about 250 and 300m respectively. IO rack shall have dedicated panel attached Air conditioner for IO Modules. Panel Air conditioner rating shall be selected according to instruments/ modules positioned in IO rack.
8.7.5. All communication speed between IO/PAC/PLC/IOs/SCADA stations shall be of 100 Mbps or better.
8.7.6. The System shall be designed with three modes of operation.
PLC/PAC Mode Operation – Command from SCADA - Remote
operation from control room operator station.
Console Mode – Command from console to iMCC - Soft
starter/VFD/Thyristor controller/Aux & Main contactors/
DOL/SD housed in iMCC without Motor Management
System(MMS) like CVMM/Basic module etc.,) - Remote operation
from control room.
MCC Mode - Local operation from service room only for blower & hot water pumps
8.7.7. In PLC/PAC Mode, all controls of the Electrical sub systems
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shall be controlled & Commanded by PLC & it’s DO and AO Modules. PLC to be linked with MMS for acquiring current, voltage, ON/OFF status etc., only for monitoring and recording wherever necessary and not for control purpose.
8.7.8. In Console Mode, All sub systems will be operated from Console, PID Controller Relays & AO Output will be connected directly to MCC (Soft starter/VFD/Thyristor controller/Aux & Main contactors/ DOL/SD housed in iMCC without MMS like CVMM/Basic module etc.,) for operation. The command from Console & PLC DO o/p shall be interfaced with Diode TBs. The Push buttons shall be interfaced to a solid state relay with latch / release mechanism in control room console and potential free point of solid state relay shall be interface with P&F 2 In 2 Out Relay in IO Panel (Blowers, Pumps & Heater Banks). The DO command from PLC & potential free point of P&F relay of PBs shall be interfaced with single solid state relay to command the sub system with Diode TBs. Analog Output from PID controller shall be interfaced to Thyristor through Diode TBs along with AO command from PLC in IO Panel.
8.7.9. In MCC mode, all systems shall be controlled from push buttons in MCC. Heaters shall be controlled from Single loop Controller in Control Console. The control for blowers & pumps shall be separated from IO rack for MCC operation.
8.7.10. The mode selection in MCC panel shall be local/ remote and in control room (Remote) shall be SCADA/ Console.
8.7.11. In PLC Mode or Console Mode, the final command from IO panel shall be one to MCC. Both PLC & Console commands shall be parallel with proper protection.
8.7.12. The Annunciator provided in the Control Console in control room shall show the status of the systems independent of mode selection. The status will be finalized at the time of commissioning. Annunciator is not in the scope of the party.
8.7.13. All Discrete/Manual mode operation contactor status shall be acquired in PLC/PAC.
8.7.14. Only one output shall leave from IO panel to MCC for operation in SCADA/ PB mode. Local/ remote isolation shall be provided in MCC.
8.7.15. All 1 in 2 out IS relays for Proximity sensors status & contactor status shall be placed in MCC panel. The dual output status from IS relays in MCC shall be interfaced to PLC DI module in IO panel.
8.7.16. PLC/PAC shall acquire all analog & digital parameters
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irrespective of Mode selection and logging of parameters in SCADA also independent of Mode selection.
8.7.17. Suitable interface converters shall be provided with redundancy to interface iMCC.
8.7.18. Three number of PID Controller in Main Oven MCC & Agni Oven MCC for hardwire tripping of over temperature in Inlet & Outlet damper and Heater bank area. The transmitters shall be placed in IO rack and signal shall sent to Controllers in MCC Panel.
8.7.19. Two numbers of Duplex RTDs shall be planned at Inlet fire damper, Outlet fire damper & in Heater bank location. Out of which One output of one of duplex sensor in each location shall be interfaced to Temperature Transmitter, shall be located in IO Panel, & to ABB Controller in MCC. The two outputs of Second Duplex RTD shall be interfaced directly to Main & Redundant PLC RTD Input module. Two runs of 24 core FOC shall be laid for each oven. All cores shall be spliced in both ends.
8.7.20. Two runs of 16 Pair, 1 sq.mm Data cable shall be laid from IO rack to control Console from each oven and shall be terminated in both ends. One run for console signals to MCC and Second run for Transmitter signals & Annunciator signals. One run of 16 pair cable from deluge system Junction box to IO rack is in the scope of the party.
8.7.21. Two numbers of 230VAC/ 10A double pole MCBs shall be provided for safety system in IO rack. One MCB shall be provided for safety deluge System and another MCB for smoke detection System in IO panel. The safety system shall be operated independent of control system PLC. The transmitters & related Isolators and other elements functioning shall be possible to use without control system. A dedicated Dual power supply shall be provided for safety deluge systems and DIN rail mounted recorder, with Modbus TCP interface, for logging safety parameters (5 AI & 5 DI) shall be provided in IO rack and recorder also shall be linked to SCADA.
8.7.22. 2 sets of DC power supplies with diode ORing Module along with Voltage & Current monitoring shall be used in both ovens. One set for acquisition/control chain, second for safety systems.
8.7.23. A dedicated memory card (4GB SD Card or more) shall be available in PLC/PAC as an option to log the data continuously in defined log intervals irrespective of communication with SCADA Station to avoid data loss.
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8.7.24. For Interlocks/Proximity Sensors P&F 1 in 2 Out dual Power rail Modules shall be used instead of Relay boards.
8.7.25. All Proximity sensors & Contactor status IS relays shall be placed in MCC Panel.
8.7.26. All the spare digital and analog inputs shall be wired up to Marshalling chamber.
8.7.27. All PID controller data shall be interfaced to SCADA via Ethernet interface available in controller.
8.7.28. Safety related status shall be brought directly through 16 pair data cable planned to annunciator and Oven related system status to annunciator via DO card or through 16 Pair cable in Control room.
8.7.29. A dedicated IO Rack shall be provided to house IO Modules, Network Accessories, CCTV Accessories with Panel AC. It shall be separated from MCC Panels. CCTV accessories & smoke detection system is not in the scope of supplier.
8.7.30. Another separate MCB shall be provided for CCTV Systems powering and to be terminated in TB. Space shall be provided for mounting two number of 12VDC power supply with Diode oring module and Infinova Video to fiber converter in IO rack.
8.7.31. A dedicated Instrumentation Marshalling chamber with screw/ Spring gage type terminal blocks shall be provided to terminate all Signals for ease troubleshooting and shall be positioned adjacent to Instrumentation Rack. Panel shall have proper earthing & isolation system.
8.7.32. General Features for PLC / PAC & IO Modules
The controller shall be supplied with the CPU, input/output scanner, inputs, outputs, memory, power supply, and all power and interface cables necessary to function as a complete and operable Programmable Automation Controller system.
Modules are defined herein as devices that can be removed individually from its position for replacement and are keyed to allow installation in only one direction. The design must prohibit upside down insertion of the modules.
The Programmable Automation Controller shall have downward compatibility, whereby all new module designs can be interchanged with all similar modules, in an effort to reduce obsolescence.
The Programmable Automation Controller shall have the
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ability to support TCP/IP data communication link like Ethernet/IP and other third-party networks.
In a single chassis system, all system and signal power to the Programmable Automation Controller and support modules shall be distributed on a single backplane. No interconnecting wiring between these modules via plug-terminated jumpers shall be acceptable.
All system modules, including the Programmable Automation Controller, may be removed from the chassis or inserted into the chassis while power is being supplied to the chassis without faulting the controller or damaging the modules (removal and insertion under power (RIUP)).
The Programmable Automation Controller shall include an integrated Real Time Clock (RTC). This clock value shall be in the form of a predefined tag and shall be accessible via logic or remotely.
The Programmable Automation Controller shall have the capability of providing proportional, integral, and derivative (PID) control in real time, preferably with pre-emptive priority multitasking.
The Programmable Automation Controller shall support Auto-Tuning functionality without additional software and it should be the in-built functionality
A controller, or I/O card, shall be capable of being inserted under power, without upsetting the process being controlled by other controllers.
Controller shall have the ability to monitor and override I/O.
IO module shall have status lights for each input and output module.
The Programmable Automation Controller shall be configurable to accept only firmware updates from authorized users.
The Programmable Automation Controller project files shall be configurable to allow modification only by authorized users.
8.7.33. General Features for Network
The system should utilize the standard TCP/IP Network to move data seamlessly throughout the system. Multiple physical networks, including the plant, supervisory, control, and device networks should appear as a single network
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making communications efficient.
The Onboard Communication port in Programmable Automation Controllers should be used only for Programming not for HMI or I/O Communication. Dedicated communication card shall be provided for IO Communication & SCADA Server communication.
The Ethernet TCP/IP interface shall support bridging between Ethernet TCP/IP networks within a Programmable Automation Controller chassis.
The Programmable Automation Controller shall be capable of direct communication with standard commercial Ethernet products, without the use of software or hardware gateways.
Supervisory Network: The open technologies of Ethernet and TCP/IP shall be utilized for communication between the control system server and the operator stations. The control system server and its associated operator stations must be capable of connecting to two fully independent Ethernets run in parallel. No repeater or bridge connection between the Ethernet is acceptable as a means of achieving this function. This Network shall be used for connection of Servers, Workstations and OWSs to the controllers.
Control Network: The process control network/remote I/O network is used to connect the controller to field (Remote) I/O and shall be an open, flexible, high performance network.
Control Network Redundancy: To ensure maximum reliability, communications shall be redundant. The communications system shall be capable of sustaining loss of one media channel without loss of data or performance and Loss of communications shall not cause loss of control at the local subsystems. Also, loss of a local subsystem (either a single node or both of a redundant pair) shall not cause the loss of network communication.
8.7.34. General Features for Redundancy
The Programmable Automation Controller system shall be true hot back up i.e., redundant with separate chassis, power supply, controller and communication modules
The Programmable Automation Controller Enhanced Redundancy System shall provide higher system availability. This shall be realized by switching control to a secondary controller chassis if anything in the primary controller chassis fails.
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The Programmable Automation Controller Redundancy System should be able to operate without any local I/O, and having all I/O configured as remote I/O
The Programmable Automation Controller Enhanced Redundancy System shall be realized by using standard revisions of hardware, including chassis, power supplies, Programmable Automation Controllers, and communication adapters.
The Programmable Automation Controller/ PLC Redundancy System shall use fiber-optic media to connect the primary and the secondary control system.
It shall be possible to implement the Programmable Automation Controller Redundancy System without additional programming.
The redundancy system shall take over the program and data from the main controller instantaneously in case of failure of main controller.
Runtime modification done in Main controller should automatically get updated in stand-by controller without any exporting and importing of logic, it should be a true Hot Back-up system.
8.8. The SCADA system
8.8.1. Two numbers of SCADA Server in Hot standby mode with full configuration SCADA license, One Nos of SCADA Historian Server dedicated for all 8 ovens and 1 Nos operator client HMI work station shall be provided for communicating with the above PLC for Data Acquisition & Control along with acquisition from Existing Ovens PLCs.
8.8.2. All the communication between SCADA Station, Historian/Alarm Server and Operator station shall be provided with redundant Ethernet port.
8.8.3. SCADA server license for Two Servers with 5000 Tags of full development version with four numbers of HMI client license (one for operator station & 3 for Thin Client units) and 2 Nos of web space clients and One No’s of Historian Licences with 1500 Tags & with 10 multiple HMI user access and 10 web user access shall be supplied. One SCADA license for programming station shall be provided by the supplier. SCADA license shall be of floating (USB Dongle) license type which shall be positioned inside the Server/ Operator Station Cabinet and also two nos of PLC programming software shall be supplied.
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8.8.4. Sub-system wise mimic screens to monitor the process status and real time operations.
8.8.5. MMI-PLC-IO network configuration screens with critical diagnostic information and messages shall be designed.
8.8.6. Diagnostics screen for PLC hardware components, 3rd party devices, transmitters and valves etc., with faceplates for each device shall be designed.
8.8.7. Event & Alarms screen (Sub-system wise filtering to be provided).
8.8.8. Trends screen & any other screens as per the user requirement
8.8.9. Statistical tool shall be provided for report generation and SCADA software should support this tool.
8.8.10. Suitable interface module/ converters & switches shall be used for effective communication between CPU rack to I/O rack & CPU to MMI. Design of redundant SCADA System shall be free from any single point failure.
8.8.11. SCADA System shall acquire (via Ethernet communication) the data from the existing ovens PLC system also. Necessary details of the existing ovens DAS will be provided by the department. All existing Ovens PLCs are with Ethernet/IP with MODBUS TCP protocol.
8.8.12. Party shall interface existing Ovens PLC to the SCADA for new ovens along with suitable MIMIC/ Data logging/ Alarms/ etc. All Servers, Operator console shall display and log all oven data. An L3 switch shall be provided to interface the system to centralised location through existing LAN. The failure of L3 Switch shall not affect the SCADA Network.
8.8.13. All internal switches shall be of L2 Managed Switch with ring features.
8.8.14. Operator Console: Operator SCADA Station, CCTV Keyboard, Wireless Base station and Intercom shall be housed in a single modular furniture of unique design and of high quality as per the details given subsequent chapters along with furniture and control room partition shall be executed.
8.8.15. A network Server rack shall be provided to house SCADA / Historian Servers, Fiber Optic Converters, another server rack with all Optical fibre Splice racks and an Operator station shall be mounted in Modular console.
8.8.16. Common Control and Monitoring Console - CCMC with provision to mount Temperature controllers and PLCs will be
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provided by the department. Party shall interface the system with this CCMC for operations.
8.8.17. Features of SCADA / HMI
It shall be scalable from small systems to very large systems.
Screen update times will be one second or less.
Security will be an integral part of the system.
The HMI shall be designed for use in latest Microsoft Operating System. It shall use ODBC, OPC, and ActiveX technologies for optimal performance and integration with other software systems.
SCADA Server shall have thin manager support. i.e. All client HMI can be managed with thin clients instead of computer/ work station.
The system will be able to browse all tags in the controller.
There will be a factory library for standard face plates and controller instructions that will be maintained and supported by the vendor
Data servers shall be configurable to run on both a primary computer and a backup computer. The system should automatically switch to a backup computer if communication with the primary computer fails.
The servers should handle failure detection and failovers automatically for all components (OWSs) of the system.
The HMI editor should allow for simultaneous collaboration by multiple developers.
The HMI shall provide a tool to show the status of installed product patch file versions currently installed on a computer.
The HMI shall support data servers as a means to communicate with any OPC server.
The HMI shall log all data in files in an ODBC database for easy retrieval in other programs such as Microsoft Excel
The HMI Server/Client should support Thin Client/ Terminal Services Architecture
The HMI clients shall be able to view tag data from any HMI server or data server in the application as well as displays.
The HMI shall support remote editing
The alarm system shall have the ability to monitor any
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analog or digital tag for alarms.
The alarm system shall have the ability to define up to 4 different severity classes to visually distinguish alarms.
In the alarm summary display, a user can acknowledge an alarm. The alarm will then appear as acknowledged to all OWSs in the application.
Custom alarm summary objects shall be able to be embedded on any display
The alarm system shall allow online export of an alarm log file to ODBC format databases.
The alarm system shall allow the operator to write a custom message to the alarm history.
Alarms can either be polled or sent by exception from the controller
The system shall ensure Operator WorkStation security by authenticating users against a set of defined user accounts and access privileges.
The available security service should protect against unauthorized use but still allow authorized users to use the system efficiently.
8.8.18. Features of Historian Servers
Data collection nodes (SCADA Server) will feed the historian
Historian trends can be inserted into the HMI graphics and browse for tags in the controller
The Plant Historian shall be an integrated software package for collection of plant floor process data and running information / reporting applications
The Historian shall support a variety of client platform technologies with primary focus on thin client access to data and reports from a web browser.
The Historian shall utilize an optimized time series database for optimal performance in both collection and storing data and for accessing data for displays, dashboards, trends and reports.
The Historian shall support redundant architectures for both redundant data interface nodes on redundant data servers.
The Historian shall support store and forward capability between the Historian and the data collector interfaces, such
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that data is stored at the interfaces if the Historian is un-available, and then forwarded to the Historian when it is available, ultimately minimizing data loss.
The Historian shall be capable of accepting data from multiple sources of inputs.
Primarily signals from Programmable Logic Controllers, Programmable Automation Controllers, Distributed Control Systems and Human Machine Interfaces shall be used for data input
All standard configurations changes shall be “on-line” without the need to stop & re-start the Historian server. Only exception to that would be licensing changes to add or remove capabilities on the server.
The Historian shall store data in time limited archive files, so only the current archive file is updated with new data, and prior archives are updated by exception only.
System must provide for the automatic creation of archive files and the ability to automatically overwrite the oldest archive for unattended operation.
The Historian shall provide a method for backing up all on-line archives on-line without the need to stop the archive system
The interface shall allow for Historian data to be trended in the native HMI trend.
The Historian shall have real-time and historical trending capabilities. It shall also have the ability to display both real-time and historical data at the same time on the same trend
8.9. Data Acquisition & Control System (DACS) programming
DACS (PLC & SCADA) programming shall be developed as per IEEE 12207 standard. User requirements document (URD) will be provided after award of the contract.
8.9.1. Environment Software
a. Environment software comprising of PLC hardware configuration, I/O acquisition, simulation tags for all I/O’s, main or redundant signal override function, scaling function etc., shall be developed.
b. The acquired I/O’s of main, redundant and triplicate are to be validated by taking into account of concerned channel diagnostics data, channel discrepancy and simulated value etc.
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c. Design of environment software shall be submitted for approval. After development, the same will be thoroughly reviewed & tested during pre-delivery inspection (Factory Acceptance Test-FAT) by department.
8.9.2. Application Software
a. The application software design shall be carried out based on URD and shall be submitted for review & approval from the department.
b. The application software shall be developed covering the following general requirements
• Automatic sequence of operation
• Initial conditions, running interlocks, surveillance checks etc.
• Failure cases, contingency conditions etc.
• Discrete mode of operation (Individual components/ overall all sub-system)
• User friendly messages and pop-up windows for guiding the operator on steps of operation, warning, alarm & trip conditions etc.
8.9.3. The PLC/PAC & SCADA software development shall be carried at Party’s Site for Functional Checks only and remaining development shall be carried at our site (SHAR).
8.9.4. Bidder shall deploy minimum 2 persons at site to carry out above software development works immediately after system configuration is approved by department. Both should have thorough knowledge on PLC/PAC & SCADA systems with minimum 5 years’ experience in PLC/PAC & SCADA programming of PLC Brand offered for the system.
8.9.5. After successful testing & commissioning, the source code should be handed over to department.
8.9.6. Steps in DACS Software Development, Review & Testing;
a. Submission of environment software design document for approval from department.
b. Development of environment software by Party at site.
c. Review & testing of environment software by Party & department.
d. Based on review, modify/update environment software, documents and submit for approval.
e. URD document for application software design will be given by department, if any modifications are required, same shall
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be carried out by Party.
f. Submission of application software design documents (SRS, SDD and SCADA design documents) shall be submitted for approval
g. Application software development & testing by Party.
h. Submission of test case (black & white box with nominal & off-nominal test cases) documents for department review & approval.
i. Review & testing of application software by Party & department.
j. Modify/update application software, documents (including URD) and submit for approval.
k. Carry out trial runs of individual sub-systems, simulation and dry runs of integrated system by Party and department.
l. Modify/update environment and application software for fine tuning and update documents, then submit for approval.
8.9.7. The DACS Application Program
a. It shall be developed for the operation, control, monitoring and data logging of following sub-systems
• Main Oven Sub Systems
• Agni Oven Sub Systems
• Hot Water Circulation System for Main Oven
• Safety System
• UPS System
b. Control room operation shall have discrete and manual mode of operation.
8.10. Power Supply Systems
8.10.1. Uninterruptible Power Supply (UPS)
3 Phase UPS AC power distribution panel (2 Nos.)
with suitable surge protection devices (SPD) shall be
provided as per datasheet and drawing.
Three phase DUAL UPS supply will be provided to
party. Party has to supply the Elegant UPS
distribution panel with SPDs at Input & Output and
take care of distributing load to all system. All Main
Power supply shall be powered from Main UPS Line &
redundant power supply from redundant line. UPS is
not in the scope of the contractor
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8.10.2. 24V DC power supply
Supply, installation and commissioning of diode OR-
ed redundant 24V DC power supplies in each PLC
rack (M/ R/ T) with SPD for Measurement and
Command chain and 24V DC power distribution
panels (3 Nos.) shall be provided as per the datasheet
and drawing.
One set of diode ORed redundant 24V DC power
supply shall be provided for Safety System.
All dual 24VDC power equipment’s shall be powered
on both supply terminals.
Status monitoring for the following shall be provided
and wired to DACS.
• ON/OFF status of UPS input/ output MCCB/ MCB / SPD.
• ON/OFF status of critical MCBs (25 Nos.) in AC & DC PDB.
• UPS output load current & voltage.
• Each DCPS Diode OR-ed Output Load Current & Voltage shall be monitored.
A dedicated single IO chain shall be planned to
acquire all power supply related parameters.
8.11. Safety Systems
8.11.1. The safety deluge system shall be interfaced from Field JB in Deluge Room to IO Rack with a 16 pair armoured cable is in the scope of the party.
8.11.2. Interfacing Smoke Detection System with SCADA system is in the scope of the supplier. Suitable interface converter to interface Smoke detection system with SCADA is in the scope of the party. The interface converter will be decided at the time award of contract.
8.11.3. Party shall provide separate dual pole UPS MCB for Deluge & Smoke detection System separately.
8.11.4. The Deluge transmitter signal shall be splitted to two using P&F Signal isolator – one for dedicate DIN Rail recorder with Modbus TCP Interface & other to PLC Main & Redundant system via 1 in 2 out P&F Isolator is in the scope of the
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supplier.
8.11.5. Party shall interface Pressure Transmitters, Pressure switches and 24VDC solenoid valves in deluge system with SCADA System
8.11.6. The solenoid valve shall be operated through hardwired Manual Call Point Key to release system, which shall be located at the entrance of control room. Provision shall be provided to interface via PLC with Diode protection TBs at Field JB. The Manual Call point button shall be hardwired to carry 24 VDC to solenoid valve. Deluge System field JB is not in the scope of the supplier. Supplier has to lay 12 Pair cable from Deluge Room to PLC Rack.
8.11.7. All status of Switches and solenoid valves shall be acquired by the recorder and PLC.
8.11.8. Recorder shall be provided with 2 GB Memory card.
8.11.9. Supply, Installation of deluge system & Smoke detection systems is not in the scope of the supply. These systems will be installed by third party. However as explained above necessary data monitoring, recording and Interlocks shall be provided.
8.12. Cables
8.12.1. Supply, laying, termination & testing of Fiber optic, Ethernet, RS 485 cables, Power, Control and Signal cables are in the scope of the contractor.
8.12.2. All the miscellaneous items like instrument fittings, Junction box (Weather Proof & Ex. Proof), cable glands, lugs, terminal blocks & internal wirings required for realizing the above scope of works are in the scope of Bidder. Bidder shall obtain approval prior to procurement of the above items for its make & model (refer datasheet & list of approved vendors)
8.12.3. The cables within the buildings shall be laid over perforated type, modular SS/ GI cable trays with SS/GI cover. Bends/ reducers/Tees shall be used as per actual requirement.
8.12.4. The cables shall be laid in trenches outside the buildings (from service rooms to control rooms). Necessary Galvanised Steel cable trays shall be used inside the buildings
8.13. Earthing
8.13.1. Separate Instrumentation earth pits are provided near to control room, main oven service room & Agni oven service room. These earth pits are not in the scope of the contractor and will be provided by SHAR.
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8.13.2. Supply, laying & termination at both ends of instrumentation Earthing cable from respective areas to pit are in the scope of the contractor.
8.13.3. Earth strips from power earth pit are provided by SHAR inside control room & service rooms. Contractor may use these strips for connecting system to power earth.
8.14. Equipment or Services not in the scope of the contract
8.14.1. Instrumentation & power (Panel) earth pits.
8.14.2. Fire detection and alarm system (FDAS), fire-fighting system (FFS), telephones and wireless sets.
8.14.3. Deluge & Smoke detection System
8.14.4. CCTV Cameras
8.15. IO Details – Main Oven
8.15.1. Analog Inputs
Table 34. Analog Inputs – RTD Inputs
S.No Details Main Red
Range Qty. Qty
1
Main oven RTD (For Monitoring) –
4 wire Duplex type of 600 mm
length
12 12 0 - 100 °C
2
Main oven RTD (For ON/OFF &
Thyristor Control) - 4 wire Duplex
type of 600 mm length
3 3 0 - 100 °C
3 Suction Fire Damper RTD – 4 wire
duplex of 400 mm Length to PLC 1 1 0 - 100 °C
4 Delivery Fire Damper RTD – 4 wire
duplex of 400 mm Length 1 1 0 - 100 °C
5 Heater Bank RTD - 4 wire duplex
of 400 mm Length 1 1 0 - 100 °C
6 Oven Room Temperature 1 1 0 - 100 °C
7
Hot water tank RTD (For
Monitoring) – 4 wire Duplex type of
800 mm Length
1 1 0 - 100 °C
8
Hot water tank RTD (For ON/OFF
& Thyristor Control) – 4 wire
Duplex type of 800 mm Length
2 2 0 - 100 °C
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9
Hot Water inlet (For Monitoring) –
4 wire Duplex type of 300 mm
Length
1 1 0 - 100 °C
10
Hot water outlet (For Monitoring) –
4 wire Duplex type of 300 mm
Length
1 1 0 - 100 °C
Total RTD Channels 24 24
20% Spare Channels 5 5
Total Channels 29 29
Total Number of 8 Channel RTD
Input Modules 4 4
Table 35. Analog Inputs – RTD Inputs for Hardwire
S.No Details Qty Range
1
Suction Fire Damper RTD – 4 wire
duplex of 400 mm Length to Discrete
Controller
1 0 - 100 °C
2
Delivery Fire Damper RTD – 4 wire
duplex of 400 mm Length to Discrete
Controller
1 0 - 100 °C
3
Heater Bank RTD – 4 wire duplex of
400 mm Length to Discrete
Controller
1 0 - 100 °C
Table 36. Analog Inputs – IO Panel
Analog Inputs (1-5 V or 4-20 mA) - In IO Panel
S.
No Details
Ma
in Red
Range
Duplic
ation
by
Isolat
or
Qty
req
Qt
y. Qty
1 Water Level Transmitter 1 1 0 -1000
mm WC Isolator 1
2 Hot Water Line Pressure
with Dual O/p Isolator 1 1
0 -10
KSc Isolator 1
3 Cold Water Line Pressure
with Dual O/p Isolator 1 1
0 -10
KSc Isolator 1
4 Temperature Transmitter
with Dual O/p Isolator 8 8
0 -100
°C Isolator 8
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S.
No Details
Ma
in Red
Range
Duplic
ation
by
Isolat
or
Qty
req
Qt
y. Qty
5
24VDC Diode Ored
Output – Single O/p
Split in to Two using P&F
Isolator
1 1 0 -24
VDC Isolator 1
6
24VDC Load Current
from Diode ORed Module
Output – Single O/p
Split in to Two using P&F
Isolator
1 1 0 -20 A Isolator 1
7
UPS 230 VAC Supply to
PLC Rack– Single O/p
Split in to Two using P&F
Isolator
2 2 0 -300
VAC Isolator 1
8
UPS Load to IO Rack–
Single O/p Split in to
Two using P&F Isolator
2 2 0 - 20 A Isolator 1
9
Raw 230 VAC to IO
Rack– Single O/p Split in
to Two using P&F
Isolator
1 1 0 -300
VAC Isolator 1
10
Raw 230 VAC Load
Current to IO Rack–
Single O/p Split in to
Two using P&F Isolator
1 1 0 - 20 A Isolator 1
11 Deluge Air Pressure with
Dual O/p Isolator 1 1
0 -10
KSc Isolator 1
12 Set Water Pressure with
Dual O/p Isolator 1 1
0 -10
KSc Isolator 1
13 Line Water Pressure with
Dual O/p Isolator 1 1
0 -10
KSc Isolator 1
14 AI Isolators - Hardwire
Damper/HB RTDs 2 2
0 -
100°C Isolator 3
15 24VDC V&I - Electrical
Panel 2 2 -- Isolator 2
Total AI Channels 26 26
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20% Spare Channels 6 6
Total Channels 32 32
Total Number of 8
Channel Analog Input
Modules
5 5
Note: 4th Module for safety System
8.15.2. Digital Inputs
Table 37. Digital Inputs
Digital Inputs (1-5 V or 4-20 mA)
S.No DETAILS Main Red
Range Duplication
by Isolator Qty req Qty. Qty
1 Blower 1 Suction Damper OPEN Proximity Sensor
1 1 0 - 1 Isolator 2
2 Blower 1 Suction Damper CLOSE Proximity Sensor
1 1 0 - 1 Isolator 2
3
Blower 1 Delivery Damper OPEN Proximity Sensor
1 1 0 - 1 Isolator 2
4
Blower 1 Delivery Damper CLOSE Proximity Sensor
1 1 0 - 1 Isolator 2
5 Blower 2 Suction Damper OPEN Proximity Sensor
1 1 0 - 1 Isolator 2
6 Blower 2 Suction Damper CLOSE Proximity Sensor
1 1 0 - 1 Isolator 2
7
Blower 2 Delivery Damper OPEN Proximity Sensor
1 1 0 - 1 Isolator 2
8
Blower 2 Delivery Damper CLOSE Proximity Sensor
1 1 0 - 1 Isolator 2
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Digital Inputs (1-5 V or 4-20 mA)
S.No DETAILS Main Red
Range Duplication
by Isolator Qty req Qty. Qty
9 Fire Damper At Suction OPEN Proximity Sensor
1 1 0 - 1 Isolator 2
10 Fire Damper At Suction CLOSE Proximity Sensor
1 1 0 - 1 Isolator 2
11 Fire Damper At Delivery OPEN Proximity Sensor
1 1 0 - 1 Isolator 2
12 Fire Damper At Delivery CLOSE Proximity Sensor
1 1 0 - 1 Isolator 2
13 Front Left Door OPEN Proximity Sensor
1 1 0 - 1 Isolator 2
14 Front Left Door CLOSE Proximity Sensor
1 1 0 - 1 Isolator 2
15 Front Right Door OPEN Proximity Sensor
1 1 0 - 1 Isolator 2
16 Front Right Door CLOSE Proximity Sensor
1 1 0 - 1 Isolator 2
17 Door CLOSE Proximity Sensor
1 1 0 - 1 Isolator 2
18 Bogie In 1 1 0 - 1 Isolator 2
19 Bogie Out 1 1 0 - 1 Isolator 2
20 Mainoven Air Flow Switch Status
1 1 0 - 1 Isolator 2
21 Hot Water Flow Switch Status
1 1 0 - 1 Isolator 2
22 Cold Water Level Switch Status
1 1 0 - 1 Isolator 2
23 Main Line Water Flow Switch Status
1 1 0 - 1 Isolator 2
24 Hot Water Line Outlet Flow Switch Status
1 1 0 - 1 Isolator 2
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Digital Inputs (1-5 V or 4-20 mA)
S.No DETAILS Main Red
Range Duplication
by Isolator Qty req Qty. Qty
25 Cold Water Line Outlet Flow Switch Status
1 1 0 - 1 Isolator 2
26 Water Level Switch Status
1 1 0 - 1 Isolator 2
27 HWCS Emergency Stop PB Status
1 1 0 - 1 Contactor 1
28 All Water Line Ball Valve Open Status
6 6 0 - 1 Contactor 1
29 All Water Line Ball Valve Close Status
6 6 0 - 1 Contactor 1
30 Mcc MCCB On Status
1 1 0 - 1 Contactor 1
31 Mcc Emergency Off Status
1 1 0 - 1 Contactor 1
32 Local Operation Selector Switch Status
1 1 0 - 1 Contactor 1
33
Remote Operation Selector Switch Status
1 1 0 - 1 Contactor 1
34 Local/ Remote Contactor Mode
1 1 0 - 1 Contactor 1
35 24VDC Main Ps Status - Elec Panel
1 1 0 - 1 Isolator 1
36
24VDC Redundant Status - Elec Panel
1 1 0 - 1 Isolator 1
37
Power Fed Module-1 of DI Isolator Status-Chain-1- Elec
1 1 0 - 1 Isolator 1
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Digital Inputs (1-5 V or 4-20 mA)
S.No DETAILS Main Red
Range Duplication
by Isolator Qty req Qty. Qty
38
Power Fed Module-2 Of DI Isolator Status- Chain-1- Elec
1 1 0 - 1 Isolator 1
39
Power Fed Module-1 Of DI Isolator Status- Chain-2- Elec
1 1 0 - 1 Isolator 1
40
Power Fed Module-2 Of DI Isolator Status- Chain-2- Elec
1 1 0 - 1 Isolator 1
41
Power Fed Module-1 Of AI Isolator Status- Chain-3- Elec
1 1 0 - 1 Isolator 1
42
Power Fed Module-2 Of AI Isolator Status- Chain-3- Elec
1 1 0 - 1 Isolator 1
42 Pump-1 On/Off Status
From iMcc
0 - 1
From iMcc
43 Pump-2 On/Off Status
0 - 1
44 Pump-1 Trip Status
0 - 1
45 Pump-2 Trip Status
0 - 1
46 Main oven Blower-1 On/Off Status
0 - 1
47 Main oven Blower-1 Trip Status
0 - 1
48 Main oven Blower-2 On/Off Status
0 - 1
49 Main oven Blower-2 Trip Status
0 - 1
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Digital Inputs (1-5 V or 4-20 mA)
S.No DETAILS Main Red
Range Duplication
by Isolator Qty req Qty. Qty
50 Main oven Emergency Stop Pb Status
0 - 1
51 Air Heater Bank-1 On/Off Status- Main Oven
0 - 1
52 Air Heater Bank-1 Trip Status
0 - 1
53 Air Heater Bank-2 On/Off Status-Main Oven
0 - 1
54 Air Heater Bank-2 Trip Status
0 - 1
55 Air Thyristor On/Off Status-Main Oven
0 - 1
56 Air Thyristor Trip Status-Main Oven
0 - 1
57 Water Heater Bank-1 On/Off Status- HWCS
0 - 1
58 Water Heater Bank-1 Trip Status- HWCS
0 - 1
59 Water Heater Bank-2 On/Off Status-HWCS
0 - 1
60 Water Heater Bank-2 Trip Status- HWCS
0 - 1
61 Water Thyristor On/Off Status-HWCS
0 - 1
62 Water Thyristor Trip Status-HWCS
0 - 1
63 24VDC Main Ps Status- Inst Chain
1 1 0 - 1 Isolator 1
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Digital Inputs (1-5 V or 4-20 mA)
S.No DETAILS Main Red
Range Duplication
by Isolator Qty req Qty. Qty
64
24VDC Redundant Status- InstChain
1 1 0 - 1 Isolator 1
65 24VDC Main Ps Status- Safety Chain
1 1 0 - 1 Isolator 1
66
24VDC Redundant Status - Safety Chain
1 1 0 - 1 Isolator 1
67 Panel AC On Status
1 1 0 - 1 Isolator 1
68 Main Foc Fault Status
1 1 0 - 1 Isolator 1
69 Redundant Foc Fault Status
1 1 0 - 1 Isolator 1
70 Power Fed Module-1 Of AI Isolator Status
1 1 0 - 1 Isolator 1
71 Power Fed Module-2 Of AI Isolator Status
1 1 0 - 1 Isolator 1
72 Power Fed Module-1 Of DI Isolator Status
1 1 0 - 1 Isolator 1
73 Power Fed Module-2 Of DI Isolator Status
1 1 0 - 1 Isolator 1
74 SCADA Mode selection Relay Status
1 1 0 - 1 Isolator 1
75 SPD Status 1 1 0 - 1 Isolator 1
76 Low Air PS (Safety)
1 1 0 - 1 Isolator 2
77 Deluge Open PS (Safety)
1 1 0 - 1 Isolator 2
78 MCP Activation (Safety)
1 1 0 - 1 Isolator 2
79 Solenoid Valve Status (Safety)
1 1 0-1 Isolator 2
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Digital Inputs (1-5 V or 4-20 mA)
S.No DETAILS Main Red
Range Duplication
by Isolator Qty req Qty. Qty
80 Power fed Module (Safety)
2 2 0 -1 Isolator 2
81 SPD Status 2 2 0-1 Isolator 2
Total DI Channels
72 72
94
20% Spare Channels
13 13
Total Channels 85 85
Total Number of 32 Channel Digital Input Modules
4 4
Note: 8th Module for safety System
8.15.3. Digital Outputs
Table 38. Digital Outputs
S No DETAILS Main Red
Range Qty. Qty.
1 Blower-1 On 1 1 0 - 1
2 Blower-2 On 1 1 0 - 1
3 Pump-1 On 1 1 0 - 1
4 Pump-2 On 1 1 0 - 1
5 Air Heater Bank
Initiation Command 1 1 0 - 1
6 Air Heater Bank-1 On 1 1 0 - 1
7 Air Heater Bank-2 On 1 1 0 - 1
8 Air Heater Bank-3 On 1 1 0 - 1
9 Water Heater Bank
Initiation Command 1 1 0 - 1
10 Water Heater Bank-1
On 1 1 0 - 1
11 Water Heater Bank-2 1 1 0 - 1
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On
12 Emergency Stop
SCADA 1 1 0 - 1
13 Over Temperature
Alarm 1 1 0 - 1
Total DO Channels 13 13
20% Spare Channels 3 3
Total Channels 16 16
Total Number of 32
Channel Digital
Output Modules
1 1
8.15.4. Analog Outputs
Table 39. Analog Outputs
S No DETAILS Main Red
Range Qty. Qty
1 Main Oven Air HB-2 Thyristor 1 1 4- 20
mA
2 Main Oven Air HB-3 Thyristor 1 1 4- 20
mA
3 Main Oven Water HB-2
Thyristor 1 1
4- 20
mA
Total 3 3
20% Spare Channels 1 1
Total Channels 4 4
Total Number of 8 Channel
Analog Output Modules 1 1
8.16. IO Details – AGNI Oven
8.16.1. Analog Inputs
Table 40. Analog Inputs – RTD Inputs
S.No Details Main Red
Range Qty. Qty
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1 Agni oven RTD (For Monitoring) – 4
wire Duplex type of 600 mm length 8 8
0 - 100
°C
2
Agni oven RTD (For ON/OFF &
Thyristor Control) – 4 wire Duplex
type of 600 mm length
2 2 0 - 100
°C
3 Fire Damper RTD – 4 wire duplex of
400 mm length 3 3
0 - 100
°C
4 Oven Room Temperature 1 1 0 - 100
°C
Total RTD Channels 14 14
20% Spare Channels 3 3
Total Channels 17 17
Total Number of 8 Channel RTD
Input Modules 3 3
Table 41. Analog Inputs – RTD Inputs for Hardwire
S.No Details Main
Range Qty.
1
Suction Fire Damper RTD – 4 wire
duplex of 400 mm Length to Discrete
Controller
1 0 - 100 °C
2
Delivery Fire Damper RTD – 4 wire
duplex of 400 mm Length to Discrete
Controller
1 0 - 100 °C
3 Heater Bank RTD – 4 wire duplex of
400 mm Length to Discrete Controller 1 0 - 100 °C
Table 42. Analog Inputs – IO Panel
Analog Inputs (1-5 V or 4-20 mA)
S.No Details Main Red
Range Duplication
by Isolator Qty req Qty. Qty
1
Deluge Air Pressure with Dual O/p Isolator
1 1 0 -10 KSc
Isolator 2
2
Temperature Transmitter with Dual O/p Isolator
6 6 0 -100 °C Isolator 6
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3
24VDC Diode Ored Output – Single O/p Split in to Two using P&F Isolator for Process, Electrical & safety
3 3 0 -24 VDC
Isolator 3
4
24VDC Load Current from Diode ORed Module Output – Single O/p Split in to Two using P&F Isolator for Process, Electrical & safety
3 3 0 -20 A Isolator 3
5
UPS 230 VAC Supply to PLC Rack– Single O/p Split in to Two using P&F Isolator
2 2 0 -300 VAC
Isolator 2
6
UPS Load to IO Rack– Single O/p Split in to Two using P&F Isolator
2 2 0 - 20 A Isolator 2
7
Raw 230 VAC to IO Rack– Single O/p Split in to Two using P&F Isolator
1 1 0 -300 VAC
Isolator 1
8
Raw 230 VAC Load Current to IO Rack– Single O/p Split in to Two using P&F Isolator
1 1 0 - 20 A Isolator 1
9 24VDC V&I - 2 2 -- Isolator 2
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Electrical Panel
Total AI Channels
21 21
23
20% Spare Channels
5 5
Total Channels
27 27
Total Number of 8 Channel Analog Input Modules
4 4
8.16.2. Digital Inputs
Table 43. Digital Inputs
S.No DETAILS Main Red
Range Duplication
by Isolator Qty req Qty. Qty
1
Blower 1 Suction damper OPEN proximity sensor
1 1 0 - 1 Isolator 2
2
Blower 1 Suction damper CLOSE proximity sensor
1 1 0 - 1 Isolator 2
3
Blower 1 Delivery damper OPEN proximity sensor
1 1 0 - 1 Isolator 2
4
Blower 1 Delivery damper CLOSE proximity sensor
1 1 0 - 1 Isolator 2
5 Blower 2 Suction
1 1 0 - 1 Isolator 2
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damper OPEN proximity sensor
6
Blower 2 Suction damper CLOSE proximity sensor
1 1 0 - 1 Isolator 2
7
Blower 2 Delivery damper OPEN proximity sensor
1 1 0 - 1 Isolator 2
8
Blower 2 Delivery damper CLOSE proximity sensor
1 1 0 - 1 Isolator 2
9
Fire damper at Suction OPEN proximity sensor
1 1 0 - 1 Isolator 2
10
Fire damper at Suction CLOSE proximity sensor
1 1 0 - 1 Isolator 2
11
Fire damper at Delivery OPEN proximity sensor
1 1 0 - 1 Isolator 2
12
Fire Damper At Delivery CLOSE Proximity Sensor
1 1 0 - 1 Isolator 2
13
Front Left Door OPEN Proximity Sensor
1 1 0 - 1 Isolator 2
14 Front Left Door CLOSE
1 1 0 - 1 Isolator 2
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Proximity Sensor
15
Front Right Door OPEN Proximity Sensor
1 1 0 - 1 Isolator 2
16
Front Right Door CLOSE Proximity Sensor
1 1 0 - 1 Isolator 2
17 Door Close Proximity Sensor
1 1 0 - 1 Isolator 2
18 Air Flow Switch
1 1 0 - 1 Isolator 2
19 MCC MCCB ON Status
1 1 0 - 1 Contactor 1
20 MCC Emergency Off Status
1 1 0 - 1 Contactor 1
21
Local Operation Selector Switch Status
1 1 0 - 1 Contactor 1
22
Remote Operation Selector Switch Status
1 1 0 - 1 Contactor 1
23 Local/ Remote Contactor Mode
1 1 0 - 1 Contactor 1
24 24VDC Main Ps Status - Elec Panel
1 1 0 - 1 Isolator 1
25
24VDC Redundant Status - Elec Panel
1 1 0 - 1 Isolator 1
26
Power Fed Module-1 of DI Isolator Status-Chain-1- Elec
1 1 0 - 1 Isolator 1
27 Power Fed Module-2 Of
1 1 0 - 1 Isolator 1
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DI Isolator Status- Chain-1- Elec
28
Power Fed Module-1 Of DI Isolator Status- Chain-2- Elec
1 1 0 - 1 Isolator 1
29
Power Fed Module-2 Of DI Isolator Status- Chain-2- Elec
1 1 0 - 1 Isolator 1
30
Power Fed Module-1 Of AI Isolator Status- Chain-3- Elec
1 1 0 - 1 Isolator 1
31
Power Fed Module-2 Of AI Isolator Status- Chain-3- Elec
1 1 0 - 1 Isolator
1
32 Agni Oven Blower-1 On/Off Status
From IMcc
0 - 1
IMCC
33 Agni Oven Blower-1 Trip Status
0 - 1
34 Agni Oven Blower-2 On/Off Status
0 - 1
35 Agni Oven Blower-2 Trip Status
0 - 1
36 Agni Oven Heater Bank-1 On/Off Status
0 - 1
37 Agni Oven Heater Bank-1 Trip
0 - 1
38 Agni Oven Heater Bank-2 On/Off Status
0 - 1
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39 Agni Oven Heater Bank-2 Trip
0 - 1
40 Agni Oven Thyristor On/Off Status
0 - 1
41 Agni Oven Thyristor Trip Status
0 - 1
42 24VDC Main Ps Status- Meas Chain
1 1 0 - 1 Isolator 1
43
24VDC Redundant Status- Meas Chain
1 1 0 - 1 Isolator 1
44
24VDC Main Ps Status- Command Chain
1 1 0 - 1 Isolator 1
45
24VDC Redundant Status - Command Chain
1 1 0 - 1 Isolator 1
46 Panel AC On Status
1 1 0 - 1 Isolator 1
47 Main FOC Fault Status
1 1 0 - 1 Isolator 1
48 Redundant FOC Fault Status
1 1 0 - 1 Isolator 1
49
Power Fed Module-1 Of AI Isolator Status
1 1 0 - 1 Isolator 1
50
Power Fed Module-2 Of AI Isolator Status
1 1 0 - 1 Isolator 1
51
Power Fed Module-1 Of DI Isolator Status
1 1 0 - 1 Isolator 1
52 Power Fed 1 1 0 - 1 Isolator 1
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Module-2 Of DI Isolator Status
53 SCADA Mode slection Relay Status
1 1 0 - 1 Isolator 1
54 SPD Status 2 2 0 - 1 Isolator 2
Total DI Channels
45 45
63
20% Spare Channels
10 10
Total Channels
65 65
Total Number of 32 Channel Digital Input Modules
3 3
8.16.3. G197
8.16.4. Digital Outputs
Table 44. Digital Outputs
S.No DETAILS Main Red
Qty. Qty
1 Blower-1 On 1 1
2 Blower-2 On 1 1
3 Air Heater Bank Initiation Command 1 1
4 Air Heater Bank-1 On 1 1
5 Air Heater Bank-2 On 1 1
6 Air Heater Bank-3 On 1 1
7 Emergency Stop SCADA 1 1
8 Over Temperature Alarm 1 1
Total DO Channels 8 8
20% Spare Channels 2 2
Total Channels 10 10
Total Number of 16 Channel Digital
Output Modules 1 1
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8.16.5. Analog Outputs
Table 45. Analog Outputs
S.No DETAILS Main -
Qty. Red - Qty
1 Agni Oven Air HB-3 Thyristor 1 1
Total 1 1
20% Spare Channels 1 1
Total Channels 2 2
Total Number of 8 Channel Analog
Output Modules 1 1
8.17. IO Details – Control Room
8.17.1. Analog Inputs
Table 46. Analog Inputs – Control Room
S.No Details
Main Rang
e Duplication by
Isolator
Qty req
Qty.
1 24VDC Diode Ored Output – For FOC
1 0 -24
VDC Isolator (2 In 2 Out)
1
2 24VDC Load Current from Diode ORed Module Output – For FOC
1 0 -
20 A
3 24VDC Diode Ored Output – For Isolator
1 0 -24
VDC Isolator (2 In 2 Out)
1
4 24VDC Load Current from Diode ORed Module Output – For Isolator
1 0 -
20 A
5 24VDC Diode Ored Output – For PLC
1 0 -24
VDC Isolator (2 In 2 Out)
1
6 24VDC Load Current from Diode ORed Module Output – For PLC
1 0 -
20 A
7 UPS 230 VAC Supply to Control Console
1 0 -300 VAC
Isolator (2 In 2 Out)
1
8 UPS Load to Control Console 1 0-80
A
9 UPS 3 Ph Supply to Curing ICS 3 Isolator (2 In 2
2 10 UPS 3 Ph Load to Curing ICS 3
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Out)
11 Raw 230 VAC to Control Console 1 0 -300 VAC
Isolator (2 In 2 Out)
1
12 Raw 230 VAC Load Current to Control Console
1 0-80
A
13 PID Controller Analog Output Current via dual o/p isolator
10 4-20 mA
Isolator (2 In 2 Out)
3
Total AI Channels 26
10
20% Spare Channels 6
Total Channels 32
Total Number of 8 Channel Analog Input Modules
5
8.17.2. Digital Inputs
Table 47. Digital Inputs – Control Room
S.No DETAILS Main
Range Duplication
by Isolator Qty req Qty.
1 24VDC Main PS Status – FOC 1 0 - 1 Isolator (2 In 2 Out)
1 2 24VDC Redundant Status –FOC 1 0 - 1
3 Main FOC Fault Status 1 0 - 1 Isolator (2 In 2 Out)
1 4 Redundant FOC Fault Status 1 0 - 1
5 24VDC Main PS Status – Isolators 1 0 - 1 Isolator (2 In 2 Out)
1 6 24VDC Redundant Status –Isolators 1 0 - 1
7 24VDC Main PS Status – PLC 1 0 - 1 Isolator (2 In 2 Out)
1 8 24VDC Redundant Status –PLC 1 0 - 1
9 Power Fed Module-1 Of Isolator Status
1 0 - 1 Isolator
(2 In 2 Out) 1
10 Power Fed Module-2 Of Isolator Status
1 0 - 1
11 PLC Mode Selector Switch Status of Main Oven
1 0 - 1 Isolator
(2 In 2 Out) 1
12 Push Button Mode Selector Switch Status of Main Oven
1 0 - 1
13 PLC Mode Selector Switch Status of Agni Oven
1 0 - 1 Isolator
(2 In 2 Out) 1
14 Push Button Mode Selector Switch Status of Agni Oven
1 0 - 1
15 Emergency Off Status of Main Oven 1 0 - 1 Isolator (2 In 2 Out)
1 16 Emergency Off Status of Agni Oven 1 0 - 1
17 All UPS & MCB Status 20 0 – 1 Isolator 10
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(2 In 2 Out)
18 All SPD Status 8 0 – 1 Isolator
(2 In 2 Out) 4
Total DI Channels 44
22
20% Spare Channels 10
Total Channels 54
Total Number of 32 Channel Digital Input Modules
2
8.17.3. Digital Outputs
Table 48. Digital Outputs – Control Room
S.No DETAILS
Main Range
Qty.
1 PLC Mode Selection to Annunciator of Main Oven
1 0 - 1
2 Manual Mode Selection to Annunciator of Main Oven
1 0 - 1
3 Local Mode Selection to Annunciator of Main Oven
1 0 - 1
4 Remote Mode Selection to Annunciator of Main Oven
1 0 - 1
5 PLC Mode Selection to Annunciator of Agni Oven
1 0 - 1
6 Manual Mode Selection to Annunciator of Agni Oven
1 0 - 1
7 Local Mode Selection to Annunciator of Agni Oven
1 0 - 1
8 Remote Mode Selection to Annunciator of Agni Oven
1 0 - 1
Total DO Channels 8
20% Spare Channels 2
Total Channels 10
Total Number of 32 Channel Digital Output Modules
1
8.18. IO Channel / Module Summary
8.18.1. Main Oven
S.No Input/ System No. of Main
No. of Red.
No. of Main
No. of Red.
Total Module
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Ch. Ch. Module Module
1 8 Ch. RTD Module
29 29 4 4 8
2 8 Ch AI Module 32 32 5 5 10
3 32 Ch DI Module 85 85 4 4 8
4 32 Ch DO Module
16 16 1 1 2
5 8 Ch AO Module 4 4 1 1 2
Total IO Channels 166 166
8.18.2. AGNI Oven
S.No Input/ System No. of Main Ch.
No. of Red. Ch.
No. of Main
Module
No. of Red.
Module
Total Module
1 8 Ch. RTD Module
17 17 3 3 6
2 8 Ch AI Module 21 21 4 4 8
3 32 Ch DI Module 65 65 3 3 6
4 32 Ch DO Module
10 10 1 1 2
5 8 Ch AO Module 2 2 1 1 2
Total IO Channels 115 115
8.18.3. Control Room
S.No Input/ System No. of
Channels No. of Module
1 8 Ch AI Module 32 5
2 32 Ch DI Module 54 2
3 32 Ch DO Module 10 1
4 PLC / Accessories -- 2
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Total IO Channels 106
3rd Party Interfaces 535
Total IO Count for New Ovens 668
Existing Ovens IO Counts including 3rd Party
Devices
500
Total Counts for all Ovens 1703
8.19. Instrumentation Items
Table 49. Instrumentation Items – List
S.No Item Make Qty Req
Spare Req
Ref Tble no:
1 Duplex RTD of 600 mm Length – Main Oven
Baumer/ Nagman/ Tempsens/ Exotherm/ Rosemount
15 15 50
2 Duplex RTD of 800 mm Length – Main Oven
Baumer/ Nagman/ Tempsens/ Exotherm/ Rosemount
3 3 50
3 Duplex RTD of 600 mm Length – Agni Oven
Baumer/ Nagman/ Tempsens/ Exotherm/ Rosemount
10 10 50
4 Duplex RTD of 400 mm Length – Main Oven
Baumer/ Nagman/ Tempsens/ Exotherm/ Rosemount
7 7 50
5 Duplex RTD of 300 mm Length – Main Oven
Baumer/ Nagman/ Tempsens/ Exotherm/ Rosemount
2 2 50
6 Duplex RTD of 400 mm Length – Agni Oven
Baumer/ Nagman/ Tempsens/ Exotherm/ Rosemount
7 7 50
7 Temperature Rosemount/ Siemens 21 0 51
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Transmitters
8 Pressure Transmitter
Rosemount 3051 (0 to 55 Bar)/ Siemens
6 1 52
9 Single Loop Controller
ABB CM10 14 0 53
10 Level Switch P&F 1 1 54
11 Level Transmitter P&F / Rosemount/IFM
2 1 55
12 Proximity sensors
P&F 36 4 56
13 Isolators (I/I or I/V) – 1 In 2 Out
P&F 52 0 57
14 Isolators (I/I or I/V) – 2 In 2 Out
P&F 10 0 57
15 Relay – 1 In 2 Out
P&F 157 10 57
16 Relay – 2 In 2 Out
P&F 22 0 57
17 Power fed Module and Power rail
P&F 22 2 57
18 Power Rail P&F 15 0 57
19 Low Air pressure Switch
Switzer/ IFM 2 2 58
20 Water flow switch
Switzer / IFM 1 1 59
21 DC Voltage transducer
Rishab/ LEM/ AE/ M- Systems/ NK Technologies
9 0 60
22 DC Current transducer
Rishab/ LEM/ AE/ M- Systems
9 0 61
23
UPS Voltage Monitoring (1 Phase) Transducer
Rishab/ LEM/ AE/ M- Systems
6 0 62
24
UPS Current Monitoring ( 1 Phase) transducer
Rishab/ LEM/ AE/ M- Systems/ NK Technologies
6 0 63
25
UPS Voltage Monitoring (3 Phase) Transducer
Rishab/ LEM/ AE/ M- Systems
2 0 62
26 UPS Current Monitoring ( 3
Rishab/ LEM/ AE/ M- Systems/ NK
2 0 63
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Phase) transducer
Technologies
27
Raw Voltage Monitoring (1 Phase) Transducer in Main & Agni Oven
Rishab/ LEM/ AE/ M- Systems
2 0 62
28
Raw Current Monitoring (1 Phase) Transducer in Main & Agni Oven
Rishab/ LEM/ AE/ M- Systems/ NK Technologies
2 0 63
29
24 V DC/20 A power supply with Diode Oring Module
Phoenix/ Siemens/ Aplab
6 0 64
30
24 V DC/10 A power supply with Diode Oring Module
Phoenix/ Siemens/ Aplab
8 0 64
31
24 V DC/5 A power supply with Diode Oring Module
Phoenix/ Siemens/ Aplab
4 0 64
32 IO Rack Rittal 2 0 65
33 Hot Standby PLC/PAC
Siemens/ Schneider/ Allen Bradley
2 1 66
34 PLC Programming Full License
Siemens/ Schneider/ Allen Bradley
2 0 66
35 16/32 Channel Digital Input Module
Siemens/ Schneider/ Allen Bradley
30 / 15 2 67
36 16/32 Channel Digital Output Module
Siemens/ Schneider/ Allen Bradley
8/ 4 2 68
37 8 Channel RTD Input Module
Siemens/ Schneider/ Allen Bradley
16 2 69
38 8 Channel Analog Input Module
Siemens/ Schneider/ Allen Bradley
21 2 70
39 4/8 channel Analog Output
Siemens/ Schneider/ Allen Bradley
4 2 71
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Module
40 SCADA Server License (For Hot stand By Server)
Siemens/ Schneider/ Allen Bradley (Unlimited Run-time + Configuration Supply of for HSBY server– 5000 Tags
2 0 72
41 SCADA Historian License
Siemens/ Schneider/ Allen Bradley (1500 tags for historian server with 10 HMI User access & 2 Web user access
1 0 73
42 SCADA Client License (HMI Clients)
Siemens/ Schneider/ Allen Bradley
4 0 73
43 SCADA (Web Clients)
Siemens/ Schneider/ Allen Bradley (Web space clients)
2 0 73
44 SCADA Historian Server
HP/Dell 1 0 73
45 SCADA Server HP/Dell 2 0 73
46 Operator Station HP/Dell 1 0 74
47 Thin Client Unit HP/Dell 3 0 75
48 PG Station (Laptop)
HP Pavilion/ Dell 1 0 76
49 A3/A4 Color Inkjet Printer
HP 1 No Each
0 --
50 A4 Color Laser Printer
HP 1 0 --
51 A4 Scanner HP 1 0 --
52
Digital camera
Compact Camera with 20x Optical Zoom or
better Model:
DSC-WX350 or better, Black
Mega Pixel: 18MP,
SONY 01
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Optical Zoom: 20X or better
Battery Charger + Extra Battery
32GB Memory or better
Camera Pouch
53 Ethernet Switch- L2 (Field)
Extreme/ Antaira / Moxa/Schneider/ Siemens
8 0 77
54 Ethernet Switch- L2 (Control room)
Extreme/ Antaira / Moxa/Schneider/ Siemens
2 0 78
55 Ethernet Switch- L3 (Control Room)
Extreme/ Moxa /
Cisco / Allied
Telesys/Planet
/ HP
1 0 79
56 Surge Suppressor – 1 Phase
Phoenix/ Dhen/ Citel 12 1 80
57 Surge Suppressor – 3 Phase
Phoenix/ Dhen/ Citel 2 0 80
58 Operator Console Pyrotech 1 0 81
59 Server Rack APC/Rittal/ Valrack 2 0 82
60 43 Inch LED TV LG/ Panasonic/ Samsung/ Sony/ Toshiba
3 0 83
61 16 Pair Armored Signal Cables
Uniflex /
Thermocables /
Thermocabs /Delton
/ Delta / Lapp /
Paramount cables /
Polycab
/ RPG /CMI
2000 Mtrs
0 84
62 1 Pair Armored Uniflex / 1000 -- 85
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Cable Thermocables / Thermocabs /Delton / Delta / Lapp / Paramount cables / Polycab
Mtrs
63 3 Pair Armored Cable
Uniflex / Thermocables / Thermocabs /Delton / Delta / Lapp / Paramount cables / Polycab
1000 Mtrs
-- 85
64 Heat Resistant Cables
Uniflex /
Thermocables /
Thermocabs /Delton
/ Delta / Lapp /
Paramount cables /
Polycab / / RPG
/CMI
5000 Mtrs
-- 86
65 Optic Fibre Cables
HFCL/3C/ Schneider/ Tyco/ RPG
4000 Mtrs
-- 87
66 Cat 6 /7 cable Belden/ Schneider 1000 Mtrs
-- --
67 Double compression Glands
Baliga/ Comet As
Reqd -- --
68 Terminals/ Stoppers/ Fuse TB
DIN Rail Wago/ Phoenix/ Weidmuller, Fuse TB with Fuse Break LED
As reqd -- --
69 Flameproof Junction Boxes
P & F/ Baliga As reqd -- --
70 Non Flame proof Junction Boxes
P & F/ Baliga / Rittal / Adarsha
As reqd -- --
71 Relay Phoenix Solid state relay module to drive contactors.
For All DOs
4 --
72 48 port OFC Splice box (Wall Mount)
3M/ FCI 2 1 --
73 19” Rack Mount 48 Port OFC
3M/ FCI 2 1 --
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Splice Tray (Rack)
74 Push Buttons, Emergency Stop Buttons
Siemens As reqd -- --
75 Chairs Godrej PCH 7003 10 -- --
76 Chairs Godrej PCH 7002 6 -- --
77 Chairs Godrej PCH 7001 4 -- --
78 Table Godrej ENZ0, Color: Beige, Dim: 1500 x 750 x 750
2
79
Modular partition with glass door in control room
6.0m x 6.0 m x 3.5m modular partition with transparent glass
As required
8.20. Technical Specifications (Data sheets)
Party shall supply the full quantities of the items mentioned in the below data sheets. Required quantities shall be issued to the party during erection.
Table 50. RTD Sensors
Description Essential Specification
Type of sensor Pt100, 4 – wire, Duplex Type
Accuracy Class-A
Termination Head Type Ex. Proof Head IIA/ IIB
No of Conduit Entry /
Entries
Double Entry
Cable Gland 1/2” NPT
Head Extension Type Adjustable connection
Process Connection M20 x 1.5 (M)
Glands Double compression cable gland in Nickel
plated Brass - FLP
Tip Length 60 mm
Tip Diameter 4.5 mm
Sheath Diameter 6 mm
Sheath Material SS316
Termination Style Nut with Knurling’s
Temperature
Coefficient:
0.00385 Ohms/ 0C
Temperature Range: 0 to 1200C
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Description Essential Specification
Sensor wire PTFE insulated, Nickel coated copper
stranded wire.
Calibration certificate Required and traceable to NIST - 40 °C, 50
°C, 60 °C, 70 °C, 80 °C, 90 °C, 100 °C,
110°C & 120 °C
Tag Plate Shall be provided with sensor details
Sensor Immersion
Length
Main Oven – 600 mm, Agni Oven – 600
mm, Hot water tank – 800 mm, Hot water
Inlet & Outlet-300mm, Dampers – 400 mm
Quantity As per the IO Count given in previous
chapter
Table 51. Temperature Transmitter
Description Essential Specification
Make Rosemount/ Siemens
Input 4 wire RTD
Output Two wire 4-20 mA HART
Approvals No Approval
Mounting To Clip onto top-hat DIN rail
Alarm High Alarm configuration feature shall be
available
Power Supply 24 VDC
Failure Mode User selectable Up or Down scale Indication
Accuracy +/- 0.2 deg C of span for RTD
Line voltage filter 50 Hz
Update time <= 0.5 sec or better
Terminals Screw terminals
Display Dual-line LC display with additional display
elements (option)
Inputs 4 wire RTD
Table 52. Pressure Transmitter
Description Essential Specification
Make Rosemount 3051/ Siemens
Operating Principle Capacitance
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Integral display LCD display
Range 0 to 55 Bar
Output Linearized
Accuracy 0.075% of span
Electro Magnetic
Compatibility
(EMC)
As per EN 61326 or equivalent.
Calibration
certificate Required and traceable to NIST/ NABL.
Power supply 24 VDC
Output signal 4- 20 mA.
Span / Zero
adjustment Required.
Transmitter
diagnostics
Standard & all advanced diagnostics are
required.
Protection IP 65
Over range
protection Required. 150 % of maximum pressure.
Application of
measurement Water Line & Deluge Pressure
Process connection ½” NPT (F)
Cable Entry ½” NPT Female with double compression cable
gland.
Area Intrinsically safe: Zone 1, Gas group IIA, IIB &
T4
2-valve manifold SS316 and shall be suitable to pressure
ratings.
Model ROSEMOUNT 3051TA 3 A 2B 2 1 A B4 K5
Q4 D4 M4/ Siemens
Table 53. Single Loop Controllers (SLC)
Description Essential Specification
Make ABB
Model CM-10
IP Rating IP20
Display Type Dual 4 Digit LED
Supply Voltage 230Vac/ 24Vdc
Input Types 4-20mA, 1-5V, Pt100RTD
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PV Accuracy 0.2% of reading ±1LSD
Control Types On/Off, PID
Output Types Logic, relay, triac, DC,4-20 mA Analog
Output
No of Alarms 4
Set-point Programmer required
Min Analogue
IO
Input 2 (4-20mA)
Output 2 (4-20mA)
Min Digital IO Input 4
Output 4
Communication interface Ethernet
Table 54. Level Switch
Description Essential Specification
Make P&F
Aux. Supply 24VDC
Output contact 3 CO
Mounting
location
On top of the hot water tank
Input sensors 3 sensors
Sensitivity 1 k ohm to 200 k ohm adjustable
Trip time delay Less than 1 sec
Protection IP 65 , Intrinsically safe certified or better
Range: 1200 mm
Fittings Required
Cable Entry ½” NPT Female with double compression cable
gland
Body material,
sensing element,
fittings
Suitable for corrosive environment
Table 55. Level Transmitter
Description Essential Specification
Make P&F / Rosemount / Vega / IFM
Aux. Supply 24VDC
Output contact 4 – 20 mA
Mounting location On top of the hot water tank
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Protection IP 65 , Intrinsically safe certified or better
Range: 1200 mm
Fittings Required
Cable Entry ½” NPT Female with double compression cable
gland
Body material,
sensing element,
fittings
Suitable for corrosive environment
Capacitive continuous level measurement.
Display Local Indication shall be available
Table 56. Proximity Sensors
Description Essential Specification
Make P&F
Type of proximity
sensor
Inductive NAMUR type
Mounting location Hazardous area
Type of mounting Threaded cylindrical type with check nuts
Enclosure Protection IP 67, Intrinsically safe certified to Zone 1,
GR-IIA, IIB & T4.
Length of integral cable
with sensor
As required to interface with IS Isolators
in IO Rack
Terminal box for
termination of integral
cable
IP 65
Table 57. Isolators & IS Relays
S. No Type of isolator Make & Model Location
1 Analog input
( 1 In 2 Out)
KFD2-STC4-EX1.2O or
KFD2-STV4-Ex1.2O-1
Main & Agni
oven
2 Analog input
( 2 In 2 Out)
KFD2-STC4-EX2 or
KFD2-STV4-Ex2-1
Main & Agni
oven
3 Digital input
(1 In 2 Out) KFD2-SR2- EX 1.W.LB
Main & Agni
oven
4 Digital input
(2 In 2 Out) KFD2-SR2- EX2.W
Main & Agni
oven
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5 Power Fed Module P&F – KFD2-EB2-
R4A.B
Main & Agni
oven
6 Universal Power
Rail P&F – UPR-03
Main & Agni
oven
Note: - Suitable power isolator modules, power rails & other
accessories shall be provided to mount the isolator.
Table 58. Low Air Pressure Switch
Description Essential Specification
Make Switzer / IFM
Medium Hot air 120 0C
No of contacts 2 NO + 2 NC 5 A rated at 250 V A.C
Mounting location In the air delivery ducts
Protection IP 65 , Intrinsically safe certified or better
Range: 0- 100 mm WC
Cable Entry ½ “ NPT 2 nos.,
Table 59. Water Flow Switch
Description Essential Specification
Make Switzer/ IFM
Sensing element Vane
Type Vane / paddle
Mounting location Pipe line
Switch type Micro switch
Accuracy ± 2% of span
Switch contacts DPDT
Contact rating 10A resistive load , 3 A inductive load at 250 V
AC
Switch setting Tamper proof and external adjustment
Over range
protection
1.5 times of Max. flow
Protection IP 67
Intrinsically safe certified.
Cable Entry ½” NPT Female with double compression cable
gland.
Body material Brass
Vane / Paddle SS 304 four vane combination – vane length
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material shall be adjustable and shall be compatible
with water pump flow rate
Temperature of
water
1000C
Note: - The dimensions of sensing element shall be suitable for the
mounting location.
Table 60. DC Voltage Transducer
Make AE / LEM/ Rishab/ M- System
Rated Input Voltage 50 VDC for 24VDC Measurement & 400
VDC for Battery Volt Measurement
Output signal 4 -20 mA
Power supply 24 VDC
Measuring accuracy +/- 0.5 % or better
Isolation available between Input, Output and Power
supply
Input Resistance > 1 Mega Ohms or better
Load Resistance >2 Kiloohms or better for Voltage output
&<=250 Ohms or better for current output
Isolation withstanding
voltage
> 2.5 KV (Min for 1 Min)
Response time 400 ms or better
Mounting DIN Rail
Table 61. DC Current Transducer
Description Essential Specification
Make AE / LEM/ Rishab/ M- System/ NK
Technologies
Use 24 VDC DideoORed Output Monitoring
in CCMC, in each IO Rack
Operating principle Scale down, rectification & conversion
Auxiliary power supply 24 VDC
Input parameter (I in Amp) As per load
Output 4-20 mA
No. of signal outputs Dual
Output ripple (Accuracy
class)
0.2 % of span or better
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Description Essential Specification
Input / output Isolation Galvanic or optical
Mount DIN Rail
Table 62. UPS Voltage Transducer
Description Essential Specification
Make Rishabh/ LEM/ M- Systems
Rated Input Voltage (
Measurement voltage)
300 VAC or Nearby range (It shall be greater
than 280VAC)
(IO Panel & Control Room) & 500 VAC -3
Phase for UPS Incoming & Outgoing
Frequency of Input
Voltage
50 Hz
Output Signal 4 -20 mA
Power Supply 24 VDC
Measuring Accuracy +/- 0.5 % or better
Isolation available between Input, Output and Power
supply
Input Resistance > 1 Kilo Ohms or better
Load Resistance >2 Kilo ohms or better for Voltage output
&<=250 Ohms or better foe current output
Isolation
withstanding voltage
> 2.5 KV (Min for 1 Min)
Response time 300 ms or better
Mounting DIN Rail
Table 63. UPS Current Transducer
Description Essential Specification
Make AE / LEM/ Rishab/ M- System/ NK
Technologies
Use UPS Output Load Monitoring at CCMC
& in Each IO Rack Load (Single Phase
& 3 Phase)
Operating principle Scale down, rectification & conversion
Mounting location MCC panel, DIN rail mounted
Auxiliary power supply 24 VDC
Input parameter (I in Amp) As per load
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Description Essential Specification
Output 4-20 mA
No. of signal outputs Dual
Output ripple (Accuracy
class)
0.2 % of span or better
Input / output Isolation Galvanic or optical
Response < 500 ms or better
Insulation resistance > 100 MΩ @ 500V DC or better
Impulse withstand voltage Peak Voltage of 5kV, Standardized
impulsed waveform of 1.2 / 50µsec or
better
Enclosure type IP 40
Mount DIN Rail
Table 64. 24 V DC Power Supply
Description Essential Specification
Make Pheonix/ Siemens / Aplab
Input voltage 230 V AC ± 10%, 50 Hz
Output voltage 24 V DC
Output current 20 A / 10A /5A
Overload & short circuit
protection type
Required
Over voltage protection Required
Load As required.
Ripple 50 mV peak – peak or better
Mounting DIN rail mounted/ panel mounted.
Coating Protective Coating Shall be available
Operating temperature Ambient to 50 Deg C
Oring Pheonix Quint Diode Oring Module
with protective coating .
Table 65. IO Rack
Description Essential Specification
Manufacturer Rittal of required dimension & to be spacious
for future addition of modules
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Service Housing PLC, I/O modules, DCPS, P&F
Isolators, P&F IS Relays, FOC, Video to Fiber
Converters, etc
Location Service rooms
Type Free standing
Cable entry Bottom entry. Base Mounting Height shall be of
Minimum 300 mm for free entry of cables.
Door Required
Front & rear door : Double leaf lockable
Concealed type hinges & a 180 degree swing.
Temperature Ambient to 50 Deg C
Painting Inner: Glossy white colour
Outer: Siemens grey colour (RAL7032)
Shield bus Through screw connection
Mounting and
wiring
• Double compression SS glands (FCG,
Baliga or equivalent)
• Separate Fuse TBs/ TB for analog, digital
and different voltage level signals (Phoenix or
WAGO) of Screw/gage terminal type
Dimensions Min 1800 mm(H) x 600 mm (D) x 2400 mm
(W) or more based on requirement
Material 1) Sheet material thickness: CRCA-COLD
rolled 2mm
2) Gland plates thickness : 3mm
3) Gasket for door & cover: neoprene
4) Plugs for spare cable entries: required
Channels Shall provide with bolt & nut
Anti-vibration pads 15 mm thickness
Panel AC Required. It is to be panel attached.
Light Fluorescent lamp
Lifting Eye-bolts
Plugs For incoming & outgoing
Metal tag name
plate
Required
Clamps Required
Fixtures Required
Bolts, nuts &
gaskets
Required
Earthing Power Earth & Instrumentation Earth shall be
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separated.
Pocket Plastic pocket shall beb provided to keep
manuals/ wiring diagrams
Lock & key Required
Spares • 20 % spare entries to be provided for
incoming & outgoing cables.
• 20 % spare for terminal blocks.
• 20 % spare space for future requirement.
Table 66. Programmable Logic Controller
Description Essential Specification
Manufacturer Siemens/ Schneider/ Allen Bradley
Location Common PLC in Control Room
CPU rack power
supply
Hot Stand by Redundancy Required. Power:
24VDC
Self-diagnostics
features
Required for each and every module available
in the PLC (i.e. CPU, PS, I/O modules, other
communication interface modules etc). and
access through Web without any software
development
Integrated
Connection
Ethernet/ Profinet HSBY Port – 1 Nos, ,
Ethernet /Profinet device network – 2 Nos,
Ethernet Ports for SCADA Network
Memory
Integrated RAM: 16 MB Program and Data or
more
External Flash: 4 GB for local Data storage or
more,
Minimum LED
Status
LED Status for Run, Error, IO Fault, Memory
card fault, HSBY Status or more.
Synchronization
between CPUs
FO communication/ Ethernet between CPUs
shall be provided.
Redundancy Media Redundancy shall be available.
Programming and
downloading to PLC
2 Nos. of Licensed latest version shall be
provided for programming. Floating type
license is preferable. Any other necessary
License required to configure PLCs
communication shall be provided.
Standards
compliance CSA, EN/EIC, UL
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Interface for
communication
between PLC and
I/O modules
1) Required – EtherNet/IP
2) PLC to SCADA Communication shall be
EtherNet IP.
3) Suitable Interface converter shall be
provided to link field devices to PLC.
4) The system shall be integrated with
existing ovens & to centralized DAS and
suitable converters shall be supplied.
Table 67. DI Modules
Description Essential Specification
Manufacturer Siemens/ Schneider/ Allen Bradley
Number of Channels 16
Input type Current sink (logic positive)
Discrete input voltage 24 V DC positive
Input compatibility Potential free Contacts
Sensor power supply 24 VDC
Insulation resistance > 10 M Ohm 500 V DC or better
Protection type Reverse polarity protection
Status LED Required for all channels
Isolation Galvanic/ Optical
Operating Temperature 0 to 50 Deg C
Relative humidity 20 - 80 % without condensation
Table 68. DO Modules
Description Essential Specification
Manufacturer Siemens/ Schneider/ Allen Bradley
Number of Channels 32
Discrete output type Solid state
Discrete output logic Positive
Discrete output voltage 24VDC
Discrete output current 0.5 A or better
Protection type Reverse polarity protection
Overvoltage protection
Overload protection
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Description Essential Specification
External short-circuit protection
Status LED Required for each channel
Isolation Galvanic/ Optical
Operating Temperature 0 to 50 Deg C
Relative humidity 20 - 80 % without condensation
Table 69. Temperature Input Modules
Description Essential Specification
Manufacturer Siemens/ Schneider/ Allen Bradley
Number of Channels 8
Analogue input type Thermocouple: S, R,K,T,K,E,L,J,U,N,B
Temperature probe: Ni 1000, Ni 100, Pt
1000 IEC, Pt 100 IEC, Pt 1000 UL/JIS, Pt
100 UL/JIS, Cu 10
Resistor: 4000 Ohm: 4 wires, 3 wires, 2
wires
Resistor 400 Ohm: 4 wires, 3 wires, 2 wires
Analogue input
resolution
16 Bits
Input impedance 10 Mega ohm or better
Common mode
rejection
70 dB or better
Measurement error 0.2% of Full scale
Status LED/ Self
Diagnostics
Required for each channel
Operating Temperature 0 to 60 Deg C
Relative humidity 20...80 % without condensation
Table 70. Analog Input Modules
Description Essential Specification
Manufacturer Siemens/ Schneider/ Allen Bradley
Number of Channels 8
Analog input type Voltage: 1...5 V,
Current: 4...20 mA
Analogue input 16
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Description Essential Specification
resolution
Input impedance 10 Mohms or better
Measurement error 0.2% of full scale
Common mode between
channels
> 75 dB or better
Isolation voltage Galvanic/ Optical
Status LED/
Diagnostics
Required for each channel
Operating Temperature 0 to 50 Deg C
Relative humidity 20...80 % without condensation
Quantity As required + 2 Spare modules
Table 71. Analog Output Modules
Description Essential Specification
Manufacturer Siemens/ Schneider/ Allen Bradley
Number of Channels 4
Measurement error 0.25 % of full scale
Common mode between
channels
>= 70 dB or better
Isolation voltage Galvanic/ Optical
Analogue output type Current: 4...20 mA and 0...20 mA
Analogue output
resolution
16
Status LED Required for each channel
Operating Temperature 0 to 60 Deg C
Relative humidity 20...80 % without condensation
Table 72. Supervisory Control and Data Acquisition system
Description Essential Specification
SCADA package Siemens/ Schneider/ Allen Bradley
Type Data acquisition & Process monitoring.
Operating system Win 8.1/ Windows 10 Ultimate or latest
Graphical user
interface
Man Machine Interface
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Essential Features:-
1. Dynamically configurable Mimics,
2. Real time & Historical data trends,
3. Data logging & Report generation in user prescribed format,
4. Tags (PLC & Third party tags).
5. Alarms & Events Logging.
6. Access security management
7. OPC Support shall be available to pool data to another
historian
8. Modbus TCP Protocol Support
Mimics 8.1. MMI-PLC-IO network configuration screen
with critical diagnostic information and messages.
8.2. Sub-system wise screens to monitor the
process status.
8.3. Sub-system wise I/O screen.
8.4. Alarms screen.
8.5. Trends screen.
8.6. Any other screen as per the user
requirement.
Trends 8.7. Real time & historical trends.
8.8. X- axis & Y- axis ranges shall be user
selectable.
8.9. Trend configuration shall be user-friendly &
shall be available during Run-time.
8.10. Trends data export to MS Excel (.xls) format
shall be provided.
8.11. Print option for trend chart shall be provided.
8.12. Trend analysis tool shall be provided as per
the user requirement.
Data logging Time based (with minimum 1sec interval) & Event
based data logging for all analog inputs shall be
provided. Data logging shall be in SQL Database.
Alarms &
Events Logging
Alarms & Events shall be logged separately.
Sub-system wise filtration option.
Logging shall be as per user defined format,
Report
Generation
8.13. Reports shall be generated for logged data,
alarms & events as per the user defined formats.
8.14. From- & To- date and time shall be user
selectable.
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8.15. Time interval shall be user selectable.
8.16. Options to export data in MS Excel, MS
Access, SQL formats.
8.17. Print report option shall be provided.
License 8.18. As per previous chapter
Table 73. Server for SCADA / Historian
Description Essential Specification
Make & Model HP/ Dell
Processor 2 x Intel twelve core Xeon processor or
better.
Memory 64 GB ECC DDR4 memories @ 2133 MHz
or more.
Drive bays 6 or more SATA/ SAS hot pluggable drive
bays.
Drive controller Integrated or add-on SATA/SAS controller.
Hard drives 4X2 TB SATA/ SAS HDD for RAID 5 or
RAID 1 configuration.
RAID controller On board or add-on RAID controller to
configure the above RAID.
Optical drive DVD-RW
HBA Dual port 8 Gbps SAN host bus adapter.
Expansion slots 2 slots or more after configuring the
requirements.
Graphics Integrated graphics controller.
Network interface
cards
• 6 x 100/1000 Mbps Ethernet ports
(Excluding management Ethernet ports
bundled for redundant and load balancing).
• Add-on cards for redundant
communication management between PLC
to SCADA Stations as recommended by
OEM.
I/O ports &
connectors 4 USB
Input device USB keyboard and mouse
Monitor 23/24” LED Monitor( OEM) + 42"/43” LED
monitor (LG)
Power supply 2 x hot plug power supply (230V AC @50
Hz) unit. Indian power cords to be supplied.
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Form factor Rack mountable.
Warranty 3-3-3 years
Hard Disk Drive (HDD) Minimum. 4 Nos. of HDD with each Min.
2TB capacity
RAM 32GB
Operating system (OS) Windows server latest edition and
compatible with the latest SCADA version.
Software with license
• System management software to
monitor the system health at local console
& over network.
• Redundant connection (red connect)
management license for CPU to SCADA
Stations with associated interface card.
• SNMP OPC server.
• Any other relevant software as
required.
DVDs to be included. Server Hardware drivers, OS and associated
software.
Location
Server shall be mounted in server rack with
monitor and located in Instrumentation
panel room.
Table 74. Operator Workstation
S.No Functionality/
Description Specification
1 Make HP/Dell
2 Type
19” Rack Mount in Server Rack is
preferable or with Support tray in Server
rack.
3 Processor Intel i7, 6th Generation Processor or latest ,
3.4GHz or better / Intel Xeon processor E3
4 Memory 2 x 8 GB DDR4
5 Hard Disk 2 TB GB Hard Disk Drive
6 BIOS 8 MB Flash memory for system BIOS or
better
7 I/O Expansion
slots
2 PCIe & 1 PCI empty shall be available for
future use
8 Optical drives 16X DVD+/-RW Super Multi drive with
dual layer facility
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9 Key board &
Mouse
OEM make standard USB Key board &
optical scrolled Mouse
10 Network
Interface
1. 10/100/1000 GBPS or better with
RJ45 Connection Port
2. Add On NIC for additional LAN Port
11 IO Ports
Front: 2 USB 3.0, 1 USB 2.0, 1 Headphone,
1 Microphone, 1 IEEE 1394a; One serial
Port
Rear: 2 USB 3.0; 4 USB 2.0, 2 x RJ-45(one
must be integrated) Gigabit LAN, 2 PS/2, 1
Audio Line-In, 1 Audio Line-Out, 1
Microphone, VGA, DVI and HDMI port.
12 Colour Monitor
• OEM
• 23/24” wide screen LED Color
Display
• Resolution – 1920 X 1200
13 Graphics
1. On-board Intel HD Graphics Card
2. Dedicated Graphics NVDIA Card with
4GB RAM PCIe Card
14 Power supply 220 ±10% VAC, 50 Hz
15 System
Management
Integrated management controller for
monitoring the health of system with
OEM’s management software
16 System Fans
Shall be provided as per system
requirement for better operation: Fans
shall be along with power supply
17 Accessories
Complete with all interconnecting cables,
cords, connectors, peripherals, adaptors
& display mounting accessories, keyboard,
mouse and external speaker (OEM make)
with microphone & mouse pads etc.
18 Documentation All Standard Documentation and Driver
CDROMs with required licenses in Original
19 Operating
System
Microsoft Windows 8.1/10 Professional
Edition 32 / 64 bit OS or latest with latest
Service Pack and original media
20 MS Office (Latest version) Licensed MS-Office with
latest service pack with original media
21 Security Power on password; administers password;
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Features and other necessary security related
features for workstations
22 Original
Software
• Recovery DVD
• Drivers & Utilities DVD
• CD/DVD Writing Software’s
• Restore CDs, smart start CDs,
Operating system CDs to install the
operating system in case of system crash
shall be in Original.
23 Warranty 3 Years 24x7 support and certificate for 3
years from OEM
25 Printer
A3 Inkjet Color Printer – 1 Nos, A4 Inkjet
color printer -1 No, A4 Color Laser Printer
– 1 Nos. and A4 Scanner - 1 Nos
Printers/Scanner shall be of HP make
Table 75. Thin Client Unit
Description Essential Specification
Operating system Windows Win 10 IoT/ Embedded Win 7/8
CPU AMD G-Series (1.4 GHz, Dual Core, 1 MB,
AMD Radeon HD Graphics Card) or latest
Flash/ SSD 16 GB Flash or better
RAM 4 GB RAM DDR3 or latest
I/O peripheral
support
1. 1 x Display Port
2. 1 x One DVI-I port with DVI-I to VGA
Adaptor
3. Min 2 x USB 2.0 ports (one front, one
rear)
Networking 1. 10/100/1000 Gigabit Ethernet
2. Dual band 802.11 a/b/g/n wireless
Resolution
1. Display Port: 2560x1600@ 32bpp
2. DVI-I: 1920x1200@ 32bpp or with
better features
Monitor 21” or equivalent size LED HD Resolution
Monitor with VGA & DVI Ports of OEM make
Audio 1/8-inch mini jack
Mountings
Vertical feet standard
VESA mounting bracket for mounting to flat
surfaces, such as walls shall be supplied
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Description Essential Specification
Security 1. Security protocols shall be available for
network connectivity
Accessories USB Keyboard and Optical Mouse
Browser IE 11 or latest
Software
MS Office Viewer
Device Manager Software & other related
software
Others Support to install IPSAN driver to access
mass storage ,
Power 240 VAC, 50 Hz. With Energy Star
certification
Temperature range Operating: 10° to 40° C
Certifications Energy Star , UL & RoHS complaint shall be
available
Make HP/Dell
Table 76. Programming Station (Laptop)
Description Specifications
Manufacturer HP / Dell
Processor INTEL CORE i7 latest generation
Hard disk capacity 1 TB
Motherboard INTEL original (Suitable for the
configuration)
DDR RAM (DDR4) 8 GB (2 x 4GB)
Network cards Ethernet card:1 Nos. (100Mbps/1Gbps)
Optical Drive DVD RW
Ports (other than those
required for connecting
monitor, keyboard and
mouse)
Ethernet ports: 1 Nos.
RS232 port: 1 Nos.
USB: Minimum 3 Nos. (with at-least one
USB 3.0)
Power supply Suitable 230V AC Adapter with Indian
Pin
Operating system Microsoft Windows 8.1/10 Professional
Edition 32 / 64 bit OS or latest with
latest Service Pack and original media
Software to be supplied
and loaded on system.
Licensed MS Office Professional Latest
version
Monitor Screen 14”, supported resolution 1280x1024 and
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above.
Optical Mouse
(additional)
Standard USB Mouse with scroll.
CD’s for all software &
drivers
Required.
Quantity 02 Nos
Table 77. Ethernet Switch – L2 (Field)
Description Specifications
Ethernet Port Min 6 x 10/100TX/1000 TX (UTP/ SFP) or more
Fibre Port Min 2 x FX (FX/ SFP) or more
Fiber Type Single Mode
Fiber Distance 30 Km or better
Wavelength 1310 nm
IEEE IEEE 802.3, IEEE 802.3u, IEEE 802.3x,
IEEE 802.1d, IEEE 802.1w, IEEE 802.1p,
IEEE 802.1Q
Backplane
communication
2 GBPS
MAC Address Table 2K
Buffer Size 1 Mbit
VLAN Available
IGMP V1
SNTP trap Available
Quality of service IPV4
Management Web Interface and SNMP
Ring redundancy
features
Available
Spanning Tree STP, RSTP
Power input Power input – Dual Power
Mounting DIN Rail
Operating Temperature 0 to 50 Deg C or better (Industrial Grade)
EMI compatibility FCC Class A, CE
Safety certification UL, cUL certification
Model As per previous chapter
Table 78. Ethernet Switch – L2 (Control Room)
Description Essential Specifications
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Type Manageable, Layer-2 Fast Ethernet
switches.
Make & Model As per previous chapter
Physical Ports • Minimum 8 UTP RJ45 Port.
• Minimum 12 Nos of SFP Port
SNMP management feature Required
Power 230 V AC/ 24VDC with Dual power
input
Diagnostics LEDs for power, duplex mode
indication, etc shall be available
IEEE
IEEE 802.3, 802.3u, 802.3ab, 802.3z,
802.3x, 802.3ad, 802.3d STP/ IEEE
8020.1w, 802.1s, 802.1p, 802.Q,
802.1ab
Protocol
IGMP v1/v2, GVRP, SNMP v1/v2/v3,
DHCP Server/Client, SNTP, RMON,
HTTP, Telnet, Syslog, LLDP, IPV6,
LACP
MAC Address Table 8 K or better
System Configuration Web console, Telnet, CLI Console
Network Redundancy STP, RSTP, MSTP, Ring Redundancy
Recovery <20 ms or better
IGMP Snooping/ GMRP IGMP V1, V2, V3 up to 256 Multicast
groups & Query
Reverse polarity protection It Shall be available in case of 24 VDC
Relay Alarm Contact 1A @ DC24V
Security Port security
Quality of service Required
Spanning tree protocol Required
Associated software Required of the same make as the
Ethernet switch
Virtual LAN capability Required
Mounting 19 “ Rack Mount
Table 79. Ethernet Switch – L3 (Control Room)
Description Essential Specifications
Type Manageable, Layer-3 Fast Ethernet switches.
Make & Model Extreme, Moxa, Cisco, Allied Telesys, Planet
Number of copper 24
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Description Essential Specifications
ports
Number of fibre
ports
4 and shall be supplied with 2 Nos. of 1G
single-mode fibre SFP of 1310 nm fibre up to 40
km &2 Nos. of 10 G single-mode fibre SFP of
1310 nm fibre up to 40 km
Forwarding rate 90 Mpps or better
Performance
a. 512 MB DDR SDRAM or more
b. 64 MB Flash memory or more
c. Packet Buffer memory: 2 MB or more
Diagnostic Tools
a. Active Fiber Monitoring detects tampering
on optical links
b. Built-In Self-Test (BIST)
c. Cable fault locator (TDR)
d. Optical Digital Diagnostics Monitoring
(DDM)
e. Ping polling for IPv4 and IPv6
f. Port mirroring
IP features
a. IPv4 static & Unicast & Multicast routing
b. Route Distribution (RIP & OSPF)
c. Policy based routing
d. DHCPv6 client
e. Device management over IPv6 networks
with SNMPv6
f. NTPv6 client and server
Management
a. Centralized management and zero-touch
device installation and recovery
b. Console management port on the front
panel for ease of access
c. Web-based Graphical User Interface (GUI)
d. Industry-standard CLI with context-
sensitive help
e. Comprehensive SNMP MIB support for
standards based device management
f. Front panel display for status & fault
information
Quality of Service
(QoS)
a. 8priority queues
b. Policy-based storm protection
c. Tail drop for queue congestion control
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Description Essential Specifications
d. Strict priority, weighted round robin or
mixed scheduling
e. IP precedence and Diff Serv marking
based on layer 2, 3 and 4 headers
Resiliency
a. Stacking ports shall be configured as 10G
Ethernet ports
b. Control Plane Prioritization (CPP) ensures
the CPU always has sufficient bandwidth to
process network control traffic
c. Dynamic link failover (host attach)
d. EPS Ring (Ethernet Protection Switched
Rings) with enhanced recovery for extra
resiliency
e. Loop protection: loop detection and
thrash limiting
f. STP root guard
Security
a. Access Control Lists (ACLs) based on
layer 3 and 4 headers, per VLAN or port
b. Configurable ACLs for management traffic
c. Authentication, Authorization and
Accounting (AAA)
d. Boot loader can be password protected for
device security
e. DHCP snooping
f. Dynamic VLAN assignment
g. MAC address filtering and MAC address
lock-down
h. Network Access and Control (NAC)
features manage endpoint security
i. Port-based learn limits (intrusion
detection)
j. Private VLANs provide security and port
isolation for multiple customers using the same
VLAN
k. Strong password security and encryption
l. Tri-authentication: MAC-based, web-
based and IEEE 802.1x
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Description Essential Specifications
Environmental
specifications
a. Operating temperature range: 0°C to 50°C
b. Operating relative humidity range: 5% to
90% non-condensing
Protocols
All standard protocols/ Algorithms such as
cryptographic algorithm, Ethernet standards,
IPV4/ IPV6, Network Management support/
Multicast protocol support/ VLAN/ Voice Over
IP, etc shall support by the switch
Power supply 230 VAC +/- 10% or better
Routing
- VRRP (Virtual Routing Redundancy
Protocol) feature shall be available
- Routing: Layer 3 switch routing
- Routing protocols: RIP v1/2, OSPF &
Static routing
Standards &
Compliance
- Safety: UL508/CSA C22.2/14 (pending);
EN60950-1, CE
- Others: RoHS, WEEE and REACH
compliant
Mounting 19 “ Rack Mount
Table 80. Surge Suppressor
Description Essential Specification
Make Phoenix/ Dhen/ Citel
Location UPS Output & IO Rack Input (Lightning & Surge
Protection for power supplies)
Use SPD between UPS Output in Control Room & IO rack
in Service room
Type Type 1/2/3
Mounting Pluggable SPDs between LN, LE , DIN Rail Mounting
Table 81. Control Consoles
Description Essential Specifications
Manufacturer Pyrotech electronics private limited/ Adarsha/
Evans/ Winstud
Dimension Drawings given in the annexure
Service Housing MMIs, Telephones & wireless sets etc.,
Location Curing Control room
General • The consoles shall be fully modular in
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Description Essential Specifications
design and construction.
• Consoles shall be ergonomically designed
for operator comforts and suitable for housing
One Operator station, Telephones & wireless sets
etc.,
• Console system shall have option of being
one or two tiers high.
Construction
features
• Cabinet shall be made of high quality wood
ASS with very good finish. The top layer of the
surface shall be capable of withstanding day to
day usage of the work surface (Free usage)
without losing the high quality finish. The surface
should be made of tough material that withstands
mild abrasions without losing finish.
• Shall have Ball bearing pull out CPU trays,
height adjustable & pull out key board trays,
mouse wire holes, Solid floor panels with cable
entries, movable equipment shelves, rails for DIN
mounting equipment’s.
• Structure: Powder Coated Aluminium
Sturdy Structure and extreme side Aesthetic Legs.
• It shall Hold one PC with 23 Inch Monitors,
Infinova V2117X Keyboard, Motorola Wireless
Base station, Phone and related Accessories
Door Front & rear hinged ASS wood doors.
Monitor tiers
• Heavy duty pipes have swivel head. The
monitor angle can be adjusted
up/down/left/right and also vertical height can
be adjusted as desired.
• Flexible telephone tray.
• Extreme ends with aesthetic elements.
Quantity Operator console - 1Nos.
Work surface
Made up of 12mm Acrylic solid surface (ASS) and
25mm of MDF wood. Desired colour shade
matching with control room interiors will be
decided by user.
Electrical • The Console System should provide a
concealed cable routing system.
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Description Essential Specifications
• The separation necessary between network
and power cabling shall be taken care off. All
trays should be easily accessible during
installation and maintenance. The horizontal
cable tray should have arrangement to
accommodate plug connectors and sockets of
varying sizes.
• Power distribution for console equipments
with 5/15-amp surge protector, 3 pin sockets,
MCBs & TBs.
• RJ-11 (2 Nos.), RJ-45 (4 Nos). Earthing kit.
Light Required. LED lamp
Chairs/ Tables Godrej (Refer Table 49, S. Nos 72, 73, 74 & 75
Dimensions Approximate Dimensions provided below
Min 1.5mts
Fig. 2. Control Consoles
Table 82. Server Rack
Description Essential Specification
Make Valrack/ APC/ Rittal
Location Control Room
Size 24U
Mount Rack Mounting for Servers
Doors Transparent Glass doors shall be provided at both
PC Monitor
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Description Essential Specification
front and Rear side.
Fans Shall be provided
Castor Castors with brake shall be provided
Cable
Manager
Shall be provided to meet system requirement
Power
manager
Shall be provided to meet system requirement
Trays Cantilever Trays & Server positioning trays shall be
provided to meet system requirement.
Earth strip Shall be provided
Tube light Fitting shall be provided
Side panels Side panels shall be provided with cam lock or Lock&
Key
Table 83. 43 Inch LED TV
Description Essential Specifications
Screen Size 43 Inch or better
Resolution 1920 x 1080
Panel IPS panel
Analog Video PAL/ SECAM/ NTSC
Smart Energy Smart energy saving feature shall be available
Video
a. Triple XD Engine shall be available
b. Active noise reduction feature shall be
available
c. Dynamic clear white feature shall be available
d. Dynamic colour enhance feature shall be
available
e. Picture modes: Minimum 3 Modes (Vivid,
Standard, Cinema)
f. Aspect Ratio: 16:9, 4:3, 14:9, Zoom, Cinema
zoom
Audio
a. Dolby Decoder shall be available
b. 2 Channel speakers shall be available
c. Audio output: 10 watts or better
Features Smart with WebOS3.0 with Magic remote
USB a. DivX HD feature shall be available
b. JPEG Picture support shall be available
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c. Audio Codec: AC3, EAC3, AAC, Mpeg, MP3,
PCM supports shall be available
Connections
a. Minimum 1 USB port shall be available at side
b. RF In: 1
c. Composite Input: 2
d. Component Input: 1
e. HDMI: 2,
f. Headphone out: 1
g. VGA IN: 1
Power supply 230 VAC
Model As per previous chapter
Table 84. 16 Pair Signal Cables
Description Essential Specification
Code used BS-5308
Conductor 1.0 Sq.mm annealed tinned copper conductor of 7
strands.
No. of Cores 16 Pair
Primary
insulation
XLPE insulated core.
No. of
twists/meter
Minimum 20 twists/meter
Core
identification
By colour
Voltage grade 1100 V
Cable
identification
Running length of the cable shall be printed at
least at every 5 meter interval.
Pair
identification
With numbers at interval of not more than 250
mm as per vendors standards.
Shielding Individual + Overall:
Aluminium Mylar tape & ATC drain wire with PTP
tape.
Drain wire size 0.5 Sq.mm or better
Drain wire Multi-stranded bare tinned annealed copper in
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Description Essential Specification
material continuous contact with aluminium side of the
shield.
Drain wire
resistance
Drain wire resistance including shield shall not
exceed 40Ω/km
% coverage /
overlap
100% / 25%
Inner sheath Extruded Black FRLS PVC type ST-2.
Armouring Galvanized steel round wire.
Outer sheath Extruded flame retardant 90 °C PVC to IS-5831
type ST-2/IEC 502. Color light blue.
a) PVC oxygen index: over 30%
b) PVC temperature index: over 250 °C
c) Fire retardant: yes, as per IEC-332 part3,
CAT A
Electrical
properties @ 20
°C
1) Conductor resistance: maximum 30Ω/km
or better
2) Insulation resistance: minimum 5000M Ω.
3) Mutual capacitance: maximum 75pF.
4) L/R ratio: maximum 40µH/ Ω or Better
5) Test voltage: Conductor to conductor: 1000
V for 1 minute.
6) Conductor to shield & Armour: 1000 V for 1
minute.
Tests All the tests shall be conducted as the part of pre-
delivery inspection.
Location From Control Room to Each Oven IO Rack
Table 85. 1 Pair / 3 Pair Signal Cables
Description Essential Specification
Code used BS-5308
Conductor 0.5 Sq.mm annealed tinned copper conductor of 7
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Description Essential Specification
strands.
No. of Cores 1 Pair/ 3 Pair
Primary
insulation
XLPE insulated core.
No. of
twists/meter
Minimum 20 twists/meter
Core
identification
By colour
Voltage grade 1100 V
Cable
identification
Running length of the cable shall be printed at
least at every 5 meter interval.
Shielding Individual + Overall:
Aluminium Mylar tape & ATC drain wire with PTP
tape.
Drain wire size 0.5 Sq.mm or better
Drain wire
material
Multi-stranded bare tinned annealed copper in
continuous contact with aluminum side of the
shield.
Drain wire
resistance
Drain wire resistance including shield shall not
exceed 40Ω/km
% coverage /
overlap
100% / 25%
Inner sheath Extruded Black FRLS PVC type ST-2.
Armouring Galvanized steel round wire.
Outer sheath Extruded flame retardant 90 °C PVC to IS-5831
type ST-2/IEC 502. Color light blue.
a) PVC oxygen index: over 30%
b) PVC temperature index: over 250 °C
c) Fire retardant: yes, as per IEC-332 part3,
CAT A
Electrical
properties @ 20
°C
1. Conductor resistance: maximum 40Ω/km
or better
2. Insulation resistance: minimum 5000M Ω.
3. Mutual capacitance: maximum 75pF or
Better
4. L/R ratio: maximum 25µH/ Ω or Better
5. Test voltage: Conductor to conductor: 1000
V for 1 minute.
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Description Essential Specification
6. Conductor to shield & Armour: 1000 V for 1
minute.
Tests All the tests shall be conducted as the part of pre-
delivery inspection.
Location From Control Room to Each Oven IO Rack
Shielding Cores shall have common shield of 0.25mm Dia
annealed, tinned copper conductor braid with
85% min coverage
Overall
sheathing
0.5mm PTFE insulation or appropriate as
mentioned above
Temperature The cable should withstand temperature of
minimum 80 to 150 deg C
Location From Each RTD Sensor to IO Rack
Table 86. Heat Resistant Cables
Description Essential Specification
Make Thermocab, Thermocables, Delton, Lapp, Polycab,
Paramount
Conductor 7/0.32 Dia stranded, annealed, tinned copper
conductor to have effective cross sectional area of
0.5 sq.mm as per IS 8130
Insulation 0.4 mm PTFE insulation or appropriate to
withstand ambient temperature of Max 150 deg C
Type Flexible cable
No. of cores 8
Color-coding Suitable distinctive color-coding with polyester
taping shall be provided over the cores
Shielding Cores shall have common shield of 0.25mm Dia
annealed, tinned copper conductor braid with
85% min coverage
Overall
sheathing
0.5mm PTFE insulation or appropriate as
mentioned above
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Description Essential Specification
Temperature The cable should withstand temperature of
minimum 80 to 150 deg C
Location From Each RTD Sensor to IO Rack
Table 87. Optic Fiber Cables
Make HFCL, Polycab, Schneider, RPG
Fiber type Single Mode
Fiber Count 24
No of loose Tubes 6 nos. (4 fibers per tube)
Colour of fibers Blue, Orange, green and natural
Attenuation at 1300 nm less than 0.5 db/km
Fiber coating diameter 245 +/- 10 microns
MFD 9.3 +/- 0.5 microns
Clad diameter 125 +/- 1 microns
Diameter of cable 15 mm nominal
Inner sheath thickness Black PE 1.0 mm
Outer sheath thickness Black HDPE> 0.5 mm
Armor Corrugated ECCS tape
Moisture barrier Water swells able tape or poly tape
Tensile strength > 2000 N
Crush resistance > 2000 N
Impact resistance 25 Nm – 10 impacts
Minimum bend radius 20 D
Repeated pending 30 times
Torsion resistance 10 cycles
9. Suggested Vendors
9.1. Main Oven, AGNI Oven & Sub Systems – Mechanical
Table 88. Suggested Vendors - Mechanical
Description Make
Centrifugal Fans
ABB Limited / Nadi Airtechnics Pvt.
Limited / CB doctor, Ahmedabad /
Patel Air temp India Limited, Mumbai
Centrifugal Pumps Kirloskar Brothers Limited
Bearings SKF
Fire Dampers Carrier / Bhupathi Associates / Belino
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Description Make
/ Juventa
Ball Valves L & T / Audco
Insulation
Lloyds Insulation (India) Limited,
Mumbai / Navbharat Insulation &
Engineering Company, Mumbai / U P
Twiga Fibre Glass Limited, New Delhi
/ Newkem Engineers Private Limited,
Mumbai
SS pipes Ratnamani / REMI
SS pipe fittings Rajamani / Aravind
Pressure gauges Wika / Atlas/ H Guru/FIEBIG
Fasteners UNBRAKO / TVS
9.2. Electrical Systems
Table 89. Suggested Vendors – Electrical Systems
Sl. No.
Item Description Suggested Vendor
1. ACB Siemens / L&T
2. MCB Siemens / Schneider / Legrand
3. MCCB Siemens / Schneider / L&T
4. MPCB/CONTACTOR/OLR/Aux Contactor
Siemens
5. Timer Siemens / L&T
6. Line / Power Monitoring Relay
Siemens
7. Limit Switches Siemens / L&T
8. CT Kappa / AE
9. CT Current Transducer / Voltage Transducer
Rishab / M-System /AE
10. Current Transducer LEM
11. Earth Leakage Relay PROK DVS
12. FLP Items Baliga / FCG / STAHL
13. Intrinsic Safe Items P&F
14. Power Cable Havells / Finolex / CCI / Universal / Polycab / IGUS / Gloster / Lapp /KEI
15. Control Cable Havells / Finolex / Polycab / IGUS / Gloster / Lapp / KEI / RR Kabel
16. Panel Wiring Cable Havells / Finolex / Lapp / RR Kabel
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Sl. No.
Item Description Suggested Vendor
17. Motor Management System (MMS)
Siemens / Schneider / Allen Bradley
18. Soft Starter Siemens
19. Thyristor Power Controller AEI
20. Digital Panel Meter AE / RISHAB / Schneider / L&T / ABB / MCIH / PMA / Conzerve
21. Multi-function Meter Siemens
22. Push Buttons Siemens
23. Indication lamps Siemens / L&T
24. IS Indication Lamps BEKA
25. iMCC Integrator
M/s SIEMENS LTD M/s ALLEN BRADLEY LTD M/s ADARSHA CONTROL &
AUTOMATION PVT. LTD, Chennai
M/s AUTOSYS ENGINEERING PVT LTD
M/s KASA ANLAGEN PVT LTD, Chennai
M/s CHEMIN CONTROLS PVT LTD , Pondicherry
M/s RSP CONTROLS LTD, Chennai
M/s FORMOPLASTIC CONTROLS (P) LTD
26. For any other make, approval to be obtained from department before placement of order.
9.3. Instrumentation & Control Systems
Table 90. Suggested Vendors – Instrumentation & Control
Systems
S.No Item Make
1 Duplex RTD of 600 mm Length – Main Oven
Baumer/ Nagman/ Tempsens/ Exotherm/ Rosemount
2 Duplex RTD of 600 mm Length – Agni Oven
Baumer/ Nagman/ Tempsens/ Exotherm/ Rosemount
3 Duplex RTD of 400 mm Length – Main Oven
Baumer/ Nagman/ Tempsens/ Exotherm/ Rosemount
4 Duplex RTD of 800 mm Length – Agni Oven
Baumer/ Nagman/ Tempsens/ Exotherm/ Rosemount
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5 Duplex RTD of 400 mm Length – Hot Water Tank
Baumer/ Nagman/ Tempsens/ Exotherm/ Rosemount
6 Duplex RTD of 300 mm Length – Hot water Inlet & Outlet
Baumer/ Nagman/ Tempsens/ Exotherm/ Rosemount
7 Temperature Transmitters Rosemount/ Siemens
8 Pressure Transmitter Rosemount 3051 (0 to 55 Bar)/ Siemens
9 Single Loop Controller ABB CM10
10 Level Switch P&F
11 Level Transmitter P&F / Rosemount/IFM
12 Proximity sensors P&F
13 Isolators (I/I or I/V) – 1 In 2 Out
P&F
14 Isolators (I/I or I/V) – 2 In 2 Out
P&F
15 Relay – 1 In 2 Out P&F
16 Relay – 2 In 2 Out P&F
17 Power fed Module and Power rail
P&F
18 Power Rail P&F
19 Low Air pressure Switch Switzer/ IFM
20 Water flow switch Switzer / IFM
21 DC Current transducer Rishab/ LEM/ AE/ M- Systems/ NK Technologies
22 DC Voltage transducer Rishab/ LEM/ AE/ M- Systems
23 UPS Voltage Monitoring Transducer
Rishab/ LEM/ AE/ M- Systems
24 UPS Current Monitoring transducer
Rishab/ LEM/ AE/ M- Systems/ NK Technologies
25 UPS Voltage Monitoring (3 Phase) Transducer
Rishab/ LEM/ AE/ M- Systems
26 UPS Current Monitoring ( 3 Phase) transducer
Rishab/ LEM/ AE/ M- Systems/ NK Technologies
27 Raw Voltage Monitoring (1 Phase) Transducer in Main & Agni Oven
Rishab/ LEM/ AE/ M- Systems
28 Raw Current Monitoring (1 Phase) Transducer in Main & Agni Oven
Rishab/ LEM/ AE/ M- Systems/ NK Technologies
29 24 V DC/20 A power supply with Diode O ring Module
Phoenix/ Siemens/ Aplab
30 24 V DC/10 A power supply with Diode O ring Module
Phoenix/ Siemens/ Aplab
31 24 V DC/5 A power supply Phoenix/ Siemens/ Aplab
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with Diode O ring Module
32 IO Rack Rittal
33 Hot Standby PLC/PAC Siemens/ Schneider/ Allen Bradley
34 PLC Programming Full License
Siemens/ Schneider/ Allen Bradley
35 16/32 Channel Digital Input Module
Siemens/ Schneider/ Allen Bradley
36 16/32 Channel Digital Output Module
Siemens/ Schneider/ Allen Bradley
37 8 Channel RTD Input Module Siemens/ Schneider/ Allen Bradley
38 8 Channel Analog Input Module
Siemens/ Schneider/ Allen Bradley
39 4/8 channel Analog Output Module
Siemens/ Schneider/ Allen Bradley
40 SCADA Server License (For Hot stand By Server)
Siemens/ Schneider/ Allen Bradley (Unlimited Run-time + Configuration Supply of for HSBY server– 5000 Tags
41 SCADA Historian License
Siemens/ Schneider/ Allen Bradley (1500 tags for historian server with 10 HMI User access & 2 Web user access
42 SCADA Client License (HMI Clients)
Siemens/ Schneider/ Allen Bradley
43 SCADA (Web Clients) Siemens/ Schneider/ Allen Bradley (Web space clients)
44 SCADA Historian Server HP/Dell
45 SCADA Server HP/Dell
46 Operator Station HP/Dell
47 Thin Client Unit HP/Dell
48 PG Station (Laptop) HP Pavilion/ Dell
49 A3/A4 Color Inkjet Printer HP
50 A4 Color Laser Printer HP
51 A4 Scanner HP
52 Digital camera SONY
53 Ethernet Switch- L2 (PLC N/w)
Extreme/ Antaira / Moxa/Schneider/ Siemens
54 Ethernet Switch- L2 (SCADA N/w)
Extreme/ Antaira / Moxa/Schneider/ Siemens
55 Ethernet Switch- L3 (Control Room)
Extreme/ Moxa / Cisco / Allied
Telesys/Planet
/ HP
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56 Surge Suppressor – 1 Phase Phoenix/ Dhen/ Citel
57 Surge Suppressor – 3 Phase Phoenix/ Dhen/ Citel
58 Operator Console Pyrotech
59 Server Rack APC/Rittal/ Valrack
60 43 Inch LED TV LG/ Panasonic/ Samsung/ Sony/ Toshiba
61 16 Pair Armored Signal Cables
Uniflex / Thermocables /
Thermocabs /Delton / Delta /
Lapp / Paramount cables /
Polycab
/ RPG /CMI
62 1 Pair Armored Cable
Uniflex / Thermocables / Thermocabs /Delton / Delta / Lapp / Paramount cables / Polycab
63 3 Pair Armored Cable
Uniflex / Thermocables / Thermocabs /Delton / Delta / Lapp / Paramount cables / Polycab
64 Heat Resistant Cables
Uniflex / Thermocables /
Thermocabs /Delton / Delta /
Lapp / Paramount cables /
Polycab / / RPG /CMI
65 Optic Fibre Cables HFCL/3C/ Schneider/ Tyco/ RPG
66 Cat 6 /7 cable Belden/ Schneider
67 Double compression Glands Baliga/ Comet
68 Terminals/ Stoppers/ Fuse TB
DIN Rail Wago/ Phoenix/ Weidmuller, Fuse TB with Fuse Break LED
69 Flameproof Junction Boxes P & F/ Baliga
70 Non Flame proof Junction Boxes
P & F/ Baliga / Rittal / Adarsha
71 Relay Phoenix Solid state relay module to drive contactors.
72 48 port OFC Splice box (Wall Mount)
3M/ FCI
73 19” Rack Mount 48 Port OFC Splice Tray (Rack)
3M/ FCI
74 Push Buttons, Emergency Stop Buttons
Siemens
75 Chairs Godrej PCH 7001
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76 Chairs Godrej PCH 7003
77 Chairs Godrej PCH 7002
78 Table Godrej ENZ0, Color: Beige, Dim: 1500 x 750 x 750
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